Академический Документы
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Iskandarabad Mainawali
Pakistan.
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Report Submitted By
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CONTENTS
HISTORY ....................................................4
PROCESS DESCRIPTION ............................4
AMMONIA SECTION .....................................5
UREA SECTION ............................................11
UTILITIES SECTION......................................15
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HISTORY
The Plant is located at Iskanderabad, District Mianwali. It was the first nitrogenous
Plant built in Pakistan. The project when commissioned in 1957, was designed
to produce 40 metric tone per day of Ammonia to be fully converted into 150
metric tone per day of Ammonium Sulphate. The unit underwent expansion in 1968
when the capacity was increased to 273 metric tones per day i.e. 90,000 metric tones
per annum of Ammonium Sulphate.
The Ammonium Sulphate Plant was closed in June, 1997 and a new Ammonia /
Urea Complex having capacity of 600 metric tone per day of Ammonia and 1050
metric tone per day of Urea, started commenced production in November, 1999.
The annual production capacity of the Plant is 346,500 metric tone of urea.
Total completion cost of the Project was Rs.9, 700.060 million, out of which Rs.6;
878.119 million was in foreign currency. The authorized and paid up capital of the
Company is Rs.3,000 million, which is subscribed by NFC.
Today the plant is running at 1176 tone per day which is the 112% of the designed
capacity 1050 tone per day of Urea and 650 tones per day of Ammonia.
PROCESS DESCRIPTION
The PAFL plant consist the following major section are
1. Ammonia Section
2. Urea Section
3. Utility Section
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A view of ammonia section
AMMONIA SECTION
Ammonia is produced in a process in which nitrogen and hydrogen react in the
presence of an iron catalyst to form ammonia. The hydrogen is formed by reacting
natural gas and steam at high temperatures and the nitrogen is supplied from the air1.
Other gases (such as water and carbon dioxide) are removed from the gas stream and
the nitrogen and hydrogen passed over an iron catalyst at high temperature and
pressure to form the ammonia. The process is shown schematically in Figure 1.
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ZnO + H2S → ZnS + H2O
Following this, the gas is sent to the primary reformer for steam reforming, where
super-heated steam is fed into the reformer with the methane. The gas mixture heated
with natural gas and purge gas to 770oC in the presence of a nickel catalyst. At this
temperature the following equilibrium reactions are driven to the right,
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converting the methane to hydrogen, carbon dioxide and small quantities of carbon
monoxide:
CO + H2O → H2 + CO2
CO + H2O → CO2 + H2
O2 + 2CH4 → 2CO + 4H2
O2 + CH4 → CO2 + 2H2
2O2 + CH4 → 2H2O + CO2
As the catalyst that is used to form the ammonia is pure iron, water, carbon
dioxide and carbon monoxide must be removed from the gas stream to prevent
oxidation of the iron. This is carried out in the next three steps.
CO + H2O → CO2 + H2
This is achieved in two steps. Firstly, the gas stream is passed over a Cr/Fe3O4
catalyst at 360oC and then over a Cu/ZnO/Cr catalyst at 210oC. The same reaction
occurs in both steps, but using the two steps maximizes conversion.
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STEP 4 - WATER REMOVAL
The gas mixture is further cooled to 40oC, at which temperature the water condenses
out and is removed.
N2 + 3H2 → 2NH3
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The ammonia is rapidly decompressed to 24 barg. At this pressure, impurities such
as methane and hydrogen become gases. The gas mixture above the liquid ammonia
(which also contains significant levels of ammonia) is removed and sent to the ammonia
recovery unit. This is an absorber-stripper system using water as solvent.
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The remaining gas (purge gas) is used as fuel for the heating of the primary reformer.
The pure ammonia remaining is mixed with the pure ammonia from the initial
condensation above and is ready for use in urea production, for storage.
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UREA SECTION
GENERAL
Urea [CO (NH2)2], also known as carbamide or carbonyl diamide, is marketed as a
solution or in solid form. Most urea solution produced is used in fertilizer mixtures, with
a small amount going to animal feed supplements. Most solids are produced as prills or
granules, for use as fertilizer or protein supplement in animal feed, and in plastics
manufacturing. Five U. S. plants produce solid urea in crystalline form. About 7.3
million mega grams (Mg) (8 million tons) of urea were produced in the U. S.in 1991.
About 85 percent was used in fertilizers (both solid and solution forms), 3 percent in
animal feed supplements, and the remaining 12 percent in plastics and other uses.
PROCESS DESCRIPTION
The process for manufacturing urea involves a combination of up to 7 major unit
operations.
These operations, illustrated by the flow diagram in Figure 8.2-1, are solution synthesis,
solution concentration, solids formation, solids cooling, solids screening, solids coating
and bagging, and/or bulk shipping.
In the solution synthesis operation, ammonia (NH3) and carbon dioxide (CO2) are
reacted to form ammonium carbamate (NH2CO2NH4).
Typical operating conditions include temperatures from 180 to200°C (356 to 392°F),
pressures from 140 to 250 atmospheres (14,185 to 25,331 kilopascals) NH3:CO2 molar
ratios from 3:1 to 4:1, and a retention time of 20 to 30 minutes. The carbamate is then
dehydrated to yield 70 to 77 percent aqueous urea solution. These reactions are as
follows:
The urea solution can be used as an ingredient of nitrogen solution fertilizers, or it can
be concentrated further to produce solid urea.
The 3 methods of concentrating the urea solution are vacuum concentration,
crystallization, and atmospheric evaporation. The method chosen depends upon the
level of biuret (NH2CONHCONH2) impurity allowable in the end product. Aqueous urea
solution begins to decompose at 60°C (140°F) to biuret and ammonia. The most
common method of solution concentration is evaporation.
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The concentration process furnishes urea "melt" for solids formation. Urea solids are
produced from the urea melt by 2 basic methods: prilling and granulation. Prilling is a
process by which solid particles are produced from molten urea. Molten urea is sprayed
from the top of a prill tower. As the droplets fall through a countercurrent air flow, they
cool and solidify into nearly spherical particles.
There are 2 types of prill towers: fluidized bed and non fluidized bed. The major
difference is that a separate solid cooling operation may be required to produce
agricultural grade prills in a non fluidized bed prill tower.
The solids screening operation removes off size product from solid urea. The off size
material may be returned to the process in the solid phase or be redissolved in water
and returned to the solution concentration process.
Clay coatings are used in the urea industry to reduce product caking and urea dust
formation.
The coating also reduces the nitrogen content of the product. The use of clay coating
has diminished considerably, being replaced by injection of formaldehyde additives into
the liquid or molten urea before solids formation. Formaldehyde reacts with urea to
from methylenediurea, which is the conditioning agent. Additives reduce solids caking
during storage and urea dust formation during transport and handling.
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SYNTHESIS
ACES21® process synthesis section consists of a reactor, a stripper and a carbamate condenser.
Liquid ammonia is fed to the reactor via the HP Carbamate Ejector which provides the driving
force for circulation in the synthesis loop instead of the gravity system of the original ACES. The
reactor is operated at an N/C ratio of 3.7, 182 °C and 152 bar.
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UTILITIES SECTION
TUBE WELLS
06 tube wells are in operative condition, designed capacity of these tube wells is 3.0
cusec but due to continuous operation, capacity of old pumps (installed in 1997and before)
has dropped to 2.0 ~ 2.5 Cusec.
PIPE LINE
1. 24” ø and 3948 meters length Pipe Line from Banian Tree to PAFL plants.
12” ~ 08 ø and 1500 meters length Pipe Line from PAFL plants to Housing Colony.
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RAW WATER ANALYSIS
pH 7.5-7.6
M. Alkalinity 120-130 ppm CaCO3
Calcium 112-125 ppm CaCO3
Magnesium 40-50
Total hardness 160-170
Chloride 10-17 ppm
Sulphate 40-50
Silica 12-16
Water Treatment plant
For the production of de-mineralized water, required for steam generation PAFL has
a water treatment plant of El-Car Company of Italy having 85-tons/hr capacity. This plant
comprises on three sand filters and two Ion Exchange Lines, each line comprising on
Cationic exchangers, de-gasifier, Anionic exchangers, mixed bed and Auxiliaries for the
regeneration of these Ion exchangers.
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Steam Generation
PAFL has the following steam generation facilities.
Boiler # 1
Boiler No. 1 is manufactured by Babcocks and Wilcox Company of U. S. A and was installed in
1954. Initially it was designed for coal firing, but in 1972 its firing method was modified and
changed from coal burning to Natural gas burning. Its steam generation capacity is 155000 Ibs/hr
and is used for supplying steam for power generation and to Phase-II for plant operation.
Boiler # 3
The Mitsui Boiler is fitted with combination firing steam using oil and gas as fuel.
Burners firing is automatic and equipped with safety tripping devices.
The unit is equipped with wind box housing adjustable blade type air regulator for
producing the necessary turbulence, air movement, provided with manual control device,
inspection and ignition doors, stainless steel damper impeller, explosion door etc.
For fuel oil firing, complete line starting from Furnace oil receiving station to all burners.
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Each burners is provided with manual shut off and electro-preumatic shut off valve connected to
flame protection devices. Steam consumption for Furnace oil atomization is not more than 1.1%
of Boiler minimum production.
Turn down ration of the Boiler is not less than 4 to 1
Package Boiler
Manufacturer HMC, Pakistan
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Power Generation
The powers station is for the supply of electric power, heating steam and
condensed water to the factory. For this purpose two set of turbo generator set of A. E. G
Company are provided. The power production capacity of each unit is 11.5 MW. Normally one
unit remains in operation and other remains stop.
Turbine
It is multi stage, condensing, extraction and compound type Turbine, used as prime mover for
three-phase synchronous generator. Turbine has total eleven (11) stages out of which first stage
is impulse type and rest of the stages are of reaction type.
For Power generation two Turbo generator set having 11.5 MW/each generation capacity
available these generator were installed in 1954 and since these are in operation.
Turbine ratings
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Generator Rating
For this purpose this section is equipped with 6 Nos. cooling fans. 3 Nos. cooling water
pumps, one motor driven cooling water pumps, 3 Nos. condensing Turbines for cooling water
pumps, surface condenser, cooling water chemical treatment unit and 2 Nos. side stream filters
for the filtration of cooling water.
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Polisher unit
This unit is for supply Polished water to Ammonia plant required for steam generation for
this purpose 2 Nos. of Polishers are provided having 75 m3/hr capacity each.
For supply of high pressure Nitrogen a booster compressor IGB 3702 and an emergency
N2 reservoir is provided.
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Furnace oil/ Diesel oil section
PAFL has Furnace oil/ Diesel oil storage and piping facility. Furnace oil is used as fuel at
Boiler # 3 during emergency and Diesel oil is used at emergency Diesel engines.
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ANALYTICAL & QUALITY CONTROL LABORATORIES.
Analysis Report Of Effluents.
Dated : 01/07/09
NH3 Zinc Cr- B.O.D Suspended
Date Time pH 40.00 Urea 10.00 5.0 1.0 80.00 Matter
6-9 ppm ppm ppm ppm ppm 150 ppm
01/06/09 0845 8.2 28.86 5.6 0.39 Nil 30.6 128
1700 8.3 35.4 6.8 --- --- --- ---
2300 8.4 38.8 7.6 --- --- --- ---
02/06/09 0730 8.3 35.8 6.4 0.42 Nil 30.8 136
1700 8.4 36.8 8 --- --- --- ---
2245 8.2 31.2 5.2 --- --- --- ---
03/06/09 0800 8.3 33.6 6 0.36 Nil 31.4 126
1530 8.4 34.5 5.6 --- --- --- ---
2315 8.3 31.2 5.8 --- --- --- ---
04/06/09 0715 8.3 32.9 6.2 0.38 Nil 31.7 130
1700 8.4 38.8 7.6 --- --- --- ---
0015 8.2 27.3 6 --- --- --- ---
05/06/09 0745 8.3 34.1 6.4 0.32 Nil 32 126
1515 8.2 29.6 5.9 --- --- --- ---
2345 8.4 36.6 6.6 --- --- --- ---
06/06/09 0745 8.3 34.7 6.3 0.35 Nil 32.8 130
1700 8.3 35.28 6.4 --- --- --- ---
2245 8.5 39.9 7.8 --- --- --- ---
07/06/09 0745 8.5 37.96 7.4 0.37 Nil 32.8 128
1800 9.9 1200 2000 --- --- --- ---
2330 9.2 400 200 --- --- --- ---
08/06/09 0800 8 225 933.0 0.27 Nil 31.4 126
1600 8.8 88.2 22.7 --- --- --- ---
0030 8.5 48.92 16 --- --- --- ---
09/06/09 0845 8.4 38.8 9.4 0.37 Nil 31.5 140
1600 8.2 31.6 6.7 --- --- --- ---
0015 8.3 33.84 6.2 --- --- --- ---
10/06/09 0900 8.4 36.86 7.6 0.32 Nil 33 128
1600 8.4 35.6 7.2 --- --- --- ---
2300 8.4 34.8 7 --- --- --- ---
11/06/09 0830 8.3 32.7 6.8 0.34 Nil 32.4 136
1615 8.2 30.9 5.9 --- --- --- ---
2315 8.4 35.1 6.3 --- --- --- ---
12/06/09 0900 8.3 34.6 7.2 0.35 Nil 33.1 128
1730 8.2 32.9 6 --- --- --- ---
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2300 8.2 30.4 5.5 --- --- --- ---
13/06/09 0930 8.4 36.8 7.2 0.29 Nil 32.8 120
1700 8.3 34.2 5.6 --- --- --- ---
0000 8.5 39.8 7.6 --- --- --- ---
14/06/09 0830 8.3 31.96 5.2 0.33 Nil --- 128
1600 8.3 33.6 5 --- --- --- ---
0030 8.4 38.4 7.9 --- --- --- ---
15/06/09 0800 8.3 34.5 6.5 0.3 Nil 33 125
1800 8.2 28.4 5.2 --- --- --- ---
2330 8.3 31.9 5.8 --- --- --- ---
16/06/09 0900 8.5 38.9 8.8 0.35 Nil 33.2 138
1700 8.2 28.6 5.6 --- --- --- ---
0015 8.4 34.8 7.2 --- --- --- ---
17/06/09 0815 8.3 35.6 6.2 0.31 Nil 33.2 144
1710 8.2 26.44 4.8 --- --- --- ---
0030 8.3 30.8 6.7 --- --- --- ---
18/06/09 0800 8.3 31.4 6.2 0.37 Nil 33.8 128
1500 8.4 35.4 7 --- --- --- ---
0030 8.3 32.6 6.8 --- --- --- ---
19/06/09 0800 8.4 35.8 7.4 0.38 Nil 32.6 134
1530 8.4 36.7 7.1 --- --- --- ---
0015 8.3 32.8 6.4 --- --- --- ---
20/06/09 0745 8.2 26.84 5.2 0.33 Nil 32.8 128
1545 8.4 39.4 7.2 --- --- --- ---
0030 8.2 32.6 6.4 --- --- --- ---
21/06/09 0800 8.3 30.42 5 0.39 Nil --- 132
1630 8.4 34.7 7.2 --- --- --- ---
2300 8.4 36.6 7 --- --- --- ---
22/06/09 0830 8.2 27.34 4.9 0.33 Nil 33.1 122
1600 8.3 31.9 5.6 --- --- --- ---
2245 8.5 37.9 7.9 --- --- --- ---
23/06/09 0900 8.3 30.92 5.2 0.39 Nil 32.8 130
1500 8.3 32.6 5.9 --- --- --- ---
2245 8.4 35.2 6.2 --- --- --- ---
24/06/09 0830 8.3 31.6 5.8 0.39 Nil 32.4 136
1630 8.4 34.7 6.4 --- --- --- ---
2245 8.3 32.9 5.6 --- --- --- ---
25/06/09 0830 8.3 30.4 4.8 0.33 Nil 33 134
1630 8.4 36.8 8.2 --- --- --- ---
2330 8.4 37.6 7.8 --- --- --- ---
26/06/09 0915 8.5 39.8 8.2 0.39 Nil 32.7 148
1640 8.4 34.8 7.2 --- --- --- ---
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2300 8.4 35.3 7.6 --- --- --- ---
27/06/09 0915 8.3 36.4 6.7 0.32 Nil 32.9 136
1530 8.4 37.9 7.9 --- --- --- ---
2300 8.5 38.8 8 --- --- --- ---
28/06/09 0815 8.4 33.9 7.6 0.36 Nil --- 128
1700 8.4 34.6 7.2 --- --- --- ---
0015 8.2 27.22 4.8 --- --- --- ---
29/06/09 0715 8.3 31.9 5.9 0.4 Nil 33.2 134
1700 8.4 36.9 7.84 --- --- --- ---
0030 8.2 28.46 5 --- --- --- ---
30/06/09 0715 8.3 33.6 6.9 0.36 Nil 33.24 130
1615 8.4 37.2 7.6 --- --- --- ---
2345 8.3 32.16 5.6 --- --- --- ---
Avg. 8.4 53.9 41.4 0.35 Nil 32.53 131.23
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