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
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.
A case study on Process Condensate Stripper in Ammonia Plant by Prem Baboo.pdfPremBaboo4
A trouble shooting case study in Fertilizers unit, India.Solving the problem of Feed/Effluent Exchanger E-3321A/B in Process Condensate stripping section of Ammonia plant by Analytical approach. The problem solved by in house experts without changing the heat exchangers while others plant change the heat exchangers. Number of modification done and huge amount of energy saved. The paper intended how to save energy by changing heat exchanger and pressure of PC Stripper. The treated process condensate was earlier cooled by CW in final cooler from about 90ºC to 40ºC. This available heat of PC is being recovered by exchanging heat with DM water in a plate heat exchanger. The pressure of PC stripper has been raised to about 1.5 kg/cm²g to make the extra heat recovery possible. Now pressure is 41.5 kg/cm2. A new Plate heat exchanger was procured & installed for the heat recovery.
ROLE OF C & I IN FERTILIZER PRODUCTION PLANTGaurav Rai
Role of control and instrumentation in fertilizer production plant.
use of different instruments in measurement of pressure, flow and temperature in fertilizer plant.
OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdfPremBaboo4
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?
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
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.
A case study on Process Condensate Stripper in Ammonia Plant by Prem Baboo.pdfPremBaboo4
A trouble shooting case study in Fertilizers unit, India.Solving the problem of Feed/Effluent Exchanger E-3321A/B in Process Condensate stripping section of Ammonia plant by Analytical approach. The problem solved by in house experts without changing the heat exchangers while others plant change the heat exchangers. Number of modification done and huge amount of energy saved. The paper intended how to save energy by changing heat exchanger and pressure of PC Stripper. The treated process condensate was earlier cooled by CW in final cooler from about 90ºC to 40ºC. This available heat of PC is being recovered by exchanging heat with DM water in a plate heat exchanger. The pressure of PC stripper has been raised to about 1.5 kg/cm²g to make the extra heat recovery possible. Now pressure is 41.5 kg/cm2. A new Plate heat exchanger was procured & installed for the heat recovery.
ROLE OF C & I IN FERTILIZER PRODUCTION PLANTGaurav Rai
Role of control and instrumentation in fertilizer production plant.
use of different instruments in measurement of pressure, flow and temperature in fertilizer plant.
OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdfPremBaboo4
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.pdfPremBaboo4
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 LP AND VACUUM SECTION FOR MS SAIPEM PROCESS...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
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.
If the material of liner changed with 2RE 69 or Duplex material instead of SS316(urea grade), then passivation air can be reduced, resulting the energy saving because the inerts vented from M.P section and loss of ammonia and problem of pollution. To enhance capacity and energy of the existing plant the internals like vortex mixture and HET may be changed the capacity may increase up to 10-15%.HET, you can changed with super cup.The CO2 and feed top of the vortex mixture nozzle and Ammonia plus carbamate feed from side of the vortex mixture. In the mixing area the initial dispersion of gas and formation of liquid – gas mixture are performed.
Environment management and advanced waste treatment system in nitrogenious fe...Prem Baboo
The paper intended to the standpoint of harmful emissions typical nitrogen-based fertilizer plants producing ammonia and urea plants using the advanced available technologies. The critical emission points are established and analyzed. Several possible actions have been taken in order to minimize the emissions are presented.The method is low cost and at the same time enhances the fertilizer value of sewage sludge. It therefore has a large potential of competing with more established methods of sanitization.
Energy saving in urea plant by modification in heat exchanger and processPrem Baboo
Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Improvement in energy
efficiency reduces cost of production & results in environmental benefits, e.g. mitigation of global warming by way of less emission of
Green house gases in the atmosphere. Over the years several energy conservation measures have been taken towards reduction in
specific energy consumption and improvement in energy efficiency. The efforts’ resulted in reduction in specific energy consumption
from 6.27G. Cal/tone of Urea to 5.421 G.Cal/tone of Urea in 2015-16 as shown in the Graph No 1 & 2 with energy & down time.
Further a major modification of all plants is under way. Most of the schemes have been implemented in 2012 and the further
modifications expected to result again reduction of energy consumption for ammonia and Urea plants. This paper described some of
the modification in urea plants implemented recently in May/June 2016.
OPERATION AND TROUBLE SHOOTING IN UREA SYNTHESI SSECTION.pdfPremBaboo4
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 LP AND VACUUM SECTION FOR MS SAIPEM PROCESS...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
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.
If the material of liner changed with 2RE 69 or Duplex material instead of SS316(urea grade), then passivation air can be reduced, resulting the energy saving because the inerts vented from M.P section and loss of ammonia and problem of pollution. To enhance capacity and energy of the existing plant the internals like vortex mixture and HET may be changed the capacity may increase up to 10-15%.HET, you can changed with super cup.The CO2 and feed top of the vortex mixture nozzle and Ammonia plus carbamate feed from side of the vortex mixture. In the mixing area the initial dispersion of gas and formation of liquid – gas mixture are performed.
Environment management and advanced waste treatment system in nitrogenious fe...Prem Baboo
The paper intended to the standpoint of harmful emissions typical nitrogen-based fertilizer plants producing ammonia and urea plants using the advanced available technologies. The critical emission points are established and analyzed. Several possible actions have been taken in order to minimize the emissions are presented.The method is low cost and at the same time enhances the fertilizer value of sewage sludge. It therefore has a large potential of competing with more established methods of sanitization.
Energy saving in urea plant by modification in heat exchanger and processPrem Baboo
Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Improvement in energy
efficiency reduces cost of production & results in environmental benefits, e.g. mitigation of global warming by way of less emission of
Green house gases in the atmosphere. Over the years several energy conservation measures have been taken towards reduction in
specific energy consumption and improvement in energy efficiency. The efforts’ resulted in reduction in specific energy consumption
from 6.27G. Cal/tone of Urea to 5.421 G.Cal/tone of Urea in 2015-16 as shown in the Graph No 1 & 2 with energy & down time.
Further a major modification of all plants is under way. Most of the schemes have been implemented in 2012 and the further
modifications expected to result again reduction of energy consumption for ammonia and Urea plants. This paper described some of
the modification in urea plants implemented recently in May/June 2016.
Calculus is the major part of Mathematis. This theoretical presentation covered all relevant definations and systematic review points about calculus. It also brings and promote you towards in advance mathematics.
An energy audit is an inspection survey and an analysis of energy flows for energy conservation in a building. It may include a process or system to reduce the amount of energy input into the system without negatively affecting the output.
Wastewater Treatment: Definition, Process Steps, Design Considerations, Plant Types (With PDF)
Written by Anup Kumar Deyin Civil,Construction,Mechanical,Piping Interface,Process
Wastewater treatment is a process to treat sewage or wastewater to remove suspended solid contaminants and convert them into an effluent that can be discharged back to the environment with acceptable impact. The plants where the wastewater treatment process takes place are popularly known as Wastewater treatment plants, Water resource recovery facilities, or Sewage Treatment Plants. Pollutants present in wastewater can negatively impact the environment and human health. So, these must be removed, broken down, or converted during the treatment process. Typical pollutants that are normally present in wastewater are:
Bacteria, viruses, and disease-causing pathogens.
helminths (intestinal worms and worm-like parasites)
Toxic Chlorine compounds and inorganic chloramines.
Metals possessing toxic effects like mercury, lead, cadmium, chromium, and arsenic.
Decaying organic matter and debris.
oils and greases.
Toxic chemicals like PCBs, PAHs, dioxins, furans, pesticides, phenols, etc.
Some pharmaceutical and personal care products
Wastewater Treatment: Definition, Process Steps, Design Considerations, Plant Types (With PDF)
Written by Anup Kumar Deyin Civil,Construction,Mechanical,Piping Interface,Process
Wastewater treatment is a process to treat sewage or wastewater to remove suspended solid contaminants and convert them into an effluent that can be discharged back to the environment with acceptable impact. The plants where the wastewater treatment process takes place are popularly known as Wastewater treatment plants, Water resource recovery facilities, or Sewage Treatment Plants. Pollutants present in wastewater can negatively impact the environment and human health. So, these must be removed, broken down, or converted during the treatment process. Typical pollutants that are normally present in wastewater are:
Bacteria, viruses, and disease-causing pathogens.
helminths (intestinal worms and worm-like parasites)
Toxic Chlorine compounds and inorganic chloramines.
Metals possessing toxic effects like mercury, lead, cadmium, chromium, and arsenic.
Decaying organic matter and debris.
oils and greases.
Toxic chemicals like PCBs, PAHs, dioxins, furans, pesticides, phenols, etc.
Some pharmaceutical and personal care products
It is part of Chemical Engineering. A lot of toxic released from Chemical Industries. How to reduce that wastewater effluent. All the techniques and measurements are included in this presentation.
Industrial Effluent Treatment by Modern Techniques.pptEr. Rahul Jarariya
Effluent Treatment Plant or ETP is one type of waste water treatment method which is particularly designed to purify industrial wastewater for its reuse and its aim is to release safe water to the environment from the harmful effect caused by the effluent. Helping achieve a greener society.
Effluent Treatment Plant or ETP is one type of waste water treatment method which is particularly designed to purify industrial wastewater for its reuse and its aim is to release safe water to the environment from the harmful effect caused by the effluent. Helping achieve a greener society
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Governing Equations for Fundamental Aerodynamics_Anderson2010.pdf
NFL Report.pdf
1. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
SNAMPROGETTI (SAIPEM) UREA PROCESS
(Ammonia Stripping Process)
Main Section of Urea Plant
1. CO2 Compressor
2. High Pressure Ammonia and Carbamate Pumps.
3. High Pressure Synthesis Loop.
4. Medium Pressure Recovery Section.
5. Low Pressure Section.
6. Vacuum Evaporation Section (With Pre-Concentrator).
7. Process Condensate Section. (Waste Water Treatment).
Daily Urea Production of Line I and Line-II Plant
Line-I Urea Plant – 3030 TPD
Line – II Urea Plant – 3231 TPD
Total – 6261 TPD
Maximum Urea Produced – 6600-6700 TPD
Toxic Chemicals in Urea Plant
1. Ammoina
2. Ammonium Carbamate
3. Chlorine (Cooling Tower)
4. Nitrogen
5. Hot Urea Solution
6. Carbon Mono Oxide (Ammonia Plant)
2. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
Process Description main process steps
CO2 compression
High pressure synthesis loop
Medium pressure recovery section
Low pressure section
Vacuum evaportation section
Process condensate section
Description of the process
The urea procution process takes place through the following main operations-
Urea synthesis and high pressure recovery
Urea purification and low pressure recovery
Urea Concentration
Urea Prilling
Wastewater treatment
Advantages of excess ammonia
Avoids corrosion
Promotes stripping
Higher conversion
Less biuret formation
Flexibility in operation
3. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
Less passivation air
Less severity in pumping
High pressure synthesis loop
CO2 compression
Reaction of NH3 and CO2
Urea formation
NH3/CO2 and H2O/CO2 molar ratio
Decomposition of carbamate
Low pressure steam production
Urea synthesis and High pressure recovery:
Urea is produced by synthesis from liquid ammonia and gaseous carbon dioxide,
In the reactor 31/41 R-1, the ammonia and Carbon dioxide react to form ammonium carbamate, portion of which dehydrates to form Urea and
water.
Carbamate, portion of which dehydrates to form Urea and Water.
The reactions are as follows,
2NH3 + CO2 = NH2COONH4
NH2COONH4 = NH2COONH2 + H2O
In Synthesis, conditions (T – 188°C and P – 155 kg/cm2
), the first reaction occure slowly and determines the reactor volume. The fraction of
Ammonium carbamate that dehydrates is determined by the ratio of the various reactants, the operating temperature and residence time in the
reaction.
4. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
Formation of biuret takes place when urea is heated to its melting point it starts decomposition with evolution of ammonia presumably, urea
first isomerizes which dissociates into isocynic acid and ammonia.
CO(NH2)2 = NH4CNO + NH3
Urea Ammonium cynate
The isocynic acid reacts with urea to form biuret.
NHCO + CO(NH2)2 = NH2CONHCONH2
In the presence of excess ammonia biuret is formed at substantially lower rate by direct reaction between urea molecules.
2CO(NH2)2 (Urea) = NH2CONHCONH2 (Biuret) + NH3 (ammonia)
Biuret + Urea = Triuret (polymer) + Ammonia
NH2CONHCONH2 (Biuret) + NH2CONH2 (Urea) = (H2NC(O)NH)2CO (Triuret) + NH3 (Ammonia)
The mole ration of NH3 to CO2 is 3.3-3.6
The mole ratio of H2O to CO2 is 0.5 to 0.7
The total flow of liquid ammonia coming directly from the battery limits is measured by turbine flow meter FQR-106 and then diverted to 31-
41 unit. The flow of liquid ammonia going to each unit is measured by FIR 104 and temperature by TI-1-113 (12°C), is collected in the
ammonia receiver tank 31-41 V-1. From V-1, it is drawn and compressed at about 22.4 kg/cm2 pressure absorber /41 C-1, the remaining part
enters the high pressure synthesis loop. The ammonia feeding the synthesis loop is compressed by two – speed, heavy duty reciprocating pumps
31/41 P-1 A/B at a pressure of about 240 ata. Before entering the reactor the ammonia feed is used as motive fluid in the carbamate Ejector
31/41 EJ-1, where the carbamate coming from the Carbamate Separator 31/41 MV-1 is compressed up to the synthesis pressure. The liquid
mixture of NH3 and carbamate enters the reactor where NH3 reacts with the compressed carbon dioxide. The co2 drawn at urea plant battery
limits at about 1.5 ata and about 40°C enters the centrifugal compressor temperature 130°C is fed to urea reactor (31/41 R-1) though K-1
discharge separator (31-41 MV-8) A small quantity of air is added to the carbon dioxide at the compressor suction in order to passivate the
stainless steel surfaces, thus protecting them for corrosion due to steam reagent and reaction product. The reaction products, leaving the reactor,
flow to the steam heated falling film type stripper 31/41 E-1, which operates at 146 kg/cm2 g pressure stripping action of the ammonia as it
boils out of the solution. For the bottom of bimetallic stripper, passivation air is required in continuous way. For this passivation air compressor
5. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
K-3A/B are installed. The carbamate decomposition heat is supplied by 24 ata saturated steam. The overhead gases and the recovered solution
from M.P. absorber (C-1), all flow to the high pressure carbamate condensers (E-5) where the total absorber, except for a few inerts, is
condensed and recycled to the reactor by means of ejector (EJ-1). The condensation of gases at high pressure and temperature permits the
production of 4.5 ata steam in the high pressure carbamate condenser. In the carbamate separator (MV-1) the incondensable gases, consisting
of inert gases containing a little quantity of NH3 and CO2 unreacted in the condenser, are separated from the carbamate solution and sent to
the medium pressure decomposer (E-2).
Urea high pressure section as following:
Urea purificaton and low pressure recovery
Urea purification takes place in two stages at decreasing pressure as follows:
1st
stage at 18 ata pressure.
2nd
stage at 4.5 at pressure.
Medium pressure recovery section
Carbonate decomposition
CO2 absorption
NH3 recovery
NH3 pumping to 225 ata
Carbonate pumping to 160 ata
6. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
7. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
8. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
9. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
10. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
11. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
12. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
13. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
14. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
15. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
16. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
NH3 make up from ammonia receiver (V-1)
1st
Purification and recovery stage at 18 ata
The solution leaving the existing urea Striper, after being let down in the level control valve, enters the vertical exchanger named pre-
decomposer (E-53) where the decomposition of carbamate occurs by means of the hear supplied through boosted steam generated in steam
booster ejector (Ej-53). This ejector utilize as motive fluid the MS saturated steam coming from stripper steam condensate separator (V-29).
The sucked fluid is low pressure steam from the heater. The operating pressure at the discharge f the booster ejector is about 6.5 kg/cm2 (a)
and the temperature about 161°C. Intake falling film type evaporator, E-52 where the low residual carbonate is decomposed and water is
evaporated. The required heat is supplied by means of partial condensation
(in shell side) of overhead gas coming from the M.P. decomposer. The required heat is supplied by means of partial condensation (in the shell
side) of overhead gas coming from the MP Decomposer.
Bottom liquid holder ME 52, where the urea solution at 83-84% wt is collected.
The mixed phase leaving the pre-Decomposer enters the existing MP decomposer separator MV-2 where the gases are separated from the liquid
which proceed to the MP decomposer for further decomposition.
The solution with a residual CO2 content, leaving the bottom of the stripper is expanded at the pressure of 18 ata and enters the medium
pressure pre decomposer (E-53) them MP decomposer E-2 (falling film type). This equipment is divided into two parts: Top separator MV-2
where the residual gases are removed flash gases are removed before the solution enters the tube bundle. Decomposition section where the
residual carbamate is decomposed and the required heat is supplied by 24 ata steam condensate flowing out of the stripper. The top gases sent
to be Pre Concentrator shell side for heating purpose. The NH3 & CO2 rich gases leaving the top separator, MV-2 are sent to the shell side of
the falling film Pre-Concentrator, E-52, where they are partially absorbed in aqueous Carbonate solution coming from the LP recovery section
via M.P. Carbonate solution Pump P-3 A/B. The total heat from the shell side, due to condensation/absorption/reaction of reagents , is removed
by evaporating urea solution coming from the low pressure decomposer holder ME-3, up to 83-84% wt in pre-concentrator, thus allowing a
considerable saving of L.P. Steam in the vacuum concentration stage. From the Pre-Concentrator, E-52 shell side the mixed phase is sent to
the existing medium pressure condenser, E-7, where CO2 is almost totally absorbed and condensation/ reaction heat is removed by cooling
water coming from ammonia condenser, E-9. This is mainly divided in the three parts:-
Top separator MV-2 , where the released flash gases are removed before the solution enters the tube bundle, vapors are extracted by the Pre-
Concentrator Vacuum System ME-51. The NH3 and CO2 rich gases leaving the top separator are sent to the medium pressure condenser (E-
7) where they are partially absorbed in aqueous carbamate solution coming from the low pressure recovery section via pump (P-3).
17. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
A tempered water circuit is provided to prevent carbamate solidification and to keep a suitable cooling water temperature at the medium
pressure condenser inlet recirculating the cooling water by means of pump (P-4 A/B). In the condenser, CO2 is almost totally absorbed. The
mixture from E-7 flows to the medium pressure absorber (C-1) where the gaseous phase coming from the solution enters the rectification
section. This is of bubble cap trays type and preforms CO2 absorption and NH3 rectification. The trays are fed by pure reflux ammonia is
which eliminates residual CO2 and H2O contained in the inters gases. Reflux ammonia is drawn from the Ammonia receiver (V-1) and sent to
the column C-1 by means of centrifugal pump (P- 5A/B). A current of inert gases saturated with NH3 with some ppm of CO2 residue comes
out from the top of the rectification section. The bottom solution is recycled by pump C-1 top is partially condensed in the Ammonia condenser
E-9 A/B. From here the liquid and gaseous NH3 phases are sent to the Ammonia receiver V-1.
The inerts gases, saturated with ammonia, leaving the receiver, enter the Ammonia recovery tower (C-5) where additional amount of ammonia
is condensed by the cold ammonia from the Urea plant battery limits. The condensed ammonia is recovered in V-1. The inert gases, containing
residue ammonia, are sent to the medium pressure falling film absorber (E-11), where they meet a countercurrent water flow which absorbs
gaseous ammonia. The absorption heat is removed by cooling water. From the bottom of E-11 the water ammonia solution is recycled back to
the medium pressure absorber C-1 by means of pump P-7 A/B. The upper part of the medium pressure absorber consists of 3 valve trays (C-
3) where the inter gases are submitted to a final washing by means of the same absorption water. In this way the inert are collected to blow
down practically free from ammonia.
Low Pressure Section:
Residual carbonate decomposition
Carbonate recovery
WWT section gas recovery
The solution leaving the bottom of medium pressure decomposer is expanded at 4.5 ata pressure nad enters the low pressure decomposer E-3.
This is divided into two parts: Top separator (MV-3) where the released flash gases are removed before the solution enters the tube bundle.
Decomposition section where the last residual carbamate is decomposed and the required heat is supplied by means of 4.5 ata saturated steam.
The gases leaving the top separator are sent to the low pressure condenser (E-8) where they are absorbed in an aqueous carbonate solution
coming from the waste water treatment section. The absorption and condensation heat is removed by cooling water. From the condenser bottom,
the liquid phase, with the remaining inert gases, is sent to the carbonate solution tank (V-3). From here the carbonate solution is recycled back
to the medium pressure condenser E-7 by means of pump P-3 A/B.
18. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
The inert gases which essentially contain ammonia vapour flow directly into the low pressure falling film absorber (E-12), where ammonia is
absorbed by a countercurrent water flow. The absorption heat is removed by cooling water. The inert gases, washed in the low pressure intert
washing tower C-4 are collected to Blow down practically free from ammonia.
Vacuum Evaporation Section
Urea concentration in tow section (0.3 and 0.03 ata) Urea solution storage and recovery Urea concentration section. As it is necessary in order
to prills urea, to concentrate the urea solution up to 99.7% a vacuum concentration section in two stages is provided. The solution leaving the
low pressure decomposer bottom with about 71% UREA is sent to the pre concentrator this solution having urea concentration E-14 operating
at a pressure of 0.3 ata. Urea concentration section. The mixed phase coming out E-14 enters the gas liquid separator MV-6 from where 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 concentration are fed by saturated steam at 4.5 ata. Urea concentration section.
The mixed phase coming out of E-15 enters the gas liquid separator MV-7 from where vapors are extracted by the second vacuum system ME-
5.
Material of Construction.
Compostion of Materials used in urea plant.
Constituents 2RE 69 316L (Mod) 316 L 304 304L HVD-(duplex)
Cr 25% 16-18% 16-18% 18-20% 18% 24-27%
Ni 22% 10-13% 12-18% 8-11% 11% 7-9%
Mo 2% 2-3% 2-3% 0.2-2% <0.4% 2-3%
N2 0.2% - -
C <0.08% 0.035% <0.03% <0.08% <0.03%
Rector – Liner SS316 L (mod)
Trays – 2 RE 69
Stripper Bimetallic tubes – Inner tube Zerconium Outer – 2 RE – 69
Dome – 2 RE – 69
19. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
MP Section equipment – SS – 316 L MV - 2 liner – SS 316 L, C-1-SS 316L, R -2-SS 316L
LP vessel, MV – 3- liner – SS – 304L, C-2 SS 304 L
Vacuum Section Equipment – SS 304 L
Urea Prilling
The melted urea leaving the second vacuum separator is sent to the Prilling bucket. ME – 8A/B by means of pump P-8 A/B. The urea coming
out of the bucket in the form of drops along the Prilling tower ME-6 and encounters a cold air flow which causes its specification. Urea Prilling.
The solid prills falling to the bottom of the Prilling towers are sent into the bely conveyor MT-1 by the rotary scrapper ME-10. From here they
are sent through lumps separator ME-11 to retain lumps only and then to the product belt conveyor MT-3 which carries the product to the Urea
storage section.
Urea lumps by means of Urea recycle belt conveyor MT-2 are recycled back to the underground Urea lumps dissolving tank V-4 where
they are dissolved. The Prills from prilling tower bottom sent to bulk flow cooler when the temp more than 65°C. In the month of May
and June the BFC take in line.
20. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
UREA – II (P)
EQUIPMENTS LIST
31 UNIT
S.No. Equipment Description Tag No.
1 MPAbsorber 31-C-1
2 Distillation Tower 31-C-2
3 STRIPPER 31-E-1
4 HPAMMONIA PREHEATER 31-E-4
5 CARBAMATE CONDENSOR 31-E-5
6 MP CONDENSER 31-E-7
7 AMMONIA CONDENSER 31-E-9 A/B
8 LP CONDENSOR 31-E-8
9 MPAMMONIAABSORBER / INTERT GAS WASHING TOWER 31-E-31/C-3
10 LP AMMONIAABSORBER /INTERT GAS WASHING TOWER 31-E-12/C-4
11 I VACUUM CONCENTRATOR 31-E-14A/B
12 II VACUUM CONCENTRTOR 31-E-15
13 DISTILLATION TOWER OVERHEAD CONSENSER 31-E-17
14 DISTILLATION TOWER OVERHEAD PREHEATER 31-E-18
15 HYDROLYSER PREHEATER 31-E-19A/B
16 PURIFIED WASTEWATER COOLER 31-E-20A/B
17 STEAM CONDENSER COOLER 31-E-41 A/B
18 I INTERSTAGE COOLER (K-1) 31-E-25
19 II INTERSTAGE COOLER (K-1) 31-E-26
20 III INTERSTAGE COOLER (K-1) 31-E-27
21 FINAL STEAM CONDENSER COOLER 31-E-30A/B
22 I AND II VACUUM SYSTEM CONDENSERS 31-E-41,42
23 CARBAMATE RECYCLE EJECTOR 31-EJ-1
24 CO2 COMP 31-K-1
25 PASSIVATION AIR COMP TO K -1 31-K-2 A/B
21. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
26 PASSVATION AIR COMP TO CT 08 K-2A/B
27 I AND II VACUUM SYSTEM 31-ME-4/5
28 PRILLING BUCKET 31-ME-8
29 PRILLING BUCKET SUPPORT 31-ME-9
30 ROTARY SCRAPPER 31-ME-10
31 BLOW DOWN 31-ME-14
32 FIRST VENT STACK 31-ME-15
33 DISCOIL 31-ME-20
34 II VENT STACK 31-ME-41
35 HPAMMONIA FEED PUMP MOTOR 31-MP-1 A/B
36 CARBAMATE SEPERATOR 31-MV-1
37 MP DECOMPOSER 31-ME-2, E-2, ME-2
38 LP DECOMPOSER 31-MV-3,E-3,ME-3
39 STRIPPER STEAM COND SEPERATOR 31-MV-4
40 I VACUUM SEPERATOR 31-MV-6
41 II VACUUM SEPERATOR 31-MV-7
42 CO2 COMP DELIVERY DRUM 31-MV-8
43 CO2 COMP K O DRUM 31-MV-9
44 I INTERSTAGE SEPERATOR (K-1) 31-MV-16
45 II INTERSTAGE SEPERATOR (K-1) 31-MV-17
46 III INTERSTAGE SEPERATOR (K-1) 31-MV-18
47 HPAMMONIA FEED PUMP 31-P-1A/B
48 COOLING WATER PUMPS 08-P-1-A/B
49 HP CARBAMATE SOLUTION PUMP 31-P-2 A/B
50 MP CARBAMATE SOLUTION PUMP 31-P-3 A/B
51 CW CIRCULATION PUMP FOR E-7 31-P-4 A/B
52 AMMONIA BOOSTER PUMP 31-P-5 A/B
53 MP STEAM COND FLUSING PUMP 31-P-6 A/B
54 AMMONIA SOLUTION PUMP 31-P-7 A/B
55 UREA MELT PUMP 31-P-8 A/B
56 UREA SOLUTION PUMP FOR V-5 31-P-9 A/B
22. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
57 HP WASHNING PUMP 31-P-11 A/B
58 DRAIN RECOVERY PUMP FOR V-7 31-P-12 A/B
59 STEAM COND TO B.L. PUMP 31-P-13 A/B
60 HYDROLYSER FEED PUMP 31-P-14- A/B
61 DISTILLATION TOWER REFLUX FEED PUMP 31-P-15 A/B
62 C2 FEED PUMPS 31-P-16 A/B
63 STRIPPER DP CELL FLUSH PUMP 31-P-17 A/B
64 PURIFIED WASTE WATER PUMP 31-P-18 A/B
65 UREA SOLUTION RECOVERY PUMP – V-4 31-P-19 A/B/C
66 CARBAMATE SOLUTION RECOVERY PUMPS 31-P-20 A
67 BUFFER WATESWATER TANK FEED PUMPS 31-P-41 A/B
68 OILY WATER PUMPS 31-P-23 A/B
69 COND PUMP OF TK-1 31-P-27 A/B
70 EFFLUENT DISPOSAL PUMPS 31-P-33 A/B
71 UREA REACTOR 31-R-1
72 HYDROLYSER 31-R-2
73 TURBINE FOR K-1 31-TK-1
74 AMMONIA RECEIVER 31-V-1
75 STEAM CONDENSER TANK 31-V-2
76 CARBAMATE SOLUTION TANK 31-V-3
77 UREA LUMP DISSOLVING TANK 31-V-4
78 UREA SOLUTION TANK 31-V-5
79 BUFFER WASTEWATER TANK 31-V-6
80 DRAIN COLLECTING TANK 31-V-7
81 REFLIUX ACCUMULATOR 31-V-8
82 WASTEWATER TANK 31-V-9
83 SLOP OIL TANK 31-V-20
84 INSTRUMENT AIR RECIVER TANK 31-V-41
85 MAIN OIL PUMP FOR K-1 31-P-24 A/B
86 EMERGENCY OIL PUMP FOR K-1 31 – P- 25
87 CONDENSATE COOLER 31 E-13
23. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
UREA – II (P)
EQUIPMENT LIST
41 UNIT
SR.NO. EQUIPMENT DESCRIPTION TAG NO
1 MPABSORBER 41-C-1
2 STRIPPER 41-E-1
3 HP AMMONIA PREHEATER 41-E-4
4 CARBAMATE CONDENSOR 41-E-5
5 MP CONDENSOR 41-E-7
6 LP CONDENSOR 41-E-8
7 AMMONIA CONDENSOR 41-E-9A/B
8 MP AMMONIAABSORBER / INERT GAS WASHING TOWER 41-E-31 / C-3
9 LPAMMONIAABSORBER / INTERT GAS WASHING TOWER 41-E-12/C-4
10 II VACUUM CONCENTRATOR 41-E-15
11 I VACUUM COOLER (K-1) 41-E-25
12 II INTERSTAGE COOLER (K-1) 41-E-26
13 III INTERSTAGE COOLER (K-1) 41-E-27
14 I AND II VACUUM SYSTEM CONDENSERS 41-E-41,42
15 CARBAMATE RECYCLE EJECTOR 41-EJ-1
16 CO2 COMP 41-K-1
17 PASSIVATION AIR COMP TO K-1 41-K2- A/B
18 I AND II VACUUM SYSTEM 41-MP-4/5
19 HPAMMONIA FEED PUMP MOTOR 41-MP-1 A/B
20 CARBAMATE SEPARATOR 41-MV-1
21 MP DECOMPOSER 41-MV-2, E-2, ME-2
22 LP DECOMPOSER 41-MV-2, E-3, ME-2
23 STRIPPER STEAM COND SEPERATOR 41-MV-4
24 I VACUUM SEPERATOR 41-MV-6
24. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
25 II VACUUM SEPERATOR 41-MV-7
26 CO2 COMP DELIVERY DRUM 41-MV-8
27 CO2 COMP K O DRUM 41-MV-9
28 I INTERSTAGE SEPERATOR (K-1) 41-MV-16
29 II INTERSTAGE SEPERATOR (K-1) 41-MV-17
30 III INTERSTAGE SEPERATOR (K-1) 41-MV-18
31 HPAMMONIA FEED PUMP 41 P-1 A/B
32 HP CARBAMATE SOLUTION PUMP 41 P-2 A/B
33 MP CIRCULATION PUMP FOR E-7 41-P-3-A/B
34 CW CIRCULATION PUMP FOR E-7 41-P-4-A/B
35 AMMONIA BOOSTER PUMP 41-P-5-A/B
36 AMMONIA SOLUTION PUMP 41-P-7 A/B
37 UREA MELT PUMP 41-P-8 A/B
38 DRAIN RECOVERY PUMPS FOR V-7 41-P-12 A/B
39 STRIPPER DP CELL FLUSH PUMP 41-P-17- A/B
40 BUF
FER WASTEWATER TANK FEED PUMPS
41-P-21 A/B
41 COND PUMP OF TK-1 41-P-27-A/B
42 UREA REACTOR 41-R-1
43 TURBINE FOR K-1 41-TK-1
44 AMMONIA RECEIVER 41-V-1
45 CARBAMATE SOLUTION TANK 41-V-3
46 DRAIN COLLECTING TANK 41-V-7
47 WASTEWATER TANK 41-V-9
48 MAIN OIL PUMP FOR K -1 41 P -24 A/B
49 EMERGENCY OIL PUMP FOR K -1 41 P -25
25. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
UREA – 2 (PRODUCTION) EQUIPMENT LIST (after revamp)
Equipment
31/41 pre-decomposer (e-53) along with booster ejector (EJ-53) and condensate separator (MV-53)
31/41 Pre-Concentrator (MV-52) along with dedicated Vacuum System and Urea pump (P-5)
31/41 New waste water tank (V-10) along with pump and motor (P-52)
31/41 replacement of carbamate ejector (EJ-1)
31/41 Replacement of carbamate ejector (Ej-1)
31/41 Heat Exchanger E-46,47 & 48
31/41 Scrubber LC 101
31/41 ejectors for pre conc system EJ-101 & EJ-102
31/41 Level Control Valve (LV 1007)
31/41 Level Control Valve (LV 1006)
31/41 Wastewater Pump P-52 A/B
31/41 Preconcentrator urea pump P-50 A/B
31/41 NG Flow control valve (FV 1007)
31/41 Ejector System for pre decomposer (EJ-63)
31/41 Condensate separator (MV-53) modified of MV-4
31/41 Pressure Control valve for ejector PV 1001
31/41 Pressure Control valve for Vaccum PV 1002
26. Re-Prepared by Stubborn Engineer / Rahul Jarariya
Wri en by Prem Baboo (Sr.Manager (Prod), , Na onal Fer lizer Limited, Vijaypur. (2017-18)
Vacuum system EJ-42B
Vacuum Ejector Ej-2B and Ej-3B
Ammonia Scrubber C-102
Steam Condensate separator V-29
Bulk Flow Cooler
LIC 502 Control Valve for DM water tank
P-60 A/B Water Circulation Pump
Plate type Heat Exchanger
ET -21 B Product dich Belt
High Rise Belt ET-21A
Two Number AC System
TIC 503 Temp Control Valve
FD Blower
Stem Coil Air Heater
Inst Air Vibrator
TIC 501 Temp Control Valve
PRV 501 Pressure Control Valve