Professional Documents
Culture Documents
96-103 (8 pages)
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CONVEYING
ElEVATORS &
DRAG CONVEYORS
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BULK STORAGE I I
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BAGGING PLANT I I
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project in year 2001-02, Train C has low water content that allows materialized later on in year 2001
been producing DAP at the lower recycle rate of 4:1. This when GSFC started production of
installed capacity of 396000 MTPY innovative approach of low ammonium phosphate sulphate
with the granulation process recycle rate has definitely given (20:20:0:13) as per agri-business
developed and licensed by energy conservation in disguise. requirement. Existing trains have
INCRO S.A. Spain. This process is been modified as following:
based on the use of two INCRO S.A. 3. Expansion of Product
designed pipe cross reactors Profile i. Higher water requirement of
installed into the granulator. For fume scrubber was fulfilled
DAP production under average Each train of the DAP plant is with additional line and
conditions, each pipe reactor can roughly grouped into two major utilizing idle phosphoric acid
produce 50% of the total sections namely wet section and (PA) line rerouting from
ammonium phosphate slurry dry section. Figure 1 gives granulator to fumes scrubber
needed. The overall pipe reactor schematic representation of the system (Figure 2).
granulator system allows great major process steps involved and
operational flexibility, enhanced grouping of various systems. ii. As sulfuric acid (SA) addition
control of operational parameters, During the design stage of these A at pre-neutralizer has
high reaction efficiency, reduced and B trains, layout provisions increased substantially, SA
ammonia emissions to the were made to produce other feed with dip pipe was modified
scrubber system and use of fertilizer compounds. This from 1-2 m depth to 4.2 m
reactor heat to reach a slurry with innovative process link was length to safeguard against
TO DRYER FAN
DRVER
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LEGEND:
OlD WORK
PA NEW WORK
DEFOAMERTANK
WATER TO VEPITlJRlES Of
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PRENUTRAUZER
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process surge on instantaneous were carried out in NPK divert and reclaim from bulk-silo
exothermic reaction (Figure 3). processing effectively in the lying in between. In due course of
years 2005 and 2007. The major time, it was experienced that multi
iii. Original plants (Train A&B) change was to provide extension of phosphatic fertilizer production
were designed for DAP product filler conveyors from Train-C to has been limited to anyone
only. Hence, augmentation of Train A&B (Figure 4) along with product at a time due to
APS manufacture required installation of receiving hoppers. infrastructural constraint of single
higher capacity sulfuric acid Thus, charging of muriate of belt gallery to bagging and a
pump at utility services which potash (MOP) is executed in a logistic field. To overcome this, the
was installed to achieve 1200 metered way to manufacture any following in-house modifications
MTPD APS production. one of the desired NPK grades at a were carried out in September
time at the rate of 1800 MTPD. 2013:
Later on, market demand of NPK
grades, especially 10:26:26 and GSFC-SU has commissioned DAP i. One more VFD-controlled
12:32:16, has increased production units with suitable conveyor belt was installed for
significantly in primary marketing infrastructure of single conveyor simultaneous metered feeding
areas of Gujarat and Maharashtra. gallery running to bagging and of MOP and filler to achieve
To meet the demand, modifications logistic section with a facility to stream factor with better
FII.LfR MOP_
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FINE CONVEYOR-4!
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supplied by GSPc. ammonia condensation and compressors could only be
auxiliary heat exchange package operated at a time due to
Existing fuel oil (FO) burner of gas compression units. limitation in existing cooling
system has also been modified to tower cooling capacity.
natural gas handling after GSFC-SU has been divided into 2
obtaining dual fuel compatible operational areas viz. Sikka Shore Ammonia storage, at - 33C,
burners and complete burner Terminal (SST) where liquid cargo through refrigeration system
management system. Anticipated berth (Jetty) has been constructed (which includes compressors
monetary expenses has been since inception so that vessels of and cooling tower) is very
worked out to Rs. 4.35 crores major raw materials can be cri tical and essential activity
including Rs.15 lakh for natural berthed and liquid ammonia can round the clock. Existing cooling
gas line laying from GSFC be transferred to SST and second tower is very old and in bad
metering station to consuming area viz. phosphatic fertilizer shape giving poor performance.
points of plants and utility manufacturing units at For revamping job, long shut
services. Motikhavdi (MK) site almost 11 km down cannot be undertaken
s away from SST and Jetty. Both and had to fully depend on
By switching over fuel oil (FO) to storage and process locations another small capacity cooling
clean natural gas, significant have a requirement to install tower as the refrigeration
saving has been observed from ammonia storage tanks with system has to be operated
earlier NG equivalent FO of 8.50 thermal- efficient cooling towers. continuously to maintain tank
Sm3/MT OAP to actual NG of 5.50 Initially, there were two towers at pressure with existing cooling
Sm3 per MT OAP. That means MK plants and one tower at SST tower in line.
actual saving is of 3.0 Sm3 NG per zone. In case of any eventuality I
MT OAP. Considering installed
failure in existing cooling tower
capacity basis of 7,22,000 MTPY Wooden cooling towers were
during ammonia rail/road
OAP and spot gas pricing as considered at MK and SST during
tankers/wagon unloading,
average out at Rs. 25.50 per Sm3 1985-86 along with ammonia
critical situation may arise due
NG, there is net monitory gain of storage and refrigeration system.
to over pressure in the tank as
Rs. 5.50 crores, resulting in cost As these cooling towers were
benefit ratio of almost 1 year. very old and in bad shape, its
no alternate I standby
arrangement is provided for
wooden structure, supporting V
Further, fuel changeover has given existing cooling tower.
bars, started falling apart
following benefits: frequently resulting in stoppage
Considering all these process
of refrigeration operation. Also,
i. Stoppage of air atomization constraints, a counter current
life of wooden structure of
compressor saving Rs. 8.75 FRP cooling tower (Figure 6) as
cooling tower had exhausted and
lakh per year standby to existing wooden
it became unsafe to work on
Paharpur make cooling tower at
cooling tower.
ii. Stoppage of fuel oil transfer Motikhavdi site was installed.
pump saving Rs. 3.25 lakh per There were many other reasons This resulted in power saving of
year for consideration of standby CT 50 kWh on daily basis. Annually,
tower to existing one as stated this resulted in power saving of
iii. Stoppage of steam below: 18250 units equivalent to Rs
consumption to heat FO 1,10,0001 -at a unit cost of Rs 6.0.
saving Rs. 10.50 lakh per year Existing cooling towers (CTs)
are designed for 27.5C wet 4.3 Installation of FRP Bottle
iv. Combustion chamber refrac- bulb temperature (WBT). Type Cooling Tower at SST Site
tory failure has totally However, actual WBT remains
stopped. around 29.5 C during pre- At Sikka Shore Terminal site, two
monsoon I monsoon period. As numbers of ammonia storage
4.2 Installation of FRP Square humidity remains on higher tanks are provided each with a
Bottle Type Cooling Tower at side during this period, cooling storage capacity of 10,000 MT. To
Plant Site of CT-circulated water was take care of radiation heat input
not sufficient, which to tank and 4 km long unloading
GSFC-SU phosphatic fertilizer ultimately affected ammonia line, refrigeration system
units without captive acid and refrigeration. To make ammonia consisting of three numbers of
ammonia do not need specific refrigeration system more reciprocating compressors are
cooling water for process but effective and improve provided. One number of twin
imported anhydrous liquid refrigeration, provision of new cell induced draft-cooling tower
ammonia refrigerated storage cooling tower suitable to with cooling capacity of 1.5 million
(cup in tank) system requires prevailing climate conditions kcal/h is provided for evaporative
small but energy-efficient cooling was required. Out of four cooling of re-circulated cooling
tower system to take care of refrigeration compressors, three water.
WBT 295"C
Figure 6. Installation of FRP square bottle type cooling tower at MK & SST site
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