The document provides information about DCM SHIRAM LTD's fertilizer and chemical plants in Kota, Rajasthan, India. It includes a brief company profile, descriptions of the ammonia and urea production processes, an overview of the distributed control system used to monitor and control plant operations, and commonly used field transducers. It concludes with the author reflecting on gaining practical experience and realizing the importance of planning and management in engineering.

1. DCM SHRIRAM LTD.
(SHRIRAM FERTILISERS&CHEMICALS,KOTA)
A PRESENTATION ON
PRACTICAL TRAINING
(20 MAY 2015 to 20 JUNE 2015)
SUBMITTED TO: SUBMITTED BY:
DR. RAJEEV GUPTA AISHWARYA VIJAY
MR. RAJESH BHATT 12/172
IV YEAR, EIC Engg.

2. COMPANY’S PROFILE
 DCM SHRIRAM has manufacturing facilities of
Fertiliser, Chloro Vinyl & Cement in Kota (Rajasthan)).
The company operates on coal-based captive power
facilities rated at 133 MW.
 The Urea plant in Kota has a Production capacity of
379,000 TPA, making Kota one of the vanguards in the
country’s production of urea, & Chlor- Alkali capacity
of 700 TPD in both Kota & Bharuch.
 DCM SHRIRAM opened doors in the year 1969 and
from then on there was no looking back for the
company.

3.  The company has marked tremendous profit that has
established its firm position in the field of fertilizers
and chemicals. Already an ISO 9001 company, the
excellent quality control procedures have resulted in
the company being nominated for the elite ISO 14001
status, exclusively for fertilizers and power plants.
 With an eye to quality, DCM SHRIRAM has adopted
SAP-R3 practices for its commercial work and also
adheres to the regulations of Total Quality
Management (TQM).
 There is a strong and proactive focus on safety, health
and environment. Some of the facilities have received
international recognition such as British Safety Council
Sword of Honour etc.

4. VALUES AND BELIEFS
CUSTOMER FOCUS
INNOVATION
AND
EXCELLENCE
PEOPLE
DEVELOPMENT
TEAM WORK
RELATIONSHIPS
AND HUMAN
DIGNITY
SOCIAL
RESPONSIBILITY
AND ETHICS

5. FERTILIZER PLANT

6. AMMONIA PLANT: PROCESS DESCRIPTION
 Ammonia plant with a rated capacity of 450 TPD was
installed and commissioned in February 1969.
 In September 1974, plant capacity was enhanced to 600
TDP.
 Natural gas is being used as feed and fuel in the plant
since September 2007 in varying proportion.
 The Ammonia plant has been divided into following three
sections:
• REFORMING SECTION
• PURIFICATION SECTION
• SYNTHESIS SECTION
All the compressors have been located in a compressor
house. Cooling towers for ammonia and urea plants are
located within the plant battery limit.

7. • REFORMING SECTION
 Natural Gas is supplied from Battery Limit by GAIL at
42kg/cm2 pressure and with sulphur of less than 5ppm
concentration.
 C2Hm + nH2O nCO + (n+m/2)H2 + 49.3Kcal
Reforming reaction in the primary reformer takes place
in the catalyst bed at elevated temperature around 960
oC reducing methane content to 0.29% at the secondary
reformer exit.
 The heat content of exit gases is used to raise 72T/hr of
36K steam in No.1 and No. 2 HP boilers, which is
subsequently utilized in primary reformer.

8. • CO CONVERSION & PURIFICATION
 The process gas coming from no. 2 HP boiler at 360 oC
and 27.5 kg/cm2 pressure and contains mainly steam,
hydrogen, carbon monoxide (CO), carbon dioxide
(CO2).
 CO is converted into CO2 by the catalytic shift reaction
b/w CO and steam, where Iron chromium and Copper
zinc are the catalysts.
 CO2 is sent to the urea plant. Residual CO and CO2 in
the raw synthesis gas is then converted unto CH4 in the
methanator in presence of nickel catalyst at 300 oC.
Methane acts as inert gas and has no adverse effect on
Ammonia Synthesis Catalyst.

9. • SYNTHESIS SECTION
 The synthesis gas, which is known as make up gas of
synthesis loop is compressed from 23kg/cm2 to 315-325
kg/cm2 by motor driven 3 stage reciprocating synthesis
gas compressors.
 In the making of ammonia, the impurities such as oil,
CO2 and H2O contained in the make up gas are
absorbed in liquid ammonia and removed together in
ammonia separator.
 After the ammonia is made, it is sent to Horton Sphere
for storage from where it is pumped out to the urea
plant.

11. UREA PLANT: PROCESS DESCRIPTION
 Urea plant was commissioned in February 1969 with an
installed capacity of 700 TPD.
 The plant is based on Stamicarbon total recycle process
technology.
 The plant was expanded to 1000 TDP in August 1974 but
can now operate at a peak level of 1250 – 1300 TDP.
 The Urea Plant has been divided into six sections:
• SYNTHESIS SECTION
• FIRST STAGE RECIRCULATION SECTION
• SECOND STAGE RECIRCULATION SECTION
• CRYSTALLIZATION SECTION
• PRILLING SECTION
• HYDROLYSER STRIPPER SECTION

12. •SYNTHESIS SECTION
 The synthesis reaction takes place at 200 kg/cm2 (19.6
MPa) pressure and 190 oC temp. The N/C ratio is
maintained at about 4.
• FIRST STAGE RECIRCULATION SECTION
 This section operates at 20 kg/cm2 (1.96 MPa) pressure.
The depressurized solution after rectification at 160 oC is
sent to second stage.
• SECOND STAGE RECIRCULATION SECTION
 The solution from first stage is further purified here
up to 68% urea at 3kg/cm2 (294 KPa) pressure and
150 oC temperature.

13. •CRYSTALLISATION SECTION
 The solution is concentrated here in an evaporator to a
concentration of 80% (Urea- 73% & Biuret- 7%). Solution
containing crystals is filtered and centrifuged.
• PRILLING SECTION
 This section constitutes of an induced draft prilling tower
of 16m dia, a remelter system and a prilling bucket.
Crystals from the dryer tube are melted in the remelter
system and sent to a prilling bucket at the temp. of 138 –
140 oC. The prilling bucket revolves at 250 – 270 rpm. The
free fall height of the tower is 54m.
• HYDROLYSER STRIPPER SECTION
 The hydrolyser is a vertical vessel and operates at 18
kg/cm2 pressure.

15. DISTRIBUTED CONTROL
SYSTEM (DCS)

16. COMPONENTS OF DCS
 Introduction
 Basic Configuration
 CPU
 Analog Input Module
 Digital Input Module
 Analog Output Module
 Digital Output Module
 Communication System
 Human Interface system (HIS)

17. INTRODUCTION
 A distributed control system (DCS) refers to a control
system usually of a manufacturing system, process or any
kind of dynamic system, in which the controller elements
are not central in location (like the brain) but are
distributed throughout the system with each component
sub-system controlled by one or more controllers. The
entire system of controllers is connected by networks for
communication and monitoring.
 A DCS typically uses custom designed processors as
controllers and uses both proprietary interconnections
and communications protocol for communication.
 Input and output modules form component parts of the
DCS. The input modules receive information from input
instruments in the process (or field) and transmit
instructions to the output instruments in the field.

18. BASIC CONFIGURATION
 Field Control station (FCS)
It consists of input/output modules,
CPU and communication bus.
 Operator station
It is basically human interface
machine with monitor, the operator
man can view the process in the plant
and check if any alarm is presents
and he can change any setting, print
reports, etc.
 Engineering station
It is used to configure all input &
output and drawing and anything
required to be monitored on the
operator station monitor.

19. THE CPU
 Model is chosen based on
software to be used.
 The main memory is ensured
of high reliability by error
correction code (ECC).
 Addition of the new error
detection and protection
functions.
 Other newly added functions
include the memory
management unit (MMU) and
write protection which ensure
data integrity, the parity check
of addresses and data, the ECC
memory, and a two wire signal
self checker.

20. ANALOG I/O
 To input an analog voltage the
continuous voltage value must be
sampled and then converted to a
numerical value by an A/D
converter.
 The data value sampled will be
somewhere between the voltage at
the start and end of the sample.
 The maximum (Vmax) and
minimum (Vmin) voltages are a
function of the control hardware.
These are often specified when
purchasing hardware.

21. DIGITAL I/O
 The digital I/O module is
configured by the card unit
and either the terminal unit
or connector unit.
 It inputs and outputs 16 or 32
signal points and converts
signals.
 Since the types or I/O signal
are software-set, no control
switch or knob is found on
this module.

22. COMMUNICATION SYSTEMS
 The communication cards
are used to realize the
general-purpose
communication of field
control station and
subsystems via serial links,
so that the subsystem may
be controlled or monitored.

23. HUMAN INTERFACE SYSYEM (HIS)
 The human interface system
programmed for a project/plan
is designed in such a way that it
would be easy for the operator
to understand all the operations
occurred in the plant.

24. COMMONLY USED TRANSDUCERS
 TEMPERATURE TRANSDUCERS
• Thermocouple
• RTD
 SPEED TRANSDUCERS
• Tachometers
 FLOW TRANSDUCERS
• Orifice type
• Venturi tubes
• Rotameters

25.  LEVEL TRANSDUCERS
• Ultrasonic
• Radar - type
 STRAIN GAUGES

26. CONCLUSION
 Training is preliminary to job and so this training
was a great experience in terms of learning. It came
out to be a great platform for practical
implementation of the theory we have read so far.
 The architecture of the plants, the way various units
are linked and the way working of the whole plant is
controlled makes the student realize that engineering
is not just about learning the structured description
and working of various machines, but a greater part
of planning and proper management.

27. THANK YOU!