final-pfr-ec -...

Pre Feasibility Report for Expansion of DAP and Proposal of Coal Handling Plant, Ammonia, Ammonium Nitrate, Urea, GSSP, Aluminum fluoride, Nitric Acid. Paradeep Phosphates Limited, Bayan Bhavan, Pt. J.N. Marg, Bhubaneswar– 751001, Orissa

Jan 2013

EIA Consultant

EQMS India Pvt. Ltd.

Project: Pre Feasibility Report For Expansion of DAP and Proposal of

Coal Handling Plant, Ammonia, Ammonium Nitrate,Urea, SSP, Aluminium fluoride, Nitric Acid.

Project Owner : Paradeep Phosphates Limited, Bayan Bhavan, Pt. J.N. Marg, Bhubaneswar– 751001, Orissa

EIA Consultant : EQMS India Pvt, Ltd Delhi

Prefeasibility report For proposed/Expansion ofPara deep phosphates

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1. TABLE OF CONTENTS

Table of Contents .....................................................................................................................ii List of Tables ........................................................................................................................... v List of Figures .........................................................................................................................vi 1. CHAPTER ..................................................................................................................... 3-1

1.1. Project proponent’s profile .................................................................................... 3-1 1.2. Paradeep Phosphate Limited – Management ...................................................... 3-2 1.3. PPL- Salient Points: ............................................................................................. 3-2 1.4. The site location: .................................................................................................. 3-3 1.5. Market Territory: ................................................................................................... 3-3 1.6. Need for the project: ............................................................................................. 3-4

2. Project Description (Existing System) ......................................................................... 3-13 2.1. Plant Production scenario: ................................................................................. 3-13 2.2. Existing Operating Plant and System : ............................................................... 3-14 2.3. Land distribution in Existing Plant: ..................................................................... 3-15 2.4. Process Description ........................................................................................... 3-15 2.4.1. Sulphuric Acid Plant. .......................................................................................... 3-15 2.4.2. Process Description of Phosphoric Acid Plant ................................................... 3-16 2.4.3. Process Description of Di-Ammonium Phosphate/NPK Plant (DAP/NPK): ........ 3-19 2.5. Utilities and Off site Facilities ............................................................................. 3-20 2.5.1. Water .................................................................................................................. 3-20 2.5.2. Power &Distribution: ........................................................................................... 3-21 2.5.3. Raw Material Handling ....................................................................................... 3-21 2.6. Specific consumptions: ....................................................................................... 3-23 2.6.1. Specific consumptions for PAP: ......................................................................... 3-23 2.6.2. Specific consumptions for SAP: ......................................................................... 3-23 2.6.3. Specific consumptions for DAP/Other complex Fertilizer: .................................. 3-23 2.6.4. Finished Product Handling ................................................................................. 3-24 2.7. Bulk Storages ..................................................................................................... 3-24 2.7.1. Ammonia Storage ............................................................................................... 3-24 2.7.2. Sulphuric Acid Storage Tank .............................................................................. 3-24 2.7.3. Phosphoric Acid Storage Tanks ......................................................................... 3-25 2.7.4. Heavy Fuel Oil/ LSHS Storage Tanks ................................................................ 3-25 2.7.5. Chlorine Storage ................................................................................................ 3-25 2.7.6. Muriate of Potash Storage .................................................................................. 3-25 2.7.7. Rock Phosphate Storage ................................................................................... 3-26 2.7.8. Sulphur Storage ................................................................................................. 3-26 2.7.9. LPG Storage....................................................................................................... 3-26 2.8. Offsite Facilities .................................................................................................. 3-26 2.8.1. Instrumentation................................................................................................... 3-26 2.8.2. Plant Lighting...................................................................................................... 3-26 2.8.3. Fire Fighting, Safety & Security .......................................................................... 3-26 2.8.4. Electrical & Mechanical Maintenance ................................................................. 3-27 2.8.5. Environment ....................................................................................................... 3-27 2.8.6. Man Power ......................................................................................................... 3-27 2.9. Environmental aspects ....................................................................................... 3-27 2.9.1. Air Emission: ..................................................................................................... 3-27 2.9.2. Effluent: .............................................................................................................. 3-29 2.9.2.1. Waste Water from Phosphoric Acid Plant ............................................................. 30 2.9.2.2. Waste Water Generation from SAP ...................................................................... 30 2.9.2.3. Waste Water from Di-Ammonium Phosphate Plant (DAP) ................................... 30 2.9.2.4. Captive Power Plant .............................................................................................. 30

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2.9.2.5. Domestic Waste water: ......................................................................................... 30 2.9.2.6. Effluent Treatment Facilities and Waste water Discharge ..................................... 30 2.10. Solid Waste Generation, Management and Handling ........................................... 33 2.10.1. By-Product Phosphogypsum ................................................................................. 33 2.10.2. Spent Catalyst ....................................................................................................... 34 2.10.3. Sulphur Muck ........................................................................................................ 34 2.10.4. ETP Sludge ........................................................................................................... 34 2.11. Charter on Corporate Responsibility for Environment Protection (CREP) Guidelines: ........................................................................................................................ 38 2.12. CSR Activities: Peripheral Development: ............................................................. 38 2.12.1. Construction of Ekta Park : .................................................................................... 38 2.12.2. Health Services : ................................................................................................... 38 2.12.3. Emergency Relief : ................................................................................................ 39 2.12.4. Distribution of School Kits : ................................................................................... 39 2.12.5. Nivedita Orphanage Building : ............................................................................... 39 2.12.6. Canteen Hall at MMITC : ....................................................................................... 39 2.12.7. Socio-Cultural Activities : ....................................................................................... 39 2.12.8. Developmental Work in Villages : .......................................................................... 39 2.12.9. Plantation and Green Belt Development: .............................................................. 40 2.12.10. Plantation within the Factory: ........................................................................ 40 2.12.11. Plantation Out Side the Factory:.................................................................... 40 2.13. New Projects under Construction .......................................................................... 40

3. Chapter : Proposed Project .......................................................................................... 46 3.1. Land Requirement ................................................................................................. 46 3.2. Process description: .............................................................................................. 46 3.2.1. Coal handling plant : Unloading System ............................................................... 46 3.2.2. Ammonia plant ( coal based) : ............................................................................... 47 3.2.3. Urea plant : ............................................................................................................ 54 3.2.4. Nitric acid plant : .................................................................................................... 67 3.2.5. Ammonium Nitrate plant: ....................................................................................... 72 3.2.6. DAP PLANT : ........................................................................................................ 77 3.2.7. GSSP PLANT : ...................................................................................................... 81 3.2.8. Aluminium fluoride plant: ....................................................................................... 86 3.3. Raw Material ......................................................................................................... 90 3.3.1. Ammonia/gasification: ........................................................................................... 90 3.3.2. Urea plant: ............................................................................................................. 90 3.3.3. Nitric acid :............................................................................................................. 91 3.3.4. Ammonium Nitrate : ............................................................................................... 91 3.3.5. Di Ammonium Phosphates : .................................................................................. 91 3.3.6. Granulated Single Super Phosphates: .................................................................. 91 3.3.7. Aluminium Fluoride : .............................................................................................. 92 3.4. Utilities ................................................................................................................... 92 3.4.1. Water ..................................................................................................................... 92 3.4.2. Power .................................................................................................................... 93 3.4.3. Land Requirement: ................................................................................................ 93 3.4.4. Man Power Requirement ....................................................................................... 94 3.4.5. Other Offsite Facilities ........................................................................................... 94 3.5. Environmental Aspects: Emissions, Effluents & Solid Waste Details from Proposed Plants: 94 3.5.1. Emission Details: ..................................................... Error! Bookmark not defined. 3.5.2. Effluents Detail: ..................................................................................................... 94 3.6. Specific Environmental aspects ............................................................................ 94 3.6.1. Gasification & ammonia plant : .............................................................................. 95 3.6.2. Urea plant: ............................................................................................................. 96 3.6.3. Nitric acid plant: ..................................................................................................... 98

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3.6.4. Ammonium nitrate plant: ..................................................................................... 100 3.6.5. Di-ammonium phosphates plant: ......................................................................... 101 3.6.6. Granular Single super phosphate plant: .............................................................. 102 3.6.7. Aluminum fluoride plant: ..................................................................................... 103

4. Site analysis ................................................................................................................. 105 5. Rehabilitation and Resettlement .................................................................................. 109 6. Project cost and Schedule ........................................................................................... 110

6.1. Project Implementation schedule: ....................................................................... 110 6.2. Pre-Project Activities ........................................................................................... 110

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2. LIST OF TABLES

Table 1.1 Financial growth of PPL ....................................................................................... 3-2 Table 1.2-PPL-Management ................................................................................................ 3-2 Table 1.3 Market Territory .................................................................................................... 3-3 Table 2.1 Plant Production scenario .................................................................................. 3-13 Table 2.2 Upcoming projects under commissioning .......................................................... 3-13 Table 2.3 Land distribution in Existing Plant ...................................................................... 3-15 Table 2.4: Raw Material Requirement, Linkages & Specific Consumption ........................ 3-22 Table 2.5 Air Emission from Existing plant ........................................................................ 3-28 Table 2.6:Solid/ Hazardous Waste from Existing plant ......................................................... 35 Table 3.1 Land Requirement for the Expansion Project ....................................................... 46 Table 3.1: Various Processes for Ammonium Nitrate ........................................................... 73 Table 3.2: Emission Details of Proposed Plant ......................................................................... Table 4.1 Site and Surrounding .......................................................................................... 105

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3. LIST OF FIGURES

Figure 2.1 Process Flow diagram of Sulphuric Acid Plant .................................................. 3-16 Figure 2.2 Process Flow diagram of Phosphoric Acid Plant ............................................... 3-18 Figure 2.3Process Flow diagram of DAP /NPK Plant .......................................................... 3-20 Figure 2.4:Water Balance diagram for Existing Plant .......................................................... 3-29 Figure 2.5 Diagram (Schematic Diagram of ETP) ................................................................. 32 Figure 2.6Diagram (Schematic Diagram of Project for Reuse of Treated Water of ETP) ....... 33 Figure 2.7Gypsum Pond ........................................................................................................ 34 Figure 2.8:GSSP PFD ........................................................................................................... 43 Figure 3.1PFD Coal Handling Plant ...................................................................................... 47 Figure 3.2 Ammonia plant ...................................................................................................... 48 Figure 3.3: PFD Urea Plant ................................................................................................... 55 Figure 3.4 Process flow scheme Weak Nitric Acid (WNA) ..................................................... 68 Figure: PFD of Conc. Nitric Acid ............................................................................................ 72 Figure 3.5 PFD of Ammonium Nitrate .................................................................................... 74 Figure 3.6:PFD of DAP .......................................................................................................... 79 Figure 3.7 Block Flow Diagram for production of SSP .......................................................... 82 Figure 3.8 anhydrous hydrofluoric acid (AHF) from FSA ........................................................ 87 Figure 3.9 High-bulk-density Aluminium Fluorides (HBD AlF3) from HF ................................ 88 Figure 3.10: Emission Details of Urea plant ........................................................................... 97 Figure 4.1: Satellite view of Site ........................................................................................... 106 Figure 4.2: Road Network Map ............................................................................................ 107 Figure 4.3: Railway Network Map ........................................................................................ 108

Prefeasibility Report For Proposed/Expansion of Paradeep Phosphates Ltd.

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1. CHAPTER

1.1. Project proponent’s profile

Paradeep Phosphates Limited (hence forth ‘PPL’; incorporated in 1981) is a premier fertilizer company engaged in manufacturing and marketing of complex Phosphatic fertilizers. The company was initially commissioned as a joint venture between Government of India and Republic of Nauru and subsequently, in 1993 it was changed into a wholly owned Government of India Enterprise. After disinvestment by Government of India in February 2002, PPL was taken over by Zuari Group the management of the company is presently with the fertilizer majors - Zuari Group and OCP of Morocco.

PPL produces about 1.2 million metric tonnes of DAP and other complex fertilizers annually. The plant also produces intermediary products like Phosphoric Acid and Sulphuric Acid, which are critical raw materials in the manufacture of Phosphatic fertilizers. The plant, located in the port town of Paradeep in the district of Jagatsinghpur in Orissa, has an installed capacity of 15, 00,000 metric tonnes per annum of DAP (2400 metric tonnes per day). PPL is one of the largest integrated DAP plants in India. With a market share varying around 13%, it has a strong presence in the complex fertilizer market its products marketed under the popular NAVRATNA brand represent a combination of multiple nutrients like Nitrogen, Phosphorus, Potash and Sulphur etc. PPL’s range of products caters to almost all agricultural applications.

With a stellar turnaround, PPL is a case study in favour of privatization. The company’s focus on performance and continuous efforts towards development are reflected in the FAI Awards for Improvement in Overall Performance of the company in 2002-03, 2005-06, 2008-09 and the “Best Technical Innovation” in the year 2005-06. PPL received the ISO 14001: 2004 certification in May 2006 for good environment management systems, reflecting the fact that along with technical advancement, the company also values maintaining and working towards a clean and safe environment.

After disinvestment on February 28, 2002, PPL has been revived to full strength with the employees' dedication and commitment under extremely difficult conditions. Remarkable achievements have been achieved in terms of financial turnover. From a loss of Rs. 23,026 lakh in the year 2001-02 the profitability of the Company has improved by achieving a profit after tax year after year.


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Table 1.1 Financial growth of PPL

S.No. Financial Year Financial Growth i. April “05” March “06” Rs. 121 Millions net profit after tax. ii. April “06” – March “07”: Rs. 1093 Millions net profit after tax iii. April “07” – March “08”: Rs. 836 Millions net profit after tax iv. April “08” – March “09”: Rs. 5,371 Millions net profit after tax v. April “09” – March “10”: Rs. 1,515 Millions net profit after tax vi. April “10” – March “11”: Rs. 1770.8 Millions net profit after tax vii. April “11” – March “12”: Rs. 1771.1 Millions net profit after tax

PPL is a leading fertilizer company with an annual turnover close to Rs. 4,700Crores.

Its primary focus is the production and marketing of complex Phosphatic fertilizers. It is committed to improving agriculture productivity and to betterment of the farming community.

1.2. Paradeep Phosphate Limited – Management

Table 1.2-PPL-Management

Address Registered address Paradeep Phosphates Limited, Bayan Bhavan, Pt. J.N. Marg,

Bhubaneswar–751001, Orissa Plant office

Paradeep Phosphates Limited, PPL Township, Paradeep – 754145, Jagatsinghpur, Orissa, Email:[email protected]

Constitution Limited company Activity Manufacturing & marketing of complex phosphaticfertilisers Group/ Promoters Adventz group

1.3. PPL- Salient Points:

Milestone Details Date of incorporation 24th December 1981 Commissioning of Phase-1 (DAP Plant) February 1986 Commissioning of Phase-2 (SAP,PAP & CPP) June 1992 Date of Disinvestment from GOI 28th February 2002 Turnover (2011-2012) 4700.14 Crores Designed / Present Annual Capacity of DAP 7,20,000 / 15,00,000 MT Designed / Present Annual Capacity of PAP 2,25,000 / 4,20,000 MT Designed / Present Annual Capacity of SAP 6,60,000 / 7,92,000 MT Captive Power Plant Two units of 16 MW each Conveyor Belt 3.4 km (from port to Plant Site) Product Manufactured DAP,NPK, grade fertilizers MarketingTerritory Products distributed in a pan-India market

covering 16 states Systems PPL has received Integrated Management

system (IMS)certificate as per : ISO 9001:2008


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ISO 14001: 2004 BS OHSAS 18001:2007

1.4. The site location:

PPL is located at Paradeep in Jagatsinghpur District, Orissa. It is 90kms from Cuttack. The site is located at 20º16’56” North Latitude and 86º38’52” East Longitude, west side of Paradeep Port. The plant encompasses 950 hectares area. Mahanadi River is 5km from the plant site and meets Bay of Bengal, which is 5.3 km away form the site. Atharbanki creek is flowing along the boundary wall of the site and is in between Paradeep Port site and the factory. The plant layout is given in the annexure-I:

1.5. MarketTerritory:

PPL products are distributed in a widespread market covering 16 states namely:

Table 1.3 Market Territory

Andhra Pradesh Assam Bihar Chattisgarh Haryana Jammu & KashmirJharkhand Karnataka Madhya Pradesh Maharashtra Orissa Punjab Rajasthan Uttar Pradesh Uttaranchal West Bengal

Figure 1.1.:MarketTerritory of PPL


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PPL also has a selling arrangement through its sister concerns viz. Zuari Industries Ltd. (ZIL) to cater to markets in other parts of the country. PPL's sales network comprises of private as well as institutional channels. The strength of each channel varies from state to state. We have been able to tap both channels successfully

1.6. Need for the project:

Agriculture which accounts for one fifth of GDP provides sustenance to two-thirds of our population. Besides, it provides crucial backward and forward linkages to the rest of the economy. Successive five-year plan have laid stress on self-sufficiency and self-reliance in food grains production and concerted efforts in this direction. This is evident from the fact that from a very modest level of 52 million MT in 1951-52, food grain production rose to about 233.88 million MT in 2008-09.

By 2012, India’s population is likely to be around 1.2 billion and its contribution to overall GDP and employment is likely to diminish significantly. Producing food to satisfy the hunger and to provide employment for buying food, remain the key concerns of agriculture.

Figure 1.2:Indian Fertilizer Market Size and Growth

1.6.1. Urea

Urea as a major source of nitrogen continued to dominate the scene of nitrogenous Fertilisers consumption in the country. Urea at present is the only controlled fertilizer and has a major share of consumption in the country. All other Fertilisers put together are consumed in lesser quantity than urea. Urea is covered under Essential Commodity Act (ECA) and the


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Government issues movement orders under ECA to different manufacturers. Under ECA, the Government also declares MRP of urea for sale. Urea import and export is also highly restricted. Urea has recorded a compound Annual Rate of Growth (CARG) in consumption of 3.6 percent during the period of 1990-91 to 2009-10. Though the level of fertilizer consumption in our country has all along been very low, the indigenous production of urea has always been lagging much behind the consumption requirement except in the year 2000-01.

The total estimated production of urea from the existing functional units will be 210 lakh tonnes. Some of the existing units are in the process of expanding their existing capacities by way debottlenecking. The projected deficit level of about 70 lakh tonnes of urea by 2011-12 which would increase to a level of 100 lakh tonnes by 2016-17. The Southern zones will continue to be in deficit and only the western zone have sizeable surpluses as at present though the surplus will lead to decline with time. On the basic premise that any fertilizer manufacturing unit wil strive to market its product as close to its production centre as possible in the interest of economizing the transport cost burden, it can be assumed that the logical preference of all units will be to market their production, as far as practicable, within the irrespective 'home' states passing onto other states only for any surpluses. Under this premise, PPL’s preferred marketing area will be the State of Orissa. Orissa, however, cannot absorb the full production from the proposed project of PPL. PPL, therefore, will have to move out of the state to market the products. The most logical market to look for to sell the surplus products will be the neighboring states of WestBengal, Jharkhand, Chhattisgarh, eastern Uttar Pradesh, and Madhya Pradesh. The proposed marketing area is highly deficit in the supply of urea

1.6.2. Di-ammonium Phosphate (DAP)

Paradeep Phosphates Ltd. (PPL) has proposal for setting up of additional capacity for Di-ammonium Phosphate (0.4 million tonnes per annum) fertilizer manufacturing facilities at the existing site which is situated at the port town of Paradeep in Jagatsinghpur District of Orissa based on external ammonia and phosphoric acid.

1.6.3. Phosphatic Fertilizer Products:

The most common of the phosphatic fertilizers presently used in India for application to improve soil fertility are:

Single Super Phosphate (SSP)

Triple Super Phosphate (TSP)

Di-ammonium Phosphate (DAP)

Nitro-Phosphates-Potash Complexes (NPK)


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Nitro-phosphates (NP)

Urea Ammonium Phosphate (UAP)

Of these, only SSP and TSP are exclusive P2O5 carriers. All other products contain N and P2O5 (and some also K2O) in various proportions. However, they are basically used for the purpose of applying P2O5 (and K2O) to the soil. When such compounds are used, the doses of nitrogen fertilizers is adjusted, after taking into account the nitrogen content in the compound fertilizers. Any additional requirement of N is commonly applied as top or side dressing.

Based on solubility, phosphatic fertilizers are graded as water soluble, citrate soluble and insoluble phosphates. Water soluble phosphatic fertilizers are generally found superior to other forms of fertilizers excepting acid soils.

At present, DAP (18:46: 0) is the most widely used phosphatic fertilizer product in India, accounting for two third of the total apparent consumption of P in 2009-10. It is considered suitable for a wide variety of crops including those which need high dose of P2O5 and low dose of N, particularly at the time of sowing, such as pulses and other leguminous crops. Studies have also shown that DAP does not affect the seeds even when applied under relatively dry farming conditions, unlike straight and some other complex fertilizers. Crops such as oilseeds and pulses are generally sown under such conditions. It has also been favoured as basal dressing for most crops. Another favourable factor with DAP is that nearly the entire P2O5 is available to the plants immediately. DAP is also compatible with all other fertilizers so that other straight nitrogenous fertilizers as well as potassium can be added to it according to requirements, without side reactions or handling problems. Since, both Urea and DAP have similar sized granules, mixing them is particularly easy. Thus, it provides scope for correct nutrient input adjustments, including provision for top dressing. As a high analysis fertilizer, the incidence of transport cost per unit of nutrient in DAP is the lowest of all phosphatic fertilizers produced in India.

The projections made by FAI in respect of DAP is like by 2016-17 demand would be 12413 thousand tonnes which would rise to 14036 thousand tonnes in 2024-25.

The total demand of P2O5 is expected to increase from 8426 thousand tonnes in 2012-13 to 9600 in 2016-17 and to 11530 thousand tonnes in 2024-25

Total supply of P2O5 is expected to

increaseatanannualgrowthrateofabout5%from4374thousandtonnesduring 2009-10 to 6155 thousand tonnes during2016-17


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On the basic premise that any fertilizer manufacturing unit will strive to market its product as close to its production centre as possible in the interest of economizing the transport cost burden, it can be assumed that the logical preference of all units will be to market their production, as far as practicable, within their respective 'home' states passing on to other states only for any surpluses. Under this premise, PPL’s preferred marketing area will be the State of Orissa. Orissa, however, cannot absorb the full production from the proposed project of PPL. PPL, therefore, will have to move out of the state to market the products. The most logical market to look for to sell the surplus products will be the neighboring states of West Bengal, Jharkhand, Chattisgarh, eastern Uttar Pradesh, and Madhya Pradesh. The proposed marketing area is highly

deficit in the supply of phosphatic fertilizers.

1.6.4. Granular Single Super Phosphate

Single Super phosphate is a chemical Fertilizer which contains Phosphorus as a major plant nutrient. It is relatively very cheap and contains many micro nutrients like Calcium, Magnesium, Iron, Aluminium, Sulphur.

It is a poor man’s fertilizer which also treats Sulphur deficiency of fertilizers and results in enhancement of yields at the least cost. SSP is an essential fertilizer. Further growth of agriculture would be possible with balanced use of fertilizer by increasing the share of SSP consumption in comparison to Urea, DAP and NPK fertilizers.

Single Super Phosphate (SSP) fertilizer industry is the pioneering fertilizer industry in the country. SSP is a poor farmer’s fertilizer. (price wise) is an option to optimize the use of phosphatic fertilizers. It also helps to treat the sulphur deficiency of soils (40% Indian soil are sulphur deficient) as well as for further enhancement of yields at the least cost. In various crops, which requires more of sulphur and phosphate like oilseeds pulses sugarcane fruits and vegetables tea etc. SSP is an essential fertilizer. Further growth of agriculture would be possible with balanced use of fertilizer by increasing the share of SSP consumption in comparison to Urea, DAP and NPK fertilizers. Following trends further reinforces this fact.

As per the Nutrient Based Subsidy (NBS), the Government is offering a Fixed per Kg subsidy for application on N, P, K & S as well as micronutrients. The NBS has brought the price parity to the farmers for P&K fertilizers based on nutrient content. The NBS was announced in March, 2010 for 2010-11 and revised again in March, 2011 for FY 2011-12.

In view of high deficit in the supply of urea (nitrogenous) and other (phosphate and potash) fertilizers in the country at present and likely to further increase substantially in future PPL has decided to initiate its activities for manufacturing urea, DAP, SSP fertilizer and some other important chemicals in the deficit state of Orissa.


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1.6.5. Ammonium Nitrate

Besides being used as a fertilizer, ammonium nitrate is the cheapest source of chemical energy available today and a vital part of every construction project. It’s an indispensable element used in making explosives, which are further used in blasting/ mining of ore, coal, limestone, bauxite, copper etc. The infrastructure boom augurs well for growth of this division. The demand has been growing at a CAGR of 8% and is expected to continue for sometime more. International Prices have risen sharply and reports indicate demand for industrial grade ammonium nitrate to remain firm with major thrust on mining & infrastructure activities in Odisha, Bihar, Jharkand & Chattisgarh. The total demand for ammonium nitrate is projected as follows:

The requirement of ammonium nitrate for explosive industry has been worked out as 844 thousand tonnes in 2014-15 and 985 thousand tonnes in 2016-17.

As mentioned earlier in the report, ammonium nitrate is required, in relatively small quantities, for manufacture of nitrous oxide- a medical gaseous anesthetic, dyes & dyestuffs and textile auxiliaries. In so far as nitrous oxide is concerned, ammonium nitrate is a critical input and so is its quality. The requirement of ammonium nitrate for dyes & dyestuffs as well as auxiliaries may increase progressively to about 1060 tonnes by the year 2016-17

At present, demand for ammonium nitrate exceeds its supply. The shortfalls are being met through imports.

A new 3,00,000 tonnes ammonium nitrate plant of Deepak Fertilisers and Petrochemicals Corporation Ltd. (DFPCL) at Paradeep (Orissa) is under planning stage but stuck somewhere half way. If this DFPCL eastern region plant is commissioned and at 100% capacity utilisation, the total supply of ammonium nitrate in the country by the year 2014-15 will increase to a level of around 560,000 tonnes. This will leave a gap ofaround 4.50 lakh tonnes by the year 2014-15 which would increase to around 7 lakh tonnes by the year 2016-17.Almost 65 per cent of the projected capacity of explosives in the country is in the states of Madhya Pradesh Chhattisgarh and Jharkhand. Hence, a new unit for production of Ammonium Nitrate in Orissa by PPL can be considered as a forward step in development of the region in particular and the country in general.

1.6.6. Nitric AcId

Nitric acid, chemical formula, HNO3,is oneof the basic„building blocks‟ of

the chemical industry. Nitric Acid is sold in different concentration. The major amongs these are 53 per cent, 60 per cent and 98 per centgrades.


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Besides these, many dealers and manufacturers of chemicals are concentratingNitricAcidto70to75per cent grade and this grade is used in bullion refining mostly.

1.6.6.1. Weak Nitric Acid:

Capacity in India:

Unit Location Annual Capacity

RCFL Maharashtra 353,100

DFPCL Maharashtra 297,000

GNFC Gujarat 247,500

Other Smallunits Gujarat, Punjab, Andhra Pradesh, Tamil

Nadu

132,200

Total 1,029,300

Production :

Weak Nitric Acid production during 2010-11wasoftheorder of around961,000 tonnes(capacity utilization level around 93 per cent).

Consumption:

Based on data furnished by units selling NitricAcid and the major consumers of this product, sector-wise consumption of weak Nitric Acid in the country has been estimated and is given below :

Sector Estimated Consumption Percentto total

Fertilizer 327 34.0

Concentrated Nitric Acid 160 16.6

Ammonium Nitrate 210 21.9

Explosives 35 3.6

Organic Compounds 38 4.0

Inorganic Nitrates 65 6.8

Drugs &Pharmaceuticals 45 4.7

Sector Estimated Percent

Dyes & Paints 30 3.1

Bullion Refining 20 2.1

Miscellaneous 31 3.2

Total 961 100.0


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Demand:

The demand projection for weak Nitric Acid in the country for the years 2008-09, 2011-12, & 2014-15 are 1324000, 1389000 & 1464000 tonnes respectively.

Against the demand of13.89 lakh tonnes of weak Nitric Acid by 2011-12,DFPCL is coming up with a new capacity (300,000 tonnes) in the eastern region for captive consumption for its ammonium nitrate production. Thus, the total production likely to be available would be around12lakh tonnes 90 percent of capacity utilization level. This will leavea gap of around120,000 tonnes by 2008-09 which would increase to a level of around 1.90 lakh tonnes in 2011-12 and 2.64 lakh tonnes by 2014-15 for which an additional capacity of weak Nitric Acid would be required in the country

1.6.6.2. Strong Nitric Acid:

Capacity:

At present there are six plants which are manufacturing Concentrated Nitric Acid (CNA), three of which are Captive- IEL Gomia manufacturing nitroglycerin and nitrocellulose, DGOF Bhandara which is manufacturing TNT and catering to the needs of the defence and third plant is of Hindustan Organic Chemicals Ltd Rasayani, which manufacture nitro benzene, para-nitro chlorobenzene, orthonitro chloro benzene, nitro toluene and di-nitro benzene.

The acid produced by all these plants is of 98per cent strength which is termedus fuming Nitric Acid.The three plants, namely RCF, GNFC and Deepak Fertilizers

& Petrochemicals Ltd. (DFPCL) are for merchan sale. The combined capacity of these units at present is of the order of 162,000 tonnes per annum

Consumption:

Present estimated consumption is around 162600 tonnes in India, where aromatic compound producing companies consume the maximum of it (65.6%)

Demand:

The demand projections for weak Nitric Acid in the country for the years 2008-09, 2011-12 and 2014-15 are 1324000, 1389000 & 1464000 tonnes respectively, Against the demand of 13.89 lakh tonnes of weak Nitric Acid by 2011-12,DFPCL is coming up with a new capacity (300,000tonnes) in the eastern region for captive consumption for its ammonium nitrate production. Thus, the total production likely to be available would be around12 lakh tonnes 90percent of capacity utilization level. This will leave


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a gap of around120,000 tonnes by 2008-09 which would increase to a level of around 1.90 lakh tonnes in 2011-12 and 2.64 lakh tonnes by 2014-15 for which an additional capacity of weak Nitric Acid would be required in the country.

No new capacity of CNA can be envisaged at present. Based on demand projections , the net overall deficits for can in the country during2010-11works out as follows

Details Quantity (Tonnes)

Projected Demand 246,000

Estimated Supply 162,400

Net Supply Gap 83,600

This shows that there is a deficit of about 83,000 tonnes of CAN by 2010-11.

With infrastructure being the prime focus of Governmentof India, there is an increase in coal, iron ore and limestone mining. Road sector is also growing atfast space with National Highway projects. The growth in the Explosives industry is directly proportional to the growth in the mining industry. With the economy poised to grow at 7–8% per annum with focus on investment in infrastructure

Mining industry is expected to grow at a similar pace, particularly in the core segments like coal, iron ore, and limestone most of which are in the eastern part of the country.

The share of Explosives demand from this sector is also expected to increase which subsequently shall increase the demand of Nitric Acid.

This necessitates the need for increasing Nitric Acid production in this part

of the country justifying the PPL‟s Nitric Acid manufacturing project at

Paradeep in Odisha.

1.6.7. AMMONIA:

Ammonia is the basic source of nitrogen for fertilizers.

Domestic ammonia production in 2010-11 was 13.53 Million MT where as of imported ammonia was 1.74 Million MT.

PPL itself imports ammonia for its production of DAP & NPK.

Ammonia would be a raw material for PPL’s proposed Urea plant, Nitric Acid Plant &Ammonium Nitrate Plant.


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So PPL intends to have an indigenous production of ammonia for its DAP &Urea & rest successive plants and help India being self sufficient in production of ammonia and lower import of ammonia.

1.6.8. Aluminium Flouride

Aluminium Fluoride (AlF3) is an inorganic compound used primarily in the production of aluminium. This colourless solid can be prepared synthetically but also occurs in nature. In Odisha, Nalco, Vedanta, Indal, Hindalco & Utkal Aluminium are the five prime consumers of Aluminium Fluoride who use it as a flux in their smelter.

Nalco’s annual consumption is around 11000 MT

Vedanta has its 2 plants operating, 2 streams in Odisha & 1 in Chhattisgarh. It has intended to expand its streams with 2 more streams in Odisha and 1 more in Chhattisgarh.

Vedanta’s annual consumption of Aluminium Fluoride is around 19,800 MT which is proposed to increase to 39,600 MTPA during 2013-14,

Indale is also a huge consumer of Aluminium Fluoride.

Looking forward to this consumption scenario of Aluminium Fluoride in Odisha itself, PPL would like to convert the fluorine recovered from its phosphoric acid, dehydrate process to a high quality aluminium fluoride (high bulk density aluminium fluoride) instead of having to dispose it by the way of neutralization and add Aluminium Fluoride to its product portfolio.

Fluorine abatement measures are to be taken care of before installing Aluminium Fluoride Plant.


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2. PROJECT DESCRIPTION (EXISTING SYSTEM)

2.1. Plant Production scenario:

In the proposed expansion project Paradeep Phosphates Limited (PPL) intends to add some new products and also expands the capacities of existing products as given below:

i. Urea (New product) ii. GSSP (New product) iii. DAP (Expansion) iv. Ammonia (Intermediate Product) v. Ammonium nitrate (New product) vi. Weak Nitric Acid (Intermediate Product), Conc. Nitric Acid (New Product) vii. Aluminium Fluoride (New product)

Table 2.1 Plant Production scenario

*SAP, UREA, HNO3, NH4NO3 production for 330 days. **SSP, PAP and DAP, AlF3, production for 300 days.

Table 2.2 Upcoming projects under commissioning

S.No. Particulars Capacity Status

Sl. No.

Particulars Existing Capacity

Expansion Proposed Total Qty.

a) SAP*

0.792 MMTPA

- - 0.792 MMTPA

b) PAP** 0.42 MMTPA - - 0.42 MMTPA c) DAP** 1.5 MMTPA 0.4

MMTPA 1.9 MMTPA

d) Coal Hand. Plant

- - 7 MTPA 7 MTPA

e) Ammonia - - 2.178 MMTPA 2.178 MMTPA f) Urea* 1.3 MMTPA 1.3 MMTPA g) Amm. Nitrate* - - 0.35 MTPD 0.35 MTPD

h) Nitric Acid* - - 0.33 MMTPA (0.05 MMTPA Conc. Nit. Acid)

0.33 MMTPA (0.05 MMTPA Conc. Nit. Acid)

i) GSSP** - - 0.5 MTPD 0.5 MTPD

j) Alu. Fluoride**

- - 9500 MTPA 9500 MTPA

k) CPP 16*2 MW - - 32 MW

THIS CHAPTER BRIEFLY DESCRIBES THE existing system i.e. operating plants, utilities and offsite facilities and also plants and facilities under project stage / construction (after due approval from statutory authorities).


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1. Zypmite plant MTPH summing upto 200 MTPD

Under commissioning

2. Sulphuric acid plant 2000 MTPD Project phase- Detailed Engineering

3. Gypsum pond

70-80 hectare area Project Phase- Basic Engineering

2.2. Existing Operating Plant and System:

2.2.1. Introduction:

Paradeep Phosphates Limited (PPL) is operating a large Fertilizer complex in Paradeep, Orissa, India where PPL manufacture various grades of NPK fertilizer. PPL is a prime player in the Phosphatic fertilizers which have applications in a wide range of crops. The fertilizer complex consists of following manufacturing units.

2400MTPD of Sulphuric Acid Plant(2stream) 1400 MTPD of Phosphoric Acid Plant 5000 MTPD of Di Ammonium Phosphate Plant/NPK Plant (4 trains) 2X16 MW Captive Power Plant

The fertilizer complex is using imported sulphur& rock phosphates to produce sulphuric acid and phosphoric acid, along with imported MOP for NPK complex production. Since captive production of phosphoric acid cannot cater to the four streams of DAP plant, part of the phosphoric acid requirement is made through imports. The entire ammonia requirement is met through imports.

The other facilities available are as follows:

Rock Silo

Sulphur Silo

MOP Silo

Sulphuric Acid Storage

Phosphoric Acid Storage

Ammonia Storage

Di-Ammonium Phosphate Storage & Bagging

Marine Jetty

ETP & STP

Other Auxiliary systems include:

a) HSD/LFO/HFO storage b) Fuel Oil Storage c) LPG Cylinder Storage d) Captive Power Plant


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2.3. Land distribution in Existing Plant:

The details of land use on core area in PPL premises are

Table 2.3 Land distribution in Existing Plant

S.No. Land-Use Area covered 1) Plant & Building 35.00acres,

2) Waste Treatment & Handling facilities 196.00 acres,

3) Raw water Reservoir 230.00 acres

4) Water Treatment Plant 4.40 acres

5) Plantation 854.00 acres (GREEN BELT-37%).

6) Road 63.00 acres

7) Colony 300.00 acres

Total 1682.4 8) Open area and Water bodies* 600.00acres.

Total 2282.4 acres *The proposed Projects will require 534 acre land. Paradeep already have sufficient Land The detail requirement of land for Proposed Plants are given in Table 3.1

2.4. Process Description

2.4.1. Sulphuric Acid Plant.

Sulphuric Acid (SA) plant is based on the most modern double conversion double absorption process of M/s Lurgi GMBH, West Germany (DCDA process). It is laid in two streams, each of 1200 MTPD capacity. The raw material, elemental sulphur is transported by means of belt conveyor to the sulphur bin. Sulphur is melted in a melting pit by means of heating coils, heating media being steam. The molten sulphur is stored in a liquid sulphur storage tank after passing through filters. The molten sulphur is fed to the sulphur furnace where complete combustion takes place which gives rise to a SO2 concentration of about 11.5%. The heat of combustion is removed by a waste heat boiler where steam (approximately 60 MT/hr) is produced.

The furnace gas cooled to a temperature of 420ºC- 430º C is fed to a converter having 4 catalyst beds. SO2 to SO3 conversion takes place in first three beds and first absorption of SO3 gases takes place in intermediate absorber. Remaining SO2 gases from Intermediate absorber is passes through the fourth bed for optimum conversion of remaining SO2 to SO3. SO3 gas from fourth bed is cooled to a


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temperature of 170 º C before entering to the final absorber where SO3 is absorbed by 98.5% sulphuric acid. In absorption towers gases are passed through mist eliminators to trap the liquid entrainments. From the final absorber after absorption of SO3 gas, remaining gases are discharged into atmosphere through stack within prescribed emission limit set by State Pollution Control Board.

SULPHURIC

ACID PLANT

Figure 2.1 Process Flow diagram of Sulphuric Acid Plant

2.4.2. Process Description of Phosphoric Acid Plant

The 1400 MTPD single stream Phosphoric Acid (PA) Plant is based on Di Hydrate Process technology where basic engineering and technology is supplied by M/s Jacob International Inc. U.S.A The Hindustan Dorr Oliver Ltd. Mumbai was the Indian partner. Wet grinding process is adopted where rock phosphate is fed to ball mill through extractor weigher where wet grinding slurry of 67-69% solids is prepared. In the ground rock hopper, a dust scrubber is provided to entrap the dust coming out of the dust hopper.From the ball mill, the rock slurry is pumped to the product tank. The slurry containing 67-69% solids from product tank is fed to the reactor


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at first and third agitator point. Concentrated sulphuric acid having 98.4% concentration and recycle phosphoric acid are fed to the reactor. The

reaction slurry proceeds through reaction section and underflows into the vacuum cooler feed compartment where degassing takes place and the slurry is then pumped to the vacuum cooler. Defoamer is added to the reactor to inhibit the formation of foam/froth.

The slurry is cooled down in the vacuum cooler by maintaining a vacuum of 150-300mm Hg absolute by evaporation of water. A barometric condenser and vacuum jet system remove the vapours. The slurry from the vacuum cooler flows down the reactor to filter feed tank through a vertical seal by a vacuum cooler tank. Filter feed is distributed on a horizontal filter through feed box, where phosphoric acid is separated from gypsum. The cake in the filter is given four successive washes by a filtrate of 12% P2O5, heated pond water and a final wash. The de- watered cake after fourth wash is removed, slurried and pumped to the gypsum pond. Air that passes through the cake is disengaged from the filtrates in the filtrate recovery system and passes through the filter condenser where gas is cooled and vapours condensed. The pond water used in the filter condenser discharges through the pond water tank.

The scrubbing system provides a preliminary pond water quench to cool the vent gases. The gases are then scrubbed in the first stage in a cross flow packed bed scrubber using cold pond water. The gases then pass through a second packed bed, which reduces the emission below 0.0058 kg flourine per tonne of acid. A mist eliminator eliminates droplet entrainment. Acid from filter is pumped to a clarifier. The clarifier overflow goes either to a product acid tank or to the evaporator as required. The sludge from the clarifier is either recycled to the clarifier or to the reactor or transferred to the DAP plant. Concentration of the acid, whenever necessary is carried out in the evaporators. The concentrated acid overflows from the flash chamber through a barometric condenser. The non-condensable are removed by a vacuum jet system in condenser operating for the cooling water system.

The byproduct Gypsum, as Gypsum slurry is discharged from the Gypsum Slurry pump of Phosphoric Acid Plant to Gypsum Pond through HDPE pipeline.

The Gypsum Pond consists mainly of four settling compartments & Perimeter surge ditch. The perimeter ditch is bound by perimeter dike. The total area of Gypsum pond is 77 hectare. Normally one settling compartment is taken on line & the other are kept as stand by. The Gypsum Slurry at about 11-15% solid is discharged to one settling compartment. It has to travel a horizontal length of approximately 1000m by which the solids get settled in the settling pond & water is decanted to


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perimeter ditch. This water is known as Pond Water. The pond water comes to a pit & pumped back to plant through Pond Water Return Pump.

Brief Details: Area : 77 Hectare Number of settling compartment : 4 Perimeter ditch length : 1000 meter Pond water circulation pump : 2 Designed by M/S Andaman & Associates Inc., USA. Lined with thick layer of Impervious Clay compacted to permeability of 10 -7cm/sec. Pond water is completely re-cycled and re-used in PAP. Motorable Ring Road around the pond.

Figure 2.2 Process Flow diagram of Phosphoric Acid Plant


2.4.3. Process Description of Di-Ammonium Phosphate/NPK Plant (DAP/NPK):

DAP/ NPK plant is based on Dorocco Granulation Process consisting of four identical streams and has capacity to produce 5000 MT per day. The main raw materials are phosphoric acid, ammonia, sand (as filler) and Defoamer Phosphoric acid(54%)and an hydrous ammonia are pumped from storage tanks to pre- neutralizers (PN Reactor) reaction takes place as a result of which DAP and mono- ammonium phosphates are formed. The slurry contains 80% solids and is pumped to rotary granulators where further ammonia is fed to convert mono-ammonium phosphate to di-ammonium phosphate in a mole ratio of 1.8.

The recycle material along with the filler mixed in the fines conveyors are fed to the granulators. Wet DAP granules flow by gravity to rotary dryers where they are dried in aco- current stream of hot air. The dried granules are screened for size separation in doubled eck vibrating screens where over sized and under sized material are sent back to the system by means of fine conveyors. The product falls into the product compartment of the screen hopper and is withdrawn through product coolers and dispatched to product storage (50000MTcapacity) or direct to the Bagging Plant as required.

The wet process system consists of scrubbing and reaction sections. Scrubbers, which are venture cyclone type, handle the ammonia and dust bearing fumes and gases evolved from the pre-neutralizer, granulator, drier and dust systems. The scrubbing medium for the three scrubbers is re-circulated phosphoric acid solution. The fumes and gases from dryer and fume scrubbers are forced by respective fans to a tail gas scrubber where as gases and fumes from pre neutralizer granulators and coolers are scrubbed na exhausted to atmosphere through the fume stack.


DAP/COMPLEX

PLANT

Figure 2.3Process Flow diagram of DAP /NPK Plant

2.5. Utilities and Off site Facilities

2.5.1. Water

Water Intake and Distribution System

Existing raw water requirement of the PPL is met from the Taladanda Canal flowing in the west – north – north east direction of the project site.

Raw water intake pump house called as Canal Pump house is located at canal side near village Bijay Chandrapur at a distance of 3 to 4 kms by road from the plant. Water so drawn is pumped to a reservoir inside the PPL township campus through a pipe line. The storage capacity of the reservoir is around 17 lac KL. Raw water from the reservoir is taken to Water Treatment Plant through a secondary reservoir. In the process the silts and mud are settled in the main reservoir. The treated water from WTP is then pumped to the plant side as well as to the township area by two different distribution systems. Water cess is being paid to Irrigation department regularly.


Two process water tanks are installed to cater to the needs of process water from the plant as well as supply of firewater. In the process water pump-bay a jockey pump is installed to keep fire hydrant pressure. There are one diesel driven and two motor driven fire water pumps. Pumps are kept connected so that they could be started immediately whenever necessary. Firewater inlet to the pumps is at a lower level than the process water intake. Process water clarifier is provided which takes water from a huge water reservoir, before pumping.

Permitted withdrawal of water from the Taladanda Canal is 5,000,000 Gallons per Day. (22730 m3/day)

As per notice on demand dated 16/10/2012, water withdrawn was 16949 m3/day quite lower than the permission level.

New SAP, CPP & DM Plant would require an extra volume of approximately 7260 m3/day.

Extra water required if any for the proposed upcoming plants will be clarified & resolved and approvals and permissions would be taken for the same.

2.5.2. Power &Distribution:

PPL has captive power generation facilities. Captive generation of power is through co-generation from the waste steam of SAP. In addition there are two Turbo Generators. These are extraction cum condensate type, manufactured by BHEL, each having capacity of 16 MW. When one TG is under operation, other works as spare and vice versa.

A new CPP is in project phase to assist the steam generation from New sulphuric acid plant-2000 TPD. The capacity would be 23 MW and wll be handling waste HP steam at 60 kg bar pressure & 480 0C.

The waste HP steam from SAP at 40 kg/cm2 pressure and 405 0C temperature is used in Turbo Generator to produce power. In case of shutdown of any stream of Sulphuric acid plant, the balance steam requirement for generation of power is met through generation of steam from oil fired boiler. The oil fired boiler has installed capacity of 110 TPH steam at 40 kg/cm2 pressure and 4050C temperature. The boiler is of BHEL make.

Total power requirement in the plant is 25.5 MW. Out of 25.5 MW captive generation is 12 MW, while balance 13.5 MW is being drawn from state electricity Grid.

In case of total power failure the backup HT power is supplied through 5 MVA DG set and LT power through two numbers of 1 KVA DG sets

2.5.3. Raw Material Handling


Basic raw materials handled are rock phosphates, sulphur, MOP, ammonia, sulphuric acid and phosphoric acids. Mostly all are imported from different countries. The solid cargo (sulphur, rock phosphates and MOP) are unloaded from ships at the company’s captive jetty by means of a cross country conveyor system. The length of the conveyor gallery is 3.3 kilometres and is completely enclosed. The liquid cargo (sulphuric acid, phosphoric acid and ammonia) are unloaded from ships at the same jetty through cross country pipeline. While the solid cargo is stored in respective silos and fed into the individual plants, the liquid cargo is stored in dedicated storage tanks in off-site areas for onward transfer to production plant.

Table 2.4: Raw Material Requirement, Linkages & Specific Consumption

Sl. No

Raw Material

Approximate Requirement (Tons / Day)

Consuming Plant User Plant

Origin Source Supplier

1 Rock 4600 Phosphoric Acid Plant

Morocco/ Togo/ Peru/ Vietnam/ Egypt

M/s OCP, Morocco, Peru

2

Sulphur

800

Sulphuric Acid Plant

UAE/ IRAN/ / QUATAR/ SIGAPORE

M/s HAVI OCEAN CO.(LLC), DUBAI, M/s MIDGULF INTERNATIONAL LTD, LIMASSOL

3 MOP 1100 DAP & Trading

Belarus / UK

M/s JSC BELARUSIAN POTASH COMPANY, BELARUS, M/s INTERNATIONAL POTASH COMPANY (UK) LTD, M/s RUSAGRO

4

Ammonia

1150

DAP

IRAN/ S.ARABIA/ MALAYSIA/ BANLGADESH

M/s TRANSAMMONIA AG, A SWISS. M/s SABIC. M/s COMPAGNIE INDO FRANCAISE DE COMMERCE(P) LTD,

5 Sulphuric Acid

5000

DAP& PAP

Japan

MITSUBISHI CORPORATION,

6

Phos. Acid

2350

DAP

Morocco

M/s MarocPhosphore,

7 Filler 250 DAP Local Paradeep


2.6. Specific consumptions:

2.6.1. Specific consumptions for PAP:

Raw Material Unit Consumption

Rock phosphate T/T 3.25 Sulphuric acid T/T 2.80 Defoamer T/T 1.00 Power KWH/T 155.000 Water T/T 1.18 Water(conc.) M3/T 0.00597 Power(conc.) KWH/T 75.0000 Steam(conc.) T/T 1.96

2.6.2. Specific consumptions for SAP:

Sl. No

Raw Material Unit Specific Consumption

1 Sulphur MT/MT 0.330 2 Ammonia Kg/MT 0.182 3 Filter Aid Kg/MT 0.135 4 Hydrazine gm/MT 0.0275 5 T.S.P Kg/MT 0.00225 6 Process water (Including make up to

C.T) m3/MT 3.156

7 D.M. Water m3/MT 1.165 8 L.P. Steam MT/MT 0.225 9 Instrument Air m3/MT 1.8 10 Hydrated Lime Kg/MT 0.075 11 Soda Ash Kg/MT Occasional 12 Elec. Power 74.4

2.6.3. Specific consumptions for DAP/Other complex Fertilizer:

Sr. No

RM

Products DAP NP-20 NPK-10 NPK-12 NPK-10

01 NH3 0.222 0.249 0.125 0.15 0.1892 02 P2O5 0.471 0.21 0.27 0.332 0.1604 03 H2SO4 0.016 0.433 0.01 0.01 0.339 04 MOP - - 0.44795 0.27519 0.2578 05 Filler 0.05 - 0.04725 0.04811 - 06 Anticaking

agent 0.0008 - 0.0008 0.0008 0.0008

07 Defoamer 0.000157 0.00009269 0.00010109 0.00011257 0.000157 08 F.O.(

KL/MT) 0.0083 0.0087 0.00813 0.0086


2.6.4. Finished Product Handling

Bulk fertilizers are received in the bagging plant directly from the production plant as well as from the product silo. This is then bagged, stitched and loaded in wagons for dispatch. There are nine numbers of slats for carrying out the activities and three numbers of platforms for loading the fertilizers in the rakes. Controlling the weight variation of the bagged fertilizers is the most important function of the bagging plant. It is a labor oriented department. Around 600 persons are deployed in the bagging plant. The average capacity of each slat is around 45 Ton per hour.

2.7. Bulk Storages

2.7.1. Ammonia Storage

Imported liquid ammonia is stored in 5 atmospheric storage tanks, each having a capacity of 10,000 MT totalling to 50,000 MT. The tank is of 'Cup-in-tank' type. These are double shelled tanks with double bottom and double cylindrical shell with a single roof fabricated from low temperature carbon steel. The space between the shells is connected with ammonia vapour. Outer tank is insulated with polyurethane foam “foamed in-situ” (100mmthick) and has aluminium sheet cladding. Insulation is secured with stainless steel hoops to withstand wind velocity of 260-km/hr. Tank bottom is insulated with foam glass and roof is insulated with fibre glass stacked to a thickness of 250 mm on deck suspended from dome roof. The roof top is painted with polyurethane paint. Ammonia is stored at atmospheric pressure and temperature of-33ºC. Each tank has three safety valves at different points for protection. These safety valves are connected to arelief header and the header is connected to vent. Normal operating pressure of the storage is 600mm water column (WC). There are two vents at a height of 60.2metres and 70.15 meters. Three safety valves provided on each tank are having following set pressures.

1stsafetyvalve: 950 mm WC

2ndsafetyvalve: 1000mmWC

3rdsafetyvalve: 1050 mm WC

Safety valves can be locked either in open or closed position. Without inserting key, these cannot be opened or closed, once locked.

All the ammonia tanks are connected to a common refrigeration system.

2.7.2. Sulphuric Acid Storage Tank

There are four numbers of sulphuric acid storage tanks three of each 10,000 MT capacity and one of 5000MT capacity. A pump bay is situated near the tanks and sulphuric acid from the storage tanks is pumped to the


day tank (2000 MT capacity) situated in Phosphoric Acid Plant premises and to DAP plant for injection. Leakage from the pump and the overflow from the storage tank are connected to sulphuric acid sump pit from where acid is pumped back to No.1 tank. Over flow from the sump is neutralized and discharged to the effluent drain, which leads to Effluent Treatment Plant (ETP).

A 10000 MT capacity of Sulphuric acid tank is to be commissioned in near future.

2.7.3. Phosphoric Acid Storage Tanks

For phosphoric acid solution, six numbers of mild steel rubber lined storage tanks of each 10,000MT capacity is installed. Pumps situated near the tank, pump phosphoric acid today tanks (2 numbers) situated in DAP plant. Spillages, over flows and leakage are connected to a sump it where phosphoric acid sludge accumulates. A sump pump installed in the pit pumps over flow back to the storage tank.

Presently 2 nos. of Phosphoric acid tanks are in commissioning stage each of holding capacity of 5000 cubic.m .One more tank is to be commissioned in near future.

2.7.4. Heavy Fuel Oil/ LSHS Storage Tanks

There are two heavy fuel oil (FO) storage tanks each having a capacity of 1800 KL. Tanks are equipped with steam heating. All the tanks are insulated with 50 mm thickness glass wool. Tanks are enclosed in a dyke wall having a holding capacity of 2000 m3. Unloading facilities by trucks exist. Leakage form tanks drain and overflow along with tank’s steam heating condensate are collected through a drainage system inside the dyke wall to control the spillage flow from pump bay and is directed to the sump pit. For reclaiming oil from the pit, one submerged oil reclaiming pump is provided which reclaims oil from the top of the pit and discharges into storage tanks provided. Water collected in the pit goes to the effluent drain pump and the fuel oil is pumped back to the storage tank.

One High Speed Diesel (HSD) oil day tank having a capacity of 15 KL is located behind the emergency power house building of off-site storages.

2.7.5. Chlorine Storage

Chlorine is stored in tonners at Water Treatment Plant. The factory stores a maximum of 2 tonners at a time. One tonner is equivalent to 930 kg. This chlorine is in liquid form and is being used to treat the water. The empty cylinders will be replaced by the filled ones on regular basis.

2.7.6. Muriate of Potash Storage

The muriate of potash is stored in a silo of capacity 35000 MT. Being transported from jetty through the conveyors.


2.7.7. Rock Phosphate Storage

The rock phosphate is stored to the extent of 65000 MT. It is stored in an enclosed shed called silo. Rock Phosphate is being transported from jetty through the conveyors. The expansion of the silo has been done to 1,30,000 MT.

2.7.8. Sulphur Storage

The sulphur is stored in solid state to the extent of 45000 MT. It is stored in an enclosed shed called silo. Sulphur is being transported from jetty through the conveyors. The storage shed approximate dimensions are 194 m x 42 m x 10 m. The stored sulphur is transported through conveyors to SAP.

2.7.9. LPG Storage

LPG cylinders are stored in a Godown. There are total 102 cylinders for industrial use and 153 cylinders for domestic use. Godown has approximate dimensions of 12 m x 8 m x 4 m.

2.8. Offsite Facilities

The important OFF Site facilities required for the smooth operation of the plant are briefly given below.

2.8.1. Instrumentation

Automation and control system being an important feature, all parameters are measured by instruments. PPL is able to regulate the production process and improve the productivity.

DAP Plant, Phosphoric Acid plant, Captive Power Plant and Sulphuric Acid Plant have adopted the Distributed Control System (DCS) whereby the intricate details also are captured by the system.

2.8.2. Plant Lighting

The entire plant along with township is provided with adequate lighting facilitated by energy efficient, high luminescent sodium vapor lamps and high mast for widespread coverage.

2.8.3. Fire Fighting, Safety & Security

The fire fighting system is very important. The fire fighting personnel and security guards are specially trained for all types of fire oriented contingencies and also other safety emergencies in a simulated real-life situation. The preventive measures for fire and Safety incidents and accidents:

Regular testing of fire pumps and fire tenders Regular inspection and upkeep of fire and safety equipment/vehicles Emergency preparedness and response /mock drills


Creating awareness and formation of safety committees in all the plants Accident reporting, investigation and analysis Well-equipped with relevant infrastructure and manned round-the-clock

PPL has a battalion of 206 well trained and efficient security personnel headed by Chief Security Officer. Security system and guards are equipped with best safety appliances adequate enough to protect the plant and personnel against any adverse situations.

The safety and security operations are carried out round the clock with meticulous planning and vigorous implementation techniques, which take into account the risk and hazards factors.

2.8.4. Electrical & Mechanical Maintenance

The company adorns a full-fledged electrical and mechanical workshop within the plant premises with state – of – the – art machines and facilities to cater to the day – to – day in-house maintenance jobs. Some of the major breakdown jobs are done by employing certified and enlisted contractors.

2.8.5. Environment

PPL is having a well-organized Environment department to take care of various environmental issues of the industry, which includes but not limited to compliance of statutory provisions of environment legislations. Operation of Effluent Treatment Plant, regular monitoring of environmental parameters and coordination with different departments in the plant for effective environmental management are some of the activities. PPL is having a well-equipped laboratory to carryout day – to – day analysis of environmental parameters. PPL has installed a Weather Station to monitor ambient temperature, wind speed, wind direction, rain fall and relative humidity.

2.8.6. Man Power

Competent and qualified personnel are employed for various jobs. Direct employment is around 1042. Out of this 602 are executives and 440 are non-executives. Indirect employment is to the tune of 1120 deployed through contractors. Temporary employment is around 39.

Summing up the figures, PPL has manpower of 2201 till 31stAug 2012.

PPL has provided housing facilities to all its personnel. Maintenance of the colony is taken care by the civil department. The complex is having all basic minimum amenities like shopping complex, school, play ground, jogging trail, gymnasium, recreational club & hospital etc.

2.9. Environmental aspects

2.9.1. Air Emission:


Table 2.5 Air Emission from Existing plant

Sl. Description ofStack

Stack Coordinate

Stack Height(m)

Stack Dia.(m)

Exit Velocity (m/ Sec)

Temp(0K)

X – Coord

Y – Cord

01

DAPA

850

550 50 2.8

13.14 343

02

DAPB

800

550 50 2.8

14.17 342

03

DAPC

800

600 50 2.8

14.91 344

04

DAPD

850

600 50 2.8

15.14 343

05

PAP

1400

400 50 1.5

11.68 321

06

SAP Stream A

1350

575 120 1.8

8.05 311

07

SAPStream B

1400

575 120 1.8

8.1 310

08

CPP

1200

650 105 1.8

3.03 433


2.9.2. Effluent:

The major sources of waste water generation from PPL are;

Sulphuric Acid Plant Phosphoric Acid Plant DAP Plant Captive Power Plant Offsite and Bagging Plant Domestic Waste Water

Scrubbers, condensers of the vacuum evaporators, leakage from pumps, spills, floor washings, cooling tower blow down, boiler blow down and wash water mainly contribute to waste water stream from the above mentioned units. It is apparent that a number of substances during the processing of the product are discharged with the effluent that primarily includes phosphates and fluorides.

PPL plant has been designed with provision of maximum recycling of the wastewater generated from some of the units like DAP plant and PAP. Water from gypsum pump oil cooler and filter pump is used in Ball Mill for grinding purpose to the tune of 90 M3

The total waste water generation from the existing plants to ETP is around 1800 M 3 /day.

Total Water – 17840 m3/day

Industrial - 13952 Domestic – 3888 ( colony and Industrial domestic both)

ETP STP

On Land

389

3499

1800 180

1620

Figure 2.4:Water Balance diagram for Existing Plant


30 | P a g e

2.9.2.1. Waste Water from Phosphoric Acid Plant

The major source of waste water from this unit is gypsum slurry. The by-product gypsum is slurried with water and pumped to gypsum pond, where the fluoride compounds form stable calcium fluoride and settle down. The plant has been designed with a zero discharge concept. The supernatant from the gypsum pond, which also accommodates the return water from various condensers, seal water, plant washings and cooling tower blow down is recycled back into the system. The phosphoric acid plant area is also paved to prevent ground percolation.

2.9.2.2. Waste Water Generation from SAP

There is as such no liquid effluent from the process area of sulphuric acid plant except plant washings, blow down from cooling tower & boilers and condensate from sulphur melting pit. During startup or upset condition of the plant the alkali scrubber is put into operation and scrubbed liquor is taken to ETP for treatment through a central effluent sump. The entire quantity is highly acidic. In case it finds its way to percolate through soil then there are all possibilities of ground water contamination. Thus steps are taken to pave the whole SAP area to prevent ground percolation.

2.9.2.3. Waste Water from Di-Ammonium Phosphate Plant (DAP)

The plant is based on negative water balance and thereby no sources of liquid effluent are anticipated except for the occasional washing and spillage. Such discharges are intermittent in nature and in small quantities. Zero discharge is attained through complete recycle of the scrubber water back into the system. Steam condensate generated during heating of the furnace oil lines forms a part of the effluent

2.9.2.4. Captive Power Plant

The sources of waste water generation from captive power plant include cooling tower blow down, DM plant backwash and boiler blow down.

2.9.2.5. Domestic Waste water:

Sanitary Waste Water

The generation of sanitary waste water from the plant and township is around 700 M3/ day and is a major source of waste water generation. An adequately designed STP is provided to treat the same.

2.9.2.6. Effluent Treatment Facilities and Waste water Discharge

The waste water generated from PAP and DAP is completely recycled into the system where as of CPP is separately treated in the neutralization tank. Occasional leakages / overflow from PAP, DAP plant, off sites and entire effluent from SAP are taken to ETP for treatment. The said ETP has been installed based on the feasibility study carried out by NEERI, Nagpur and comprises of a collection sump, grit chamber, oil & grease trap, equalization basin and physio-


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chemical treatment units like clarifloculators, thickener, filter press etc. ETP process is based on double stage lime treatment. The treated effluent is neutralized using sulphuric acid before discharge. A schematic diagram of ETP is given in the following Diagram

A project is under way for total reuse of treated effluent water from ETP in Ball Mill of PAP. A schematic diagram of the project is given under in Figure 2.5


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Figure 2.5 Diagram (Schematic Diagram of ETP)


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Figure 2.6 Diagram (Schematic Diagram of Project for Reuse of Treated Water of ETP)

2.10. Solid Waste Generation, Management and Handling

The solid waste generated in PPL can be classified into solid waste from the processing plant and domestic refuse from the colony.

Solid wastes from the plant are by-product phosphogypsum, sulphur muck, spent catalyst, phosphoric acid tank sludge, ETP sludge etc.

2.10.1. By-Product Phosphogypsum

Rock phosphates are treated with sulphuric acid producing phosphoric acid and calcium sulphate. The slurry from the reactor is routed through the filtration unit where calcium sulphate is obtained as a filter cake. This is called by-product phosphogypsum. It is slurried with recycle pond water and pumped to the gypsum pond. There is two compartments in gypsum pond. It is located within the factory area. The area occupied by the pond including perimeter ditches and dykes is 77 hectares. The pond is provided with compacted embankments. The supernatant flows out of the pond and is collected in a perimeter ditch. From the perimeter ditch, the supernatant is pumped and reused in the process according to the requirement. It is utilized to slurry the gypsum and also to wash the filter cake.

The quantity of phospho gypsum generated at present is 7000 tones / day. Considerable quantity of it is sold to outside parties for cement manufacturing and also as calcium supplement. PPL is planning to put a granulation plant to utilize phosphogypsum. Initially the plant will be set up as a trial unit. The details of the plant are explained in the next chapter. Location of gypsum pond is shown in the master plan in Figure 2.7


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Figure 2.7Gypsum Pond

2.10.2. Spent Catalyst

Spent vanadium catalyst is generated occasionally from the sulphuric acid manufacturing process. Spent catalyst (V2O5) is being stored in a covered shed inside the plant premises in ETP area.

2.10.3. Sulphur Muck

Sulphur muck is obtained during melting of sulphur ore in melting pit and subsequent filtration of molten sulphur. The impurities are obtained as residue. Daily generation of sulphur muck is 5 Metric Ton. It is used in the DAP plant as filler.

2.10.4. ETP Sludge

The ETP sludge is produced during the wastewater treatment facilities. About 2100 ton of sludge is generated per annum. Sulphur muck and ETP sludge are stored in a covered shed and reused in the process.


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Table 2.6:Solid/ Hazardous Waste from Existing plant

Sl. No.

Waste Description, Waste Stream, Waste Category and Schedule.

Source of Generation and Quantity

Method of Handling including Disposal

01 Spent Catalyst (Process Based),

Converters of SAP Quantity of Generation: It variesfromyear to year depending upon activity of the catalyst.

Collection: During annual shutdown deactivated catalyst is segregated. This deactivated catalyst is called Spent Catalyst. It is collected in plastic bags. Storage: Spent Catalyst so collected is taken to a designated Storage Site located at the ETP using tractortrolley. Storageareais well covered and protected from rain water. Disposal: PPL have located a party.who has obtained authorization from its state Environment Conservation Board for collection, storage, treatment, transport and disposal of vanadium pentoxide spent catalyst. PPL have written to OSPCB for NOC for sale of spent catalyst to this party.

02 Sulphur Muck (Concentration Based)

Sulphur Filter cake at SAP

Collection: Filtercake is collected on the concrete floorin the SAP. Storage: The material is shifted to RMS (Raw Material Silo) of DAP Plant by using pay loaders. Disposal: The total quantity of Sulphur muck enerated is used in house as filler in DAP production.

03 Acid Residue

During Cleaningof Acid Storage Tanks. (Process Based)

H2SO4 &H3PO4 Storage Tanks at offsites

1. Sludge from H2SO4 Storage Tank at offsite : Storage Tank of H2SO4 is made up of carbon steel. The threshold concentration of sulphuric acid for possibilities of corrosion and generation of sludge is 88% or below. PPL maintains the concentration >98% as a process requirement. Sludge generation due to lime treatment from H2SO4 Storage Tank during cleaning is used in DAP. 2. Sludge from H3PO4 Storage Tank at offsite. Collection: Phosphoric acid is stored in MSRL tanks at offsite. The fine particles of gypsum present in acid settles in the tank bottom. When the level of bottom sludge increases to a considerable height it is cleaned. The clear acid form top is pumped out. Next the sludge is collected in a sump by a slurry


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pump. From the sump it is pumped to Gypsum Slurry Tank in PAP. Disposal: The sludge along with gypsum slurry is pumped from the Gypsum Slurry Tank to the Gypsum Pond. Note:1 Residues are generated only during tank cleaning. 2. We have not yet discarded any of the storage tanks.

04 Discarded Containers/ Liners usedfor Hazardous Waste/ Chemicals

Discarded Container of Lube Oil Barrel fromSAP,PAP andDAP

Collection: It is collected ati ndividual plant. Storage: Presently allempty barrels are shifted to a designated storage room near Labour Canteen by tractor trolley. Disposal: Mostly these are used for storing spent oils and disposed off to authorized re-processor along with spent oil.

05 Sludge from Wet Scrubber (Phos Acid Process Based),

Scrubber Settling Pit of PAP

Collection& Storage: In PAP the Fume Scrubber is used for scrubbing fumes coming from various sections of the plant. Scrubbing is done using the Gypsum Pond Recirculation water. Sludge from the scrubber accumulates in a sump. Disposal: Sludge from this sump is taken to the Reclaim Pit from where it is flushed to the Gypsum Pond along with the Gypsum Slurry for disposal.

06 Drain & ETP Sludge Generated from sump, filter press. (Concentration Based)

Effluent Drains, Sump and ETP

Collection: It is collected manually, kept aside along the drain/ ETP Sludge Drying Bed. Once dried the material is shifted to RMS (Raw Material Storage) by tractor trolley. Storage: It is stored in the RMS. Disposal: It is used as filler in DAP Plant.

07 Cooling Tower Sludge (Concentration Based)

Cooling Tower Sump of PAP

Collection: Sludge of cooling tower sump of PAP is gypsum in slurry form. The sludge removal is done after dewatering the cooling tower pit. Then the material is shifted to Reclaim Pit. Disposal: From Reclaim Pit it is flushed to gypsum pond along with gypsum slurry.

08 Spent Resin

from DM Plant (Process Based)

DM Plant of CPP

Collection: Spent resin in DM plant is generated only at the time of replacement with fresh resin. The spent resin is collected manually in barrels.


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Storage: Around 400 Ltrs are kept inside the DM plant. Disposal: The material is not yet disposed off outside the premises or sold to any external agency. It is kept in a safe condition at the above mentioned area.

09 Used Oil or Spent Oil (Process Based),

SAP, PAP, DAP, CPP & Offsites

Collection: It is collected at individual plant in barrels. Storage: Used oil is stored in barrels. Temporary storage is at the generating plants from where it is shifted to the designated storage room near canteen by tractor trolley from time to time. Diposal: Dispossed off to authorized reprocessor.

10 Waste containing Oil (Process Based),

Mechanical Workshop and other departments such as CPP FO area, 5 MW DG room, Bagging Plant, DAP plant, Diesel store, SAP, PAP Mechanical Maintenance &OffsitesFO Handling areas

Collection: It is collected in containers separately for oily sand/soil and oily cotton waste. Storage: Temporary storage is at the generating plants which are shifted to DAP plant by tractor trolley from time to time. Disposal: Oily sand/soil is used as filler in the plant. Whereas oily wastecotton is used as fuel in the DAP furnace.

11

Phosphogypsum (Both process based and concentration based),

Phosphoric Acid Plant

Collection: It is generated in PAP Reactor and separated in the filters. The filter cake is then collected by scroll drives and made slurry by adding return gypsum pond water. Storage: The gypsum slurry is pumped to gypsum pond where the gypsum settles down and supernatant liquid decanted into the perimeter ditch. Disposal: Water from the perimeter ditch is re-circulated to PAP. From gypsum pond ordered quantity of phosphogypsum is lifted and transported to Railway Siding by using excavator and dumpers. From Railway siding the said material is dispatched to the user agencies both by rail and road bulk and in bags. PPL has constructed a 0.7 Km. long covered shed for handling gypsum at the railway siding.


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2.7.2. Noise Environment 2.7.2.1. Impact:

Present noise levels in study area are below the standards except near a station close to Railway crossing. As all the plant equipment are adequate noise control measures thus there is not much impact to noise in the plant premises. Major transportation are by either rail or ship.

2.7.2.2. Mitigation Measures:

Towards mitigation measures the following are in practice. Less noise generating machines/vehicles, maintenance of machines/requirements/vehicles in good condition, ear muffs or other protecting device or sound proof cabins to employees near noise generating source. In addition there is development of green belt barriers and plantation.

2.11. Charter on Corporate Responsibility for Environment Protection (CREP)

Guidelines:

PPL has adopted the Charter on Corporate Responsibility for Environment Protection (CREP).

2.12. CSR Activities: Peripheral Development:

PPL has carried out numerous CSR activities and contributed significantly for the peripheral development of the area. A few of such activities recently carried out are enumerated below.

2.12.1. Construction of Ekta Park :

PPL has developed a children park in Jagatsinghpur collectorate campus. The same is being maintained by PPL. So far the expenses on this head have been to the tune of about Rs.5.00 lacs. The annual maintenance cost, which is a running expense, comes to about Rs.1.00 lac every year.

2.12.2. Health Services:

PPL provides free health services in its own hospital through company doctors and the services are open to the people of the community around.

PPL organise health camps in nearby villages. Company also conducted Typhoid vaccination camp, Diabetic camp at its own hospital as well as a general health check-up camp in village Chanakana of Paradeep Gram Panchayat. The expenses on this head have been to the tune of Rs.2.5 lacs.

A part of the hospital building has been renovated by spending of about Rs.20.00 lacs and the same facility is being used for providing health services by M/s. Sun Hospital which is open for public. It may be worth mentioning here that up to date


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diagnostic equipments and surgery facility has been made available in this health centre.

2.12.3. Emergency Relief:

The Company felt it necessary to extend relief at the time of natural calamities, such as;

Distribution of relief materials to the flood affected people of Kujang and Tirtol block. The materials included cooked food for about 15,000 people as well as relief kits containing dry food materials. Company has spent about Rs.9.00 lacs on this account.

Providing relief materials like utensils, clothing’s, tarpaulin sheets etc. to the fire victims when there were incidents of fire in nearby localities viz, Balijhara and Atharbanki Bali Plot and incurred expenses of about Rs.0.55 lacs on this account.

Distribution of insecticides / herbicides spraying machines and organized a campaign to create awareness among the farmers about know - how for combating the swarming caterpillars when there was a problem of swarming caterpillars in Jagatsinghpur district resulting in damage to crops. About Rs.0.65 lacs has been spent on this account.

2.12.4. Distribution of School Kits:

For encouraging the rural children, the Company has undertaken distribution of school kits containing a good quality school bag, tiffin box, geometry box, pencil box, note books etc. among 425 students of 4 primary schools of Mangarajpur, Kothi, Bagadia and Paradeep Garh Gram Panchayats. The expenses on this head have is to the tune of Rs.2.10 lacs.

2.12.5. Nivedita Orphanage Building :

There is an orphanage called Nivedita Ashram at Patalipanka, about 15 KMs away from Paradeep. About 100 inmates live there. PPL have constructed a hall with attached toilets spending of about Rs.2.5 lacs and also distributed warm clothing amongst the boarders spending about Rs.0.20 lacs.

2.12.6. Canteen Hall at MMITC :

PPL have constructed a canteen hall for the students of Madan Mohan Industrial Training Centre (MMITC), Mangarajpur at a cost of Rs.4.00 lacs. This facility has added to the infrastructure of the said institute and is a welfare facility for the students of the institute

2.12.7. Socio-Cultural Activities:

PPL have been participating in socio cultural activities of the district / locality since long and is spending about Rs.3.00 lacs per annum on this account.

2.12.8. Developmental Work in Villages:


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PPL is keen in developing the living standard of the villagers. Two Gram Panchayats, Bagadia and Mangarajpur have been identified. Accordingly PPL has entrusted the task of economic upliftment of these villages to a non-profit organization called Forum for Integrated Development and Research (FIDR), Bhubaneswar. They have been undertaking activities related to health, sanitation, literacy, drinking water, child rights with a focus on the girl child, HIV etc. The expenditure for the quarter Oct-Dec’ 09 for the purpose has been to the tune of Rs.5.00 lacs. The total expenditure on the above mentioned CSR activities comes to Rs.54.05 lacs (approx.).

2.12.9. Plantation and Green Belt Development:

PPL is having 2282.40 Acres of land out of this around 854 Acres of land has been developed as a green belt and landscaping, which is around 37% of the total land. Preference has been given for the local and fast growing plant species for the green belt development; i.eaustralian acacia, paltaforam, Neem, phycus, karanj, ashoka, kajurina, etc.

2.12.10. Plantation within the Factory:

Attenuation of Noise levels: It is possible to reduce the noise levels by 3–5 dBA per 50m width of the greenbelt. However, a thinner strip of trees with in the industry, outside the administrative and canteen building can reduce the noise resulting from constant movement of trucks, tankers, wagons etc. within the campus. To arrest particulate and gaseous emissions: Aerosols are trapped effectively by trees. Few units from the industry, through in significant in size, would possibly generate aerosols with gases like SO2, NOx Protection against cyclonic wind: Area of PPL, being cyclonic prone, is protected against damaging action of cyclonic winds. The tree species that exhibit significant check and break force can thus be potentially useful to protect, glass windows and other weak structures within industry from wind force.

2.12.11. Plantation Out Side the Factory:

Existing green belt around the industry is strengthened to improve its efficiency in reduce the level o pollutant. More than 200 m thick massive plantation has been done.

2.13. New Projects under Construction

PPL is carrying out expansion (construction / commissioning) of existing plant facilities. Some of the projects under execution are:

2.13.1. Zypmite Plant

PPL had developed a product Zypmite which is a mixture of Phospho Gypsum, dolomite/Bentonite/basic slag, Zinc sulphate and Borax. to provide secondary and micronutrients to plants as soil up grading fertilizer and also as an R&D unit for formulation of different grades.


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Typical standard size of a granulation plant available in India is 240 TPD of NPK with a recycle ratio of 1:1. However, the same plant with some modification can produce about 160 TPD Zypmite per day consider a recycle ratio of 2:1. NPK market is seasonal and hence the manufacturers operate the plant for 150 days per years. Thus, the annual capacity of Zypmite plant will be 24000 MT. Rest of the period the plant may be utilized for other NPK grades. Another option is the produce Zypmite during off-season and warehouse the same.

Plant Capacity: 10 TPH equivalents to 200 MTPD

The Zypmite produced shall be of following composition:

Gypsum 75.25% Dolomite/Slag 10.00% Bentonite 5.00% Zinc Sulfate 9.00% Borax pentahydrate 0.75%

The nutrient analysis will be: Calcium as Ca 20.0% Sulphur as S 14.7% Magnesium as Mg 1.84% Zinc as Zn 1.93 % Boron as B 0.11%

The process involved in zypmite production is described below:

Zypmite Fortified is simple physical mixture of Gypsum, Basic slag, Zinc Sulphate, Borax Penta-hydrate. The physical mixture is granulated in a simple granulation unit of 10MT/hr capacity. The product will be bagged in 25kg / 50kg bags.

The manufacturing process of Granulated Mixed Fertilizers will involve following steps.

a) HANDLING, STORAGE AND PROPORTIONING OF RAW MATERIALS

Different raw materials (like Phospo Gypsum, Dolomite or Iron slag, micronutrients all in solid form) are taken from Raw Material storage using Payloader and are stored in different silos (Raw material hoppers), one each for a different Raw Material. A fixed quantity of each Raw Material is drawn from the silo through a volumetric Feeder and is fed to a Paddle Mixer. The quantities drawn vary according to raw mix design for a particular grade.

b) MIXING OF RAW MATERIALS

Designed quantities of different Raw Materials are fed to a Double Shaft Paddle Mixer wherein they are thoroughly mixed. Mixed Raw Materials along with recycle material are fed to a Rotary Drum Type Granulator by Bucket elevator.

c) GRANULATION


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Adequate quantity of water [Granulating aid ] is sprayed in the drum. Due to moistening and rolling action of the material in the drum, granules are formed. The granule size depends upon the speed and size of the granulator, amount of water sprayed and the residence time of granules.

d) DRYING

In the drier, the granules are lifted to the top of the drum by means of lifters and then they fall to the bottom by gravity. A transverse current of hot mixture of air and flue gases flow continuously from one end of the drier to the other end and takes away the moisture from the falling granules. The hot current of the air and flue gas mixture is generated by an oil fired furnace and a blower. The hot and dried granules coming out of the drier are fed to a cooler.

e) COOLING, SEGREGATION AND RECYCLING

Two single deck vibrating screen wherein undersize and oversize granules are separated and recycled to the Granulation Drum for reprocessing. (Oversize granules are crushed using pulverizers). The granules in the size range of 1 mm to 4 mm are passed on for packing.

f) PACKING and AIR POLLUTION CONTROL EQUIPMENTS

Cyclonic dust collectors are installed for coarse & fine dust separation with negative pressure developed by ID Fans. These are provided for sucking gas from dryer and cooler drums.

The gases are then passed through wet scrubbing chamber where fine particles are retained and only gases are passed through chimney.

The SPM level is well within 150 mg/nm3. The material scrubbed in dust scrubber system is recycled to granulator through scrubbing liquor.

Utilities

Power requirement is 500 Kwh. Water consumption is 0.55 m3 per MT Zypmite produced. F.O required is 28 Litres per MT Zypmite Produced. Land acquired for this plant is around 400 m2

Block Flow Diagram:


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Figure 2.8: GSSP Process Flow Diagram

Emission/Effluent/Solid Waste:

Zypmite has 3 stacks : cooler chimney, dryer chimney & granulator chimney each of 30 m height with SPM limit of below 150 mg/Nm3. The diameters are 1.03 m, 0.85 m & 0.50 m respectively with flow rate 48500,32000 & 10900 m3/hr.

The outlet temperature of cooler & granulator chimney is around 40-500 whereas of dryer chimney is higher to 80-90 0C.

o The plant being zero discharge plant has no effluent generation outside the plant.

o No solid waste is generated.

Paddle Mixer

Granulator

Dryer

U/S Screen

Prod Cooler

Pulveriser

Bagging

oversize

undersize

Product

Cyclone Separators

Cyclone Separators

CombstnChamber

Air Scrubbing Chamber

STACK

Fuel oil

Anticaking agents

Batch Mixer

Raw Matl. Bins

Process Water

Gypsum, Dolomite/Slag, Micronutrients

Recycle Conveyor

O/S Screen

Dust

Dust

10 MTPH Product

Steam

Air

GRANULATION PLANT PROCESS DIAGRAM

Sp.consn of RM (MT/MT prod) Budget Ferti-trial

Gypsum 0.7525 0.5600

Slag/Dolomite/bentonite 0.1500 0.4150

Zinc Sulphate 0.0900 -

Boron Pentoxide 0.0075 -

S/MgSO4 0.0900 0.0250


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Zypmite Plant project of 15 Crores budget is under erection and will be operational in near future.

Land requirement for this project is 4000 Metre Square.

3.1.1.1 Specific consumption:

The specific consumption of the raw materials are as follows: Sl. No. Raw Material Sp. Cons( per MT

Product) 1. Gypsum 0.75 2. Dolomite 0.10 3. Bentonite 0.05 4. Zinc 0.09 5. Borax 0.0075

The water requirement for the zypmite plant is 0.55 m3 /per tonne zypmite and is added only to the granulator. The plant works at zero discharge and has no effluent generation outside the plant. The scrubber used is a dry one.

3.1.2. New Sulphuric acid plant:

Sulphuric Acid Plant-III of capacity 2000 MTPD is under project stage with a capital cost of 486.18 Crores. The Sulphuric acid produced would be of 96%..and the process would be the same DCDA as explained before for the existing 2400 TPD sulphuric acid plant,

Total area required is 16986 M2 including the area required for Turbo generator –III of capacity 23 MW

Plant - 12236 M2 (161m*76m) Turbo generator-III - 4750 M2 (95m*50m)

3.1.2.1 Specific Consumption:

Raw Material For 1MT sulphuric acid (96% H2SO4) Sulphur 0.3275 MT DM water 1.805 MT Power 72 kWH / ton of 100% acid

3.1.2.2 Environmental Aspects:

Stack Details: Height 120 m Diameter 2700 mm Temp. 82oC Flow rate 137, 289 Nm3/Hr SO3 conc. 0 SO2 Conc. 29 Nm3/Hr (1 Kg/ T H2SO4) O2 Conc. 6147 Nm3/Hr N2 Conc. 131112 Nm3/Hr


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Acid Mist 30 mg/Nm3 Water Balance

Effluent:

Boiler Blow down: Exported continuously to B/L from atmospheric blow down tank. Normal flow rate is around 2182 kg/hr with a temperature of 1000C. Quality is Ph: 10-11 SiO2: <10 ppm PO4: 10-30 ppm T. Hardness: Nil.

Start –up Scrubber Effluent: Start up flow rate: 25,775 kg/hr with Ambient temp. It contains 20% dissolved solids includes 85% sodium sulfite, 5% sodium bisulfite & 10 % sodium sulphate.

New Cooling tower Circulation rate = 2500 m3/Hr.

3.1.3. New Gypsum Pond

New gypsum pond west of existing pond using latest technology from M/S Ardman Associates Inc. Florida, USA is under construction

Covering about 70-80 hectare area New pond will be with geo-textile and HDPE liner. HDPE liner from world class manufacturer. Use of natural resources to level the surface

New SAP total water requirement (1020) m3/day)

New CT (768) Acid Dilution in IAT & FAT (216)

Gland Cooling Tower (24)

Misc Water (12)


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3. CHAPTER: PROPOSED PROJECT

This Chapter gives brief details of the proposed expansion project of PPL plant including land requirement, process, environmental aspects and cost.

3.1. Land Requirement

The Project will be located in the existing compound of PPL is Paradeep in Jagatsinghpur District, Orissa. It is 90 kms from Cuttack. The site is located at 20º16’56” North Latitude and 86º38’52” East Longitude, west side of ParadeepPort. The plant encompasses 950 hectares area. MahanadiRiver is 5km from the plant site and meets Bay of Bengal, which is 5.3 km away from the site. Atharbanki creek is flowing along the boundary wall of the site and is in between Paradeep Port site and the factory. The expected land requirement for the proposed project is given below:

Table 3.1 Land Requirement for the Expansion Project

Sl. No. Plants Land

1 COAL HANDLING PLANT 150 Acres

2 GASIFICATION

3 AMMONIA

4 UREA

4 DAP 1.2 Acres 6 NITRIC ACID 13.5 Acres 7 AMMONIUM NITRATE Acres 8 SSP 8.42 Acres 9 ALUMINIUM FLUORIDE 1.16 Acres

Total 174.28 Acres

Note: No fresh land is to be acquired for the expansion project and hence no R&R is involved.

3.2. Process description:

3.2.1. Coal handling plant: Unloading System

(-) 300 mm domestic coal will be received at plant through railway and (-) 150 mm imported coal will be received through conveyor system from the jetty of Paradeep port. Two separate dedicated conveyors has been envisaged for power plant and gasification plant. 7 MMTPA coal assuming 7 MMTPA coal could be domestic or 7 MMTPA could be imported depending upon availability. And. 2 nos. Rota Side Wagon Tippler has been envisaged for domestic coal unloading through railway conforming the latest RDSO guideline. Wagon tippler will discharge the coal at wagon tippler hopper. From the hopper material shall be extracted by apron feeder and which will feed to the subsequent conveyors for screening and crushing the incoming coal at desired output size. Crushed material can be directly fed to gasification plant simultaneously or coal can be stacked at stockpile through


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individual Stacker Reclaimer. Imported coal shall be received at plant through conveyor shall be stacked at shed. From the shed, imported coal shall be dozed to reclaim hopper by bull dozer. Vibrating feeder will extract the material from the hopper and shall feed to conveyor. Domestic coal coming from wagon tippler hopper and imported coal coming from reclaim hopper can be blended at required proportion at junction tower where both the conveyor is feeding to the same conveyor. Imported coal capacity can be controlled through vibrating feeder and domestic coal capacity can be controlled through apron feeder. There will be a layer of domestic coal over which another layer of imported coal will exist. In the process subsequent blending of coal will be carried out at transfer chutes, crusher house and junction tower.

Figure 3.1PFD Coal Handling Plant

3.2.2. Ammonia plant (coal based) :[Capacity – 2200 MTPD] (Description of 1 stream, PPL

intends for 3 streams)

The process utilizes a single gasifier block with two gasifiers (2+1) to provide syngas for ammonia production and for power generation. The following block flow diagram shows the arrangement of unit blocks.


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Block Flow Diagram

Coal handling & Storage

Gasifier

ASU

Sour Water Treatment

Syngas Compression NH3 Synthesis

Heat Recovery,Gas Cleaning, Ash

Acid Gas Removal

Liquid N2 Wash Acid Gas Removal

CO Shift

Sulfur Recovery Unit

WHRU

GT

Sulphur

Flue

Steam

NH3

Steam

Steam

O2

Air

Coal

Steam

Air

N2/H2

Liq N2

HP N2

Ash

Flue

CO2

Recycle N2/H2

Figure 3.2 Ammonia plant


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Coal Preparation:

The coal preparation is designed at the coal handling plant itself to prepare the coal feed to the required standard for the gasification plant. The coal from the coal handling plant area is conveyed to a kiln type dryer that contacts the coal with heated air, ina way reducing the moisture content in it.

A bucket conveyor lifts dried coal to the top of the coal hoppers.

Air Separation Unit

The Air Separation Unit (ASU) supplies high pressure oxygen to the gasifiers and the Sulfur Recovery Unit (SRU). The ASU also supplies nitrogen for the ammonia process, utility usage, liquid for storage and the Nitrogen Wash Unit. The ASU produces O2 and N2 via cryogenic distillation and generates its own refrigeration by compression of the inlet air. The inlet air compressor is one of the largest drivers on site and can be either electric or steam powered. At this time the air compressor is listed as electric.

GasifierFeedSystem

The gasifier feed system consists of weight bins, conveyors, and lock hopper systems that supply the gasifier with coal at pressure. Carbon dioxide from the acid gas removal system (AGS) is used as transport gas to improve the syngas yield. The coal feed is pressurized in a lock hopper system and metered into the gasifier using a rotary or screw feeder. Steam and Oxygen are injected at the bottom of the gasifier, beneath the grid. Together they provide the energy to fluidize the gasification mixture.

Gasification

Within the fluidized bed the coal reacts with steam and oxygen. The process accomplishes four important functions; it decakes, devolatilizes, and gasifies the feedstock and if necessary, agglomerates and separates ash from the reacting coal. At the specified operating conditions, coal is gasified rapidly to produce a synthesis gas product consisting of hydrogen, carbon monoxide, water vapor, and methane. Additionally the gas contains small amounts of ammonia, hydrogen sulfide, and other impurities. The syngas exits the top of the gasifier through a refractory lined to the inlet of the primary cyclone.

Fines Recovery

The primary fines recovery and recycle system consists of two cyclones in series, the primary and secondary cyclones. The cyclones collect most of the fines from the gas stream leaving the gasifier. The primary cyclone is refractory lined due to the temperature. Syngas from the


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primary cyclone enters the secondary cyclone which is similarly refractory lined. The fines collected in the cyclones are returned to the fluidized bed of the gasifier by means of a dip-leg.

Ash Disposal

Coarse ash is removed from the bottom of the gasifier, cooled, and discharged through a lock hopper system. Ash is conveyed by water cooled screw conveyors for further cooling and discharged to an ash storage silo. Ash from the silo is mixed with water in a pug mill before loading on a truck for disposal.

Waste Heat Recovery

The heat recovery steam generator (HRSG) increases the plant’s efficiency by generating steam from the hot syngas leaving the secondary cyclone. The HRSG is a natural circulation boiler which has a single drum and steel structure. The syngas flows sequentially through the steam generator section, the superheater, and the economizer before leaving the bottom of the HRSG. Steam produced by the HRSG is used as feed to the gasifier and produced in excess for use elsewhere.

Syngas Clean-up

The cool syngas from heat recovery passes to a third high efficiency cyclone and then to a ceramic/metal filter for further dust removal. The collected fines are recycled to the gasifier through the fines management system. The syngas is then washed in counter current scrubber to remove the residual solids. Evaporation of water in the scrubber cools the gas and concentrates the water so a continuous blow-down is required.

Fines Handling

Dry fines collected from syngas clean-up are routed to a fines silo through a lock hopper system. They are collected in the silo and returned to the gasifier. The system is referred to as the Fines Management System and is included to maximize the carbon conversion. Normally all fines are recycled to the gasifier where they agglomerate and are discharged with coarse ash.

Sour Water Treatment

The blow-down water from the syngas scrubber is saturated with hydrogen sulfide that is produced in the gasifier from sulfur in the coal. The blow-down is stripped in packed column and the overhead gas sent to the sulfur recover unit. The stripped bottoms is cooled and treated by a clarifier to settle the ash. The solids containing underflow is used to wet the dry ash in the pug mill during loading. Clarified overflow is reused in the process if possible or treated for discharge.


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Sour Gas Shift

Clean syngas from the scrubber is mixed with steam prior to entering the three stage sour gas shift reactors. The syngas from the gasifier is rich in hydrogen, carbon monoxide, and carbon dioxide. The shift reactors convert carbon monoxide and steam to more hydrogen and carbon dioxide. The first shift reactor is operated at high temperature to encourage the rate of conversion. The second two reactors operate at reduced temperatures to encourage complete reaction of the carbon monoxide. Heat exchange at the exit of the first reactor produces high pressure steam which can be used to drive power turbines.

After the shift reactors a mercury guard bed is provided. The guard bed is filled with sulfur impregnated activate carbon. Any mercury present from the coal is reacted with the sulfur and retained.

Acid Gas Removal(AGR)

At this point in the process the syngas contains Hydrogen Sulfide (H2S) and approximately 40 mole percent carbon dioxide (CO2). These acid gas components are removed in a two step absorption process. Selexol is a UOP licensed process that absorbs acid gases and upon regeneration releases the H2S and CO2 in two separate streams. This allows the H2S to be recovered in the SRU and the CO2 to be safely vented. AGR unit includes a refrigeration package for chilling the absorption solution. The SES based gasifier utilizes CO2 to inject coal into the gasifier. The CO2 affects the reaction equilibrium in the gasifier and improves efficiency of the system. CO2 from the AGR is at low pressure, therefore a CO2 compressor has been provided.

Nitrogen Wash

Ideally the syngas feed to the ammonia synthesis loop has a ratio of 3 moles of hydrogen per mole of nitrogen, and no other components present. Following the AGR there remains trace impurities in the syngas that include methane, water, carbon monoxide, and carbon dioxide. Oxygen containing components must be removed because they will oxidize the ammonia synthesis catalyst and reduce its activity. Methane in the synthesis loop is an inert that accumulates and must be purged. The nitrogen wash unit accomplishes both cleaning of the syngas and addition of nitrogen to produce a stoichiometric mixture.

The syngas to the nitrogen wash unit is first dried in molecular sieve dryers to remove all traces of water. The dry syngas is cooled and then washed by direct contact with liquid nitrogen. Nitrogen and hydrogen have the lowest boiling point of the components present, so the liquid nitrogen stream from the tower contains all the unwanted components. The syngas from the top of the tower is virtually pure and in the correct hydrogen to nitrogen ratio.


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The nitrogen wash unit also recovers purge from the ammonia synthesis loop. The liquid nitrogen wash stream is vaporized for heat recovery and then sent as fuel to the gas turbine.The technology that this system is based upon produces the fuel gas at relatively low pressure, therefore a fuel gas compressor is provided.

Synthesis Gas Compression

Syngas from the Nitrogen Wash Unit is ready for addition to the ammonia synthesis loop as make-up. The syngas is compressed to approximately 155 barg by the Syngas Compressor. The last stage of the compressor is the synthesis loop circulator. The compressor is driven by HP superheated steam generated by the process.

Ammonia Synthesis

Hydrogen and Nitrogen are reacted to produce ammonia in a fixed bed converter. The converter is multi-staged with inter-cooling. Each bed is filled with promoted iron catalyst. Converter effluent is cooled by producing steam and preheating boiler feed water. Make-up gas and recycle gas from the syngas compressor is preheated by cross exchange with converter effluent. Converter effluent is further cooled by cooling water. The reactor effluent is then chilled by ammonia refrigeration in two stages to produce a liquid ammonia stream. The separated syngas is warmed by cross exchange with reactor effluent and recycled by the syngas loop circulator Ammonia Refrigeration

The liquid ammonia from the synthesis loop is flashed at two levels to provide the refrigerant to the synthesis loop chillers. The refrigeration compressor recovers the refrigerant ammonia vapors by recompressing and condensing the ammonia with cooling water. The refrigeration compressor is driven by HP steam turbine.

The refrigeration system is configured for production of ammonia at warm conditions for storage at ambient temperatures and pressure. The refrigeration system can be configured to produce liquid ammonia at atmospheric pressure and -33°C for storage in atmospheric tanks. Atmospheric pressure storage requires additional refrigeration and power.

Fuel Gas Treatment

A portion of syngas from the gasifier block is used as fuel for power generation. The fuel gas contains sulfur from the coal as Hydrogen Sulfide. There is currently no need to remove carbon dioxide from the fuel. Therefore the amine system for treating the fuel gas, MDEA, is selective for H2S. The fuel gas is scrubbed by amine solution in an absorber. The amine solution is stripped in a second tower to regenerate the solution and produce an H2S rich stream.


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Sulfur Recovery Unit

The sulfur laden streams from fuel gas treatment and from the AGR are combined and processed by the Sulfur Recovery Unit (SRU). The SRU is a package unit also referred as a “Claus Unit.” The sulfur laden stream is burned over catalyst that reduces the H2S to molten elemental sulfur. Molten sulfur from the unit would be consumed in the sulfuric acid plant already operating at the site. The SRU produces some steam for export.

Electric Power Generation

Power for the entire plant site, 120 MW, will be produced by a gas turbine driven generator (GTG). Fuel gas from fuel gas treating will be combined with the nitrogen/methane rich fuel from the fuel gas compressor. The GTG drives its own air compressor for combustion air. The exhaust from the gas turbine will be used to generate and superheat HP steam. To meet a discharge limit of 25 ppm of NOx, the gas turbine vendor has included a steam diluents flow of 77.6 Tons per hour. The steam flow has been added to the steam balance and produces approximately 19 additional MW of electric power.

At this time no other special equipment is included for boosting power generation (e.g. inlet air chilling, fuel gas saturation) or for environmental control (e.g. selective catalytic reduction). Since natural gas is not available and the gasification block cannot operate continuously, the operation of the GTG on diesel fuel oil as an alternate fuel is anticipated.

Steam System

The steam system recovered as waste heat by cooling process streams and powers some major equipment. Steam is generated at 103 barg by process heat in the CO shift area, the ammonia synthesis loop, and the waste heat recovery unit on the exit of the GTG. HP steam is also superheated by the waste heat recovery unit. The superheated HP steam is let-down to MP steam through the Syngas Compressor Turbine. To provide sufficient HP steam, supplemental fuel (treated syngas) is fired in the WHRU.

MP steam at 41 barg is generated and superheated by the gasifier unit. The MP steam is used as feed to the gasifier, but a significant amount of steam is exported for use by the rest of the plant. The SRU also produces some saturated MP steam for export. MP steam is also used as process feed in the CO shift area, power for the Syngas Compressor and Ammonia Refrigeration Compressor. Both compressor turbine drives are condensing type.


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LP steam at 10 barg is provided by letdown from the MP. The steam is used in the Sour Water Stripper and Sulfur Pit Eductors. LLP steam at 2 barg is also provided. The some steam is provided by flashing condensate from process heaters. The Deaerator is the largest user.

Condensate and Boiler Feed Water Systems

The deaerator is the centre of the condensate and boiler feed water systems. The packed section of the deaerator strips dissolved gases from the water entering the deaerator. The deaerator collects condensate from the process heaters, condensate from the turbine condensers, and fresh demineralized water for make-up.

The deaerator drum is the reserve of treated boiler feed water available for feed to the various boilers. Boiler feed water is provided at the appropriate pressure by the HP BFW Pump and the MP BFW Pump. Both pumps are currently included as electric powered but BFW pumps are usually the first pumps to be made steam turbine drive.

3.2.3. Urea plant : [Capacity – 3850 MTPD]

3.2.3.1. Main Plant Details

The capacity of Urea plant has been considered as 3850 MTPD. The most popular and widely used urea process technologies at present are ammonia stripping process of Saipem (SNAM Progetti) and CO2 stripping process of Stamicarbon. The ACES process of M/s. Toyo, has also been adopted in quite a number of plants across the globe, and is very much in commercial operation. However, for this process, the reference list is much shorter. In terms of overall efficiency, plant cost, specific consumption etc., all the three processes are very much competitive. The SnamProgetti ammonia stripping process has a major share of the urea plants in India with very good operational records in terms of achieving target production with very high on-stream efficiencies. The share of Snam Progetti is around 70% of the total urea capacity installed all over the world in last 10 years.

The raw material Ammonia and CO2 shall be provided at battery limit. The plant will have a normal on stream efficiency of 330 days.

3.2.3.2. Plant Description (Urea Plant)

Urea Plant has many renowned technologies which are equally comparable with respect to plant cost and energy consumption. For the proposed study, Saipem’s ammonia stripping process technology has been considered as depicted in below given figure3.3.


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Figure 3.3: PFD Urea Plant

Saipem ammonia stripping process is characterised by an urea synthesis loop operating at about 160 ata with an ammonia to carbon dioxide molar ratio at urea reactor inlet of 3.3 –

This allows a CO2 conversion of 63% into urea in the reactor itself, fitted with approximately 10-12 nos. of perforated trays which helps in preventing back-flow of the reactants as well as enhances the rate of absorption of the gaseous phase into the liquid phase of reactants. It may be mentioned that, urea synthesis reaction takes place in liquid phase only. Two major type of chemical reactions take place simultaneously inside the urea reactor:

2NH3+CO2=NH2-CO-O-NH4+32560 kcal/kmol of carbamate (at 1 atm, 25oC)

NH2-CO-O-NH4=NH2-CO-NH2+H2O -4200 kcal/kmol of urea(at 1 atm, 25oC)

First reaction is very strongly exothermic while the second reaction is moderately endothermic and takes place in the liquid phase at low speed.

In the downstream of the urea synthesis, the decomposition along with associated recovery of unconverted chemical reactants are carried out in three subsequent stages, namely, High Pressure Decomposition in HP


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Stripper, MP Decomposition in MP Decomposer and, finally, LP Decomposition in LP Decomposer. The decomposition reaction is the reverse of the first reaction one as shown above, viz.,

NH2-CO-O-NH4=2NH3+CO2 -Heat

As can be inferred from the aforesaid chemical equation, the reaction is favoured by reducing pressure and/or adding heat.

The urea reactor effluent solution enters the stripper, operating at the same pressure level as urea reactor, where a fair part of the unconverted carbamate is decomposed, by heat liberated from condensing steam on the shell side along with combined stripping action of excess NH3. As a result the overall yield of the HP synthesis loop referred to conversion of CO2 fed for urea synthesis, is as high as 83 to 85% (on molar basis).

Downstream of the stripper, the residual carbamate solution and ammonia are recovered in two recycle stages operating at 18 ata (namely MP section) and 5 ata (namely LP section) respectively.

Ammonia and carbon dioxide vapours from the stripper top, after mixing with the carbonate recycle solution from MP section, are condensed, at the same pressure level of the stripper itself, in the HP carbamate condenser, thus producing LP steam which is used in downstream sections. After separating the inert gases which are passed to MP section, the carbamate solution is finally recycled to the reactor bottom by means of a liquid/liquid ejector, which exploits HP ammonia feed to reactor as the motive fluid.

The liquid/liquid ejector and the kettle-type HP carbamate condenser as mentioned above, are arranged in a horizontal layout which is considered to be one of the main features of Saipem process.

Waste heat recovery from process streams in some parts of the process layout have been introduced as a part of recent modifications, thus allowing considerable savings in overall steam and fresh water consumption, viz.:

HP ammonia to urea reactor preheating with off-gas from LP decomposition stage

Heat to vacuum preconcentrator with off-gas from MP decomposition stage

Total recovery of process condensate as boiler feed water.

Urea plant based on Saipem urea technology is, characterised by the following main process steps:


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Urea Synthesis and NH3, CO2 recovery at high

Pressure

Urea Purification and NH3, CO2 recovery at medium and low Pressure

Urea Concentration

Urea Prilling

Waste Water Treatment

Auxiliary Installation

Steam Networks

Flushingnetworks Urea Synthesis and NH3, CO2Recovery at High Pressure

Urea is produced by synthesis from liquid ammonia and gaseous carbon dioxide. In the urea reactor, the ammonia and carbon dioxide react to form ammonium carbamate, a portion of which dehydrates into urea and water. The reactions are as follows:

2NH3+CO2 ↔ NH2COONH4

NH2COONH4 ↔ NH2CONH2+H2O

The conditions prevailing inside urea synthesis reactor, i.e., (T = 188-190oC, P =160 ata), favours reaction rate for the first reaction which occurs rapidly and goes to completion. The second reaction is very slow and reaction rate of second reaction determines the reactor volume.

The fraction of ammonium carbamate that dehydrates is determined by the ratios of the various reactants, the operating temperature and the residence time in the reactor.

The mole ratio of ammonia to carbon dioxide is maintained around 3.3 -3.6. The mole ratio of water to carbon dioxide is maintained around 0.5 -0.7.

The liquid ammonia feed provided at BL at around plus 20oC, to urea plant, is filtered through NH3 filters which, then enters urea plant via NH3 recovery tower and is collected in the ammonia receiver tank. From receiver, it is drawn and pumped to about 24 ata pressure by means of centrifugal ammonia booster pump. Part of this ammonia is sent to


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medium pressure absorber, the remaining part enters the high pressure synthesis loop.

The ammonia is pumped by centrifugal HP ammonia pump to the urea synthesis loop, at a pressure of about 230 ata. Before entering the reactor, ammonia is heated in the ammonia preheater and used as propelling fluid in the carbamate ejector is propelled up to the synthesis pressure.

The liquid mixture of NH3 and carbamate enters the urea reactor from the bottom where it reacts with the compressed carbon dioxide feed.

Carbon dioxide from regenerator of decarbonation section of ammonia plant is drawn as feed to urea plant via CO2 booster compressor, and enters the suction of CO2 compressor at around 1.4-1.5 ata and 40oC where it is compressed to a pressure of about 160 ata.

A small quantity of air is added to carbon dioxide feed at CO2 compressor suction in order to passivate the stainless steel surfaces of HP loop equipment, thus protecting them from corrosion from the reactants and reaction products.

The reaction products, leaving the reactor, flow to the upper part of stripper which operates at about 150 ata. It is a vertical falling film decomposer in which the liquid is distributed on the heating surface as a film and flows by gravity to the bottom. The HP stripper is essentially a vertical shell & tube exchanger with heating medium on the shell side, with an extended tube side top channel head specially designed for permitting uniform distribution of carbamate/urea solution over the top/inlet tube sheet. In fact, each tube has an insert-type distributor (ferrule) designed to distribute the feed uniformly around the tube wall in the form of a film. The holes of the ferrule act as orifices and their diameter and liquid head control the flow rate. As the liquid film flows downwards, it is heated and decomposition of carbamate and surface evaporation occurs. The carbon dioxide content of the solution is reduced by the stripping action of the ammonia as it boils out of the solution. The vapour formed (essentially ammonia and carbon dioxide) flows out from the top of the tube. The carbamate decomposition heat is supplied by condensation of saturated steam at 23 ata.

The mixed stream of overhead gases from the stripper and the recovered solution from the bottom of medium pressure absorber enters carbamate condenser where the condensing components of overhead gases other than the non-condensable get condensed and the solution is recycled back to the urea reactor through carbamate ejector.


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Condensation of overhead gases from stripper at a high pressure and temperature permits production of steam at 6 ata in the carbamate condenser and steam at 4.5 ata in the carbamate condenser.

The non-condensable gases coming out from the top of the carbamate separator consist of inert gases (passivation air plus inert with CO2 from B.L) containing little quantities of NH3 and CO2, which are sent directly to the bottom of the medium pressure decomposer.

Urea Purification and NH3, CO2recovery at Medium & Low Pressures

Urea purification and associated recovery of the overhead gases take place in two different pressure stages as mentioned below:

1ststage at 18ata pressure 2nd stage at 5 ata pressure

The exchangers where urea purification takes place are generally termed as decomposers because in these equipment the residual carbamate present in urea solution, are decomposed.

1stPurification and Recovery Stage at 18atm Pressure

The solution, with low residual CO2 content leaving the bottom of the stripper is expanded to a pressure of around 18 ata and enters the upper part of medium pressure decomposer. This equipment is mainly divided into three sections.

Top separator: The released flash gases are removed here before the solution enters the tube bundle.

Falling film type decomposer: The carbamate solution is decomposed here. Required heat is supplied by means of condensing steam at 6.0ata (in the upper part of the shell) and sub-cooling of steam coondensate flowing out of the stripper steam saturator (in the lower part of the shell). Urea Solution Holder: Purified urea solution obtained from the1st stage and having a concentration ofaround60-63%wt., is collected here.

The NH3 and CO2 rich gases, leaving the top of separator are sent to the shell side of the falling film vacuum pre concentrator, where they are partially absorbed in aqueous carbamate solution coming from the recovery section at 5 ata.

The total heat generated in the shell side, due to condensation/absorption/reaction of the reactants, is removed by evaporation of urea solution, coming from the 2nd purification step. In the process, concentration of urea solution increases to 84-86% wt., thereby resulting in considerable saving of LP steam in the vacuum concentration stage.


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From the shell side of vacuum pre concentrator, the mixed phase is sent to medium pressure condenser where CO2 is almost totally absorbed and condensation/ reaction heat is removed by cooling water coming from ammonia condenser.

The mixed phase effluent from MP condenser flows to medium pressure absorber bottom where the released gaseous phase moves upwards across tower and enters the rectification section. The medium pressure absorber tower is fitted with bell cap trays. The bottom section of the tower is used for CO2 absorption while the top part of the tower is utilised for NH3 rectification.

Pure ammonia is added as reflux to the top trays in order to balance the energy entering the column, and to remove residual CO2 and H2O contained in the rising stream of gaseous ammonia and inerts. Reflux NH3 is drawn from the ammonia receiver and sent to column by means of ammonia booster pump.

Saturated ammonia vapour along with inert, containing few ppm of CO2 (20-100 ppm), and coming out from top of the rectification section, is partially condensed in the ammonia condenser and the condensate is sent to the ammonia receiver.

Uncondensed vapours, saturated with ammonia, from ammonia receiver goes to ammonia recovery tower where additional amount of ammonia is condensed out from the vapours by scrubbing with liquid ammonia coming from the B.L.

The gaseous stream, leaving from top of ammonia recovery tower enters at the bottom of medium pressure falling film absorber. The residual ammonia content in the gas is drastically reduced by absorption in a counter current downward flow of ammonia water solution. Heat generated by ammonia absorption, increases the temperature of descending liquid, thereby tending to impede further ammonia absorption. To maintain the temperature at a reduced level, the heat of absorption is removed by cooling water flowing through the shell side of MP ammonia absorber.

The MP inert washing tower connected to the upper part of MP absorber consists of three valve trays where the inert gases are subjected to last stage of washing by means of pure water. Here the ammonia content of rising gas stream is minimal and consequently the temperature is less sensitive to absorption heat. Inerts containing traces of ammonia are finally vented through the vent stack.

From the bottom of MP ammonia absorber the NH3-H2O solution is recycled back to the medium pressure absorber by means of a centrifugal pump.


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The MP absorber bottom effluent is recycled by means of centrifugal HP carbonate solution pump to the synthesis recovery section.

2nd Purification and Recovery Stage at 5 ata

The solution, with very low residual CO2 content, leaving the bottom of the MP decomposer is expanded to a pressure of 5 ata and enters the upper part of low pressure decomposer, which is mainly divided into three sections:

Top separator: Released flash gases are removed here, before the solution enters the tube bundle. Falling film type Decomposer: Decomposition of carbamate solution is carried out here and the required heat is supplied by means of condensing LP steam at 6 ata (saturated). Urea Solution Holder: Purified urea solution obtained from the 2nd stage and having a concentration of around 69-71%wt., is collected here.

The gases leaving the top of separator are first mixed with the vapours coming from rectification section of the distillation tower and subsequently sent to shell side of HP ammonia preheater where they are partially condensed. The condensation heat is recovered by preheating of HP liquid ammonia (feed to urea reactor) in the tube side.

The ammonia pre heater shell side effluent is sent to LP condenser where the remaining NH3 and CO2 vapours are totally condensed. Condensation heat is removed by cooling water flowing in the tube side.

The carbonate solution at the exit of LP condenser is collected in carbamate solution accumulator. The carbonate solution is recycled back to the MP absorber, bottom by means of centrifugal, MP carbonate solution pump through the shell sides of vacuum pre concentrator and MP condenser respectively.

It is also possible to use part of the low-pressure carbamate solution as reflux in rectification section of distillation tower.

The carbonate solution accumulator is designed with a low pressure-washing tower in order to help the pressure control of 2nd recovery stage.

Urea Concentration

In order to prill urea, it is necessary to concentrate the urea solution up to 99.7% by wt. For this, two vacuum concentration stages are provided.

The solution leaving the LP decomposer bottom having about 70 % wt. urea, is sent first to the tube side of vacuum pre-concentrator and then


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pumped by to 1st vacuum concentrator both operating at a pressure of 0.33 ata.

The urea solution leaving the bottom of LP decomposer is expanded to the pressure of 0.33 ata and enters the upper part of vacuum pre-concentrator.

The vacuum preconcentrator is mainly divided in three parts:

Top Separator: Released flash gases are removed before the solution enters

the tube bundle. Vapours are extracted by1stvacuum system: Falling Film Type Evaporator: In evaporator, low residual carbonate is decomposed and water is evaporated. The required heat is supplied by partial condensation (in the shell side) of over head gas coming from the MP Decomposer; Bottom Liquid Holder: Urea solution having concentration 84-87%wt., is collected here.

The urea solution leaving the vacuum pre concentrator holder is sent by urea solution pump to the bottom of 1st vacuum concentrator operating at around the same pressure (i.e. 0.33 ata) of tube side.

Saturated steam at 4.5 ata is supplied to the1st vacuum concentrator shell side to concentrate the urea solution flowing in the tube side.

The mixed phase of gas and liquid coming out from the process side of 1st vacuum concentrator enters 1st vacuum separator from where vapours are again extracted by the 1st vacuum system while the urea melt (~95% by wt.), enters the bottom of 2nd vacuum concentrator operating at a pressure of 0.03 ata by gravity flow.

Saturated steam at 4.5 ata is supplied to the 2nd vacuum concentrator shell side to concentrate the urea solution flowing in the tube side.

The mixed phase of gas and liquid coming out from the process side of 2nd vacuum concentrator enters 2nd vacuum separator, from where vapours are extracted by the 2nd vacuum system while the urea melt (~99.75% by wt.) is sent to prilling section by means of urea melt pumps.

Urea Prilling

Urea melt leaving the 2nd vacuum separator holder is sent to the prilling bucket by means of a centrifugal pump.

Droplets of molten urea from the prilling bucket fall downwards along the natural draught prilling tower and gets solidified and cooled while encounters a counter current air flow. The solid prills are collected at the centre of prilling tower bottom by means of the conical double arm rotary scrapper and through a conical hopper, they fall on prilling tower belt conveyor.


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The urea lumps separator downstream removes any urea lumps or agglomerates which are eventually discharged directly and dissolved in the underground urea close drain Tank. Finally, the urea product is sent to B.L by belt conveyor.

Waste Water Treatment

This section treats the water containing NH3-CO2 and urea coming out of vacuum system, so as to have an almost NH3-CO2-urea free process condensate to be sent to B.L.

The process water containing NH3, CO2 and urea, coming from the vacuum systems, is collected in the process condensate tank, together, if necessary, with the drain solutions accumulated into underground carbonate close drain tank and fed to process condensate tank by means of pump. From process condensate tank the condensate is pumped by means of distillation tower feed pump to the upper part of distillation tower.

Before entering the column, the process condensate picks-up heat from the purified condensate leaving the bottom of distillation column itself, by means of distillation tower preheater.

The distillation column is provided with 55 nos. of trays and is separated into two main portions by a chimney tray between the trays numbered (from the bottom) 35 and 36.

Column process conditions are: � Pressure (top) : 5 ata

� Temperature (top) : 130oC

The condensate from the chimney tray is pumped by centrifugal hydrolyser feed pump to urea hydrolyser where process conditions are suitable to decompose urea into CO2 and NH3. In the hydrolyser live steam is added so as to provide enough heat to decompose urea.

Hydrolyser process conditions are:

� Pressure : 35 ata

� Temperature : :2 35oC� Steam availableat B.L :Temp. 380oC, press. 45-42 ata

The vapours coming out from the hydrolyser as well as the vapours from the top of the distillation tower are mixed with the LP decomposer overhead gas, upstream of ammonia preheater for heat recovery.

The hydrolysed condensate leaving the bottom of the hydrolyser is cooled by passing through hydrolyser preheater before entering


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distillation tower at the bottom of chimney tray where the final NH3 and CO2 stripping take place. LP steam (at a press. of 6 ata), injected directly at the column bottom, provides the necessary driving force for stripping.

The purified process condensate leaves the column bottom at 155oC and subsequently cooled to around 50oC in the following manner:

Distillation tower feed preheating by means of preheater.

Process condensate cooler.

The contaminants (i.e. NH3-CO2-urea) in this treated water are reduced to few ppm.

During start-up and upsets in waste water treatment section, the processed condensate is generally recycled to the process condensate tank until specified ppm of NH3 and urea are obtained.

Auxiliary Installation

In addition to main plant the following auxiliary installations are being provided for its smooth operation.

Flare System

The flare system shall comprise of the following two flares:

� Continuous Flare from MP section. � Discontinuous Flarefrom the following streams: - Vents from tanks - Process Condensate Treatment Section vent - Low Pressure Section vent - High Pressure Section vent

Carbonate Close Drain Tank

Tank is used to collect the drain solutions from various section of urea plant. These solutions by means of pump are sent to the process condensate tank for further processing in the waste water treatment section.

Urea Solution Tank

Tank is used to collect both the 70-75% urea solution in case of tripping of concentration sections, or urea melt in case of prilling section failure.


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In the same tank it has also been envisaged to recover the urea solution recycle coming from urea close drain tank after being filtered through filters.

Urea Solution Recovery Pumps

This pump is used for recycling the urea solution from urea solution tank to 1st vacuum concentrator. The urea solution contained in urea solution tank can be heated by means of LP saturated steam.

Urea Close Drain Tank

The buried tank is used for collection of urea solution drains and dissolving of lumps by means of stirrer. The submerged pump is used to send back the urea solution to the urea solution tank. The duty required for the urea lumps dissolution and the heating of the urea solution has been envisaged by direct injection with LP saturated steam.

Steam Networks provided in the Urea Plant

Following steam network have been provided in urea plant.

1. KP steam network at P=111 ata &T= 510oC 2. HP steam network at P=45 ata &T=385oC 3. MPsteam network at P=24.5 ata &T=325oC 4. MPsaturated steam network at P=23.2 ata &T=219oC 5. LMPsteam network at P=6-6.5 ata&T = 158-161oC 6. LPsaturated steam network at P=4.5 ata &T= 147oC

KP Steam Network P=111 ata and T =510oC

This steam is used to drive the CO2 compressor by means of CO2 compressor steam turbine driver.

HP Steam Network P=45 ata and T =385oC

This steam is used to feed the urea hydrolyser.

MP Steam Network P=24.5 ata and T = 325oC

This steam is withdrawn from the CO2 compressor steam turbine driver and/or HP networks. After desuperheating, this is used in stripper.

MP Saturated Steam Network P= 23.2 ata and T = 219oC

This steam is used in stripper. The condensate coming from stripper is collected in the stripper steam saturator and utilised in the lower part of MP decomposer. The condensate coming from decomposer is used to feed the carbamate condenser.

LMP Steam Network P= 6-6.5 ata and T = 158-161 oC


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The steam of this network is produced in boiler. It is utilized in the following equipment: � MP Decomposer � LP Decomposer � Distillation Column

The condensate is used to feed the carbamate condenser.

LP Saturated Steam Network P= 4.5 ata and T = 147oC Thesteamofthisnetworkisproducedinboilerandisutilisedinthefollowing equipment:

� 1stvacuum concentrator

� 1stvacuum system ejector

� 2ndvacuum concentrator

� 2ndvacuum system ejector � Steam tracing, flushing � Reinjection to turbine

The condensate coming from exchanger and tracing is collected in the steam condensate accumulator. Inside steam condensate accumulator the flash steam is condensed in steam recovery tower by means of the sub-cooled steam condensate coming from steam condensate cooler.

The condensate collected in the steam condensate accumulator is returned to Battery Limits by means of centrifugal pump.

Flushing Networks

Three flushing networks are being provided in the plant operating at the following pressures:

1) Very high pressure flushing (KW) P=176 ata 2) High pressure flushing (HW) P=24 ata 3) Low pressure flushing (LW) P=10 ata

Very high pressure flushing is used in the urea synthesis and HP recovery stages. High pressure flushing is used in the purification and recovery cycle, which operates at about 18 ata.

Low pressure flushing is used in the remaining parts of urea melt sections.

The condensate required for feeding the above flushing networks is taken from steam condensate accumulator at a temperature of 120oC.


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Centrifugal pump is used for 24 ata and 10 ata flushing. Reciprocating pump is used for 176 ata flushing.

3.2.4. Nitric acid plant: [Capacity – 1000 MTPD]

3.2.4.1. Process Description: Weak Nitric Acid (WNA)

Theproposed NitricAcid project is based onAmmonia as feed stock.

Nitric Acid processes can be classified into 4 categories according to pressure. Atmospheric pressure process

Medium pressure process

High pressure process

Dual pressure process

The choice of process route to be adopted in a specific project depends on factors like capacity of the plant, cost of raw material & utilities and NOx content in tail gases. Notable amongst them as offered by various licensors are:-

Low-pressure of about 1 ata: Khulman, Sumitomo, Stamicarbon, UHDE, PDIL.

Medium pressure of about 5 ata: Technimont, Pochiney, St. Gobin, UHDE, PDIL

High pressure of about 8-9 ata: Chemico, Du Pont, Bemag, Grand Parroisse, UHDE, PDlL

Duel pressure (where oxidation is effected at medium pressure and absorption reaction occurs at high pressure):

UHDE, Chemico, Stamicarbon,Grand Parroisse & Bemag

The different variation of process mentioned above follows common process principles. Ammonia gas is mixed with air and oxidized over Platinum-Rhodium (Pt-Rh) catalyst. The heat of reaction, to the large extent, is used to produce steam which is used to heat tail gas from the absorption unit. The generated steam and heated tail gas are utilized to drive air compressor. The oxides of N2 are further oxidized and absorbed in water to form Nitric Acid.

The pressure converters are most compact, but associated with lower conversion efficiency, which require multi layers of Pt-Rh catalyst gauge. The reactor is operated at higher temperature range upto 960oC. The conversion efficiency is lower because side reactions are enhanced due to greater contact time between ammonia and converted gas as they travel through greater depth of catalyst bed.


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Weak Nitric Acid(WNA)

The WeakNitricAcid (WNA) plant process description is based on UHDE’s Mono-High pressure technology.. As per process flow scheme, following sequence will be followed.

Figure 3.4 Process flow scheme Weak Nitric Acid (WNA)

Air Compression System

Air shall be made available at the battery limit of the unit. The required pressure is around 9.0 to 8.5 kg/cm2. The air shall be compressed to the required pressure, if required, by an Air Compressor through an air prefilter. To utilize the energy of the tailgas and generated steam the air compression system shall consist of the following items:


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Air Compressor TailGas Expander Steam turbine

The air is compressed to 8.5 kg/cm2 absolute and is divided into two parts; one is primary air going to Air-Ammonia Mixer and the other is secondary air stream. In case air at required pressure, is provided at B.L the steam and tail gas energy shall be utilized elsewhere.

Ammonia Evaporation

Liquid ammonia from the battery limit is passed through Liquid Ammonia Filter before entering Ammonia Evaporator in which ammonia is evaporated by close Circuit Cooling Water System. Oil and water present in the ammonia feed is separated out in Oil Separator. The vapour ammonia is superheated to about 80oC.

Combustion and Heat Recovery

Primary airflow is measured and ammonia flow is automatically controlled in a pre-determined ratio. Both are intimately mixed in Air Ammonia Mixer, which is of special design and then filtered in Mixed Gas Filter.

Thoroughly mixed air ammonia mixture enters the top of the ammonia burner and is distributed over the catalyst gauge through an integrated perforated plate located at the top of the Burner in order to provide an optimum gas distribution over the total surface of the catalyst. The platinum and rhodium catalyst gauge is there in the catalyst basket at the lower part of the burner. Ammonia is oxidized to nitrous oxide over the catalyst gauge at a temperature of about 860-870oC. The hot gas then passes through Waste Heat Boiler whereby the gas is cooled down to about320oC. Beneath the catalyst gauge a filling ring package is inserted into the lower catalyst basket in order to support the catalyst and to create an equalized gas and heat distribution by a certain gas pressure drop. The burner load is selected in view of optimized ammonia conversion rates and reduced pressure losses considering a certain margin to the flame velocity of the ammonia

Cooling of Nitrous Gas

The nitrous Gas mixture leaving the boiler is further cooled down in a series of heat exchangers including Tail Gas Heater-II, Boiler Feed Water Heater, Tail Gas Heater-I and Cooler Condenser. The final gas temperature is about 50oC. The reaction water gets condensed in the Cooler Condenser and is separated as Weak Nitric Acid. The weak acid is pumped to the appropriate plate in Absorption Tower.


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The cooled nitrous gas is mixed with secondary air from Bleaching Tower and is fed to the bottom of the Absorption Tower.

Catalyst Recovery System

The oxidation catalyst comprises a number of platinum/rhodium gauges. Provision is made for catalyst recovery. Catalyst is recovered in PLUSPAC Recovery System. It is placed below oxidation catalyst gauge. Recovered catalyst is refined for reuse.

Absorption System

The absorption system consists of Tower equipped with sieve trays and cooling coils. Demineralised water, pre cooled with chilled water, is fed at the top of the Absorption tower. The absorption heat is removed in the tower by circulating cooling water. Arrangements of the cooling coils are governed by process design consideration. The product at 60% concentration is extracted from the bottom tray of Absorption Tower and fed to the Bleaching Tower.

Denitration

The brown nitric acid containing absorbed nitrous gases is denitrated in the Bleaching Tower by contacting hot secondary air in bubble cap trays. The nitric acid is extracted from the bottom of the tower and sent to storage tank under the system pressure after cooling it in Product Acid Cooler. The secondary air laden with nitrous gas is mixed with main nitrous gas flow before feeding to Absorption tower.

TailGas

The tail gas after absorption tower having NOx 500 ppm goes to Catalytic Converter for lowering NOx level in the Tail gas. Tail gas after NOx reduction through Catalytic Converter is returned back to weak Nitric Acid plant and passes through Tail Gas Pre heater, Tail Gas Heater-I and then Tail Gas Heater-II in sequential order. The hot tail gas is then led to the Tail Gas Turbine for recovery of part of the total compression power. Finally, the tail gas having ≤ 50 ppm is sent to NOx abatement section after exchanging heat with DM water. The residual gas which has NOx well below the Permissible limit is vented to the atmosphere through Tail Gas Stack.

Steamand Boiler Feed Water System

Steam is produced in the Waste Heat Boiler at a pressure of about 42 kg/cm2abs and 420oC, part of which is supplied to steam turbine and excess steam is exported. A minimum flow of saturated steam is required for process heating duties for Deaerator, Oil Separator and


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Ammonia Superheater. Deaerator accepts Deminerelized water from battery limit. Deaerated boiler feed water is pumped by boiler feed water pump to the Boiler Drum through BFW heater where it is heated at 160oC.

Cooling System

Cooling water from battery limit runs in parallel through lower part of absorption tower and product acid cooler. Exit water from lower part of absorption tower runs through cooler condenser. The rest of the trays of absorption tower are cooled with recirculated chilled water available by the evaporation of liquid ammonia through ammonia evaporator.

Weak Nitric Acid (60% conc.) of annual capacity 0.33 MMTPA is produced as an intermediate product which will be used for the production of ammonium nitrate.

Concentrated Nitric Acid which has a vast demand market in India will also be produced from PPL using weak nitric acid as raw material for it.

Out of 0.33 Mil MTPA, 0.05 Mil MTPA will be concentrated to 98-99 % and termed as concentrated nitric acid and would be in the final product portfolio of PPL.

3.2.4.2. Process Description: Concentrated NitricAcid(CNA):

Concentrated Nitric Acid (98 to 99 percent concentration) can be obtained by concentrating the weak nitric acid (30 to 70 percent concentration) using extractive distillation. The distillation is carried out in the presence of a dehydrating agent. Concentrated sulfuric acid (typically 60 percent sulfuric acid) is most commonly used for this purpose. The nitric acid concentration process consists of feeding strong sulfuric acid and 55 to 65 percent nitric acid to the top of a packed dehydrating column at approximately atmospheric pressure. The acid mixture flows downward, countercurrent to ascending vapors. Concentrated nitric acid leaves the top of the column as 99 percent vapor, containing a small amount of NO2 and oxygen (O2) resulting from dissociation of nitric acid. The concentrated acid vapor leaves the column and goes to a bleacher and a countercurrent condenser system to effect the condensation of strong nitric acid and the separation of oxygen and oxides of nitrogen (NOx) by-products. These by-products then flow to an absorption column where the nitric oxide mixes with auxiliary air to form NO2, which is recovered as weak nitric acid. Inert and unreacted gases are vented to the atmosphere from the top of the absorption column. Emissions from this process are relatively minor. A small absorber can be used to recover NO2. The enclosed figure presents a flow diagram of concentrated nitric acid production from weak nitric acid.


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Emissions consist primarily of NO, NO2 (which account for visible emissions), trace amounts of HNO3 mist, and ammonia (NH3). By far, the major source of nitrogen oxides (NOx) is the tailgas from the acid absorption tower. In general, the quantity of NOx emissions is directly related to the kinetics of the nitric acid formation reaction and absorption tower design.

The 2 most common techniques used to control absorption tower tail gas emissions are extended absorption and catalytic reduction. Extended absorption reduces NOx emissions by increasing the efficiency of the existing process absorption tower or incorporating an additional absorption tower. An efficiency increase is achieved by increasing the number of absorber trays, operating the absorber at higher pressures, or cooling the weak acid liquid in the absorber. The existing tower can also be replaced with a single tower of a larger diameter and/or additional trays.

Figure: PFD of Conc. Nitric Acid

3.2.5. Ammonium Nitrate plant:[Capacity – 1100 MTPD]

3.2.5.1. Technology(Ammonium Nitrate Plant)

Ammonium nitrate is manufactured by neutralization of nitric acid with ammonia. Products can be made available in solution, crystal and prilled form. There are number of processes available in the international market for ammonium nitrate production. The main differences between these processes are, concentration of reactants, pressure of neutralization and method used to remove solid phase from the solution. The following Table-3.1 shows the various processes with special features.


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Table 3.1: Various Processes for Ammonium Nitrate

Name of Process Special Features

Espindesa Process High versatility, different grades can be made.

Mississippi Process Good efficient control prilling.

Fisons Process Low solution hold up of Ammonium Nitrate. Simplicity and ease of control.

ICI Process Neutralization, evaporation, incorporating anticaking treatment prilling.

Stamicarbon Process Low & high-density products.

NameofProcess SpecialFeatures

Mitshubishi Process High purity,non-caking,adequatehardness,high oil absorption for ANFO.

Sumitomo Process Prilled or crystal form produces High yield, improved product quality by additives.

UHDE Process Low temperature & high concentration in single step.

NorksHydro Process Pressure neutralization, high concentration melts to prilling resulting less water to be removed from drying section, high-density product.

The chemistry and basic process steps followed in all these processes are essentially same with minor changes in design of particular equipment or control system. The processes offered by various licensors are all proven and plants based on these processes are in operation in various parts of the world.

3.2.5.2. Process Description

The proposed Ammonium Nitrate project is based on Ammonia & Nitric Acid as a feed stock. Ammonium nitrate is manufactured by neutralization of nitric acid with ammonia. Products can be made available in solution, crystal and prilled form. There are number of processes available in the international market for ammonium nitrate production. The main differences between these processes are, concentration of reactants, pressure of neutralization and method used to remove solid phase from the solution. The process description of Ammonium Nitrate plant is given in Figure 3.5


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The process will be based on neutralization of ammonia and nitric acid in one stage. The scheme envisages production of low density Ammonium Nitrate prills. The main sections of the plant are described below:

Vapour Ammonia Superheating

Vapour ammonia will be received from weak Nitric Acid plant at 7.0 kg/cm2 abs pressure and 13oC temperature. It will be superheated to 120oC by steam before feeding to the neutralizer.

Figure 3.5 PFD of Ammonium Nitrate

Neutralization

60% nitric Acid will be directly taken to the Head Tank located within the plant. Nitric acid from Head Tank will be fed to the Neutralizer. Liquid entrained in neutralizer vapour will be separated and returned to Neutralizer. Then the vapour will be scrubbed with acidic liquor to minimize loss. Recovered liquor will be fed to Neutralizer. The Neutralized Ammonium Nitrate at about 82% concentration will be taken to a tank where small amount of ammonia vapour will be bubbled to make the liquor alkaline.


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Neutralization will take place according to the following exothermic reaction at about 130oC temperature and 1.1 kg/cm2 pressure.

NH3 (g) + HNO3 (1) = NH4 NO3 (1) + 350 kcal/kg

The neutralized liquor will be stored in Evaporator Feed Tank and will be pumped to the Evaporator Head Tank through a solution filter.

Concentration

The feed liquor and the recycle solution will be concentrated to 97-98% melt in a single effect natural circulation type evaporator provided with one steam heated external calendria heater. A pressure of 250 mmHg will be maintained in Evaporator by a Surface Condenser and Steam Ejector. The Ammonium Nitrate melt will be taken to Melt Tank via a filter. A submerged pump will be provided in Melt Tank to pump melt to Head Tank at the top of the Prilling Tower.

Prilling

Ammonium Nitrate melt will flow by gravity from Prilling Tower Head Tank to the sprayer provided at the top of the Prilling Tower chamber. Droplets of the melt will shower down the tower counter-current to an upward flowing stream of air forced through the tower by centrifugal fans provided on ground floor. Melt droplets will be cooled by the air stream to approximately 80oC and formed into small prills with 2 to 3% moisture. Prills will be collected at the base of the tower over a belt conveyor.

Salt Handling

Wet prills will be conveyed to the Feed Hopper where lumps will be separated and recycled back. Correct size material from the hopper will be elevated by a Bucket Elevator and fed to the Dryer. In the Dryer moistures content in Prills will be reduced to 0.3% (max) by hot air. The air will be heated by steam in Dryer Air Heater. The dry prills will be cooled in Cooler with dehumdised air. The prills from cooler will be fed by a Bucket Elevator to product screen in which oversize and undersize prills will be separated from the correct size prills. The correct size prills will be coated with liquid coating agent in Coating Drum.

Bagging

Correct size prills will be taken to the product bunker from the bottom of the product bunker. The prills will be weighed in 25 kg batches by weighing cum tipping machine and filled in polythene-lined bags, which are kept inside hessian bags to provide strength. After heat-sealing the polythene bags the hessian bags will be separately stitched. The bagged product will be shifted to the product storage.


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Recovery Section

Dust laden air from dryer and cooler will be sucked by exhaust fans and scrubbed in a Dust Scrubber with dilute Ammonium Nitrate solution. A circulation pump will be provided to circulate the solution. Condensate from Surface Condenser will be collected in a tank and pumped to Head Tank. Condensate from Head Tank will be fed to the top of Neutralizer Scrubber and the suction side of the Dust Scrubber Circulation Pump for make up. Overflow from the Dust Scrubber bottom and recovered liquor from Neutralizer Scrubber will be taken to the Dissolution Tank.

Lumps from the Feed Hoper will be shifted by a Wheel Burrow. Oversize and undersize prills will be directly discharged from the Product Screen. All the recycle Ammonium Nitrate will be taken to the Dissolution Tank where these will be dissolved in dilute solution coming from the Dust Scrubber. The recycle solution will be transferred to Evaporator by Recycle Solution Pump through Solution Filter and Head Tank.


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3.2.6. DAP PLANT: [Capacity – 1300 MTPD]

3.2.6.1. Technology

The proposed fertilizer complex shall have the facilities for the production of Di- ammonium phosphate (DAP) as finished product with raw materials Sulphuric acid, Phosphoric acid and Ammonia being supplied along with all required offsites and utility facilities at the plant battery limit. The process descriptions of the main and intermediate plants are discussed below in Figure 3.6

3.2.6.2. Chemistry of the Process

Di ammonium phosphate (DAP) is formed when phosphoric acid reacts with two moles of ammonia.

H3PO4+ 2NH3 → (NH4)2HPO4 The above reaction is exothermic.

3.2.6.3. Plant Description

Raw materials Dosing system

Solid raw material fed to the process plant is mainly filler viz. sweet river sand or ETP sludge,-spec material is also transferred from off spec/filler storage to process plant.

Filler material is charged either manually or by pay loaders into the offspec/filler hopper placed over inlet chute of offspec/Filler bucket elevator Filler/offspec will be fed to this elevator uniformly by vibratory feeder.

Slurry Preparation

The process is based on the operation of single pipe reactor fitted within the granulator, operating on gas Ammonia. Ammonia is supplied from Ammonia transfer pumps from Ammonia storage tanks to pipe reactors.

The required N/P ratio is finally reached in the granulator by injection of additional liquid Ammonia into the solids bed through a ploughshare ammoniation system.

The production of DAP shall be controlled by flow controlling of ammonia and phosphoric acid in the pipe reactor accurately through ratio control. The N:P ratio is controlled within the range of 1.8 to 2.


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The pipe reactor installation facilitates the slurry of Ammonium phosphate and small amount of sulphate formed by neutralization reaction inside pipe reactor to be sprayed directly onto the solids bed of the granulator this pipe reactor (P.R.) slurry have temperatures ranging from 135 to 150oC and moisture content between 4 and 8%.

Phosphoric acid fed to pipe reactor is made by the acid coming from the scrubbing system, complemented by the concentrated acid fed to pipe reactor vessel plus, occasionally, some process water.

Granulation

To make DAP, all the raw materials and recirculated solids will be fed to the granulator. Recycle flow put normally an upper limit in the solids capacity of the plant. The recycle is constituted by fines, crushed oversize and part of the commercial product, which is returned to the granulator to keep the water and heat balance.

Granulator is equipped with a lump kicker to prevent any lump from remaining inside the drum disturbing the flow of solids and avoiding their normal flow in the dryer. Lumps kicker will reject the lumps to an attached grizzly, which will disintegrate them by the rotating action.

Solids leaving granulator, normally with moisture content around 1.8-2.4% are gravity fed to dryer, in order to achieve the final guaranteed moisture of 1.0%.

Gases emitted in the granulator are sucked towards the Granulator Pre-scrubber to recover most of the evolved dust and ammonia.


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Figure 3.6: PFD of DAP

Product Drying, Screening and Grinding

In the Rotary Drum Dryer, the moisture in the solids coming from granulator is reduced with a preheated air in a co-current flow.

Dryer drum exit is equipped with a grizzly, to avoid any lump, which could block the dryer elevator. If any lump is coming out, grizzly takes it up and throws it into a hopper, which feeds the lump crusher. Crushed lumps will join the rest of dryer discharged product on exist dryer belt conveyor. Air leaving the dryer contains some Ammonia escaped from the product as well as dust and water evaporated from product when drying.


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Cyclones separators are used to separate the carried dust and the air is subsequently scrubbed to get free from ammonia.

Dried product is fed to the process screens. The on-size product from screen passes directly to a recycle regulator. The separated over-sizes fall by gravity into oversize mills.

Undersize product from screen falls by gravity to the recycle belt conveyor.

Air Desaturation Unit

The purpose of the Air De-saturation Unit is to chill air to low temperature to reduce moisture content and to heat the outgoing air from the chilling unit to reduce the relative humidity of the air going to the Rotary Cooler. This is required to prevent moisture pick up by outgoing product from the ambient air provided for cooling.

Final Product Treatment

On-size product is cooled down using conditioned air from the Desaturation unit. DAP having critical relativity humidity (CRH) of about 75% at 30oC, the product DAP picks up moisture if the ambient air has a higher relative moisture. Air heater increases air temperature and consequently decreases air relative humidity.

Dust coming out with the air leaving the cooler and plant dedusting system is recovered and fed back to the recycle conveyor. Cooled product is fed to the final product belt conveyor.

Gas Scrubbing

The gas scrubbing is carried out in several washing steps e.g. in a granulator pre- scrubber, dryer scrubber, Granulator scrubber, Cooler and dedusting scrubber and final tail gas scrubber, where the streams leaving the mentioned three scrubbers will be washed.

The gases leaving Dryer scrubber together with the gases from the granulator scrubber and Cooler & Dedusting scrubber are fed to the Tail gas scrubber. Scrubber exhaust gases will be cleaned with acidulated water to reduce its dust, fluorine and ammonia content. To achieve this, the scrubber liquor is slightly acidulated with sulphuric acid in order to absorb both Ammonia and Fluorine. Process water is used as a washing liquid in the scrubber.

Defoamer is used in the scrubbers and vessels where phosphoric acid is used to prevent the formation of foams.


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3.2.7. GSSP PLANT: [Capacity – 1650 MTPD]

3.2.7.1. Technology

The unit operation of SSP production is a very simple. The process involves rock phosphate grinding and mixing with sulfuric acid. No process license etc. is required to be obtained from any process licensor. It has been considered that the proposed plant shall achieve 300 days of operation at 100% capacity utilization. This requirement is vital for profitability as well. This can be achieved only through robust plant design, equipment selection, reliable equipment fabricator and a competent plant designer with proven capabilities.

3.2.7.2. The Chemistry

Single super phosphate is produced in a twosteps process.

2Ca5(PO4)3F+7H2SO4+3H2O → 7CaSO4+3Ca(H2PO4)2.H2O +2HF

Step1 -Phosphate rock blending andgrinding

The phosphate rock is ground until at least 75% is less than 75 µm (microns) in diameter, and then analysed for composition. The proportions of various rock varieties are blended to give the desired composition.

Step2 – Superphosphate manufacture

Ground Phosphate rock, sulfuric acid and water are mixed and then allowed to dry and react to give the superphosphate - a mixture of CaSO4 and Ca(H2PO4)2.H2O.

The SSP manufacturing process will comprise of two basic steps: The basic reaction in the manufacture of superphosphate is the reaction of insoluble phosphate rock with Sulfuric Acid to form the soluble Calcium di- Hydrogen Phosphate, Ca(H2PO4)2.

This is described by the following equation:

(PO4)-3+H2SO4→ H2PO4-+ (SO4)-2

The phosphate rock imported from various sources, is mainly fluorapatite, (Ca5 (PO4)3F). The actual composition of the phosphate rock varies with the source. The reactions occurring during the production of superphosphate are complex and are usually summarised as follows:

Ca5 (PO4)3F + 5H2SO4 → 5CaSO4 + 3H3PO4 + HF


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Ca5 (PO4)3F + 7H3PO4 + 5H2O → 5Ca(H2PO4)2.H2O + HF

These reactions can be combined to give the overall equation:

2Ca5 (PO4)3F + 7H2SO4 + 3H2O → 7CaSO4 + 3Ca(H2PO4)2.H2O + 2HF

There are other reactions occurring at the same time. For example, virtually all the HF reacts with other silica minerals associated with the fluorapatite (silicates, quartz) to form silicon tetra fluoride. These gaseous emissions are recovered as hydro flurosilicic acid (H2SiF6) in the scrubbing system. Carbonates in the rock also react with sulfuric acid.

Figure 3.7: Block Diagram for production of SSP

The production of super phosphate consists of three distinct steps.

Step1 - Phosphate rock blending and grinding

Phosphate rocks, from different sources have different phosphate, fluoride and silica contents. These rocks are mixed in the blending plant to produce a product with a total phosphate concentration of 31.5%. The phosphate rock mixture is passed through a ball/hammer mill which reduces the particle size to 0.5cm or less. The coarsely ground rock is then passed through an air swept roller mill (Bradley Mill) to attain a rock


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grist of approximately 75% less than 75 microns. The powdered rock is stored in a large hopper. The powder handling system is fitted with a dust collection system.

Fine Phosphate is transported to ground Phosphate Hopper to be used for PSSP production. Dilution and Cooling Systems are used to Dilute the concentrated Sulphuric Acid 98.5% to 70% concentration, and to cool down the produced Diluted Acid (178°C), because the Dilution Process is exothermic. Dilution Process (as a result of mixing water with Conc. Acid) and cooling system is sophisticated systems due to the highly corrosive effect of the Diluted Acid. For that, all parts in contact with Diluted Acid made from special Graphite can bear the operating conditions such as: Diluted acid inlet Temperature: 178 °C Pressure inside the cooler: > 2 bars

This system is fully automated and provides all the safety precautions necessary to guarantee safe operation not only for operators but also for the Graphite Cooler and cable to control the outlet concentration and temperature. The Diluted Acid (DSA) is stored in Storage Tank lined with Rubber and acid bricks. The cooling water necessary to cool the DSA is re-circulated in water Cooling Tower to minimize the consumed water and in turn the waste water.

Step2 –Super phosphate manufacture

Ground Phosphate is sent to the PSSP production plant using suitable material handling equipments such as completely sealed Screw Conveyors, Bucket Elevators etc. Diluted Acid is pumped to PSSP production plant using special chemical pumps. PSSP plant is designed to use 70% Sulphuric Acid, recycled scrubber liquor and ground phosphate rock. It is based on the most technically and economically up to date feasible process and is compatible with Environment Protection Requirements

Feed Metering is achieved with Automatic Control System. The ground rock and sulfuric acid are reacted in a horizontal mixer. A continuous flow of the sloppy mix drops out of the mixer into the Broad field Den. Broad Field Mixer developed specially for PSSP manufacture is a large two stage horizontal paddle mixer, the two stage design ensures complete mixing and good chemical reaction (quality) of SSP powder. Varying speed drive and adjustable paddle configuration allows selection of optimum mixing conditions for all phosphate rocks with Acid.

The den consists of a slowly moving floor (approx. 300 mm/min), built from steel tee slats, with polypropylene sealing strips, to prevent leakage, to enable setting of the cake and reciprocating sides, lined with cement fondu (special tile) and are driven by two geared motor units through two heavy crank arms which prevent the superphosphate


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adhering to the walls. The partially matured superphosphate cake is cut out of the den with a rotating cutter wheel after a retention time of approximately 30 minutes.

A sturdy steel framework carries the den and mixer. A rotary cutter excavates the SSP cake from Den. Stainless steel blades are mounted on a steel frame and shaft carried on externally mounted Plummer block bearings. The outlet PSSP fertilizer conveyed to storage area where remaining reaction of the SSP is completed by spreading the cut lumps on the floor and reshuffling the hips by means of aover head crane situated in the curing building. The SSP is allowed to complete the reaction and attain the powdered form which takes around 21 days.

Granular Single Super phosphate

The SSP powder will be fed to the granulation plant. In the rotating granular drum the powder SSP will be mixed with water up to 14%, which results in the formation of granules. The granules will then be sent to the Dryer Drum for heating up to 600°C temperatures to reduce of the moisture content to 6 %. The hot granules will then be cooled in the cooler drum from where they will be send to the vibrating screens for desired mesh. Two types of screens will be used; Undersize Vibrating Screen and Oversize Vibrating Screen.

Under Size Vibrating Screen (Size-1mm)

The oversize material of this screen will be sent to the grinding unit and the undersize material will be recycled to the granulator drum.

Oversize Vibrating Screen(Size+1.4mm)


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The oversize material of this screen will be sent to the crusher from where it will be taken to the granulator drum. The properly sized material will be packed in 50kg HDPE Bags.

SSP dust evolved in the process of granulation will be scrubbed with the help of twin cyclone system through blower provided for dryer drum and the clean air will then be discharged through a stack of 30 m height.

The grinding of rock phosphate may lead to emissions of dust. Pulse jet dust collector will be provided to control dust emissions. A stack will be provided at the ball mill. At mixer and Den, during acidulation, gases will be liberated. These gases from mixer and Den will be passed through absorption stages as under;

a) Ejector b) Cyclone separator c) Venturi Scrubber d) Multi Stage Scrubbing Towers

Fresh water or effluent water will be charged in to sumps of the ejector, Cyclone separator, Venturi and scrubbing towers on the day to day basis. After utilization of water in the circulation for gas scrubbing system, the dilute acid (H2SiF6) will be taken from all the circulation sumps to a common thickener sump every day. The ejector, Venturi and separator will scrub the gases and gases will go further to blower and will be discharged through stack of 30 meter height where the wind velocity is high and thus get further diluted.

The effluent will be collected in a common sump along with silica. This silica will settle down and will be used as filler material for SSP. The dilute acid (H2SiF6) will be discharged in to the same sump and will be reused for acid dilution in SSP Process. Thus a Zero Discharge system will be achieved.


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3.2.8. Aluminium fluoride plant: [Capacity – 9500MTP Annum]

3.2.8.1. Anhydrous hydrofluoric acid (AHF) from FSA

HF Gas Generation:

Hydrogen fluoride (HF) is produced by the decomposition of an aqueous solution of strong Fluosilicic acid (45% H2SiF6.SiF4) in the presence of Sulphuric acid (H2SO4) in a stirred reactor under closely controlled conditions. Strong sulphuric acid 98% is fed and is acting as a dehydrating agent.

Products of decomposition of fluosilicic acid are gaseous silicon tetra fluoride (SiF4) and hydrogen fluoride (HF). The HF is adsorbed into the sulphuric acid and leaves the reactor with the sulphuric acid. Hydrogen fluoride (HF) is recovered by evaporation and dried with fresh sulphuric acid. A two-stage evaporation system using boiler and stripper column is used. Gaseous hydrofluoric acid generated as described is then condensed and purified by distillation to obtain the desired product quality and finally is sent to the intermediate AHF Storage Tank.

H2SiF6.SiF4 (aq.) + H2SO4 2 SiF4 + 2 HF (aq.) + H2SO4 (aq.)

Next the Silicon tetra fluoride (SiF4) gas leaving the reactor after drying column is absorbed into the Fluosilicic acid (H2SiF6) feed solution to generate additional acid and silica according to the chemical reaction:

5 SiF4 + 2 H2O 2 H2SiF6.SiF4 (aq.) + SiO2 (hydrate)

The strong solution of flurosilicic acid is sent to the silicon tetra fluoride reactor.The diluted sulphuric acid stream obtained after stripper is cooled down prior storage and recirculation to the phosphoric acid plant.

AHF liquefaction and Purification

The crude HF gas is sent the purifying column. From this column the gases pass to two condensers in series, where the bulk of the hydrofluoric acid is liquefied using chilled water of controlled temperature.

Condensed hydrofluoric acid from the first condenser is sent back as reflux to the top of the purifying column. From the second condenser the partially purified hydrofluoric acid is fed to a pressurised rectifying column, where light impurities, mainly sulphur dioxide and silicon tetra fluoride, are removed as overhead stream. The pure hydrofluoric acid leaves the rectifying column via the distilled acid cooler to AHF storage tank, using the pressure of the rectifying column as the driving force. The gaseous overhead products stream from the rectifying column and second HF condenser are passed through a packed H2SO4 absorption column, down which sulphuric acid is circulated to absorb most of the


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remaining hydrofluoric acid. A stream containing hydrofluoric acid in sulphuric acid is then pumped back. Gases leaving the H2SO4 absorption column are contacted with water in two ejector scrubbers in series. These remove silicon tetra fluoride as fluosilicic acid. This stream is re-circulated.

Water effluent sent to the neutralisation is adjusted to minimize the losses of fluorine and decrease the costs of treatment. Tail gases leaving these scrubbers via the tail gas exhaust fan are given a final cleaning in the central absorption scrubber washed with water before emission to atmosphere.

Figure 3.8 Anhydrous hydrofluoric acid (AHF) from FSA

AHF Safety Storage

HF sub-cooled is stored under atmospheric pressure in tanks installed inside a larger containment tank. The heat losses are minimized by drying the air inside the containment tank. The air is monitored continuously to detect any leaks of HF. A back-up chiller is provided on emergency power. The system is corrosion free after 20 years operation.

The product AHF delivered by Containers flows under pressure via the AHF Circulation Cooler to the AHF Storage Tanks. The main storage system comprises of AHF Storage Tank(s), T-421 A/B/C, within the AHF Storage Containment Tank, T-422. The stored acid is re-circulated through the AHF Circulating Cooler, E-420 and can be cooled down to say +5 to -8 °C according to coolant.

The combination of storing AHF acid at low temperature within a double skin system offers maximum safe storage of this dangerous chemical.

The storage system is equipped with adequate pressure control and safety instrumentation. The gas from the inside of the outer containment


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is being continuously dried and sampled for HF. A cabinet including a detector for fluorine is included. Hardwired level switch is provided to trip in case of high high alarm all feeds of fluorspar, acid, oleum, acid recycling and any pump that could fill the tanks with AHF.

Double bottom valves welded are provided on each tank for maximum safety. Manual operated is making the system simpler and more safe to operate.

3.2.9. High-bulk-density Aluminium Fluoride (HBD AlF3) from HF

The Alumina hydrate is stored into the “Day-Shift” Silo (Hydrate Silo). The Hydrate is discharged batchwise from the Silo by operating the Discharge Screw (Hydrate Silo Discharge Screw) for feeding the Hydrate Feed Bin.

The Discharge Screw is controlled by switches onto the Hydrate Feed Bin which is suspended on two Load cells and switch onto the Hydrate Distributor Bin. The Hydrate is then fed batchwise from the Hydrate Feed bin to the Hydrate Distributor Bin where a level of hydrate is maintained which acts as a vacuum seal and keeps the vacuum in the system.

Figure 3.9 High-bulk-density Aluminium Fluorides (HBD AlF3) from HF

The load cells are used to totalize the alumina fed to the Aluminium Fluoride Reactor. It is furthermore indicating exactly the capacity of the


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Aluminium Fluoride Reactor. The alumina tri-hydrate is fed continuously to the Reactor via two Feed Screws.

First Hydrate Feed Screw is feeding most of the material and is controlling the temperature in the top bed. The speed of the Hydrate Feed Screw is adjusted according to the temperature in the bottom bed and top bed.

The Feed Screw is feeding the material via a fluidisation cup and this for avoiding the agglomeration of hydrate especially at start-up. Hydrate Bottom Feed Screw feeds the bottom bed at a small feed rate for diluting the bottom bed and for obtaining a lower grade for the aluminium fluoride product. This is controlled manually by setting the speed of this screw manually.

The reaction can be represented by the following equations:

Al2O3.3H2O Al2O3 + 3 H2O

Al2O3 + 6 HF 2 AlF3 + 3 H2O

Since the overall reaction is exothermic, the AlF3 Reactor does not need supplementary heat during normal operation. During start-up it does need to be preheated using the Combustion Chamber. This item is also used for keeping warm the aluminium fluoride Reactor if the feed of HF gas is interrupted. Solids carried out of the Reactor are recovered by cyclone separators. Under rated capacity, the dust collected in cyclone 1 is not re-circulated to the Aluminium Fluoride Reactor. Only under high load or if the quality needs to be improved dusts are re-circulated to the aluminium fluoride reactor preferably to the top bed if the grade has to be increased and preferably to the bottom bed if both the grade has to be improved and the content of silica to be reduced significantly. Whether or not dusts are re-circulated to the Aluminium Fluoride Reactor, the discharge of dusts from Cyclone directly to product into the Aluminium Fluoride Cooler, is always operated.

Vacuum is kept at discharges of cyclones by level maintained in Cyclone Bin installed underneath and equipped with discharge device and valve.

The aluminium fluoride is discharged from the bottom bed of the Aluminium Fluoride Reactor through the discharge and then cooled down into a fluidised bed cooler to a temperature preferably lower than 80°C.

The Off-gases from aluminium fluoride reactor after Cyclones are quenched and condensed in the absorber and then are scrubbed.

The condensation of HF, H2O, etc occurs in the Absorber and HF Scrubber without addition of water. The concentration of fluorine in the


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liquor formed provides a good indication of the efficiency of the reactor and is used for its control.

The diluted acid solution produced will be sent to the neutralization plant or reused.The second column is used to remove the traces of Fluorine, S, dusts, etc. This column is the stand-by unit for the third column in case of fouling and vice versa.

The fluidisation in the Aluminium Fluoride Reactor is maintained by the vacuum obtained from the operation of a Steam Ejector. An Absorption System common to the aluminium fluoride plant and hydrofluoric acid is provided Water is sent to the final absorber in order to absorb totally HF and reach the emission limit for F in the off-gases in all modes of operation of the plant. This effluent water is also sent to the neutralization plant or reused.

3.3. Raw Material

3.3.1. Ammonia/gasification:

Raw material Consumption for 2200 TPD Ammonia: SES BASED. SL. No. Input Requirement UOM 1. Coal 5,633 TPD 2. Oxygen 70,000 Kg/Hr 3. Power 70,553 KW 4. Cooling Water 17,582 TPH 5. BFW-(HP+LP) 431 (227.9+203.1) TPH 6. Raw Water 800 TPH 7. Service Water 425 TPH 8. DM Water 273 TPH 9. Portable Water 13.6 TPH 10. Instrumental Air 2,038 Nm3/Hr 11. Plant Air 510 Nm3/Hr 12. LP Nitrogen 43 Nm3/Hr 13. HP Nitrogen 82,237 Nm3/Hr 14. Diesel 0.8 M3/Hr 15. Fuel Gas 11,703 Nm3/Hr 16. Steam-(LP+MP+HP) (645.8)1.8+421+223 TPH 17. Condensate-(LP+MP) 33 (2+31)

3.3.2. Urea plant:

Sl. No.

RawMaterial/Utilities

Unit(hourly) Requirement

1.0 Ammonia MT 91.67

2.0 CO2 MT 118.7 3.0 HP Steam MT 126 4.0 MP Steam MT 21


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5.0 Power KWh 8000

6.0 Makeup Water m3 256

3.3.3. Nitric acid :

Sl. No.

RawMaterial/Utilities Unit(Hourly) Requirement

1.0 Ammonia MT 13

2.0 Process Air 1000 m3 180

3.0 MP Steam MT 14

4.0 Power kW 3000

5.0 Treated Water m3 190

3.3.4. Ammonium Nitrate :

Sl. No. Raw Material/Utilities Unit(Hourly) Requirement

1.0 Ammonia MT 10.00

2.0 NitricAcid MT 36.67

3.0 MP Steam MT 6

4.0 Power KW 5000

4.0 Makeup Water m3 47

3.3.5. Di Ammonium Phosphates :

Sl. No. Plant /Rawmaterial/ Utility Unit Consumption

1.0 Sulphuric Acid MTPD 59 2.0 Phosphoric acid MTPD 605 3.0 Ammonia MTPD 293 4.0 Filler MTPD 59 5.0 Electric Power MWhPD 75 6.0 Process Water m3/day 500 7.0 Fuel Oil KLPD 8 8.0 Steam MTPD 130

3.3.6. Granulated Single Super Phosphates:

Sl. No. Plant /Raw material/ Utility Unit(Daily) Consumption

1.0 Sulphuric Acid MT 594


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2.0 Rock Phosphate MT 957 3.0 Electric Power MWh 41.25 4.0 Process Water m3 480 5.0 Fuel Oil KL 18.15

3.3.7. Aluminium Fluoride:

Sl. No. Plant / Raw material/ Utility Unit Consumption

1.0 H2SiF6 T/T 1.05 2.0 Sulphuric acid( T/T 20.5 3.0 Sulphuric acid(*) T/T 16.1 4.0 Al(OH)3 T/T 1 5.0 Limestone/Lime as required T/T --

*with optimized recirculation

3.4. Utilities

3.4.1. Water

The total water requirement of the proposed project is 1891 m3/hr. The plant wise water requirement is as given below: The water Balance diagram is also given in Figure

The water will be made available from the existing source i.e. Taladanda canal.

Sl. No. Particulars Water Requirement (cubic. metre/hr)

1. DAP 20.83 2. Coal Hand. Plant 90 3. Gasification & Ammonia 420 * 3 4. Urea 256 5. Amm. Nitrate 47 6. Nit. Acid 190 7. GSSP 20 8. Aluminium. Fluoride 6.6


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Water Balance ( Proposed Expansion)

3.4.2. Power

The total power requirement for the proposed project will be ~ 239 MW. The plant wise requirements are as given below:

The power will be sourced from:

Captive generation--- DG set State grid:

Total 238584 KW

3.4.3. Land Requirement:

DAP 20.83 m3/Hr CHP 90 m3/Hr Ammonia –Gasification (1260)420 * 3 m3/Hr Urea 256 m3/Hr Ammonium Nitrate 47 m3/Hr Nit. Acid 190 m3/Hr GSSP 20 m3/Hr Aluminum Fluoride 6.6 m3/Hr

Sl. No. Particulars Power Requirement (KW)

1. DAP 3125 2. Coal Hand. Plant 5500 3. Gasification & Ammonia 70553 * 3 4. Urea 8000 5. Amm. Nitrate 5000 6. Nit. Acid 3000 7. GSSP 1720 8. Alu. Fluoride 580

Sl. No. Particulars Land Requirement (Acres)

1. DAP 1.2

Input Water 1891 m3/Hr

Effluent to ETP 1341.0 cubic met


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3.4.4. Man Power Requirement

Total 1017

3.4.5. Other Offsite Facilities

Other off site facilities like fire fighting system, laboratory, safety set up, stores, first aid/medical Township etc will joined with existing facilities. The existing facilities will be suitably augmented.

3.5. Environmental Aspects: Emissions, Effluents & Solid Waste Details from

Proposed Plants:

3.5.1. Effluents Detail:

*Coal handling Plant’s used water is drained to strom drainage.

3.6. Specific Environmental aspect

3.6.1. COAL HANDLING PLANT EMISSION DETAILS:

2. Coal Hand. Plant 150 3. Gasification & Ammonia 4. Urea 5. Amm. Nitrate 13.5 6. Nit. Acid 7. GSSP 8.42 8. Alu. Fluoride 1.16

Total 174.28 acre

Sl. No. Particulars Man Power Requirement

1. DAP 133 2. Coal Hand. Plant 200 3. Gasification & Ammonia 70 *3 4. Urea 170 5. Amm. Nitrate 110 6. Nit. Acid 80 7. GSSP 64 8. Alu. Fluoride 50

Sl. No. Particulars Waste Water Generation (cubic. metre/hr)

1. DAP Total recycled 2. Coal Hand. Plant -- 3. Gasification & Ammonia 366.5 *3 4. Urea 90 5. Amm. Nitrate 15 6. Nit. Acid 1.20 7. GSSP ZLD 8. Alu. Fluoride 135

Total 1341.0


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- Only emission from CHP would be the dust generated. - The dust extraction emission would be kept below 50 mg/Nm3. - Water spraying would be done to suppress the dust. -

3.6.1. Gasification & ammonia plant:

Based upon gasifier design, the facilities are anticipated to produce the following emission and effluents.

Atmospheric vents Carbon Dioxide Vent The vent stream from the Acid Gas Removal Unit will be vented to the atmosphere. Total CO2 emissions from the site including the gas turbine exhaust is estimated to be 327tonneperhour. Gas Turbine Flue Gas All of the flue gas from the gas turbine will be vented via the waste heat recovery boiler. Flue Gas Flue gas from the Auxiliary Boiler will be vented to the atmosphere. Flared Gas An emergency flare will be provided forth eventing of syngas during start-upandshut-down operations. No gas is normally vented to flare. Other Vents

o Other atmospheric vents have been identified. They include:

o Deaerator vents, consisting of steam and non-condensables.

o Steam ejector vents, consisting of steam.

o Coal Dryer vent, consisting of hot wet air.

o Miscellaneous vents from dust collection associated with coal handling. The vent specific emission details would be available at DPR staged. However, PPL will ensure discharge to meet applicable emission discharge standards. Liquid Effluents

The following liquid streams, totalling 2,11,408.1 Kg /hr, will be treated by the waste water treatment facilities:

Item

Composition

NormalRate (kg/hr)

GasifierSump Oily Water 5700 Power AreaSump Oily Water 5700 AmmoniaAreaSump Oily Water 5700


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Cooling Tower BD CW Blowdown 157000 Gasifier BD Oily Water 7200

Selexol Sump Amine Sewer 5700 MDEA Sump Amine Sewer 5700 Water Softeners Hard Water 7500 Condensate Polishers Hard Water 8000 Sanitary Waste Water Waste Water 3200 Other Sources Waste Water 8.1

Oil collected from API separator An API separator will skimoil from a variety of oily watersources. The oilisbarreled and shipped away by truck. Solids Disposal

The Gasifier will produce 51,380 kg/hr of Bottom Ash. The material may be shipped to landfill if no beneficial use is available.

Solid waste produced by the biological waste water treatment is sent by truck to landfill.

Spent catalyst frequently contains valuable metals, therefore, it is typically returned to catalyst vendors for recovery. The following quantities and frequencies are anticipated.

Usage Type Volume,m3 Weight,kg Life,years

COShiftR.1 Catalyst KatalcoK8-11HA 85 55,845 3 COShiftR.2 Catalyst KatalcoK8-11HA 131 86,067 5-7 COShiftR.3 Catalyst KatalcoK8-11HA 114 74,989 8-10 HGRemovalAdsorb. Activated carbon 21.7 12,152 - AmmoniaSynthesis Katalco 126 340,200 10

3.6.2. Urea plant:

Emission Details

The details of the emission sources and quantities are shown in following figure 3.10.


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Figure 3.10: Emission Details of Urea plant

Emissions into air: Continuous gaseous effluents:

Sources of this emission are: The point of the plant from where inerts, effluents are continuously discharged is medium pressure inert washing tower. This vent is collected to flare and burnt.

The process steps responsible for and approx quantity of emissions into air are:-

NH3, N2, CO2, vented through continuous flare as scrubber vent-gas from MP decomposition section. The approximate

quantity ofventis1600NM3/Hr. Ammonia in the vent is around 12ppm max.

Inerts from urea hydroliser stripper and vent from LP section containing inerts with ammonia content 10 ppm max

Exhaustairfromprillingtoweraround1500000Nm3/hr containing urea fine dusts 40-50 ppm max.

Prilling tower size: 30 m Dia X 130 m height approx.

Discontinuous gaseous effluents

The HP vent and the remaining process vents, normally closed, are collected to discontinuous flare to be burnt in case of vents opening.

Effluents:


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Continuous liquid effluent

No effluent is emitted to water source. Treated condensate is sent to battery limit at 50oC and 5.0 Kg/Cm2 pressure. The quantity generated is process water 90MT/hr. and steam condensate 50 MT/hr. approx. ammonia and Urea are 1 ppm Wt max.

Discontinuous liquid effluent

All the occasional drains containing carbamate or ammonia solutions from process are collected in carbonate close drain tank to be recovered later.

Solid waste

No solid waste is produced in the urea production process.

Fugitive emissions

These are discontinuous releases of NH3, CO2, urea dust, oil and steam. Typical sources include: storage tanks, valves including PRVs, flanges, pumps/compressor seals, sewer system vents/drains, waste water treatment units, solid urea transfer points, screens, etc.

3.6.3. Nitric acid plant:

Emissions

Continuous Gaseous Effluents The residual nitric oxide is, in practice, re-oxidized to nitrogen dioxide for further conversion to nitric acid. There is an economic limit to the size of the absorption tower that is practical and the adsorption efficiency achieved is generally in the range 98.2 to 99.3%. It is the residual concentrations of nitrogen dioxide and nitric oxide (commonly referred to as NOx) that give rise to the pollution problem in the vent stack.

Tail Gas

Sources of this emission are the point of the plant from where inerts, effluents are continuously discharged is NOx abatement section vent. This is discharged to atmosphere through vent.

The following TG quality will be discharged to atmospheric under design operation conditions. A typical composition of the tail gas is as follows:

Typical composition (Volume/Volume):

Gas Percentage composition

N2 95.62%

H2O 0.68%


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O2 2.2 %

NOx <50 ppm

N2O Approx500 ppm

NH3 <15 ppm

Discontinuous Emissions

Gaseous effluents from safety devices i.e. from Ammonia line, Compressor air, steam and feed water and Gaseous effluents from acid containing equipments like sample collection box and drip acid tanks are categorized in this type of effluent.

Quality of Gaseous Effluent

Gas composition at absorption tower outlet exit to stack is described below:

NOx : 100-3500 ppmv

N2O : 300-3500 ppmv

O2 : 1-4% H2O : 0.3-2% N2 : balance NOx at scrubber outlet : 100 ppmv max

Quantity of StackGas : 130,000-142,000 NM3/hr Stack Size : 1.25 m Dia X50 m height approx Effluents Continuous Liquid Effluent

Mainly Blow Down from Steam Generation (2% approximately) is continuous effluent generated from the unit. No Continuous liquid effluent is emitted to water source.

Discontinuous Liquid Effluent

Ammonical water from NH3 Stripper is the major discontinuous liquid effluent. The stripping of Ammonical water outlet from ammonia evaporator will be done batch wise and the drained liquid is collected for disposal. Liquid effluent is mainly from waste heat boiler blow down.

Quantity : 1.20 MT/hr

Composition: Residual Phosphate-20-40ppm,TDS–300ppm,

Silica –15 ppm.


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Due to use of relatively high steam pressure of 15bar abs instripping, astripping temperature of approximately 160 oC can be reached at the end.Therefore the liquid drain can be kept to aminimum and will mainly contain oil. This liquid drain will be collected in barrels for disposal. The stripping period per day depend on the purity of ammonia liq. entering B.L.

Solid Waste

No solid waste production is envisaged in the Nitric Acid production process.

Fugitive Emissions

All the discontinuous and contaminated water e.g. wash water containing lube oil etc and occasional drains shall be treated for oil recovery and send to neutralization pond in ETP before using it in non process non drinking purposes.

Typical sources include: flanges, pumps/compressor seals, sewer system vents/drains, waste water treatment units, etc

3.6.4. Ammonium nitrate plant:

The details of the emission sources and tentative quantities are discussed in following paragraphs:

Emissions into Air Continuous gaseous effluents

Atmospheric effluents result from the loss of ammonia and ammonium nitrate. Small particles of ammonium nitrate (mini prills) are carried out with the air. Ammonium nitrate fume is also lost from the surface of the prills and this is sub- micron in size

Source of these are neutralisers, evaporators and prilling towers. These give rise to the pollution problem in the vent stack and prilling tower top.

Stack Exit Gas(temperature of gases entering stack: 40-450C)

Composition:

Ammonia : 50 mg/NM3max

Particulate Matter : 150 mg/NM3max Quantity : 135,000 m3/hr approx. Stack Size : 1.8 m Dia X40 m Height approx.

Discontinuous Emmissions

Gaseous effluents from safety devices i.e. from Ammonia line, Compressor air, steam and feed water and Gaseous effluents from acid


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containing equipments like sample collection box and drip acid tanks are categorized in this type of effluent.

Effluent

Continuous Effluents

No liquid effluent is generated in Ammonium nitrate plant. Around 15 MT/hr of process condensate produced is treated and reused.

Discontinuous liquid effluent

Ammonium nitrate, ammonia or nitric acid (which are normally neutralised) can arise from equipment cleaning and a wide range of points specific to a given site.

Solid waste

No solid waste production is envisaged in the Nitric Acid production process.

Fugitive emissions

All the discontinuous and contaminated water e.g. wash water containing lube oil etc and occasional drains shall be treated for oil recovery and send to neutralization pond in ETP before using it in non process7non drinking purposes. Typical sources include: flanges, pumps/, sewer system vents/drains, waste water treatment units, etc.

3.6.5. Di-ammonium phosphates plant:

The possible pollutants from the complex and their sources are explained below:

Gaseous Emissions

The emissions from this unit arise mainly from the reactor and granulator. These emissions include gaseous NH3 and HF. It is caused by the volatilization due to incomplete chemical reactions and excess free ammonia. Also, fluoride and V2O5 emissions due to the dissociation of the fertilizer product, and particulate emissions due to the DAP dust entrainment in the ventilation air streams; are expected. Added to that; SOx, NOx, CO, and CO2 gases are expected due to heavy fuel oil combustion in the burner.

Quality of Gaseous Effluent

The quantity of gaseous effluent of the proposed DAP plant is described below:

Ammonia : 50 mg/Nm3max

Particulate Matter : 150 mg/Nm3max

Fluorine as „F‟ : 20 mg/Nm3max


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Quantity of stack exit gas: 200,000 Nm3/hr approx. Stack Size : 1.5 m Dia X50 m height approx.

Hot Air Generator

Flue gas emission through stack of granulation section furnace shall conform the following standards:

Particulate Matter : 150 mg/Nm3max SO2

100 ppm max

NOx : 50 ppm Stack Size : 1.0 m Dia X30 m height approx.

All other contaminated water steams in the plant are connected in an accumulation system and returned to the process.

Liquid Effluents

The only source is the washing water from the scrubbers installed at the stack. It is usually mixed with diluted phosphoric acid and make-up water and recycled to the scrubbers.

Solid Wastes

No solid waste has been envisaged for the proposed fertilizer complex.

3.6.6. Granular Single super phosphate plant:

The acidulation of rock phosphate with sulphuric acid shall lead to emission of HF, SiF4, acid mist etc

Gaseous Effluent

Ball Mill Exit Air(Exitvelocity:20m/s, Exit temperature:400C)

Particulate Matter : 150 mg/Nm3max

Stack Size : 0.8 m Dia X 40 m height approx.

Scrubber Outlet Gas (Exit velocity: 20m/s, Exit temperature: 400C)

Quantity : 120,000 m3/ hr approx Composition

Flourine as„F‟ : 20 mg/Nm³max

Particulate Matter : 150 mg/Nm³max

Stack Size : 1.0 m Dia X 40 m height approx.


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Hot Air Generator

Particulate Matter : 150 mg/Nm³max

SO2 : 100 ppm max

NOx : 100 ppmmax

Stack Size : 0.6 m DiaX 30 m height approx.

The emission control of these fumes and gases shall be achieved by venturi scrubbing followed by efficient wet scrubbing to limit total fluoride emission well below statutory requirement of 25 mg/ Nm3.

Effluents

There shall be no wastewater effluent discharge to outside of plant B/L. The acidic effluent generated in the gas scrubbing section shall be recycled in the acidulation process. The plant is being operated as Zero discharge system.

Solid Wastes

No solid waste has been envisaged for the proposed fertilizer complex.

3.6.7. Aluminum fluoride plant:

The details of the emission sources and tentative quantities are discussed in following paragraphs:

Gaseous Emissions: Off-gas

Effluent : Wastewater

With reduced and optimized utilization of sulphuric acid Diluted Sulphuric Acid :

Quantity per hour (approx.) 4’000 m3/h F ppm Max.

Quantity per ton AlF3 (expected) 4 m3 F 1 % wt

Quantity per ton AlF3 (expected) 9 m3 F 1 % wt

Quantity per ton AlF3 (expected) 28 T H2SO4 70 - 75 % wt. HF 0.2 % wt. max


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With reduced and optimized utilization of sulphuric acid Silica:

Solid Waste: Wastewater sludge (synthetic fluorspar) Quantity per ton AlF3 (expected) 0.15 - 0.40 m3 CaF2 40 - 45 % wt H2O 30 Max. % wt

Quantity per ton AlF3 (expected) 22 T

Quantity per ton AlF3 (expected) 0.9 T SiO2 40 (approx.) % wt. H2SiF6 2 - 5 % wt. H2O balance


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4. SITE ANALYSIS

The project is within the existing plant premises as well in the same factory building of the said Company at Paradeep, in Jagatsinghpur district of Orissa State. The project site is well connected by rail and road. The Daitary – Paradeep Express Highway is at a distance of 2 kms approximately from the project site. The location is shown in the Map Below .The other salient features are given in the Table 4.1

Table 4.1 Site and Surrounding

S.No. Particulars Description 1)

Village, Tehsil, District, State P. S. Paradeep, Kujanga Tehsil, Jagatsinghpur district, Orissa state

2) Longitude and Latitude 3) Land 2282.40 Acres 4)

Land status The entire land is already under possession of the company.

5) Most Populated area

Paradeep with population of 73625 as per 2001 Census.

6) Nearest Water Source

TaladandaCanal at 2 to 3 kilometers Kms in the NE direction of the PPL.

7) Nearest High Way

Express High Way 01 at a distance of 2.0 Kms (approximately)

8) Nearest Railway Station

Paradeep Railway Station at distance of 2 Kms

9) Nearest Village Jhimani at 3 kms 10)

Nearest Town Paradeep, around 06 kms from the project site

11) Nearest AirPort Bhubaneswar at 130 kms 12) Nearest Forest None 13) Recorded Sensitive Places None (Within 10 Kms) 14) Historical Places. None (Within 10 Kms) 15) Location of National

parks /Wildlife Sanctuary within 10 km radius of the project site

None (Within 10 Kms)


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Figure 4.1: Satellite view of Site


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Figure 4.2: Road Network Map


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Figure 4.3: Railway Network Map


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5. REHABILITATION AND RESETTLEMENT

The objectives of the National Rehabilitation and Resettlement Policy are: to minimize displacement and to promote, as far as possible, non-displacing or least- displacing alternatives; to ensure adequate rehabilitation package and expeditious' implementation of the rehabilitation process with the active participation of the affected families; to ensure that special care is being taken for protecting the rights of the weaker sections of society, especially members of the Scheduled Castes and Scheduled Tribes, and to create. obligations on the State for their treatment with concern and sensitivity; to provide a better standard of living, making concerted efforts for providing sustainable income to the affected families; to integrate rehabilitation concerns into the development planning and implementation process; and where displacement is on account of land acquisition, to facilitate harmonious relationship between the requiring body and affected families through mutual cooperation.

In view of above, it is apodictic fact that the proposed project is not going to acquire any additional land thereby displacing any permanent settlement. The proposed project shall be installed within the boundary limit of Paradeep Phosphates Limited fertilizer complex which is located at Port town of Paradeep in Jagatsinghpur District of Orissa.

This proposed project has been considered to be installed in vacant area of existing fertilizer complex. Hence Rehabilitation and Resettlement (R&R) Plan in respect of the affected persons including home oustees, land oustees and landless labourers does not arise for the proposed project


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6. PROJECT COST AND SCHEDULE

The estimated cost (in Rupees / US dollar) of the proposed project (plant wise) and the estimated expenditure on pollution control measure are as given below:

Sl. No.

Plants Cost in Rupees Environmental Measures Cost

1 CHP 2750 Million Adequate provision will be made for meeting the required environmental costs requirements. However this is expected to be of the order of 5-7% of project costs.

2 Ammonia 54489 Million 3 Urea 17605.6 Million 4 Nitric Acid 7907.7 Million 5 Ammonium Nitrate 5839.5 Million 6 Di-Ammonium

Phosphate 4417.4 Milliom

7 Granulated single super phosphate

1484 Million

8 Aluminium fluoride 1860000 USD(98.5 million INR)

6.1. Environmental measure expenditure by PPL:

Year Wise Expenditure for implementation of environmental safeguard :

Items Details 2009-10 2010-11 2011-12 2012-13 (Expected)

Expenditure for implementation of environmental safeguard

3.5 Crores 17.8 Crores 18.7 Crores 4.03 Crore

6.2. Project Implementation schedule:

The proposed project shall be implemented based on either LSTK (Lump Sum Turnkey) mode or EPCM mode. In LSTK mode, the owner can engage LSTK engineering contractor for B/L proposed plant, or, if found more economical or more convenient, PPL may adopt EPCM mode (cost plus fee mode). In either mode of implementation the overall project monitoring, progress review, reporting and coordination between the different agencies could be entrusted to an independent Project Management consultant. Alternatively, these functions could be performed by experienced project group, specially set up by the owners for this purpose.

6.3. Pre-Project Activities

The pre-project activities to be completed before the physical execution of the project are briefly enumerated below:

a) Preparation of feasibility report and submission of same to DoF for

getting clearance

b) Clearance and approval of the project, by the board of the company.


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c) Firming up of arrangement for supply of power & water, ifrequired,

from concerned agency.

d) Preparation of ITB for selection of LSTK/EPCM Contractor for B/L

Plants by appointing an experienced engineering consultant.

e) Selection of Prime Engineering Consultant (PEC). PEC will mainly

prepare engineering packages for all off site and utility units and assist

the Owner in procurement, construction and commissioning

supervision.

f) Soil investigation work for ascertaining soil characteristics of the area

identified for location of the new facilities.

g) Preparation of Environment Impact Assessment (EIA) study and

clearance by State and Central Pollution Control Boards.

h) Preparation of DFR/DPR based on selected LSTK Contractor for B/L

Plants.

i) Preparation of Risk Analysis Study.

j) Final approval of the project by Government.

k) Obtaining financial clearance and commitment from financial

institutions and creditors for financial closure of the project.

All the project execution related activities, as mentioned earlier, are interlinked and have impact on the final outcome. The execution of the relevant project activities has to be planned and controlled in such a way that the goals of the project are achieved in the set time frame. During the execution, the main time consuming activity is delivery of critical equipment and machineries. The implementation time is for mechanical completion & commissioning.

Sl. No. Projects Project Implementation Period

1. Coal Handling Plant 30 Months

2. Gasification based Ammonia Plant 36 Months

3. Urea Plant 36 Months

4. Nitric Acid Plant 24 Months

5. Ammonium Nitrate Plant 24 Months

6. Di-ammonium Phosphate Plant 18 Months

7. Single Super Phosphate Plant 18 Months

8. Aluminium Fluoride Plant 24 Months

final-pfr-ec -...

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