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NATIONAL FERTILIZERS LIMITED Panipat (Haryana) Unit Profile

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NATIONAL FERTILIZERS LIMITED Panipat (Haryana) Unit Profile First Prize Fertilizers (Urea) NATIONAL FERTILIZERS LIMITED Panipat (Haryana) Unit Profile The present installed capacity of National Fertilizers Limited (NFL) is 3.568 million tonnes urea per annum. It is the 2 nd highest producer of urea in the country. NFL as a whole is also contributing ~16 % towards total production capacity of India and total share of Panipat unit in Urea production from total NFL is also ~16%. PANIPAT UNIT • NFL Panipat Project was executed with the help of foreign contractor, M/s. Toyo Engg. Corporation, Japan and Indian consultant M/s. Engineers India Ltd. • The cost of project was Rs. 2210 million with Rs. 550 million as foreign components. • Unit has a total area of 574 acres. Factory area is 442 acres and a beautiful township spread over an area of 132 acres • Urea plant was designed to produce 1550 TPD urea. Ammonia plant was designed to produce 900 MT/day Ammonia based on partial oxidation of Residual fuel oil/LSHS by SHELL GASIFICATIION process. Commercial production of Urea was achieved in Sept. 1979. • A Captive Power Plant was also installed with 30 MW capacities at a cost of Rs. 1100 million in the year 1988. • In the year 2001-02, Unit introduced the concept of Neem coating on urea. After rigorous R&D the product was stabilized and test marketed. Seeing the overwhelming response from the farmers unit started large scale production. In view of this unit was awarded Golden Peacock Innovation Award by Institute of Directors, New Delhi in 2005 (till date unit has produced 963485.65 MT of Neem coated Urea). Energy consumption in oil based plant was high. In view of this, Government of India announced a policy for revamp of the FO/ Naphtha based fertilizer plants for changing feedstock from FO/LSHS to NG/RLNG in January 2004 with equity to debt ratio of 1:19. In order to reduce the energy consumption under this policy, Unit has undergone for revamp of the plant by changing the feedstock from fuel oil to NG/RLNG based on proven process route of Steam Methane Reforming (AFCP). Zero date for the project was 29th Jan, 2010. Commercial production was achieved on 28.3.2013. Till date 112 Panipat unit has produced 16059551 MT of Urea. Of this 927083 MT has been produced after the project of AFCP. DESCRIPTION IN BRIEF OF AMMONIA FEEDSTOCK CHANGEOVER PROJECT UNDERTAKEN TO REDUCE ENERGY IS AS UNDER FEED PREPARATION (HYDROGENATION AND DE-SULPHURISATION) The natural gas feedstock contains minor quantities of sulphur compounds which have to be removed in order to avoid poisoning of the reforming catalyst in the primary reformer, and the low temperature shift catalyst in the CO converter. Particularly the low temperature shift converter is sensitive to deactivation by sulphur and sulphur bearing compounds. The sulphur contained in the natural gas will be reduced to a very low level, i.e. less than 0.1 ppm sulphur by weight. REFORMING The reforming of the hydrocarbon feed takes place in two stages, a direct fired primary reformer and an auto thermal catalytic secondary reformer. The hydrocarbon feed coming from the desulphurization unit is mixed with steam. The steam/carbon ratio is 3.0. The reaction mixture is preheated and taken to the primary reformer, where it is decomposed into hydrogen, carbon monoxide, and carbon dioxide over a nickel catalyst by heat supply. In the secondary reformer preheated air is added, and the heat thus generated by burning of the gas decomposes the methane. The methane concentration in the outlet gas from the secondary reformer is 0.6 vol% (dry basis) HIGH TEMPERATURE AND LOW TEMPERATURE CO SHIFT CONVERTER The CO conversion takes place in two adiabatic stages. After reforming, about 12.7% CO is present in the gas (dry basis). In the high temperature CO converter, the CO content is reduced to approximately 3.1 vol%, and the temperature increases from 360 oC to 429 oC. It is then cooled to 205 oC and passed on to the low temperature CO converter, in which the CO content is reduced to approximately 0.3 vol%, while the temperature increases to 226 oC. 113 CO 2 REMOVAL For removal of the carbon dioxide, the activated MDEA process is used. Main equipment in the MDEA process is the CO 2 absorber and the CO 2 stripping column. CO 2 is removed from the process gas by counter-current absorption in two stages. In the lower part of the absorber, flash- regenerated solution is used for bulk CO 2 removal. In the upper part of the absorber, strip-regenerated solution is used for scrubbing. Thus, nearly a complete removal of CO 2 with only 0.05 vol % CO 2 (on dry basis) left in the treated gas. METHANATION After the CO 2 removal, the gas contains 0.05% CO 2 and 0.3% CO (dry basis). These compounds are poisons to the ammonia catalyst and must be removed before the gas is taken to the synthesis section. This is done in the methanator, where CO and CO 2 react with H2 to form CH 4, which is harmless to the ammonia catalyst. The content of CO + CO 2 is reduced to less than 5 ppm. The inlet temperature to the reactor is 300oC, and the outlet temperature is 323 oC. AMMONIA SYNTHESIS The synthesis gas after compression to 186 kg/cm 2 is taken to synthesis loop for recovery of Ammonia. In the synthesis loop, the make-up gas is sent directly to the ammonia converter (S- 300). The make-up gas contains about 1.04 % of inert gases (Ar+CH 4). The purge is taken from the outlet and is sent to the new ammonia recovery unit. AMMONIA RECOVERY and STORAGE Purge gas from the ammonia separator is sent to the purge gas absorber together with letdown gas from the product let-down tank. In purge gas absorber, ammonia 114 is washed out of the gases with water. The aqueous ammonia from purge gas absorber is sent to the distillation column, where the ammonia is distilled off and added to the ammonia product drawn from the product let-down tank. The off-gas from the purge gas absorber is used as fuel in the primary reformer. Ammonia produced is stored in two Horton spheres having a capacity of 1500 MT each. BAR CHART SHOWING SPECIFIC ENERGY CONSUMPTION / MT OF UREA With the commissioning of Ammonia feed stock changeover project at the end of 2012-13, reduction in specific energy consumption/MT of Urea has been achieved from 10.097 GCal/MT Urea to 7.687 GCal/MT Urea. 115 Second Prize Fertilizers (Urea) GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED Bharuch (Gujarat) Unit Profile Gujarat Narmada Valley Fertilizers & Chemicals Limited. (GNFC) is a joint sector enterprise promoted by the Government of Gujarat and the Gujarat State Fertilizer Company Ltd. (GSFC). GNFC started its manufacturing and marketing operations in 1982. Over the next few years, GNFC successfully commissioned different projects - in fields as diverse as chemicals, fertilizers and Information Technology. Since beginning GNFC has embarked itself on the path of continuous modernization and technology up gradation for almost all the plants with the help of In house innovations as well as by incorporating latest technological advancements, not only for production enhancement but also to reduce energy consumption as well to improve environmental performance. Production Performance (GNFC Bharuch) 2012-13 2013-14 Installed Product Units Capacity Capacity Capacity Actual Actual Utilization Utilization Ammonia MT 4,45,500 591,861 132.85% 608279 136.54 % Urea MT 6,36,000 708,795 111.29% 696428 109.35 % Methanol-II MT 1,88,100 130,456 69.35% 145347 77.27 % Formic Acid MT 10,000 20,153 201.53% 20492 204.92 % 116 Acetic Acid MT 1,00,000 157,093 157.09% 155236 155.24 % Weak Nitric Acid-I MT 2,47,500 287307 116.08% 291183 117.65 % 2012-13 2013-14 Installed Product Units Capacity Capacity Capacity Actual Actual Utilization Utilization Weak Nitric Acid-II MT 100000 112,690 112.69% 123322 123.32 % Conc. Nitric Acid - I MT 33,000 29,784 90.26% 32871 99.61 % Conc. Nitric Acid - II MT 33,000 28,908 87.60% 35120 106.42 % Conc. Nitric Acid III MT 50000 49,408 98.82% 53504 107.01 % Amm. Nitro 188865 132.54 % phosphate MT 1,42,500 200,895 140.98% Aniline MT 35,000 41,717 119.19% 40473 115.64 % TDI MT 14,000 17,875 127.68% 16317 116.55 % Ethyl Acetate MT 50000 Under Under 52088 104.16 % Commissio Commissio ning till ning till October October 2012 2012 Energy Consumption At GNFC Ltd., Steam was generated mainly from 3 pulverized Coal fired Boilers, each having capacity of 180 MT/hr of HPSH steam and HRSG of GT unit. The fourth Boiler is gas based and was operated only in case of requirement. Required Power is generated with the help of 2X25 MW Steam Turbines and a 35 MW Gas Turbine based Co-generation unit. Natural Gas and LSHS were used as feed stocks in Feed Stock Conversion Unit (ASGP Plant) and FO based Ammonia plant respectively. Natural Gas was used as Fuel for Turbo generators and as well as Feed Stock in Methanol / SGGU plants. Small quantity of Natural Gas is also used as fuel in some of the plants. GNFC has also installed Wind Turbo Generators (WTG) having total capacity of 21 MW, in Kutch District of Gujarat state in the years 2007 and 2008 and operative since then. A 300 kW PV Solar plant was added to renewable portfolio and commissioned in April 2014.
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