Material expert mr prem baboo

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material Expert mr. Prem Baboo

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Operation of the plant is mainly supervised by the operators in the control room, who monitor the various instruments and adjust operating conditions in order to obtain satisfactory operation. They should also react when an alarm is activated. In some cases they can re-establish normal conditions by adjusting the controls in the control room; in other cases they give instructions to a field operator to make the necessary adjustments at various locations in the plant. Field operators work in regular shifts in the plant, especially in the reforming section, in order to supervise the firing of the reformer and the temperature of the tubes in the reformer, to record local instrument readings, and to notice any irregularities such as leaks. Every change of temperature of the reformer a little change can bring big change resulting energy losses, e.g. temperature of the primary reformer and CO slip losses in methanation etc.

Some fact about Ammonia Production by Prem Baboo.pdf

PremBaboo4

The present paper description of Ammonia Plant, Production of Green Hydrogen, Different types of revamp option of Ammonia & urea plant different types of ammonia process, calculation. This paper is very useful for Engineering students, new comers in fertilizers Industries .Practical data detail of vessel, Electric heating primary reformer and what is the difference of Gas fired primary reformer and Electric heating, calculation, efficiency etc.

General Knowledge on Ammonia Production By Prem Baboo.pdf

PremBaboo4

The centrifugal Compressor is designed for gas and vapour if the separation efficiency goes down then the water carryover in next stage and this is very dangerous for compressor internals because the gas & vapours are compressible fluid while the liquid is incompressible fluids. As a result a rapid and exponential rise in hydraulic pressure will be occurred and also Vibration. So, overall, vanes and impellers are the main victims of liquid droplets in a centrifugal compressor, or any compressor. Two phase flow in a compressor always damage its internal and it may damage the casing and deposition takes place on internals

How to Calculate Separation Efficiency of compressor separators By Prem Babo...

PremBaboo4

78-80 % energy of Urea process depends upon ammonia process and rest on power & steam. If the energy of ammonia plants is improved then the urea plant energy automatically improves. The specific consumption of urea stoichiometrically is 0.566 but due to losses it generally found 0.569-0.574 depends upon loses of urea/ammonia in the process etc. steam consumption if you are using 40 ata steam turbine then you will have to change into 100 ata steam turbine. The energy will be improved about 0.097 G.Cal/ton of urea. In this quiz how to improve energy in urea plants. Indian urea manufacturers are on a par with the best of the world in terms of low energy consumption and greenhouse gas (GHG) emissions, Besides becoming a global concern for pollution of groundwater and surface water bodies, the production and use of urea has also significantly contributed to GHG emissions. “Energy conserved is energy produced “Energy conserved is energy produced “

Question Answer on Energy Conservation Vol 2 by Prem Baboo.pdf

PremBaboo4

G.Cal/ton of Ammonia, G.Cal/ton of urea is the most important data in fertilizers industries for performance evaluation. The energy of the fertilizers is depends upon Reformer feed & fuel. Earlier thinking Fertilizers should be produced at any cost we have nothing to do with energy & pollution and what environment we don’t know? But today time has changed. We have to meet the energy & environment conditions otherwise penalty will be imposed and your factory will be closed. In this quiz we will discuss about energy. How to reduced energy and how to reduced pollution how to save environment? Etc. Hydrogen and could be a boon for renewable energy demand. But greening ammonia, the chemical primarily used to make fertilizer, will take a lot of heavy lifting. Green ammonia is two to three times more expensive than gray ammonia. Depends upon power source means where we are getting power from, i.e. Hydro power or non renewable source.

Question Answer on Energy Conservation Vol 1 By Prem Baboo.pdf

PremBaboo4

Dear friends today we will discuss on urea product quality. What are the factors on which urea product quality depends? How to improve urea product quality. Urea produced by prilling and granulation rout. In India Prilling is very popular and other countries Granulation rout is adopted. There are some merits and demerits are prilling and granulation routs. Different types of question with their answers

Discussion on Urea Product Quality by Prem Baboo.pdf

PremBaboo4

After the success of Vol-1, now here is Vol-2, Vol-1 is very much liked by people. There was a time when people did not share their knowledge in public and his knowledge used to be buried with him but he did not tell anything throughout his life. But I want to share my rich experience with people before dying. The practical knowledge is an important part of life, which is not found in books, this volume contains unprecedented experience of my chemical & fertilizers industries experience. This volume contains Urea HP/MP/LP/Vacuum and waste water questions & answer with trouble shooting.

Question & Answer on Fertilizers Industries Vol 2.pdf

PremBaboo4

Fire network & Fire prevention device with fire station is essential for all industries. The fire Industries have very dangerous substances and gases that can catch fire at any time. Most of the accidents/injuries are caused by human errors. Industry says, human error accounts for 96% of accidents. The rest takes place due to external conditions and failure factory equipment. In which fertilizers industries account for most of such fatal accidents. Safety is a condition or state of being resulting from the modification of human behavior, and/or designing of the physical environment to reduce the possibility of hazards, thereby reducing accidents. Safety is an ever changing condition in which one attempts to minimize the risk of injury, illness or property damage from the hazards to which one may be exposed. Perfect fire network is must for fertilizers Industries. Life is god's special gift to mankind. It is therefore important to treasure & protect it from all kinds of potential threats. Regardless of the precautions that we take in our day-to-day life, fire accidents are seldom averted. Risky jobs with a potential to put your life at risk can be a cause for concern especially to your family & friends. Moreover,constant exposure to dangerous surroundings increases the chances of enduring major/minor injuries with a likelihood of developing a permanent handicap.

Fire Safety Network for Fertilizers Industries.pdf

PremBaboo4

There are numbers of Fertilizers are used for improve productivity of grain, N; P &K are important fertilizers among them. Commercially Urea is more produced because the Nitrogen percentage is higher than all fertilizers. These three NPK are primary nutrient. There are some question arises about these industries, present paper intended to attempt the answer those questions. These question are very useful in interview point of view and also for new comers joining in Fertilizers Industries.

Question Answer on Fertilizers Industries.pdf

PremBaboo4

In Urea Process corrosion/Erosion also observed in LP and vacuum section. The paper indeed how to tackle this type of problem? Root cause of corrosion in LP & vacuum section. Construction of material used in these sections. Operation of LP section with trouble shooting How to balance water in the process, Distillation Tower Versus LP carbonate solution tank with operation of LP decomposer. Water balance in whole plant prilling rout as well as granulation rout. How a small variation of Pressure & temperature makes a drastic change in the process including waste water section? How Distillation tower feed related to LP decomposer pressure & temperature? The detail described in this article. The intensity of corrosion is greatest in the reaction section and the first recycle, where pressures, temperatures and concentrations are higher than downstream. The reactor liner, pumps, decomposers, strippers and condensers are more vulnerable to attack by ammonium carbamate. But the corrosion is also important in LP and vacuum sections. The typical corrosion is observed in 2nd stage of vacuum in some plants of urea.

OPERATION AND TROUBLE SHOOTING IN LP AND VACUUM SECTION FOR MS SAIPEM PROCESS...

PremBaboo4

OPERATION AND TROUBLE SHOOTING IN LP AND VACUUM SECTION FOR MS SAIPEM PROCESS...

PremBaboo4

In Fertilizers industries the material plays a very important role. Right material can save energy as well as plant life and wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In urea plant very corrosive chemicals are used for urea production. The raw material of urea plant is Ammonia and Carbon Dioxide gas which makes very corrosive chemical ammonium Carbamate. For reduced corrosion passivation air is used in reactor as well as stripper according to material of selection different quaintly of air is used. Controlled and less quantity of passivation air is required for Titanium and Zirconium material and hence saving of energy because the huge amount of ammonia is waste with venting of inerts, i.e. saving of energy and environments also. Passivation oxygen given in CO2 is directly proportional to ammonia losses in MP section. This paper intended how to increase life of urea reactor liner and energy saving with low passivation air and high N/C ratio, Ammonia is the noncorrosive and ammonia to CO2 Ratio is an important parameter for process optimization occurring less losses and less explosion probability in urea reactor because it affects the amount of produced urea and corrosion to the material in the reactor. Generally we are using urea reactor liner 316L (urea grade), now adopted 2RE69 for large capacity plant (world largest) and Duplex stainless steel.

The Role of Material in Fertilizers IndustrieswithEnergy saving.pdf

PremBaboo4

Risk Management is the Identification, Analysis and Economic Control of those Risks which can Threaten the Assets (Property, Human) or the Earning Capacity of an Enterprise” Risk management is the process of identifying, assessing and controlling threats to an organization's capital and earnings. These risks stem from a variety of sources including financial uncertainties, legal liabilities, technology issues, strategic management errors, accidents and natural disasters. The article intended The Fertilizer Plant pose fire, explosion and toxic hazards due to unwanted and accidental release of natural gas as well as process gas containing CO, H2, Methane and toxic gases like Ammonia and Chlorine. The effect zones of the fire and explosion hazard are generally restricted within the plant boundary limits and near the source of generation itself. However, effect of accidental release of Ammonia and other toxic gases may go outside the factory premises. This section deals with the failure modes, listing of failure cases leading to different hazard scenarios, consequence modeling and the risk evaluation. Consequence analysis is basically a quantitative study of the hazard due to various failure scenarios to determine the possible magnitude of damage effects and to determine the distances up to which the damage may be affected using internationally accepted mathematical models.

RISK MANAGEMENT IN AMMONIA UREA PLANTS.pdf

PremBaboo4

Prills /granular urea are not only costly for the producer but may be harmful to humans and the environment. Furthermore, nano Urea may also be used for enhancing abiotic stress tolerance. Nano-Urea prevents environmental pollution and improves physiological traits of wheat grown under drought stress conditions. The nano urea consist of higher surface area because lesser in size of the nano particle and have high reactivity, solubility in water. Nano Urea are the important tools in agriculture to improve crop efficiency, yield and quality parameters with increase nutrient use efficiency, reduce wastage of fertilizers and cost of cultivation. Nano-urea is very effective for precise nutrient management in precision agriculture with matching the crop growth stage for nutrient and may provide nutrient throughout the crop growth period. Nano-Urea increase crop growth up to optimum concentrations further increase in concentration may inhibit the crop growth due to the toxicity of nutrient. Nano-Urea provide more surface area for different metabolic reactions in the plant which increase rate of photosynthesis and produce more dry matter and yield of the crop. It is also prevent plant from different biotic and abiotic stress.

Nano Urea the Philosophy of Future.pdf

PremBaboo4

Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission control system in prilling tower is a considerable burden. It not only presents a substantial investment but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of strong demand for environment friendliness and effective use of power it is then an issue of utmost importance to pick the legally emission control solution, the one that can guarantee, if not a full return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea dust and ammonia, wet processes are generally applied. The available technologies vary with regard to the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is directly proportional to temperature. Dust emission can control by internal and external process. In India generally followed internal routs. The pollution control Board sample should be ok just thinking so. Either reduction of plant load or bypassing the recovery system at the time of sampling or manipulating data. It is the bitter truth. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.

HOW TO CONTROL PRILLING TOWER DUST EMISSION.pdf

PremBaboo4

In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H2 is demineralized water and the hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The present article intended the description of ammonia plant for natural gas based plants and the possible material balance of some section

AMMONIA PLANT MATERIAL BALANCE.pdf

PremBaboo4

In M/S. Saipem process the HP loop operation is very typical including HP stripper and Reactor N/C ratio, H/C ratio and conversion of the reactor. The MP loop also very typical in operation point of view in which the level of Medium pressure absorber is fluctuating frequently when plant starts up /shut down or any process disturbances/upset. This article intended how to tackle theses type of problem and the MP absorber level and why the level is so important? Why density variation in startup/shut down or any upset of the process by any reason. Why the level transmitter of MP absorber is showing erratic level? How to prevent CO2 Carryover to ammonia receiver through ammonia condenser. Can we replace the DP type transmitter with radar type in stripper as well as MP absorber?

OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdf

PremBaboo4

OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdf

PremBaboo4

In Ammonia plant numbers unwanted products are formed such as CO2 & methanol, Methanol is the by-product and it is very dangerous for environment and cations and anion resin also, which is used treated waste water through urea plant. Methanol is also dangerous for Ozone layers.CO2 is also by-product in ammonia process but it is used for production of urea. The paper intended how it is generate in ammonia plant as a by-product.how to control and minimized. How does this damage the environment? It is desirable to minimize methanol by-product formention for several reasons: Methanol emissions are being regulated to protect the environment. Several ammonia plants are already facing regulations that limit methanol emissions to the atmosphere. These regulations affect plants that vent the CO2 stream as well as plants that are not designed to recover methanol from the various vents. The methanol recovers from CO2 compressor separators are using in anaerobic water treatment plant as bacteria feed.

BY-PRODUCT AND CONTROL IN AMMONIA PROCESS.pdf

PremBaboo4

How to control prilling tower dust emission

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