(IFFCO ) 2018
TRAINING REPORT
(Topic)
AMMONIA
MANUFACTURING PLANT
By-
Neha Gupta
3rd year B.Tech Undergraduate
I.E.T. Lucknow
Under Guidance of:
Mr. Subrata Sur
Sr. MANAGER (TRAINING)
INDIAN FARMERS FERTILISER COOPERATIVE LIMITED (IFFCO)
Phulpur (U.P)
(IFFCO ) 2018
CERTIFICATE
This is to certify that vocational training report titled ‘ammonia manufacturing plant’ which
is submitted by Ms. Neha Gupta, to the training cell (IFFCO Phulpur), in partial fulfillment
of requirement for award of bachelor of technology degree in chemical engineering, is a
record of the advert work successfully carried out by the student under my guidance and
supervision .She has exhibited sincere efforts and keen interest in the preparation of this
report.
- Mr. Subrata Sur
Sr. Manager (Training)
IFFCO, Phulpur.
(IFFCO ) 2018
ACKNOWLEDGEMENT
I would like to express my gratitude to all those who gave me the imperative opportunity for
a pragmatic exposure and helped to complete this project report. I would like to thank Indian
Farmers Fertilizer Cooperative Limited, Phulpur for providing me this training and for
guiding throughout the training.
I am deeply indebted to MR. Subrata Sur (Sr. Manager of Training Department,
IFFCO) who permitted me to pursue my summer training at IFFCO, phulpur .
Last but not the least, I would like to thank Dr. R.P. Ram H.O.D.(Department Of
Chemical Engineering, Hbtu Kanpur ) and Mr. Arun Mittal (faculty Incharge, Training
and Placement, I.E.T., Lucknow ) who allowed me for the training in summer vacations of
third Year.
Though it is tough to collect the necessary information within a short period of time, with
the support that I got from the operators of different plants an most helpful library of
IFFCO, I was able to complete the report in the given course of time.
Thanking you.
Neha Gupta
(IFFCO ) 2018
Table of Content
1. Introduction
About IIFCO
Ammonia
2. Ammonia plant
Desulfurization
Primary Reformer
Secondary Reformer
Shift Conversion
Condensate Stripping
Methanation
Ammonia Synthesis
Refrigeration
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1. Introduction-
About IFFCO: Indian Farmers Fertiliser Cooperative Limited (IFFCO) is one of India's
biggest cooperative society which is wholly owned by Indian Cooperatives. Founded in 1967
with just 57 cooperatives, we are today an amalgamation of over 36,000 Indian Cooperatives
with diversified business interests ranging from General Insurance to Rural Telecom apart
from our core business of manufacturing and selling fertilisers. The turnover is of 20,788 Cr.,
with the total income of 23,514 Cr. The total production that includes both the plant of
Ammonia and Urea manufacturing unit is of 84.79 lakh MT.
Ammonia: IFFCO, Phulpur has a production of Ammonia in two plants that is mainly
Phulpur-I and Phulpur-II that produces Ammonia-I and Ammonia-II, respectively. Both the
plant uses different technology as well as the raw material. The detailed production of the
individual plant is explained further.
Phulpur-I has made great strides in reducing Energy consumption. From initial energy
consumption of above 12 GCal/MT of Urea in early eighties, it was brought to level of below
9.8 GCal/MT of Ammonia by 2001-02. This was further brought down to below 8.2
GCal/MT after implementing a dedicated energy saving Project (ESP) in two phases. It is
expected that the energy consumption for Phulpur-I Unit shall be around 7.95 GCal/MT of
Ammonia in the year 2011-12. There were design bottlenecks in operation of Phulpur-I
Ammonia Plant at rated capacity. In the year 1987-88, remarkable in-house modification,
especially to the Primary Reformer, were carried out to remove the capacity constraints.
Further Capacity Enhancement Project was successfully implemented in the year 2008 to
enhance the capacity of Ammonia Plant. The Plant capacity went up from 900 MTPD to 1215
MTPD. Subsequently, Ammonia Plant was also successfully converted to Gas in the year
2006 replacing liquid fuels Naphtha. Phulpur was the first Unit in India which was converted
to Gas.
Plant: Ammonia-I
Process Licensor: MW Kellogg, U.S.A.
Annual Capacity: 4 lakh MT
Plant: Ammonia-II
Process Licensor: Haldor Topsoe AS, Denmark
Annual Capacity: 5.7 lakh MT
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2. AMMONIA PLANT-
Ammonia is a important raw material to manufacture Urea. Ammonia is manufactured in
Ammonia Plant. Ammonia plant is based on HALDOR TOPSOE TECHNOLOGY.
To manufacture ammonia, we need hydrogen and nitrogen in gaseous form. We get
Nitrogen from Inert Gas (From Atmosphere) plant and hydrogen from Natural Gas.
Natural Gas is supplied at the battery limit by GAS AUTHORITY OF INDIA
LIMITED (GAIL) from gas wells located in Bombay through HAZIRA-BIJAPUR-
JAGDISHPUR (HBJ) Pipeline. GAIL has plans to set up certain facilities for
extraction of higher hydrocarbons from the gas due to which the gas would become
leaner.
To get the Ammonia manufactured, the following steps should be followed:
1. Desulphurization
2. High Pressure Catalytic Reforming
3. Water Gas shift reaction
4. Carbon Dioxide absorption and stripping
5. Ammonia Synthesis
6. Refrigeration
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FLOW CHART OF AMMONIA PLANT
RLNG
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DESULPHURIZATION
Natural Gas contains sulphur compounds in the form of
sulphides, disulphides, mercaptions, thiophenes etc. which
are poisonous to the catalysts used in Ammonia plant.
Two steps in Desulphurization:
Hydrogenation of sulphur compounds in the presence of
catalyst. Hydrogen reacts with organic sulphur
compounds to form hydrogen sulphide in HYDROGENATOR.
This hydrogen sulphide is absorbed by zinc oxide in
sulphur absorber.
HYDROGENATION
Common type of sulphur compounds present in
Natural Gas:
Hydrogen Sulphide
(H2S)Mercaption sulphur (R
-SH) Sulphides (CH3-S-CH3)
Disulphides (CH3-S-S-CH3) Cyclic
Sulphides (-S-CH2-)Reactions in the
hydrogenation process: RSH + H2 ⟶ RH +
H2S COS + H2 ⟶ CO + H2S
Favorable temperature for this reaction is between
380 to 390 °C.
SULPHUR ABSORPTION
Each reactor contains 13.8 m3 of Zinc O xide.
Reactions:
ZnO + H2S ⥨ ZnS + H2O
ZnO + COS ⥨ ZnS + CO2
Now the gas is sent to primary reformer.
PRIMARY REFORMER
In primary reformer hydrocarbons are converted
into hydrogen
. Reforming Reactions:
CnH2n+2 + nH2O + Heat ⟶ nCO + (2n+1)H2
Heat is supplied by burning mixed fuel gas in 216 fired wall.
Catalyst used in primary reformer is Nickel based.
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PRIMARY REFORMER
SECONDARY REFORMAR
In the secondary reformer combustion and reaction of the
primary reformed gas with process air takes place.
Secondary reformer is a conical cylindrical vessel. High
pressure shell is insulated from inside with refractory
material to protect shell from high temperature. The
reaction with air in the secondary reformer combustion zone
is as follows:
3H2 + 1.5O2 + 3.715N2 ⥨ 2H2O + 3.175N2 + H2O
2CH4 + 1.5O2 + 13.00N2 ⥨ CO2 + CO + 4H2 + 13.00N2 + Heat
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SECONDARY REFORMER
SHIFT CONVERSION
Shift conversion means the reaction of carbon mono oxide
and steam to produce carbon dioxide and hydrogen. The
conversion takes place in two reactors high temperature shift
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reactor and low temperature shift reactor.
HIGH TEMPERATURE SHIFT CONVERSION
The following reaction takes place:
CO + H2O ⥨ CO2 + H2 + Heat
As indicated by the reaction carbon mono oxide is
converted into carbon dioxide and getting an additional
mole of hydrogen. The reaction gives about 65 °C
temperature rise when passes through catalyst bed.
Approximate analysis of the gas leaving high temperature
shift converter is given below:
Gas Mole %
H2 60.22 %
N2 20.73 %
CO 3.15 %
CO2 15.37 %
Ar 0.25 %
CH4 0.28 %
Steam 0.394 %
LOW TEMPERATURE SHIFT CONVERSION
The gas coming out of high temperature shift converter
contains 3.15% of carbon mono oxide that should be
reduced to lower values before sending to CO2 removal
and methanation. Temperature in LT shift converter is
maintained between 200 to 240 °C.
Approximate analysis of gas leaving the LT shift converter:
Gas Mole %
H2 61.34 %
N2 20.15 %
CO2 17.25 %
Ar 0.24 %
CH4 0.27 %
Steam 0.355 %
PROCESS CONDENSATE STRIPPING AND CO2 ABSORPTION
After low temperature shift conversion the process
condensate is sent to process condensate stripping section.
Process condensate is sent to the stripper to remove volatile
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gases such as ammonia, methanol, and carbon dioxide.
Process condensate stripper has 28 trays. Steam is pumped at
bottom and condensate is flooded at top of vessel.
Carbon dioxide (CO2) is removed from the process gas by
absorption in a solution of potassium carbonate known as
Benfield. The gas is contacted with the Benfield solution in
an Absorber and leaves at the top. The solution itself is
regenerated by heating in a stripper column and the released
CO2 is used as a feedstock in the production of Urea.
Absorption of carbon dioxide by Benfield solution:
K2CO3 + H2O + CO2 ⥨ 2KHCO3
METHANATION
The gas stream leaving the Absorber consists primarily of
hydrogen and nitrogen in addition to small quantities of
unabsorbed carbon oxides. Since carbon dioxide and carbon
monoxide would poison the ammonia synthesis catalyst, the
concentration must be reduced to less than 10 ppm. In the
Methanator the carbon oxide and carbon monoxide is
converted back to methane over a Nickel catalyst in a reaction
which is reversed to that of steam reforming .
METHANATOR
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Reactions in Metanator:
CO + 3H2 ⥨ CH4 + H2O + Heat (Nickel Catalyst)
CO2 + 4H2 ⥨ CH4 + H2O + Heat
AMMONIA SYNTHESIS
The process gas leaving the Methanator is compressed and sent
to the ammonia synthesis reactor which is a vessel containing
four beds of catalyst. The first bed is Iron Oxide i.e. magnetite
while the other three contain a Ruthenium based catalyst . This
latter catalyst allows conversion of hydrogen and nitrogen into
ammonia at lower pressure and temperature and with greater
yield.
AMMONIA REACTOR
REFRIGERATION
The effluent from the ammonia converter is cooled
successively with incoming feed gas, cooling water, and
refrigerated ammonia liquid to condense the ammonia in the
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stream at -280F. The liquid is then pumped to storage tanks
where the temperature is maintained in order to keep it in the
liquid state. The unreacted hydrogen and nitrogen is returned
to the synthesis converter as an uncondensed recycle gas
stream.
At IFFCO refrigeration circuit is three level chiller (chiller
cools but don’t change state while condenser changes state as
well):
High Level Chiller
Medium Level Chiller
Low Level Chiller
Flow chart of Refrigeration cycle:
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III. References
Ammonia-2 Training Manual, IFFCO Phulpur .
Offsite Plants Training Manual, IFFCO Phulpur .
Power Plant Training Manual, IFFCO Phulpur .
Urea-2 Training Manual, IFFCO Phulpur .
Urea - Wikipedia, the free encyclopedia,
http://en.wikipedia.org/wiki/Urea
The Urea Technology, Snamprogetti Training Manual.
