IFFCO Industrial Training Evaluation.pptx

This PowerPoint presentation offers a detailed evaluation of an industrial training program at the Indian Farmers Fertiliser Cooperative Limited (IFFCO), with a specific emphasis on the production processes of ammonia and urea. It meticulously outlines the journey from raw materials to finished products, delving into the technical parameters, chemical reactions, and engineering principles that underpin these critical agricultural inputs.

The presentation begins with an introduction to IFFCO, highlighting its pivotal role in India's agricultural sector and its commitment to sustainable and efficient manufacturing practices. It then transitions to the core subject matter: the manufacturing processes of ammonia and urea.

Overview of Raw Materials: A thorough examination of the raw materials used in the production of ammonia and urea, including natural gas, air, and water. This section also explores the significance of sourcing and preparing raw materials to ensure quality and efficiency in the production process.

Ammonia Manufacturing Process: An in-depth look at the ammonia synthesis process, covering the Haber-Bosch process, reaction conditions, catalysts used, and the importance of temperature and pressure parameters. This section explains how nitrogen from the air and hydrogen from natural gas are combined to form ammonia, a crucial building block for urea production.

Urea Manufacturing Process: A detailed analysis of the urea synthesis process, including the chemical reactions that convert ammonia and carbon dioxide into urea. It highlights the key stages of the process, such as carbamate formation, urea conversion, and finishing processes, alongside discussing the operational parameters that ensure high efficiency and product quality.

Overview of Raw Materials: A thorough examination of the raw materials used in the pr

1. Industrial Training Evaluation IFFCO By – SAUMYA SHAH (20BCH010) KARAN MEHTA (20BCH083) Abhay Rajput (20BCH122D) Ayush Doshi (20BCH124D)

2. IFFCO Plant : Kalol

3. About IFFCO Indian Farmers Fertilizer Cooperative Limited, also known as IFFCO, is a multi-state cooperative society and owned by Cooperative Societies of India. Started in 1967 with 57 member cooperatives, it is today the biggest co-op in the world by turnover of nearly ₹27,852 Crores (F.Y 18-19) on  GDP  per capita with around 35,000 member cooperatives reaching over 50 million Indian farmers . The cooperative was ranked 66th on the Fortune India 500 list of India's biggest corporations as of 2017 with a net worth of $2.6 billion as on March, 2021.

4. Brief History of IFFCO

5. In order to help India become self-sufficient in the production of food grains, the fertilizer cooperative IFFCO, which is owned by farmers, is planted as a seed on Indian soil. Seeds at IFFCO sown in the year 1967 Visionary Shri Paul Pothen becomes the first MD of IFFCO -

6. Through the establishment of two cutting-edge fertilizer facilities in Kandla and Kalol, IFFCO played a significant role in India's industrial revolution. Kalol Plant dedicated to Nation by then PM Shrimati Indira Gandhi - 1974 Shri Paul Pothen, then MD IFFCO awarded with Padma Shree for his contribution in Fertilizer Sector - 1977

7. By constructing two additional urea plants in Phulpur and Aonla, IFFCO solidifies its position as the industry leader in India's fertilizer market. Indian Farm Forestry Development Cooperative (IFFDC) is established with the aim to conserve environment - 1986 First Expansion of Kandla Plant completed - 1987

8. Aonla Plant inaugurated by then PM Rajiv Gandhi - 1989 Expansions at Kalol and Phulpur Plants IFFCO’s new management leads the transformation of IFFCO into a truly modern, efficient and technology driven organization.

9. Through properly selected acquisitions and joint ventures, IFFCO transforms into an independent cooperative, diversifies its product line, and increases its market share in both domestic and foreign markets. IFFCO forms Joint-Venture with Japan’s Tokyo Marine Group to form IFFCO Tokyo General Insurance Company (ITGI) - 2000 IFFCO decides to set up a Plant at Edisha , Jordan by forming Joint Venture with Jordan Phosphate Mines Company Limited (JPMC) called Jordan India Fertilizer Company (JIFCO) - 2008

10. In order to advance India's agricultural industry, IFFCO has launched new initiatives in the fields of microfinance, Agri-insurance products, food processing, skill development, and ICT-based knowledge dissemination. Joint Venture with Mitsubishi Corporation IFFCO-MC formed to set up agrochemical business in India - 2015 IFFCO e-Bazar Limited Formed to promote retail and eCommerce in the field of Fertilizer and Agriculture - 2016

11. With the use of cutting-edge agricultural techniques, increased productivity, modern technology, diversification into other industries, and environmental sustainability, IFFCO seeks to improve the farming community and achieve farmer prosperity. IFFCO Launches its Nano Technology based Products IFFCO Forms a Joint Venture with Congelados de Navarra (CN Corp.), Spain to set up a food processing plant at Ludhiana, Punjab

12. Primary Nutrients NP(S) 20-20-0-13 DAP 18-46-0 NPK 10-26-26 NPK 12-32-16 Neem Coated Urea (N)

13. Kalol Unit The Kalol Production Unit, the first urea and ammonia production facility built by IFFCO, was commissioned in 1974 and has a production capacity of 1200 MTPD of urea and 910 MTPD of ammonia. The IFFCO Kalol Production Unit has grown and reinvented itself over the past four decades to keep up with contemporary production units in terms of both production capacity and technology. The current production capacity of the IFFCO Kalol plant is 1100 MTPD of ammonia and 1650 MTPD of urea.

14. Kalol unit manufacturing plants Ammonia Desulphurization of Natural Gas Catalytic Steam Reforming Carbon Monoxide Shift CO2 Removal Methanation Ammonia Synthesis Urea CO2 supply and compression NH3 supply and pumping Reaction/High pressure systhesis Low pressure/Recirculation system Evaporation and Prilling system

15. About Ammonia Ammonia is an inorganic compound of nitrogen and hydrogen with the formula NH 3 . The IFFCO Kalol plant features an 1100 MTPD Ammonia Plant, which has been meticulously designed and engineered by M/S. M.W. Kellogg Within the plant, the following raw materials are employed: R-LNG (Re-liquefied Natural Gas): This component is in a gaseous state and originates from the GAIL station. MDEA (Methyl Diethanolamine): This substance is present as a 40% solution and is sourced from BASF and HUNTSMAN. Water: Water, in its liquid state, is sourced from the Narmada Water Canal. Air: Gaseous air is procured from the atmosphere and used as an essential element within the plant's processes.

16. Primary Reformer In primary reformer hydrocarbons are converted into hydrogen Reforming Reactions: CnH2n+2+ nH2O + Heat⟶nCO + (2n+1)H2 The gas then passed through 336 n0 of tubes filled with nickel catalyst and heated up to 790-815 ° C by external firing from top Total 126 burners are provided at top for heating of gas . The cooled fuel gas is discharged through the stack . From primary reformer a mixture of hydrogen , carbon monoxide , carbon di oxide and methane is obtained .

17. Secondary Reformer The partially reformed gas from Primary Reformer enters the Secondary Reformer inlet chamber tangentially through Transfer line . The temperature of the gas inlet to Secondary Reformer is around 786°C . 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: 3H 2 + 1.5O 2 + 3.715N 2 ⥨ 2H 2 O + 3.175N 2 + H 2 O 2CH 4 + 1.5O 2 + 13.00N 2 ⥨ CO 2 + CO + 4H 2 + 13.00N 2 + Heat

18. Shift Conversion HIGH TEMPERATURE SHIFT CONVERSION CO + H 2 O⥨ CO 2 + H 2 + Heat As indicated by the reaction carbon mono oxide is converted into carbon dioxide and getting an additional mole of hydrogen. The reformed gas enters the H.T section of S.C at 366°C temp and about 30.9kg/cm 2 g pressure, flows through the catalyst bed . The catalyst used in H.T.S.C is copper promoted iron oxide catalyst in reduced state . LOW TEMPERATURE SHIFT CONVERSION The gas coming out of high temperature shift converter contains 3.15% of CO 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

19. CO 2 Removal In this section the bulk of CO2 in the raw synthesis gas is removed by absorption , using 40 % aqueous activated methyl dithranol amine ( a - MDEA ) solution , at relatively high pressure and low temperature . The absorption of CO2 involves the reaction of dissolved CO2 in water with a - MDEA to form a loose chemical compound which can be easily dissociated at higher temperature and lower pressure . Carbon dioxide (CO2) is removed from the process gas by absorption in a solution of MDEA known as Benfield. CO2 + H2O → H2CO3

20. Methanator For ammonia synthesis a very pure gas mixture of H2 and N2 in the ratio of 3:1( by volume ) is required and the small amounts of CO2 and CO are poisonous to the ammonia synthesis catalyst . These oxides are removed by converting them into methane in Methanator by a highly active nickel-based catalyst in presence of H2. This step is known as Methanation. Methanation reactions are given below: CO + 3H2 →CH4 + H2O H=-49.28kcal/mole CO2 + 4H2 → CH4 + 2H2O H=-39.44kcal/gmole

21. 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. Finally, syn gas is chilled to about 80°C in Inter Stage Chiller before entering to Dehydrator . Recycle gas mixture at about 134kg/cm2g pressure and 38.2°C temperature , containing ammonia ( 1.99 % by volume ) and unreacted reactants from synthesis converter .

22. Refrigeration The primary purpose of the refrigeration system is to make available liquid refrigerant ammonia at different temperature which is required to circulate through chillers for condensing product ammonia from converter feed . 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

23. UREA PRODUCTION BY STAMICARBON STRIPPING PROCESS

24. UREA Urea is a chemical compound with the molecular formula CO(NH2)2   The facility was put into service in January 1975. It was the country of India's first substantial manufacturing facility, and it underwent an update in 1997. The factory can currently produce 1650 tonnes per day.  

25. PROCESS DESCRIPTION CO2 supply and compression NH3 supply and pumping HP Stripper HP Condenser Autoclave Pre-evaporator Urea storage tanks Evaporation and prilling tower system Material handling 2NH3 + CO2 ⇌ CO(NH2)2 + H2O

26. USES Fertilizer Laboratory Reagent Plastics and Resins Cosmetics and Personal Care Medical Diagnostics Textile Industry Hydrogen Production Pharmaceuticals Paint and Coatings Animal Feed

27. WHY STAMICARBON PROCESS IS USED? Energy Efficiency Lower Carbon Footprint Waste Reduction High Urea Yield Less Corrosion Economic Viability Reduced Byproduct Formation Flexibility

28. OFFSITES Water Treatment Plant Cooling tower Inert Gas Generation Steam Generation Plant Plant and Instrument Air Ammonia Storage and Handling Effluent Treatment Plant Narmada Water

29. Water Treatment Plant Water treatment plant ( WTP ) is required to treat Narmada water for producing specified quality of cooling tower make - up water and boiler feed make up water . A demineralization-based water treatment plant has been provided to generate the entire quality of make - up water for cooling tower and boiler feed water of high quality for high pressure from the raw water .

30. Cooling Water Most industrial processes need cooling medium for efficient and proper operation . Water is the most effective cooling medium used today because, It is normally plentiful It is easy to handle and can carry large amount of heat per unit volume It does not decompose. The system using water as coolant is called as cooling water systems . During process, the cooling water gets heated up and must be either cooled before it can be used again or replaced with fresh water .

31. Inert Gas generation : Inert gas ( IG ) is used for the preservation of catalyst and for purging of pipelines and vessels mainly in ammonia plant before handling over for maintenance . IG can also be supplied to ammonia , naphtha and LSHS storage areas , CO₂ compressor and steam generation plant . At Kalol plant , nitrogen is used as inert gas . During the plant turn around and shutdowns of ammonia plant the fresh catalyst can be reduced using the cracked gas and inert gas generated in inert gas generation plant. IG thereby saving around 6 to 7 days of start up time of ammonia plant .

32. Steam Gas generation : The steam generator is pressure vessel into which liquid water is pumped at the operating pressure . After heat has vaporized the liquid , the resulting steam is then ready either for delivery to the use or for flirter heating in a super heater . At IFFCO - Kalol plant , a BHEL make boiler of 80 t / h ( net ) capacity was commissioned on 5th October 1982 and is in operation since then . The BHEL boiler is water tube , bid rum , forced draft furnace . It is oil and / or gas fired boiler of 80 t / h capacity at 61.5 Kg / cm²g pressure and 410 ( +/- 5 ) C temperature .

33. Plant and Instrument Air The objective of installing compressors and maintaining the compressed air system is to provide service air ( plant air ) and instrument air at the point of application in sufficient quantity and with adequate pressure for efficient operation of instruments , controls , air tools and appliances on - line air masks and for emergency start - up of 0.860MW diesel generation set in case its air compressor is not available . The plant air is supplied to : Ammonia plant Urea plant Utility / offsite plant Workshop Bagging and material handling plant On line air masks Various local connections The instrument air is supplied to: Ammonia storage tank • Water treatment plant • Urea plant • Bagging and material handling plant • Steam generation plant • Effluent treatment plant • Cooling towers • Inert gas generation plants

34. Ammonia Storage Handling 10000 tons ammonia storage tank: 10,000 tons liquid 𝑁𝐻3 storage tank was built by Ms Vijay tanks & vessels Pvt . Ltd. It is as single wall cylindrical vessel with a fixed self - supporting cone roof & insulated with polyurethane foam Its diameter is 30m & height is 21.5m . The tank is provided with refrigeration system & sufficient safety gadgets .

35. Ammonia Storage Handling 5000 tons ammonia storage tank: 5000 tons liquid𝑁𝐻3 storage tank constructed by India tube mills Ltd. & it was installed in year 1992. It is in cup double wall type , cylindrical vessel with suspended deck on inner wall fixed self - supporting cone roof on outer wall . The space between two walls remains filled with NH3 vapour which works as an insulator . The outer shell diameter is 23.29m & height is 21. 74m while inner diameter is 21.79m & height is 20.25m .

36. Effluent Treatment Plant Approximately 18000m³ / day of raw water is utilized at IFFCO Kalol mainly for process water & boiler feed water generation. Effluent treatment facilities have been installed to handle the 3500-4000m3 / day bulk & 50-600m³ / day strong effluent coming out of various out of various plants every day. Effluent treatment system is installed to control the undesirable element in the liquid effluent before discharging outside IFFCO premises . Effluent discharge outside IFFCO should statutory requires norms imposed by state & central pollution control boards .

37. Narmada water system in IFFCO (Kalol unit) IFFCO Kalol plant is away from the river and no lake is available in the nearby vicinity. Thus, the water required is received from SSNNL ( Sardar Sarovar Narmada Nigam Limited ) Raw water is required in the plant mainly for: Cooling tower ( CT ) make up water after partial treatment in WTP . Blending to cooling tower make up water . Boiler feed water make up tower after treatment in WTP . Drinking water . Fire water Service water & other miscellaneous uses Water to township . This plant is designed for the treatment of 1800M³ / Day water which is received from SSNNL ( Sardar Sarovar Narmada Nigam Ltd. ) Dholka branch canal near Jaspur village

38. Associates & subsidiaries National

39. Associates & subsidiaries International