1. The document summarizes the processes at an IFFCO fertilizer plant in Phulpur, India. It describes the production of ammonia and urea through the dissociation of natural gas and reaction of ammonia with carbon dioxide. 2. The plant uses four boilers - three coal-fired and one oil/gas-fired - to generate high pressure steam for power and process needs. It also has two turbo generators that produce electricity. 3. The key production cycles discussed are feedwater, steam, fuel (coal, oil, gas), air, and flue gas. Fly ash is collected and sold to cement plants while bottom ash is disposed of in ash ponds.

1.  Training Centre: IFFCO, Phulpur Unit PRESENTED BY :-
 Training Duration: 09/06/2015 to 09/07/2015 Sandeep yadav
 Training Area: Plant Area MEE2k12
 Project Topic: Boilers CSJMA12001390272
UIETCSJMU KANPUR UP

2.  Indian Farmers Fertiliser Co-operative
Limited(IFFCO) was registered on November
3,1967 as a multi-unit co-operative society.
 IFFCO society is engaged in production and
distribution of fertilisers.
 IFFCO Phulpur is a ammonia-urea plant in
state of Uttar Pradesh in 1980.
 Today IFFCO is making substantial
contribution to increase food grain
production.

3. 1. Two Power plants.
2. Two Furnaces & Two Chimneys.
3. Water Treatment System & Brick making unit.
4. Single ECU System.
5. Packaging & Transportation Division.

4.  Natural gas is taken from GAIL through pipe
lines and stored in gas reservoirs.
 Natural gas is dissociated at high temperature
& pressure into a furnace.
 Hydrogen, Nitrogen and Carbon dioxide gases
are obtained after dissociation.
 Hydrogen & nitrogen is send to ammonia plant
while Carbon dioxide is stored separately.
 3H2 + N2 = 2NH3

5.  Ammonia and hydrogen is reacted into mixing
plant where urea in vapour form is obtained.
 2NH3 + CO2 = NH2CONH2
 This urea vapour is condensed by natural
convection in a chimney of hieght 104 mitres.
 At the base of chimney small spherical urea is
obtained which is further sent to packaging
unit by means of conveyer belt.

6.  “As per Indian Boiler Act 1923, a boiler is a
closed vessel with capacity exceeding 22.75
liters used for generating steam under
pressure”

7.  The steam produced may be supplied to:
 Power Generation
 Heating
 Space heating
 Hot water supply
 Industrial Processes
 Sugar mills
 Chemical industries

8. Boiler Make & Year :XYZ & 2003
MCR(Maximum Continuous Rating) :10TPH (F &
A 100oC)
Rated Working Pressure :10.54 kg/cm2(g)
Type of Boiler: 3 Pass Fire tube
Fuel Fired: Oil

10.  Steam Generator # 1,2 & 3 :
Manufacturer :M/S BHEL
Type of unit :Radiant, High pressure, balanceddraft,
Water tube, Bi drum, pulverized coal fired.
Max. continuous rating ( MCR) : 125 MTPH of each boiler
Rated steam pr. & temp. at S.H. outlet : 108 kg/cm2(g) and 465 deg c
 Steam Generator # 4 :
Manufacturer : M/S BHEL
Type of unit : High pressure, pressurized furnace ,
single drum dual fuel fired (oil+ gas )
Max. continuous rating ( MCR) : 200 MTPH
Rated steam pr.& temp. at S.H. outlet : 115 kg/cm2 (g) and 515 deg c
 Turbo generator # 1:
Maximum output : 12.5 MW
Rated voltage : 11 KV
Turbine speed : 6500 RPM
Reduction G.B. output shaft Speed : 3000 RPM
 Turbo generator # 2:
Maximum output :18 MW
Rated voltage : 11 KV
Turbine speed : 5500 RPM
Reduction G.B. output shaft Speed : 3000 RPM

11.  Pressure parts :
 1. Boiler drum.
 2. Economizer.
 3. Super heater & Desuperheater.
 4. Water wall tubes.
 5. Safety valves
 6. Drum level gauge glass
 7. Blow down with valves & CBD tank
 8. Bank Tubes
 9. Remote control impulse lines with valves
 10. Down comers and Riser tubes

12. Other auxiliaries:
1. Furnace wind box and secondary air damper
2. Soot Blowers
3. Coal mills for coal pulverization
4. Oil & Gas burners with igniters
5. Induced draft and forced draft fan
6. Electrostatic precipitator and rapping system
7. Boiler feed pumps
8. Make up water pumps
9. Deaerator
10. H.P. heater /L.P. heaters
l1. Air pre heater

13.  There are requirement of fuel, air & water to
run the Boilers for steam generation.
 Therefore the power plant operation comprises
of following cycles:
 1) Feed water cycle
 2) Steam cycle
 3) Fuel cycle
 4) Air cycle
 5) Flue gas cycle

14.  The feed water cycle of power plant run with closed loop
(based on Rankine cycle) with about 10-15% make up water
demand because of loss of steam and continuous blow down
in process.
 The condensate from Urea/Ammonia and TG condenser
collected in makeup water tanks. The shortage of condensate
is made up by DM water from water treatment plant.
 The required feed water quality is maintained by adding
chemicals & controlling the purity of condensate returned
from process plants.
 It is then pumped to Deaerators via LP heaters by running
makeup water pumps (total 4 nos.). The deaerator will
remove dissolved gaseous impurities and residual is removed
by Hydrazine dosing in outlet of Deaerator.
 Then Boiler feed water pumps takes suction from the
deaerator and pumped water to boiler drum through a HP
heater & Economizer

15. TOMWTB
FROMDM
PLANT
TG#2
TOMWTB
LSL
LSLL
U#2TURBINE
COND
I/CSUCTION
MWP P#1
MWP
C
MWP
D
RECIRCULATION
I/CMWP P#1
DISCHARGE
TOHOTWELL
PT FT
PT FT
FT
VENT
PROCESS I/C
P#1- P#2
U#2PROCESS
CONDENSATE FT
FEED TANK
DEARATOR# 2
CTP
1
CTP
2BFP#5 TBFP#6
I/CD2-D1
I/CFEEDWTR
HEADER
TO BOILER#4
CBDRECOVERY
4ataSTEAMFROMA# 2
4ataI/CP1-P2
13/4 ata PRDS
MWT
CL P HEATER
CONDENSATE AND MAKE UP WATER CYCLE
LT
LIC
FT
FT
TOTRIP MWP
LIC
LT
P
T
TE
LT
LIC
PT
TE
DEA OVER
FLOW LSLL LSLL LSLL
PT
I
TO TRIP BFP

16. Steam Cycle:
Saturated steam generated in boiler is further superheated in
primary super heaters & final super heaters so as to achieve design
steam temperature to 465C at 105 kg/cm2(g)& 515C at 115
kg/cm2(g) in P-1 & P-2 header respectively for use in process and
Turbines.
Different type of steam & its uses :
1) 115 Ata steam:
Oil & gas fired boiler generates to supply it ammonia-2 /
urea-2 plant and to Turbo generator-2 for power generation.
2) 105 Ata steam:
The All three coal fired Boilers generate steam at this
pressure & supply steam to ammonia-1, urea-1 and turbo gen-1.
3) 13 Ata steam:
This steam is used for feed water heating in HP heaters , soot
blowing, driving BFP turbine & FD fan turbine, steam coil air pre
heater, steam jet air ejectors of condenser, LSHS drive turbine..

17. Urea-1
Amm-1 TG-1
BOILER
VENT
AMMONIA#2
AMM#2 BYPASS LINE
5505- B
MSSV1A MSSV- 4B
BOILER# 4
START UP
VENT
TO CEP
PUMPS
TURBINE
CONDENSERFROM FW
HEADER
FROM FW
HEADER
TO CONDENSER
TO L P HEATER
TBFP# 6
TO DEARATOR
13/4 ATA
PRDS
P2-P1
I/C
ATOMISING
STEAM
LSHS
TUBINE
FD FAN
4A
5505- A
TO GSC
TO EJECTOR
115/11 ATA
PRDS
B#3 SB LINE
TO HOT WELL TO GLAND SEALING
FROM FW
HEADER
TO VENT
TO MWT
TO VENT
TO CONDENSER
TO GSC
TO SCAPH
B#3
B#2 B#1

18. Fuel Cycle:
In coal fired Boilers coal of low grade (which are given to the
fertilizers) is used as fuel to boil the water. In oil & gas fired boiler oil
called LSHS/FO and gas named as RLNG is used.
The furnace of coal fired boilers is supplied with 2-types of fuel viz.
1) RLNG for initial light up with gas igniters (8 nos.) & for
supporting flame of coal fire 2) Pulverized coal.
The coal fired boilers are design for high ash low grade coal having
quality as :
Calorific value (kcal/kg) : 4700 (design)
Fixed carbon : 36 %
Moisture : 7%
Ash content :33%
Volatile Matter : 24%

19. DRUM
F.S.H
FURNACE P.S.H
ECONOMISER
VENT
PILOT G.V
PCV FCV
PCV FCV
FGTV
LSHSTV
STEAM VALVE
4
1
5
6
2
3
FT
DRUM
9602
PR.REGULATOR
9602
RTV
Fuel Firing Overview:

20. Air Cycle:
Two Nos. of Forced draft fans in each coal fired
Boilers supply air through regenerative APH to bowl
mill and furnace.
The primary air for coal pulverization & coal dust
conveyance to furnace and secondary air for
combustion of fuel. The air at outlet of FD fans is pre
heated in steam coil air pre heater prior to entry in
APH.
The heat of hot flue gases is utilized to raise the temp.
of air before entry to furnace for fuel combustion.

22. Flue Gas Cycle:
The product of combustion are withdrawn by two nos.
Induced Draft fans through bank tubes, Economizer,
APH & ESP and finally discharge to atmosphere through
tall chimney.
The coal contains approximately 33 % ash of which 15
% fall in bottom hopper and rest 85 % fly with flue gas
to be collected in economizer hoppers and EP hoppers.
The Fly ash collected in ash hoppers is conveyed to ash
silo using dry fly ash disposal system & then transported
to cement plants by trucks and tankers. The bottom ash
is removed & disposed off in the ash ponds in the form
of slurry by means of hydro vectors.