CHAPTER-1

INTRODUCTION

Gujarat State Fertilizer & Chemical Limited (Sikka Unit) is one of the large scale companies, which started in 1986.investment of the company is more than 300 corers.

It is located at Moti Khavdi 25 km away from Jamnagar.G.S.F.C. has 500 acres of land at plant site and 50 acres at Sikka Shore Terminal (S.S.T.) for raw material storage and transportation.

S.S.T. is 10 km away from the plant and jetty of the company is 4.5 km away to S.S.T.

There is no adequate source of water, hence required water is provided by Jamnagar Municipal Corporation. Power is provided by thermal Power Station.

G.S.F.C. is very helpful for Jamnagar district socially and economically i.e. in education and cultural uplifting.

Raw Materials used for the DAP are liquid ammonia, phosphoric acid and sulphuric acid. Plant capacity is 1200 MT DAP per day.

To meet the fertilizer requirement of the country, GSFC established a Costal Diammonium phosphate plant at Sikka (Jamnagar) based on imported ammonia and phosphoric acid.

Capacity and name of the Contractor is as below.

Name of thePlant

Capacity Per Annum(MT)

Year of Commissioning

Name of Technology Provider

ProcessTechnology

Diammonium PhosphateTrain (A+B)

3,26,000 1986 M/S HindustanDooroliver,Bombay.

M/S LurgiGmbh , westGermany

Diammonium PhosphateTrain “C”

3,96,000 2002 M/S Udhe India Ltd.

Incro PipeReacterTech., Spain

CHAPTER-2

RAW MATERIAL

The main raw materials for production of Dap grades are phoshphoric acid, Liquid Ammonia, Bentonite silo & sulphuric acid as trimming agents. We are adding Bentonite silo to get the granutes of DAP and Sulphuric Acid to maintain the mole ratio of Phosphoric Acid and Ammonia.

The raw materials specification are given below:

1. AMMONIA

Sr. No. Property Description1 Source Bharain, Kuwait2 Molecular wt. 17.031 gm/mole3 Physical state Gas at ambient condition Liquid

in pressure condition4 Color Colorless5 Odor Strong, Pungent6 Boiling point -33 deg c at 1 atm7 Melting point -77 deg c at 1 atm8 Specific gravity .771 at 0 deg c9 Vapour density .6 at 25 deg c10 Vapour pressure 760 mm Hg at 25.7 deg c11 Solubility Extremely soluble in water12 Auto ignition -651 deg c13 Threshold Limit 25 ppm

2. Phosphoric Acid

Sr. No. Property Description1 Source Morocco,Senegal,Tunisia,Florida2 Molecular wt 97.99243 Physical state Liquid at ambient condition4 Color Colorless5 Odor Odorless6 Boiling point 158 deg c at 1 atm7 Melting point 42.35 deg c at 1 atm8 Specific gravity 1.675 at 0 deg c9 Vapour density 3.4 at 25 deg c 10 Vapour Pressure 2 hpa at 20 deg c11 Solubility Completely Soluble in water12 P2O5 52-54 % by wt

3. Sulphuric Acid

Sr. No. Property Description1 Source GSFC(Baroda),India and

Rayon(Veraval),Hindustan Zinc(Vapi)

2 Molecular wt 98.1 gm/mole3 Physical state Liquid at ambient condition4 Color Colorless5 Corrosiveness Highly Corrosive6 Boiling point 338 deg c at 1 atm7 Melting point -10.3 deg c at 1 atm8 Density 1.84 gm/ms

4. Furnace Oil

Sr. No. Property Description1 Source I.O.C. ,Baroda, India2 Flash point 66 deg c3 Physical state Solid or Liquid at ambient

temperature4 Color Like Black Boot Polish5 Pour point 42 deg c6 Storage point 80 deg c7 Density 91 gm/cc at 16 deg c8 Viscosity 370 cp at 50 deg c9 Water Content 1% by vol10 Sulfur Content 4.5 % by vol

5. DeformerHere, we use generally oleic acid & PARK-81 since they are found more effective and also can be mixed with water in 1:1 ratio without any kind of pumping problem.

6. Bentonite Soil

Sr. No. Property Description1 Source Local(in terms of loose material

also in bags.)2 Silica 85% by wt.3 Physical state Solid at ambient condition

CHAPTER-3

ENGINEERING SERVICES

A. Mechanical Engineering :

In GSFC – S.U. following equipment’s are there:

1. Boiler 2. Pump

3. Compressor 4. Heat Exchanger

5. Blower 6. Turbine

7. Conveyors 8. Elevators

9. Dryer 1o. Cooler

11. Granulator etc.

The utility related equipments are boiler,compressor,pumps,valves etc. The brief description of each is as under.

1. BOILER:

There is a steam boiler. It is a closed vessel, strongly constructed of steel, in which steam is generated from water by application heat. The function of steam boiler is to convert chemical energy of fuel by consumption into heat and to water and thus produce the steam. In boiler there is the water in shell side and the gasses passed on the surface of it through the tubes. The temp. of fine gases are 800 to 1400 deg c.

The mountings and accessories of boiler as shown underMOUNTINGS:

Special provision is always made on the boiler to mount stop valve, high steam and low water alarm, feed check valve, pressure gauge. Blow off coke etc. They are provided for safety working of boiler and complete control of the process of steam generation. Mountings are surface of equipment are listed as under:

Safety fittings are:-

- Safety valve- Water level indicator- Combined high steam and low safety valve

- Fusible plug

The control fittings are:-

- Steam pressure gauge- Feed check valve- Stop valve- Blow off valve

Accessories: - To increase the efficiency of the boiler plant and help in the smooth working of the plant accessories are as under:

- Oil pump- Feed water pump - Super heater- Ejector

SUPER HEATER:

It is placed on the path of furnace gases recovery heat from hot gases. It converts steam to super heated steam due to passing on the hot flue gases. These hot flue gases are coming out from boiler & contact with steam at the “U” shape bending. Hence, the contact area reduces & saturated steam converts into superheated steam. This super heater is heated externally by the furnace gases of the boiler.

Here, steam is heated out of contact with water is said to be superheated. To protect the super heater from overheating, flooding with water or diverting the hot gases is carried out. The brief description of the boiler mountings & parts as under.

(A) Safety Fittings:

1. Explosive Windows : It works as safety devices and to see the boiler. Hence, it provide for dual purpose if water level is low, there is chance of tank fusion. It is known as fusible plus which normal condition is covered with water in the boiler, which keeps the temperature of the fusible metal below its melting point.

2. Gauge glass (water level indicator) : It makes the water in the water level more than 0.5 to start the boiler with the help of gauge glass. There are usually two gauges provided on each boiler. One is placed at left of the boiler & at the right side.

3. Safety valve : To prevent the steam pressure in the boiler exceeding the pre determined max. working pressure by automatically opening the valve & discharging the steam as soon as this max. is reached. It is classified as1. Weight headed & 2. Spring headed safety valve

(B) Control Fittings: 1. Pressure gauge: It indicates the pressure of the steam & help in process controlling. It is

mounted in front of the shell or drum. The most common type of pressure gauge is bounded type.

2. Feed check valve: It is provided for process control purpose only. The feed water pipe carrying water from the feed pump usually enters the boiler in the water space of the boiler. A NRV is placed in the pipe control or regulates the water flow into the boiler which permits flow of water from the boiler when feed water pump is not working. To start the boiler following steps are taken.

- Check the tank valve- Start oil pump- Open the air vent valve- Open the steam stop valve- After generator of steam close the air vent valve & open main valve of the boiler placed

on the top. Now from this point steam goes to super heater.

To increase the efficiency of the Boiler Mountains the good quality of water & fuel oil, as well as the fuel ratio. Because efficiency of the boiler depends on the fuel & water quality & air fuel ratio.

Generally Air – Fuel ratio maintained –4

3. Compressor There are two type of compressor.

- NH3 Gas compressor- Air compressor

(a) NH 3 Gas compressor Type: Rotating (reciprocating) , blowing, two stage, double acting , horizontal, non lubricating, reciprocating type compressor.- Bore: 18.5/10.24- RPM: 506- Stroke: 9- Capacity: 2, 92,000 K.cal/hr. –M.K.

1, 92,000 K.cal/hr. –M.K

Function:

It provides devices services air and instrument air and also NH3 gas compressor, compresses the NH3 gas compressor and convert into liquid phase and help in storage of NH3 and its stored condition parameter , i.e. -33 deg c temperature at atmospheric pressure.

Ready to start signal for compressor:

- Compressor suction pressure is not low- 1st stage & 2nd stage dis. Pressure is not low

- 1st stage & 2nd stage dis. Temperature not high- Lube oil temperature not high- Auxiliary lube oil pump running- Saturator level not high- Flash vessel level not high- Oil temp of forced lubrication system for gear box is not high- Forced lubrication system oil pump is running condition- Forced lubrication system oil pressure is not low.

(b) Air Compressor: There are 4 nos. of air compressor out of them,- 1 for plant air- 1 for instrument air- 2 for automizing air

Type: 2 stage double acting, non lubricating, vertical reciprocating

Capacity: 600 m3/hr.

All air compressors are working between 5 to 7 kg/cm2 pressure in case of power failure, the pressure can be present half an hour. The instrument air is free from dust, moisture and oil. It provides plant air for cleaning purpose only.

- Stroke : 150/min- Pressure:8.5 kg/cm2- RPM: 580 per min

4. VALVES: (a)NRV – (non return valve)

Check valve

- With or without spring- Used in boiler

Lift type valve

- Used in P.A. storage tank

(b) Plug valves; Plus with hole

- Used in P.A. storage section

- It provides tight fitting and leakage avoids

(c) Gate valve: only for ON-OFF (open – close)

- It can be used only for water line.

(d) Globe valve: - It is used for steam and NH3 storage section.

- It checks the flow and also does flow control.

(e) Butterfly valve:

- It is known as motorize valve. It is use for air and flow limit.

(f) Ball valve.

- It provides balls with the holes for immediately ON-OFF. Hence, utilized in safety shower.

(g) Safety valve:

- It provide for equipment safety. It is known as click valve or relief valve.

- NH3 storage tank has this safety valve at the top, where pressurized the tank to release the pressure.

(h) Foot valve:

- It’s function is to reverse of check valve. It is placed on Honda pump to give suction to the pump.

5. PUMPSTypes of pumps:

- Rotary pumps.- Reciprocating pump.- Centrifugal & positive displacement.

1. Rotary pumps:

Gear pump:

- Used for semi –solid & non corrosive liquid.- Gives constant circulation pressure.- It requires oil pump for lubrication.

Lobe pump: it is the blower or drinking water system.

Screw pump: At L.S.H.S. tank, screw pump is there. It is used for semi solid or viscous liquid.

2. Reciprocating pump:

It is used when there is constant pressure & pulsating flow. Flow control is not possible in it. It is used for infinite head & low pressure. It is utilized for sludge separation.

B.Electrical Services:

G.S.F.C. – S.U. is the purchasing the electricity from G.E.B. Sikka. The thermal power unit with the help of 66 KW line. Then, it has step down transformer to supply the electricity to individual plant in 11 KW, 3.3 KW as per requirement of the plants and equipments. It contains A.C. supply only.

Electrical Instrumentation:

1. Main sub –station2. Utility3. Ammonia installation4. Bagging

CHAPTER –4

UTILITY SPECIFICATION

The utility provide for the production of DAP are given below:-

1. Middle Pressure Steam2. Low Pressure steam3. Condensate4. Cooling tower5. Process water6. Portable Water7. Plant air8. Instrument air9. Nitrogen10. Furnace oil11. Electricity

Details about all utilities are given below:-

1. Middle Pressure steam:-

Pressure : 8.4 kgf/cm2 at tap off point within existing facility.

8.0 kgf/cm2 at DAP ‘C’ train battery limit.

Temperature: 180 deg C.

2. Lower Pressure Steam :-

Generated from M.P. stream within the DAP plant.

Pressure : 3.1 normal

3. Condensate :- Pressure at DAP plant is 2 kg/cm2 minimum.Temperature 90-100 deg C

4. Cooling water :-

Supply temperature : 34 deg centigrade

Return temperature : 40 deg centigrade

Supply pressure : 3.5 kgf/cm2

Return pressure : 2.0 kgf/cm2

Design temperature : 75 deg centigrade

Design pressure : 6 kgf/cm2

5. Pressure water :- Supply water : 4.0 at DAP train Density pressure : 5.7 Supply temperature : ambient Design temperature : 75 deg centigrade

6. Portable water:-

Supply pressure : 5.0 kgf/cm2

Design pressure : 7.5 kgf/cm2

Supply temperature : ambient

Design temperature : 75 deg centigrade

7. Plant air:- Temperature : ambient Pressure : maximum 7.0 kgf/cm2 Minimum 5.3 kgf/cm2 Pressure at DAP : 6.0 kgf/cm2 Design temperature : 75 deg centigrade Design pressure : 9.35 kgf/cm2

8. Instrument Air :-

Temperature : ambient

Pressure : maximum 7.0 kgf/cm2

Minimum 4.2 kgf/cm2

Pressure at DAP plant : 4.0 kgf/cm2

Dew point temperature : -20 deg centigrade

Design temperature : 75 deg centigrade

Design pressure : 9.35 kgf/cm2

9. Nitrogen :-

Temperature : ambient

Pressure : normal 7.0

Max 8.8

Min 4.0 kgf/cm2

Purity : 99.5 mole %

Dew point : -40 deg centigrade

10.Furnace oil :-

Net heat value : 9500 to 9600 kcal/kg

Gross heat value : 10500 kcal/kg

Flash point : 66-72 deg centigrade

Pressure : 6.5 min, & 5.0 normal kgf/cm2

Temperature : minimum 60 deg centigrade

Design temperature : 100 deg centigrade

11.Electricity :-

Voltage : 11kv +- 5%

3.3kv +- 5%, 415v +-5%

Phase : 3

Frequency : 50 Hz +- 6 to 12%

Less voltage : 415 v

For motor 151 kW &

Less than 750 kW, voltage : 3.3 kV

For motor 751 kW : 11 kV

BOILER

The plant has 2 boilers. Each is a Thermax Revotherm 3 passes boiler. Both are from 1987 construction. Revotherm is the first reversal fuel gas, oil packed boiler. It s manufactured in India. Its unique principal of fuel gas reversal and spiral agitators make it most efficient smoked tube boiler.

Specification:-

Steam output from & at 100 deg C : 8000 kg/hr.

Boiler design pressure : 15 kgf/cm2

Superheater design pressure : 15 kgf/cm2

Efficiency : 83%

Fuel oil consumption : 541 kg/hr

Heating surface area of boiler : 138 m2

Super heater : 86.63 m2

No of tubes : 118

CHAPTER-5

PROCESS DESCRIPTIONThe whole process of production of DAP is divided into two sections:

1. Wet section2. Dry section

Wet section is generally helpful to reduce the cost of raw material and increase the fertilizer value of product.

In dry section main production of granular DAP is carried out so both are very important section and both have its individual significance.

PROCESS DESCRIPTION:-

Two parallel and identical trains of equipment are considered in the DAP plant. Both the trains have same capacity and operate separately. These trains are grouped into two section i.e.

1. Wet section2. Dry section

1. Wet section:-

This section is sub divided into two sections:-

a. Scrubbing Sectionb. Neutralisation

(a) Scrubbing section :-

Scrubbers are used to scrub dust, efficient fumes and gases from their respective equipment to recover fertilizer values they contain P.A.

Cyclonic type primary scrubbers are used for handling dust bearing fumes and ammonia and gases evolved from reaction and granulation system, dust system and drying system.

Partially neutralized scrubber solution is scrubber liquor. From here it is transferred to the reaction section.

The quantity of the scrubber in the system is held constant by metering fresh water into the system for holding scrubber efficient tank level constant. The efficient air from the product cooler, which contains small amount of fertilizer dust, is scrubbed with re-circulated water in a spray type scrubber. Fresh water is introduced into the cooler scrubber efficient tank. A fan is provided to each scrubber for forcing the air. The fumes and gases from the reactor and granulator are forced by a fan to a spray type tail gas scrubber. Stack is provided for discharging the scrubbed gas.

(b)Neutralization:-

Neutralization of the P.A. by NH3 takes places in the pre-neutralizer; Pre-neutralizer is made of stainless steel. It is agitated type vessel equipped which sparkers for introduction of liquid NH3.Fresh 54% P2O5, S.A., and recovered scrubber liquor are metered to the pre-neutralizer. Liquid NH3 also metered into the pre-neutralizer.

Heat is released by the neutralization, which rises the temperature of the reacting slurry up to its oiling point. Large quantity of water is vaporized and vented to the fumes scrubber through and exhaust system. The fumes contain NH3 gas and fluorine which are recovered in fumes scrubber. Reaction slurry is pumped from P.N. to the granulator; specific gravity of the slurry is 1.45.

CHAPTER-6

PROCESS EQUIPMENTIn the main process equipment are:-

1. Pre-neutralizer2. Granulator3. Dryer4. Combustion chamber5. Cooler6. Screen drag feeder7. Scrubber8. Conveyor9. Cyclone separators10. Vibrating screens11. Fumes stack12. Mist eliminator

GRANULATOR:-

Granulator is the heart of the plant. It is the rotary form type granulator. Granulator converts the slurry fines into the granulator. It gives the main product to the plant depending upon the load. The granulator is having feed as PN slurry, solid raw material and NH3 to increase the mole ratio up to 1.8. The shell of granulator is made up of M.S.R.L. neutralized slurry from PN tank is fed to the granulator is made of provided for spraying the slurry. Steam jacket is provided to maintain the temperature. Breathing holes are provided for removing the chocking material by the means of air.

The feed is too granulated by two types of process.

1. Agglomeration: - Fine particles are blinding with other particles and make granules just cementing. These types of granules are weak and break at higher temperature.

2. Layering method:- Slurry sprays particles making layers of slurry and make granules. Each granule is having 6 to 7 layers. These types of granules are very hard and hot don’t break at high temperature.

Granules formed by layering are almost harden, more spherical and durable then these formed by agglomeration.

Crushing strength of layering types of granules is higher than the agglomerated granules.

Factors affecting granules:-

1. Liquid phase of granulator 2. Particle size of feed3. Granulator temperature4. Recycle ratio 5. Mole ratio of granulator mixture and slurry6. Bed depth in granulator7. Location of spur gear and angle of spray

Granulator temperature maintained at 80-90 deg centigrade and reaction raise temperature by changing wet action of water to dry solid, we and attain proper granulator size.

Here, higher temperature means increase in solubility of solid which in turn increase the solution to solid phase ratio and calling for more recycle and may damage the product and lower temperature make granulation difficulty due to low plasticity.

RECYCLE RATIO:-

It is the most important & easiest mean of controlling the process of granulation. The recycle ratio depends on the atmosphere of water input to granulator and water required in granulation for proper granulation. Our granulation process is called “Recycled limited/water balance limited.” As there is excess water is present so that the raw material such that additional dry solids have to recycle to receive to achieve desired water content.

3. Dryer

Co-current hot gas rotary type dryer is used for drying the DAP. This DAP is coming from the granulator. Knockers are provided at the outside of the wall, which carrying 20kg balls for removing the chocking materials inside the wall. The dryer used to reduce the moisture contain from 3% to 1%. Normally the dryer gear oil lubricating system needs to cool the oil during working condition of drying. So for the solution of this problem they installed FLS system for lubricant of the dryer gear system.

Diameter 3.6 mLength 24.5 mCapacity 296 MPTMMaterial of construction Stainless steelInclination 1/6 of its lengthRetention time 6 minutes

4. Combustion chamber

It is mainly used for circulating not the air to the dryer. The fuel off ratio in the combustion chamber is 1:13. The air blower is provided for the air proper combustion of fuel in the

chamber. The temperature generated by burning the fuel is about 1000-1200 deg C, so this high temperature will melt all parts in combustion chamber. So a quench air fan is provided for rapid cooling of high temperature gas. The temperature of gas from the outlet of this combustion chamber is different, depending upon the grade. For grade 1, 230-250 C for grade 2, 200-230 C.

5. Cooler Cooler is generally provided for cooling of product discharged from the screen. The product from the screen is about 84-90 C and been cooled to 45-50 C. Now the products being cooled by such suction of cooler fan. The fan sucks atmosphere air from cooler open discharge and having suction point at screen product entrance to the cooler. So this show that cooling is done counter-currently. The product from the cooler discharge goes to the product elevator. This elevator send this product to product to product conveyer and conveyer send product to the product storage silo or direct for bagging after degusting product.

6. Screen Drag Feeder

This SDF is located upon the screen and its main function is to uniformly distribute the product from the primary elevator. The SDF is simple conveyer having tripper door at the top of screen through product flow to the screen and distribute in oversize, undersize and product size. So if the failing product is in not in uniform manner then screen will chock to higher load on it. So SDF is also more for getting good product size from screen.

7. Scrubber:-

There is venture type scrubber, which scrubbed gasses into liquor. Gasses and ammonia are separated NH3 is recycled into the plant.

1. Fumes Scrubber:-

It is venture type scrubber. It is made up of M.S.R.I. this scrubber has the capacity of 55400 ACMH (actual cubic meter per hour) and pressure drop about 300 mm.

2. Tail gas scrubber:-

It is spraying wet type scrubber. It is made up of M.S.R.I. this scrubber has the capacity of 49600 ACMH and the pressure drop of 75 mm.

3. Dust scrubber:-

It is venture with fixed throat type scrubber is made of M.S.R.I. This scrubber has capacity of 42,500 ACNH and pressure drop about 30 mm.

4. Dry scrubber:- It is venture with variable throat cyclone type scrubber. It is made up M.S.R.I. it has the capacity of 1, 18,000 ACMH and pressure drop about 300 mm.

5. Cooler gas scrubber:-

It is wet spray type scrubber. It is made of M.S.R.I. it has capacity of 51,000 ACMH and pressure drop of 100 mm.

8. CONVEYERS:-

The conveyers are main part of the plant dry section. The conveyers are having capacity of 300 MTPH normally. The raw material enters from conveyers 178 and through tripper it flows in respective feeder. From feeders the raw material goes to fines conveyers. This fines conveyer is also called recycle conveyer and is the left hand of the plant. SDF is also conveyer, which provides the product uniformly to screen. The product from product elevator and then product conveyer. This product conveyer sends the cooled product to bulk storage or directly to bagging through conveyer. So plant is fully distributed with conveyer. This conveyer system is distributed with interlocks system, which trips all the equipment in the reverse flow if any conveyer is stopped due to certain reason.

1. HANDWHEEL: - The spooked hand wheel is fabricated from steel pipe. The hub is coupled with the yoke sleeve by means of tongue.

2. YOKE SLEEVE: - The yoke sleeve is made from cast aluminium bronze having high resistance to wear and a high melting point. It is designed to permit removal from the bonnet or the yoke whilst the value is in service gate values 6 class 600 and above are fitted ball thrust bearings.

3. GLAND AND FLANGE: - They are in forged steel and are supplied in two pieces, self aligning design to permit the gland to descend parallel to the system even if the eyebolts are unevenly tightened.

4. GLAND BOLTS AND NUTS: - The forged steel gland bolts are of the eyebolt type which can be swung outward for ease of gland repacking. They are fixed to the bonnet by hinge plans.

5. BONNET BOLTING: - Bonnet studs and nuts are manufactured from alloy steel to the relevant ASTM standard.

6. BODT: - The body is in card steel and is carefully designed in all its details. The basic dimension, i.e. wall thickness, face to face and flanges compile with the relevant API and ANSI standards. The body to bonnet flange is circular, except in the class 150 which is oval. The body to bonnet joint are flat face on class 150 valves, male and female on class 300 and ring joint on class 400 and above.

7. BONNET:- The bonnet is in cast steel. It is machined to accept yoke sleeve and incorporates a stuffing box dimensioned in accordance with the API standard.

8. BONNET BUSHING: - The bonnet bushing or backseats is in form of stainless and forms part of the trim.

9. STEM:- The stem is in forged stainless steel and is part of the trim. The stem is provided with a T head. A ground backseat is provided to ensure a perfectly tight seal to the stuffing box when the valve is fully open. The stem is grounded to minimize friction and prevent damage of gland packing. The threading is trapezoidal ACME type.

10. SEAT RINGS: - The rings are in forged stainless and are part of the trim. They are completely threaded outside and notched on their inner surface to ease installing.

11. WEDGE: - The wedge is a part of the trim. It is forged stainless steel for diameters up to 12 and is in cast steel for larger valves. It normally supplied as the solid wedge type. It is connected to the stem by means of a T joint. The guides on a each side of the wedge are machined. Special attention is given to the seating which are ground and lapped.

CHAPTER-6

VALVESThere are many kinds of valves are used in the company for specific reasons. Some of the valves are given below:-

1. Safety valves2. Plug valves3. Gate valves4. Globe valves5. Non return valves6. Control valves

1. Safety valves: - It is known as tight value and plot values. It is provided for the safety of equipment. The NH3 storage tank has safety value at the top of the tank, when the tank is pressurized; some of the pressure is release from this valve.

2. Plug valve: - This valve provide tight fitting and avoid the leakages and therefore used for acidic services. Plug valves in P.A. storage section.

3. Gate valve: - It just provides the function of open-close or on-off the water pipelines.4. Globe valve: - These valve checks and control the flow of fuel. It is used for steam and NH3

storage sectors.5. Non return valves:-

There are three types of NRV:

Lift type valve: - This type of valve is used in P.A. storage tank.

Check valve:-It is used inside the boiler.

Foot valve:-It is used to give suction of the pump.

6. Control valve:- Control valves are fully automatic type pneumatic type valve. It is used to control the flow of fluid by using instrument air. This is used to open or closed the position of valve.

CHAPTER-7

BAGGINGGeneral introduction:-It consists of silo the bulk storage of DAP, product handling & bugged material handling. The capacity is 24,000 M.T.

A. Types of wt. machine:-- Power build pneumatic- Richardson electric

B. Two types of striking machine each of 70-75 stitches to each bag having capacity of 1200 bags/hr.

Material of construction:-S.S.

Capacity:-30 M.T. hr.

C. There is one type of bag.

HDPE size:-24”x32”

There are plastic net wt. of empty bag HDPE is 120 gm. Wt. filled bag is 50 kg +-30 gm.

D. Belt:-Material of construction:-Rubber belt 4 ply (larger)Type of belt joint:-V joint, Step joint, Diamond joint, Albert jointAngle of belt: - 11, 13, 15

A. Process Description Of Conveying: - In bagging plant, finished product conveyed, stored finally bagged by means wt. machine into different types.

Specifications of some part:-

1. Magnetic pulley:-It is electromagnetic type provided at heat end.2. Cross belt magnetic separator:-To separated foreign particles along with supporting

structures3. Head pulley:-Lagged with 10 mm thick carrion pattern rubbers.4. Zero speed switches:-Each conveyer is provided with zero speed switch at all end for

sequential operation of system.5. Analysis of DAP to handled:-Characteristic of DAP has

- Type in the form of free following granules.- Size of granules 14 mm to 4 mm.- Bulk density 1040 kg/m3- Angle of repose 32 degrees- Rate of 2200 tonnes per day bagging- Deducting system to minimize dust & to make. Bagging plant free from dust & pollution.

B. Capacity:-1. Bunker capacity:-35 M.T. each(8 bunker)2. Belt conveyer product handling system:-25 M.T./hr.3. Reclaimer:-250 M.T./hr4. Belt conveying system:-1200 bag/hr5. Speed of belt:-25 feet/min6. Godown capacity:-8000 M.T.7. Empty bag stock:-40000 bags

C. There are many safety devices arranged in bagging section:-1. Pull churd:-To stop the belt manually for any emergency case.2. Belt sway:-To prevent any damage of belt conveyer of (when belt goes out of centre or

one side of centre).3. Over load tripping relay:-to stop the belt conveyer when load material on the belt4. Magnetic pulley:-To remove any entrainment of the iron material which is suited bottom

layer of the material.5. Cross belt:-To remove any iron trim from pulley upper layer of the material6. Anti run back:-To stop reverse motion of device belt.7. Electromagnetic:-To stop the feed hopper at exact break point which is suited at the top

of the bunker(because due to inertia fundamental the feed hopper will not stop at exact position on the bunkers

-

A TRAINING REPORT

ON

GUJARAT STATE FERTILIZERS

&

CHEMICALS LIMITED.

SIKKA UNIT

TRAINING DURATION

(1/06/2011 to 18/06/2011)

PREPARED BY

PARTH D. VIRAMGAMA

(CHAROTAR INSTITUTE OF TECHNOLOGY,CHANGA)