UREA & AMMONIA

MANUFACTURING – NFL BATHINDA

SUBMITTED BY: SUBMITTED TO:

RAKESH (12112059) Dr. SANGEETA GARG
JATIN SINGLA (12112036) (Associate professor)
RAJ KUMAR THAKUR(12112056)
SUNNY TRIVEDI (12112078)
 Index
 ABOUT NFL BATHINDA
 INTORDUCTION
 WHY NEED TO MANUFACTURE UREA
 WHY NEED TO MANUFACTURE UREA
 UREA PROPERTIES
 UREA PROCESS TECHNOLOGY
 EFFECT OF VARIOUS PROCESS PARAMETERS
 ADVANTAGE OF UREA
 MANUFACTURING PROCESS OF AMMONIA
 DIFF. PLC USED IN AMMONIA –II
 DESCRIPTION OF DISTRIBUTED CONTROL SYSTEM
 ARCHITECTURE OF DCS SYSTEM
 Bathinda unit of NFL was commissioned on 1st Oct 1979
based on gasification technology of Feed Stock on LSHS
/Fuel Oil with the annual installed capacity of 511500 MT of
Urea. Subsequently as per guidelines of GOI, in order to
reduce subsidy burden & Carbon footprint, NFL revamped
the Bathinda Unit on LSTK basis for changeover of
Feedstock from LSHS/FO to Natural Gas and commercial
production on Gas was commenced during Jan 2013.

SALIENT FEATURES OF BATHINDA UNIT

Installed
511500 MTPA
Capacity:
Capital
349.41 Crores
Investment:
Introduction
 Fertilizer is an organic or inorganic natural or
synthetic substance which supply required
nutrients for the growth of plants..

 For healthy growth of plant, essential nutrients

such as nitrogen, phosphorus, potassium,
calcium, magnesium, sulphur, iron , manganese,
zinc, boron and copper are required.
Why need to manufacture UREA
 India is a agriculture country.

 80% population of India lives in the village.

 To meet the basic need in concern of food of a fast

growing India’s population.

 To achieve this task, need good quality of fertilizers

to increase productivity of crops.
Physical Properties
 Mol Wt 60

 Melting Point 132oC

 Density (gm/cc at 25oC) 1.330

 Bulk Density of Prilled Urea 0.65 Te/M3

 Angle of repose 23o

 Viscosity at 132oC 2.58cp

Chemical Properties
 Colorless white crystalline substance

 Odorless

 Soluble in water, alcohol, & Liq. NH3 when heated

under vacuum

 Decomposes to NH3 & Carbamate at 160~190oC

Urea Process Technology
Urea process is divided into four section

1. Urea synthesis

2. Decomposition

3. Recovery section

4. Crystallization and prilling section

 Urea synthesis
 The reaction between liquid ammonia & gaseous CO2 is
carried out at elevated temp & pressure in a plug flow
reactor.
2NH3 + CO2 = NH2COONH4 + Heat (37.6 KCal) ------I
NH2COONH4 = NH2CONH2 + H2O - Heat (6.32KCal)--II

 Whereas the first reaction is highly exothermic & rapidly

goes to completion & second reaction is endothermic & is
always incomplete. The overall reaction is exothermic &
hence heat has to be recovered continuously for the
equilibrium reaction to proceed.
 The conversion of ammonium carbamate to Urea depends
upon following three conditions
a) Reaction temperature
b) Molar ratio of NH3 to CO2 & H2O to CO2
c) Residence time
 The conversion increases with the increase in temperature,
N/C ratio & decreases with increase in H/C ratio.
 The presence of water tend to shift the equilibrium reaction
(II) In the backward direction.
 The pressure employed depends upon the temp of reaction
& has to be kept higher than the dissociation pressure of
Ammonium Carbamate at that temperature.
 Higher N/C ratio increases conversion & helps to minimize
corrosion
COMPOSITION OF VARIOUS CONSTITUENTS
 The equilibrium percentage conversion increases with
increased temperature in the presence of excess Ammonia
but decreased with increased water content of reaction
mixture. As the reaction take place in the liquid phase, the
pressure required will depend upon the composition of the
reaction mixture and the temperature which has a
significant effect on the rate of reaction of carbamate to
urea. At increasing temperature, reaction rate increases
and residence time to approach equilibrium decreases
Decomposition
 The outlet product from the reactor contains Urea,
unconverted Carbamate, excess NH3 & Water. Next step in
the process is to Separate out the Urea from the
unconverted reactants. The decomposition takes place
according to the following reaction:

NH4COONH2 = 2NH3 + CO2

 Since it is reverse of reaction (II), it is favored by low

pressure.
 The process where decomposition is effected by lowering
the pressure in successive stages followed by indirect
heating with the help of steam are called Conventional
Process.
 Here decomposition is carried out in three stages i.e.
17.5Kg/cm2, 2.5kg/cm2 and 0.3Kg/cm2.
 The main consideration during Decomposition is that
minimum water evaporation should take place, since any
such water will enter the Urea reactor along with recycle
solution which would adversely affect the conversion
efficiency. The process where decomposition is effected by
lowering the pressure carbamate is utilized either in
generating steam or supplying heat of crystallization.
 During decomposition the following unfavorable
reaction occurs. These are as given bellow

1. Hydrolysis of urea
NH2CONH2 + H2O = 2NH3 + CO2
The hydrolysis of urea is favoured by high temperature, low
pressure and long residence time. Since it consume desire product so
these condition are to be minimized.

2.Biuret Formation
2 NH2CONH2 = NH2CONHCONH2 + NH3
The biuret formation reaction is reversible and favoured by high
temperature, low pressure of ammonia and high residence time. The
rate at which biuret is produced in molten urea and in concentrated urea
solution with low ammonia conc. is very rapid. But in the synthesis
step the excess ammonia helps to keep the biuret content low.
Recovery
 The basic difference between the various urea process
related to the method of recovery of unconverted ammonia
and carbon dioxide gases from the ammonium carbamate
decomposers.
 In actual practice, to compress the NH3-CO2 mixture and
return to the reactor is not possible because compression
causes a recombination of NH3 and CO2 to solid
ammonium carbamate and clogging the compressor.
 The method of recycling is classified into two types
1. separate and recycle as gases
2. recycle in a slurry form
 Bathinda unit follows recycle solution method.

 The NH3-CO2 mixture gases from the various

decomposers are absorbed in the water and urea solution
in the various absorbers and recycled back to the reactor.

 The excess ammonia is purified in high pressure absorber

and recycled separately to the reactor through ammonia
condensers, ammonia reservoir , liquid ammonia feed
pumps and ammonia preheater.
Crystallization and prilling section
 The urea solution leaving the carbamate decomposer is
vacuum crystallized and urea crystals are separated by
centrifuge.
 To use efficiently the heat of crystallization and to evaporate
water at lower temperature , vacuum crystallizer is often
used.
 Crystals formed in the crystallizers are centrifuge and then
dried to less than 0.3% moisture by hot air. To keep the
biuret content about 0.1% in crystal urea, a certain quantity
of mother liquor which contain almost all of the biuret
originally present is recycled to the recovery section, but
now a days it is sended to the vacuum crystallizers directly
as it contain less biuret.
 Dry crystals of urea collected in the air dryer in which it is
dried by passing dry air from F.D. fan.
 Air passing through F.D. fan is first heated through steam
condensate and 4Kg/cm2 steam so that it should be free
from moisture and attain a temperature less than melting
point of urea i.e. 1200C.
 Dry crystals are conveyed to the top of prilling tower
passing through pneumatic duct and send to the melter via
cyclone and screw conveyor to melter.
 In melter dry urea crystals are melted by using 7Kg/cm2
steam and finally reaches to the Head tank . In melter
temperature of molten urea control up to 1370C to avoid the
biuret formation.
 Molten urea solution comes from head tank to acoustic
granulator and then sprayed in the form of prills form a
rising column of prilling tower.

 These prills get cooled down by F.D. fan air which take
suction from atmosphere and send it through continuous
fluidized dryer.

 After cooling of prills not less than 450C, it is conveyed to

bagging plant via passing through trommel and belts and
finally stored in the silos.
CRYSTALLIZATION PROCESS
.
TO P.T. (By pneumatic
conveyor)

EJECTOR Dry Powder

HEATER

FEED

CENTRIFUGE
C.W 85%
Urea
For further
processing

Hot air
DRYER
CRYSTALLIZER M.L.T.
(Oslo evaporator Maximum biuret
crystallizer)
Process Features
Reactor Operating Conditions
 Temp. ºC 200

 Pressure Atm 250

 NH3 :CO2 3.7:1

 H2O: CO2 0.563

 CO2 Conversion Efficiency % 70

Process parameters
1. Temperature lowering : i) High flow rate of the recycle
solution ii) High NH3 excess rate
Effect: CO2 conversion decreases.
2. Temperature rising : Excess ammonia Preheat
temperature
Effect: The erosion and corrosion will be accelerated
specially at the Letdown valve
3. Pressure lowering : CO2 conversion decreases
4. Pressure rising: Rising pressure in the reactor very
dangerous, so shut all the feed down manually as soon as
possible
5. Mole ratio of NH3/CO2 lowering:
• The temperature in reactor and the down stream of letdown
valve rise
• The CO2 conversion deceases
• The load on the downstream and recovery section
increases

6. Mole ratio of NH3/CO2 rising:

The temperature in the reactor and down stream of let
down valve decreases
Advantage of urea
 Nitrogen content is highest among various nitrogenous
fertilizers (46%).
 Cheapest fertilizer from transportation point of view
 CO2 which is one of the raw materials for the manufacture
of urea is available at negligible cost from ammonia plant.
 It is not subject to fire or explosion hazard
 It has got better flowing characteristics
 As such it is not toxic and used in preparation of various
types of medicines and in other industries.
MITSUI TOATSU TOTAL RECYCLE “C” IMPROVED PROCESS
L.P.ABSORBER
L/D VALVE P-17
KG/CM2 VACUUM
T-1600C CRYSTALLIZER
HPD

L.P.DECOMPOSER
L.S.
STEAM
H.P.DECOMPOSER UPPER
P-245
Kg/Cm2 COND. PART

T-200OC P-3.0 Kg/Cm2

COND
LINER T-1400C

TI
LOWER
PART

HAC

SLURRY RECYCLE FOR

HEAT RECOVERY
AMMONIA M.L.T.
PREHEATER SLURRY
steam
NH3 PUMP
c.w. HOT
AMMONIA AIR
MOTHER LIQUIR
RECEIVER
CARB.BOOSTER
PUMP
PUMP
NATIONAL FERTILIZERS LIMITED

National Fertilizers Limited is a major Indian producer of

Inorganic and organic fertilizers and industrial chemicals.
Established in 1974. it operates 5 major plants across India.

NFL was established in 1974, as a public-sector

Undertaking of the Government of India. The company
Operates under the administrative controls of the
Department of Fertilizers in the ministry of chemicals and
Fertilizers.
NFL initially operated two plants in Bathinda and Panipat. In 1978, the
ownership and operations of the Nangal plant was transferred to NFL.

In 1988, the company built and commissioned its Vijaipur plant

in Guna district of Madhya Pradesh.
The plant's capacity was doubled to 1.45 million tonnes in 1997.

NFL was granted the Mini-Navratna status with additional autonomy

due to its profitable operations.
In 2001, the company went public, with listings on the Bombay Stock
Exchange and the National Stock Exchange.

NFL, a Schedule A and Mini Ratna Company, is the second largest

producer of Nitrogenous
Fertilizers in the Country with 15.8% share in domestic
production of Urea achieved in the
country during 2009-10.
NFL was incorporated on 23rd August 1974
with two manufacturing Units at Bathinda and
Panipat. Subsequently, on the reorganization
of Fertilizer group of Companies in 1978, the
Nangal Unit of Fertilizer Corporation of India
came under the NFL fold. The Company
expanded its installed capacity in 1988 by
installing and commissioning of its Vijaipur
gas based Plant in Madhya Pradesh.
Manufacturing process of Ammonia

A typical modern ammonia-producing plant first converts natural

gas (i.e., methane) or LPG (liquified petroleum gases such
as propane and butane) or petroleum naphtha into gaseous hydrogen. The
method for producing hydrogen from
Hydrocarbons is referred to as "Steam Reforming". The hydrogen is then
combined with nitrogen to produce ammonia. Starting with a natural
gas feedstock, the processes used in producing the hydrogen are:

•The first step in the process is to remove sulfhur compounds from the
feedstock because sulfur deactivates the catalysts used in subsequent
steps. Sulfhur removal requires catalytic hydrogenation to convert sulfur
compounds in the feedstock to gaseous hydrogen sulfide:
H2 + RSH → RH + H2S(gas)

The gaseous hydrogen sulfide is then absorbed and removed by passing

it through beds of zinc -oxide where it is converted to solid zinc sulfide:
H2S + ZnO → ZnS + H2O

• Catalytic steam reforming of the sulfur-free feedstock is then

used to form hydrogen plus carbon monoxide:
•CH4 + H2O → CO + 3H2

The next step then uses catalytic shift conversion to convert the carbon
monoxide to carbon dioxide and more hydrogen:
CO + H2O → CO2 + H2
•The carbon dioxide is then removed either by absorption in
aqueous ethanolamine solutions or by adsorption in pressure swing
adsorbers (PSA) using proprietary solid adsorption media.

•The final step in producing the hydrogen is to use catalytic methanation

to remove any small residual amounts of carbon monoxide or carbon
dioxide from the hydrogen:
CO + 3H2 → CH4 + H2O
CO2 + 4H2 → CH4 +2H2O
To produce the desired end-product ammonia, the hydrogen is then
catalytically reacted with nitrogen (derived from process air) to form
anhydrous liquid ammonia. This step is known as the ammonia synthesis
loop (also referred to as the Haber-Bosch process):
3H2 + N2 → 2NH3

The steam reforming, shift conversion, carbon dioxide removal and

methanation steps each operate at absolute pressures of about 25 to 35
bar, and the ammonia synthesis loop operates at absolute pressures
ranging from 60 to 180 bar depending upon which proprietary design is
used. There are many engineering and construction companies that offer
proprietary designs for ammonia synthesis plants. Haldor-Topsoe of
Denmark, Uhde GmbH of Germany, Ammonia Casale of Switzerland
and Kellogg Brown & Root of the United States are among the most
experienced companies in that field
The advantages of this process are:
1. Greater compactness, simplicity in case of converter design since
under high pressure gases have smaller volume.
2. Elimination of expensive heat exchanger required in processes
operated at low pressure.
3. Removal of ammonia with water cooling alone.

Against these are the disadvantages:

1. Shorter life of converters.
2. High apparatus upkeep in the high pressure operation.
3. Efficiency loss in approximately 20% of making up gas,
which is unconverted.
TYPE MAKE MODEL
HRU SIEMENS S5-SERIES
SYNTHESIS COMPRESSOR GEFANUC LM-90-70
REFRIGERATION GEFANUC LM-90-70
INTRODUCTION:

The Distributed Control System (DCS) for the expansion plant has been
procured from M/s Yokogawa Blue Star Ltd., Bangalore; the Indian
manufacturer of DCS system in collaboration with YOKOGAWA,
JAPAN. The system is known as Centum-XL (Centum Excellence)

The control and monitoring philosophy for ammonia & urea plants
have been split into two categories I.e closed loops & open loops (
including the alarms ) .All closed loops are being powered monitored
and controlled in the DCS, while the open loops are being powered and
configured in the field MUX system (R-STAHL Germany) and
monitored in DCS
SUB DIVISIONS OF DCS SYSTEM:

1. POWER DISTRIBUTION SYSTEM

2. MASHALLING SYSTEM

3. SIGNAL CONDITIONING + HART MANAGEMENT SYSTEM

4. CONTROLLER SYSTEM

5. DATA HIGHWAY SYSTEM

6. I/O SYSTEM

7. OPERATOR INTERFACE
Power Distribution: The power supply for the DCS system is 115V
AC +/- 10%, 50 Hz +/-3%. The power supply is distributed to
each DCS components from PDC through separate MCBs

Marshalling System (AIC, ARC, FIC etc.): The field cables

carrying the signals from /to the field are directly terminated on
the isolating barriers. The isolators supply +24V DC power to
the field Instruments
L
115 VAC

MCB

BUS BAR

MCB MCB MCB MCB MCB

EFCD EOPS EOPC PRINTER

ENGS
24 VDC
BUS BAR

ISOLATORS RELAYS FANS

SIGNAL CONDITIONING+HART MANAGEMENT:

In the marshalling cabinets the isolators supply 24V DC power to

the field transmitters and receive 4-20mA signals and a FSK
digital signal from the field transmitters. Then this 4-20mA is fed
to the HART card ( TB-16 cards) where this 4-20mA signal is
converted to 1-5 V DC signal Through 250 ohm resistance and
these signals are transmitted to the input card, which is located in
the I/O nest 0f EFCD.

CONTROLLER SYSTEM (EFCD): The control station is known

as EFCD. The control station is housed in a cabinet which
includes :- Different I/O cards, HF bus control card ( FC- 11 ),
Power Supply cards ( PS 33), Station internal Communication
card ( SI -11) , PROCESSOR CARD ( CP 11) , Duplex Control
Card ( DX-11)
 Power Supply for Signal Conditioner: The power supply ( PS-
40)supplies 24vdc power to the signal conditioner nest , relay
boards and fan units. This power supply is installed at the top of the
cabinet in (EFCD) on a dual redundant basis

HF Bus: A communication bus that transmits real time signals directly

taking part in control mainly between control stations and
operator station. This is duplexed (redundant) as standard.
Transmission distance: Standard 1 Km., Max 20 (together with
optical communication system)
No. of stations that can be connected : 32
Data transmission rate: 1 Mbit/sec
 FIELD MULTIPLEXER SYSTEM

The Field Multiplexer System in LINE-II is taken as subsystem of DCS.

It is one of the Foreign system connected to the DCS known as Intrinsic

safe I/O unit.

This system does not have Automation System or Operator Station.

The non critical open loops have been connected to the MUX System.

The Field Multiplexer is of Baliga Sthal , GERMAN make.

This system is designed to record & output process signals in Hazardous
areas.
SYSTEM CAPACITY

One Field Station can have up to 96 channels.

One channel can handle up to one analog I/O or 12 binary I/Os.

One Master Station can have max. up to 10 field stations. While one field
station can have max. upto 96 analog tags and 1024 digital tags.
One Master Station can have interfacing with max. up to 3 nos. Of
EFCD.

So a fully loaded Field Bus System can handle a max. of 960 analog I/Os
, 11,520 binary I/Os or mixture of both.
Characteristics features of CENTUM-XL:

Redundancy and Huge Data Bank.

Flexibility to be configured with other systems.

Operator interface makes process visible to the operators.

No need of separate alarms systems and trend recorders.

Online maintenance of the system is possible.

Maintenance of field instruments easy due to cal mode facility.

 LONG
MUX ENGS TREND PC
PC PC EOPS EOPC
ALARM LOG REPORT EOPS EOPC EOPS EOPS EOPC
… … PRINTER PRINTER PRINTER …
ETHERNET

DUAL REDUNDANT HF BUS

EFCD EFCD EFCD

AIC AIC ARC FIC GPMC PDC
1 2 3 1 2
MASTER
CONTROL
STATION

DUAL REDUNDANT FIELD BUS

Layout of
M M M M M M M M M M
DCS
U U U U U U U U U U system
X X X X X X X X X X Urea-II
01 02 03 04 05 06 07 08 09 10
THANK YOU