`SUMMER TRAININGAT
BABRALA (U.P)PROJECT REPORT ONEVALUATION OF AMMONIA VAPOUR LOAD
ON REFRIGRATION COMPRESSOR K-451 AND MARGIN FOR OPEN ANTISURGE
INDIAN INSTITUTE OF TECHNOLOGY ROORKEEROORKEE, UTTARAKHAND,
INDIASubmitted by:Joyal Dubey( Department of Chemical Engineering
)Under the supervision of:Mr. Maneesh Sankhyadhar(Manager Ammonia
Department) CERTIFICATEWe hereby certify that the work which is
being presented in the training project report entitled EVALUATION
OF AMMONIA VAPOUR LOAD ON REFRIGRATION COMPRESSOR AND MARGIN FOR
OPEN ANTISURGE by Joyal Dubey in partial fulfillment of
requirements for the award of degree of B. Tech. (Chemical
Engineering) submitted at INDIAN INSTITUTE OF TECHNOLOGY ROORKEE,
INDIA is carried out during a period from 3rd June 2013 to 6th July
2013 under our supervision .
(Joyal Dubey)This is to certify that the above statement made by
the candidate is correct to the best of his knowledge.Project Head:
-
Mr. S.K.S. Chauhan (Head of Department Ammonia Section) Project
Guide:-
Mr. Maneesh Sankhyadhar (Manager Ammonia)
Mr. B Chaitanya Babu (Deputy Manager Ammonia)
ACKNOWLEDGEMENT
Words are inadequate and out of place at times particularly in
the context of expressing sincere feelings in the contribution of
this work, is no more than a mere ritual. It is our privilege to
acknowledge with respect & gratitude, the keen valuable and
ever-available guidance rendered to us by Name and Designation of
Training Guide/Mentor of industry without the wise counsel and able
guidance, it would have been impossible to complete the training in
this manner.I am always be highly grateful to Mr. S.K.S. Chauhan,
(Head of Department), and Mr. Maneesh Sankhyadhar, (MANAGER) for
providing this opportunity to carry out the present work. I would
like to thank Mr. Chaitanya Babu for his appreciations that made me
more enthusiastic in delivering my best efforts for completion of
the project We express gratitude to other faculty members of
Chemical Engineering Department, IITR for their intellectual
support throughout the course of this work.Finally, we are indebted
to our family and for their ever available help in accomplishing
this task successfully. Above all we are thankful to the almighty
god for giving strength to carry out the present work.
Name of Candidate : Joyal Dubey
DECLARATION
I hereby declare that all the information mentioned in the
project report is best to my knowledge; I have not submitted the
same report in any other organization. All the findings are based
on my own effort and research.
Joyal Dubey
CONTENTSS.No. Name
1. Certificate 2. Acknowledgement 3. Introduction to Company 4.
Fire & Safety Fire Prevention Classification of fire Fire
fighting gadgets & appliances Safety programme at T.C.L. 5.
Ammonia Plant (Process Description) De sulphurisation Section Steam
Reforming Section Shift Conversion Section CO2 Removal Section
Methanation Section Compression Section Ammonia Synthesis and
Refrigeration Section Ammonia Recovery Section Purge Gas Recovery
Unit
6. Project Objective Theory Design Data 7. Calculations Design
calculations Operating calculations 8. Results 9. Proposed Scheme:
Possible Queries10. References11. Experience
INTRODUCTION TO TATA CHEMICALS LIMITED BABRALATata Group,
India's foremost business conglomerate. Tata Chemicals, by itself,
is one of the largest inorganic complexes in the world beginning to
TATA Group. Its first plant, which is also called inaugurated
establishment of TATA. It is India's leading manufacturer and
marketer of inorganic chemicals and fertilizers, with a turnover of
over Rs. 4000 crores and is part of the Rs 65,000-crore ($14.25
billion) TCL's products and production processes are benchmarked
with the best of global touchstones, and meet the most rigorous
international specifications., Established in 1939. An
ISO-9001/14001 OHSAS 18001 certified company, TCL has a varied user
industry base comprising glass, paper, textiles, food additives,
petroleum, refining, chemicals, dyes, pesticides, direct farm
application etc. The products go into numerous end-use applications
in a variety of industries: glass, detergents, paper, textiles,
agriculture, photography, pharmaceuticals, food, tanning, rayon,
pulp, paints, building and construction, and chemicals.
Tata Chemicals is also one of India's leading manufacturers of
urea and phosphatic fertilizers. With an export presence in South
and Southeast Asia, the Middle East and Africa, it has set itself
the objective of achieving global cost competitiveness in soda-ash.
Its foray into phosphatic fertilizers follows the merger of Hind
Lever Chemicals Limited into Tata Chemicals Limited. TCL's
phosphatic fertilizer complex at Haldia in West Bengal is currently
the only manufacturing unit for DAP/NPK complexes in West Bengal.
The Haldia plant has production volumes exceeding 1.2 million tons
per annum. Tata Chemicals makes urea at its fertilizer complex in
Babrala. The complex has an installed capacity of 8, 64,000 tons
per year, which constitutes nearly 12 per cent of the total urea
produced by India's private sector. Tata Chemicals is among the
world's largest producers of synthetic soda ash, with the largest
domestic market share, produced at the company's integrated complex
at Mithapur on the Gujarat coast in western India.
The fertilizers, sold under the brand name 'Paras', lead the
market in West Bengal, Bihar and Jharkhand. TCL is also a pioneer
and market leader in the branded, iodized salt segment. Its salt
has a purity percentage of 99.8 per cent, the highest in the
country.
CREDENTIALS OF TATA CHEMICALS LIMITED BABRALA AWARDS:
Prestigious Industry Award, Govt. of UP., 1995. National Energy
Conservation Award, Ministry of Power, 1997. National Energy
Conservation Award, Ministry of Power, 1998. Best Production
Performance Award for Nitrogenous Fertilizers, Fertilizers
Association of India. Second best productivity performance in
Nitrogenous Fertilizers Industry, 1997-98. Yogyata Praman Patra
Award, 1998. Jawaharlal Nehru memorial National Award for Pollution
Control and Energy Conservation, 2000-01. Golden Peacock
Environmental Management Award, World Environment Foundation,
2001-02. Best Technical Innovation Award, Fertilizer Association of
India, Dec.2004. Excellence in Safety, Fertilizer Association of
India, Dec.24. Commendation Certificate for Strong Commitment to
TQM, CII-Exim Bank Award for Business Excellence, Nov.2004. 5 Star
Rating in Safety, British Safety Council, UK, Safety Gold Awards,
Greentech Foundation, Delhi. Indian Chemical Council (ICC) confers
the ICC award for social responsibility 2005-06. NSCI safety award
for 2006. ICC Aditya Birla Award for Best Responsible Care
Committed Company and ICC Award for Social Responsibility for
2005-06. Fertilizers Association of India Award for the Best
Technical Innovation 2007. Nine ABCI (Association of Business
Communicators of India) Awards, 2008.
TCL BABRALA: THE NATIONS CONCEIT Substituting a part of the
imports of Urea, TCL, Babrala is estimated to save the country
about Rs. 500 crores in foreign exchange every year and provide the
farmer with nitrogenous nutrient, which could help raise the food
production by about 4 million tones/year. First major steps towards
the fulfillment of a long standing TATA CHEMICALS commitment to
provide the farmer with an optimal package of agriculture inputs to
safe guard the food security of the company. Produced more than
100% of the designated production during the first year of
commercial production. Produced more than 8, 40,102.35 tons of Urea
achieving a capacity of 113% in the year1995-96, and produced 9,
51,764 tons of Nitrogenous Urea in year 1996-97. Now produce
capacity of 8, 64,000 tons of Urea per year, which constitutes
nearly 12 per cent of the total urea produced by India's private
sector. Total production of urea at Babrala is 3575 tons/day
maximum and 3500 tons/day average. Current maximum capacity is
101%. The Babrala facility, among the best of its kind in India and
comparable to the best in the world, has set new standards in
technology, energy conservation, productivity and safety It is the
only fertilizer plant in the country to use dual feedstock: natural
gas or naphtha, or a combination of both.
MILESTONES OF TATA CHEMICALS LIMITED, BABRALA
Commercial Production Started onDecember 21, 1994
AMMONIA UNIT
First firing of Reformer Furnace for dry out of
refractoryOctober 12, 1994
First feed into Primary ReformerOctober 20, 1994
First Carbon Dioxide for making UreaOctober 23, 1994
First Ammonia productionNovember 14, 1994
UREA UNIT
Urea Prill Test conductedOctober 04, 1994
First Prill Test conducted through Unit 2November 05, 1994
Second Prill Test conducted through Unit 2December 09, 1994
ISO 14001 certificate obtained in October 2000.
ISO 14001 certificate for Babrala township obtained in 2004.
COMPOSITION OF TATA CHEMICALS LIMITED, BABRALA
Ammonia Plant
Capacity: 2000MTPD Technology: HALDOR TOPSE Process, DENMARK
Plant (Single Stream) Production: 2000 tons/day of liquid Ammonia.
After de-bottlenecking Plant at TCL, Babrala is the first low
energy plant in the country.
Basic scheme involves the following steps:
Desulphurization. Primary, Secondary Reforming and fired heater
Carbon Dioxide Shift. Methanation. Synthesis and Chilling. Storage
and supply to Urea unit
2.Urea Plant
Capacity: 3500 MTPDTechnology: SNAMPROGETTI Process, ITALY
Carbon Dioxide requirements supplied from ammonia plant. Two urea
strings have a common Prilling section. Maximum Urea production:
3574 tonnes per day
Basic scheme involves the following steps:
Urea Synthesis Waste Water Treatment section
3.Offsite and Utilities
S. N.UNITCAPACITYTECHNOLOGY
1.Ammonia Storage Tank2X5000 MTM/S Kaveri Engineering
2.Captive Power Plant1X110 TPHTHERMAX/ L&T
3.Cooling Tower24000 M3/hrM/S Paharpur Cooling Tower
4.D. M. Water Plant3X450 M3TCL, Mithapur
5.Gas Turbine Generator2X20 MWTHOMASSON, Holland
6.Heat Recovery Unit2X90 TPHL&T
7.Naptha Bulk Storage Tank3X6300 KLM/S Technofab Engg. Ltd.
SALIENT FEATURES OF TATA CHEMICALS LIMITED, BABRALA Location
Babrala, District Sambhal, Rajpura block, Gunnor Tehsil, Uttar
Pradesh. Approx. 160km. south-east of Delhi.
Land Area 1519 acres Plant area:1,069 acres Township area:350
acres Green belt: 100 acres
Fuel Natural gas (main) Naphtha (alternate)
Fuel Source Natural gas supplied by GAIL (HBJ Pipeline) Naphtha
from IOCL, Mathura
Consumptive water source Eight deep bore wells.
Present installed capacity Ammonia:2000 MTPD Urea: 3500 MTPD
Man power Deployment (During Commissioning/ Erecting phase )
Total 7,855,128 man-hours. Peak (month) 405,799 man-hours.
Beneficiary states U.P., Bihar, West Bengal, Punjab, M.P.,
Assam.
UNIQUE FEATURES OF TATA CHEMICALS LIMITED, BABRALA
An integrated energy network, which is the key, factor in
achieving high energy efficiency. The flexible range of the ratio
of natural gas and naphtha as a fuel/ feed is a major reason for
this. The current low operating energy record is 5.13 Gcal/MT of
Urea. The second unique feature is common single central control
room (CCR) for ammonia, Urea to captive power and steam generation
plant (CPSSGP) and other offsite and utility plants. This provides
a well-coordinated and integrated control of the entire complex
from one location and on line inters plant sharing of information.
This has been found extremely beneficial especially during plant
startups and upsets.
QUALITY POLICY OF TATA CHEMICALS LIMITED
To provide customer satisfaction and timely delivery of quality
products. Maintain good quality management systems and incorporate
regular improvements to meet our customer changing needs.
Continuously upgrade product quality by improvements in process
technology. Develop and upgrade employee skills and provide an
environment for their effective participation through teamwork to
meet our customer expectations. Take adequate care to ensure safety
at the work place, environmental preservations and to respond to
the needs of the community.
FIRE AND SAFETY
FIRE CHEMISTRY: The well-known Fire triangle requires the three
ingredients of fire namely fuel, oxygen and source of ignition.A
fire is a combination of fuel, oxygen and source of ignition.2.1
FIRE PREVENTION:Fire prevention can be done in three ways:
Eliminate sources of ignition. Eliminate combustible substances.
Eliminate air excess to combustible substances.
FIRE PREVENTION THROUGH ELIMINATION OF IGNITION SOURCES:To
prevent fire the first is to remove the cause of fire. Studies made
by fire insurance company shows that majority of fires are caused
by following general sources of ignition: Electrically limited
fire: Improper earthing, short circuiting, loose electrical
contacts, temporary direct connections without proper fittings,
high current, over heating of electrical equipment are among the
common cause of electrically initiative fires. Smoking ignited
fire: Smoking or even carrying cigarettes/ beedies/matches/lighter
etc. in the following areas is a serious offence. All non-smoking
areas should carry NO SMOKING signboards. Friction and overheated
material: In flame proof areas, frictional fires can also be
started by the friction of moving parts of machinery which are
overheated due to excess friction. This is likely in non-lubricated
and not well maintained machinery.
FIRE PREVENTION THROUGH ELIMINATION OF COMBUSTIBLE
MATERIALS:
Waste and combustible materials: All combustible wastes and
materials like waste paper, cotton waste etc. accumulated after a
job should be transported to waste bins and is the responsibilities
of the person doing the job that creates the wastes. Tins and cans
of flammable materials like paints, oils, spirit etc.: These should
be handled carefully ensuring that no undue spillages takes place
during their uses and any spillages takes place during their use
and any spillage should be cleaned immediately. Fueling of vehicle
tanks: Engine should be always switched off while fueling a
vehicle. If diesel or petrol spills over during fueling, dry sand
should covered over the spill immediately till only dry sand is
visible on the spilled area. Waste disposal: All combustible waste
must be regarded in such a way that can be disposed of as such and
not burnt.
PREVENTION THROUGH ELIMINATION OXYGEN SUPPLY: Smoothening: It is
a process of covering the burning area with a non-combustible
substance like asbestos or fire proof blanket, wet thick cotton
blanket or sand.
2.2 CLASSIFICATION OF FIRES:Fires are classified according to
the nature of fuel burning and fire extinguishing methods that can
be applied and the following is the fire classification under the
Indian fire code.
CLASS A FIRE CLASS B FIRE CLASS C FIRE CLASS D FIRE CLASS E
FIRECLASS A FIRE: Fires where the burning fuel is a cellulosic
material such as wood, clothing, paper etc. is called class A
fire.It can be extinguished by the water and sand. Class A fires
can also be extinguished by all the available means of
extinguishing fires like foam, soda acid, dry chemical powder,
carbon dioxide etc.CLASS B FIRE: Fires where the burning fuel is a
flammable liquid Naphtha, petrol etc. are categorized as class B
fire.Blanketing is a useful first aid fire control for B class
fire. Water is forbidden as a fire fighting means on class B fires.
Foam, carbon dioxide, dry chemical powder extinguishers are the
desired means of controlling B class fires.CLASS C FIRE: Fire
involving flammable like natural gases hydrogen are classified as
class C fire. The best means of extinguishing C type fire is by
stopping the gas supply to the leaking vessels or pipe lines if
possible. This must be the intermediate and very first step. Dry
chemical powder and carbon dioxide are useful in controlling C
class fire.CLASS D FIRE: Fire involving material like magnesium,
aluminum, zinc, potassium etc. are classified as class D fire. Sand
buckets are useful in most cases of metallic fires. Special dry
chemical powder also works on class D fires.CLASS E FIRE: Fires
involving electrical equipments are classified as E class fires.
Only carbon dioxide and D.C.P extinguishers are used on class E
fires.
2.3 FIRE FIGHTING GADGETS AND APPLIANCES:- CO2:- It contain
under pressurized liquid carbon dioxide. SODA ACID:- Contain a
double container with sodium bicarbonate solution in outer
container and dilute sulphuric acid in the inner container. After
the inner container both react and produce a liquid of entrapped
CO2. FOAM:- Contain aluminous sulphate in inner container and
sodium bicarbonate in outer one. After cracking the container both
reacts to produce carbon dioxide and the foam stabilizer makes
stable form of carbon dioxide. DRY CHEMICAL POWDER:- It contains an
inert dry chemical powder of sodium bicarbonate or potassium
bicarbonate or potassium chloride and diammonium phosphate along
with liquid carbon dioxide under pressure. HALON/ BROMOCHLOROFLUORO
METHANE:- Halon is in the form of a liquid gas under pressure that
is released on pressing the knob.
2.4 SAFETY PROGRAMME AT T.C.LThe company conducts regular
programs for safety measures, which not only creates awareness
about safety but also maintains it; the fire and safety department
of T.C.L organizes many programs to motivate in this direction and
to make the employees aware. National safety day 4th march is being
celebrated each year with earnestness and includes various
awareness programs, competitions and includes various awareness
programs, competitions etc. Some of these are listed below:
Training programs on safety. Home safety. Use of safety equipment.
Safety quiz. Safety slogan competition.
SAFETY PROVISIONSPersonal protective equipment (PPEs): The
various types of PPEs are:- Helmet for head protection. Goggles for
eye protection. Ear plugs and muff for ear protection. Safety shoes
for foot protection. Gloves for hand protection. Face shields foot
protection. Full body protection suits. Hoods for head, neck, face,
and, eye protection. Safety belts or life belts or harness.
Breathing apparatus or respiratory protection equipment.Fencing of
machinery.Devices for power cut.Hoists and lifts.
AMMONIA PLANT Process Description
Flow Chart of Ammonia PlantThe ammonia process can be divided
into the following sections: De-sulphurisation Section Steam
Reforming Section Primary and Secondary Reforming Shift Conversion
Section Medium Temperature Conversion Low Temperature Conversion
CO2 Removal Section Methanation Section Compression Section Ammonia
Synthesis and Refrigeration Section Ammonia Recovery Section Purge
Gas Recovery Unit
3.1 DESULPHURISATION SECTIONThe feed gas contains some sulfur,
which is to be removed before the reforming section. This is done
in the Hydro Desulphurisation (HDS) Section. This section contains
a HDS Reactor (R 201) having a nickel based hydrogenation catalyst
(TK-261) and two ZnO Absorbers (R 202 A/B). In presence of HDS
catalysts, the sulfur containing compounds of the feed gas reacts
with a hydrogen rich recycle gas at a temperature of 380 400 C to
form H2S. H2S thus formed is absorbed by the ZnO Absorbers (R 202
A/B). At the exit of HDS section, the S content in the feed gas
will be