IFFCO has four fertilizer plants located in India that produce urea. The largest plant in Phulpur was converted from using naphtha to using natural gas. The plant receives reliquified natural gas via pipelines. Urea produced is a major source of nitrogen for crops and is also used as cattle feed and in plastics production. The plant uses the Kellogg process to produce ammonia from natural gas cracking and then produces urea through a high pressure, medium pressure, low pressure, and vacuum process before prilling the urea into solid prills. Quality standards require the urea have less than 1% moisture, 46% minimum nitrogen content, and less than 1.5% biuret content.

1. PREPARED BY-
UTKARSH GUPTA
CHEMICAL ENGINEERING
0904351031

2. IFFCO has four fertilizer plants in India:
 At Phulpur in Uttar Pradesh
 At Kalol in Gujarat
 At Kandla In Gujarat
 At Aonla in Uttar Pradesh

3.  IFFCO has completed conversion in its largest naphtha based
ammonia urea complex at Phulpur into a gas based unit.
 IFFCO lead to enter an agreement with GAIL in 2004 for
supply of Reliquified Natural Gas (R-LNG).
 IFFCO’s urea is a major source of 46% of nutrients nitrogen
for crops.
 Urea also used as cattle feed supplement.
 It also has numerous industrial uses, as for production of
plastics.

4. PRODUCT CAPACITY PROCESS
Urea 2380 MT/Day Snam Progetti , Italy
Ammonia 1255 MT/Day Kellogg's, U.S.A

5. • Power generation plant
• Ammonia synthesis plant
• urea plant
• offsite plant
 reverse osmosis plant
 demineralization plant
 water softening plant

6.  R-LNG received from pipelines cracked by
Kellogg's process.
 Ammonia and Carbon Di-Oxide from the ammonia
plant, moved to the Urea plant.
 Steam generated in Ammonia plant is also used in
Urea plant.
3H2 + N2 2NH3 + Heat

7. Urea Plant consist following sections:
 H.P Section (32%)
 M.P Section(62%)
 L.P Section(72%)
 Vacuum Section(99.8%)
 Prilling Section

9.  NH3(l)and CO2(g)from the Ammonia plant fed
to a reactor at temperature of 168-170°C and a
pressure of 155 Kg/cm2.
2NH3 + CO2 NH2COO NH4 + 38.1K.cal/g.mol
NH2COONH4 NH2CONH2 + H2O
-7.1 K.cal/g.mol
 Carbamate recycled and attain a concentration
of 32%.

10.  A mixture of Carbamate, Urea, Ammonia and
CO2 send to the medium pressure(MP)
decomposer and in this section the
concentration of urea gain 62%.
 Low pressure section consist CO2 Absorber,
because we did not leave the CO2 in this form
into the environment.
 In this low pressure section the concentration
of Urea increase to the 72%.

11.  In vacuum section solution brings in 1st
vacuum at 0.3 atmospheric pressure and in 2nd
vacuum at 0.03 atmospheric pressure.
 In vacuum section concentration of urea
increase to 99.8%.
 With the help of molten urea pumps urea send
to the top of the Prilling tower.

12.  Urea has a melting point of 132.6 °C.
 Air by natural draft flows upward and counter
currently and cools and solidify Urea droplets.
 Solid prills fall to the bottom and sent on to a
belt conveyor by means of a rotating scrapper,
urea prills are then transported to bagging
plants through belt conveyor.

13. Moisture % by weight, maximum 1.0
Total N % by weight (on dry basis) minimum 46.0
Biuret % by weight, maximum 1.5
Particle size 90% of the material shall pass
through 2.8 mm IS sieve and
not less than 80% by weight
shall be retained on 1 mm IS
sieve.

14.  Corrosion
 Biuret Formation:
2 NH2CONH2 NH2 CO NH CO NH2 + NH3
(Urea) (Biuret )
 The formation of biuret is favored by higher
temperature, higher concentration of urea solution, low
NH3 content and higher residence time.