1. REPORT
“OVERVIEW OF AMMONIA PLANT”
REPORT TO:
Mr. Uday Pal Singh
(HOD of Ammonia Department)
Tata Chemicals Limited, Babrala
REPORT BY:
Shubhi Garg
Banasthali University, Rajasthan
College ID- BTBTH14896
garg.shubhi.069@gmail.com

2. ACKNOWLEDGEMENT
Itgives me immense pleasureto get an opportunity to work with Tata Chemicals. The
training opportunity I had with Tata Chemicals limited, Babrala was a great chance for
learning and professionaldevelopment. Itprovides a platform to unfold my queries. I
express my deep senseof gratitude to HR Team to provide me an opportunity for training
here. I also had a chance to meet so many wonderfulpeople and professionals who led me
through this training period. I would like to express my deepest thanks to my mentor Mr.
ManeeshShankhyadhar (Senior Manager, Ammoniaplant) for giving me necessary
advices and guidance throughoutmy training period and special thanks to Mr. Uday Pal
Singh (HOD of Ammonia Department) and Mr. SandeepKumar (Fire & Safety
Department) to guide and keep me on correctpath..My mentor’s endeavour inspire and
empower me to become life long learner, critical thinker and productivemember of ever
changing global society. Itis my radiantsentiment to place on record my best regards to
Mr. Dhananjay Dwivedi , Mr. Pankaj, Mr. Tanuj, Mr. Anant Kumar Dubey, Mr. Brijesh, Mr.
Mithlesh Prajapati, Mr. Pushpendra, Ms. Neetika. I would also like to thank Mr. Pradeep
Kumar Goel , Mr. SandeepKumar and their family for supporting me and making me feel
like home.
I perceived this opportunity as the firstbig milestone in my career development. Hope to
continue co-operation with all of you in future.
Sincerely,
ShubhiGarg
Banasthali University
13/06/2016

3. TATA CHEMICALS LIMITED
TATA CHEMICALS LIMITED is a state of art fertilizer complex known for its best operation
with lowestenergy consumption in manufacturing urea across thecountry as well as for
setting higher standards of safety. Head quartered in Mumbai, it is a global company with a
range of business interest focussing on three sectors- living essentials, industry essentials
and farmessentials. The Tata Chemicals group is the world’s second largestproducer of
soda ash.
The Tata Chemicals classifies its productunder three categories
1. living essentials
 Consumers salt:Tata salt, I-Shaktietc
 Pulses- I-Shakti
 Water purifier-Tata Swach
2. Industry essentials-
 Soda ash
 Allied chemicals
 Industrialsalt
 Cement
3. Farmessentials
 Fertilizers-urea
 Customized fertilizers
Plant Locations:
1. Mithapur, Gujarat
2. Babrala, U.P.
3. Haldia,West Bengal
4. Northwich, U.K.
5. East Hanover,U.S.
6. Green river, U.S.
7. Magadi, Kenya
The research and development centre, Tata Chemical Innovation centre is located at Pune.
The team of scientist is working on following areas: Advance material, green chemistry,
biochemical etc.
The total revenue of Tata Chemicals group is 17320.91croreINRin the year of2014-2015
with the profitof 807.39 croreINRafter tax.
At Babrala in Uttar Pradesh is India’s mostenergy efficient plant. Around 2000 tonnes of
ammonia are produced and reacted with CO2 to make 3500 tonnes of urea per day. Babrala
township is home to some 400+employees and their families.

4. My Experience in Tata Chemicals, Babrala
Firstday, I went to HR office. While entering, I observed TATA CHEMICALS LIMITED was
written in front of door with its logo and many trophies were there which made me feel
grateful since it was my firstvisit to a corporate world. Therewere 2-3 persons morewho
were waiting for their interview and to meet other employees. Entry was allowed with the
permission of respective person. Then I filled the form and left.
Next day, I again come to the HR office. There I met Mr. Paras Varshney and Ms. Radhika
Raman waiting for their interview, talking to them, I got to know that they were MBA
trainees here. Then Mr. Pradeep Kumar Goel introduced me to Mr. Rajendra who took me
to some apprentices and Ms. Priyanshiand sent us for the fire and safety training & a form
had to be signed by Fire and Safety department on the completion of fire and safety
training by evening.
Ms. Priyanshitook us to the Fire and Safety department wherewe saw two fire brigades
and wereexcited a lot to know aboutsafety measures and equipments. There wereguards
who give us manuals of fire and safety to read. Later on, a guard told us about fire brigade
sections by showing various compartments of firebrigade and the working and use of
equipments with equal excitement .In lunch time, we wentto canteen and had lunch. Again
we came back to the Fire and Safety department & now guard told us about the emergency
contact numbers and various safety suits and explained how to wear BASET and safety belt.
Now overview of what I learnt in Fire and Safety department.
Fire & Safety System in Babrala-
There are various safety measures used in fire and safety department;
Safety belt, Detector, Fire Detector, Photo & smokedetector, BA Set( Breathing Apparatus
Set), Nozzle, Coupling, Fire Extinguisher, Gloves, Suits, Rope, Dividing Branch, MSA fire
fighting helmet, Face shield, Ejector pump, MCP( Manual Call Point), Helmet, Ear plugs,
Goggles, Safety shoes, Full sleeves shirt.
Nozzle is shortin length. They are connected to tubes and perform many functions i.e.
spray, jetetc. at the fire.
There are various types of suits such as PVC suits, Tychem suit, Proximity suit, Fire entry suit
etc.
High heating and welding types gloves are generally used.
Detectors notify dust, heat and alarm with Yellow, Green and red colour respectively.

5. Wind socks: They are used to notify the wind direction. In caseof gas leakage, one should
move perpendicular to the direction of wind socks. They are placed at many places such as
Time office, Ammonia plant, Urea plant etc. They are coloured in red and white alternately.
There are five assembly points in caseof emergency.
 Time Office
 Near fire station
 Industrialcanteen
 ProductPackaging Plant
 Customized Fertilizer Plant
Emergency Numbers:
 Fire and Safety: 4100
 Ambulance: 4101
In caseof emergency, There are many MCP’s (Manual Call Point ). There is hammer which
to break the glass and it will notify in Fire and Safety department through siren.
In caseof fire, siren will ring for 30 seconds with a pause of 5 seconds and ring again. On
gas leakage, siren will ring for 10 seconds with a pauseof 5 seconds and ring again. After
regaining normalsituation, siren will ring for 2 minutes continuously. Daily, siren rings at
6:30 pm for 2 minutes continuously for checking.
While entering the plant, we should wear proper safety measures, i.e. fullsleeves shirt,
Helmet, Safety goggles, Normal goggles, Gloves, Ear plugs & Safety shoes.
One should wear safety belt while driving car inside the township. Speed should be
maintained at 40km/h. Mobile phones are strictly prohibited inside the plant.
One has to report to shift in-chargewhile entering the plant. Vehicles are strictly
prohibited inside the plant.
One should not touch any equipment with barehands.
On third day, I went to library and read manuals of ammonia plant since I don’t havesafety
shoes so I was not allowed to go to the plant .Next day ,I met my mentor Mr .Maneesh
Sankhyadhar who asked my purposeto come here. He sent me to the CCR whereI met Mr.
Dhananjay Dwivediwho gaveme schedule and sent me to 03 cabin.I wentto the plant and
reached that cabin .Here I introduced to Mr. Dhruv Maheshwari , Mr. Mithlesh Prajapati
and others. They told me the overview of Ammonia plant.
There are mainly three plants and various departments in TCL.
 Ammonia plant

6.  Urea plant
 Off-siteplant
DEPARTMENTS:
 Electrical
 Instrumentation
 Fire and Safety
 Civil
 Mechanical
 Urea
 Ammonia
 Off- site
 Materials
 Accounts
 Business Excellence
 Human Resources
 ProductPackaging
AMMONIA PLANT:
Ammonia plant, designed by Halder Topsoe , uses Haber’s process to manufacture
ammonia. Ituses natural gas as feed and fuel. Naphtha also could be used as feedstock and
fuel.Itis a firstplant in our fertilizer company. The sourceof nitrogen is atmospheric air and
that of hydrogen is hydrocarbons in the form of natural gas and desulphurized naptha. The
production of ammonia is 2000 MTPD.
AMMONIA PLANT:
The various sections in Ammonia plant are:
1. Desulphurization
2. ZnO absorbers
3. Fire heater
4. Adiabatic pre-convertor
5. Primary reformer
6. Secondary reformer
7. Medium temperature shift convertors
8. Low temperature shift convertors
9. CO2 removalsection
10. Methanation
11. Compression
12. Synthesis section
13.Refrigeration unit
14. Purgegas recovery unit
15. Regeneration

7. Different laws are applied in various sections of ammonia plant.
HENRY’s LAW: The solubility of a gas in a gaseous mixture is directly proportionalto its
partial pressure.
Ithas found application in regeneration section. While regenerating, one increase the total
pressureand hence, reducing the partial pressureof CO2 . Hence, its solubility decreases
and it is stripped out of GV solution.
LE CHATLIER PRINCIPLE:The equilibrium reaction proceeds in the direction to avoid
change in approach equilibrium stage. Ithas found application in Ammonia synthesis
section.
Conduction, Convection& Radiation modes of heat transfer are used in Ammonia plant.
Desulphurization:
Desulphurization unit have2 steps i.e. hydrogenation and adsorption of H2S.hydrogenation
Desulphurization happens in the HDS section with a tag no. R 201 in which inlet
temperature is maintained at 362-400ᶱC.Thesulphur contentis reduced to 0.05 ppm. The
sulphur-containing compounds arein the presence of hydrogen are converted into
hydrogen sulphidewhich is adsorbed by the zinc oxide in the adsorption vessels. Catalyst
TK-251, nickelbased is used in HDS reactor with volume 24.4 m3
. Catalyst catalco-32-4 &
catalco-32-4/C7-DD , zinc based are used in ZnO adsorbers.
The natural gas is mixed with recycle gas and heated to 400 °C in two coils installed in the
reformer flue gas section, E 204 B and E 204 A.
After preheating, the gas is passed through the HDS reactor, R 201, containing 21.6 m3
of
hydrogenation catalyst, TK-251 (NiMoX), which hydrogenates theorganic sulphur
compounds to H2S. The catalyst also hydrogenates olefins to saturated hydrocarbons. After
the hydrogenation, the process gas passes through theZnO adsorbers, R202 A/B, for
removalof H2S.
After analysing this section I questioned, why it is necessary to removesulphur .
Then I get to know that it acts like a poison for primary reformer and shift converter.
Fire Heater:
Fire heater has 15 burners and 5 coils named-
1 .H202 C5
2 .H202C4
3 .H202C3
4 .H202C2
5 .H202C1
Fire heater is used for preheating and to reduce the load of heating .Hereprocess gas is
Preheated by passing through a coil and send to the adiabatic pre-converter
R206.Combustion air is introduced to the fire heater through natural draughtat a

8. temperature of 30ᶱC with a flow rate 45552 Nm3
/h then introduced to the primary
reformer. Boiler feed water is passed through the coil then introduced to the steam drum.
Natural gas as a fuel is passed through the coil with a latent heat of 8563 kcal/Nm3
from
steam drum condensate is sentto the blow down vesselwhere pressureis reduced while
gas is again sent to the coil for the production of superheated steam.
Adiabatic Pre-Converter:
Adiabatic Pre-Converter reduces higher hydrocarbons to methane. Hydrocarbon feed
coming fromHDS section is mixed steam and preheated upto 610ᶱC in E-201 and C-1 and C-
2 of H-202. All higher hydrocarbons arereduced to methane in the presenceof pre-
converter catalyst. RKNGR catalyst with a volume of 26.9 m3
is used in pre-converter.
The reaction is endothermic.
Primary Reformer:
The process gas coming frompre-converter is introduced to the primary reformer with the
tag number H 201.Thereare 432 tubes filled with RKNR catalyst and 300 burners. Natural
gas is supplied as a feed and fuel to the burners. Process gas flows through thetubes
passing the catalyst .Furnaceis divided into two chambers. Flue gas recovery section has 9
coils. Induced draughtand forced draughtare being used in the primary reformer. Through
Forced draughtcombustion air is being pushed into primary reformer and through induced
draughtit is passed to stack while passing through flue gas heat recovery section to utilize
the heat of the flue gas. After then, the gas is exposed to air at high altitude through stack X
201. Process gas flows through outlethairpins and enters refractory lined cold collector
through high alloy intermediary hot collector. The outlet temp of primary reformer is
approximately 773ᶱC. Thecold collector is provided with thermal indicative paint having a
refractory line inside it.
Secondary Reformer:
The process gas coming fromcold collector is entered to the secondary reformer & mixed
with combustion air is introduced to the reformer from atmospherefor the nitrogen
required for ammonia. Steam is introduced to reformer. Process gas is passed to the RG
boilers whereit goes to 2 waste heat boilers and a medium pressuresuperheater. Then, it is
passed to the steam drum. Itis provided with a thermal indicative paint in which green
colour indicates temperature below 250®C,blueindicates temperature below 350ᶱC and
white colour indicates very high temperature.
Medium Temperature Shift Converter:
Medium temperature shift converter is used to convertcarbon mono-oxide to carbon
dioxide at medium temperature. R 204 contains a total of 124 m3
shift catalyst(Copper
based).
Upper protection layer 6.4m3
LK-811
Lower protection layer 18.5m3
LK-821
Main charge 99.1m3
LK-811.

9. Chlorine, Sulphur& Silica are common poison to the Shift Catalyst (Copper based). Main
part of shiftconversion takes place in R 204 and the temperature rise is around 90-120ᶱ C.
Outlet temperature is upto 340ᶱC is fully acceptable for this catalyst.
Low Temperature Shift Converter:
The process gas at 185 ᶱ C exit E 210 A/B enters LTS converter (R 205). 0.8% CO exit of R 204
is further converted into CO2. The CO exit concentration will be around 0.12-0.13 R 205
contains 118 m3
of Topsoecatalyst (Copper based) LK 821 in a single bed. Itis made of
oxides of Cu, Zn and Al. In order to ensuresufficiently low content of CO and CO2 in the
effluent gas, the inlet temperature will typically be within 290-300ᶱC depending on the
catalyst activity and gas composition.
CO2 Removal Section:
Process gas exit from LTS contains about 19% CO2.left CO2 is absorbed by the GV solution
which contains Potassium Carbonate( 25% ),Vanadium penta-oxide( 0.5%), Di-ethylene
amine ( 0.5%), Glycine( 0.5%).
Potassium carbonateis used to absorb CO2. Vanadium penta-oxideis corrosion inhibitor.
Glycine is used as activator. Di-ethylene amine is used as promotes the rate of reaction.
Regeneration:
Absorbed CO2 GV solution is introduced to the firstRegenerator and steam is introduced for
direct heating and GV solution fromthe outlet of vetro-cokeabsorber .Then, based on the
content of CO2 rich, semi-lean and lean solutions are introduced to the second Regenerator
F 302. Now, gas is circulated to the separator and condensateis sent to the pre-heater. CO2
is finally sent to the urea plant.
Methanation:
The traces of CO and CO2 are removed by converting it to methane. Since it acts like poison
for the ammonia synthesis catalyst. Inlettemperature of methanator R 311 is 298ᶱC and
outlet temperature is 312ᶱC. R311 contains 30 m3
of PK5 in a single bed. Itis Ni based
catalyst on a ceramic base. The catalyst is very sensitiveto S, As and Cl. R311 temperature is
290-300ᶱC.
Compression Section:
There are 4 compressor units in compression section-
1. Process Air Compressor K-421- Theprocess gas introduced in secondary reformer is
compressed in this section. Instrumentair is obtained.
2. Synthesis Gas Compressor K-431- Itis used to compress makeup gas and recovered gas
fromPGRU. Ithas 4 stages.
3. Ammonia RefrigerationCompressor K-451- Itis used to refrigeration duty to
refrigeration circuit in synthesis loop.
4. FlashAmmonia compressor K-441- Theflashed ammonia from B 503 flash vesselis
compressed under this section to send ammonia for storage.

10. Synthesis Section:
In the synthesis section there are two ammonia synthesis converters R 501 and R
502.Catalystused areKM1R for firstbed and KM1 for second bed used in firstconverter
and KM1 for second converter.H2/N2 ratio, Inertlevel and NH3 concentration. H2/N2 ratio of
3:1 is to be kept at R501 inlet. Synthesis loop contains compressor, convertor, refrigeration
section and separator. Makeup gas is introduced and purgegas is removed after E 508.
Ammonia chiller is used to maintain the inert concentration.
Refrigeration Cycle:
Refrigeration cycle contains compressor, condenser, expansion and evaporator. Ithas B502
Let down vessel, B 503flash vesseland chillers etc. compressor K-451compresses the
gaseous ammonia then condenses ammonia, then the control valvedecrease the pressure
and temperature of the ammonia .Then it passes through the evaporator whereliquid
ammonia vaporizes.
Ammonia Recovery Unit:
Ammonia is recovered fromPGRU by ammonical water in distillation column while
hydrogen is recovered from bottle by reducing the pressureso throttling process happens
Under chilling effect, all the gases areseparated out from bottom and hydrogen gas is
recovered. Off gases are removed from X-560 PGRunit. Ammonia is removed from
condenser and steam condensateis taken out by passing through reboiler.
OFF-SITE PLANT:
Off-Siteplant includes DM water plant, Cooling tower, Purenitrogen extraction plant etc.
DM water treats the underground water and converts it into DMwater. Dissolved solids are
removed by demineralizer. Cooling towers are used to removethe undesirableheat for
optimal energy use. The basic principle used in cooling tower is evaporative cooling and
exchange of sensible heat.
I had also gathered some practical knowledgeof industry which is summarized as follows-
Pumps:
There are two types of pumps basically centrifugal and positive displacement pumps.
Reciprocating pumps are being included in positivedisplacement type, which are also called
continuous flow pumps, while centrifugal pumps use the centrifugal theory. Reciprocating
pumps include plunger, gear, screw pumps etc. in which shaft has to and fro motion.
Pumps haveimpellers which are connected to the motor.
Valves:
There are various flow controlling valves in the ammonia plant which performs different
functions varying for different types of fluids.
1. PSV-PressureSafety Valve
2. PRV-PressureReduced Valve

11. 3. NRV-Non Return Valve
4. Plug Valve
5. Butterfly Valve
6. Ball Valve
7. Globe Valve
8. Gate Valve
9. Angular Valve
10. Needle Valve
Heat Exchangers:
Though I have read heat exchangers in heat transfer but practically I gained the knowledge
of heat exchangers in plant.
1. Shell and tube
2. Co-currentflow
3. Counter-currentflow
4. Single pass flow
For the insulation glass wool is used inside pipelines.
Here, I get to know the difference between technology and process. Thatis being used in
plant i.e. Haldor Topsoe and Haber’s process respectively.
I have seen back flushing process thatwas held on 21st
May 2016 in which scaling of stainer
was removed in heat exchanger of 05 area.
I have seen many other equipments in plant.
1. Spectral blind
2. Turbine
3. Compressor
4. Vibration metre analyzer
5. Pyrometer
6. Flow transmitter (FT)
7. Temperature transmitter (TT)
8. Safety shower
9. Paging System
10. High level switch(LSH)
11. Glass wool( Insulating material)
12. F-key stand
13.Motor
14. Flanges
15. MSDS

12. Since I had only theoretical knowledgebeforecoming to Tata chemicals. Now I come to
know the link between theoretical and practical knowledge. Here I go through different
types of safety measures and equipments first then manuals ,PFD, heat exchangers-shell
and tube, co-current, counter current, tubes, stainer of heat exchangers; centrifugal,
reciprocating, plunger pumps; needle, plug, ball, gate, globe, angular valves etc.; turbine,
compressor with differentstages, reformer, thermal sensitivepaint, pyrometer, vessels,
separators, regenerators, pipelines, vent, drain etc. So, finally I find this training to be very
helpful in my technical subjects like heat transfer , fluid mechanics etc. which I have
already read and also providemethod for proceeding in mass transfer operations , process
designing etc.