ammonia plant changeover study
TRANSCRIPT
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PROJECT AT A GLANCE Annual Production Capacity
Urea : 5,11,500 MT
Daily Capacity
Ammonia : 900 MT
Urea : 1550 MT
Plant On Stream Days : 330
Project Time Schedule : 36 months
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MILES STONE
1 ZERO DATE 29-01-2010
2 MECH.COMPLETION
28-10-2012
3 HOOKING UP 28-12-2012
4 COMMISSIONING 28-01-2013
5 ACCEPTANCE 28-03-2013
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Annual requirement of Raw
Material & Utilities
Natural Gas (LHV=8685 kcal/ Sm3)248 million Sm3
Support Natural Gas : 25.07 millionSm3
Coal (LHV=4150 kcal/ kg) : 320712 MT
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CAPITAL EXPENDITURE
Project Capital Cost
Total : Rs. 1294.19 Crore
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REIMBURSEMENT OF
CAPITAL EXPENDITURE(i) 80% of the Project Capital Cost,
disbursement in 5 Years, interest accrued on
it & income tax liabilities on above due torevenue generation in the form of SpecialFixed Cost.
(ii) Pre-set Energy norms allowed under NPS-IIIto be given post revamp for 5 (five) years formeeting balance Project Capital
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ENERGY/ MT AMMONIA(ISBL
UNIT Sp.cons.Heat value
(Gcal/unitEnergy
(Gcal/MT
NG KNM3 0.81 8.6857.078
100k steamimport MT 3.920 0.800 3.136power MWH 0.23 2.860 0.67040k steamexport MT -2.13 0.761 -1.621BFW export MT -0.87 -0.871total 8.392
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Ammonia
Plant
OilHandling/Storage
3 Aux Boilers1 Power Boiler
BaggingPlant
IA Dryers
UreaPlant
LPGStorage
MethanolStorage
CoalHandlingplant
TurboGenerator
DM Plant SulfurRecovery
CoolingTower
CO2 /dry ice
Treated water for irrigationE.T.P
Effluent from plants
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Ammonia
Plant
OilHandling/Storage
3 Aux Boilers1 Power Boiler
BaggingPlant
IA Dryers
UreaPlant
LPGStorage
MethanolStorage
CoalHandlingplant
TurboGenerator
DM Plant SulfurRecovery
CoolingTower
CO2 /dry ice
Treated water for irrigationE.T.P
Effluent from plants
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Air Separation Unit
Gasification section
Rectisol Section
SGP & CPP Section
De aerator, BFW Pumps& Steam section
N2 Compressor
Air Compressor
N.W.U
Synthesis Compressor
Synthesis Section
O2Compressor
Steam to Process& Turbines Ref.Compressor
NH3to Urea/storage
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Air Separation Unit
Gasification section
Rectisol Section
SGP & CPP Section
De aerator, BFW Pumps& Steam section
N2 Compressor
Air Compressor
N.W.U
Synthesis Compressor
Synthesis Section
O2Compressor
Steam to Process& Turbines Ref.Compressor
NH3to Urea/storage
New Ammonia Plant
CO2to Urea
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REDUNDANT SECTIONS OF THE PLANT Rectisol and ARU. CO-Shift Conversion. ASU and Nitrogen Wash Unit. Air, Oxygen and Nitrogen compressors. Gasification and Carbon Recovery. 64-ata steam network. Sulfur Recovery Plant.
Fuel Oil Storage and related facilities. CO2 supply to outside (dry Ice) plants shall be
stopped. S-200 Reactor. 3-ata steam net work shall reduce greatly. 3-ata
steam is required only in De-aerator.
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SECTIONS ON REDUCED LOAD Two Boilers shall be required to run instead
of present three Boilers.
Coal Handling and Ash Handling shall reducedby about 45%.
Cooling Tower (CT-1) load shall reduce frompresent 18000 M3/Hr. to about 12000 M3/Hr.
of CW flow. PW and BFW flows shall reduce by about
30%.
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