NATIONAL FERTILIZERS LIMITED

(Naya Nangal Unit)

14th

May, 2015

CERTIFICATE OF TRAINING

Institutes name: Beant College of Engineering & Technology, Gurdaspur (Pb)

Branch: B.Tech (Mech) 4th year

Training Period: January 15, 2015 to May 14, 2015

Submitted to: Submitted By: Ashish Kumar

Contents

1. Introduction

2. Steam Generation Plant

3. Mechanical Workshop

Introduction

1.0 INTRODUCTION TO ORGANIZATION

A VIEW OF NATIONAL FERTILIZER LIMTED NANGAL

Figure 1.1 view of NFL NANGAL

1.1 INTRODUCTION TO NFL NANGAL

My training was at NFL Nangal. Nangal is a beautiful town situated in Distt. Ropar (PB). This is

the first key industry set up by Govt. Of INDIA with coming up of Bhakhra Dam & surplus

power available from the project at the time. It was derived by Govt. Of India to set a fertilizer

plant at Nangal, which went to production in 1961.The plant at that time produce Ammonium

Nitrate (25% Nitrogen) and heavy water.

Subsequently In 1978 went an Ammonia Plant based on fuel oil gasification which added Urea

(46% Nitrogen) to its main product in 1990.

In 1978, In urea formation the hydrogen was available from electrolysis of the water which on

electrolysis treatment produce hydrogen and oxygen & from this hydrogen further ammonia is

formed, but after short time of gap Electrolysis plant was replaced with Front End Plant(NMP-I)

based on reforming of Naphtha production of hydrogen and reducing the electrical power

consumption.

1.2 NFL PLANTS

NFL has several plants in all over India and the location of various fertilizer plants In India as:-

1. National Fertilizer Limited Vijaipur (MP)

2. National Fertilizer Limited Panipat(HR)

3. National Fertilizer Limited Bathinda (PB)

4. National Fertilizer Limited Naya Nangal (PB)

1.3 PRODUCTS OF NFL

NFL Nangal mainly deals with production of Urea but there are several by products which get

produce

Products Capacity( in MTPD)

Urea 1450

Methanol 67

Sulphur 24

Ammonium Nitrate As per Reqd.

Liquid Carbon Dioxide 24

Sodium Nitrite 9

Sodium Nitrate 6

Nitric Acid 554

Ammonia 900

Table 1.1 products of nangal

There is also the formation of poisonous gases such as CO, CO2, CH4, H2, & H2S etc.

The NFL, Nangal Unit has been broadly classified into two parts:-

a) UGP ( UNIT GROUP OF PLANT):-

WTP - WATER TREATMENT PLANT

NAP- NITRIC ACID PLANT

urea

methanol

sulphur

Ammonium Nitrate

Liquid Carbon dioxide

Sodium Nitrite

Sodium Nitrate

Nitric Acid

Ammonia

b) EGP (EXPANSION GROUP OF PLANT):-

SGP- STEAM GENERATION PLANT

UREA BAGGING PLANT

Statistic Data

The input and output data of company is as in which it informs about the name of the

product and the consumption of raw material

Raw material Name of The

Product

Consumption

Fuel oil Ammonia 832.04 MT/Unit

Coal Steam 191.25 MT/Unit

Caustic Soda NOx 1547 MT/Annum

Water Consumption

River Satluj is the exclusive source of raw water to NFL, Nangal unit.

1. Process Water (m3) for EGP 5538481

2. Process Water (m3) for UGP 307010

3. Domestic Water 4042120

Raw water Analysis

S. No. Parameters Range Value

1. pH 7.8-8.0

2. Total Hardness (as CaCO3

mg/L)

29-34

3. Magnesium hardness, mg/L 4-6

4. Sulphates (as SO4 mg/L) 2-4

5. Chloride (as Cl, mg/L) 6-20

6. KMnO4 Value, mg/L 4-6

7. Calcium Hardness (as

CaCO3, mg/L)

46-52

pH

Total Hardness (as CaCO3

mg/L)

Magnesium hardness,

mg/L

Sulphates (as SO4 mg/L)

Chloride (as Cl, mg/L)

1.4 COMPANY OUTPUT

Overall Turnover of NFL is 3800 crores.

The employee strength is as:

Total Employee 1542

Officers 232

Workers 1310

Main Product & its Objective:-

Kisan Urea Specifications:-

Moisture Less than 1%

Nitrogen on Dry Basis- More than 46%

Biurate by weight 1%

Physical and chemical properties of urea:-

S.No. Property Assigned Value

1. Formula Weight 60.06

2. Melting Point 132.7oC

3. Boiling Point Decomposes at atmospheric

pressure (

soil colloids for longer duration. Urea is available in granular form and can be applied by

drill and broadcasting. Kisan urea is ideally suitable for all types of crops and for foliar

spray which instantly removes nitrogen deficiency. Kisan also has a strong and long

lasting effect on crops resulting in bumper crops. Carbonic acid present in kisan urea help

in absorption of other nutrients like phosphate and potash by roots crop.

STEAM GENERATION PLANT (SGP)

2.0 STEAM GENERATION PLANT

2.1 Objective of SGP:-

In NFL, Nangal Unit Plant, all the basic unit operations need steam for their work and must of

the industrial equipment are driven by steam such as Turbo Compressors, Steam jet ejectors,

preheater etc.

In unit operations

1) For evaporation supply the steam to evaporate

2) For crystallizations supply the steam to crystallizer

3) To create the negative suction pressure mostly supply in the steam jet ejector

4) For combustions purpose such as gasification process

5) To exchange the heat of desire product by use of steam.

SGP starts from-

1) Handling &Storage of Coal ,Fuel Oil ,LHSH , LDO & Methanol

2) Boilers-

a) Coal Fired Boiler

b) Gas Fired Boiler

3) Pollutions Control Sections

4) Steam Network Section

Figure 2. Unloading of coal

a) - COAL UNLOADING THROUGH TRIPLER

Tippler Wing Conveyor

Vibrators, ET-1(Underground)

(Cap. =550-600 MT/hr) ET-2 Coal Yard

ET-3

Coal Yard Storage Capacity = 30,000 Tons

b) - COAL FEEDING SYSTEM

Feeding Hopper Magnetic Belt

Vibrators Magnet Magnet

ET-4 (Underground) ET-5 ET-6

(Cap. =110-130 MT/hr)

Mill Bunkers (6 Nos.)

Coal from Wagon

Coal from Yard

Crusher

2.2 COAL FIRED BOILER

2.2.1 INTRODUCTION:-

The integrated service boilers for the Nangal Expansion Fertilizer Project are different from

conventional boilers. These boilers are radiant, outdoor, bidrum, high head, non-reheated type &

pulverized coal is used as principal fuel

These boilers are designed to heat up external high pressure saturated steam from heat boilers,

along with generated steam coal is used as principal fuel

These boilers are designed to heat up external high pressure saturated steam from waste heat

boilers, along with generated steam in the boiler to the same final superheated steam

These boilers generated 117t/hr of steam and 65t/hr external import steam. The final superheated

steam generated 182t/hr will have a pressure of 91kg/cm2 & temperature of 510

2.2.2 MAIN BOILER STRUCTURE:-

The boiler designed of the top supported type & allowed to expand downwards. The main boiler

is supported four rows of column on either side of the boiler (S1, S2, and S3 &S4)

Boiler feed water which is coming from NH3-II plant which is preheated to 145 & then passing

through the economizer where its temperature is rises to 182-188 then it is transferred to the

steam drum. In the steam drum it is converted to the saturated steam & remaining water is not

converted to steam is transferred to mud drum through bank tubes

In the mud drum temperature of the condensed water is raises by the flow of the flue gases from

the mud drum through bank tubes.

In the mud drum temperature of the condensed water is rises by the flow of the flue gases. From

the mud drum preheated water is then transfer through the tubes along the sides of furnace and

recirculated to the steam drum and the above processes continuously running. The purpose of

recirculation is that, we cant leave the steam drum empty.

The temperature of the saturated steam leaving the steam drum is around 310 to 315C. The

saturated steam is then given to platin super heater where its temperature is rises to about 405 to

410C. The temperature of the platen super heater is 905C

2.2.3 COAL PULVERSIZING SECTION;-

In this section ball mill is used to pulverize the coal. Firstly coal which is crushed in the hammer

crusher to the size about size 25 mm is then transferred to the coal bunkers & from coal bunkers

& from coal bunkers through feeder to the centre of revolving ball of the ball mill. Hot air is

given to the Ball which is coming by passing through the air heater for the following two

purposes:-

1. for the drying of the pulverized coal

2. for the movement of the pulverized coal to the furnace

Hot air enters the mill housing below the ball and is directed upward passes through the classifier

vanes. The rising hot air around the ball picks up the pulverized coal, the lighter particles carried

by the air passes through the classifier & heavier particles are returned from the classifier to the

ball for additional grinding. Finally the pulverized coal having particle size 200 meshes & air

leaves the Ball Mill through classifier

2.2.4 COAL COMPOSITION

MOISTURE 6-10%

VOLATILE MATTER 16-20 %

FIXED CARBON 39-45%

ASH 30-35%

Table 2.1 coal composition

2.2.5 COMBUSTION CHAMBER OR BIOLER FURNANCE

At the four corner of the combustion chamber or boiler furnace one wind box is installed. At

each corner one burner is located. Each burner will comprise of four streams which are given to

the furnace, these are coal +Air, Tail Gas, LDO+ steam & hot air nozzles arranged vertically in

an insulated wind box

Moisture

Volatile matter

fixed carbon

ash

Air is sucked from the atmosphere by the forced draft fans & supplied to the air heater. After

passing through the heater temperature of the air is increased and then it is passed through the

heater temperature of the air is increased and then it is transferred to the wind box. For the

burning of the coal oil gun is used & all the other streams are given for the complete combustion

of the coal & unburned coal particles are dropped to the bottom where screen is used to transfer

them to bottom ash hopper

The flue gases which are produced after the combustion of the fuel moves upward to the furnace

with centrifugal force. Centrifugal force is developed when all the streams from the four corners

will meet at a single where the burning is taking place

The temperature of the combustion chamber, where burning of the coal is done is 1070C.

During the upward movement of the flue gas temperature difference between lower and upper

part of the of boiler which is going to be in between 100C to 150C

2.2.6 TAIL GAS COMPOSITION

H2 7.00%

Ar 3.80%

N2 16.10%

CO 27.90%

CH4 3.30%

H2O 41.90%

Table 2.2 tail gas composition

Tail gas which is coming out from ammonia II plant contains an appreciable amount of CO

which is not directly disposed to the atmosphere because of its harmful effects. So this gas is

ignite in the furnace and convert the CO to CO2 and reduced the content of the gas

Due to the large content of non-combustion of gases i.e. N2 & H2O, the ignition of the CO gas is

difficult& is not self sustaining. After ignition is converted to the flue gases and are disposed to

the atmosphere

2.2.7 PROCEDURE FOR DISPOSAL OF ASH:-

We used coal as a fuel for the running of the boiler, approximate 1000MT/day of coal is used

and huge amount of ash is generated. For efficient running of the boiler continuous removal of

H2

Ar

N2

CO

CH4

H2O

ash contents is essential .Heavier particles of burned coal are retained in the bottom ash hopper

of the boiler and the light particles are collected in the Electrostatic Precipitator

Finally the mixture of ash & water is discharged through feed gate & clinker, grinder, which

reduces the size of the clinker to about 50 mm to the ash slurry pit. Then ash slurry is disposed to

ash pond area

2.2.8 BOILER FEED WATER SPECIFICATIONS:-

TEMPERATURE 145C

TOTAL HARDNESS AS CaCo3 0.3ppm

SILCA 0.1 ppm

O2 0.02ppm

IRON 0.02ppm

COPPER 0.005ppm

pH 7.5-9.0

Import steam which is coming from the NH3-II plant at a temperature 313C and pressure105ata

is given to the import steam super heater where we get superheated steam whose temperature is

around 510-520C. The temperature of the final super heater is 872C

For controlling the temperature of the superheated steam, one desuperheater is used whose

temperature is ling in between 370-400C. So after desuperheater finally we get superheated

steam whose temperature is 500C and pressure is 91 ata, which is then given to different

sections in the plant. It produces 182 Ton/hr of superheated steam.

The flue gas which leaves from the furnace is leaving at the temperature of 530-540C, so

arrangement is made for the waste heat recovery. Firstly the flue gases pass through import

steam super heater where some amount of heat is recovered and temperature of the flue gas

reduces to 430C.

Then it passes to economizer where the temperature is reduced to 338C and then it is passed

through air heaters which are used for preheating the air sucked by forced draft fan the

temperature of the flue gases are sucked by force draft fans and are given to the ESP for the

removal of fly ash or dust.

2.3 Main Boiler Structures

The boiler design of top supported type &allowed to expand downwards. The main boiler

supported four rows of the column on either side of the boiler (S1.S2, S3AND S4)

Boiler feed water which is coming from NH3-2 Plant which is preheated to 125c &then passing

through the gilled tube economizer where temperature is rise to 182-188c then it is given to

steam drum & in the steam drum it is converted to saturated steam.

The temperature of the saturated steam leaving the steam drum is around 320-325c the water

which is remaining in steam drum is transfer through the tube along the side of the furnace and

recirculated to the steam drum & the above process continuously running .the purpose of

recirculation is that, we cant leave the steam drum empty .the saturated steam is then given to

the platen super heater where its temperature rises to about 405-410c. The temperature of platen

super heater is 920c.

Import steam which is coming from the NH3-2 plant at a temperature 313c and pressure 105 ata

is given to the import steam super heater where its temperature is rises around 405 -410c.then

finally mix both stream i.e. saturated steam & import steam &given to the final super heater

from where we get superheated steam whose temperature is around 510-520c. The temperature

of final super heater is 872c.

For controlling the temperature of the superheated steam ,one desuperheater is used to

whose temperature is lies in between 370-400c so after desuperheater finally we get superheated

steam whose temperature is 510&pressure 91ata ,which is then given then to different section in

the plant .it produces 140T/hr of superheated steam

The flue gas which leaves from the furnace is leaves from the furnace is leaves at a temperature

of 660-670c ,so arrange is made for waste heat recovery .firstly the flue gases pass through bare

tube economizer and then from import steam superheater where some amount of heat is

recovered &temperature of flue gas reduced to 360c

Then it is passes through gilled tube economizer where temperature is reduced to 299c 7 then it

is passed through rotary air heater is 121c

The flue gas after passing through rotary air heater is going to the chimney & from the chimney

it is disposed to atmosphere the height of the chimney is 80m &flue gas from other source of the

plant are also disposed from the same chimney the flue gas which is disposed to atmosphere with

following compositions (SO2=500-600mg/Nm3, SPM=110mg/Nm3)

2.4 POLLUTION CONTROLL SECTION

2.4.1 Electrostatic Precipitator:-

Flue gas are sucked by the Forced Draft Fan and supplied to ESP .Fly ash or dust is collection is

done in the Electrostatic Precipitator by imparting the negative charge to the dust particles &

attracting them towards positive plate disposal of the collected dust is done by rapping the

electrode.

The ash or dust which is collected in ESP is coming to hydrovecter then this ash is transfer red

along with water which is coming from NH3-2 plant to the ash slurry pit. Then ash slurry is

disposed to ash pond area.

2.4.2 Stack:-

The flue gas after removal of dust id thrown to the outside the chimney to atmosphere by the use

of induced draft fan .the height of the chimney is 80m &flue gas from the other source of the

plant is also disposed to same chimney the flue gas which is disposed to atmosphere with

following composition (SO2=500-600mg/Nm3, suspended particles=110mg/Nm3)

MECHANICAL WORKSHOP

Mechanical workshop at NFL unit mainly committed to the maintenance and repair work.

Various maintenance jobs are done here as per the job orders given by different plants of NFL

unit. The mechanical department has futher different workshops namely-:

Machine shop

Fabrication shop

Fitting shop

Earthmoving shop

Refrigeration shop

Details of the different workshops is given as following.

Machine shop

Fitting shop

Fabrication shop

Earthmoving shop

Refrigeration shop

MACHINE SHOP

Machining of a material involves repeated removal of material from the job to give away the

required shape and size.

Machine shop has various machines that are being used for the machining processes of the jobs

from the plant. Some of the machines in the shops are

SLOTTER MACHINE

LATHE MACHINE

GRINDER MACHINE

BORING MACHINE

DRILLING MACHINE

MILLING MACHINE

PLANNER MACHINE

SHAPER MACHINE

SHEARING MACHINE

SHEET CUTTING MACHINE

LATHE MACHINE

Lathe is a power driven, genral purpose machine used for producing mostly

cylindrical jobs or work pieces. As the piece of metal to be machined is rotated on the lathe, a

single point cutting tool is advanced racially in to the work

piece,removing the metal marterial in forms of chips.Main difference between

lathes where as in the the other machines cutting tools is moved an the work

piece remains stationary.

Parts of Lathe Machine

HISTORY OF LATHE

Most versatile machine tool in the machine shop

Oldest ancestor is the potters wheel(4000B.C)

Next came pole lathe

This was developed into current lathe which are able to make threads

Father of modern lathe HENRY MAUD SLAYS

Types of lathe machines found in the NFL mechanical workshop-

Central lathe

Turret lathe

Capstan lathe

Centre lathe or engine lathe

It is most important and widely used machine in the lathe family.its name is derived from the fact

that the earliermachine tools were driven by separate engines or from the central engine with

over head belt and shafts .The stepped cone pulley or gear head are often used for varying the

speed of the lathe machine

Turret lathe

It is a production machine used to perform a lot of task or operation on a single job with

minimum wastage of time.Indexable square tool is Provided on the cross slide or the mounting

turning and parting of tool. The Turret usually accommodates tools for different operations like

drilling ,counter sinking etc

Capstan lathe

These are similar to turret lathe and incorporate capstan slide which moves on a clamped in any

position.It is the best suited for the large scale production of small parts because of its light

weight and short stroke of capstan slide

SLOTTER MACHINE

Slotter machine is also called as vertical shaper machine .the difference being that the ram is in

vertical direction instead of horizontal position.Also the table or bed is mounted on a heavy base

and provided with mechanism that make possible forward backward and side to side movement

. it also has adjusted head mechanism .

Advantages of vertical shaper or slotter machine :-

1. Setting of the job is more convenient because it is easier to see, align, measure, clamp

2. Press generated by the cutting stroke is better supported by the table bed

3. Circular and hollow jobs can be worked upon

4. Ram of vertical shaper can be adjusted up to 10 degrees.

Main functions of slotting machine :-

Internal key ways

Tapered key ways

Slots

Centric slots

Internal gear

SHAPER MACHINE

Shaping machine is generally called as shaper. Shaper is being used for both

production and tool room work. The shaper can machine a flat surface on a

horizontal , vertical , angular plane. On this tyoe of machine ,many types of work pieces can be

machined depending upon the tools used and the manner of

adjusting the various parts of the machine . Size of the shaper is determined by

the largest sized cube that can be machined on it. Working principal is quick

return mechanism and forward stroke is cutting stroke and backward is idle

stroke.

Difference in shaper and lathe machine :-

In shaper straight cutting is done where as in lathe circular cutting is done In shaping machine

the tool moves in reciprocator fashion whereas in the lathe machine the tool remains stationary

and the work piece moves.

Parts of Shaping Machine are :-

BASE : it is the reservoir for supply of oil circulated to the moving parts of machine

ARPON: it supports the table

RAM: It is the main moving part of the shaper machine. It holds and

drives the cutting tool back and forth across the work .

This is attached to rocker arm which is given an oscillating motion by

turning of a large driving gear .this also has an adjustable pin attached to

driving gear which acts as a crank which determines the length of the ram

TOOL HEAD: it holds the cutting tool. it is attached to the front of the

ram. Tool post is fastened to the clapper box

Main functions of the shaping machine :

Making slots

Tapered slots

external key on shaft

Hexagonal nut heads

Square nut head

MILLING MACHINE

Milling machine is one of the most versatile and widely used machine tool for

tool room and production purposes.

Milling is the process of removal of the material with the help rotating multiple cutting tools

called as milling cutter. In general the work piece is fed into the rotating milling cutter

Parts of the milling machine :-

Column

Knee

Saddle

Table

Spindle

Over arm

COULMN: It includes the base which I the main casting which supports the other parts of

machine . The front of the column, the column face is machined to provide an accurate guide for

the vertical travel of the knee

KNEE: It supports the saddle .feed change gearing is enclosed within the

knee.knee can be raised or lowered on the column face.it is supported and can

be adjusted with a elevating screw.

SADDLE: It supports the table . It is supported by the surfaces of the knee

TABLE: It holds the workpiece. It has T-slots and is used to hold the

jods .bolts fit loosely in the T-slots and are used to clamp the vice.

SPINDLE: it holds and diverts various cutting tools.it has the shaft mounted

on the bearing supported by the column.

OVER ARM: it is mounted on the top of the column. It is guided by the

machined dovetail surfaces

GRINDING MACHINE

Grinding is the process of finishing surface by means of revolving abrasive wheel

In order to finish the job piece efficiently one must not only be able to operate

The grinder but also understand abrasive and grinding wheels ,their shapes and

sizes for different type of work

ABRASIVE: An abrasive is any material that can wear material softer than

itself .sand and sandstone are perhaps the oldest abrasives known to mankind.

Abrasives can be natural or manmade.

Natural Abrasives: Emergy and corundum are two commonly used in the

Industry to sharpen tool edge They occur as a miner deposit in the earth crust .Aluminum oxide

is the best suited for grinding material that has high tensile strength such as high spee steel and

high carbon steel.

Man made Abrasives: these are better than natural ones because in these

purity and grain size can be controlled.

GRINDING WHEELS: Grinding wheel are formed by using a suitable material to cement, bond,

abrasives grains together in the desired shape and size. Hardness of the wheel is dependent upon

the amount and kind of binding

material being used. Hardness of wheel is always understood by means of

strength of bond.

TYPES OF GRINDING MACHINES

Surface Grinder

Cylindrical Grinder

Internal Grinder

Thread Grinder

SURFACE GRINDER: Surface grinding is the process of producing a finished flat surfaces by

means of grinding machine employing revolving abrasive wheel. Surface grinder machine

consist of spindle mounting a grinding wheel and table or magnetic chuck for holding the work

piece

Uses of Abrasive Grinding : -

Sharpening cutting

Snagging

Finishing

PLANNER MACHINE

Planer is one of the basic machine tools used in machine shop. Main function is

to produce flat surface on piece of work. The main difference between planer

and shaper is that in planer machine the work piece moves In reciprocating

motion while tool is fixed where as in the shaper machine it is other way

round. It can be distinguished in two either Hydraulic or Mechanical.

Main parts of Planer Machine are:

Bed

Table

Saddle

Tool head

FABRICATION The process of joining metals or non-metal to from an object which has specific

shape .This process is known as fabrication. Different types of machines and welding are used in

the fabrication process or to fabricate an object.

THE WORKDONE AT THE SHOP ARE CLASSIFIED AS :

1) Metal cutting method :-

Oxy fuel gas cutting

Plasma cutting

2) Metal joining method :-

Oxy-acetylene welding

Arc welding

Tungsten inert gas welding

Oxy-acetylene Gas welding:

This process is particularly suitable for joining metal sheet and plates and having thickness 2

to 50mm.

The filler metal is the addition metal, which is added to weld in the form of welding rod.

The composition of the filler rod is usually the same or nearly the same as that of the part

being welded.

To remove the impurities and oxides present on the metal to be joined and to obtain stationary

bond flux is always implied during the welding expect sheet.

Various gas combustions can be used for producing a hot flame for welding metals. Common

mixture of gases oxygen and other fuel gases.

The oxy-acetyl welding mixture is used to a much greater extent than other in the welding

industry.

The temperature of this welding flame in its hottest region is about 3200 C.

CaC2 + 2H2O C2H2 + Ca(OH)2

ARC WELDING METHODS

Metal arc welding: In the arc welding metal rod is used as an electrode,

while the work being welded is used as another electrode. The temperature

produced is about 2400C and 2600C on the ve and +ve electrode

respectively. During the welding operations, this metal electrode is melted

by the heat of the arc and is fused with the base metal, thus forming a

solid union after the metal has been cooled. Both AC and DC can be

used .Adjusting the machine to correct amperage, which is determined by

then size of the rode to be used ,start the welding operations. The correct

welding speed is important.

SPECIFICATION OF ELECTRODES:

Where

1. E is used for covered electrode that is for coated electrode.

2. Next two XX multiplies with 1000spin shows the tensile strength.

3. Next X shows the position of joint to be welded in current condition i.e. it may horizontal,

vertical or inclined

4. Last X shows the types of coating.