Unit4 dr mansisingh

Noida Institute of Engineering and Technology, Greater
Noida
RETROFITS, COMPUTER CONTROL AND
ENERGY EFFICIENCY OF FERTILIZER
INDUSTRY
Dr. Mansi Singh
Noida Institute of Engineering
and Technology, Greater Noida
Department of Chemical
Engineering
6/6/2021
1
Unit: 4
Fertilizer Technology
B Tech 8th Semester
Dr. Mansi Singh RCH081 FT Unit 4

• Course Objective
• Course Outcome
• CO-PO and PSO Mapping
• Topic-wise Objective and Outcomes
• Prerequisite and Recap
• Retrofits and modernization
• Computer control and Instrumentation
• Energy conservation and diversification.
• Faculty Video Links, Youtube &
NPTEL Video Links and Online Courses
Details
• Daily Quiz
• Weekly Assignment
• MCQ s
• Old Question Papers
6/6/2021 2
CONTENT
• Expected Questions for University
Exam
• Topic Objective
• References

The objectives of this course are to:
4.1Introduce students to the different types of nutrients that plants need to
grow up.
4.2Introduce students to the use of fertilizers to improve soil productivity and
crop yield.
4.3Introduce students to different organic and inorganic fertilizer production
methods. .
4.4Introduce students to the classification of fertilizers: solid, liquid, and
suspension fertilizers.
4.5Introduce students to the different types of the nitrogenous, phosphatic and
potash fertilizers.
4.6Expose students to numerical exercises in the compounding of fertilizers.
4.7Expose students to a practical exercises to produce NPK fertilizers
6/6/2021
3
COURSE OBJECTIVE (UNIT-4)

Once the student has successfully completed this course, he/she will be able to:
CO4.1. Use reactions and unit operations steps in manufacturing of various
fertilizers
CO4.2. Characterize fertilizers on the basis of different properties.
CO4.3. Identify engineering problems in fertilizer manufacturing.
CO4.4. Handle the fertilizers.
CO4.5. Select appropriate synthesis fertilizer.
6/6/2021 Dr. Mansi Singh RCH081 FT Unit 4 4
COURSE OUTCOMES (UNIT-4)

CO-PO AND PSO MAPPING (UNIT-4)
Course
outcome
Program Outcomes (POs) PSOs
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
4.1 3 3 3 2 3 2 2 1 1 1 1 1 3 3 2
4.2 3 3 3 2 3 2 2 1 1 1 1 1 3 3 3
4.3 3 3 3 2 3 2 2 1 1 1 1 1 3 2 1
4.4 3 3 3 2 3 2 2 1 1 1 1 1 3 3 2
4.5 3 3 3 2 3 1 1 1 1 1 1 1 3 2 3
Average
3- Highly related; 2- Moderately related; 1-Slightly related

TOPIC OBJECTIVE
At the end of this presentation student should have learned that
•How Retrofits and modernization of existing fertilizer industry can be done?
• Computer control and Instrumentation, is very important aspect?
•What are the different methods of Energy conservation and diversification?

6/6/2021 Dr. Mansi Singh RCH081 FT Unit4 7
TOPIC-WISE OBJECTIVE AND OUTCOMES (UNIT-4)
UNIT TOPIC OBJECTIVE OUTCOMES
4
4.1Retrofit
s and
modernizat
ion
To impart knowledge on
different methods of
modernization
Student will able to identify
various modification
methods as per particular
fertilizer unit
4.2Comput
er control
and
Instrument
ation
controlling various
process parameters by
computerization and
instrumentation
Student will able to .
Characterize computer
control and instrumentation
according to different
processes
4.3Energy
conservati
on and
diversificat
ion
different methods energy
conservation depending
on the process
Student will able to identify
various energy conservation
measures

6/6/2021 Dr. Mansi Singh RCH081 FT Unit4 8
PREREQUISITE AND RECAP
UNIT TOPIC PREREQUISITE RECAP
4
4.1Retrofit
s and
modernizat
ion
Knowledge about
composition of fertilizers
Manufacturing procedures
and manufacturing
conditions of different
fertilizers
4.2Comput
er control
and
Instrument
ation
Manufacturing
procedures and
manufacturing conditions
of different fertilizers
Major engineering problems
of different manufacturing
processes
4.3Energy
conservati
on and
diversificat
ion
Major engineering
problems of different
manufacturing processes
Computer control and
Instrumentation of different
fertilizer industry

• Ammonia production is an energy intensive process, so the recovery of
relatively small quantities of heat can accumulate to become sizeable
energy savings.
• The highly energy consuming nature of the process is the key driving force
for improving the technology and reducing the overall cost of
manufacturing.
• Hence, any attempt for energy conservation in the process goes a long way
in many aspects.
• In recent years, some potentially significant development and concepts
have been done, that may impact the way in which ammonia is produced.
• This includes reformer combustion air preheat, control of steam to carbon
ratio, hydrogen recovery from purge gas, improved CO2 removal system
and co-generation. Other attempts include optimization, safety, advanced
control, improved catalysts and heat integration.
INTRODUCTION (CO4.1)

The design policies for retrofitting a hot-end threshold problem are as follows:
• Elimination of exiting heaters in the network.
• Substitution of existing coolers in process-to-process region with new heat
exchangers.
The retrofit study of the low-temperature processes is dominated by
• the shaft work or power consumption of the refrigeration system and
• it is important to determine optimum temperatures and pressures in a
refrigeration system.
RETROFITS AND MODERNIZATION(CO4.1)

• Since the industrial processes are complicated, it is not possible to control
them without instrumentation.
• Primary objective of instrumentation is to control plant processes rationally
and safely.
• Term instrumentation refers to the design and installation of a measuring
and controlling instrument system for an industrial process.
Effect of instrumentation
• At the design and construction stage of the plant rationally designed
instrumentation system affects the capacities of plant equipments and costs.
• At the running stage, good instrumentation system provides effective
utilisation of raw materials ensures highest and uniform quality of products
and reduces running costs.
• It greatly economises manpower.
• It also releases workers from routine toils.
• It also safeguards the plant against hazards.
COMPUTER CONTROL AND INSTRUMENTATION
(CO4.2)

To plan an effective instrumentation system it is essential to study in detail and
consider following points:
 Operating principle and capacity
 Characteristics of instruments
 Standard methods for start and stop of operation
 Actions to be taken in case of strategy.
The characteristics of instruments can be divided into:
1. Static characteristics
2. Dynamic characteristics
(CO4.2)

Static characteristics:
• These are those characteristics that must be considered when the system or
instrument is used to measure a condition that is not varying with time.
• The static characteristics consist of following:
 Accuracy
 Sensitivity
 Reproducibility
 Drift
 Dead zone
Dynamic characteristics:
These characteristics are considered when measuring conditions are varying
with time.
(CO4.2)

Measuring instruments
• There are different instruments for measuring different process parameters
(pressure, temperature, flow and level).
• There are instruments in field area for local indication and then transmitting
the measured signal to the control room for controlling process.
There are four main equipments for measuring and maintaining the
process parameters:
• Gauges
• Transmitters
• Switches
• Control valves
(CO4.2)

Measurement of pressure:
• Instruments used in the plant for local pressure measurement are
 Bourdon tubes
 Diaphragms gauges and
 Bellows.
• Transmitter is there for transmitting pressure signal to the control room in
form of current signal (4-20 mA).
Measurement of temperature
• Different methods for temperature measurement are as follows:
• bimetallic temperature gauges:
• thermocouples
• RTD (resistance temperature detector):
(CO4.2)

Measurement of flow
• constant area variable pressure drop meter:
• other than this other flow measuring practical devices are
• flow nozzle, venturi tube, dall flow tube etc.
• Rotameter
Measurement of level
• different methods are in use for level measurement and transmission.
following are some of them:
 capacitance type
 differential pressure type
 radiation level detector
(CO4.3)

Transmitters
• The signal measured by gauges needs to be sent to the control room for
analyzing and controlling purpose.
• It consists of two functional units namely: primary unit and secondary unit
Primary unit:
• Includes the process interface and sensor.
• The process fluid exerts pressure into the sensing unit i.e. the diaphragm.
As the measuring diaphragm deflects in response to input pressure changes,
it produces vibrations in the gap between the magnetic disk and core of the
coil mounted rigidly into primary body. As a result the inductance of coil
changes, which is compared to that of reference inductor. The two
inductance values are combined to provide a proportionally standard signal.
(CO4.3)

Secondary unit:
Here a microprocessor compares precisely primary output compensating the
combined effect of sensor non linearity and temperature changes.
Control valves
• control valves manipulate a flowing fluid such as gas, steam, water or
chemical component to compensate for the load disturbance
• keep the regulated process variable as close as possible to the desired set
point.
I/P signal converter
• The electro-pneumatic signal converter is used as a linking component
between electric and pneumatic system.
• Converts standard electric signals (4-20ma) respectively into standard
pneumatic signal 0.2-1bar.
(CO4.3)

Distributed control system
• DCS is a microprocessor based control and acquisition system comprising
of multiple modules over a network
• system functions can be geographically and functionally distributed.
• operator interface to a system is through a console with CRT display and
keyboards.
• typical DCS are as follows:
 PID control
 discrete control
 advanced control
 graphical and schematic display
 communication with other systems and subsystems
 data aquisition
 report generation
(CO4.3)

A DCS system has following properties:
1. Measurement, control and communication are performed by groups of
modules that are distributed in function and location.
2. The control of the process by the plant operator is performed in centralized
control room.
3. Local operating control stations may be scattered over the plant.
4. A communication channel runs through the plant and connects to all parts
of the DCS.
5. A distributed control system can start small and expand as need requires
and circumstances permit.
6. It provides improved control of the plant by the plant operator.
7. It provides greater flexibility to the control system with easy
8. Changes of control plan.
(CO4.3)

• Fertilizers enable high yields on less crop area than would be required
without the use of fertilizers; therefore, they are an important element in
worldwide food production.
• As the population continues to grow, more and more agricultural output
will be required, and fertilizers will play a vital role.
• In spite of their benefits, fertilizers are associated with high energy
consumption. In particular, they are very dependent on natural gas for
production.
• Energy constraints and high fuel costs necessitate the implementation of
energy efficiency measures in the production and use of fertilizers.
ENERGY CONSERVATION AND DIVERSIFICATION.
(CO4.4)

Categories for Energy Efficiency Improvement
• The following factors have already been identified as affecting energy
consumption in ammonia-urea plants:
 capacity utilization,
 type of feedstock,
 technology employed, and
 vintage of the plant.
• For an older ammonia plant a typical revamp would include the following:
a) capacity increase,
b)energy-saving,
c) reduction in raw material and utility consumption,
d) reduction in environmental impact,
e) improved safety and reliability, and
f) improved control systems.
(CO4.4)

All of this would directly or indirectly benefit energy consumption.
• Specifically, improvements to the energy efficiency of various process
components of ammonia (and to a lower extent of urea) include
improvements in the reforming,
• CO2 removal, synthesis, and purge gas recovery (all of these can further
broken down into process optimization, maximization of heat recovery, and
the fine-tuning of process parameters), and energy savings from
development of new better catalysts
ENERGY CONSERVATION AND DIVERSIFICATION
(CO4.4)

Energy Intensity of Fertilization
• Inorganic fertilizers are major consumers of energy in the agricultural
sector.
• In the United States, inorganic fertilization accounts for about a third of
total energy input to crop production.
• In contrast to tractors, irrigation pumps, and other types of equipment,
fertilizers are indirect energy consumers. That is, the bulk of energy use
associated with fertilizers is not consumed directly at the agricultural site,
but indirectly during its production, packaging, and transportation to the
site.
• Additional energy is then used on-site during fertilizer application.
• Most fertilizer energy use is attributable to the production of nitrogen
fertilizers with natural gas.
• Natural gas is the principal energy resource for creating anhydrous
ammonia
ENERGY CONSERVATION AND DIVERSIFICATION
(CO4.4)

• Producing ammonia is a very energy intensive process; it requires about
1090 to 1250 m3 of natural gas to produce 1 metric ton of anhydrous
ammonia (35 000 to 40 000 ft3 natural gas per short ton).
• Natural gas is also used in other ways in the fertilizer industry. For
example, natural gas as a fuel provides the process heat for producing other
types of fertilizers. It is estimated the natural gas supplies between 70 and
80% of all energy for fertilizer production.
• Moreover, the energy requirement for nitrogen fertilizer is 4.5 times that of
phosphate fertilizer, and 5.7 times that of potash fertilizer
(CO4.4)

Energy-Efficient Fertilization Practices
• Since natural gas is such a critical resource in fertilizer production, natural
gas price fluctuations have a dramatic effect on fertilizer costs.
• As energy costs continue to rise, and the demand for fertilizers increases,
this effect is becoming more pronounced.
• The implementation of energy-efficiency measures in the production and
use of fertilizers will help curb the effects of rising gas costs, as well as the
effects of energy costs in general.
(CO4.5)

Measures to Increase the Efficiency of Ammonia Production
 Replace process equipment with high-efficiency models.
 Improve process controls to optimize chemical reactions.
 Recover process heat.
 Maximize the recovery of waste materials.
• The next area of energy consumption to address is the application of
fertilizers to crops.
• Measures to improve the use of fertilizers are the responsibility of the
farmer.
(CO4.5)

Measures to Increase the Efficiency of Fertilizer Use
• Test the soil
• Maintain soil pH
• Use high-analysis fertilizers
• Use known products
• Apply fertilizers efficiently
• Apply fertilizers at the appropriate time
• Mulch to prevent nutrient loss
• Consider rotating crops with legumes
(CO4.5)

Controlled release fertilizers
• Reduce risk of environmental losses.
• Nutrient release is controlled
• Improved fertilizer use efficiency, reduced fertilizer pollution in wastewater
• Coated fertilizers are excellent alternatives to soluble fertilizers because of
slow release of nutrients amidst the season.
• Plants can take up most of the nutrients without waste by leaching.
• Eliminating the need for multiple fertilizer applications
• Prolonged nutrient release can provide more uniform plant nutrition, better
growth, and improved plant performance
• Best efficiency of nutrient use
(CO4.5)

• https://nptel.ac.in/courses/103107086/
• http://fert.nic.in/sites/default/files/Annual_Report_2017-2018.PDF
• https://www.osti.gov/servlets/purl/764326
Faculty Video Links, Youtube & NPTEL Video Links and
Online Courses Details

1. Two types of characteristic of instruments are………………..
2. Different measuring instruments for measuring pressure are………………
3. Different measuring instruments for measuring temperature……………..
4. Different measuring instruments for measuring flow rate are………
5. The energy requirement for …………….is 4.5 times that of………, and
5.7 times that of ………
6. Natural gas provides…….. and used as ……..that provide process heat to
fertilizer plant
7. Dynamic characteristics are those characteristics that must be considered
when the system or instrument is used to measure a condition that is……….
8. What is telemetering?
9. What is 'Retrofitting of a chemical plant?
10.Define the term Automation in a plant.
11.How the fertilizer industries would causes air pollution.
DAILY QUIZ

12. What do you mean by the term 'Energy Conservation?
13.What is the term instrumentation?
14.Explain two types of characteristic of instruments.
15.What are the different measuring instruments for measuring pressure
16.What are the different measuring instruments for measuring temperature
17.What are the different measuring instruments for measuring flow
18.What are transmitters.
19.Measures to Increase the Efficiency of Ammonia Production
20.What would include in a typical revamp For an older ammonia plant
DAILY QUIZ

1. Write the short note on Modernization of fertilizer plant.
2. What do you mean by energy conservation?
3. Write different energy conservation methods for fertilizer plants.
4. Explain two types of characteristic of instruments.
5. What are the different measuring instruments for measuring pressure
6. What are the different measuring instruments for measuring temperature
7. What are the different measuring instruments for measuring flow
8. What are transmitters.
9. Measures to Increase the Efficiency of Ammonia Production
10. Write a note on Computerized fertilizer plant.
11. Discuss the role of computerized system to control the process of a fertilizer
industry.
12. Correlate the economy and energy saving for a fertilizer industry along with the
detail plan for energy conservation
WEEKLY ASSIGNMENT

1. Good instrumentation system provides
a) effective utilisation of raw materials
b) ensures highest and uniform quality of products
c) reduces running costs and economises manpower.
d) All of the above
2. Static characteristics are those characteristics that must be considered when
the system or instrument is used to measure a condition that is
a) not varying with time.
b) Varying with time
c) Both
d) None
3. For an older ammonia plant a typical revamp would include the following:
a) capacity increase,
b) energy-saving,
c) reduction in raw material and utility consumption,
d) all of the above
MCQ s

4. Fertiliser plants get their N₂ requirements
a) By fractionation of liquified air
b) By dissociating oxides of nitrogen
c) From coal gas (coke oven gas)
d) From producer gas
5. Which of the following is not a mixed fertiliser?
a) Nitrophosphate
b) Calcium ammonium nitrate (CAN)
c) Ammonium phosphate
d) None of these
6. Nitrogenous fertiliser is required
a) During the early stage of growth to promote development of stem and
leaves
b) For accelerating fruit formation in later stage of growth
c) To lessen the effect of excessive potash application
d) None of these
MCQ s

7. There are four main equipments for measuring and maintaining the process
parameters:
a) gauges
b) transmitters
c) control valves
d) all of the above
8. The implementation of energy efficiency measures in the production and use
of fertilizers is necessary due to
a) Energy constraints
b) high fuel costs necessitate
c) none of these
d) both a and b
MCQ s

9.Static characteristics are those characteristics that must be considered when
the system or instrument is used to measure a condition that is
a) not varying with time.
b) Varying with time
c) Both
d) None
10. Fertiliser plants get their N₂ requirements
a) By fractionation of liquified air
b) By dissociating oxides of nitrogen
c) From coal gas (coke oven gas)
d) From producer gas
MCQ s

OLD QUESTION PAPERS

1. Write the short note on Modernization of fertilizer plant.
2. What do you mean by energy conservation? Write different energy
conservation methods for fertilizer plants.
3. Write a note on Computerized fertilizer plant.
4. Discuss the role of computerized system to control the process of a fertilizer
industry.
5. Correlate the economy and energy saving for a fertilizer industry along with the
detail plan for energy conservation
6. Explain two types of characteristic of instruments.
7. What are the different measuring instruments for measuring pressure
8. What are the different measuring instruments for measuring temperature
9. What are the different measuring instruments for measuring flow
10. What are transmitters.
11. Measures to Increase the Efficiency of Ammonia Production
EXPECTED QUESTIONS FOR UNIVERSITY EXAM

References
1. Mortvedt J.J.,Murphy L.S.& Follett R.H., Fertilizer Technology
& Application, Meister Publishing Company
2. Shreves Chemical Process Industries, McGraw Hill
3. Drydens Outlines of Chemical Technology, East West Press

Unit4 dr mansisingh

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