A

VOCATIONAL TRAINING REPORT

ON

WEAK NITRIC ACID-1 PLANT AT GNFC

(G.N.F.C. LIMITED, BHARUCH)

During 01.06.2019 to 15.06.2019

PREPARED BY:-
PATEL AXITKUMAR RAMESHBHAI

CHEMICAL ENGINEERING DEPARTMENT

GOVERNMENT ENGINEERING COLLEGE,
BHARUCH

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 PREFACE

Practical knowledge means the visualization of the knowledge, which we read in our books. For
this, we perform experiments and get observations. Practical knowledge is very important in every
field. One must be familiar with the problems related to that field so that he may solve them and
become a successful person.
After achieving the proper goal in life, an engineer has to enter in professional life. According to
this life, he has to serve an industry, may be public or private sector or self-own. For the efficient
work in the field, he must be well aware of the practical knowledge as well as theoretical
knowledge. To be a good engineer, one must be aware of the industrial environment and must
know about management, working in the industry, labor problems etc. so he can tackle them
successfully in future.
Due to all the above reasons and to bridge the gap between theory and practical, our engineering
curriculum provides a practical training of 16 days.
During this period, a student works in the industry and gets all type of experience and knowledge
about the working and maintenance of various types of machinery.

PATEL AXITKUMAR R.
160140105031
CHEMICAL DEPARTMENT
GEC BHARUCH

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 ACKNOWLEDGEMENT

The internship opportunity I had with GNFC (BHARUCH) was a great chance for learning and
professional development. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so
many wonderful people and professionals who led me though this internship period.
I perceive as this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with all of
you in the future.

In this journey, A group of people we might call them INDUSTRY EXPERTS have helped me so
as a sincere student I would like to thank all the people that helped me.
First of all a big thank you to,

Mr. S.T. Sharma (Sr. Manager)

Mr. D. C Jadeja (Sr. Manager)
Mr. H.K. Parekh (Training Officer)

Tarang mistry (Shift engineer)

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 ENVIRONMENTAL POLICY

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 INDEX

Sr. No. Title Page No.

1 Introduction 7
1.1 Vision 8
1.2 Mission Statement 8
1.3 Product Profile 8
1.4 Production Highlights 10
1.5 Technology Partners 10
1.6 Hall of Fame 11
2 Process Description 12
2.1 Introduction 12
2.2 Description of Process Unit 13
2.2.1 Steam system 22
2.2.2 Cooling system 24
2.2.3 Ammonia air ratio 25
2.2.4 Ammonia conversion efficency 25
2.2.5 Degree of oxidation 25
2.2.6 Surging of compressor 26
2.2.7 Ammonia gas to air ratio control 26
2.2.8 Anti surge of air compressor 27
2.2.9 Capacity of plant 28
2.2.10 Quality of the product 28
2.2.11 Consuption figures for normal operation 29
2.2.12 Production figures for by product 30

3 Important Units 31
3.1 Air filtration system 31
3.2 Boiler feed water system 31
3.3 Turbo compresor set 33

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 3.4 Some important system of WNA-1 34
4 Health and safety hazard data 40
5 First aid 45
5.1 Nitric acid properties 46
5.2 Nox gas properties 47
6 Special measures to prevent accident 50
6.1 Fire protection devices 51
6.2 Properties of catalyst 52
7 Conclusion 53

8 QUESTION-ANSWER 54

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 1. INTODUCTION

GNFC at Glance

 Gujarat Narmada Valley Fertilizers & Chemicals Limited (GNFC) is an Indian

manufacturer of fertilizers and Chemicals. GNFC was founded in 1976.
 The company was jointly promoted by the Government of Gujarat and the Gujarat State
Fertilizer Company Limited (GSFC). It was set up in Bharuch Gujarat.
 GNFC started its manufacturing and marketing operations by setting up in 1982, one of the
world's largest single-stream ammonia-urea fertilizer complexes. Over the next few years,
GNFC successfully commissioned different projects - in fields as diverse as chemicals and
fertilizers.
 Since inception, GNFC has worked towards an extensive growth as a corporation. A
growth which respects the environment and springs from the progressive vision of GNFC.
 GNFC today has extended its profile much beyond fertilizers through a process of

horizontal integration. Chemicals/Petrochemicals, Energy Sector,

Electronics/Telecommunications and Information Technology form ambitious
andchallenging additions to its corporate portfolio. GNFC has an enterprising, strategic
view towards expansion and diversification.

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1. Vision

“To be a technology driven environmentally responsible joint sector company

manufacturing fertilizers, commodity, and specialty chemicals maintaining highest
standards of operational excellence and innovation for creating sustainable value for all
stakeholders.”

2. Mission Statement:

 To be a leading provider of chemicals and agricultural inputs through adoption of state of

the art Technologies and business processes.
 Have a firm commitment to quality environment, health and safety.
 Enrich human resources and promote teamwork innovativeness and integrity.
 Achieve sustainable economic growth based on corporate excellence driven by ethical
business practices, professionalism, dynamism and social responsibility.

3. Product Profile

 Ammonia
 4,45,000 MTPA,
 Technology: From M/s Linde AG, Germany, GE Energy, USA, BASF, Germany,
HaldorTopsoe, Denmark

 Methanol
 The Counties largest capacity. 1,85,000 MTPA available for sale.
 Technology: From ICI, UK, Product conforms of highest purity grade of US Federal AA.

 Acetic Acid
 The Countries largest capacity. 1,15,000 MTPA available for sale.
 Technology: From M/s B.P.Chemicals, UK. The only manufacture in the country to
employ Methanol route.

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  Formic Acid
 The Countries largest capacity. 20,000 MTPa available for sale.
 Technology: From Kemira OY, Finland.

 Methyl Formate
 3,000 MTPa available for sale.
 Technology: From Kemira OY, Finland.

 Weak Nitric Acid

 75,000 MTPA available for sale.
 Technology: M/s UDHE, Germany.

 Ammonium Nitrate [melt]

 1,50,000 MTPA available for sale.
 Technology: M/s UHDE, Germany.

 Aniline
 The Countries largest single stream capacity. 40,000 MTPA available for sale.
 Technology: M/s Du Pont, USA.

 Toluene Di-Isocyanate
 The only producer in South East Aisa. 67,000 MTPA available for sale.
 Technology: M/s Du Pont, USA.

 Nitrobenzene
 2,000 MTPA available for sale.
 Technology: M/s Chemtur Engineering AB, Sweden.

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 1.4. Production Highlights

Products Production (MT) Capacity Utilization (%)

Ammonia 6,36,766 142.93
Urea 7,66,718 120.38
Methanol ( I + II) 1,32,449 55.63
Methyl Formate 27,110 118.90
Formic Acid 21,530 215.30
Acetic Acid 1,57,905 157.91
Weak Nitric Acid (I + II) 4,20,860 121.11
Concentrated Nitric Acid(I + II + 1,21,621 104.85
III)
Toluene Di-Isocynate (TDI – I) 19,166 136.90
Toluene Di-Isocynate (TDI – II) 26,514 53.03
Aniline 39,401 112.57
Nitro Benzene 56,763 120.13
MTD – I – Bharuch 15,472 131.08
MTD – II Dahej 20,016 53.73

1.5. Technology Partners

 LINDE AG, Germany  G E - ENERGY, USA  BASF, Germany

 SAIPEM, Italy  ICI, UK  KEMIRA OY, Finland
 PLINKE, Germany  UHDE, Germany  BP CHEMICALS, UK
 MES CO., Japan  ENTRUST, USA  TOYO ENGG., Japan
 CHEMATUR AB,  DU PONT, USA  HALDOR TOPSOE,
Sweden Denmark
 KBK – CHEM ENGG. PVT. LTD., India

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6. Hall of Fame:

 Set up the world's largest single stream, fuel oil based Ammonia - Urea plant
 All fertilizers under the brand name of Narmada, along with extensive support activities,
have been well accepted by the country's farmer community.
 India's largest producer of Formic Acid, Acetic acid, Methanol and premium quality Ethyl
Acetate.
 India's only manufacturer of Glacial Acetic Acid through the cutting-edge Methanol route.
 India's largest single stream plant of Aniline.
 The only manufacturer of Toluene Di-Isocyanate in South East Asia.
 Record capacity utilizations in all plants, defying the vintage through ingeniously innovative
maintenance measures.
 Development of the first indigenous, eco-friendly technology for H2S removal, CATSOL, a
much awarded product of the Company's R&D labs.
 Set up 21 MW wind turbo generators.
 Cogeneration power and stream unit with capacity of 33 MW power and 61 MT / HR steam
Commissioned.
 Ammonia synthesis gas generation plant for LSHS to natural gas conversion has been
commissioned.
 Ethyl Acetate plant for 50,000 MTA a capacity has been commissioned.
 Facilities for Neem coated urea have been established.
 Neem project: GNFC has undertaken a solo economic Neem project for manufacturing its
sown requirement of Neem oil for coating urea and for selling, also to make Organic Neem
cake fertilizer with main objective of women empowerment and uplifting of poor rural
population.

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INTRODUCTION

The following instructions have been prepared for the start-up and
operation of the H.P Nitric Acid Plant of GNFC at Bharuch, India. This
plant was developed, designed, engineered and procured by Uhde
GmbH, Dortmund and Uhde India Private Limited, Mumbai.

The instructions included here in are guidelines and can not be

considered as

definitive standards. It may be necessary to make minor changes in these

guidelines during or after the start-up, so as to adapt the instructions to
the existing situation.

A sound knowledge of the process remains the first and most essential
pre-

requisite for proper operation of the plant.

We reserve the copyright of these instructions and all corresponding

annexure. They are made available to the addressee for personal use
only. It is not permitted to copy or reproduce the same without our
written agreement.

Furthermore, the instructions must not be disclosed to third persons, in

particular to competitors.

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GENERAL DESCRIPTION

The plant is designed to produce 300 TPD nitric acid as 100 % HNO3 at
62 % concentration when operating continuously under designed
climatic and utility conditions.

The process applied is a "UHDE MONO HIGH PRESSURE PROCESS"

wherein the oxidation of ammonia and the absorption of nitrogen
oxides, are performed at near about same pressure of approximately
7.5 bar a. A safe continuous operation of the plant is granted between
75 % load (225 TPD) to 100% load (300 TPD).

The NOx-content in the undiluted tail gas will not exceed 50 ppm by
volume.

The plant is connected to all necessary facilities.

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OXIDATION OF AMMONIA

The oxidation of ammonia with atmospheric oxygen is affected at

platinum

rhodium gauzes according to the following stoichiometric reactions:

Reaction I -Reaction II -
Reaction III -
.
4 NH3 + 5 O2 = 4 NO + 6 H2O 4 NH3 + 3 O2 = 2 N2 + 6 H2O
4 NH3 + 4 O2 = 2 N2O + 6 H2O

The oxidation process is controlled in such a way that reactions II and III
are suppressed. Consequently, the yield of oxidation of the ammonia
corresponding to the contribution of reaction I is approximately 95 %. The
remaining part of the ammonia is reacting in about equal portions
according to the side reactions II and III.

Following measures are applied in order to maximize reaction I:

• Homogeneously mixed and clean ammonia/air mixture.

• Oxidation at a temperature of about 900°C and uniform
distribution of the mixed gas over the catalyst area.
• A well designed catalyst basket to support the platinum gauzes
firmly.
•Use of specified platinum-rhodium gauzes (for example 95%
& 5% Rhodium).

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 OXIDATION AND ABSORPTION OF NITROUS GASES

The nitric oxide (NO) formed according to reaction I is oxidised as follows

under further influence of oxygen (O2):

Reaction IV - 2 NO + O2 = 2 NO2

In this reaction, the reaction rate which is proportional to the third power
of the total pressure is the limiting step of the absorption process. The
equilibrium is almost completely on the NO2 side at T < 327°C. During the
absorption of nitrous gases, NO2 is dissolved in water and nitric acid is
formed according to the overall equation:

Reaction V - 3 NO2 + H2O = 2 HNO3 + NO

This reaction is promoted by square of the pressure. It will be noted from

this

reaction V that 2 moles of the NO2 are converted to nitric acid while one
mole is reduced to NO. The NO formed is in turn oxidised with O2
according to reaction IV and converted to HNO3 according to reaction V.
This process is continued until almost all nitrogen oxide is converted to
nitric acid.

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 CATALYTIC REDUCTION OF NITROUS OXIDES

In this process, NO and NO2 are selectively reduced to N2 and H2O in a

reaction with ammonia. The reduction takes place in the presence of
catalyst. The main reactions read as follows:

Reaction VI - 6 NO + 4 NH3 = 5 N2 + 6 H2O, ∆ HR = - 391 kJ/mole N2

Reaction VII - 6 NO2 + 8 NH3 = 7 N2 + 12 H2O, ∆ HR = - 362 kJ/mole N2

For a tail gas of 50 % degree of oxidation, these reactions can be

summarised to

Reaction VIII - NO + NO2 + 2 NH3 = 2 N2 + 3 H2O

For a tail gas with less than 50 % degree of oxidation, also an equimolar
conversion (1 mole NH3 per 1 mole NOx) has to be considered. That
means the NO will be oxidised according to:

Reaction IX - 4 NO + 4 NH3 + O2 = 4 N2 + 6 H2O

According to design, the reactio2ns take place at temperature of approx.

370°C. The rise in temperature depends on the reduction of NOx content
of the treated tail gas. Considering a reduction from 500 ppm to 50 ppm
during normal operation, a temperature rise of approx. 6°C will occur.

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PROCESS DESCRIPTION

PROCESS PLANT

Refer: 0139-PE-UPF-0001

0139-PE-UPF-0002

At a temperature of approx. 11°C and an abs. pressure of 12 – 21 bar,

liquid ammonia is fed via the ammonia filter (liquid) 12 F003 to Ammonia
evaporator (CHW) 12 E001 where approx. 70 % of the liquid ammonia is
vaporized at a temperature of 22°C and abs. pressure of 9 bar by chilled
water.

The remaining quantity is fed to the Ammonia evaporator (CW) 12 E002

and

is vaporized by cooling water at the same pressure as in Ammonia

evaporator (CHW) 12 E001. By the cooling water flow and the liquid level
in Ammonia evaporator (CW) 12 E002 the required evaporation pressure
will be adjusted.

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If the vaporization temperature in the ammonia evaporator (CW) 12 E002
due to a H2O-enrichment increases, a part of the NH3/H2O mixture of the
Ammonia evaporator (CW) 12 E002 has to be
drained into the Ammonia stripper 12 E003, where
the residual ammonia is expelled at temperature of about 110°C.

The ammonia gas leaving the vaporization system reaches Ammonia

preheater 12 E004, where it is superheated to approx. 90°C by means of
steam to avoid carry-over of droplets or mist of liquid ammonia.

In the Ammonia filter (Vapour) 12 F004 impurities of the gas stream,

which might contaminate the catalyst gauzes, are retained. Most of the
ammonia gas is fed to the ammonia air mixer 12 N001 while a very small
part stream is fed to the Ammonia tail gas mixer 12 N002 required for NOx
reduction.

The air required for the process is drawn from the atmosphere through a
three stage Air intake filter with silencer 12 F005 and compressed by bull
gear type and four stage Air compressor with intercooler 12 U001-K01 to
7.5 bar a.

The air compressor is driven by a tail gas turbine 12U001-MTO2 and a

steam turbine 12U001-MT01. By utilizing the process heat in an optimum
way, a part of the power required for the compressor is recovered from
the tail gas turbine and the balance power is provided through the steam
turbine driven by steam produced in the plant. The tail gas turbine is an
integral part of the bull gear compressor unit, so called “compander”.

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The compressed air leaving the compressor is divided into two streams.
The main stream of about 78 % of total air is fed to Ammonia - air mixer
12 N001 where air and ammonia are mixed thoroughly.

The ammonia-air mixture enters the ammonia burner system 12 U001-

R01 / 12 U001-R02 where ammonia oxidation reaction takes place on
Platinum-Rhodium catalyst gauzes. The process gas at approx. 900°C
passes through the superheater and evaporator of Process gas cooler 12
U002-E01 where heat of reaction of ammonia as well as part of oxidation
heat from NO to NO2 is used to generate medium pressure superheated
steam of 28 bar(a) and 400°C.

Process gas leaving Process gas cooler is further cooled in the Tail gas

heater-3, 12 E012 and Economiser 12 E006. Before entering Cooler

condenser 12E007, the gas passes through Boiler feed water preheater 12
E014. The final cooling takes place in the Cooler condenser 12 E007 by
means of cooling water. In cooler condenser, a major part of water formed
during ammonia combustion is condensed to weak nitric acid of approx.
40 % concentration. This low concentration nitric acid is pumped to the
Absorption tower 12 C001 by means of Acid condensate pump 12
bleaching

section of the Absorption tower 12 C001 after having been cooled down
in Tail
P007 A/B.

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The secondary air stream (about 22 % of the total air) is fed to
gas heater 1, 12 E010 in exchange with the tail gas leaving the absorption
tower.

The cooled process gas from the cooler condenser is fed to the absorption
tower. In the bottom part the gas is mixed with the bleaching air from the
bleacher section. In the absorption tower the nitrous dioxides are
absorbed in process water which is fed from the top to produce weak
nitric acid. The absorption tower is equipped with sieve trays.
Demineralised water is used as process water which is fed to the top tray
by means of process water pump 12 P008A/B via Process water tank
12D009. Alternatively, condensate from CNA III plant containing 1% HNO3
can be used as absorption water, if available.

Cooling water cooled coils located directly above selected sieve trays
remove the heat of reaction and absorption.

The raw acid is bleached in the bleacher section of the absorption tower
by means of secondary air. The bleacher equipped with sieve trays is an
integral part of the absorption tower. The produced nitric acid with 62 %
w/w concentration is fed to existing storage tanks.

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Tail gas leaving Absorption tower top is heated first with secondary air in
Tail gas heater 1, 12 E010 and thereafter by means of steam in Tail gas
heater 2, 12 E011. The second phase of heating before entering Tail gas
turbine 12U001-MT02 takes place in Tail gas heater 3, 12 E012 by means
of NO gas from Process gas cooler 12 U002-E01.

Heated tail gas is then mixed with necessary amount of gaseous ammonia
from Ammonia filter (vapour) 12 F004 in the Ammonia - tail gas mixer 12
N002 and fed to the Tail gas reactor 12 R003. In presence of a catalyst the
NOx-content of the tail gas is reduced by reaction of ammonia with the
nitrous oxides to a concentration below 50 ppm (vol.) generating nitrogen
and water. Tail gas from this unit drives the Tail gas expander 12 U001-
MT02 before being vented to atmosphere via stack.

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STEAM SYSTEM

Refer: 0139-PE-UPF-0003

The heat recovered from process gas in Process gas cooler 12 U002-E01
and Economiser 12 E006 is used to generate medium pressure steam of 28
bar(a) and 400°C. Part of the steam produced is used to drive Steam
turbine 12 U001-MT01 in the turbo set which in turn drives the air
compressor. The steam exhausted from steam turbine is condensed under
vacuum.

The balance steam is depressurized and saturated to 16 bara. This 16 bara

steam (STM) at approx. 200°C is used internally and the remaining steam
is expor.ted to battery limit to existing 16 Bar a header.

During start-up, high pressure superheated steam (STH) at 94 bar abs. and
500°C is imported from battery limit. This steam is depressurized & de-
superheated to 28 bara and 400°C and then utilized in the steam drum 12
U002-D01 and steam turbine 12 U002-MT01.

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During start-up, medium pressure saturated steam of 16 bara (STM) is
taken from B.L for internal consumers like Tail gas heater 2, 12 E011,
Ammonia preheater 12 E004, Ammonia stripper 12 E003 and Boiler feed
water deaerator unit 12 D006/D007. During normal operation, internally
produced steam is used for these consumers.

The process gas cooler 12 U002-E01 is a La Mont type system consisting of

a steam superheater and evaporator system. Separation of steam and
water takes place in Steam drum 12 U002-D01. From there the separated
steam is fed to the superheater section where it is superheated to the
required temperature of 400°C. The necessary boiler water flow through
the individual evaporation layers of the process gas cooler unit will be
maintained by the PGC circulation pump 12 U002-P01A/B and controlled
by the La Mont orifice nozzles at the inlet of each water way. Connected
to this system is also the wall cooling section of the shell which also acts
as evaporator.
Condensate from various heat exchangers is collected and routed back to
the Boiler feedwater tank 12 D006. The condensate from the Steam
turbine condenser 12U001-E02 is fed by Steam condensate pumps 12
U016A/B together with the make-up demin water (received at plant
BATTERY LIMIT) to the Boiler feed water preheater 12 E014 where it is
heated by means of NO gas and is then fed to the Deaerator 12 D007 to
physically deaerate the water. This deaerated water is fed into the Boiler
feed water tank 12 D006. In the boiler feed water tank 12 D006 the boiler
feed water is treated with O2-scavenger which chemically deaerates the
water. Boiler feed water is pumped by Boiler feed water pumps 12
P006A/B to Steam drum 12 U001-D01 via Economiser 12 E006 which
heats the water by NO gas from Tail gas heater 3, 12 E012. The O2
scavenger will be delivered by the O2 scavenger dosing pump 12U003-
P01.

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COOLING WATER SYSTEM

Refer: 0139-PE-UPF-0004

0139-PE-UPF-0005

Considering the requirements of the plant, a countercurrent cooling tower

equipped with two cells, each of 1200 m3/h is provided.

The total cooling water flow is split in two main streams. One stream
pumped by Cooling water pumps (Absorption tower circuit) 12 P023A-C,
will be used for the Absorption tower 12 C001 (lower trays) followed by
Cooler condenser 12 E007 which is followed by Ammonia evaporator (CW)
12 E002; all in series. Second stream which is pumped by Cooling water
pumps (Turbine Condenser circuit) 12 P024A/B will be used for the
Intercooler 12U001-E01, Steam turbine condenser 12 U001-E02, Ejector
condenser 12U001-E03, Oil cooler 12 U001-E04A/B & other small
consumers in the plant.

The upper trays (above 17) of the Absorption tower 12 C001 will be
cooled by chilled water. The chilled water is pumped in a closed circuit by
Chilled water pumps 12 P022A/B and is cooled by means of evaporating
ammonia in Ammonia evaporator (CHW) 12 E001. The chilled water
system is equipped with the Chilled water head tank 12 D022 to remove
any trapped vapour in the circuit.

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11. Cooling Tower

 Cooling water system caters to the cooling water requirement of various

process units and utilities. Cooling water from the cooling tower sump is
pumped to various users by the cooling water pumps (P 60901 A/B/C).
 Cooling water is supplied at a pressure of 3.5 bar g and 33°C temperature.
Cooling water return from various consumers at 43°C is returned back to the
cooling tower where it is cooled to 33°C. Cooling water system comprises of
the following:
 Cooling Tower including fans
 Side stream filter
 Cooling water pumps
 Chemical (corrosion inhibitor/biocide) dosing system is provided for cooling
water system to prevent corrosion and fouling in the circulating system.
Chemicals/biocide are dosed directly into the cooling tower sump.
 Side stream filtration unit will be provided on the cooling water circuit wherein
a small stream of circulating cooling water will be circulated through a filter
to remove the suspended impurities from the water.
 The effluent generated from the backwash of the side stream filter will be
routed to the Cooling tower blowdown pit and pump to B/L for further
processing by GNFC.
DEFINITION OF SPECIAL TERMINOLOGY

AMMONIA/AIR-RATIO

Ammonia-air ratio means the percentage of ammonia in the ammonia-air

mixture expressed as % vol.
Ratio = 100 * NH3 / (NH3 + primary air)

AMMONIA CONVERSION EFFICIENCY

The percentage of ammonia, which is converted at the burner into NO

according to reaction I as described under clause 2.2.1

DEGREE OF OXIDATION

The percentage of NO2 calculated expressed as % vol. ω = 100 * NO2 / (NO +

NO2)

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SURGING OF COMPRESSOR

Surging is an operating condition during which the compressor can not

deliver

against the back pressure thus causing back flow of gas. Because of this,
the back pressure drops till the compressor is able to build up pressure
and forward flow commences. This process will be repeated periodically
depending on volume of equipment and pipe work on the discharge side
of the compressor.

DESCRIPTION OF THE MOST IMPORTANT CONTROL LOOPS

AMMONIA GAS /AIR RATIO CONTROL

The ammonia gas / air ratio, which is defined as the ratio of ammonia flow
by

primary air plus ammonia flow, is controlled by FFC120202, whereby the

air is used as master flow, which controls the ammonia as the slave flow.

The output signals of the air flow transmitter and the ammonia-flow

transmitter, which are both, pressure and temperature compensated, are

fed into the ratio controller FFC120202. The FFC120202 controller output
signal is fed to the ammonia control valve FFV120202.

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ANTI-SURGE OF AIR COMPRESSOR

The effective suction volume flow and the discharge pressure of the air
compressor are measured and compared with the surge protection curve.
The protection curve is plotted based on conditions when actual surging
takes place.

In addition to the surge curve, a trip set curve is plotted based on 5-10%
higher flow compared to the surge curve. When actual operating point
coincides with the trip set curve, compressor trip Z 12B occurs.

The distance between the actual operation point and the surge protection
curve can be checked at any time.

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DESIGN DATA

CAPACITY OF THE PLANT

The rated output of the plant is 300 metric tons per day (MTPD) HNO3 -
100 % basis. The minimum production rate at which the plant will run
under steady conditions is 75 % of rated production i.e. (225 MTPD).

As a by-product, 0.42MT of superheated steam is produced Per MT of

HNO3-100% (28 bar a, 400°C)

QUALITY OF THE PRODUCT

The quality of the nitric acid is as follows:

Strength

Nitrous oxides as HNO2

Fe

: min 62.0 % wt.

: Max. 90 ppm. (Vol.)

: Max. 3 ppm (w/w)

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 CONSUMPTION FIGURES FOR NORMAL OPERATION

Figures given hereunder are expected consumption figures for

major items valid when the plant is operating at 100 % of the
design capacity.
Raw material / Utility Unit Value / m. ton HNO3

Ammonia gaseous (100 % NH3) Kg 287

Demineralised water Kg 600

Platinum without recovery system G 0.18

Cooling tower make up (delta t = 8 K) m3 3.42

Electric energy 55
kWh
(Without lighting / AC etc.)

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 PRODUCTION FIGURE FOR BY-PRODUCT

Figure given hereunder is the expected production

figure for by product i.e.
steam valid when the plant is operating at 100 % of
the design capacity.

Raw material / Utility Unit Value / m. ton HNO3

Export steam (16 bar a, Saturated) kg 397

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AIR FILTRATION SYSTEM

• The air filtration system consisting of a three stage air filter (with
silencer) shall be thoroughly cleaned before the start of the
compressor.
• The filter housing will be physically cleaned to remove all the dirt
inside before fixing the filter panels.

BOILER FEED WATER SYSTEM

• Before cleaning the boiler feed water tank 12D006, the lines in
connection with the tank (directly and indirectly) must be cleaned
carefully by flushing.
• Clean the feed water pipes to the tank thoroughly. Flush the line from
B.L. upto BFW Preheater 12E014 inlet & then upto BFW tank inlet so that
the dirt does not enter boiler feed water preheater 12E014.
• Fill the boiler feed water tank 12D006 with boiler feed water
and drain the water via line 2”-WB4-12184-BG55CA.
• Fill the boiler feed water tank 12D006 with fresh Boiler Feed water
from B.L.

32 | P a g e
After the tank is filled, stop the BF water feed and slowly heat up using
steam to the boiler feed water tank. Make sure that the vent valve above
deaerator 12D007 is fully open. Use both steam lines (2"-STM-12192-
BG57CI-H60 and 1 1/2"-STM-12185-BG57CI-H60) to the tank.

•When a small overpressure is reached, stop the heating-up and drain

the tank fully via suction line 3"-WB4-12197-BG55CA-H50 and line
2"-WB4-

12184-BG55CA-P30 into the blow down vessel II. The pumps 12P006 A/B
must be disconnected and the flushing controlled by shut-off valves in the
suction lines.
•If necessary repeat cleaning procedure until tank and pipelines
are cleaned.
•After flushing, the pumps must be connected again. Install start
up strainer.

•Start & check the boiler feed water pumps 12P006A/B operation in
accordance with the supplier’s instructions.
Flush the discharge lines of pumps thoroughly till clear water is observed
at each of the consumers. Remember to remove the orifice (FI 120601) in
the line going to steam drum.
• Reinstall the flow meter & normalise the system

• Fill the boiler feed water tank 12D006 again to normal level and
heat up the water till the operation temperature and pressure is reached.
Switch the level controller LIC120603 and PIC120602 to ‘automatic’ and
adjust the set points to the required values. Check the low level interlock
I12.03 for 2 out of 3 voting condition.

33 | P a g e
 TURBOSET COMPRESSOR

The Turbo set consists of:

Steam turbine

Air compressor

Tail gas turbine

Intercooler

steam condenser 12U001-E02

Vacuum unit 12U001-F01

Oil system etc.

After completion of erection and before the commissioning, alignment, all

tests

and checks shall be carried out as required by the manufacturer under the
supervision of the manufacturer's specialist and in strict accordance with
the manufacturer's operating instructions. The tests include over speed
test, checking of anti-surge protection, interlocking system, internal trip
system and measuring / control instruments. Prior to the first start-up, the
compressor set and all accessories should be thoroughly cleaned.

34 | P a g e
 Steam turbine condensate & vacuum system

• Flush the steam turbine condenser 12U001-E02 in accordance

with the instructions given by the compressor manufacturer.
• Check the operation of steam condensate pumps 12P016A/B
and adjust the switch points of the pumps. If necessary, clean the start-up
strainers. Check the proper operation of VFD for steam condensate
pumps.
• Check by a vacuum test that all connections in the vacuum area
are tight. • Keep cooling water circulation through the condensers so that
system is
ready for compressor start up.
• The steam ejectors will be put in operation in accordance with
instructions given in the operating manual from the manufacturer.

Steam turbine 12U001-MT01

The steam turbine will be put into operation according to the

instructions given by the manufacturer.
• Steam turbine can be put in operation (for no load) if the oil
system, steam condensate system & vacuum system is ready. The
condensate from turbine in this situation should be diverted to cooling
tower. Before the first start of the steam turbine the control and shut
down system has to be checked very carefully and then the over speed
test should be performed. For this test the steam turbine has to run
uncoupled from the set.
•

35 | P a g e
Air compressor 12U001-K01 / Tail gas turbine 12U001-MT02

Start up of the compressor will be done in accordance with the

manufacturer's
instructions. Before any operation with the air compressor is done following
preparations / checks will be done.
• The control and trip system for the turbo compressor should be
tested by simulation of all compressor trips.
• The suction line to the air compressor should be clean & air intake
filter 12F005 ready for operation.
• The flow orifice in the primary & secondary air line (FO120203 &
FO 121005) should be removed
• Remove the instruments in ammonia system (vapour & liquid).
Also, Ammonia filter internals (vapour & liquid) should be removed.

• The cooling air valve HV129002 should be removed. The cooling

air line will be blinded on the tail gas side. The line towards the tail gas
expander should be cleaned as it will not be cleaned in blowing operation
by compressor. The main line to the tail gas turbine has to be kept open by
removing XV120201 to allow air to be sucked in for cooling. However, take
care that no dirt can be sucked in.

• Compressor discharge valve XV120202 should be kept closed &

line blinded at inlet of the valve.

After all the abovementioned preparations are over, start the

machine as per the operating instructions of the manufacturer. Initially, the
compressor set shall be operated at low speed only, until it is absolutely
certain that assembly has been performed in a perfect manner. Adjustments
shall be made in small steps, waiting after each step until operating
conditions have been stabilised, before the next step can be commenced.
36 | P a g e
 Throttle the blow off valve HV120201 to blow the plant bypass
(cooling air line) for approx. 10 min.
• Reinstall the cooling air valve HV129002 after cleaning the rest of
the line with instrument air.

After the first operation, the surge test should be performed

under supervision of manufacturer's specialists. Test the surge line
according to the instructions of the manufacturer and the supervisor in the
following way:
• Remove the final stage of the suction air filter 12F005. • Open
the cooling air valve HV129002.
• Open the air blow off valve HV120201.
• Start the machine following the instructions of the manufacturer.
• Throttle the blow off valve HV120201 until the surge line is
reached.
• During the blow off and the runs into the surge lines the anti
surge protection has to be overridden. Therefore these runs have to be
done with the possibility of operating the air compressor blow off valve
manually and tripping the compressor set (Z12.B) locally.
• At least three different surge points should be taken at different
loads. If the surge point cannot be reached with closed blow off valve the
cooling air valve HV120231 must be throttled for a short time. The surge
pointsobtained should be compared with the operating curves of the
compressor & resulting surge curve must be adjusted for complete range of
operation & connected to the interlocking system. After adjustment of the
surge protection line (approx. 8% distance to the real surge line (8% of
pressure at const. flow, see 7.7), the interlocking of the compressor set has
to be checked again.

37 | P a g e
ABSORPTION TOWER & NITRIC ACID CIRCUIT

The absorption tower needs to be flushed properly to make it

perfectly clean and free of any foreign material. The various high-level
alarms and trips on the absorber should be checked very carefully. A
malfunction of such a high-level alarm/ trip system may cause a back flow
of acid into the gas lines and equipment up stream of the absorber where
it may cause severe damages in case of unexpected shutdown. Therefore,
the absorber has to be filled with demineralised water to simulate the
alarm and trips interlocks.
• Before the filling of the tower ensure that shut-off valve
upstream of LV121002 in line 3"-NA1-12126-EC55CB is closed.
• Make sure, that the process water tank 12D009 is cleaned and
filled up and process water of desired quality is available.
• Start process water pump 12P008A/B and flush the line up to
12C001. Ensure that the flow meter FI 121004 is removed before the
flushing of this line. Re-install the flow meter & fill the absorption tower
12C001 till the required levels are reached. The outer sump has to be
filled by overfilling of the inner sump. During this operation all the 35
absorption trays & A-D bleaching trays of the tower will get flushed.
• Open the inlet line to Filling pump & flush thoroughly. Clean the
strainer after the flushing is over. Start the acid filling pump 12P015 and
flush the line upto absorption tower inlet. After cleaning of this line over
connect the discharge pipeline in such a way, that the process water will
be circulated via pipeline 3"-NA1-12005-EC55CB. Remove the instrument
FI120401 in line from filling pump to cooler condenser & flush the line
upto inlet of cooler condenser. Connect the line to cooler condenser &
add water to cooler condenser so that the sump of the cooler condenser
is filled.

38 | P a g e
 Using the filling pump, flush the product line till the existing
storage tanks. If required, remove the control valve & flow meter in this
line. Care should be taken not to dilute / contaminate the acid in the tank
(if the tank is in operation).
•

• Check all flange connections for possible leakage. After

arresting all leakages, splashguards should be installed on all flange joints
in nitric acid service lines.
• It must be ensured that the strainer for the pump is cleaned
early enough. See the special operating instructions of the pump
manufacturer. Stop the acid filling pump 12P015 and remove the suction
strainer. Clean the suction strainer of the filling pump and reinstall. Drain
the inner and outer sump of the absorption tower one after the other by
opening the suction line.

After flushing, the absorption tower 12C001 is ready for

operation with the compressor set.

NOX-ABATEMENT SYSTEM

After the cleaning of process gas circuit is over, the iron zeolite NOx
abatement catalyst has to be put into the tail gas reactor 12R003 as per
following procedure:
• Open the 24” flange in the tail gas inlet line of the reactor.

• Loosen and remove flange bolts between upper and lower part
of the reactor.
• Remove the upper shell.

39 | P a g e
 Make sure that the perforated plates as well as the wire mesh are
tightly fixed to avoid loss of catalyst.

• The catalyst takes up atmospheric humidity. Therefore the

packing should be opened just before filling is started. As the catalyst is very
sensitive against rain (water) the whole area must have a temporary rain
cover if required.

• Fill the catalyst basket with the catalyst. The filling can be done
using a funnel or tube. In order to avoid fragments, the falling height should
not exceed 0.5 m. The catalyst basket should be filled up loosely and
equally. Pay attention to the safety instructions (see chapter 8 of operating
manual).
•

40 | P a g e
HEALTH AND SAFETY HAZARD DATA

GUIDING PRINCIPLES FOR SAFETY

The guiding principles for safety contained herein are an extract from
official regulations of particular importance. These principles are therefore
by no means complete, and the relevant regulations for the prevention of
accidents should be studied in conjunction with them.

For start-up, shutdown and operation the following safety regulations

should be strictly followed.

41 | P a g e
NOXIOUS PROPERTIES OF PROCESS FLUIDS

AMMONIA

Noxious Properties of Ammonia

Under normal circumstances, ammonia is a colourless gas and its density

is less than that of air. It is easily recognisable by its extremely pungent
odour. Ammonia is easily liquefiable under pressure. At atmospheric
pressure, ammonia will evaporate at a temperature of about -33°C, while
absorbing heat from ambient matter.

Ammonia is easily soluble in water; such solutions can contain up to 35%

ammonia (ammonia water). Liquid ammonia, high-percentage ammonia
water and highly concentrated gaseous ammonia will irritate human skin
and cause severe burns. Gas of high concentration will paralyse
respiratory organs. The following are particularly endangered:
• Eyes

• Mucous membranes (mouth, throat, respiratory ducts, lungs,

genitals)

• Larynx, gullet and stomach, particularly if aqueous ammonia

solution is swallowed.

Injuries to the larynx and lungs can be fatal. The pungent odour is an
adequate warning and will therefore prevent severe injuries to health,
since the real danger begins when the endurability limit is exceeded. The
maximum permissible concentration in a working area over eight hours is
acc.

43 | P a g e
to German regulations 20 ppm, equivalent to 14 mg/m3. Irritation of the
larynx and the eyes will be noticeable when the concentration is ten times
as great. At an ammonia concentration of 0.15%, uncontrollable coughing
will set in, and at a concentration of 0.5% paralysis of the respiratory ducts
will begin. Concentrations of around 2% will perceptibly irritate uncovered
skin.

If liquid ammonia comes in contact with human skin, there is a danger of

undercooling. Great care should be exercised when handling ammonia.
A mixture of air and ammonia can be explosive. This is particularly the
case, whenever the ammonia content of air at normal temperatures and
pressures is from 15.5 to 27% by vol. In the presence of other combustible
substances, such as hydrogen or acetylene, at higher oxygen contents of
air or at abnormal pressures and temperatures, the hazard limits cover a
greater range, thus the danger will be bigger.

Thermometers, pressure gauges, and the like installed on ammonia-

bearing equipment or piping should therefore not be of the mercury type.

44 | P a g e
Protective Measures

Whenever ammonia is escaping from a piece of equipment or a pipe, the

room must be evacuated at once, using gas masks. The endangered zone
should be thoroughly ventilated as soon as possible. In view of the fact
that ammonia is lighter than air, ventilation by upward draught will be
most effective.

If any work has to be carried out in rooms contaminated with ammonia

(e.g. for lessening the hazards), respiratory equipment and protective
clothing must be worn. A gas mask can be regarded as limited respiratory
equipment. Providing there is sufficient oxygen in the atmosphere, the gas
mask fits tightly and the special ammonia filter has been screwed into the
gas mask, contaminated rooms may be entered for a limited period of
time, if certainty exists, that the ammonia content is below 2%. The filter
manufacturer's data will give precise information on the time limit, the
maximum permissible ammonia concentration and the life of a new gas
mask filter the container seal of which has not yet been broken. A
sufficient number of gas masks should be available at all points where
ammonia might possibly escape to enable operating personnel to
evacuate the plant quickly. If, for any reason, a gas mask should not be
available, the next best protection will be afforded by holding a wet rag
over nose and mouth. In emergencies, a dry handkerchief or a sleeve will
afford some protection. In all such cases it is important to choose a route
of escape against the wind.

The breathing apparatus is used whenever the ammonia concentration

exceeds the limit value mentioned above or if it is not known (or if it is
likely to alter), if the oxygen content is too low, or if the life of the gas
mask filter is likely not to be adequate.

45 | P a g e
 • a long-sleeved working jacket,

 • long trousers and underwear,

 • if possible, made from cotton, since cotton is more resistant to

alkalis than wool,

 • rubber boots,

 • rubber gloves,

 • Protective helmet with rim.

46 | P a g e
First Aid

It is of primary importance to take the injured person out of the endangered

area as quickly as possible. In case of serious injuries or of any injuries to the
eyes, a medical practitioner must be summoned at once. In the meantime,
as much ammonia as possible must be eliminated, e.g. by dousing with
plenty of water, discarding contaminated clothing including underwear. The
patient should then be made to lie down and wrapped in blankets to keep
him warm.

Eyes affected by ammonia must immediately be washed with plenty of clean

water. This can be followed by an eye bath in diluted acetic acid (0.5 %) or
boric acid (3 %), after which the eyes should again be washed with clean
water.

If ammonia has been breathed in, inhalation of steam or vinegar vapour is

recommended. Artificial respiration is forbidden. If possible, the breathing
air should be enriched with oxygen. If ammonia-bearing water has been
swallowed, the patient may be given milk to drink providing he is fully
conscious.

47 | P a g e
NITRIC ACID

Properties Injurious to Health

Nitric acid is a colourless liquid which gradually turns yellow owing to

decomposition phenomena under the influence of light or heat.
When the acid is kept in open vessels, it will discharge vapours which
generally contain nitrous gases.

Nitric acid figures among the strong acids; in addition, it features

marked oxidising characteristics and will seriously attack numerous
metals and organic substances. In case of contact with the human
skin, it will produce burns whose seriousness depends on the
concentration of the acid. The affected zones of the skin assume a
yellow colour.

Large-area acid burns of the skin might be lethal, serious injury of the
eyes might lead to a loss of the eyesight. When drinking nitric acid,
mucous membranes will suffer burns that might be lethal.

Protective Measures

Persons working on piping or vessels containing nitric acid must wear

protective goggles. Better safety is achieved through the use of
protective globes of transparent plastics that cover head and neck.
Hands can be protected through rubber gloves which, however, have
only a limited resistance to concentrated acid.

Suits of felt or special plastics (acid suit) are adequate for use as
protective clothing.

48 | P a g e
NITROUS GASES

Properties Injurious to Health

The oxidation of ammonia, the reaction of nitric acid with reducing

substances,

and the decomposition of nitrate-bearing substances are accompanied

by the formation of the extremely poisonous "nitrous gases" which are a
mixture of various oxides of nitrogen.

Nitrous gases are a very malicious poison because the immediate

nuisance

after inhaling is negligible and the seriousness of the poisoning does not
appear before expiration of several hours.

Few breaths in a fairly poisoned atmosphere might be sufficient to

destroy the

tissue of the lungs to a point where a lethal oedema of the lungs might
occur even 8 hours or more after exposure, unless adequate aid is
administered in good time. The symptoms of serious affection, such as
headaches, fatigue, low blood pressure, will sometimes commence after
several hours only. Subsequent effects are the blueing of the lips, shallow
breathing, and death from suffocation.

It is absolutely imperative that any person who has inhaled nitrous gases
consults a physician even if no signs of indisposition are apparent. The
maximum permissible concentration of oxides of nitrogen at the working
place is about 9 mg/m3 (5 ppm). A short-time exposure to an
atmosphere containing 25 ppm NO2 might be injurious to health; a lethal
effect must be expected at 200 ppm.
Protective Measures

In case of an eruption of nitrous gases, the personnel shall leave the

place of eruption as quickly as possible and in a direction opposite to
the wind

direction. Actions to be taken for eliminating the evolution of oxides of

nitrogen depend on the cause of such evolution. Personnel shall
approach the point of leakage from a direction which is opposite to
the wind direction. As mentioned before, the protective effect of gas
masks is limited by the gas concentration and the time of exposure.

For further details, reference should be made to the specifications

furnished by the manufacturers of the gas masks. Better safety is
achieved with respiratory equipment. The use of suitable gas
protective clothing is also recommended.

First-Aid Measures

Any person who has inhaled nitrous gases should immediately be

removed to fresh air and should be covered with blankets and kept
quiet until the physician arrives. The patient shall not move even if he
feels able to do so. It is recommended to enrich the breathing air with
oxygen and to allow the patient to inhale the fumes of an ammonium
bicarbonate solution. Artificial respiration should not be administered.

If no physician is available at short notice, the patient should be taken

on a stretcher to the nearest hospital.
Protective Equipment

In order to prevent accidents and to lessen their effect, suitable

clothing should be worn covering the whole body other than head and
hands and, in addition, the following items of protective clothing and
respiratory equipment should be readily available:

 • Protective helmets
 • Goggles and acid-proof hoods
• Gloves, partly of rubber, wool and leather
 • Rubber boots
 • Rubber protective suits
 • Gas masks with appropriate filters
 • Breathing apparatus
 • Tight anti-gas suits and acid suits
 • Shower-baths for washing off corrosive substances
 • Sodium carbonate solution (5-7 %) for post-treatment after
acid burns on skin
• Eye-bath flasks with clean water

• Eye-bath flasks with 0.5 % acetic acid or 3 % boric acid

 • First-aid outfits

 • Stretchers with blankets

SPECIAL MEASURES TO PREVENT ACCIDENTS DURING WELDING
WORKS

Rooms where welding works are to be carried out, should be vented

correspondingly. Small rooms or vessels must be constantly vented
with fresh air, or the personnel must use oxygen equipment. Before
starting work it must be made sure that no danger of fire or
explosion exists.

When working on containers and vessels, these must be opened

and cleaned beforehand.

When working on hollow bodies the formation of a dangerous

overpressure

must be avoided.

During welding works in the neighbourhood of inflammable building

parts, i.e. wood or similar, safety precautions must be met to avoid
fires, e.g. by

covering all inflammable parts, disposal of extinguishing water or

other suitable fire extinguishing instruments. The heated spot or the
endangered neighbourhood must be watched until there is no
longer a noticeable over-temperature.
Safety :-

General remarks

The safety procedures described in this chapter are those which

specifically apply to potential hazards within battery limit. It is assumed
that safety practices with general application or with specific application
to other processes outside battery limit is described elsewhere. The
general safety practices referred to above should include:

 Traffic safety
 Fire-fighting
 First aid
 Work permit procedures
 Vessel entry procedures
▪ Sampling procedures.
 RESCUE TOOLS

Automatic Rescue Device:-

Fire Rescue
Helmet:-
FIRE PROTECTION DEVICES

The operating personnel must be made familiar with the fire

protection and fire extinguishing equipment. The fire extinguishing
equipment should be easily accessible and clearly marked. A use
for other purposes should be prohibited. In case of fires
aggregates to equipments which are under electric voltage, the
use of foam extinguishers or the spraying with water should be
waived due to the connected danger of accident (electric shock).
In this case carbon dioxide or dry extinguishers are suited for use.

Carbon dioxide and foam extinguishers can also be used in case of

oil fire.

Fire extinguishers containing tetra-chlorine dioxide, often develop

toxic gases. For this reason use of these instruments is
appropriately waived.

If the fire stretches over to the nitric acid tanks, it is recommended

to use water, if this is not prohibited due to special circumstances.

Due to-gases and vapours forming up during fires, and also due to
the fire-extinguishing agents applied, the wearing of proper gas
masks is absolutely necessary.
PREPARATION OF CATALYST BASKET 12U002-R02

Before process gas lines are purged the honeycomb of the catalyst
basket is installed into the Process gas cooler shell. Following
procedure shall be followed for the catalyst basket installation.
• When installing the honeycomb into the La Mont boiler
shell it must be regarded that the L-profiles of the honeycomb
grating are horizontally located on the upper tube coil. Avoid
inclined position of the catalyst basket and ensure that the L-
profiles are completely placed on tube mountings.
• The shell length must be checked regarding the length
applied in the factory of the boiler manufacturer.
• The thermowells shall be fixed (distance between top
edge of thermowell and support gauze approx. 20 mm) and
connected with honeycomb grating by tack welding and stiffening
rib.

Note:

The thermowells shall not be welded to the shell plate of the

basket.

• Before installation of the bottom gauze on the

honeycomb grid, cleaning of the catalyst basket, the honeycomb
grid and the bottom gauze by acetone is necessary.
CONCLUSION

 Here, I learn about the various Application of Equipment of the

process that were theoretically learned during our college
curriculum.
 In weak nitric acid plant-1, I learned about the process based on
the WNA-1 in which there is oxidation reation between ammonia
and air ,oxidation of nitrous gases,absoption of nitrogen dioxide
and SCR reaction in these most of reaction is exothermic.our final
product was weak nitric acid which is 61 percent concentrated.it
is sent to ANP REAR and ANP FRONT plant for further
processing.
 I also Learned What type of problems can occur during the
operation.
 I also Came to know about the safety precautions taken by the
industrialists while operating a plant.I learned about fire and
safety and how to operate pump and different type of pump.
 I am sure that knowledge for my experience during this industrial
training will help me in future to the get a better and quicker
understanding of Plants, Process, Techniques and Working
Principle of various Equipments.
1) what is used for case of acid contact with eyes?
- 0.5% acetic acid or boric acid 3%

2) what is max permissible limit of NOx for work place?

-20 ppm

3) what is the pressure drop for filter ?

- 1 bar for 12 F003
0.5 bar for 12 F004

4) what is the pickling agent ?

- 20-25% of hydrochloric acid

5) why ph value of cooling tower drops?

- because of cooler condnsar leakage

6) what is the life time of catalyst gauzes ?

-6 months

7) which kind of boiler is used in plant?

- La mont type Boiler
8) Which Type of compressor set has been used?
- Bull gear type

9) which kind of steam turbine is used in plant?

- Extraction of steam

10 what is the campign lenght of catalyst?

- it is the capacity of catalyst
11 what is the life time of catalyst gauzes ?
-6 months

12 which kind of boiler is used in plant?

- La mont type Boiler

13 Which Type of compressor set has been used?

- Bull gear type

14 which kind of steam turbine is used in plant?

- Extraction of steam

15 what are the main components on the shaft?

- compressor , steam turbine ,tail gas expander.

16 what is diffrent betwenn cooling water and chilling water ?

- cooling water is at ambient temprature where chilling water is at 18* c.

17 who much trays are present in absoration tower ?

- 41.

18 what is the feed location of process water ?

- top tray.

19 which pttern of fiow is deploy for cooling tower ?

- cross current flow.

20 which acid is use for chemical dosing ?

- shulphric acid.

21 why shulphric acid is use for chemical dosing ?

- beacuse it is cheap in price and don not form hasasias botter.

22 which equpipment is use for heat recovering ?

- economiser tail gas heater .
26 which chemical is use for removal of greas and oil ?
-dry sodium phosphate .

27 which kind are valve are used in plant ?

- needdle valve, gate valve,glob valve,ball valve,plug valve

28 which valve are used in chemical dosing ?

- needdle valve

29 which are the most common valve in plant ?

- gate valve

30 which valve are use for less space and big diameter pipe ?
- butterfly valve

31 which type of cooling tower are deployed for plant?

- induced type counter current

32 what is the main diffrence between wna 1 and wna 2 plant?

- pressure for reaction

33 which pressure system is used for WNA 1 plant ?

-dual pressure

34 what is content of NOx in stack gas?

- 50ppm

35 what are the favorable condition for oxidation of Ammonia?r

- 900 degree

36 What is the equalibirum temp for nitrous gas absorption?

-327 degree

37 which catalyst is use for tail gas reactor?

-vanadium pentoxide
38 which is the master flow for reaction?
- Air flow

39 which is the slave flow for reaction?

- Ammonia flow

40 which are the main trip system for safe plant operation?
- 1 compressor trip
2 Ammonia supply trip

41 why provison of cooling water in absorption tower is given?

- For temperture distribution and control

42 which type of centrifugal pumps are used for pumping water in

absorption tower?
- multistage pump

43 How suction and discharge pipe can be determined?

- by analysing diameter and location of pipe

44 which seals are provided for storage tank?

-vaccum seal and pressure seal

45 what is the minimum capacity of plant?

- 225 MTPD

46 what is the strength of product ?

- 62% of nitric Acid

47 what is the by product of the plant?

-0.42 MT of steam

49 why blowdown of cooling tower is needed?

- for removal of slurry and extra water
53 which gas is used for ignition of boiler?
- hydrogen gas

54 why pickling necassary for catalyst?

- for removing impurites

55 which pump is used for circulation of TSP?

- Resiprocating pump

56 what are the diffrent types of fire?

- A,B,C,D

57 which is the most efficent fire extinguiser?

- Dry chemical Powder

58 whicht steps of saftey is taken for storage tank?

sprinkling system and fog distibution

59 what is relation betweem diameter and power for pump

power is in third power for unit diametet

60 what are the types of steam blowers?

slience steam blowing quenchers .slincers

61 why static mixure is emplyoed ?

- for mixing of ammonia and compressed Air

62 why bleaching of nitric acid is done?

- for color removal

64 which agent is used for bleching/

- air from compressor

65 which eqipment is used for chlorination?

- chlorinator
67 which solution is used for NOx detecation?
- HCL

69 which temp measurig device is used in plan?

- RTD

70 what is used for case of acid burn on skin?

- sodium carbonte solution ( 5-7%)

71 what is used for case of acid contact with eyes?

- 0.5% acetic acid or boric acid 3%

72 what is max permissible limit of NOx for work place?

-20 ppm

73 what is the pressure drop for filter ?

- 1 bar for 12 F003
0.5 bar for 12 F004

74 what is the pickling agent ?

- 20-25% of hydrochloric acid

75 why ph value of cooling tower drops?

- because of cooler condnsar leakage
 76 what is the life time of catalyst gauzes ?
-6 months

77 which kind of boiler is used in plant?

- La mont type Boiler

78 Which Type of compressor set has been used?

- Bull gear type

79 which kind of steam turbine is used in plant?

- Extraction of steam

80 what are the main components on the shaft?

- compressor , steam turbine and tail gas expander

81 why efficency is poor when catalyst looks clean?

-dust pentrate the nitric acid plant

82 why PGC circulation water flow rate decreese?

-PGC circulation pump problem

83 why increase of pressure drop through steam superheater?

-feed water overdose with phosphate

84why evopration tempreture decreases at constant pressure?

- water content in ammonia is too high

85 flow of acid condensate is incresing?

- Leak in PGC system

86 What are the composition of catalyst gauzes?

-95% pt + 5%Rh

87 How much gauzes are installed in reactor?

-9
 88 what is the total weight of 9 gauzes?
- 77.61 kg

89 why rhodium is mixed with platinum?

- for strengh of materialt

90 which metal is used for recovery of platinum?

- paldium

91 what is the campign lenght of catalyst?

- it is the capacity of catalyst for production

92 why NOx content inlet of NOxabatment is too high?

-insufficent oxygen in Tail gas

93 why NOx content inlet of NOxabatment is too high?

- opreating pressure of absorption tower too low

94 why NOx content inlet of NOxabatment is too high?

- tail gas heater 3 is leaking

95why NOx content inlet of NOxabatment is too high?

- cooling tube in absorption tower is fouled
96 which chemical is use for removal of oxedaru ?
- hyadrazin poweder.

97 which chemical is use for removal of gress and oil ?

-dry sulphonium phospate .

98 which kind are valve are used in plant ?

- neddie valve, gate valve,glob valve,ball valve,plug valve

99 which valve are used in chemical dosing ?

- neddle valve
100 which are the most common valve in plant ?
- gate valve

101 which valve are use for less space and big diameter pipe ?
- butterfly valve

102 all reactio invlved in process is........?

- exothermic

103 which condition is favourable for high yield of NO?

- low Pressure

104 what is the color of nitroge dioxide?

- brown

105 Reaction of formation is high at?

- lower temperature

106 Reaction of formation of Nitric acid is low at?

- higher temperature

107 what is color of NO and NO2?

- colour less

108 Which kind of trays are provided in absorption tower?

- sieve tray

109 How many trays are provided for bleacing in tower?

- 4 tray

110 Why seprate bleching tower is not provided in wna 2 plant?

- Low capacity

111 why mono pressure system is choosen in plant:?

- low capacity
113 why steam line are provided in reactor?
- for preventing leackage

1114 which gas is used for ignition of boiler?

- hydrogen gas

115 why pickling necassary for catalyst?

- for removing impurites

116 which pump is used for circulation of TSP?

- Resiprocating pump

117 what are the diffrent types of fire?

- A,B,C,D

118 which is the most efficent fire extinguiser?

- Dry chemical Powder

119 whicht steps of saftey is taken for storage tank?

sprinkling system and fog distibution

120 what is relation betweem diameter and power for pump

power is in third power for unit diameter
121 what is consequnces of higher concentrtion of NOx ?
- acid rain

122 which system is deployded for removal of NOx?

- selective catayltic reaction

124 With Which NOx is reacted to reduce NOx?

- Ammonia from evaporator

125 which gas is used for purging of system?

- nitrogen

126 At High pressure HNO3 abosrption rate is?

- higher efficency

127 At low pressure HNO3 absorption rate is?

- lower efficency

128 why oxidation and absorption at same pressure is deployed?

- for lower capacity it can be good compromise

129 what is concentration of Fe in product?

- < 3 ppm

130 what is concentraion of HNO2 in product?

- < 90 ppm
131 what is permissible limit of NOx emission?
- < 50 ppm

132 By which means tail gas are cololed in boiler?

-circulating water

133 what are the content of the steam drum?

- 50% steam +50 % water
134 how prevention of overheating can be done?
-well defined and adjusted water flow

135 what are the types of steam blowers?

slience steam blowing quenchers .slincers

136 which step prevent scalling?

- position of superheater in modrate gas temp range

137 safe opration due to adopted...........?

- interlocks

138 cooling water flows inside tube , because ....?

-Minimize fouling and easy cleaning

139 liqiud waste is reduced by?

- Neutralization of unburnt Ammonia during start up

140 pressure drop at gas side is?

- Minimized

141 Which catalyst is used in NOx reactor?

-Uhde EnviNOx

142 what is diffrent betwenn cooling water and chilling water ?

- cooling water is at ambient temprature where chilling water is at 18* c.

143 who much trays are present in absoration tower ?

- 35.

144 what is the feed location of process water ?

- top tray.
145 which pttern of fiow is deploy for cooling tower ?
- counter flow.

146 which acid is use for chemical dosing ?

- shulphric acid.

147 why shulphric acid is use for chemical dosing ?

- beacuse it is cheap in price and don not form hasasias botter.

148 which equpipment is use for heat recovering ?

- economiser tail gas heater .

149 why chillwater is use ?

- for providing cooling in absoration tower.

150 What cause Explosion of ammonia?

- Reverse flow causing platinum dust deposition on upstream of gauzes

151 what is the lower explotion limit of NH3 in air?

- 14% vol.

152 How much stages are there in compreser ?

- four stge .
153 which chemical is use for removal of oxedaru ?
- hyadrazin poweder.

154 What is WNA2 normal Operating or ammonia Ratio ?

- 10.7% vol. NH3

155 what is ammonia feed trip at ratio ?

- 11.5% vol

156 what is done to prevent sneak of NH3?

- Ammonia is preheated to superheater vapour

157 what is more stable than ANi?

- AN

158 under which condition ANi solution is stable?

-Under alkali solution

159 when problem occur in cooler condensor?

- during start up

160 when problem occur in tail gas turbine ?

-temperature is low in downstream

161 when solid AN and ANi decompose ?

- when heated

162 what is TSLL tempreature ?

- 200 degree

163 which equipment is used for condension of nitric acid?

- vertical BFW preheater

164 what is acceptable chloride concentration?

- 300 mg\ liter
165 what amount of chlorides are found in our plant?
- have not been observed

166 what is the solution for corrosion risk?

- sample tray acid weekly
-purge to drip acid tank as required

167 How many types of protective equipment is avalible?

-1 resiporatry
2 non resiporatry

168 How many safe assembly points are there in gnfc?

- seven
169 How many levels of emergency are there?
- leval 1
leval 2
leval 3

170 what are the diffrent capacity for carbon dioxide extengusir?
- 2 kg 4 kg 9.5 kg and 22.5 kg

171 By how many ways fire can be extanguse ?

- cooling
breaking chain reaction
smoothering

172 why platinum -rhodium catalyst?

- better conversion efficency
better strength
optimum catalyst varaible cost

173 what is campaign length of wna 2 plant?

- 145000 MT of HNO3
174 At which condition lower catalyst consumption is done?
- at higher ammonia conversion efficency

175 what is the amount of catalyst losses?

- 0.168 gm /MT of HNO3 produced

176 what is composition cathment system?

- 95% palladium + 5 % nickel

177 The reaction is proportional to the .....

- third power of pressure.

178 How evaporation pressure will be adjusted?

- via cooling water flow and leval in 10 E002

179 what kind of arrangment is provided for removal of pulsation?

- two plunger and piston assembley

180 what is NPSH a?

- net positive suction head avalible

181 what is priming in pump?

- it is the removal of air from casing .

182 what is suction lift?

- when pump is above the tank .

183 what is cavitation?

- Abnormal sound and vibrtoion or pitting on impeller

184 what is NPSH r? who provides it?

- it is Net positive suction head - required , it is given by vendor .
185 what is relation between NPSH a and NPSH r?
- NPSH a should be greater than NPSH r.

186 what is use of NRV?

- it is used for controling the back flow as per its name non returning valve

187 what is shut off head ?

- Max pressure at no flow ,it is not found in positive displacment pump.

188 what is reason of pitting at impeller ?

- collapse of bubble

189 what is discharge head ?

- it is the discharge pressure.

190 what is differantial head?

- it is the diffrence of discharge head- suction head.
191).what is plant capacity of wna-1 plant?
ANS=730 mt per day
192).what is cocentartion nitric acid?
ANS=61%
193).WNA-1 process is also known as….
ANS=dual pressure process.
194).what is fullform of scr?
ANS=selective reduction process.
195).What kind of reaction occur between ammonia air?
ANS=exothermic

196).which type of valves is in WNA-1 plant

ANS=gate,globe,butterfly,plug
197).which type of compressur are there?
ANS=primary,nox