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A
REPORT
ON
INDUSTRIAL VISIT
(Under TEQIP-II)
TO
NATIONAL FERTILIZERS LIMITED,
VIJAIPUR, GUNA (M.P.)
&
GAS AUTHORITY OF INDIA LIMITED (GAIL)
VIJAIPUR, GUNA (M.P.)
DATE OF VISIT
20, 21 & 22 MARCH 2013
DEPARTMENT OF PETROCHEMICAL ENGINEERING
SAMRAT ASHOK TECHNOLOGICAL INSTITUTE (DEG),
VIDISHA (M.P.)
PREFACE
It is well known that for making a fine engineer apart from thorough bookish and
theory knowledge eminent practical knowledge is also required. Hence the importance of this
visit can be justified. This visit helped the students to grasp a bit of knowledge about the
common machineries and technologies used in an industry.
An industrial visit was arranged for the B.E. IV semester Petrochemical engineering
students on 20, 21 & 22 March 2013.
The industries visited were:-
1. National Fertilizers Limited, Vijaipur, Distt. Guna (M.P.).
2. Gas Authority of India Limited, Vijaipur, Distt. Guna (M.P.).
ACKNOWLEDGEMENT
The students of B.E. IV Semester Petrochemical Engineering are grateful to Director, Dr,R.
C. Jain for giving kind permission to industrial visit (Under TEQIP-II) these well known industries
of Petrochemical field. The students would like to acknowledge Dr. Manoj Datar, Professor &
Head of the Department, Petrochemical Engineering, for his pains taking effort to arrange this
visit. Also, special thanks to Mr. Ankit Kadam for his guidance & help during the visit.
Date: 26/03/2013 Students of B.E. IV Semester
Vidisha (M.P.) Petrochemical Engineering
INTRODUCTION
An industrial visit of two industries has been arranged for the students of B.E. IV Semester
Petrochemical Engineering. The industries visited were namely National Fertilizers Limited,
Vijaipur, Guna (M.P.) & Gas Authority of India Limited (GAIL), Vijaipur, Guna (M.P.) on 20, 21
& 22 March 2013 .The purpose of the visit was to make students aware of the general machinery
and processes involved in an industry.
Students of B.E. IV Sem Petrochemical Engg proceding for Industrial visit to
NFL & GAIL, Vijaipur
VISIT TO NATIONAL FERTILIZERS LIMITED (NFL)
About National Fertilizers limited:-
NFL is a Schedule A and a Mini Ratna Category-1 Company which was incorporated on
23rd August, 1974 for implementation of two fertilizer plants, based on gasification technology of
Feed Stock / LSHS at Bathinda in Punjab and Panipat in Haryana having an installed capacity of
5.11 lakh tones of Urea each. The Govt. of India, in 1984, entrusted the Company to execute the
countrys first inland gas based fertilizer project of 7.26 lakh tones Urea capacity in District Guna
in Madhya Pradesh. The Vijaipur plant commenced commercial production w.e.f. 1.7.1988.
(Vijaipur-I) Subsequently, Expansion of Vijaipur Plant was taken up in 1993 for doubling its
annual production capacity (Vijaipur-II)
National Fertilizers Ltd, Vijaipur unit is one of the four units of M/S National Fertilizers
Limited. With the commencement of commercial production of the Expansion project the gas
based unit at Vijaipur now comprises of two 1520 ton per day (tpd) Ammonia streams and four
1310 tpd Urea streams and related off-site facilities. The gas is being received from the HBJ gas
pipe line being operated by M/s Gas Authority of India Ltd (GAIL) another government of India
undertaking. The Ammonia stream completed under the Expansion Project can also be operated
with 50 % feed of Naphtha in case of shortage of the gas supply. The industry also has 3 power
plants each of capacity 17 MW and at a time 2 power plants is used and 1 kept for standby
purpose.
The main product of this industry is Kisan Urea. The total production capacity of Kisan
Urea is 6,261 Tonnes/day which is the second largest production in the country.
Raw materials used:-
The raw materials for the production of Urea are Ammonia (NH3) and Carbon-di-oxide
(CO2). These are obtained by NG / Naphtha, Power, Water. Water used here is taken from Sanjay
Sagar dam. The process for the production of ammonia and carbondi oxide are :
(A). Ammonia (NH3):- For Ammonia production, we want Nitrogen (N) and Hydrogen (H). And
Nitrogen is present in the air at surplus amount so Nitrogen is obtained from air and
Hydrogen is obtained from Methane (CH4) by catalytic reforming which is obtained from
Natural Gas (NG) which contains about 85% - 90%. And GAIL supply the Natural Gas by
HBJ pipeline.
(B). Carbondi-oxide (CO2): - CO2 is obtained from the atmosphere or air.
Manufacturing process:-
Urea is manufactured by reacting ammonia and carbon dioxide in autoclave to form
ammonium carbamate. The operating temperature is 1350C and 35 atm pressure, the chemical
reaction is endothermic reaction and so ammonia is maintained in excess to shift the equilibrium
towards urea formation. Urea production consists of main two reactions.
1. Formation of ammonium carbamate
2. Dehydration of ammonium carbamate to produce molten urea.
Shri R S Gupta, Sr. Manager addressing the students about safety measures in the plant.
Description or Plant Layout:
1. Ammonia pumping : Liquid ammonia is pumped from the multistage pump which maintain the
reaction pressure in the vertical stainless steel vessel
2. Carbon dioxide compression: Ammonia plant directly boosts the carbon dioxide from the
compression section as it readily forms at the CO2 section of ammonia production plant.
3. Urea synthesis tower: It is lined with film of oxides to protect form corrosion. Catalyst bed is
placed in the inner side of the autoclave structure and 180- 200 atm pressure at temperature about
180-200 deg centigrade is maintained. Plug flow operation take places and molten urea is removed
from the top of the tower.
4. Distillation tower and Flash drum: This high pressure slurry is flashed to 1 atm pressure and
distilled to remove excess ammonia and decomposed ammonia carbamated salts are removed and
recycled.
5. Vacuum Evaporator: The solution is fed to vacuum evaporator for concentrating the slurry.
6. Prilling Tower: It is dryer where the molten slurry is passed from top of the tower into a bucket
which rotates and sprinkles the slurry and air is passed from the bottom. All the moisture is
removed as the urea form into granules during it journey to the bottom of the tower. These
granules are sent by conveyor to the bagging section.
Students of B.E. IV Sem Petrochemical Engg with Shri R S Parihar, DGM (HR), NFL, Vijaipur
VISIT TO GAS AUTHORITY OF INDIA LIMITED (GAIL)
Introduction:-
GAIL (India) Ltd was incorporated in August 1984 as a Central Public Sector Undertaking
(PSU) under the Ministry of Petroleum & Natural Gas (MoP&NG). The company was initially
given the responsibility of construction, operation & maintenance of the Hazira Vijaypur
Jagdishpur (HVJ) pipeline Project. It was one of the largest cross-country natural gas pipeline
projects in the world. Originally this 1800 Km long pipeline was built at a cost of Rs 1700 Crores
and it laid the foundation for development of market for natural Gas in India.
Production:-
1. Natural Gas:
Natural Gas is a new age fuel. With only one carbon and four hydrogen atoms per
molecule, Natural Gas has the lowest carbon to hydrogen ratio, hence it burns completely,
making it the cleanest of fossil fuels. Natural Gas satisfies most of the requirements for fuel
in a modern day industrial society, being efficient, non-polluting and relatively economical.
The periodic uncertainties and volatility in both the price and supply of oil, have also
helped Natural Gas emerge as a major fuel in the energy basket across countries.
Natural Gas comes in 4 basic forms:
Liquefied Natural Gas (LNG) - Natural Gas which has been liquefied at (Minus)
160 degree Centigrade. Natural Gas is liquefied to facilitate transportation in large
volumes in cryogenic tankers across sea.
Regasified Liquefied Natural Gas (RLNG) LNG Re-gasified before transporting it
to consumers through Pipelines.
Compressed Natural gas (CNG) - Natural Gas compressed to a pressure of 200-250
kg/cm2 used as fuel for transportation. CNG decreases vehicular pollution on the
virtue of being cleaner fuel than liquid fuels.
Piped Natural gas, PNG - Natural Gas distributed through a pipeline network that
has safety valves to maintain the pressure, assuring safe, uninterrupted supply to the
domestic sector for cooking and heating / cooling applications.
Students with Mr. Sanjay Jain, Sr. Manager, GAIL, Mr. N Patni, Sr. Manager, GAIL &
Dr. Manoj Datar, Professor and Head, Petrochemical Engineering Deptt.
2. LPG:
GAIL is the first company in India to own and operate pipelines for LPG
transmission. It has 1,900 km LPG pipeline network 1,300 km of which connects the
western and northern parts of India and 600 km of networks is in the southern part of the
country connecting Eastern Coast. The LPG transmission system has a capacity to transport
3.8 MMTPA of LPG. LPG transmission through pipelines was 3337 TMT in the year
2010-11.
GAIL produces LPG through fractionation in Gas Processing Units, known as
Straight Run LPG. GAILs LPG is an eco-friendly fuel and provides a cheaper and
effective means of reducing pollution and increasing productivity.
3. Other Products:
In the process of production of main products viz. LPG & Polymer through
GPU/GCU except Usar, the following by-products- Liquid Hydrocarbons (LHC) are
produced:
Plant By-product
Vijaipur Propane, Pentane, Naphtha
Auraiya Propane, Pentane, Naphtha, MFO, Hydrogenated C4 Mix,
Propylene and Slop Oil
Vaghodia Naphtha
Gandhar Pentane, Naphtha
Lakwa Solvex-GL / Naphtha
GAIL is India's major producer of Propane, popularly known as GAIL Propane. It is an eco-
friendly fuel and provides an effective way of reducing pollution and increasing
productivity.
GAIL produces and markets Pentane. It is primarily being used for reprocessing into iso,
normal & commercial pentane used in EPS, PU, LAB industry.
Naphtha is primarily used by Power, Fertilizer, Steel and Petrochemical Units. In Power,
Steel units it is used as a fuel, whereas in Petrochemical, Chemical, Fertilizer units it is used
as a feedstock.
CONCLUSION
The Industrial visit provided the students to observe several unit operations/unit processes
taking place in a chemical industry live. It was a great experience to observe the magnitude and the
quantum of machinery/equipments used in a manufacturing process. Thus the students found the
visit to be a great learning experience and a source of practical knowledge. Hence overall, the visit
has been successful and concluded without any hurdles and hindrances.