Industrial Tour: Indo-Gulf Fertilizers Jagdishpur
Industrial Tour: Indo-Gulf Fertilizers Jagdishpur
Industrial Tour: Indo-Gulf Fertilizers Jagdishpur
Industrial Tour
To
Indo-Gulf Fertilizers
Jagdishpur
Submitted to
Submitted by
S R No. 503/08
Salient Features
Indo Gulf Fertilisers is an Indian company which unit of Aditya Birla Nuvo Ltd
based in Mumbai. and is part of the Aditya Birla Group of companies. It is among
the largest private sector fertilizer companies in India.
The company is located at Jagdishpur, near Lucknow in Uttar Pradesh. Indo Gulf is
ISO 27001:2005, ISO 9002, ISO 9001:2000, OHSAS 18001:1999, ISO 14001:2004
Certified.
1. General Profile:
2. Corporate Office:
MD Shri B.N.Puranmalka
Address 106, Free Press House, 10th Floor, Free Press Journal Marg, Nariman
Point, Mumbai-400021
PABX 2846375 to 81
STD 022
Code
Telex -
E-mail igfcc.mum@sme.sprintrpg.ems.vsnl.net.in
3. Plant: Jagdishpur
Fax 05361-70165
E-mail igfcc.jia@sme.sprintrpg.ems.vsnl.net.in
4. Production Performance:
5. Sales Performance:
(Qty. in Thousand MT)
6. Financial Performance:
(Rs. Crores)
Industries in Jagdishpur
Jagdishpur is an industrial area. The three major factories operating here are:
Demographics
As of 2001 India census, Jagdishpur had a population of 31,029. Males constitute
52% of the population and females 48%. Jagdishpur has an average literacy rate
of 50%, lower than the national average of 59.5%: male literacy is 60%, and
female literacy is 40%. In Jagdishpur, 18% of the population is under 6 years of
age
PROCESS DESCRIPTION of Urea Manufacturing by
Snamprogetti Process
The urea production process takes place through the following main
operation----
The mole ratio of ammonia to CO2 is around 3.6:1. The mole ratio of water
to CO2 is around 0.67:1. The liquid ammonia, coming from ammonia storage, at a
temperature of around -10C is preheated in the ammonia preheater E-10 and
then received in ammonia receiver V-1 and hot liquid ammonia at 35C from
ammonia plant is received directly in ammonia receiver V-1.
From V-1 ammonia is drawn and pumped by mean of centrifugal pump P-5
(operating at 23 ATA discharged pressure), partially to medium pressure absorber
C-1 and the remaining volume is directed to the high pressure synthesis loop.
The ammonia to the synthesis loop is first taken to low speed, heavy duty
reciprocating pumps P-1 A/B/C. These pumps discharge ammonia to a pressure of
about 240 atm. Before entering the reactor, the ammonia at this high pressure is
used as a driving fluid in the carbamate ejector EJ-1, where the carbamate coming
from the carbamate separator MV-1 is taken to the synthesis pressure. The liquid
mixture of NH3 and carbamate enters the reactor where it reacts with
compressed CO2.
The CO2 drawn at urea plant battery limit at about 1.1 atm pressure and
about 45C temperature enters the centrifugal compressors K-1 and leaves it at a
final discharge pressure of about 155 atm.
A small quantity air is added to the CO2 at the compressor suction in order
to passivate the stainless steel surfaces, thus protecting them from corrosion due
to both the reactant and reaction product.
The reaction product leaving the reactor flow to the steam heated falling
film stripper E-1, which operates at essentially the same pressure as the reactor.
The mixture is heated (by medium pressure steam on shell side) as it flows down
the falling film exchanger. The CO2 content of the solution is reduced by the
stripping action of the ammonia as boiled out of the solution.
The medium pressure decomposer has been divided into two parts …….
1. Top Separator (MV-2): where the released flash gases are removed before
the solution enters the tube bundle.
2. Decomposition section (E-2, falling film type): where the residual
carbamate is decomposed and the heat required for decomposition is
supplied by mean of 26 ata steam condensate flowing out from the shell
side of the stripper.
The NH3 and CO2 reach gases leaving the top separator (MV-2) are sent to
medium pressure condenser E-7, where they are partially absorbed in aqueous
carbamate solution coming from the low pressure recovery section. The
absorption heat is removed by tempered cooling water circulation is the tube
side of medium pressure condenser E-7.
Tempered water circulation is provided to prevent carbamate solidification
maintaining proper cooling water temperature inlet to the tube side of the
medium pressure condenser. The cooling water temperature inlet to
condenser is maintained by mean of in-line pump P-19.
In the MP condenser the CO2 is almost totally absorbed. The effluent from
E-7 flows to the MP absorber C-1. The gaseous phases (entering C-1 along with
liquid effluents from E-7) enter the rectification section of MP absorber C-1.
The rectification section has bubble cap trays and effect CO2 absorption and
NH3 rectification.
The bubble cap trays are fed by pure reflux ammonia at the top trays which
eliminates residual CO2 and H2O from gases leaving MP absorber from the
top. Reflux NH3 is drawn from the NH3 receiver and pumped to the
rectification column by mean of centrifugal pump P-5.
Inert gases (H2, N2, O2) saturated with ammonia and having max. of 100
ppm CO2, leave the top of the rectification section of MP absorber. The
bottom solution is recycled by the pump P-2A/B to synthesis recovery section.
NH3 with inert gases leaving the MP absorber top is partially condensed the
ammonia condenser E-9. Both uncondensed gases phase and condensed liquid
ammonia are sending to ammonia receiver V-1.
The inert gases, saturated with ammonia living the receiver V-1 enter
ammonia preheater E-10 where an additional amount of vapor ammonia is
condensed by heating cold ammonia (at around -10C) coming from ammonia
storage area and used as makeup feed to urea plant in addition to hot
ammonia taken directly from ammonia plant. The condensed ammonia from
E-10 is received in the receiver V-1 and so is the ammonia make um feed.
The inert gases with residual ammonia content are sent to medium
pressure ammonia absorber E-11, which is a falling film type and where they
meet counter-current condensate flows which absorb gaseous ammonia. The
absorbing heat is removed by cooling water flow on the shell side of E-11.
From the bottom of E-11 the water ammonia solution is pumped to the MP
absorber C-1 (at second bubble cap tray from the top) by mean of centrifugal
pump P-7A/B.
The inert leaving the top of E-11/C-3 are practically free from Ammonia.
- Top separator (MV-3), where the released flash gases are removed before
the solution enters the lower tube bundle.
- Decomposition section E-3 (falling film type), where the residual carbamate
is decomposed. The required heat for decomposition is supplied by mean
of saturated seam at 4.5 ata.
The gases leaving the top separator (MV-3) are sent to the low pressure
condenser E-8 where they are absorbed in an aqueous carbonate solution
coming from the waste water recovery section. The absorption and
condensation heat from LP condenser E-8 is removed by cooling water. From
the LP condenser E-8 the liquid phase , with remaining inert gases, is sent to
the carbonate solution tank V-3. From there the carbonate solution is recycled
back to the medium pressure condenser E-7 by mean of centrifugal pump P-
3A/B. the inert gases from V-3 which essentially contain ammonia vapor and
some inert flow directly into the low pressure falling film absorber E-12, where
the ammonia is absorbed by a counter current water flow. The absorption
heat is removed by cooling water flow on shell side of E-12. The top portion of
E-12 has three valve trays and is designated as C-4. Pure condensate is
introduced into the top tray which flow down through other trays of C-4 and
then E-12 to recover ammonia. Vent gases leaving C-4 are only inert and are
free from ammonia.
The solution leaving the LP decomposer E-3 bottom having about 72% by
wt. of urea is sent to the first vacuum concentrator E-14, operating at a pressure
0.3 ata. The liquid/vapor phase coming out from E-14 enters the gas liquid
separator MV-6, where from the vapors, are extracted by the first vacuum system
ME-4 while the solution enters the second vacuum concentrator E-15, operating
at a pressure of 0.03 ata.
The two concentrator E-14 and E-15 use saturated steam at 4.5 ata. The
liquid vapor phase coming out from E-15 enters gas-liquid separator MV-7 where
the vapors are extracted by the second vacuum system ME-5.
Non condensed gases are drawn by the ejector EJ-5 (motive fluid being 4.5
ata steam) and discharged to the shell side of second inter condenser E-29 where
the latent heat of condensation is again removed by cooling water. Liquid flow to
V-5 and non condensed gases are sucked by ejector EJ-6 and discharged to the
after condenser E-27 where non condensable from first vacuum system also join.
d. Urea Prilling
The melted urea leaving the second vacuum separator is pumped to the
prilling bucket ME-8A/B by mean of centrifugal pump P-8A/B.
The molten urea coming out from the prilling bucket in the form of drops
falls along the prilling tower ME-6 and encounters a cold air flow which causes its
solidification and subsequent cooling.
The solid prills falling to the bottom of the prilling tower are sent to the belt
conveyer MT-1 by the rotator scraper ME_12. From here urea prills are passed
through screen ME-10 which retains lumps only. Product prills are conveyed by
belt conveyer MT-3 to the bulk urea storage or bagging plant.
The distillation column is operates at the pressure of 2.5 kg/cm3. The distillation
column (C-2) is consists of 45 sieve trays. The feed means waste water is
introduced at the tray numbers 37, 39 and 41 counting first from the bottom.
Before introducing in the column the feed waste water is get preheated in the
tube side of a shell and tube heat exchanger by the effluent of the reboiler. In the
distillation column ammonia and CO2 in the feed are stripped by mean of vapor
product produced in the reboiler, which is supplied by 4.5kg/cm 2 saturated steam.
The liquid steam from the holder above 20 th tray is taken out to hydrolyser urea in
hydrolyser by means of steam. The vapor from the hydrolyser enters at the 37 th
trays and liquid is recycled back to the distillation column at 20th trays.
The vapor leaving the top of the distillation column are condensed in an
overhead condenser. The condensate (the carbamate solution) is received in the
reflux accumulator. By means of centrifugal pump a part of solution is recycled
back to the top of the distillation column as reflux, while the remaining part is
supplied to LP carbamate condenser.