PRESENTATION ON IFFCO
(INDIAN FARMERS FERTILIZER CO-OPERATIVE LTD.)
SAURABH SINGH CHAUHAN
TRAINING DIRECTOR 11204730
The fertilizer in India consists of three major players:
The Government owned Public Sector undertakings
Cooperative Societies like IFFCO
units from Private sector.
The fertilizer industry has organized itself through Fertilizer Association India (FAI)
to coordinate with the Government of India to achieve the macro-economic
objectives related to agricultural sector and to provide other services.
IFFCO, is the world's largest fertiliser cooperative federation based in
India which is registered as a Multistate Cooperative Society. On 3
November 1967 IFFCO was registered as a Multi-unit Co-operative
Five units of IFFCO are:-
Aonla unit of IFFCO is one of the five natural gas based fertilizer
plants to be setup in the country on HBJ( HAZIRA-BIZAPUR-
JAGDISHPUR) pipeline which runs through states.
Two production units Urea-I and Urea-II and each of these two units
has two sub units.
Storage of NEPTHA as a alternate fuel.
UREA MANUFACTURING PLANT
STEAM AND POWER GENERATION PLANT
STEAM GENERATION PLANT
All the major rotating equipments of ammonia and urea plant are
driven by electric motors ,so steam and power generators are
Two gas turbine generators.
Capacity of 18 MW each.
Involves three main sections ; Compressor , Combustion system ,
To support the production plant
Without it ,there is no existence of production plant.
Offsite plants are LIKE :-
RAW WATER SYSTEM
WATER TREATEMENT PLANT
AMMONIA STORAGE PLANT
RAW WATER STORAGE
CHARACTERSTICS OF STORAGE TANK:-
Total storage capacity= 32760 cubic meter
one raw water storage tank=33696 cubic meter
volume of storage tank= 78m * 108m *45m
Underground water contains little impurities and high concentration
of dissolved salts.
To get rid of these impurities (chlorides, sulphates , carbonates,
bicarbonates) DM plant is used.
The water that could be used in plant should have following
ph = 6.8 to 7.3
silica <0.02 ppm
total electrolytes =0.1 ppm
Hardness = nil
Most important unit of any chemical plant
Cold fluid is water and the plant to cool the water is called the
A type of heat exchanger
In IFFCO ,
Heat absorbing fluid is AIR and heat releasing fluid is water.
INSTRUMENT AIR PLANT
Atmospheric air can’t be used directly to open and close valves
Air used in plants is moisture and impurities free and is known as
INERT GAS PLANT
Inert gas (N2) is generated, which is used for purging and for Production of
Ammonia in Ammonia Plant.
In case of any problem in the Ammonia Plant, Ammonia could be
supplied from these tanks.
Ammonia is stored at a gage pressure of 400 mm water at a
temperature of -33 °C in liquid form. Gaseous Ammonia is
continuously returned back to Ammonia Plant.
To get the Ammonia manufactured, the following steps should be
High Pressure Catalytic Reforming
Water Gas shift reaction
Carbon Dioxide absorption and stripping
The effluent from the ammonia converter is cooled successively with
incoming feed gas, cooling water, and refrigerated ammonia liquid.
At IFFCO refrigeration circuit is three level chiller (chiller cools but
don’t change state while condenser changes state as well):
High Level Chiller
Medium Level Chiller
Low Level Chiller
Urea is manufactured by direct synthesis of gaseous CO2 and liquid
NH3. The process consists of following operations:
High Pressure Recovery
Medium Pressure Recovery
Low pressure Recovery
Waste Water Treatment