Introduction of IFFCO

Indian Farmers Fertilizer Cooperative Limited in short as IFFCO is a cooperative society registered under multi-unit cooperative societies act (Act 6 of 1942) as multi unit cooperative society under the Bombay societies act (Act 7 of 1925) on 3rd November 1967. The registration of this society is CR 1 with a head quarter at New Delhi. The area of this society was extended to whole of Indian Union. IFFCO has started with a seed capital of Rs. 2.5 million in 1967 as an experiment in sophisticated industry. Today it occupies a place of pride not only amongst cooperatives but also in the fertilizer industry. The Society alone contributed about 17.1 % of nitrogenous and 17.7 % phosphatic fertilizers produced in the country during 2001-02. IFFCO today, is a leading player in Indias Fertilizer Industry and is making substantial contribution to the efforts of on Indian Government to increase food train production in the country.

PLANTS
IFFCO commissioned the Ammonia-urea complex at Kalol and the NPK/DAP plant at Kandla both in the state of Gujarat in 1975. Ammonia - urea complex was set-up at Phulpur in U.P. in 1981. The Ammonia - urea unit at Aonla also in U.P. was commissioned in 1988. And Last but not the least also a DAP plant at Paradeep in Orrisa in 2004. So at present, there are total five units of IFFCO as under: 1. IFFCO Kandla (Gujarat) 2. IFFCO Kalol (Gujarat) 3. IFFCO Phulpur (Uttar Pradesh) 4. IFFCO Aonla (Uttar Pradesh) 5. IFFCO Paradeep (Orrisa).

OBJECTIVE
IFFCO was setup with the objective of manufacturing and marketing fertilizer through corporative of its kind in India. The objective of this society is to promote the economic interest of its members by undertaking activities which are conclusive and incidental for member of societies. Under above objective societies undertake one or more activities which are indicative but not limited to a) Setup plant for the production & marketing of chemical fertilizer & allied products of agriculture use & agricultural production. b) To provide technical consultancy & other services to members of the societies. c) To under take such other activities which are conducive to the attainment of the members.

ISO 14001
IFFCO has voluntary earned ISO 14001 standardization in 1996 which has proved effective to manage activities of industry to minimize environmental impact. It is implemented through pollution prevention and green productivity. It is certified by M/s. BVQJ for the apparitional scope of Manufacture of DAP and NPK Fertilizer with effect from 27th November 2000.

IFFCO Kandla

This unit is located at Kandla near Kandla Port Oil jetty. This plant was setup on 26 th November 1974 and production was started on 1st January 1975. This plant was built at the cost of Rs. 30 Cr with two streams having a licensed capacity of 1, 27,000 Tones of P2O5. This was designed and installed by M/s. DORR OLIVER INC. with increased demand for complex fertilizers.

AWARDS WON BY Kandla Unit

Nineteen Safety Awards from National Safety Council U.S.A. Twelve Safety Awards from the National Safety Council, Bombay. Twelve Three Safety Awards from Gujarat Safety Council, Baroda. Five Fertilizer Association of India (FAI) Awards for the best overall production performance during the years 1981,82,96-97,97-98,98-99. One National Productivity Council (NPC) Award in 1997-98 for best Productivity in the category of Fertilizer Industry Phosphatic Sector presented in August 2000. One Safety Award from FAI for Excellence in Safety for 1999-00. One Safety Award from Directorate General Factory Advice Service & Labour institutes, Ministry of Labour, Government of India, Runner, National Safety Award in 1999.

IFFCO Kandla Unit Location

Country State State Capital District Distance from New Delhi Distance from Mumbai Nearest Airport : : : : : : : India Gujarat Gandhinagar Kachhch Approx. 1100 km by rail Approx. 806 km by rail Kandla Airport, Near Gandhidham & Bhuj Airport 65 km from Gandhidham. Gandhidham (12 km from plant) and Kandla. 3 km from plant, adjacent to Kandla Port Trust, National highway 8-A, 365 km from Ahmedabad. 174.48 Acre 196.81 Acre 7001326 E 2300000 N IFFCO Kandla Unit, Post box no. 12, Gandhidham 370210, Kandla (Kachhch), Gujarat, India.

Nearest Railway Station Road

Area under plant Area under Township Longitude Latitude Address

: : : : :

Fire & Safety Department

Introduction
Safety is first & foremost requirement of any plant or industries dealing with large & small equipment. IFFCO plant is dealing with various types of inflammable hazardous chemical fluids which require safety of plants & personnel. Fire & Safety regulations are issued for the information and guidance of employees of IFFCO and all other persons connected to chemical hardly conduct to do their work. IFFCO safety regulates care to be regards as supplementary to the central and state government legal requirements.

Plant Layout
IFFCO has the two sections which deals with the chemicals products namely offsite & NPK. Both these sections are under Production department. Various Causes of Accident Rules & instruction not followed Improper tools & devices Method used not suitable Protective devices not used Lack of proper inspection & maintenance Loose clothing.

Safety in Operation & Maintenance

All operators must wear an approved dress. Proper tools maintained in good condition must be used. They should be used correctly. This applies not only to hand tools but also to portable power tools lifting tackles slingate. Horse play, wrestling, playing or throwing materials etc. must be prohibited. Employees must not tampered with any machines, switches, equipments not connected with their work. No machinery tools or materials which are not in proper condition or safety should be operated.

Tagging Procedure
In tagging procedure, three tags are mainly used as under: Red Tag which is for Danger. Yellow Tag which is for Electrical shock.

 Green Tag which is for Isolation of any equipment.

First Aid
First aid facility Mechanical facility Ambulance facility

Colour Safety
Various colours are used for identification of any material used in plant which also provides warning against hazards. Red Danger, stone sign, Fire protection installation. Green Safety, first aid requirements. Yellow Caution, transport, equipments. Overhead cranes, changes in Floor level etc. Orange Electric installations, inside machinery guards. Blue Less urgent signal Purple Radiation White Cleanliness

Product Specifications
Grade
It represents the analysis of pre-nutrients in fertilizer, e.g. Grade 12:32:16 means Nitrogen = 12% by wt., Phosphate = 32% by wt., & Potash = 16% by wt. First number always represents nitrogen, second number Phosphate & third is Potash. Fertilizer with two nutrients may be graded as 5:0:15 or 18:46:0 etc.

NPK Grade 1 [10:26:26]

1. 2. 3. 4. 5. 6. 7. 8. Moisture % by wt. min 1.0 Total N2 % by wt. min 10.0 Ammoniac N2 % 7.0 N2 in urea form % by wt. max. 3.0 Neutral NH3 Citrate soluble phosphate as P2O5 by wt. min 26.0 Water soluble Potash as (K2O % by wt. min.) 26.0 Water soluble Phosphates (K2O % by wt. min.) 22.1 Particle Size : Particle of the material will be such that 90% of the material will be between 1 mm & 4 mm is sieve & not more than 5% will be below 1 mm size.

NPK Grade 2 [12:32:16]

1. 2. 3. 4. 5. 6. 7. 8. Moisture % by wt. min 1.0 Total N2 % by wt. min 12.0 Ammoniac N2 % 9.0 N2 in urea form % by wt. max. 3.0 Neutral NH3 Citrate soluble phosphate as P2O5 by wt. min 32.0 Water soluble Potash as (K2O % by wt. min.) 16.0 Water soluble Phosphates (K2O % by wt. min.) 27.2 Particle Size : Particle of the material will be such that 90% of the material will be between 1 mm & 4 mm is sieve & not more than 5% will be below 1 mm size.

DAP [18:46:0]
1. 2. 3. 4. Moisture % by wt. min Total N2 % by wt. min Ammoniac N2 % N2 in urea form % by wt. max. 1.5 18.0 15.0 2.5

5. 6.

Neutral NH3 Citrate soluble phosphate as P2O5 by wt. min Water soluble Potash as (K2O % by wt. min.)

46.0 0

7. 8.

Water soluble Phosphates (K2O % by wt. min.) 41.0 Particle Size : Particle of the material will be such that 90% of the material will be between 1 mm & 4 mm is sieve & not more than 5% will be below 1 mm size.

Water Soluble P2O5

The portion of P2O5 in fertilizer which is soluble in water includes practically all the P2O5 which is present in the form of mono ammonium phosphate & dia ammonium phosphate.

Citrate Soluble P2O5 (C.C. P2O5)

The portion of P2O5 in fertilizer which is insoluble in water but soluble in a neutral solution of ammonium citrate includes practically all the P2O5 which is present in the form dicalcium phosphate, iron & aluminum phosphate. These three compounds originate as impurities in the phosphoric acid used in the process.

Available P2O5 (Also known as available phosphoric acid A.P.A.)

The sum of water & citrate soluble P2O5.

Citrate Insoluble P2O5 (C.I. P2O5)

The portion in P2O5 fertilizer which is insoluble in both water & ammonium citrate solution includes practically all the P2O5 which is present in the form of tricalcium phosphate (form impurities in the phosphoric acid).

Total P2O5
Total sum of water soluble, citrate soluble & citrate insoluble P2O5.

B.P.L. (Bone Phosphate of Lime)

It is the amount of tricalcium phosphate in the rock % P2O5 = B.P.L.*0.458

 Nitrogen
Refers to elemental nitrogen present in the form of a) Nitrate Fertilizer such as ammonium, sodium & calcium nitrates etc. b) Organic compounds such as urea c) Ammonia salts such as mono & diammonium phosphate. The quantity of nitrogen is expressed in terms of N (monotonic).

Potassium
Refers to the element K present in chemical compounds such as potassium chloride (KCl) & Potassium sulphate (K2SO4). The amount of potassium in a fertilizer compound or mixture is generally expressed in terms of potassium oxide (K2O).

Primary Nutrients
Nitrogen, Phosphorus, Potassium are essential elements & are needed by the plant in relatively quantities. Therefore, these are called primary or major nutrients.

Secondary Nutrients
Calcium, Magnesium, Sulphur normally are required in lesser but still considerable amounts. These are classified as secondary nutrients.

Micro Nutrients
Zinc, Iron, Boron, Molybdenum etc. are required by the plant in very small quantities, hence these are called micro nutrients.

High Analysis Fertilizer

It is fertilizer of relatively high nutrients concentration. Normally fertilizer containing total nutrients below 36 units is called as high analysis fertilizer.

Low Analysis Fertilizer

It is fertilizer of relatively low nutrients concentration. Normally fertilizer containing total nutrients below 36 units is called as low analysis fertilizer.

Nutrients Ratio

 Straight Fertilizer

The ratio existing between the percentages of Nitrogen, available P2O5 & K2O e.g. nutrient ratio for C.D. 10:26:26 would be 1-2, 6-2, 6. Fertilizer containing only one nutrient is called straight fertilizer.

Mixed Fertilizer
Fertilizer containing only two or more nutrients is called mixed fertilizer.

Complex or Compound Fertilizer

It is multi nutrient fertilizer made by process based mainly on neutralization of an acid.

Ammoniation
It is molecular ratio of ammonia to phosphoric acid with ammonia or nitrogen solution.

Mole ratio (also Mol ratio)

It is molecular ratio of ammonia to phosphoric acid in any mixture of ammonia & phosphoric acid, i.e. Mole ratio of pure Mono ammonium phosphate 1.0 Mole ratio of pure Dia ammonium phosphate 2.0 A mixture of mono ammonium phosphate & dia ammonium phosphate will therefore have a mole ratio of between 1.0 & 2.0.

Source & Storage of Raw Materials

Various Raw Materials & their source of supply are as under:

Phosphoric Acid
Imported concentrated wet process Phosphoric acid (50 to 54%) is used in the plant. The major suppliers of Phosphoric acid in the world are as under: M/s Marco Phosphor, Morocco. M/s Industries Chemiques Maghrebins, Tunis, Tunisia. M/s Mitsui & Co., New York, U.S.A. M/s Gardiner & Co., U.S.A. M/s International Phosphates Ltd., Iran/Mexico. M/s Industries Chemiques Senegal, Senegal. Analysis of Phosphoric acid (Imported Quality) Constituents Percent by weight P2O5 52 to 54% CaO 0.05 to 0.2% MgO 0.6 to 1% Fe2O3 0.33 to 1.4% Al2O3 0.3 to 1.9% H2SO4 1.03 to 5.61% Cl Traces or upto 0.02% Suspended solids 0.39 to 3.6% Density at 300C 1.62 to 1.74 gms/cc. Properties Molecular Formula Boiling Point (A.P.P.) Colour Molecular weight

: : : :

H3PO4 2130 C Water white Liquid 98

Storage Storage tanks are A, B, C, D, E, F, G, H & three day tanks also A, B, C. The first 8 tanks are rubber lined tanks of 28m dia & 10m height, and are having a capacity of 10000 MT. The other three tanks are of 11.23m dia & 8.23m height in dimension & having a capacity of 1350 MT. The tanks are built of carbon steel rubber lining inside. The rubber lining is bounded to steel by a technique called Cold bonding.

Ammonia
Ammonia is supplied from IFFCO Kalol, R.C.F., GNFC, KRIBCO in rail tankers at ambient temperature & ships at fully refrigerated conditions. It is unloaded in to two Horton Spheres, each having a capacity of 1500 MT.

The pressure & temperature in Horton spheres is maintained at 3.0 kg/cm2 & 00C. Ammonia is also unloaded in three atmospheric tanks which are having a capacity of 5000, 10000 & 15000 MT. Also the pressure & temperature is also maintained at 1 atm & -330C. Specifications of Ammonia Chemical Symbol : NH3 Molecular weight : 17 Boiling point : 00 C Melting Point : -330 C Hazardous Properties When stored in closed container, liquid ammonia exerts a vapour pressure which increases rapidly with rise in temperature. Ammonia turns explosive when mixes with air & oxygen. The use of mercury in contact with ammonia should be avoided, since under certain conditions it results in explosive chemical compound. Ammonia is an irritant gas which affects mucous membrane & eye. Liquid ammonia causes caustic burn when comes in contact with the skin or the body.

Muriate of Potash (MOP)

MOP also known as Muriate of Potash or simply Potash is imported from West Germany & Canada through Government Agency (Indian Potash Limited). There are two departments where potash is stored: 1. Old Potash storage with capacity 10000 to 20000 MT & 2. New Potash storage with capacity is 80000 to 95000 MT. It is stored in heaps by dropping potash from the top so as to utilize the full space of the storage. Raw material coming by trucks from KPT is unloaded into hoppers & transferred to raw material conveyer with the help of vibrating pan feeders provided at the bottom of hoppers. On the raw material conveyer electro magnetic type iron separator is suspended near the head end for the removal of ferrous material from raw material. By the means of pay loaders potash is scooped towards slit openings with grating provided on potash storage flooring to feed traveling hoppers with belt feeders. Underneath the floor in the tunnel, potash is discharged to potash cross conveyer which conveys potash to potash transfer elevator through end discharge chute. Capacity of unloading is about 278 MT/hr. Specifications of MOP Colour K2O % by wt. Equivalent KCl by wt.

: : :

White/Red crystals 60 to 62 % 95 to 98 %

Moisture Chloride % by wt. Particle size Bulk density Angle of repose Melting point

: : : : : :

1% 47 to 48 % -1 to +85 Mesh. 1.1 to 1.15 tons/cu.m. 30 to 330 C 7720 C.

Prilled Urea
Urea is supplied by IFFCOs Kalol unit in 50 kg bags. It is transported by rail as well as by trucks. Through unloading platform, it is taken to Raw Material storage which is also known as Old Potash storage. Specifications of Urea Nitrogen by wt. Particle size Biuret by wt. Moisture by wt. Bulk Density Angle of repose Melting Point : : : : : : : 46% min. -6 to +16 Mesh. 0.78 % 1 % max. 45 lbs./cu.ft. = 0.72 Te/cu.m. 30 to 330 C 132.70 C.

Filler or Silica sand

It is made available locally & is transported by trucks. It is unloaded at unloading platform & stocked in Raw Material storage. Specifications of Filler It should not contain any abrasive quartz particle. Colour : White or light gray Silica : 85 % min. NaCl : Traces Acidity/ Alkalinity : Preferable neutral or alkalinity 0.1 (max.) Moisture : 1 % max. Particle size : -28 mesh Tyler : 100 % +85 mesh Tyler: 95 % +100 mesh Tyler: 100 % Bulk Density : 42 to 100 lbs/cu. Ft. (1.6 Te/cu.m) Angle of repose : 30 to 330 C.

Offsite Utilities
Fuel Oil Storage
There are three storage tanks of capacity 1200, 390, & 250 kl to store fuel oil with unloading & handling facilities. Fuel oil has a calorific value of 10,210 cal/gm approximately.

Power
IFFCO Kandla gets power through a double circuit 66kv from GEB. Source of power is Dhuvaran power station 132kv line from Dhuvaran to Jamnagar has been tapped at Vankaner to feed Bhuj through single circuit line. Same line has been tapped at Anjar station where it is stepped down to 66kv & double circuit lines direct circuit lines directly feed IFFCO power station. In addition to this there are two sets of emergency power generators of 310kva & 620 kw 415 volts ac. Maximum demand of IFFCO is 11mva.

Water
Water is supplied by KPT through 12 inch pipe & is stored in 3 tanks out of which two are MS tanks & one is RCC tank. Total storage capacity is 10800 MT.

Water Treatment Plant

Water contains impurities like dissolved gases, dissolved solids, suspended solids, living organisms etc. Most common dissolved gases are oxygen, nitrogen & carbon dioxide. Dissolved salts are usually salts of sodium calcium & magnesium. The corrosiveness of water is determined by the nature of salt present in it. Under operating conditions of a Boiler concentrated alkalis & nitrogen attack steel. The presence of dissolved oxygen & carbon dioxide cause corrosion. Hard water is those containing objectionable amounts of dissolved salts of calcium & magnesium. These are usually present as bicarbonates, chlorides & sulphates. Temporary hardness is usually caused by bicarbonates of calcium & magnesium & can be greatly reduced by heating. Permanent is due to the sulphates & chlorides of calcium & magnesium. Ion exchange treatment is used for the treatment of Boiler water. Ion exchange is really a chemical reaction which mobile hydrated ions of solids

are exchanged for equivalent ions of like charge in the solution. Raw water available at plant is having pH of 8.2 & totals hardness 340 ppm. The water treatment plant consists of: Cation exchangers Softners One degasser One deareator The water from this plant is then supplied to the boiler. Thus the Boiler receives soft water free from alkaline salts & thus reducing scaling & surging of the boiler.

Steam Generation Plant

Steam generation plant consists of 3 fire tube package Boilers capable of producing saturated steam at a pressure 10.5 kg/cm2. One of them is I.A.E.C. Boiler, other is NESTLER & the last is THERMAX boiler. The boiler feed water is treated in the water treatment plant before feeding to the boiler. I.A.E.C. Boiler This boiler is fully automatic fire tube, fuel oil fired package boiler, with three passes having a capacity of 10 MT/hr at 10.5 kg/cm2 working pressure. This boiler is equipped with 2 gauge glasses, 2 safety valves, 2 fuel oil pumps which is capable of developing high pressure if about 25.0 kg/cm2, two boiler feed pumps & one complete oil firing equipment with forced draught fan. Besides it has blow down connection for blowing out water from boiler shell & main stream stop valve for isolation. It has a master pressure gauge for indicating boiler drum pressure. NESTLER Boiler It is also a fire tube package boiler with 3 passes having a capacity to produce 4 MT/hr of stream at 10.5 kg/cm2 when water is fed at 950 C. This Boiler has been provided with 2 feed water pumps, one furnace oil injection pump capable of pumping oil at a pressure of about 25 kg/cm2 with built in by-pass valve, two gauge glasses, one oil heater & one forced draft fan. It is also provided with blow connection & flue gases duct with damper. THERMAX Boiler This Boiler is most efficient of all three. It is provided with fire tube type shell construction. Furnace oil is used as fuel. There is an economizer configuration which is useful to increase the boiler efficiency.

Sewage Treatment Plant

Sewage coming from different location of the plant is collected in a common pit near workshop before transferring the main sewage treatment plant. This sewage plant is provided with two deep well sump pumps. Process Description This plant works on two basic processes which are as under: 1. Aeration In this process, the organic matter is oxidized with the help of oxygen. 2. Clarification In this process to remove the dead organic mass formed as flow in the aeration tank.

Air Compressor Unit

Air compressor unit comprises of four non lubricated horizontal reciprocating compressors. These are two stage double acting of Khosla & two stage double acting Chicago compressor. Khosla Compressor Type Manufacture Suction Pressure Gas handled Piston dia. Stroke Temp. of gas at inlet Temp. of gas at outlet Cooling system Speed of crankshaft Air Receiver Capacity Design pressure Working pressure Design temp. Working temp. 2 stage non lubricated balanced K.G. Khosla Ltd. 7 kg/cm2 Air 370mm, 115mm ambient 430 C water cooled 750rpm. 10 m3 10 kg/cm2 7 kg/cm2 1000 C 430 C

: : : : : : : : : : : : : :

IFFCOs NPK 1 Plant

The NPK complex fertilizer plant at Kandla is designed for producing various grades of ammonium phosphate based on NPK products. The grades being manufactured at present are 18:46:0 (DAP), 10:26:26 (Grade 1) & 12:32:26 (Grade 2). The design capacity of each train for the above grades is as under: 18:46:0 (DAP) 10:26:26 (Grade 1) 12:32:16 (Grade 2) : : : 600 Tons/Day 800 Tons/Day 1000 Tons/Day.

The annual production capacity in terms of P2O5 out-put is of 3, 09, 130 MT. The design capacity is of 2, 60, 000 MT Licensed/Installed. In first phase, two trains namely A & B were commissioned in 1974, & in phase 2, additional two trains namely C & D trains were commissioned in June 1981, one month ahead of schedule.

Process Description
The manufacturing process uses the well known conventional slurry granulation process. The plant consists of four identical streams with a common product handling, storage, reclaiming & bagging facilities. Phosphoric acid containing 52 to 54 % P2O5 & scrubber liquor containing 20 to 25 % P2O5 at NH3/H3PO4 mole ratio of 1.2 to 1.3 are fed to a vertical cylindrical reactor called Preneutraliser where it is reacted with anhydrous liquid ammonia to a mole ratio of 1.4 or a pH of 5.6 to produce an ammonium phosphate slurry containing 18 to 20 % water. About 70% of the total phosphoric acid requirements are fed to the Preneutraliser. The rest is fed to the scrubber system from where it goes to the Preneutraliser in the form of scrubber liquor at a pH of 8 to 5.2. The ammonium phosphate slurry from the Preneutraliser is pumped to a rotary drum called Granulator where it is sprayed over the rolling bed of recycles fines & solid raw materials feeds like potash, urea & filler to form granules. Further, ammoniation up to a mole ratio of 1.8 to 1.85 is carried out inside the granulator by means of ammonia spurges located below the bed of materials. The granulated product containing 2.5% water is then dried in a co-current rotary drum Dryer with hot air produced by combustion of fuel oil/LSHS. The dried product is elevated over double deck vibrating screen by means of a drag flight conveyor. Product of the required size i.e. between 1mm & 4mm, is separated in the screen from the oversize & undersize. The on size products collects in a

compartment in the product bin & is withdrawn at the required rate by a vibrating pan feeder. Excess product size materials & oversize materials pulverized in a chain mills & are discharged into the recycle flights conveyor. The undersize material collects in a fines bin & discharged in to the recycle conveyor, where it mixes with the crushed oversize & fresh solid raw material feeds to form the recycle feed to the Granulator. The recycle conveyor, which is a drag flight conveyor, discharges the material into a continuous discharge bucket elevator which in turn discharge into the Granulator. The product discharge from the vibrating pan is conveyed to a rotary drum Cooler where the product is cooled from 700 to about 400. The product discharged from the cooler is elevated by a product elevator in each train which discharges into the product conveyor common for all four trains. The scrubbing system consists of a fumes scrubber, Dust scrubber, Dryer scrubber & Cooler scrubber. The first three are venture cyclonic type. Scrubber liquor supplement by fresh phosphoric acid feed is circulated by pumps in all the scrubbers except the cooler scrubber where only water is circulated. Dust laden air from the dryer, cooler & other equipments pass through cyclones where a major portion of the dust is separated before being scrubbed in the respective scrubbers. Fumes from the Preneutraliser & Granulator are scrubbed in the fumes scrubber. Each scrubber is provided with a fan for creating the required draft. The scrubbed gases are let out into the atmosphere through a common Stack. Raw materials of required quantity are fed to the recycle conveyor, through gravimetric feeders from respective use bins. The recycle conveyor is a drag flight conveyor & conveys the above material to the Granulator via secondary elevator, thus completing granulation loop.

Main Equipments used in NPK - 1

Granulator It is installed in all the four trains. The granulator receives recycled fertilizer from secondary elevator. It is also supplied with the slurry as solution of fertilizer, salt in sea water & with liquid NH3. These materials are thoroughly mixed within the granulator. The mixture is discharged by gravity through chute to dryer. The granulator is special rubber lined cylindrical steel drum inclined from feed to discharge & rotating on tires &

trunions. Solid fertilizer materials are fed through an inclined chute at the fed end as a rolling end bed from a source of spraying nozzle mounted on a manifold pipe. Liquid ammonium is sprayed into the rolling wetted fertilizer bed via an ammonia sprayer pipe which is submerged in the rolling fertilizer bed. The drum is driven by an electrical motor speed reducer pinion & ring gear. The drum is held under slight negative pressure & a current of air is exhausted to remove fumes vapours, water & dust.
Construction Features

A cylindrical shell 11 dia & 22 length is rotating on steel tires & trunions. Looking at feed & the normal rotation is clockwise; the feed chute is to the right & the drive to the left of the vertical line. Allowable run-out from true cylinderis +4 mm. The shell is provided with: Feed end retaining ring of 0.25 carbon steel plate with 68 opening. A discharge end retaining ring of 0.5 carbon steel with 78 dia opening & two full heights hinged clean out doors. Two bar lifters at discharge end for removable of over size. A flexible rubber lining to prevent fluid up on the inside of the shell bolted to the shell with bolts, nuts & steel straps. Suitable mounting pads for the tires of mild steel welded to the steel to support the tires. Both sets of trunions rollers are mounted on a heavy structural steel frame arranged for adjustment of trunions. Lubrication of tires & trunions is done monthly. Thrust rollers on heavy duty shafts, heavy duty dust proof roller bearings are mounted on an adjustable steel extension to the supporting frame of the discharge end trunions rollers. Drive is designed to allow temporary reversal of rotation at start up in order to break up the charge after a chute down. Pinion shafts bearings housings are of cast steel & all bolts of high tensile strength. The 3/6 L stainless steel ammonia sprayer capacity is 0.6 2.0 MTPH of spraying liquid NH3 containing a small fraction of ammonia gas. Product Cooler Four product coolers are in each stream of NPK -1 plant. The colour coolers are used to cool granular ammonium phosphate fertilizer. The coolers are rotary drums counter current type coolers. The cooling medium is ambient air. The coolers receive the material to be cooled from cooler feed conveyor end discharge the product to the product elevator. Coolers A & C rotate in counter clockwise & coolers B & D in clockwise direction when looking in the direction of material.

Cooler Drum size Cooler Speed Cooler Slope Opening Condition Material Handled Moisture content Capacity Product Inlet Temp. Product Outlet Temp.

: : :

9 feet outer dia 50 feet overall length 6.5 rpm 11/16 per feet.

: : : : :

Granular ammonium phosphate fertilizer 1% 50 MTPH 1850 F 1150 F

Rotary Dryer Four rotary dryers are installed in NPK 1 plant, one in each stream. Looking in the direction of flow material for A stream dryer rotates in clockwise direction while dryer B in counter clockwise direction. Dryer receive material from granulator & discharge to primary elevators & lump crushers. Both dryers are direct fired in parallel flow by air quenched combustion gases from combustion chambers. An extra set gears is provided to change the dryer speed from 4.5/5 rpm to 2.5 rpm.
Construction Features

o Shell of welded mild steel construction 16 mm thick, & properly reinforced knocker section. o Tires machined finished on all side for slip mounting on the mounting pads welded to the shell. o Trunions with shafts & dust prevent heavy roller bearing & pillow blocks mounted on heavy welded structure steel frame arranged for arrangement of trunions. One trunion roller per tires is equipped with a graphite in a holding bracket to lubricate carrying surfaces. o Thrust rollers acting on discharge end tire with heavy duty roller bearing in dust proof housing & mounted on welded steel base. o Dryer consist of: a). Motor: single speed, 350hp, 3.3kv b) Centrifugal clutch coupling with low speed on input shaft. c) Speed reducer to turn dryer at 4.5 rpm. An extra set of gears & shafts for a speed of 2.5 rpm are also placed. d) Flexible shaft coupling between output & pinion shaft. e) Pinion gear with cut spur teeth & dust proof heavy duty rollers bearings & pillow blocks. f) Gear & coupling guards of 3 mm steel plate.

Combustion Chamber Four combustion chambers are installed in each stream in NPK 1 plant to supply air quenched combustion gases to the rotary dryers. The combustion chambers are refractory lined, direct oil fired & consist of air heaters with burners & auxiliary equipments. Fuel The main burners operate on furnace oil. The pilot burner operates on LPG. Oil atomization is via combustion air pressure. Flash point of oil is 730 C & carbon residue is 6.8 % by wt. gross calorific value is 10,515 cal/by gm. Operating Condition Exit gas flow to dryer Exit gas temperature : : 3645 lbs / min of dry gas. 9000 F.

Scrubbers Each stream produces four gas streams which require scrubbing for the removal of dust & toxic fumes & recovery of valuable constituents. All are venturi cyclonic except cooler gas scrubbers which are only cyclonic type. The scrubbing liquid is 30 40% P2O5 wet phosphoric acid 20 - 1500 F. Except in case of cooler scrubbers, where water containing small amounts ammonium phosphate, urea & KCl is used. a) Dryer scrubber Dust laden gases are induced through the dryers, cyclones & the scrubbers by means of dryer fans which are located after the scrubber & before the fumes stack. b) Dust scrubber Air containing dust from various sources in the plant is induced through the dust collection system & dry cyclones by dust fans. The air which is then relatively free of dust is then forced through the dust scrubbers & to the fumes stack. The dust scrubbers operate under a +ve pressure. c) Cooler gas scrubber The cooler gases are included through the coolers & dryer cyclones by cooler fans. The gas which is relatively free of dust is forced through cooler scrubber to the fumes stack. It operates under +ve pressure. d) Fumes scrubber Wet fumes from the granulators & preneutraliser are induced through the scrubber by fumes fan. The fumes are forced into the fumes stack. The fumes scrubber operates under a ve pressure.

The scrubbers have flanged nozzles for gas & liquor. The throat section of each venture scrubber is flanged for replacement all parts within the scrubber such as wire plate, baffles are completely rubber covered. All valves are rubber lined diaphragm type. Vibrating Screens In vibrating screen different size of product separation is done. The powder product is further sent to the fines conveyor & is reused. The lumps from the granules are sent to the pulveriser or crusher.
Application

Separation of product granules from over size pulveriser & under size dusty particles.
Principle

Electromagnetic vibrating twin coil unit installed on each frames middle position at top side for producing 1500:1800 vibrations/min by pulsating current of variable intensity at a low frequency.

IFFCOs NPK 2 Plant

Grade
There are three grades produced in NPK 2. 1. DAP (18:46:0) 2. NPK 1 (10:26:26) 3. NPK 2 (12:32:16) There are two trains E & F in NPK 2 which were commission in 1999. All the machines used for the production of fertilizers of different grades in NPK 2 are some what larger than that in NPK 1.

Description of AZF process

The AZF pipe reactor process is carried out in the granulator loop which includes: A granulator ammoniator A dryer A screening & crushing system But the AZF pipe reactor process presents a marked difference from other process because the neutralizer of phosphoric acid by ammonia is carried out in a pipe reactor instead of the usual single preneutraliser. These acids are partially used in the scrubbing system of the exhaust gases from the granulator & the dryer in order to recover the ammonia that may have been released during the process. The phosphoric acid is mixed with the scrubber liquor in order to spray at the outlet of the granulators pipe reactor a melt allowing the liquid phase required fan an easy granulation. This ammonia flow rate to the granulator pipe reactor is controlled to obtain in the product at the outlet of this pipe reactor a mole ratio R equal to 1.4 or fertilizer with a high ammoniation ratio in the end product (such as DAP) or a mole ratio equal to 0.75 for fertilizers with a low ammonia is added through a final product. Complementary liquid ammonia is added through a sparger into the rolling bed of solid materials in the granulator to adjust the mole ratio R to the required value for the formulation. With the introduction of a pipe reactor into granulation system, the input water in the granulator is subsequently the solid recycle ratio can be kept to very low value to 3.0 for DAP production with dual pipe reactor system 2.5 to 3.0 for NPK production depending on the product formulation & raw materials.

Polishing Screens There are two polishing screens installed in NPK 2 for making the product size more efficient. The product is fed to polishing screens through product elevator after cooling the product. This screen is also one the major difference from NPK 1. Polishing screen is a double deck type, gyrator linear motion screen having continuous duty. Earlier, the product elevator discharging to product conveyors 102 C/D, but after the installation of these screens the product elevator feeds the product to these screens first. After the installation these screens, the oversized product has been reduced resulting greater sharpness in product size.

Scrubbing system & Gas treatment

As we know that the main function of scrubbing system is to scrub the gases & dust that is coming from various equipments in the plant & also to maintain the atmospheric conditions as per EMS. The scrubbing system at NPK - 2 is somewhat different then at NPK 1. Here this system consists of mainly five scrubbers as under: 1. Tail gas scrubber 2. Fumes scrubber 3. Cooler scrubber 4. Dryer scrubber 5. Dust scrubber. In addition process uses as particularly efficient gas deducting & scrubbing system providing an excellent ammonia recovery by complying with the most severe standard requirements concerning the maximum total fluorine emission to the atmosphere. Moreover in normal operation, there are no polluted liquid wastes discharged to the sewer. This gas treatment is carried out by a conventional deducting of the dryer off gases in cyclones followed by a two stages scrubbing system. The first one in a venturi scrubber ensures an excellent contact between the gases & the scrubbing liquor & the second in a cyclonic tower providing a perfect demisting of the scrubbed gases. The granulator lamp gases are only washed in a two stages scrubbing system (venturi first then cyclonic tower). The scrubbing liquor is made of part of phosphoric acid & sometime sulphuric acid (depending on the grade of the fertilizer). A slightly acidic pH (5 to 6) is maintained in the first stage (venturi) in order to obtain in the scrubbing liquor the recovery of the most part of the ammonia released with the gases while fixing fluorine in the second scrubbing stage. Cyclonic tower circulates a distinctly more acidic solution

so as to recover the ammonia escaped from the first scrubbing stage. The scrubbing liquor is sprayed in counter flow to the gases. Then the scrubbing liquor from the scrubbing system is recovered & returned to the granulator pipe reaction. The off gases from the handling pieces of equipments, screens, mills are deducted through cyclones & recycled to the feed end of the dryer. The recovered dust (as well as that coming from the deducting of the dryer gases) is recycled product to the granulator. Possibly gases from product cooler are also recycled to the feed end of the dryer. Those recycling flows of hot air participate also to the reduction of fuel consumption.

Materials Handling at IFFCO Kandla

Various raw materials necessary for the plant are handled as per their specifications. The handling system of various raw materials is as under:

o Phosphoric Acid
Phosphoric acid is made available to the plant from various suppliers as discussed earlier. It is unloaded from the ship & is pumped to storage tanks at the rate of around 1000 MT/hr. The acid from the storage tanks is pumped to the day tank at the rate of 100 MT/hr by acid pumps. Lastly from the day tank, it is taken to the plant process by acid supply pump as per requirement.

o Ammonia
Ammonia is unloaded to the storage tanks of capacity 5000, 10000, & 15000 MT either by rail tankers or by ship at the rate of 550 650 MT/hr. Before these atmospheric storage tanks, it was unloaded on two Horton spheres at the rate of 525 MT/hr. It is stored at a temperature of -330 C which is liquid state for ammonia. Then it is pumped directly to the plant for production of fertilizer.

o Muriate of Potash (MOP)

Muriate of Potash or simply Potash is the oxide form of potassium which is imported through Government Agency (Indian Potash Limited). For unloading it, two storages are there namely Old potash & New potash. The capacity of old potash is nearly 20000 MT while that of new potash is 80000 MT. at present only new potash is used for storing potash. Old potash is used for storing other raw materials such as Urea, Filler, and MAP. Potash is carried to the plant through elevators mainly. Lastly it is elevated to the Raw Material Discharge Conveyor (RMDC).

o Filler or Silica sand

It is made available locally & is transported by trucks. It is unloaded at unloading platform at old potash. It is also conveyed & then elevated to the Raw materials discharge conveyor (RMDC).

o Urea
It is supplied by Kalol unit of IFFCO in 50 kg. bags which is transported by rail as well as trucks. Then it is unloaded at unloading platform at old potash. Lastly it is conveyed & then elevated to the Raw materials discharge conveyor (RMDC). The flow of materials is shown by the following flow chart as described before:

Water from storage tanks

Ammonia from storage tanks

PRENEUTRALISER
Through secondary elevator

Phos. Acid from storage tanks

Raw materials such as Potash, Urea, Filler etc. Fines conveyor RMDC
through Primary Elevator

Granulator

Dryer

Heat from combustion chamber

Screen Drag Feeder (SDF)

Pulveriser for crushing oversize product

Vibrating Screens
Through Cooler feed conveyor

Product Cooler
Through Conveyer 101A/B & 102A/B Through Product Elevator

Bulk storage
Through various Belt conveyors

Bagging plant

Path of Raw materials to a Complete Product

Product Handling at IFFCO Kandla

o Bulk Storage
This plant comes next after both the NPK units in the line of process. It is capable of storing 30000 MT of fertilizer. The storage has been divided into equal compartments with the help of retaining walls. This is done to store four different grades of fertilizer separately. Detailed process After the completion of the product, the fertilizer from both the plants is conveyed to this plant. This plant works on to types of handling process, direct & indirect. In direct process, the product is directly conveyed to the bagging plant while in indirect, the product is conveyed at some procedure. There are total two Bulk storage plants in IFFCO, Kandla. In direct process after the completion of product in NPK 1, the product is conveyed from 102 A/B conveyors to 103 A/B conveyors then to 104 A/B conveyors & lastly is taken to the Bunker in the Bagging plant. In indirect process, product is taken from 102 A/B conveyors to 105 A/B conveyors then 106 A/B to Bulk storage. Then with the help of Scrapper loaders A/B, it is taken to 107 A/B & 107 C/D conveyors. Finally it is conveyed to 104 A/B to Bunker in the Bagging plant. The path of product from NPK 2 to bagging plant is also similar as NPK 1. Here also direct & indirect path of product takes place. Just single difference is there between both the paths of product & that is here in NPK 2, the product is taken through 102 C/D to 103 C/D to 104 C/D then lastly to 104 E/F conveyors to the Bunker. This is the single difference in both the path of the product. In indirect process, the product is taken from 102 C/D to 105 C/D to 106 C/D which is a sliding conveyor then to Bulk storage. Then through Scrapper Loaders C/D, it is taken to 107 E/F & 107 G/H. Then it is conveyed to 112 & 108 conveyors to 104 C/D to 104 E/F to 121 to 122 to 123 & lastly to the Bunker. This is the pathway of complete product from plant to bagging. So Bulk storage is used to store the complete product, & then convey it to the bagging plant as per requirement or say as per order or stock.

o Bagging Plant
This plant is the terminus plant of the Kandla complex. The process here consists of automatically weighing a fixed amount of product into bags, stitching & then exporting them to different suppliers of the fertilizer through wagons & trucks.

The NPK fertilizer is brought to bagging plant through the conveyors 104 A/B to Bunker in the Bagging plant. There are total 4 bunkers in bagging plant each with a capacity of 30 MT. Each bunker is equipped with two bag filling & two weighing machines which can give 600 650 tips per hour of 50 kg weight. The filled bag is conveyed with the help of slat conveyors. At the end of the slat conveyors, stitching machines have been installed which close the bags & then these bags are discharged into Rota table type of chutes. The chutes carry the bags on the lower floor for loading into wagons or trucks alternately stacking on the platform. Necessary dust collection equipment consisting of dust fan, dust collector etc. is designed for limiting the emission of dust in the bagging plant. This dust is extracted from the dust forming areas such as bunkers, conveyor discharge point & hoppers of bagging machines. The chart describes the complete process starting from Bulk storage to Bagging plant which is on the next page.

Direct 102 A/B 103 A/B 104 A/B

Indirect 102 A/B 102 A/B

Direct 102 A/B 103 C/D

Indirect 102 C/D 105 C/D 106 C/D

105 A/B 106 A/B Bulk storage Scrapper loader A Scrapper loader B

104 C/D

Bunker

104 E/F

Bulk Storage Scrapper loader C Scrapper loader D

Bunker

107 E/F 112

107G/H 108 104 C/D

107 A/B 104 A

107 C/D 104 B 104 E/F Bunker 121 122

Flow of Product from NPK 1 to Bagging plant

123 Bunker

Flow of Product from NPK 2 to Bagging plant

Materials Handling Equipments at IFFCO Kandla

IFFCO plant is depended on mechanical handling of materials. So no labour is involved except the treatment of say maintenance of that machine. The materials handling system in IFFCO Kandla includes mainly Belt Conveyors, Elevators, Scrapper Loaders, Slat conveyors etc. So we will discuss in detail all these equipments.

o Belt Conveyors
IFFCO Kandla plant is fully depended on these conveyors. Each & every movement of materials as well as product is done on these conveyors. Total seven throughing type belt conveyors are installed in NPK plant for the movement of the raw materials to complete product & then Bagging. The conveyor belts are made endless by means of a vulcanized rubber splice. Mechanical fasteners are not advisable for this purpose. The conveyor carriage is separately driven by a reversible chain drive. A locking mechanism is supplied to maintain the carriage in place at any position along the track. The conveyor belt is separately driven. Tripper is of motorized type mounted upon flanged wheels to allow horizontal movement on tracks. The tripper mechanism allows the belts in the normal fashion when the belt is run in forward direction. Each conveyor is driven through roller chain from speed reducer which is directly connected to the drive motor through flexible coupling. Loading a Belt conveyor If a belt conveyor is functioning effectively, it must be loaded centrally & at a uniform rate in such a manner that material velocity in the direction of belt travel is as nearly as possible, equal to the velocity of the belt itself. Provided that the material is delivered centrally on to the belt, the ideal loading is attained when the forward velocity in the dia of the belt is exactly same as the velocity of the belt. When this condition exists, there is minimum wear on the belt cover, the minimum power is required to operate the belt, the material takes proper load shape quietly without spillage & the minimum degradation or dusting of the material is assured.

o Elevators
Elevators used in this plant are known as Bucket Elevator. There are total three types of elevators used to lift the material vertically namely Primary elevators, Secondary elevators, Product elevators. They are available in a wide range of capacities & may operate entirely in the open or totally

enclosed. Elevators bucket may handle up to 12 inch sizes depending on factors such as percentage of lumps & bucket size. Normally lift ranges up to 100 ft but by special construction, it can lift up to 300 ft. Above this height chain or belt tension develops that are beyond the economical range of this type of equipment. In IFFCO Kandla, the elevators are of vertical continuous super capacity type. A super heavy capacity elevator is a continuous bucket elevator in which the bucket are mounted between one or two strands of chain & protect back towards the centre of the elevator. The material is fed to the bucket through to the bucket through a loading leg & discharged over the face of the preceding bucket while passing round the head sprockets. This design assures gentle handling of material & also eliminates trouble due to scaling in the loading boot.

o Scrapper Loaders
Two numbers semi-portal type scrapper loaders are installed in bulk storage one each on either side capable of moving along the entire length of the product storage building. Bulk storage is suitable for storing approx. 30000 MT of fertilizer. It is divided into four different grades of fertilizers. The middle portion of the floor supporting bulk storage is stopped. Each scrapper loader is capable of reclaiming the fertilizer approx. 15 mt high stock pile along the entire length of the pile in each day at the rate of 125 MTPH & delivers the same to one of the product conveyors located along its respective side of the bulk storage building. The Scrapper loader has a retractable device to knock down intermediate fertilizer build up between columns. The piled up material is spanned by a traveling semi portal construction in which is arranged the scraper boom adjustable in light. By means of the rake chains, the product is drawn towards & supplied on to the conveyor being situated at the longitudinal side of stock pile.

o Slat Conveyors
It is meant to convey NPK fertilizer bags (80*500*170 mm size) weighing 50 kg each at the rate of maximum 950 bags per hour from the two weighing machines feeding approx. 450 bags/hr each. It carries the filled bags to stitching machine & finally discharges stitched bags into the rotary chute. The running speed of the slat conveyor is 48 rpm suitable for 950

bag/hr spaced at nearly 3 ft pitch to meet the stitching machine requirements. Slats Slats having nearly 600 mm length & 30 mm thickness made of seasoned teak wood are fitted to chain attachment with outer sunk bolt nuts. The slats have been spaced at 4 pitch of chain. Chain 4 pitch ISUMBAKI MOTO Japan make steel roller chain having breaking strength of 7900 kg & specifically meant for slat conveyors is provided. Every link of chain is having attachment, for fixing the seats.