PCE_NFL-GAIL Industrial Visit Report

A

REPORT

ON

INDUSTRIAL VISIT

(Under TEQIP-II)

TO

NATIONAL FERTILIZERS LIMITED,

VIJAIPUR, GUNA (M.P.)

&

GAS AUTHORITY OF INDIA LIMITED (GAIL)

VIJAIPUR, GUNA (M.P.)

DATE OF VISIT

20, 21 & 22 MARCH 2013

DEPARTMENT OF PETROCHEMICAL ENGINEERING

SAMRAT ASHOK TECHNOLOGICAL INSTITUTE (DEG),

VIDISHA (M.P.)

PREFACE

It is well known that for making a fine engineer apart from thorough bookish and

theory knowledge eminent practical knowledge is also required. Hence the importance of this

visit can be justified. This visit helped the students to grasp a bit of knowledge about the

common machineries and technologies used in an industry.

An industrial visit was arranged for the B.E. IV semester Petrochemical engineering

students on 20, 21 & 22 March 2013.

The industries visited were:-

1. National Fertilizers Limited, Vijaipur, Distt. Guna (M.P.).

2. Gas Authority of India Limited, Vijaipur, Distt. Guna (M.P.).

ACKNOWLEDGEMENT

The students of B.E. IV Semester Petrochemical Engineering are grateful to Director, Dr,R.

C. Jain for giving kind permission to industrial visit (Under TEQIP-II) these well known industries

of Petrochemical field. The students would like to acknowledge Dr. Manoj Datar, Professor &

Head of the Department, Petrochemical Engineering, for his pains taking effort to arrange this

visit. Also, special thanks to Mr. Ankit Kadam for his guidance & help during the visit.

Date: 26/03/2013 Students of B.E. IV Semester

Vidisha (M.P.) Petrochemical Engineering

INTRODUCTION

An industrial visit of two industries has been arranged for the students of B.E. IV Semester

Petrochemical Engineering. The industries visited were namely National Fertilizers Limited,

Vijaipur, Guna (M.P.) & Gas Authority of India Limited (GAIL), Vijaipur, Guna (M.P.) on 20, 21

& 22 March 2013 .The purpose of the visit was to make students aware of the general machinery

and processes involved in an industry.

Students of B.E. IV Sem Petrochemical Engg proceding for Industrial visit to

NFL & GAIL, Vijaipur

VISIT TO NATIONAL FERTILIZERS LIMITED (NFL)

About National Fertilizers limited:-

NFL is a Schedule A and a Mini Ratna Category-1 Company which was incorporated on

23rd August, 1974 for implementation of two fertilizer plants, based on gasification technology of

Feed Stock / LSHS at Bathinda in Punjab and Panipat in Haryana having an installed capacity of

5.11 lakh tones of Urea each. The Govt. of India, in 1984, entrusted the Company to execute the

countrys first inland gas based fertilizer project of 7.26 lakh tones Urea capacity in District Guna

in Madhya Pradesh. The Vijaipur plant commenced commercial production w.e.f. 1.7.1988.

(Vijaipur-I) Subsequently, Expansion of Vijaipur Plant was taken up in 1993 for doubling its

annual production capacity (Vijaipur-II)

National Fertilizers Ltd, Vijaipur unit is one of the four units of M/S National Fertilizers

Limited. With the commencement of commercial production of the Expansion project the gas

based unit at Vijaipur now comprises of two 1520 ton per day (tpd) Ammonia streams and four

1310 tpd Urea streams and related off-site facilities. The gas is being received from the HBJ gas

pipe line being operated by M/s Gas Authority of India Ltd (GAIL) another government of India

undertaking. The Ammonia stream completed under the Expansion Project can also be operated

with 50 % feed of Naphtha in case of shortage of the gas supply. The industry also has 3 power

plants each of capacity 17 MW and at a time 2 power plants is used and 1 kept for standby

purpose.

The main product of this industry is Kisan Urea. The total production capacity of Kisan

Urea is 6,261 Tonnes/day which is the second largest production in the country.

Raw materials used:-

The raw materials for the production of Urea are Ammonia (NH3) and Carbon-di-oxide

(CO2). These are obtained by NG / Naphtha, Power, Water. Water used here is taken from Sanjay

Sagar dam. The process for the production of ammonia and carbondi oxide are :

(A). Ammonia (NH3):- For Ammonia production, we want Nitrogen (N) and Hydrogen (H). And

Nitrogen is present in the air at surplus amount so Nitrogen is obtained from air and

Hydrogen is obtained from Methane (CH4) by catalytic reforming which is obtained from

Natural Gas (NG) which contains about 85% - 90%. And GAIL supply the Natural Gas by

HBJ pipeline.

(B). Carbondi-oxide (CO2): - CO2 is obtained from the atmosphere or air.

Manufacturing process:-

Urea is manufactured by reacting ammonia and carbon dioxide in autoclave to form

ammonium carbamate. The operating temperature is 1350C and 35 atm pressure, the chemical

reaction is endothermic reaction and so ammonia is maintained in excess to shift the equilibrium

towards urea formation. Urea production consists of main two reactions.

1. Formation of ammonium carbamate

2. Dehydration of ammonium carbamate to produce molten urea.

Shri R S Gupta, Sr. Manager addressing the students about safety measures in the plant.

Description or Plant Layout:

1. Ammonia pumping : Liquid ammonia is pumped from the multistage pump which maintain the

reaction pressure in the vertical stainless steel vessel

2. Carbon dioxide compression: Ammonia plant directly boosts the carbon dioxide from the

compression section as it readily forms at the CO2 section of ammonia production plant.

3. Urea synthesis tower: It is lined with film of oxides to protect form corrosion. Catalyst bed is

placed in the inner side of the autoclave structure and 180- 200 atm pressure at temperature about

180-200 deg centigrade is maintained. Plug flow operation take places and molten urea is removed

from the top of the tower.

4. Distillation tower and Flash drum: This high pressure slurry is flashed to 1 atm pressure and

distilled to remove excess ammonia and decomposed ammonia carbamated salts are removed and

recycled.

5. Vacuum Evaporator: The solution is fed to vacuum evaporator for concentrating the slurry.

6. Prilling Tower: It is dryer where the molten slurry is passed from top of the tower into a bucket

which rotates and sprinkles the slurry and air is passed from the bottom. All the moisture is

removed as the urea form into granules during it journey to the bottom of the tower. These

granules are sent by conveyor to the bagging section.

Students of B.E. IV Sem Petrochemical Engg with Shri R S Parihar, DGM (HR), NFL, Vijaipur

VISIT TO GAS AUTHORITY OF INDIA LIMITED (GAIL)

Introduction:-

GAIL (India) Ltd was incorporated in August 1984 as a Central Public Sector Undertaking

(PSU) under the Ministry of Petroleum & Natural Gas (MoP&NG). The company was initially

given the responsibility of construction, operation & maintenance of the Hazira Vijaypur

Jagdishpur (HVJ) pipeline Project. It was one of the largest cross-country natural gas pipeline

projects in the world. Originally this 1800 Km long pipeline was built at a cost of Rs 1700 Crores

and it laid the foundation for development of market for natural Gas in India.

Production:-

1. Natural Gas:

Natural Gas is a new age fuel. With only one carbon and four hydrogen atoms per

molecule, Natural Gas has the lowest carbon to hydrogen ratio, hence it burns completely,

making it the cleanest of fossil fuels. Natural Gas satisfies most of the requirements for fuel

in a modern day industrial society, being efficient, non-polluting and relatively economical.

The periodic uncertainties and volatility in both the price and supply of oil, have also

helped Natural Gas emerge as a major fuel in the energy basket across countries.

Natural Gas comes in 4 basic forms:

Liquefied Natural Gas (LNG) - Natural Gas which has been liquefied at (Minus)

160 degree Centigrade. Natural Gas is liquefied to facilitate transportation in large

volumes in cryogenic tankers across sea.

Regasified Liquefied Natural Gas (RLNG) LNG Re-gasified before transporting it

to consumers through Pipelines.

Compressed Natural gas (CNG) - Natural Gas compressed to a pressure of 200-250

kg/cm2 used as fuel for transportation. CNG decreases vehicular pollution on the

virtue of being cleaner fuel than liquid fuels.

Piped Natural gas, PNG - Natural Gas distributed through a pipeline network that

has safety valves to maintain the pressure, assuring safe, uninterrupted supply to the

domestic sector for cooking and heating / cooling applications.

Students with Mr. Sanjay Jain, Sr. Manager, GAIL, Mr. N Patni, Sr. Manager, GAIL &

Dr. Manoj Datar, Professor and Head, Petrochemical Engineering Deptt.

2. LPG:

GAIL is the first company in India to own and operate pipelines for LPG

transmission. It has 1,900 km LPG pipeline network 1,300 km of which connects the

western and northern parts of India and 600 km of networks is in the southern part of the

country connecting Eastern Coast. The LPG transmission system has a capacity to transport

3.8 MMTPA of LPG. LPG transmission through pipelines was 3337 TMT in the year

2010-11.

GAIL produces LPG through fractionation in Gas Processing Units, known as

Straight Run LPG. GAILs LPG is an eco-friendly fuel and provides a cheaper and

effective means of reducing pollution and increasing productivity.

3. Other Products:

In the process of production of main products viz. LPG & Polymer through

GPU/GCU except Usar, the following by-products- Liquid Hydrocarbons (LHC) are

produced:

Plant By-product

Vijaipur Propane, Pentane, Naphtha

Auraiya Propane, Pentane, Naphtha, MFO, Hydrogenated C4 Mix,

Propylene and Slop Oil

Vaghodia Naphtha

Gandhar Pentane, Naphtha

Lakwa Solvex-GL / Naphtha

GAIL is India's major producer of Propane, popularly known as GAIL Propane. It is an eco-

friendly fuel and provides an effective way of reducing pollution and increasing

productivity.

GAIL produces and markets Pentane. It is primarily being used for reprocessing into iso,

normal & commercial pentane used in EPS, PU, LAB industry.

Naphtha is primarily used by Power, Fertilizer, Steel and Petrochemical Units. In Power,

Steel units it is used as a fuel, whereas in Petrochemical, Chemical, Fertilizer units it is used

as a feedstock.

CONCLUSION

The Industrial visit provided the students to observe several unit operations/unit processes

taking place in a chemical industry live. It was a great experience to observe the magnitude and the

quantum of machinery/equipments used in a manufacturing process. Thus the students found the

visit to be a great learning experience and a source of practical knowledge. Hence overall, the visit

has been successful and concluded without any hurdles and hindrances.