The document provides details about a mid-term training evaluation at the National Fertilizers Limited plant in Nangal, Punjab, India. It describes the urea production process used at the plant, including key stages like ammonia production, CO2 compression, urea synthesis, and prilling. It discusses the plant's installed capacity, consumption rates, equipment specifications, and some disadvantages of urea fertilizer. The trainee concludes that India depends on international licensors for urea technology and more local R&D is needed.
The document provides details about a mid-term training evaluation at the National Fertilizers Limited plant in Nangal, Punjab, India. It describes the urea production process used at the plant, including key stages like ammonia production, CO2 compression, urea synthesis, and prilling. It discusses the plant's installed capacity, consumption rates, equipment specifications, and some disadvantages of urea fertilizer. The trainee concludes that India depends on international licensors for urea technology and more local R&D is needed.
The document provides details about a mid-term training evaluation at the National Fertilizers Limited plant in Nangal, Punjab, India. It describes the urea production process used at the plant, including key stages like ammonia production, CO2 compression, urea synthesis, and prilling. It discusses the plant's installed capacity, consumption rates, equipment specifications, and some disadvantages of urea fertilizer. The trainee concludes that India depends on international licensors for urea technology and more local R&D is needed.
The document provides details about a mid-term training evaluation at the National Fertilizers Limited plant in Nangal, Punjab, India. It describes the urea production process used at the plant, including key stages like ammonia production, CO2 compression, urea synthesis, and prilling. It discusses the plant's installed capacity, consumption rates, equipment specifications, and some disadvantages of urea fertilizer. The trainee concludes that India depends on international licensors for urea technology and more local R&D is needed.
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MID-TERM TRAINING
EVALUATION.
Mechanical Engineering Department, Submitted by,
Chitkara University, Vishal Sharma Punjab, India 1510992416 ME – 8Z Place of training
National Fertilizers Limited, Nangal
FEATURES OF NANGAL UNIT
Installed Capacity: 478500 MTPA
Capital Investment: 229.19 Crores Commencement of Production: November 1, 1978 Commercial production after revamping started on Feb 1st,2001. NFL Nangal plant
NFL Nangal plant can be divided into 4 parts-
1.Steam Generation Plant
2.Ammonia Production Plant 3.Urea synthesis Plant 4.Nitric Acid Generation Plant Glimpse of nangal unit View from Prilling tower UREA PROCESS BRIEF DESCRIPTION : It is a Montedison total recycle process. Before revamping its capacity was 1000 T/day But today its capacity is 1650 TPD Ammonia: KBR SMR(Steam Methane Reforming) with Purifier Technology Urea: Technimont Total Recycle Process Raw material: Coal , LNG/ RLNG, Power, Water UREA PRODUCTION
Carbon dioxide 0.745 Te/Te of urea Steam 30ata 1.23 Te/Te of urea Power 135 kwh CO2 Compressor
There are two motor driven reciprocating compressors
Old Compressor No. of Stages 3 Capacity 17510 Nm3/hr. Suction/Discharge press 11/220 Kg RPM 300 Motor Power 2250KW Oxygen content maintained 2200ppm NEW COMPRESSOR: No. of Stages 4 Capacity 9500 Nm3/hr. Suction/Discharge press 1.5/220 Kg RPM 350 Motor Power 2400KW Oxygen content 3500ppm Reactions The principal raw materials required for this purpose are NH3 & CO2 .Two reactions are involved in the manufacture of urea. First, ammonium carbamate is formed under pressure by reaction between CO2 & NH3. CO2 + 2NH3 <-→ NH2COONH4 ΔH= -37.4 Kcal This highly exothermic reaction is followed by an endothermic decomposition of the ammonium carbamate. NH2COONH4 ↔ NH2CONH2 + H2O ΔH= + 6.3 Kcal Urea Separation 1st stage Pressure 70 Kg/cm2 Temperature 185 C Urea conc. 54.5% 2nd stage Pressure 12 Kg/cm2 Temperature 150 C Urea conc. 65% 3rd stage Pressure 3 Kg/cm2 Temperature 130 C Urea conc. 72% Vacuum Section
1st stage vacuum system
Pressure 0.75 ata Temperature 128 C Urea conc. 95% 2nd stage vacuum system Pressure 0.35 ata Temperature 138 C Urea conc. 99.6% New Reactor
Fresh ammonia & carbon dioxide are fed to mixer, then
to carbamate condenser, where ammonium carbamate is formed. Heat of reaction is taken out in the form of 6.0 ata steam generation. The hot carbamate flows to reactor R-2 where residence time is enough to get 69% conversion . It is once through reactor, no carbamate solution is fed to it. Priling tower
A prill is a small aggregate or globule
of a material, most often a dry sphere, formed from a melted liquid. Prilled is a term used in mining and manufacturing to refer to a product that has been pelletized. The pellets are a neater, simpler form for handling, with reduced dust. Prilling section Tower Height 104.5mtr Free fall ht. 80mtr Diameter 22mtr Air flow 8,00,000 nm3/hr Urea in emission 40mg/nm3. Scrapper typeconical Bucket Make Tuttle/Simco Number TX-267, 268 & 130 Specification of Urea being produced at Nangal Total Nitrogen 46.5% Moisture 0.5% Biuret 0.8-0.9% Mean prill dia 1.75mm Sieve analysis Over size nil Proper size 98.5% Under size 1.5% Plant Start up Reactor is filled with dilute solution. In case of empty reactor, it is to be filled with start up solution. In case of cold start up, reactor solution is first heated up to 125 OC . First stage{70ata} remain by passed. Plant is started in once through operation. Once through operation means the solution is send to urea solution tank and Carbamate is send to start up solution tank from 2ndstage. Ammonia feed to reactor and pressure is maintained at 150ata for 5 minutes and then CO2 is send to reactor. Plant Start up Reactor pressure will increase according to the temperature and feed ratio. As the temperature and pressure reaches to the desired condition then the Carbamate from 2ndstage is diverted to the 1ststage. As the level of 1ststage condenser increases, start the Carbamate pump and feed Carbamate to the reactor.{known as total } After total recycle, temperature and pressure of each stage are maintained. The urea solution is sent to vacuum section. After normalizing vacuum section, melt urea diverted towards bucket. Cooling tower
A cooling tower is heat removal
device that uses water to transfer process waste heat into the atmosphere. All cooling towers operate on the principle of removing heat from water be evaporating a small portion of water that is recirculated through the unit. forced draught cooling tower contains horizontal shaft for the fan and it is placed at bottom of the tower and induced draught cooling tower contains vertical shaft and it is placed at top of the cooling tower Disadvantages
When applied to a bare soil surface, urea hydrolyzes
rapidly result into loss of significant quantity of ammonia by volatilization. Such losses vary from soil to soil and are greater for urea in a pellet form rather than in solution form. It is phytotoxic due to rapid hydrolysis of urea in soils can cause injury to the seedlings by ammonia, The fertilizer grade urea may contain toxic biuret which is formed during urea manufacture by an excessive temperature rise. Above 2% concentration of biuret in urea is harmful to plant Conclusion
For the development and upgradation of urea
technology. Indian industry depends on the already established international process licensors and design and companies. There is hardly any R & D effort towards development of process technologies for urea except for development of modified total recycle process by PDIL which has been utilised in Namrup-III plant. R&D unit should be set up to deal with the development of fertilizer technologies.
