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` SUMMER TRAINING AT BABRALA (U.P) PROJECT REPORT ON EVALUATION OF AMMONIA VAPOUR LOAD ON REFRIGRATION COMPRESSOR K-451 AND MARGIN FOR OPEN ANTISURGE JAYPEE UNIVERSITY OF ENGINEERING AND TECHNOLOGY A.B. ROAD, RAGHOGARH, GUNA (M.P.) INDIA Submitted by: Samvid Arora ( Department of Chemical Engineering )

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`SUMMER TRAININGAT

BABRALA (U.P)

PROJECT REPORT ONEVALUATION OF AMMONIA VAPOUR LOAD ON REFRIGRATION COMPRESSOR K-451 AND MARGIN FOR OPEN ANTISURGE

JAYPEE UNIVERSITY OF ENGINEERING AND TECHNOLOGYA.B. ROAD, RAGHOGARH, GUNA (M.P.) INDIASubmitted by:Samvid Arora( Department of Chemical Engineering )Under the supervision of:Mr. Maneesh Sankhyadhar(Manager Ammonia Department) CERTIFICATEWe hereby certify that the work which is being presented in the training project report entitled EVALUATION OF AMMONIA VAPOUR LOAD ON REFRIGRATION COMPRESSOR AND MARGIN FOR OPEN ANTISURGE by Samvid Arora in partial fulfillment of requirements for the award of degree of B. Tech. (Chemical Engineering) submitted at JAYPEE UNIVERSITY OF ENGINEERING AND TECHNOLOGY GUNA (M.P) is carried out during a period from 1st June 2013 to 13th July 2013 under our supervision .

(Samvid Arora)This is to certify that the above statement made by the candidate is correct to the best of his knowledge. Project Head: -

Mr. S.K.S. Chauhan ( Head of Department Ammonia Section )

Project Guide:-

Mr. Maneesh Sankhyadhar ( Manager Ammonia )

Mr. B Chaitanya Babu (Deputy Manager Ammonia) ACKNOWLEDGEMENT

Words are inadequate and out of place at times particularly in the context of expressing sincere feelings in the contribution of this work, is no more than a mere ritual. It is our privilege to acknowledge with respect & gratitude, the keen valuable and ever-available guidance rendered to us by Name and Designation of Training Guide/Mentor of industry without the wise counsel and able guidance, it would have been impossible to complete the training in this manner.I am always be highly grateful to Mr. S.K.S. Chauhan, (Head of Department), and Mr. Maneesh Sankhyadhar, (MANAGER) for providing this opportunity to carry out the present work. I would like to thank Mr. B Chaitanya Babu (Deputy Manager) for his appreciations that made me more enthusiastic in delivering my best efforts for completion of the project We express gratitude to other faculty members of Chemical Engineering Department, JUET for their intellectual support throughout the course of this work.Finally, we are indebted to our family and for their ever available help in accomplishing this task successfully. Above all we are thankful to the almighty god for giving strength to carry out the present work.

Name of Candidate : Samvid Arora

DECLARATION

I hereby declare that all the information mentioned in the project report is best to my knowledge; I have not submitted the same report in any other organization. All the findings are based on my own effort and research.

Samvid Arora

CONTENTSS.No. Name

1. Certificate 2. Acknowledgement 3. Introduction to Company 4. Fire & Safety Fire Prevention Classification of fire Fire fighting gadgets & appliances Safety programme at T.C.L. 5. Ammonia Plant (Process Description) De sulphurisation Section Steam Reforming Section Shift Conversion Section CO2 Removal Section Methanation Section Compression Section Ammonia Synthesis and Refrigeration Section Ammonia Recovery Section Purge Gas Recovery Unit

6. Project Objective Theory Design Data 7. Calculations Design calculations Operating calculations 8. Results 9. Proposed Scheme: Possible Queries10. References11. Experience

INTRODUCTION TO TATA CHEMICALS LIMITED BABRALATata Group, India's foremost business conglomerate. Tata Chemicals, by itself, is one of the largest inorganic complexes in the world beginning to TATA Group. Its first plant, which is also called inaugurated establishment of TATA. It is India's leading manufacturer and marketer of inorganic chemicals and fertilizers, with a turnover of over Rs. 4000 crores and is part of the Rs 65,000-crore ($14.25 billion) TCL's products and production processes are benchmarked with the best of global touchstones, and meet the most rigorous international specifications., Established in 1939. An ISO-9001/14001 OHSAS 18001 certified company, TCL has a varied user industry base comprising glass, paper, textiles, food additives, petroleum, refining, chemicals, dyes, pesticides, direct farm application etc. The products go into numerous end-use applications in a variety of industries: glass, detergents, paper, textiles, agriculture, photography, pharmaceuticals, food, tanning, rayon, pulp, paints, building and construction, and chemicals.

Tata Chemicals is also one of India's leading manufacturers of urea and phosphatic fertilizers. With an export presence in South and Southeast Asia, the Middle East and Africa, it has set itself the objective of achieving global cost competitiveness in soda-ash. Its foray into phosphatic fertilizers follows the merger of Hind Lever Chemicals Limited into Tata Chemicals Limited. TCL's phosphatic fertilizer complex at Haldia in West Bengal is currently the only manufacturing unit for DAP/NPK complexes in West Bengal. The Haldia plant has production volumes exceeding 1.2 million tons per annum. Tata Chemicals makes urea at its fertilizer complex in Babrala. The complex has an installed capacity of 8, 64,000 tons per year, which constitutes nearly 12 per cent of the total urea produced by India's private sector. Tata Chemicals is among the world's largest producers of synthetic soda ash, with the largest domestic market share, produced at the company's integrated complex at Mithapur on the Gujarat coast in western India.

The fertilizers, sold under the brand name 'Paras', lead the market in West Bengal, Bihar and Jharkhand. TCL is also a pioneer and market leader in the branded, iodized salt segment. Its salt has a purity percentage of 99.8 per cent, the highest in the country.

CREDENTIALS OF TATA CHEMICALS LIMITED BABRALA AWARDS: Prestigious Industry Award, Govt. of UP., 1995. National Energy Conservation Award, Ministry of Power, 1997. National Energy Conservation Award, Ministry of Power, 1998. Best Production Performance Award for Nitrogenous Fertilizers, Fertilizers Association of India. Second best productivity performance in Nitrogenous Fertilizers Industry, 1997-98. Yogyata Praman Patra Award, 1998. Jawaharlal Nehru memorial National Award for Pollution Control and Energy Conservation, 2000-01. Golden Peacock Environmental Management Award, World Environment Foundation, 2001-02. Best Technical Innovation Award, Fertilizer Association of India, Dec.2004. Excellence in Safety, Fertilizer Association of India, Dec.24. Commendation Certificate for Strong Commitment to TQM, CII-Exim Bank Award for Business Excellence, Nov.2004. 5 Star Rating in Safety, British Safety Council, UK, Safety Gold Awards, Greentech Foundation, Delhi. Indian Chemical Council (ICC) confers the ICC award for social responsibility 2005-06. NSCI safety award for 2006. ICC Aditya Birla Award for Best Responsible Care Committed Company and ICC Award for Social Responsibility for 2005-06. Fertilizers Association of India Award for the Best Technical Innovation 2007. Nine ABCI (Association of Business Communicators of India) Awards, 2008.

TCL BABRALA: THE NATIONS CONCEIT Substituting a part of the imports of Urea, TCL, Babrala is estimated to save the country about Rs. 500 crores in foreign exchange every year and provide the farmer with nitrogenous nutrient, which could help raise the food production by about 4 million tones/year. First major steps towards the fulfillment of a long standing TATA CHEMICALS commitment to provide the farmer with an optimal package of agriculture inputs to safe guard the food security of the company. Produced more than 100% of the designated production during the first year of commercial production. Produced more than 8, 40,102.35 tons of Urea achieving a capacity of 113% in the year1995-96, and produced 9, 51,764 tons of Nitrogenous Urea in year 1996-97. Now produce capacity of 8, 64,000 tons of Urea per year, which constitutes nearly 12 per cent of the total urea produced by India's private sector. Total production of urea at Babrala is 3575 tons/day maximum and 3500 tons/day average. Current maximum capacity is 101%. The Babrala facility, among the best of its kind in India and comparable to the best in the world, has set new standards in technology, energy conservation, productivity and safety It is the only fertilizer plant in the country to use dual feedstock: natural gas or naphtha, or a combination of both.

MILESTONES OF TATA CHEMICALS LIMITED, BABRALA

Commercial Production Started onDecember 21, 1994

AMMONIA UNIT

First firing of Reformer Furnace for dry out of refractoryOctober 12, 1994

First feed into Primary ReformerOctober 20, 1994

First Carbon Dioxide for making UreaOctober 23, 1994

First Ammonia productionNovember 14, 1994

UREA UNIT

Urea Prill Test conductedOctober 04, 1994

First Prill Test conducted through Unit 2November 05, 1994

Second Prill Test conducted through Unit 2December 09, 1994

ISO 14001 certificate obtained in October 2000.

ISO 14001 certificate for Babrala township obtained in 2004.

COMPOSITION OF TATA CHEMICALS LIMITED, BABRALA

Ammonia Plant

Capacity: 2000MTPD Technology: HALDOR TOPSE Process, DENMARK Plant (Single Stream) Production: 2000 tons/day of liquid Ammonia. After de-bottlenecking Plant at TCL, Babrala is the first low energy plant in the country.

Basic scheme involves the following steps:

Desulphurization. Primary, Secondary Reforming and fired heater Carbon Dioxide Shift. Methanation. Synthesis and Chilling. Storage and supply to Urea unit

2.Urea Plant

Capacity: 3500 MTPDTechnology: SNAMPROGETTI Process, ITALY Carbon Dioxide requirements supplied from ammonia plant. Two urea strings have a common Prilling section. Maximum Urea production: 3574 tonnes per day

Basic scheme involves the following steps:

Urea Synthesis Waste Water Treatment section

3.Offsite and Utilities

S. N.UNITCAPACITYTECHNOLOGY

1.Ammonia Storage Tank2X5000 MTM/S Kaveri Engineering

2.Captive Power Plant1X110 TPHTHERMAX/ L&T

3.Cooling Tower24000 M3/hrM/S Paharpur Cooling Tower

4.D. M. Water Plant3X450 M3TCL, Mithapur

5.Gas Turbine Generator2X20 MWTHOMASSON, Holland

6.Heat Recovery Unit2X90 TPHL&T

7.Naptha Bulk Storage Tank3X6300 KLM/S Technofab Engg. Ltd.

SALIENT FEATURES OF TATA CHEMICALS LIMITED, BABRALA Location Babrala, District Sambhal, Rajpura block, Gunnor Tehsil, Uttar Pradesh. Approx. 160km. south-east of Delhi.

Land Area 1519 acres Plant area:1,069 acres Township area:350 acres Green belt: 100 acres

Fuel Natural gas (main) Naphtha (alternate)

Fuel Source Natural gas supplied by GAIL (HBJ Pipeline) Naphtha from IOCL, Mathura

Consumptive water source Eight deep bore wells.

Present installed capacity Ammonia:2000 MTPD Urea: 3500 MTPD

Man power Deployment (During Commissioning/ Erecting phase ) Total 7,855,128 man-hours. Peak (month) 405,799 man-hours.

Beneficiary states U.P., Bihar, West Bengal, Punjab, M.P., Assam.

UNIQUE FEATURES OF TATA CHEMICALS LIMITED, BABRALA

An integrated energy network, which is the key, factor in achieving high energy efficiency. The flexible range of the ratio of natural gas and naphtha as a fuel/ feed is a major reason for this. The current low operating energy record is 5.13 Gcal/MT of Urea. The second unique feature is common single central control room (CCR) for ammonia, Urea to captive power and steam generation plant (CPSSGP) and other offsite and utility plants. This provides a well-coordinated and integrated control of the entire complex from one location and on line inters plant sharing of information. This has been found extremely beneficial especially during plant startups and upsets.

QUALITY POLICY OF TATA CHEMICALS LIMITED

To provide customer satisfaction and timely delivery of quality products. Maintain good quality management systems and incorporate regular improvements to meet our customer changing needs. Continuously upgrade product quality by improvements in process technology. Develop and upgrade employee skills and provide an environment for their effective participation through teamwork to meet our customer expectations. Take adequate care to ensure safety at the work place, environmental preservations and to respond to the needs of the community.

FIRE AND SAFETY

FIRE CHEMISTRY: The well-known Fire triangle requires the three ingredients of fire namely fuel, oxygen and source of ignition.A fire is a combination of fuel, oxygen and source of ignition.2.1 FIRE PREVENTION:Fire prevention can be done in three ways:

Eliminate sources of ignition. Eliminate combustible substances. Eliminate air excess to combustible substances.

FIRE PREVENTION THROUGH ELIMINATION OF IGNITION SOURCES:To prevent fire the first is to remove the cause of fire. Studies made by fire insurance company shows that majority of fires are caused by following general sources of ignition: Electrically limited fire: Improper earthing, short circuiting, loose electrical contacts, temporary direct connections without proper fittings, high current, over heating of electrical equipment are among the common cause of electrically initiative fires. Smoking ignited fire: Smoking or even carrying cigarettes/ beedies/matches/lighter etc. in the following areas is a serious offence. All non-smoking areas should carry NO SMOKING signboards. Friction and overheated material: In flame proof areas, frictional fires can also be started by the friction of moving parts of machinery which are overheated due to excess friction. This is likely in non-lubricated and not well maintained machinery.

FIRE PREVENTION THROUGH ELIMINATION OF COMBUSTIBLE MATERIALS:

Waste and combustible materials: All combustible wastes and materials like waste paper, cotton waste etc. accumulated after a job should be transported to waste bins and is the responsibilities of the person doing the job that creates the wastes. Tins and cans of flammable materials like paints, oils, spirit etc.: These should be handled carefully ensuring that no undue spillages takes place during their uses and any spillages takes place during their use and any spillage should be cleaned immediately. Fueling of vehicle tanks: Engine should be always switched off while fueling a vehicle. If diesel or petrol spills over during fueling, dry sand should covered over the spill immediately till only dry sand is visible on the spilled area. Waste disposal: All combustible waste must be regarded in such a way that can be disposed of as such and not burnt.

PREVENTION THROUGH ELIMINATION OXYGEN SUPPLY: Smoothening: It is a process of covering the burning area with a non-combustible substance like asbestos or fire proof blanket, wet thick cotton blanket or sand.

2.2 CLASSIFICATION OF FIRES:Fires are classified according to the nature of fuel burning and fire extinguishing methods that can be applied and the following is the fire classification under the Indian fire code.

CLASS A FIRE CLASS B FIRE CLASS C FIRE CLASS D FIRE CLASS E FIRECLASS A FIRE: Fires where the burning fuel is a cellulosic material such as wood, clothing, paper etc. is called class A fire.It can be extinguished by the water and sand. Class A fires can also be extinguished by all the available means of extinguishing fires like foam, soda acid, dry chemical powder, carbon dioxide etc.CLASS B FIRE: Fires where the burning fuel is a flammable liquid Naphtha, petrol etc. are categorized as class B fire.Blanketing is a useful first aid fire control for B class fire. Water is forbidden as a fire fighting means on class B fires. Foam, carbon dioxide, dry chemical powder extinguishers are the desired means of controlling B class fires.CLASS C FIRE: Fire involving flammable like natural gases hydrogen are classified as class C fire. The best means of extinguishing C type fire is by stopping the gas supply to the leaking vessels or pipe lines if possible. This must be the intermediate and very first step. Dry chemical powder and carbon dioxide are useful in controlling C class fire.CLASS D FIRE: Fire involving material like magnesium, aluminum, zinc, potassium etc. are classified as class D fire. Sand buckets are useful in most cases of metallic fires. Special dry chemical powder also works on class D fires.CLASS E FIRE: Fires involving electrical equipments are classified as E class fires. Only carbon dioxide and D.C.P extinguishers are used on class E fires.

2.3 FIRE FIGHTING GADGETS AND APPLIANCES:- CO2:- It contain under pressurized liquid carbon dioxide. SODA ACID:- Contain a double container with sodium bicarbonate solution in outer container and dilute sulphuric acid in the inner container. After the inner container both react and produce a liquid of entrapped CO2. FOAM:- Contain aluminous sulphate in inner container and sodium bicarbonate in outer one. After cracking the container both reacts to produce carbon dioxide and the foam stabilizer makes stable form of carbon dioxide. DRY CHEMICAL POWDER:- It contains an inert dry chemical powder of sodium bicarbonate or potassium bicarbonate or potassium chloride and diammonium phosphate along with liquid carbon dioxide under pressure. HALON/ BROMOCHLOROFLUORO METHANE:- Halon is in the form of a liquid gas under pressure that is released on pressing the knob.

2.4 SAFETY PROGRAMME AT T.C.LThe company conducts regular programs for safety measures, which not only creates awareness about safety but also maintains it; the fire and safety department of T.C.L organizes many programs to motivate in this direction and to make the employees aware. National safety day 4th march is being celebrated each year with earnestness and includes various awareness programs, competitions and includes various awareness programs, competitions etc. Some of these are listed below: Training programs on safety. Home safety. Use of safety equipment. Safety quiz. Safety slogan competition.

SAFETY PROVISIONSPersonal protective equipment (PPEs): The various types of PPEs are:- Helmet for head protection. Goggles for eye protection. Ear plugs and muff for ear protection. Safety shoes for foot protection. Gloves for hand protection. Face shields foot protection. Full body protection suits. Hoods for head, neck, face, and, eye protection. Safety belts or life belts or harness. Breathing apparatus or respiratory protection equipment.Fencing of machinery.Devices for power cut.Hoists and lifts.

AMMONIA PLANT Process Description

Flow Chart of Ammonia PlantThe ammonia process can be divided into the following sections: De-sulphurisation Section Steam Reforming Section Primary and Secondary Reforming Shift Conversion Section Medium Temperature Conversion Low Temperature Conversion CO2 Removal Section Methanation Section Compression Section Ammonia Synthesis and Refrigeration Section Ammonia Recovery Section Purge Gas Recovery Unit3.1 DESULPHURISATION SECTIONThe feed gas contains some sulfur, which is to be removed before the reforming section. This is done in the Hydro Desulphurisation (HDS) Section. This section contains a HDS Reactor (R 201) having a nickel based hydrogenation catalyst (TK-261) and two ZnO Absorbers (R 202 A/B). In presence of HDS catalysts, the sulfur containing compounds of the feed gas reacts with a hydrogen rich recycle gas at a temperature of 380 400 C to form H2S. H2S thus formed is absorbed by the ZnO Absorbers (R 202 A/B). At the exit of HDS section, the S content in the feed gas will be