APractical Training Report

ON

“INDIAN FARMER COOPERATIVE LIMITED, KANDLA UNIT”

Submitted to

Rajasthan Technical University, Kota

In partial fulfillment of the

Bachelor’s Degree In TechnologySpecialization in

MECHANICAL ENGINEERING

By DARSHAN.J.SINGH (12EJEME203)

2014-2015

Under the Guidance of Mr.Rohit jain Mr.D.N Naresh Lecturer H.O.D.Deptt. of Mech. Engg.

Deptt. of Mech. Engg JEC, Kukas JEC, Kukas

i

Department of Mechanical EngineeringJaipur Engineering College, Kukas, Jaipur (Rajasthan)

RAJASTHAN TECHNICAL UNIVERSITY, KOTAJuly,2014

JAIPUR ENGINEERING COLLEGE KUKAS, JAIPUR (RAJASTHAN)

DEPARTMENT OF MECHANICAL ENGINEERING

2014-2015

CERTIFICATEThis is to certify that this practical training Report entitled “IFFCO- KANDLA UNIT”,

which is being submitted by Darshan.j.Singh in partial fulfillment for the award of the

Degree of Bachelors of Technology in Mechanical Engineering, of Rajasthan Technical

University, Kota is a record student’s own work carried by him under my guidance and

supervision.

To the best of my knowledge, the matter presented in this report has not been

submitted for the award of any other diploma or degree certificate.

Under the guidance of:

Mr.Vaibhav Singh Mr.D.N Nareshii

Lecturer H.O.D.Deptt. of Mech. Engg. Deptt. of Mech. Engg JEC, Kukas JEC, Kukas

Date: 31-07-2014Place: Jaipur

iii

ACKNOLEDGEMENT

A research work owes its success from commencement to completion, to the people in love

with researchers at various stages. Let me in this page express my gratitude to all those who

helped me in various stage of this study.

It comes out to be a great pleasure and experience to me to have practical training for the

fulfilment in the Bachelor of Technology. I would express appreciation to all who assisted to

me in one or another way.

I am thankful to my facilitator Mr.Vaibhav Singh for his continuous guidance & support. I

would like to thank him for giving me excellent suggestion and affectionate, encouraging

through development of seminar and for devoting his precious time.

I would like to express my grateful thanks to guide all the teachers. As their cooperation and

knowledge proved as a foundation of inspiration to me at all time I worked. Also I would like

to thank all faculty members and to the entire staff of Mechanical Engineering Department of

Jaipur Engineering College, Kukas, Jaipur for their valuable help throughout the work for

boosting me for creative thinking and helping me to think practically.

I am also thankful to all my colleagues for their co-operation and support.

Darshan.j.Singh

(12EJEME203)

iv

PREFACE

Engineering is not only a theoretical study but it is a implementation of all we study for

creating something new and making things more easy and useful through practical study. It is

an art which can be gained with systematic study, observation and practice. In the college

curriculum we usually get the theoretical knowledge of industries, and a little bit of

implementation knowledge that how it work’s. But how can we prove our practical knowledge

to increase the productivity or efficiency of the industry.

To overcome such problem I have taken the training at INDIAN FARMER FERTILIZER

COOPERATIVE LIMITED,KANDLA -UNIT(GUJARAT).

v

ABSTRACT

It contains ¾ page without changing the paragraph and highlights.

vi

TABLE OF CONTENTS

S.no. Page No.

1. Certificate ii

2. Acknowledgement iii

3. Preface

iv

4. Abstract v

Chapter-1 Indian Farmer Fertilizer co-operative Limited

1.1 Introduction 8

1.2 Company profile 10

1.3 Organization chart 11

Chapter-2 Types of fertilizer produced in kandla unit

2.1 Grades produces in kandla unit 13

2.2 process description 14

2.3 Raw material used 15

Chapter-3 Kandla phase-1&Kandla phase-2

3.1Process Description in Phase-1 20

3.2 Process Description in Phase-2 22

3.3 Urea phosphate Plant 24

3.4 Equipment performing in phase1&2 30

Chapter-4 Off-Site &Bagging Unit

4.1Raw material Storage 35

4.2 Bagging Process 40

Conclusion 42

References 43

vii

LIST OF FIGURESFig No. Name of Figure Page No.

1.1 IFFCO kandla plant

1.2 Company logo

1.3 Organization chart

2.1 Images of product

2.2 Process flow chart

2.3 Rotary drum dryer

2.4 Conc sulphuric acid storage tank

2.5 Ammonia storage tank

2.6 Potassium chloride

3.1 IFFCO kandla unit phase-2

3.2 Primary elevator

3.3 Screen drag figure

3.4 Fine conveyor

3.5 Cyclones dust collector

4.1 Steam boiler

4.2 Air cooling system

4.3 Thermax boiler

4.4 Bagging filling plant

4.5 Bags after filling

4.6 Bags in loading condition

viii

Chapter -1

INDIAN FARMER FERTILIZER COOPERATIVE LIMITED

1.1. Introduction

FIG:-1.1 IFFCO KANDLA PLANT

The fertilizer in India consists of three major players: The Government owned Public

Sector undertakings, Cooperative Societies like IFFCO, KRIBHCO and units from

Private sector.

The fertilizer industry has organized itself through Fertilizer Association India (FAI) to

coordinate with the Government of India to achieve the macro-economic objectives

related to agricultural sector and to provide other services.

Indian Farmers Fertiliser Cooperative Limited, also known as IFFCO, is the world's

largest fertilliser cooperative federation based in India which is registered as a

Multistate Cooperative Society. IFFCO has 40,000 member cooperatives.

IFFCO has been ranked#37 in top companies in India in 2011 by Fortune india 500 list.

ix

IFFCO commissioned an ammonia - urea complex at Kalol and the NPK/DAP plant at

Kandla both in the state of Gujarat in 1975.

IFFCO’s Kandla plant is located on the western bank of Kandla creek adjacent to

Kandla Port Trust Jetties.

The plant produces NPK/DAP complex phosphatic fertilisers of various grades, namely

NPK grades 10:26:26, 12:32:16 & DAP 18:46:00 in terms of N:P2O5:K2O. There are

four identical streams A,B,C & D of equal capacity.

The plant originally consisting of only 2 streams A&B with related facilities was

designed & erected by M/s Dorr Oliver Inc. USA at a cost of Rs. 30 crores having an

annual licensed capacity of 1,27,000 MT P2O5. The plant was commissioned on 28th

Nov. 1974 and commercial production declared on 1st Jan,1975.With increased

demand for complex fertilisers, the capacity was doubled by addition of two more

streams C & D designed & erected by HDO, India at a cost of Rs. 28.60 crores.

Licensed capacity was increased from 1,27,000 MT P2O5 per annum to 2,60,000

MT P2O5 per annum. Construction of C & D streams was completed one month

ahead of schedule. The expanded unit was commissioned on 4th June 1981 and the

commercial production was started from 6th Sept. 1981.

Subsequently due to introduction of production of DAP grade also the total capacity

increased to 3,09,000 MTPA of P2O5. 

Kandla Phase – II

Kandla phase-II NPK/DAP project conceptualised the setting up of two additional E

& F streams for manufacture of the same grades of NPK/DAP fertilisers using the

latest dual pipe reactor technology with an annual production capacity of 2,52,000

MTPA of P2O5 thus increasing the total capacity from 3,09,000 MTPA of P2O5 to

5,61,000 MTPA of P2O5. The actual cost of the project was Rs. 205.30 crores

against a budgetted cost of Rs. 212.20 crores.

x

The main consultant for the NPK/DAP plant was M/s Hindustan Dorr Oliver,

Mumbai with the pipe reactor technology obtained from process licensor

M/sGrande paroisse France, The construction of E&F streams was completed 77

days ahead of schedule. The E & F streams were commissioned on 10th June 1999

& 9th July 1999 respectively and the commercial production started from 5th

August, 1999.

M/s PDIL was the main consultant for all related offsite facilities like bulk storage,

bagging plant expansion, phos,acid & fuel oil tanks etc.

1.2 .COMPANY PROFILE

IFFCO is the largest producer of fertilisers in the country.

A total of 24.49 lakh MT imported urea and 14.71 lakh MT imported DAP were

handled by marketing division from various ports directly.

Fertilisers marketed through 39877 cooperative societies and 158 farmers service

centers.

Only fertiliser institution in the country to produce 85.83 lakh MT of fertilisers and

125.88 lakh MT of sales during 2010-11. This is highest sales in India as well as the

whole world by a single fertiliser Industry.

Attaining an annual turnover of Rs.15000 crore by 2011 which increased to Rs.28516

crore by 2013 .

VISSIONS:-

Attaining an annual turnover of Rs.15000 crore by 2011 which increased to Rs.28516

crore by 2013 .

Backward integration to meet feedstock requirement such as Phosphoric Acid etc.

Generation of power

Exploration of Hydrocarbons

Value addition to Agro-products and marketing

IT enabled services and financial services/

MISSIONS:-

IFFCO's Mission is "to enable Indian farmers to prosper through timely supply of reliable, high quality agricultural inputs and services in an environmentally sustainable manner and to undertake other activities to improve their welfare"

xi

To provide the farmers high quality fertilizers in right time and in adequate quantities with an objective to increase crop productivity.

To make plants energy efficient and continually review various schemes to conserve energy.

Commitment to health, safety, environment and forestry development to enrich the quality of community life.

Commitment to social responsibilities for a strong social fabric. To institutionalise core values and create a culture of team building, empowerment

and innovation which would help in incremental growth of employees and enable achievement of strategic objectives.

Foster a culture of trust, openness and mutual concern to make working a stimulating and challenging experience for stake holders.

Building a value driven organisation with an improved and responsive customer focus. A true commitment to transparency, accountability and integrity in principle and practice.

To acquire, assimilate and adopt reliable, efficient and cost effective technologies. Sourcing raw materials for production of phosphatic fertilisers at economical cost

by entering into Joint Ventures outside India. To ensure growth in core and non-core sectors. A true Cooperative Society committed for fostering cooperative movement in the

country.

Emerging as a dynamic organisation, focussing on strategic strengths, seizing opportunities for generating and building upon past success, enhancing earnings to maximise the shareholders' value.

FIG 1.2 COMPANY LOGO

ORGANIZATION CHART:-

xii

FIGURE 1.3 ORGANIZATION CHART

AWARDS&ACHEIVEMENT:-

IFFCO Kandla had been selected by Dynamic CIO as one of the top 30 innovative heroes compendium IT Award held on 8th August,2013 in Mumbai.

xiii

IFFCO-Kandla employee have won safety competition-2013 held by Gujarat Safety Council, Vadodara.’

IFFFCO Kandla won the best Unit Trophy for implementation of suggestion scheme at third Inter Unit Innovation & Creativity Meet organised at FMDI, Gurgaon during 15-16th May-2013.

IFFCO - Kandla wins "Idea Champion award" at 15th National Summit of INSSAN, New Delhi during 26th -27th July 2013.

Chapter-2

TYPES OF FERTILIZER PRODUCES IN KANDLA UNIT2.1 GRADES PRODUCES IN KANDLA UNIT:-

There were 4 streams in IFFCO kandla plant they are named as A,B,C,D. They produce

three product in IFFCO Kandla plant they are:-

NPK1

NPK2

DAP

These products should have their standard ratio like:

NPK1 have (10:26:26) (800 Ton /Day)

NPK2 have (12:32:16) (1000 Ton/Day)

DAP have (18:46:00) (600 Ton/Day)

FIGURE 2.1 PICTURE OF PRODUCT

2.2 PROCESS DESCRIPTION:-

xiv

FIG:-2.2 PROCESS FLOW CHART

The manufacturing process uses the well known conventional slurry

granulation process.

4 streams- product handling, storage, reclaiming , and bagging facilities.

Cylinder reactor(knownas preneutralizer) through which the Ammonia

&phosphoric acid in the from slurry is supplied to rotary drum granulator

Where it is sprayed over the rolling bed of recycles fines and solid raw materials feeds

like potash, urea and filler to form granules.

The granulated product containing 2.5 % water is then dried in a co-current rotary drum

dryer with hot air produced by combustion of fuel oil.

The dried product is elevated by means of continuous discharge type bucket elevators

and distributed over double deck vibrating screen by means of a drag flight conveyor.

Product of the required size (between 1 mm and 4 mm) is separated in the screen from

the oversize and undersize.

xv

The undersize material collect in a fines bin and discharge into the recycle conveyor,

where it mixes with the crushed oversize and fresh solid raw material feeds to form the

recycle feed to the granulator.

product discharge from the vibrating pan is conveyed to a rotary drum cooler where the

product is cooled from 70 deg. to about 40 deg.

Then product dicharge from product elevator is discharge to the each 4 train through

elevator.

FIG:-2.3 ROTARY DRUM DRYER

The scrubbing system consists of a fumes scrubber, Dust scrubber, Dryer scrubber &

Cooler scrubber. (first three are venturi cyclonic type)

Scrubber liquor supplemented by fresh phosphoric acid feed is circulated by pumps in

all the scrubbers except the cooler scrubber where only water is circulated.

RAW MATERIAL USED:-

The raw materials used in IFFCO are:-

Ammonia

Phosphoric acid

Urea

Potassium chloride

Conc. Sulphuric Acid

xvi

FIG:-2.4 CONC SULPHURIC ACID STORAGE TANK

Sulfuric acid is one of the most important industrial chemicals. More of it is made each

year than is made of any other manufactured chemical; more than 40 million tons of it

were produced in the United States in 1990.

It has widely varied uses and plays some part in the production of nearly all

manufactured goods.

The major use of sulfuric acid is in the production of fertilizers, e.g., superphosphate of

lime and ammonium sulfate. It is widely used in the manufacture of chemicals, e.g., in

making hydrochloric acid, nitric acid, sulfate salts, synthetic detergents, dyes and

pigments, explosives, and drugs.

It is used in petroleum refining to wash impurities out of gasoline and other refinery

products. Sulfuric acid is used in processing metals, e.g., in pickling (cleaning) iron and

steel before plating them with tin or zinc.

Rayon is made with sulfuric acid. It serves as the electrolyte in the lead-acid storage

battery commonly used in motor vehicles (acid for this use, containing about 33%

H2SO4 and with specific gravity about 1.25, is often called battery acid).

When heated, the pure 100% acid loses sulfur trioxide gas, SO3, until a constant-boiling solution, or azeotrope, containing about 98.5% H2SO4 is formed at 337°C.

Concentrated sulfuric acid is a weak acid (see acids and bases) and a poor electrolyte because relatively little of it is dissociated into ions at room temperature.

When cold it does not react readily with such common metals as iron or copper. When hot it is an oxidizing agent, the sulfur in it being reduced; sulfur dioxide gas may be released. Hot concentrated sulfuric acid reacts with most metals and with several nonmetals, e.g., sulfur and carbon.

xvii

Because the concentrated acid has a fairly high boiling point, it can be used to release more volatile acids from their salts, e.g., when sodium chloride (NaCl), or common salt, is heated with concentrated sulfuric acid, hydrogen chloride gas, HCl, is evolved.

Concentrated sulfuric acid has a very strong affinity for water. It is sometimes used as a drying agent and can be used to dehydrate (chemically remove water from) many compounds, e.g., carbohydrates.

It reacts with the sugar sucrose, C12H22O11, removing eleven molecules of water, H2O, from each molecule of sucrose and leaving a brittle spongy black mass of carbon and diluted sulfuric acid.

The acid reacts similarly with skin, cellulose, and other plant and animal matter.

When the concentrated acid mixes with water, large amounts of heat are released; enough heat can be released at once to boil the water and spatter the acid.

To dilute the acid, the acid should be added slowly to cold water with constant stirring to limit the buildup of heat.

Sulfuric acid reacts with water to form hydrates with distinct properties

Although sulfuric acid is now one of the most widely used chemicals, it was probably little known before the 16th cent.

It was prepared by Johann Van Helmont (c.1600) by destructive distillation of green vitriol (ferrous sulfate) and by burning sulfur.

The first major industrial demand for sulfuric acid was the Leblanc process for making sodium carbonate (developed c.1790). Sulfuric acid was produced at Nordhausen from green vitriol but was expensive.

A process for its synthesis by burning sulfur with saltpeter (potassium nitrate) was first used by Johann Glauber in the 17th cent. and developed commercially by Joshua Ward in England c.1740.

It was soon superseded by the lead chamber process, invented by John Roebuck in 1746 and since improved by many others.

The contact process was originally developed c.1830 by Peregrine Phillips in England; it was little used until a need for concentrated acid arose, particularly for the manufacture of synthetic organic dyes.

xviii

FIG:- 2.5 AMMONIA STORAGE TANK

The Ammonia storage tank has a total storage capacity 10000MT, The ammonia is used

in making of the NPK-1&NPK-2 Grades.

Ammonia is a very valuable source of nitrogen that is essential for plant growth. 

Depending on the particular crop being grown, up to 200 pounds of ammonia per acre

may be applied for each growing season.

Ammonia is used in the production of liquid fertilizer solutions which consist of ammonia, ammonium nitrate, urea and aqua ammonia.  It is also used by the fertilizer industry to produce ammonium and nitrate salts.

Ammonia and urea are used as a source of protein in livestock feeds for ruminating animals such as cattle, sheep and goats.  Ammonia can also be used as a pre-harvest cotton defoliant, an anti-fungal agent on certain fruits and as preservative for the storage of high-moisture corn.  

Ammonia is used in the manufacture of nitric acid; certain alkalies such as soda ash; dyes; pharmaceuticals such as sulfa drugs, vitamins and cosmetics; synthetic textile fibers such as nylon, rayon and acrylics; and for the manufacture of certain plastics such as phenolics and polyurethanes.

POTASIUM CHLORIDE:-

xix

 

FIG:-2.6 POTASSIUM CHLORIDE

Potassium fertilizers are commonly used to overcome plant deficiencies. Where

soils cannot supply the amount of K required by crops, it is necessary to

supplement this essential plant nutrient.

Potash is a general term used to describe a variety of K-containing fertilizers

used in agriculture. Potassium chloride (KCl), the most commonly used source,

is also frequently referred to as muriate of potash or MOP (muriate is the old

name for any chloride-containing salt).

Potassium is always present in minerals as a single-charged cation (K+).

Potassium chloride is the most widely used K fertilizer due to its relatively low cost and because it includes more K than most other sources...50 to 52% K (60 to 63% K2O) and 45 to 47% .

Over 90% of global potash production is used for plant nutrition. Potassium

chloride is often spread onto the soil surface prior to tillage and planting.

It may also be applied in a concentrated band near the seed. Since dissolving

fertilizer will increase the soluble salt concentration, banded KCl is placed to

the side of the seed to avoid damaging the germinating plant

xx

FIG:- 2.6 Potassium chloride is found in various shades and particle sizes..

Potassium is essential for human and animal health. It must be regularly ingested because the body does not store it.

Potassium chloride can be used as a salt substitute for individuals on a restricted salt (sodium chloride) diet.

It is used as a deicing agent and has a fertilizing value after the ice melts. It is also used in water softeners to replace calcium in water.

Potassium chloride is primarily used as a source of K nutrition. However, there are

regions where plants respond favorably to application of Cl-. Potassium chloride is

usually the preferred material to meet this need.

There are no significant impacts on water or air associated with normal application

rates of KCl. Elevated salt concentrations surrounding the dissolving fertilizer may be

the most important factor to consider

xxi

Chapter-3

IFFCO KANDLA UNIT PHASE-1&KANDLA PHASE-2

3.1 PROCESS DESCRIPTION IN PHASE -1:-

The iffco kandla phase -1 unit has total four stream which is known as A,B,C&D.

The manufacturing process uses the well known conventional slurry granulation

process. The plant consists of four identical streams with a common product handling,

storage, reclaiming and bagging facilities.

Phosphoric acid containing 52 to 54 % P2O5 and scrubber liquor containing 20 to 25

% P2O5 at NH3/H3PO4 mole ratio of 1.2 to 1.3 are fed to a vertical cylindrical reactor

called preneutraliser where it is reacted with anhydrous liquid ammonia to a mole ratio

of 1.4 or a pH of 5.6 to produce an ammonium phosphate slurry containing 18 to 20 %

water.

About 70 % of the total phosphoric acid requirement are fed to the preneutralizer.

The rest is fed to the scrubber system from where it goes to the preneutralizer in the

form of scrubber liquor at a pH of 8 to 5.2.

The ammonium phosphate slurry from the preneutraliser is pumped to a rotary drum

granulator where it is sprayed over the rolling bed of recycles fines and solid raw

materials feeds like potash, urea and filler to form granules.

Further, ammoniation upto a mole ratio of 1.8 to 1.85 is carried out inside the

granulator by means of ammonia spargers located below the bed of materials.

The granulated product containing 2.5 % water is then dried in a co-current rotary

drum dryer with hot air produced by combustion of fuel oil/LSHS.

xxii

The dried product is elevated by means of continuous discharge type bucket elevators

and distributed over double deck vibrating screen by means of a drag flight conveyor.

Product of the required size (between 1 mm and 4 mm) is separated in the screen from

the oversize and undersize.

The on-size product collects in a compartment in the product bin and is withdrawn at

the required rate by a vibrating pan feeder.

Excess product size materials and oversize materials pulverized in a chain mills are

discharged into the recycle flights conveyor. The undersize material collect in a fines bin and discharge into the recycle conveyor,

where it mixes with the crushed oversize and fresh solid raw material feeds to form the

recycle feed to the granulator.

The recycle conveyor, which is a drag flight conveyor, discharge the material into a

continuous discharge bucket elevator which in turn discharge into the granulator.

The product discharge from the vibrating pan is conveyed to a rotary drum cooler

where the product is cooled from 70 deg. to about 40 deg.

The product discharged from the cooler is elevated by a product elevator in each train

which discharge into the product conveyor common for all four trains.

The scrubbing system consist of a fumes scrubber, Dust scrubber, Dryer scrubber &

Cooler scrubber.

The first three are venturi cyclonic type. Scrubber liquor supplemented by fresh

phosphoric acid feed is circulated by pumps in all the scrubbers except the cooler

scrubber where only water is circulated.

Dust laden air from the dryer, cooler and other equipments pass through cyclones

where a major portion of the dust is separated before being scrubbed in the respective

scrubbers.

Fumes from the preneutraliser and granulator are scrubbed in the fumes scrubber. Each

scrubber is provided with a fan for creating the required draft.

The scrubbed gasses are let out into the atmosphere through a common stack.

xxiii

3.2 PROCESS DESCRIPTION PHASE -2:-

In the IFFCO kandla unit phase-2 there are total two stream which is E&F.

Merchant grade Phosphoric acid containing 54% P2O5 is reacted with liquid

Ammonia in dryer pipe reactor (DPR) installed inside the rotary dryer upto a

mole ratio of 1:1.05 (moles of Ammonia to moles of H3PO4 ) and in the

granulator pipe reactor (GPR) installed inside the rotary drum granulator upto a

mole ratio of 1:1.4.

FIG:-3.1 IFFCO KANDLA UNIT PHASE-2

The reaction is highly exothermic resulting in the evaporation of water content of the

phosphoric acid and recycled scrubber liquor.While discharging from the granuator

pipe reactor the pressure is 4 to 5 Kg/cm2 and temperature between 130 to 150 deg C.

While discharging from dryer pipe reactor the pressure is between 3 to 4 Kg/cm2 and

temperature is between 130 to 150 deg C.

xxiv

The discharge from the GPR & DPR fall on the rotating bed of recycle fertiliser

material in the corresponding equipments i.e. Granulator & Dryer.

Dry raw materials like Urea, Filler & Muriate of Potash are added into the granulator

through independent feeders which discharge into a common recycle conveyor

alongwith recycle material like crushed oversize, fines and excess product.

The fertiliser material in the granulator is further ammoniated to a mole ratio of 1.8 by

sparging ammonia through the bed in the granulator.

The granulated fertiliser containing about 2.5% moisture is then discharged into the

rotary dryer where it is dried with hot air from the fuel oil fired combustion chamber in

a co-current flow.

The moisture of the fertiliser material gets reduced to 1%.

The fertiliser material is then screened in double deck vibrating screens. The separated

oversize material (above 4mm) is crushed in roll crushers and forms part of the recycle

sent to the granulator, the product size material (-4mm to 1mm) goes to a rotary cooler

and is the final product, the fines material (less than 1mm) is also recycled back to the

granulator.

The off gases from dryer and cooler are passed through respective dryer and cooler cyclones and then sent for wet scrubbing.

The off gases from the granulator are first scrubbed in an inclined venturi scrubber followed by a wet venturi type fumes scrubber.

The exit gas from the dryer and granulator scrubbers are once again passed through a tail gas scrubber for maximum recovery of nutrient from these gases, before being discharged to the stack.

Dust from various dust generation points at different locations are sucked by the dust fan through a network of ducting lines

The dust is then dedusted in cyclones and later sent for wet scrubbing. The scrubbing medium is weak phosphoric acid solution. The scrubber liquor is consumed in the granulator pipe reactor and the dryer pipe reactor.

3.3 UREA PHOSPHATE PLANT:-

xxv

Plant capacity 50 MTPD Annual installed capacity 15000 MTPA. Consultant M/s. KSJ, Ghaziabad (UP).

The manufacture of water soluble Urea Phosphate is carried out in a continuous process plant. 

REACTION VESSEL

Phosphoric acid of 54% P2O5 concentration is taken into the reaction vessel through a pipeline from the existing phosphoric acid storage tank pump discharge.

The phosphoric acid feed into the reaction vessel is metered by using a magnetic flow meter in the reactor inlet line.

Urea feed into the reaction vessel shall be from the urea hopper having measuring arrangement at the bottom of the hopper.

Required quantity and urea at ambient conditions is fed into the reaction vessel.

All raw materials are added to the reaction vessel at ambient conditions. An agitator is provided for gentle agitation to increase the contact of urea particles with phosphoric acid in the reaction vessel.

The following reaction takes place between phosphoric acid and urea :

H3PO4 + NH2CONH2 ---------> NH2CONH2.H3PO4(Phosphoric acid) (Urea) (Urea Phosphate)

Crystalline urea phosphate is an adduct of urea and phosphoric acid. There is no chemical reaction taking place, the physical attachment of urea crystals to phosphoric acid creates a slurry of urea phosphate in the reaction vessel.

Urea phosphate crystals are stable and are separated out from the phosphoric acid solution. For better crystallisation, cooling and to reduce the viscosity, a saturated solution of urea phosphate mother liquor is added to the reaction vessel.

xxvi

Due to acidic conditions existing in the reaction vessel during crystallisation process, the solubility of the contaminating water insoluble iron & aluminum phosphate salts is increased and these remain in solution.

The urea phosphate reaction and crystallization are both exothermic in nature. The temperature of the solution in the reaction vessel rises to about 70oC and is allowed to cool for some time under ambient conditions.

Providing residence time allows for higher crystal formation and lowering of the temperature gives better yield of urea phosphate crystals.

CRYSTALLISER

The solution from the reaction vessel is pumped to a Draft Tube Type continuous crystalliser.

The feed enters the crystallizer at about 60 deg. C and feed liquor containing urea phosphate, water, phos.acid and urea is cooled by adiabatic cooling.

Feed is flashed under vacuum to reduce the temperature and by flashing of water, feed temperature reaches to 25-30 deg. C.

Water evaporation takes place in the crystallizer due to vacuum. Vacuum is created in the crystallizer using steam jet booster/ejectors followed by its condenser and two stage water ring vacuum pump.

Due to lowering of the temperature, mother liquor will become super saturated and crystallization takes place.

Slurry is kept in suspension using propeller at low rpm. Flow of the slurry is directed by draft tube.

Slurry is taken out from the bottom of the crystallizer and sent for filtration in the continuous pusher type centrifuge.

CENTRIFUGAL SEPARATION

Urea phosphate crystals and solution from the crystalliser shall be pumped to the continuous pusher type centrifuge.

xxvii

The crystal is separated out and the mother liquor generated shall be collected into the mother liquor tank which shall be reused in the process or in the existing NPK / DAP plant to be used in the manufacturing process. 

DRYING

Urea Phosphate crystals obtained from the centrifuge contains around 2 to 3% moisture. High moisture levels in the product causes caking problems during storage and transportation.

Moreover, the Fertiliser Control Order (FCO) has specified a maximum of 0.5% moisture in final product which requires drying.

The urea phosphate crystals are passed through a Rotary dryer. Hot air is generated by steam heating and blowers are provided for passing the hot air through the Rotary dryer. Drying is carried out at 80-90oC.

At the outlet of the Rotary dryer, the moisture content of urea phosphate is reduced to less than 0.5% as per specifications. Dry crystalline Urea Phosphate from the Rotary dryer is transported through conveyors to a product hopper.

FIG:-3.2 ROTARY DRUM DRYER

The rotary drum dryer is mostly used to reduce the moisture contain from the raw material.

By the help of this rotary drum dryer the moisture contain from 4% is reduced up tp the 1%.

xxviii

ZINC SULPHATE MONOHYDRATE PLANT

Plant capacity 100 MTPD. Annual installed capacity 30000 MTPA. Consultant M/s. Vimal Organics Limited, Ghaziabad (UP).

REACTION:

Process water/liquor is transferred to Reactor. Sulphuric acid and zinc ash of desired quantity are fed into Reactor slowly to have homogeneous reaction to get Zinc Sulphate Monohydrate reaction mass.

Certain quantity of Defoamer at fixed intervals during reaction is added to suppress level of foaming.

Measured quantity of Flocculent is also added during reaction for flocking of small particles.

Then the reaction mass is transferred to Reaction Holding Tank. From The Reactors acid mist comes out when Sulphuric Acid is added.

Sulphuric Acid addition as well as its reaction with Zinc Ash is exothermic process, therefore some vapor is generated. Also because of effervescence, some dust may tend to exit.

To arrest this, a simple water scrubber is provided. The water condenses the steam, captures mist and carries away the dust particles. This water is recycled. Consequently there are no effluents in this plant.

FILTRATION:-

There after reaction mass from Reaction Holding Tank is pumped to Process FilterPress where separation of Mother liquor and cake takes place.

Mother liquor is then transferred to Spray Dryer feed tank. The cake (solid) is transferred via ducting arrangement to Mud washer for recovery of undissolved zinc during reaction.

xxix

Then it is taken to Mud washer filter press for separation of Solid & Liquid. The Liquid obtained is used for next batch of reaction.

The solid cake is further treated in Secondary Mud washer and taken to Mud washer filter press.

The liquor termed as weak liquoris reused for Mud washings. The cake obtained at this stage is disposedoff.

SPRAY DRYING & PACKING:

The Mother liquor (received from filtration section) from mother liquor feed tank is fed to Spray Dryer where it is dried to get product Zinc Sulphate Monohydrate.

A special Hot Air Generator is used.

This HAG heats secondary air to 330-350oC (free of minute Carbon particles generated from combustion of FO) which is introduced into Spray Drier chamber.

The feed material and hot air come in contact with each other and drying takes place. The moisture removed from the product is carried away by the exhaust air.

The exhaust gas is then passed through cyclone separator for fines recovery. The product is separated and collected at the bottom. Product from cyclone outlet is further pneumatically cooled and conveyed to Silos.

The exhaust gases are then passed through Scrubber for Scrubbing. The product in water solution/slurry is separated and collected at the bottom and is recycled to Reactors. Clean air is then exhausted to the atmosphere.

Material from Silos is conveyed to Form Fill and Seal Machines for packing in 5 kg pouches. The 5 kg pouches are packed in 40 kg HDPE bags.

The entire process is with zero effluent discharge.

xxx

3.4 EQUIPMENT PERFORMING IN KANDLA UNIT PHASE -1:-

Equipment performing in Kandla phase-1 plant:-

1. Combustion chamber2. Rotary dryer3. Granulator4. Product cooler5. Bucket elevator6. Screen drag feeder (SDF)7. Fines conveyor8. Cyclone dust collector9. Scrubbers

Combustion chamber:-

Operating conditions1. Capacity: minimum 21 million BTU/hr and maximum 37 BTU/hr.2. Exit gas temp: minimum 3000 - 4500F and maximum 9000F.3. Quench air flow: minimum 48000 SCFM and maximum 54000 SCFM.4. Turn down ratio – 8:1.

Properties of Fuel:1. Density: 0.9474gm/ml2. Gross calorific: 10515 cal/gm3. Flash point: 730C4. Water content: traces5. Ash: 0.02 % wt6. Total sulphur 2.48% wt

Rotary dryer:

Feed rate 200 to 306 MT/hr

Density 801 to 104 kg/cm3

Temprature in discharge 80o to 85o C

Hot air temperature 180o to 250o C

Shell size Diameter-3.5m Length-24.4m

xxxi

Speed 5 rpm

Shell slope 1:30 in AB and 1:35 in CD

Motor 400 HP,1500 rpm

Granulator:

Length 7.32 m

Diameter 3.66 m

Molar ratio 1:8

Speed of rotation 8.8 rpm

Slope 1:16

Capacity 200 to 360 MT/hr

Material of construction M.S.(outer) Rubber (inner)

Moisture content 2.5 to 3%

Temprature feed 80 o to 85oC

Product cooler:

Length 15.24 m

Diameter 2.74 m

Cooler speed 6.5 rpm

Cooler slope 11/16” per feet

Inlet temperature 85o C

Outlet temperature 45o to 46o C

Capacity 500 MTPH

Exit air flow 40000 ACFM

Exit temperature 67o to 73o C

Pinion Shaft 7” diameter

xxxii

Motor 100 HP,1500 RPM

Bucket elevator:-

FIG:-3.3 PRIMARY ELEVATOR

There are three types of bucket elevator used in IFFCO Kandla.1. Primary elevator2. Secondary elevator3. Product elevator

These are similar in structure but different in function.

The function of primary elevator is to transfer the product from drier to screen drag feeder.

The function of secondary elevator is to transfer raw material from fines conveyor to the granulator and that of product elevator is to transfer product from product cooler to the product conveyor.

Screen drag feeder(SDF):

Product of dryer is fed to the SDF with the help of primary elevator.This SDF is located up on the screen and its main function is to distribute the product uniformly from the primary elevator.

xxxiii

FIG:-3.4 SCREEN DRAG FEEDER

The SDF is a simple conveyor having tripper door at the top of screen through product flow to the screen and distribute in oversize,undersize and product will choke due to higher load on it.

Fines conveyor:-

FIG :-3.5 FINE CONVEYORS

xxxiv

Fines contain no. of flights to convey material from one place to another place.

It collects under size material from screen,pulveriser product and dust from various scrubber.

Raw material such as Urea, Potash,Filler & MAP are fed through bins to the fines conveyors.

The material from fines conveyors is fed to the granulator through secondary elevator.

Cyclone dust collector :-

FIG:-3.6 CYCLONES DUST COLLECTOR

xxxv

1. Four dryer cyclones2. Four dust cyclones3. Four cooler cyclones

Scrubber: 1. Fumes scrubber2. Cooler scrubber3. Dust scrubber4. Dryer scrubber

Chapter-4

4.1 OFF-SITE AND BAGGING UNIT:-

Offsite at IFFCO KANDLA includes:-

Raw Material Storage

Ammonia storage Phosphoric acid storage Potash storage Urea storage Filter storage Fuel oil storage

xxxvi

Steam generation plant:-

FIG:-4.1 STEAM BOLIER

xxxvii

Air compressor unit:-

FIG:-4.2 AIR COOLING TOWER

FIG:-4.3 AIR COMPRESSOR COOLING TOWE

1) Raw Material Storage:-

xxxviii

i) Ammonia storage:There are two types of storage tanks for ammonia in the plant.a) Atmospheric tankb) Horton spheres.There are in total 5 tanks, 3 atmospheric and 2 horton spheres tank.The total capacity for Atmospheric tank is 30000 Mt. and for 3000 Mt. for Horton spheres.ii) Phosphoric Acid Storage:The Phosphoric acid storage facilities consists of six rubber lined steel tanks having total capacity of 10000 Mt.The tanks are build of carbon steel with rubber linning inside by cold bounding.iii) Potash Storage:The total storage capacity of Potash is about 80,000 Mt. It is stored in heaps by dropping potash from top so as to utilize the full space of storage.Raw material by trucks is unloaded into hoppers with the help of feeders provided at the bottom of hoppers.The capacity of unloading is about 278Mt/hr.iv) Urea and Filler Storage:Urea and filler is stored in 6 nos.; asbestos covered storages. Material can be heaped up to 1-1.5 m height above the retaining wall of compartment. Capacity of a single compartment in case of filler is max. up to 2500 Mt and for urea is 1250 Mt. V) Filler:It is used for balancing nutrients.

2) Steam Generation Plant:-

FIG:- 4.4 NESTLIER BOLIERxxxix

Steam generation plant consists of three fire tube boilers capable of producing saturated steam.

One of them is I.A.E.C boiler, the other one is NESTLER boiler and the third one is THERMAX boiler.

The boiler feed water is treated in water treatment plant before feeding to the boiler.

i) I.A.E.C. Boiler: This Boiler is fully automatic fire tube, fuel oil fire packaged boiler, with three passes having a capacity of 10 Mt/hr at 10.5 Kg/cm2 working conditions.

This boiler is equipped with 2 guage glasses, 2 safety valves, 2 fuel oil pump which is capable of developing high pressure of about 25 kg/cm2. One complete oil firing equipment with forced draught fan. And also contains a master pressure guage for indicating boiler pressure.

ii) NESTLER Boiler: This is also a fire tube boiler with three passes having capacity to produce 6 Mt/hr of steam at 10.5 kg/cm2.

This boiler has been provided with 2 feed water pumps, one furnace oil injection pump capable of pumping at a pressure of 25kg/cm2. It is also provided with blow connection and flue gasses duct with damper.

iii) THERMAX Boiler: This type is the most efficient of all three. It is provided with fire type shell connection. Furnace oil is used as fuel. There is economizer configuration which is useful to increase the efficiency of the boiler.The capacity of the boiler is 16 Mt/hr and at a pressure of 12kg/cm2.

FIG:-4.5 THERMAX BOLIER

xl

3) AIR COMPRESSOR UNIT:

Air compression unit consists of four compressors 3 reciprocating two stage compressors and one rotary compressor.

The capacity of discharge pressure is 7 kg/cm2 and at atmospheric pressure. The temperature of air at inlet is ambient and the temperature of outlet air is 430C. The cooling system used is water cooled. The speed of crankshaft is 750 rpm.

4.2 BAGGING UNIT:-

FIG:-4.6 BAGGING FILLING PROCESS

FIG:- 4.7 BAGS AFTER FILLING

xli

FIG:-4.8 BAGS LOADING IN THE RAILWAYS WAGONS

The urea phosphate or NPK fertiliser product from product hopper is then sent in the

Form Fill Seal Type Packaging Machine (FFS) for packaging in 1 kg pouches.

These are packed in 40 kg HDPE bags. In future, it is proposed to have 5 kg packaging

for urea phosphate.

After packing, Bags are transported through different Rail routes & Sea Ports.

xlii

CONCLUSION:-

IFFCO,to day IS a leading player in india’s fertilizer industry and is making

substantial contribution to efforts of Indian government to increase food

grain production in the country.

At,IFFCO the thrist for ever improving the service to farmers and member

co-operatives is insatiable,commitment to quality is insurmountable and

harnessing of mother earth’s bounty to drive hunger away from india in an

ecologically sustainable manner is the prime mission.All that IFFCO

cherises in the exchange is an everlasting smile on the face of Indian farmer

who form the moving spirit behind this mission.

xliii

xliv