8/3/2019 sunny ppt

1/40

TRAINING PRESENTATION

ON

IFFCO

(INDIAN FARMERS FERTILIZERS

COOPERATIVE LIMITED)

PRESENTED BY:

JAINENDRA MANI TIWARI

EC(08)

8/3/2019 sunny ppt

2/40

INTRODUCTION

Indian former fertilizer co-operative limited

(IFFCO) was established on 3 November 1967.

In Bareilly district IFFCO unit is located in Aonla.Aonla unit an ammonia-urea complex i.e comprised

of two phases ,AONLAI AONLA-II.

AonlaI was commissioned in May 1988

Aonla-II in December 1996.

8/3/2019 sunny ppt

3/40

OBJECTIVES OF IFFCO

Provide latest and reliable information and extend

other services to all those actively involved in the

development of Indian agriculture and rural

development.

To evolve appropriate dissemination strategies for

effective use of IT Enabled Services in RuralIndia.

8/3/2019 sunny ppt

4/40

MISSION AND VISION IFFCO's mission is "to enable Indian farmers to

prosper through timely supply of reliable, highquality agricultural inputs and services in anenvironmentally sustainable manner and toundertake other activities to improve their welfare

To augment the incremental incomes of farmers byhelping them to increase their crop productivitythrough balanced use of energy efficient fertilizers,maintain the environmental health and to make

cooperative societies economically &democratically strong for professionalized servicesto the farming community to ensure an empoweredrural India.

8/3/2019 sunny ppt

5/40

8/3/2019 sunny ppt

6/40

AMMONIA PLANT

Capacity-1740MTPD

Consultant- M/s Haldor

Topsoe, Denmark Tech.

8/3/2019 sunny ppt

7/40

UREA PLANT

Capacity-1515MTPD

Consultant- M/s Snam

Progetti, ItalyBased on-snamprogetti,

ammonia stripping process

8/3/2019 sunny ppt

8/40

POWER PLANT

Two gas turbines

Capacity-24MW

Supplied by Hitachi,Japan

Main boiler- 150MT/ hr

steam

8/3/2019 sunny ppt

9/40

KALOL UNIT

Year of Commissioning - 1975

Annual Ammonia Capacity - 3.63

Lakh MT

Annual Urea Capacity - 5.45Lakh MT

Year of Commissioning - 1975

Annual NPK/DAP Capacity-

24.15Lakh MT

KANDLA UNIT

PHULPUR UNIT

Year of Commissioning -

1981/1997

Annual Ammonia Capacity - 8.24

Lakh MT

Annual Urea Capacity - 14.1Lakh MT

Year of Commissioning -1988/1996

Annual Ammonia Capacity -

10.03 Lakh MT

Annual Urea Capacity -

17.29 Lakh MT

Year of Acquiring - SEP-

2005

Annual Capacity -20.00

Lakh MT

(DAP + COMPLEX)

AONLA UNIT

CORPORATE OFFICENEW DELHI

PARADEEP UNIT

IFFCOIn Brief

8/3/2019 sunny ppt

10/40

AMMONIA PLANT

8/3/2019 sunny ppt

11/40

INTRODUCTION

This plant is based on HALDOR TOPSOE

technology with natural gas and naphtha as araw materials.

The total capacity of Aonla complex isenhanced to 2700 te/day of Ammonia.

8/3/2019 sunny ppt

12/40

HOW AMMONIA IS MADE Ammonia is produced by the reaction between H2

and N2 ,where the ratio is 3:1,besides these two

components the synthesis gas also contains inert

gases such as- Ar and CH4 to a limited degree.

N2 + 3H2 ---> 2NH3

Source of H2natural gas , naphtha , heavy oil.

Source of N2- is atmospheric air.

8/3/2019 sunny ppt

13/40

DESCRIPTION OF AMMONIA

PROCESSDesulphurization of natural gas.

Primary reforming.

Secondary reforming.

High temperature shift conversion.

Methanation.

Refrigeration system.

Ammonia wash section.

8/3/2019 sunny ppt

14/40

8/3/2019 sunny ppt

15/40

8/3/2019 sunny ppt

16/40

USES OF AMMONIA I t is used for direct application to the soil and in

aqua condition with solutions of other nitrogenous

fertilizers like ammonium nitrate and urea.

It uses in the production of nitric acid, soda ash,

cleaning agents, leather tanning, petroleum refining,

pulp and paper industry, textiles, refrigeration ,

rubber, and synthetic resin industries, explosives and

food and beverage industries.

8/3/2019 sunny ppt

17/40

PLANT HAZARDS

The major hazards in ammonia production plant are as

follows:--

Fire/explosion due to leaks from hydrocarbon feed

system.

Fire /explosion hazard due to leaks of synthesis gas inthe CO removal/synthesis gas compression areas(75%

hydrogen).

In ammonia storage the release of liquid ammonia is acredible major hazard event.

8/3/2019 sunny ppt

18/40

UREA PLANT

8/3/2019 sunny ppt

19/40

8/3/2019 sunny ppt

20/40

INTRODUCTION

In IFFCO Aonla urea plant having the capacity 4x

1100 MT/Day.

IFFCO's Urea is not merely a source of 46% of

nutrient nitrogen for crops, but it is an integral

part of millions of farmers in India.

8/3/2019 sunny ppt

21/40

PHYSICAL AND CHEMICAL

PROPERTIES

MOLECULAR WEIGHT-60.05

BOILING POINT-Decomposes at atmospherebefore boiling

DENSITY(crystal) -1.315

HEAT OF COMBUSTION-2531cal/gm

8/3/2019 sunny ppt

22/40

NAME OF EQUIPMENT USED

TURBINE

Co2 COMPRESSURE

TURBINE CONDENSOR

UREA MELT PUMP

PRILLING TOWER

ROTARY SCRAPER

8/3/2019 sunny ppt

23/40

HOW UREA IS MADE??

N2 + 3H2 -> 2NH3

(AMMONIA)

2 NH3 + CO2 ->H2N-COONH4

(AMMONIUM CARBAMATE)

H2N-COONH4 (NH2)2CO + H2O

(UREA)

8/3/2019 sunny ppt

24/40

DESCRIPTION OF UREA PLANT

Main operations performed:

Urea synthesis and high pressure recovery

Urea purification and low pressure recovery

Urea concentration

Urea prilling

Waste water treatment

8/3/2019 sunny ppt

25/40

UREA SYNTHESIS & H.P.

RECOVERY

Urea is produced by the synthesis from liquidammonia and gases CO2 , both being supplied by

ammonia plant.

8/3/2019 sunny ppt

26/40

UREA PURIFICATION & L.P.

Urea solution from the H.P. stripper enter the M.P.

decomposer after pressure reduction through a

level control valve.

The urea solution from MP decomposer bottom

enters the LP decomposer after expansion throughthe level control valve.

8/3/2019 sunny ppt

27/40

UREA CONCENTRATION

The liquid from the bottom of LP decomposer isfurther concentrated in two vaccum concentrators

in series.

8/3/2019 sunny ppt

28/40

LADDER LOGIC

8/3/2019 sunny ppt

29/40

PROGRAMMABLE LOGIC

CONTROLLERS

8/3/2019 sunny ppt

30/40

INTRODUCTION

Before the advent of solid state logic circuits,logical control systems were designed & builtexclusively around electromechanical relays.

In late 1960s an American company namedBedford Associates released a computing devicethey called the MODICON.

Modular Digital Controller

Other engineering firms developed their ownversion of this device and it eventually came to beknown in non-proprietary term as PLC.

8/3/2019 sunny ppt

31/40

Purpose is to replace electromechanical relay as

logic elements.

PLC has many input terminals ,through which it

interprets high & low logical states from

sensors & switches.

It also have many outputs.

In efforts to make PLCs easy to program theirprogramming language was designed to resemble

ladder logic diagrams.

8/3/2019 sunny ppt

32/40

CONTROL SYSTEMS

A control systems is the electronic equipment

needed to control particular process.

It many include everything from a process control

computers, if one is used to the factory computer

down through the PLCs

There may be many of them networked together.

8/3/2019 sunny ppt

33/40

ROLE OF PLC

PLC is the part of control system that directly

controls the manufacturing process.

Accepts the data from the input devices connected

to it & uses data to monitor the control systems.

PLC sends data to the output device connected to

it cause that action to take place.

8/3/2019 sunny ppt

34/40

INPUT DEVICES

PLCs can receives input from either automatic or

manual devices.

PLC can receives the data from the user via push

button, keyboard or similar devices.

8/3/2019 sunny ppt

35/40

OUTPUT DEVICES

A PLC can output to devices for use in automated

control.

Output devices may be motors, solenoids,

servomotors, stepping motor, & valves.

8/3/2019 sunny ppt

36/40

WORKING OF PLC

PLC operate by monitoring input signals &

providing output signals.

When changes are detected in the signals PLC

react through the user programmed internal logic

to produce output signals.

PLC continuously scans the program.

8/3/2019 sunny ppt

37/40

FRONT VIEW OF PLC

8/3/2019 sunny ppt

38/40

ADVANTAGES & DISADVANTAGES

Flexibility

Correcting error

Space efficientLow cost

Testing

Visual observation

8/3/2019 sunny ppt

39/40

8/3/2019 sunny ppt

40/40