2017

PRE- FEASIBILITY REPORT

FOR
TECHNICAL AMMONIUM NITRATE PRODUCTION
UNIT

AT
VILLAGE BAGDIA, CHAUKIMATHA, RANGIAGARH
TEHSIL PARADEEP, DISTRICT JAGATSINGHPUR,
DISTRICT ODISHA

Project Proponent
M/s DEEPAK FERTILISERS &
PETROCHEMICAL CORP. LTD

Submitted to
Ministry of Environment, Forest & Climate Change
New Delhi

Proposed Consultant-: EQMS INDIA PVT. LTD.

Corporate Office :304-305,111 Floor,Rishabh Corporate Tower
Plot no 16, Community Centre,KarkardoomaDelhi-110092 INDIA
. +91-11-30003200

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 TABLE OF CONTENTS

1 EXECUTIVE SUMMARY Pg3

2 INTRODUCTION Pg6

3 PROJECT DESCRIPTION Pg8

4 PROCESS DESCRIPTION Pg12

5 TECHNOLOGY AVAILABLE Pg18

6 PLOT & SITE DIAGRAM Pg19

7 RAW MATERIAL & UTILITY Pg19

8 PROCESS FLOW BLOCK DIAGRAM (SEE Pg33

ANNEXURE-1)

9 RAW MATERIAL & PRODUCT SPECIFICATION Pg33

10 ENVIRONMENTAL CONSIDERATION Pg34

11 PROJECT IMPLEMENTATION PLAN AND TIME Pg39

SCHEDULE

12 PROJECT COST & FINANCIAL (PRELIMINARY Pg49

LAYOUT)

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EXECUTIVESUMMARY

1.1. Project Outline

The project will consist of 900 MTPD Weak Nitric Acid plant, 1,140 MTPD Ammonium
Nitrate Solution plant and a Technical Ammonium Nitrate Prilling plant out of which
both LDAN and HDAN can be produced. The plant will be located at Paradeep, Orissa.
The plant will utilize nearly 83.26 acres of land.Ammonia plant of 380 TPD will be
relocated from Taloja to this site also.

The main raw material Ammonia will be imported through Paradeep port. Existing
Ammonia storage tanks / terminals of one of the industries, which is near of project
site, will be used on hired basis through a long-termcontract for importing and storing
Ammonia. TheAdditionally NG from Dharma pipeline Adani will be sourced from cross
country pipeline.

Water is available from Taladanda canal and will be sourced from the same
for which required applications are already submitted to concerned
departments. A dedicated power line will be installed from nearby substation

ofCESCO/GIRDCO.

Nitric Acid will be produced from Ammonia and will serve as an Intermediate
for manufacturing TAN

The Ammonium Nitrate will be trucked from the site to the customer. The

Ammonium Nitrate plant is expected to be on stream for 330 days per year.

2. INTRODUCTION

2.1. Background
Deepak Fertilizers& Petrochemicals Corporation Limited (DFPCL) is a 35-year-
old company engaged in manufacture and marketing of Ammonia/ Nitric
Acid/Sulphur based fertilizers, Formulated Nutrients based fertilizers, Technical
Ammonium Nitrate (TAN), Nitrogenous and Phosphatic Fertilizers, Methanol, Iso-
Propyl Alcohol (IPA) & other Industrial &Petrochemical products.

DFPCL’s Fertilizers/Petrochemicals Complex is located at Taloja industrial Area,

about 50 Kms from Mumbai, the financial capital of India.

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Some of the notable attributes of the company are:

 A 600 plus million US$ company having over three decades of experience of

manufacturing Ammonia, Ammonia down-streams, Petrochemical & fertilizer

products

 A company listed on the National & Bombay Stock Exchanges having

majority of the board members with eminent/professional background as

independent board of directors

 Ranked Fourth among chemicals manufacturers in India by Dun &Bradstreet

 Credit rating of AA for long term borrowing, byICRA

 Consistently paying dividend for 18years

 The only IPA and TAN manufacturer in India and the largest Nitric Acid and

AN producer in South East Asia

 ISO 9001:2000, ISO 14001:2004, OHSAS 18001:2007 certified company

running its business processes through SAP based ERPpackage

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  The process plants are controlled through most modern DCS based control

systems.

DFPCL has prominent position in manufacture and distribution of both specialty

fertilizers and technical Ammonium Nitrate (which forms the backbone of mining
industry).

DFPCL currently manufactures 410,000 MTPA of high density and low density
Ammonia Nitrate products at its Taloja complex in addition to 40,000 MTPY TAN at
Smartchem, Srikakulum which is 100 % subsidiary company of DFPCL.

The company has worked with all major technologies for Nitric Acid and Ammonium
Nitrate (M/s Uhde Germany, GPN France, Chematur Sweden, Plinke Germany,
Weatherly, Spain etc) and over years improvised the same to achieve higher
productivity, better efficiencies and lesser effluents.

DFPCL intends to enhance it’as the Ammonium Nitrate manufacturing capacity by

setting up a 1140 MTPD {3,76,200 (MTPY)} Ammonium Nitrate Solution
manufacturing complex at Paradeep situated in state of Odisha on eastern coast of
India to meet the growing demand of the mining explosives emerging out of the
spurt in coal and iron mining activities.
The set-up will support, manufacturing of Ammonium Nitrate solution and the end
products shall be
 LDAN-Upto 1,000 MTPD {330,000 MTPA}
 HDANUpto 1000 MTPD{330,000 MTPA}
 AN Meltup to 47000MTPA (140TPD)
and various combinations of above products based on the market
requirements. The major raw materials for making Ammonium Nitrate are
 Ammonia and
 Nitric Acid

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 Ammonia shall be manufactured in house having capacity of 380 TPD & balance
will be outsourced as mentioned.

Nitric Acid will be made within complex by setting up

 Nitric Acid unit of 900 MTPD {297,000 MTPA} capacity.

The company already has the basic & detailed engineering packages ready and key
equipment are readily available from reputed manufacturers. The project is based
on the feasibility study carried out internally by the company.

2.2. Promoter Highlights:

DFPCL was incorporated in the year 1979 and commenced commercial
production of Ammonia in 1983. DFPCL went in for forward integration projects
for adding various downstream products to their portfolio. These projects, which
commenced production in 1992, include Diluted & Concentrated Nitric Acid,
Ammonium Nitrate, ANP fertilizerand Methanol as a diversification initiative.
Thereafter, DFPCL implemented expansion projects for various products like
Dilute Nitric Acid, Concentrated Nitric Acid and Ammonium Nitrate. The company
also implemented projects for diversification to produce Liquid Carbon dioxide,
Isopropyl Alcohol and Sulphur Bentonite Fertilizer. In 2011 DFPCL commissioned
300 KTPA plant to produce both High Density (HDAN) and Low Density (LDAN)
grade Technical Ammonium Nitrates at its Taloja site at a cost of around Rs
600crores.

This state of the art complex with fixed assets of more than 1,700 crores is
located at MIDC, Taloja near Mumbai. The company has impeccable record of
over 30 years in the industry with excellent reputation and relationship with its
Bankers, Customers, Suppliers and Shareholders. The company’s shares are
listed and traded on BSE and NSE.

DFPCL follows the best safety practices and has won British Safety Awards
multiple times. It has maintained excellent environment records.

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 The World class facilities to manufacture Nitric acid / Technical Ammonium
Nitrate along with related off-sites and utilities facilities proposed to be set up at
Paradeep,Also Ammonia Plant will be relocated from Taloja
Odisha requires apart from financial strength, project execution skills,
experience in operating large scale continuous process plants and the ability to
maintain high safety and environmental standards.

DFPCL has demonstrable experience and track record in all these areas.

2.3. Location &Infrastructure

The proposed project will be coming up at Village Bagadia, Chuakimatha, Rangiagarh
Tehsil Paradeep, District Jagatsinghpur, Odisha. The location map of the proposed unit
shown below.

Figure 1: Project Location with Surrounding vicinity

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 Figure 2:Project Location (Topo Map)

The project location, in addition to proximity to major markets (Coal and Iron
Ore mining) is selected based on the following criterion.

1. TAN Plant will be in the eastern part of India at “Kujang (Tehsil),

Jagatsinghpur (Dist.), Paradeep”.

The site is located along the Cuttack-Paradeep railway line and adjacent to
IOC Refinery township.
2. The distance from the Paradeep sea port to Plant site is a @ 10-12Km.
3. Location of plant is close to the major Mining hub especially coal i.e.
Chhattisgarh, Jharkhand, Odisha.
4. DFPCL already have possession of 340,000 Sq. Meter of prime land suitable for
industrial activities. The IOCL refinery, Paradeep Phosphates Limited (PPL),
IFFCO etc refinery/petrochemicals/Fertilizer complexes are within the radius of
10 Kms of DFPCL land
5. DFPCL Plan to capture both domestic market (eastern & central India) as well as
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 export market (Australia, SEA etc) from the aforesaid plant.

6. Proximity to major port to facilitate export of finished product.

7. Location is well connected with rest of the country for movement of finished
product by land.

The project is proposed to be set up in a part of a total 83.26 Acre plot of land.
This area has good infrastructure of roads and good connectivity with the port.

The process plants area will be around 20 acres. The area required for
supporting facilities shall be about 20 acres more. Hence land acquired is
sufficient to accommodate the main process plants, other offsite facilities, road,
drains, green belt required for the project and most importantly to meet the
revised AN regulation related to storage and transportation of AN products.

2.4. Project Implementation

The implementation of the project will be carried out with the Deepak Project
team and the reputed engineering company under engineering, procurement
& construction management (EPCM) Contract working in parallel and
interfacing where appropriate. The EPCM team will consist of the Technology
Provider and Engineering Contractors.

The basic process engineering for the Ammmonia, Nitric Acid plant and the
Ammonium Nitrate plant will be carried out in the office of the technology
provider.

The detailed engineering and procurement of the non-proprietary equipment

will be carried out by the EPCM Contractor. Based on the data from the
technology suppliers, EPCM Contractor will carry out utility and infrastructure
requirements. Project construction will be carried out by construction
contractors operating under the management of Deepak and the local EPCM
contractor’s site team.

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 2.5. Capital Cost

The estimated total cost for TECHNICAL AMMONIUM NITRATE

(TAN)PROJECT is approx.1,750 /-Crores.

3. PROJECTDESCRIPTION

Deepak intend to produce Ammonium Nitrate Melt and TAN Prills at Paradeep,
Odisha utilizing Imported/domestic anhydrous Ammonia and NG as feedstock.

The project will consist ofAmmonia 380 TPD and 900 MTPD Nitric Acid plant and a
total capacity of 1140 MTPD Technical Ammonium Nitrate plant. These facilities will
comprise of the following:

 Nitric acid storage tank for minimum 3 days’ capacity;

 Bagged Ammonium nitrate storage, including fully automatic bagging and

handling facilities ofup to 1500 MTPD capacity for filling of 25 Kgs, 50

Kgsbags in the initial stage and 1000 Kgs and 1200 Kgs jumbo

bags(later ifrequired).

 Loading of bagged AN prill in trucks for transportation;

 All the required utilities including cooling systems, instrument air system,

and demineralized water to the extent required;

 Ammonium nitrate Melt storage (2000 tonnes) and dispatch facilities for

400 MTPD;

 Diesel/ Thermal emergency power generation or Dynamic Un-Interrupted

Power Supply (UPS)systems;

 Boilers for start-up and normal plant operation;

 General facilities such as site development, boundary fencing, security

system, offices, stores & maintenance buildings, administration building,

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 laboratory, canteen, control room, gatehouse, weigh-bridge, internal

roadways, plant lighting, housing colony for employees;

 Storm water handling;

 Effluent treatment and handling;

 Fire water systems to meetstatutory requirements;

The TAN prills will be transported from the site in enclosed trucks or by
containers using 25 Kgs, 50 Kgs bags or 1000 Kgs, 1200 Kgs Jumbo bags. The
Ammonium Nitrate Solution will be transported in Road tankers.

For the power supply to the plant, a dedicated power line from the nearest Power
substation of CESCO / GRIDCO will be erected.

Raw water will be available from Taladanda Canal via dedicated pipeline to

the site. Catalysts and chemicals will be delivered to the plant by truck via

the public roads.

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3.1. General Requirements – Codes &Standards

1.0 Codes & Standards

1.1 Engineering standard Contractor’s Standard

Customer’s Standard
1.2 National standard DIN, BIS
1.3 Material specification DIN
ASTM
1.4 Petroleum industry code API
1.5 Pressure vessels and boiler AD
code ASME, IBR, SMPV
1.6 Heat Exchanger DIN
TEMA Class R/C/B
1.7 Pumps and compressors DIN
API
Manufacturer Standard
1.8 Machines Manufacturer Standards
1.9 Piping DIN
ANSI
1.10 Electrical code IEC
1.11 Instrumentation IEC
1.12 Civil code DIN
1.13 Hazardous area classification Ex-RL
API
1.14 Tanks DIN
API
1.15 Pressure relieving devices DIN / AD
API

3.2 General Requirements – Laws &Regulations

1.0 Laws & Regulations

The following laws and regulations shall be observed for
1.1 Pressure Vessels ASME SEC VIII, SMPV, IBR
1.2 Boilers ASME SEC VIII, IBR
1.3 Buildings and Structures IS 875, IS 1893, IS 4326
1.4 Electrical IER, BIS
1.5 Fire Fighting Fire insurance regulation
1.6 Water Pollution OPCB
1.7 Air Pollution OPCB
1.8 Safety NSC, NFPA, Factory Act
1.9 Sanitation Local Authorities,
1.10 Aircraft Warning DGCA norms
1.11 Noise Statutory laws
1.12 Storage Tanks API 620/API 650 / API 653

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3.3 General Requirements – Measuring Units
Following measuring units are to be used.

Temperature Deg C
Pressure, gauge Bar
Pressure, absolute Bar abs
Vacuum mBar
Weight Kg
Volume, liquids m3
Volume, gases (or at flow condition) Nm3
Flow rate – liquid m3 / hr
Flow rate gases Nm3/h
Flow rate steam Kg/h
Heat kJ
Power kW
Heat transfer coefficient W/m2 K
Viscosity cP
Liquid density Kg / m3
Vapor density Kg / m3
Equipment dimension mm
Piping length mm, m
Pipe diameter mm
Area m2
Tube sizes (ND) mm
Velocity m / sec
Vessel / Nozzle sizes (ND) mm
Sound pressure dB
Stresses N /mm2
Force N
Flange Rating lbs

3.4. General Requirements – Pollution Control Measures

1.0 Water Disposal

Disposal Allowable
treated mg/l
Treated Effluent COD, BOD, Ammoniacal Nitrogen, suspended
solids, TDS, Nitrate Nitrogen, Phosphates
Treated effluent water from the plant shall meet the local regulatory
(OPCB) requirements
2.0 Solid Waste Disposal
Incinerable wastes
Non incinerable wastes
Solid waste collected from the chemical store, offices, control room and
general

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 areas will be segregated and disposed safely.
3.0 Gaseous Emission
Nitric Acid plant:Stack Gas vented to atmosphere after going through a
NOx Abatement Unit which brings the emission levels within norm)

Ammonium Nitrate Plant: Air is vented to atmosphere after passing

through scrubbers to remove any dust.
4.0 Additional Requirements
Noise: All rotating equipment and noise generating equipment shall follow
the Company’s own guidelines for noise attenuation. The noise level shall
be < 85 dBA at 1 meter from the source.

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 4. PROCESSDESCRIPTION
4.1 AmmoniaPlant
Existing Ammonia plant at Taloja will be relocated to Paradeep which was based on
license provided Fish International Engineering Ltd, USA.

Original capacity of 272 MTPD has been enhanced to 380 TPD step by step.

4.1.1. Overall conversion

The process conversions are based on NG/methane feedstock, are given in the following
overall chemical reaction: -

0.88CH4 + 1.26Air + 1.24H2O 0.88CO2 + N2 + 3H2

N2 + 3H2 2NH3

For more detailed refer Annexure-1 as block diagram.

4.1.2. Gas receiving, Treatment& metering station

Gas received from battery limit is first passed through knockout drum to remove
condensate, slugs/droplets and then through a filter separator D8-0119 to eliminate dirt,
dust scales and condensate mist. The pressure of the gas to the battery limit is regulated
at 27 Bar g before metering. The total gas to the plant is metered.

4.1.3. Feedstockdesulphurization

Most of the catalysts used in the process are sensitive to sulphur and sulphur compounds.
The feedstock normally contains up to 5mg S/Nm3 as sulphur compounds. The feed-gas
is preheatedto 350-400°C, usually in the primary reformer convection section, and then
treated in a desulphurization vessel / reactor D8-0101, where the sulphur compounds are
hydrogenated to H2S, typically using a cobalt molybdenum catalyst, and then adsorbed on
pelletized zinc oxide desulphuriser D8-0102:-

R-SH + H2 H2S + RH
H2S + ZnO ZnS + H2O

In this way, the sulphur is removed to less than 0.1ppm S in the gas feed. The zinc
sulphide remains in the adsorption bed. The hydrogen for the reaction is usually recycled
from the synthesis section.

4.1.4. Primaryreforming

The gas from the desulphuriser is mixed with process steam, usually coming from an
extractionturbine, and the steam/gas mixture is then heated further to 500-600°C in the
convectionsection before entering the primary reformer. Preheated steam/gas mixture is
passed through an adiabatic pre-reformer and reheated in the convection section, before
15
entering the primary reformer). Part of the process steam is supplied by feed-gas
saturation. The amount of process steam is given by the process steam to carbon molar
ratio (S/Cratio), which should be around 3.57 for the. The optimum ratiodepends on
several factors, such as feedstock quality, purge gas recovery, primary reformer capacity,
shift operation, and the plant steam balance.
The primary reformer consists of many high–nickel chromium alloy tubes
filled with nickel-containing reforming catalyst. The overall reaction is highly endothermic
and additional heat is required to raise the temperature to 780-830°C at the reformer
outlet.
The composition of the gas leaving the primary reformer is given by close approach to the
following chemical equilibria: -

CH4 + H2O CO + 3H2

CO + H2O CO2 + H2

The heat for the primary reforming process is supplied by burning natural gas or other
gaseous fuel, in the burners of a radiant box containing the tubes.
The flue-gas leaving the radiant box has temperatures more than 900°C, after supplying
the necessary high level heat to the reforming process. Thus, only about 50-60% of the
fuel’s heat value is directly used in the process itself. The heat content (waste heat) of the
flue-gas is used in the reformer convection section, for various process and steam system
duties. The fuel energy requirement in the conventional reforming process is 40-50% of the
process feed gas energy.
The flue-gas leaving the convection section at 100-200°C is one of the main sources of
emissions from the plant. These emissions are mainly CO2, NOx, with small amounts of
SO2 and CO.

4.1.5. Secondary reforming

Only 30-40% of the hydrocarbon feed is reformed in the primary reformer because of the
chemical equilibria at the actual operating conditions. The temperature must be raised to
increase the conversion. This is done in the secondary reformer by internal combustion of
part of the gas with the process air, which also provides the nitrogen for the final synthesis
gas. In the reforming process the degree of primary reforming is adjusted so that the air
supplied to the secondary reformer meets both the heat balance and the stoichiometric
synthesis gas requirement. The process air is compressed to the reforming pressure and
heated further in the primary reformer convection section to around 600°C. The process
gas ismixed with the air in a burner and then passed over a nickel-containing secondary
reformer catalyst. The reformer outlet temperature is around 1,200°C, and up to 99% of the
hydrocarbon feed (to the primary reformer) is converted, giving a residual methane content
of 0.6% ( dry gas base) in the process gas leaving the secondary reformer. The process
gas is cooled to 350-400°C in a waste heat steam boiler or boiler/superheated
downstream from the secondary reformer.

4.1.6. Shift conversion

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The process gas from the secondary reformer contains 9.54 % CO (dry gas base) and
most of the CO is converted in the shift section per the reaction: -

CO + H2O CO2 + H2

In the High Temperature Shift (HTS) conversion, the gas is passed through a bed of iron
oxide/chromium oxide catalyst at around 360°C, where the CO content is reduced to about
1.8 % ( dry gas base), limited by the shift equilibrium at the actual operating temperature.
There is a tendency to use copper containing catalyst for increased conversion. The gas
from the HTS is cooled and passed through the Low Temperature Shift (LTS) converter.
This LTS converter is filled with a copper oxide/zinc oxide-based catalyst and operates at
about 260 °C. The residual CO content in the converted gas is about 0.1 % (dry gas base).
A low residual CO content is important for the efficiency of the process.

4.1.7. CO2 removal

The process gas from the low temperature shift converter at 220 °C contains mainly H2,
N2, CO2 and the excess process steam. The gas is cooled and most of the excess steam
is condensed before it enters the CO2 removal system. This condensate normally contains
1,500-2,000ppm of ammonia 800-1,200ppm of methanol. Minor amounts of amines, formic
acid and acetic acid could be present in the condensate. All these components should be
stripped from the condensate and/or recycled in processes. The heat released during
cooling/condensation is used for: -

– The regeneration of the CO2 scrubbing solution

– Driving an absorption refrigeration unit
– Boiler feed water preheat

The amount of heat released depends on the process steam to carbon ratio. If all this low-
level heat is used for CO2 removal or absorption refrigeration, high-level heat must be
used for the feed water system. An energy-efficient process should therefore have a CO2
removal system with a low heat demand.
The CO2 is removed in a chemical or a physical absorption process. The solvents used in
chemical absorption processes are aqueous amine solutions Methyl Diethanolamine
(aMDEA.)
Residual CO2 contents are usually in the range 100-1,000ppmv, dependent on the type
and design of the removal unit. Contents down to about 100ppmv are achievable.

4.1.8. Methanation

The small amounts of CO and CO2, remaining in the synthesis gas, are poisonous for the
ammonia synthesis catalyst and must be removed by conversion to CH4 in the methanator
by following reactions: -

CO + 3H2 CH4 + H2O

CO2 + 4H2 CH4 + 2H2O

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The reactions take place at around 355°C in a reactor filled with a nickel containing
catalyst. Methane is an inert gas in the synthesis reaction, but the water must be removed
before entering the converter. This is done firstly by cooling and condensation downstream
of the methanation and finally by condensation/absorption in the product ammonia in the
loop or in a make-up gas drying unit.

4.1.9. Synthesis gas compression and ammonia synthesis

Centrifugal compressors for synthesis gas compression, driven by steam turbines, with the
steam being produced in the ammonia plant. The refrigeration compressor, for
condensation of product ammonia, is driven by steam turbine.
The synthesis of ammonia takes place on an iron catalyst at pressures usually in the range
310 bar g and temperatures in the range 40 °C: -

N2 + 3H2 2NH3

Only 16.5 % is reacted per pass in the converter due to the unfavorable equilibrium
conditions. The ammonia that is formed is separated from the recycle gas by
cooling/condensation, and the reacted gas is substituted by the fresh make-up synthesis
gas, thus maintaining the loop pressure. Synthesis loop arrangements differ with respect to
the points in the loop at which the make-up gas is delivered and the ammonia and purge
gas are taken out. The best arrangement is to add the make-up gas after ammonia
condensation and ahead of the converter. The loop purge should be taken out after
ammonia separation and before make-up gas addition. This configuration is dependent on
the make-up gas being treated in a drying step before entering the loop. A make-up gas
containing traces of water or carbon dioxide must be added before ammonia
condensation, with negative effects both to ammonia condensation and energy.
The size of this purge stream controls the level of inert in the loop to about 10-15%. The
purge gas is scrubbed with water to remove ammonia before being used as fuel or before
being sent for hydrogen recovery.

4.2. Nitric Acid Plant

The technology for the Nitric Acid plant is already decided based on performance
evaluation of different Licensors technology by our internal core team who hold
professional operating experience of operating such plants.
Basically, there are three types of process involved for manufacturing of Nitric
Acid.

4.2.1 Mono Medium Pressure

4.2.2 Mono High-pressure

4.2.3 Dual Pressure

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 Each process is not substantially different from the others and hence there is
little difference in overall cost due to process adopted. The outline of the process
flow description and process flow diagram are given below:

The process steps involved in production of Nitric Acid plant can be divided into
(8) eight main sections described as follows:
- Air Compression

- Ammonia Evaporation

- Ammonia Oxidation

- Heat Recovery of low pressure nitrous gas

- Nitrous gas compression

- Absorption

- Acid Bleaching

- Tail gas treatment and NOx abatement

- Steam and Condensates

4.2.4 Air Compression

At this section, air is compressed in air compressor and mixed with ammonia. A
small part of air, called secondary air, is used during the bleaching process.

4.2.5 Ammonia Evaporation

Liquid ammonia coming from battery limit is filtered to eliminate any unwanted
particles present and evaporates in evaporator. Ammonia Gas coming from
evaporator is superheated and mixed with them.

4.2.6 Ammonia Oxidation

The ammonia combustion in the Oxidation Reactor produces nitric oxide,
following this equation:
4 NH3 + 5 O2 → 4 NO + 6 H2O
Other secondary and undesired reactions in the
reactor are: 4 NH3 + 3 O2 → 2 N2 + 6 H2O

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 NH3 + 2 O2 → N2O + 3 H2O
The ammonia oxidation takes place over a set of Platinum-Rhodium gauzes at a
temperature around 890 ºC. The efficiency of this reaction varies between 96.7%
(with new gauzes, beginning of campaign) to 94-95% ( end of campaign, just
before changing the gauzes).

4.2.7 Heat Recovery of LP Nitrous Gases

From the reactor, the gases are sent to a train of heat exchangers, where its
temperature is reduced. While cooling of the Nitrous gases, two reactions are
taking place inside the exchangers in the gas phase:
2 NO + O2 +NO2
2 NO2 + N2O4
Both reactions, nitric oxide oxidation and nitric dioxide dimerization, are
exothermic, producing an additional heat, also recovered in the exchangers.

4.2.8 Absorption
The absorption of the nitrous dioxide and nitrous tetra oxide in water to produce
nitric acid at 60- 62 %w/w takes places in the upper trays of the Absorption
Tower. These are perforated trays with refrigeration coils to reduce the
temperature of the gases, improving the absorption process.
The nitric acid production is achieved through the following
reactions: 2 NO2 or N2O4 + H2O + HNO3 + HNO2

3 HNO2 +HNO3 + 2 NO +H2O

This could be merged in a single
reaction: 3 NO2 + H2O +2
HNO3 + NO
The nitric oxide (NO) produced in the reaction is oxidized inside the column, to
nitric dioxide (NO2), which is absorbed in the column.
The process water needed for the absorption can be added as demineralized
water or as clean condensate from Ammonium Nitrate Solution Plant.

4.2.9 Acid Bleaching

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 Nitric acid coming from the bottom of the absorption tower flows to the bleaching
tower where NOx gases dissolved in the acid are removed. To do this operation,
secondary air is flow counter current, removing the dissolved gases. Bleached
Nitric Acid goes to the Battery Limit.

4.2.10 Tail Gas Treatment and NOx Abatement

Tail gas comes out from the absorption tower having a residual content of
nitrogen oxides of 500 ppm v. It is heated in heat exchanger to recover its
energy. The heated tail gas from the absorption tower with NOx content about
500 ppmv, are mixed with a stoichiometric amount of ammonia in the Ammonia/
Tail Gas Mixer and sent to the DE NOx Abator, where a Selective Catalyst
Reduction takes place decreasing the nitrogen oxides concentration in the tail
gas below 50 ppm v.
Gas coming out from the DE NOx unit is superheated in normal operation in Tail
Gas Super heater and is sent to the expander that supplies around 57% of the
required energy to compress the air. The additional energy required in the
process is supplied by the steam turbine. Once tail gas is cleaned and expanded
it is sent to the atmosphere through stack. The entire steam produced in the
Nitric Acid Plant is sent to the steam turbine coupled to an electric generator, to
generate power for the Nitric Acid plant and/or to export.

4.2.11 Steam and Condensate

High pressure steam is required for Air compressor steam turbine. In normal
operation HP steam is produced in the nitric acid plant during the cooling of
nitrous gases from converter. But during start-up it is necessary to import steam
to move the turbine.
Steam condensate is generated in the surface condenser of turbine and
transported by means of turbine condensate pumps to the de-aerator.

4.3 Technical Ammonium Nitrate (TAN)Plant

The process description for the preparation of Technical Ammonium Nitrate can
be divided in two parts:

21
  Ammonium nitrate solution preparation (wet zone)
 Prilling, drying/ and cooling the product (solid zone)
The ammonium nitrate is obtained by the reaction between the gaseous
ammonia and the nitric acid per the following reaction:
NH3 + HNO3 =NO3NH4 + Heat
This reaction is exothermic. When the temperature is above 200°C the
ammonium nitrate decomposes violently per the below shown reactions:
NO3NH4 =N2O + 2 H2O + Heat
2 NO3NH4 =2 N2 + O2 + 4 H2O + Heat

4.3.1. Solution Section (Wet Zone) – AN Solution Plant

The wet zone consists on the preparation of an ammonium nitrate concentrated
solution from Ammonia and Nitric Acid as raw materials. We can divide this zone
in three sections:
• Reaction of reactants in pipe reactor.
• Concentration of the diluted AN solution

a) Reaction of reactants in pipe reactor

Liquid ammonia is evaporated / superheated and fed to Pipe Reactor where it
reacts with the nitric acid, to form ammonium nitrate liquor. The pH of the
ammonium nitrate solution obtained in the reactor controls the feed of ammonia
gas to the Reactor. This flash produces process steam and concentrated
solution. Ammonium Nitrate solution of (ANS) of about 85 - 92% concentrations
from the bottom of separator flows to a Tank. Mist of ammonium Nitrate is
removed from Process steam in a scrubber. The clean steam is used to
evaporate and heat the ammonia gas.

b) AN Liquor Concentration
85 – 92 % Ammonium nitrate solution is pumped to the tube side of Falling Film
Evaporator. Steam is fed to the shell of evaporator to supply necessary heat to
concentrate the solution. The concentrated AN solution (96-99.8% AN) leaves the
bottom of the Falling Film Evaporator and either collected in the intermediate
22
 tank or goes for prilling depending on the grade of Technical Ammonium Nitrate.
In case of former, the tank has internal coils, which are fed with LP steam to
increase the solution temperature. The concentrated AN solution/melt is pumped
to the upper part of the prilling tower.

4.4. Dry Section – LDAN &HDANPlant

The Ammonia Nitrate Dry zone is generally divided in three sections:
• Prilling of ammonium nitrate solution
• Drying
• Screening, Cooling and Coating of the product

a) Ammonium Nitrate SolutionPrilling

The hot concentrated melt is either granulated (fluidize bed granulation, drum
granulation etc) or prilled. Ammonium nitrate is formed into droplets by a prilling
bucket or spray nozzles which then fallen by gravity within a tall tower (prill tower)
where they get cooled and solidified against a counter-current air stream.
Technical Ammonium Nitrate (TAN) prills are collected on the belt conveyors
located at thebottomoftheprillingtower. The temperatureofsolidammonium
nitrateatthebottom of the prilling tower is around 80 °C – 110 °C depending upon
the product cycle (start-up and stable operation respectively).
The air stream leaving the top of the prilling tower is scrubbed and cooled in the
prilling scrubber by means of an AN solution, which is recycled by the prilling
scrubber pumps and recovers most of the AN contained in the air.
The washing AN solution is cooled in exchanger with cooling water. In the
scrubber, the washing AN solution cools the air which is partially recycled the
prilling tower, by means of the air blowers while the rest of the air is sent to the
stack.
Ammonium nitrate prills collected at the bottom of prilling tower are sent by belt
conveyors to the drying section

b) Drying of theprills
The drying of the prills involves slow vaporization of most of the water of the prills

23
allowing a progressive drying which does not damage the prills and gives
hardness required to the product.

The exhausted hot air loaded with dust leaving the dryer drums is sucked into the
scrubbers by means of blower. The washing of the air is done in the Ventures
and scrubber with an AN washing solution. Clean air is then sent to the stack by
means of the air blower. From the dryer, the prills are sent to the screens through
belt conveyors.

c) Screening, Cooling and Coating of the product

Oversized and fines prills from screen are recycled, to the Wet Zone to be re-
melt with the ammonium nitrate solution. The on-size product is cooled in the
fluidized bed cooler against air conditioned air or in the bulk flow cooler against
chilled water.
Depending upon the product application, prills are sent to coating drum after
cooling and sprayed on the outer surface with a coating agent to attain the anti-
caking characteristics. Subsequently the coated/un-coated product is sent to
storage/ Bagging Plant through belt conveyor for storage or Bagging.

d) Product Handling &Bagging

The coated/un-coated prills are sent to the bin/hopper in the Bagging plant,
where they are packed in HDPE bags for selling. Two automatic bagging
machine of sufficient capacity shall be installed to bag entire production in
different packing size as per the Customer need.

f) Bagged Storage and Dispatch:

To load these bags on trucks, two portable type truck loaders with provision of
one more truck loader in future shall be provided to load bags directly on trucks.
During the non- availability of trucks, the same truck loader can be moved to
other side for loading the bags on pellet with same work force. On the availability
of trucks, truck loader shall be diverted to truck end again. Bags from pellets also
24
 to be put on truck loader manually for dispatch.

Bagged storage area equivalent to 5 days’ final production capacity shall be

created to store bagged product during the non-availability of trucks.

g) AN Melt dispatch
Facilities shall be provided to load 85- 87 % concentrated AN melt by installing
loading bays for tanker. Facilities to include blast proof wall

5. TECHNOLOGIESAVAILABLE

There are number of process licensors offering the technologies to manufacture

Nitric Acid and Technical Ammonium Nitrate. A list of some of the reputed
Process Licensor is given below:

 Udhe/TKIS, Germany

 Espindesa, Spain

 Grande Paroisse, France (now owned by Casale, Switzerland)

 Weatherly Inc, USA (now owned by KBR, USA

 Orica Australia

Basically, each of the technologies is not substantially different from the others
and hence there is little difference in cost due to technology adopted.

DFPCL over the years has not only absorbed but improvised these technologies
and is in position to carve out best possible process configuration towards most
cost-effective manufacture of AN- products.

For the Paradeep Project DFPCL has selected the technologies from one of the
above, and with whom DFPCL has the experience of installation, commissioning

25
 & operation.

6. PLOT & SITE DIAGRAMS – EMPHASIZING TOTALAREAS

6.1 Site information

The plant is to be located at the site OFF IOCL ROAD, NEAR IOCL
OVERBRIDGE, BAGADIA- RANGIAGARH, DIST: JAGATSINGHPUR,
PARADEEP – 754141, ODISHA.
The preliminary layout of the plot is shown on end of Section 12 of this report.
The site is located along the Cuttack-Paradeep railway line and adjacent to
IOCL Refinery Township.

The existing ground level of the site is approximately 2.5 M to 3.0 M above the
Mean Sea Level. It is planned to have the Finished ground level as 5.5 M from
the Mean Sea level as per the available site conditions. Hence, filling of app. 3.00
M depth is envisaged.

6.2 Power and Water

Power requirement for the plant will be met through CESCO/ GRIDCO.
Depending on the voltage at which power is available, suitable step down
transformers will be provided. The app. length of power supply line will be 4 –
5 KM.

The water requirement for the Plant will be met through a water reservoir
having a storage capacity of 10 days. The source of water supply will be
from Taladanda canal. A Pump house and water supply line from Taladanda
canal will be laid up-to reservoir. The length of water supply line is estimated at
10 - 12 KM from Distributary point16.

7. RAW MATERIAL ANDUTILITIES

7.1 Plant Capacities
The plant design is based on the following production capacities:

26
 Product Production
s Capacity Metric

Nitric Acid (capacity as 100 %) Ton

900 MTPD / Day
/ 297 KTA
Ammonium Nitrate Solution (100%) 1140 MTPD/ 376.2 KTA
Technical AN (TAN) Prill 1,000 MTPD / 330 KTA
( as LDANHDAN
orcombination
AN Melt 390 MTPD / 140.0/46 KTA max
thereof)
Ammonia 380 MTPD/126 KTA

Note: Nitric Acid produced will be used by Ammonium Nitrate plant.

7.2 Consumption Norms
The requirement of raw materials, Chemicals and utilities for the proposed
project has been worked out based on rated capacity operation of the plants.
The requirement of various inputs is summarized in table below
Raw Material & Utility Requirement

S. Raw Material / Unit Requireme

No Chemicals/Utilities nt
A Raw Material
Ammonia MT/day 380
NG Gas Sm3/day 830 NG

B Utilities
Power MWh 8.5
Raw Water M3/day 15000

Steam MT/hr 55

7.3 Ammonia
Currently DFPCL sources Ammonia from Middle East. The additional requirement of
Ammonia for the Project shall be met through relocated Ammonia plant of 380 TPD which
will also cater requirement of nitric acid plant to full fill additional requirement.,.

DFPCL is in advance stage of entering long term contract with one of the
industries in Paradeep for utilizing their Ammonia receiving, storage and transfer
facility. Existing Ammonia storage tanks of this company shall be used on hired
27
 basis thru a long-term contract for receiving, storage and pipe line delivery of
imported Ammonia. The Ammonia pipeline length between the nearby factory

and DFPCL plot will be around 6 Kms.

7.4 Raw Water

The raw water requirement is 15000KLD which shall be supplied from the local
irrigation canal located at approx.10 - 12 Kms away from the plant site. The
water availability from this canal is restricted to 310 days in a year; hence the
average lifting/ day capacity of water shall be kept with 20% margin of normal
requirement.

Suitable water intake facilities shall be created at canal site to lift the required
volume of water through two number of pumps (one operating and one stand by)
and discharge to the raw water storage reservoir located inside the plant
premises. Water from canal intake station to plant site reservoir shall be supplied
through pipeline. Decision of underground or above ground pipeline shall be
taken during the further development stage of the project.

The requirement of water is mainly for cooling water make up. Other requirement
of process water is as make up to DM plant, utility water, etc. Water requirement
indicated above has been worked out based on recycle of majority of steam
condensate to DMplant.

Raw Water Treating

The overall water users are listed below

 Dematerialized water production

 Portable water and safety showers
 Fire water and make-up
 Chemical mixing(Intermittent)
 Other users in the plant
 Cooling water (circulating water) make-up

28
Raw water shall be sourced from Taldanda Canal and will be stored in a
reservoir before feeding to the treatment unit.

Raw Water Reservoir

Water reservoir shall be designed to store the water for 10 days’
continuous operation of the plant considering non-availability of canal
water for maximum 10 days in one stretch. A Raw Water reservoir of
capacity 60000 M3 shall be provided, considered with 24 hrs pumping basis
at a rate of 250 m 3/h flow to the plant.

Raw Water Consumption Basis

Water Demand Normal, m3/h

Portable Water 4
Dematerialized Water make-up 10
Other users 4
Cooling Tower make up 232
Ammonia plant 150
Total 400

29
7.5. Potable Water

Potable water is to be sourced from Taldanda canal. The total

requirement of whole plant is likely to be 96 M3/day, which is further

used for various applications within the plant premises.

Basis of Design

 10 nos of 500 letters capacity Sintex tanks will be installed at different

locations of the plant for storage of potable water.

 These tanks will be fed by filtered water pumps.

 UVR unit will be provided wherever potable water shall be used for
drinking purpose.

 Network of piping for safety shower and eyewash.

 Number of safety showers and eye wash points required.

 pH and free Chlorine analyzer at the pump discharge.

7.6 DMWater
The DM water plant capacity has been considered as 25 m3/h without any stand
by unit. Plant shall be in line for 22 hrs. in day and remain out for 2 hrs. for resin
regeneration. Provision shall also be made for storage of DM water, process
water and steam condensate with associated pumps.

Demineralized / Polish Bed Water

Water contains various impurities such as dissolved salts of Chlorides

andcalcium which should be removed before feeding to Boiler. 25 M3/Hr.
demineralization plant is proposed for boiler Feed water. 200 M3 storage tank is
proposed for storage of Demineralized water. Polishing bed is proposed at this
stage for reuse of Steam condensate as a boiler feed water, the capacity of
which will bedecided later.

30
Design Basis

The design basis for the demineralization plant would consist of the following:

 Normal demineralization water requirement is 10m3/h

 At this stage 25 m3/h unit consisting of Cation and Anion exchanges are

considered

 Cation exchanger would be counter current - counter pressure design.

 Anion exchanger would be counter current - counter pressure design.

 Chemical requirement per regeneration

 Acid (H2SO4) = in kg 100% (vendor specific) as in detail engineering

 Alkali (NaOH) = in kg 100% (vendor specific) as in detail engineering

 Requirement of a condensate polishing unit shall be verified to treat the

return contaminated condensate from the plants.

 The return condensate water from the plant could be quite hot and the ion

exchange resin while specifying should be capable of withstanding high

temperature.

 Polished water storage of 100 m3 capacity can be considered.

Demineralization / Polish Bed Piping and Vessel Design

 The ion exchanger vessels, CS and internally rubber lined or of suitable

material for demineralization plant.

 The piping shall be carbon steel rubber lined or of suitable material for

demineralization/polish bed units (acid and alkali).

 All the valves and fittings shall be rubber lined or Polymer based suitable

for both the units.

31
  The vessel and piping should can withstand a pressure of 1000 kPag and

temperature of 100 degC.

 The regeneration circuit piping and valves shall be PVC or equivalent

material that can withstand Sulfuric acid and Sodium Hydroxide.

 Ejectors used to draw the dilute acid/alkali from the regeneration day tank

shall be suitable for acid and alkali.

 Flow transmitter is required at the outlet of the Ejector to measure the

regenerated flow to the ion exchangers. Its material should be suited to

acid and alkali.

 Bulk acid and alkali storage is required.

 The water storage tank should be made from SS or suitable material.

 The neutralizing pit pump suction piping and the pumps should be

capable of pumping salt and water from the reaction of acid and alkali

7.7 Catalyst
For Ammonia plant:
 Desulfurization catalyst – Cobaltmolybdenum.
 Reforming catalyst- Nickel chromium alloy.
 Shift conversion reaction - Iron oxide.
 Methanation – Nickel.
 Ammonia Synthesis – Iron.

For Nitric Acid Plant:

 For ammonia Oxidation -Precious metal (Pt /Rh) gauze. The net
catalyst consumption per ton of nitric acid is including the credit of Pt /Rh
recovery from the “getter” made by the gauzes manufacturer is 50 mg/
ton of acid100%.

 DeNOxAbater catalyst for tail Gas Treatment to meet the

strictest environmental standards related to NOx emissions.
32
  Ammonium Nitrate manufacturing process does not require any
Catalyst.

7.8 Electrical Power

A reliable power supply arrangement is a pre-requisite for stable operation of the

plant at rated capacities on long-term basis. The normal power requirement for
the project would be around 8.5 MW. The entire power requirement is proposed
to be taken fromthe State Electricity Board grid. The power to the plant shall be
fed through 132 KV state grid/transmission lines passing along the plot
boundaries.

Dynamic UPS system with Diesel Generator shall be provided for supply of
uninterrupted / emergency power. To meet the emergency power

requirement in plant, one DG set of 2000 KVA shall be installed.

The Nitric Acid plant is also equipped with turbo generator coupled to air
compressor and can supply 5-6 MW if required.

Emergency Power Supply and Diesel Fuel Supplies

In the case of a power outage, an emergency diesel driven generator would

be provided and sized to run critical users in the plant. Storage facilities will
be needed for diesel fuel. 50 m3 bulk storage has been considered at this
stage, will be confirmed after carrying out detail engineering. The bulk diesel
storage tank capacity will be determined in the next phase based on the
requirements for the consumers listed below:

 Firewater diesel
 Emergency diesel driven generator

The emergency power will be supplied by a diesel driven engine generator,

capable of supplying essential LV consumers for at least 12 hours. Except for

33
 the firewater pump, an 8 hours’ storage capacity day tank or vendor standard

supply package item with the equipment should be allowed in the design.

Emergency Power

The essential (critical users) loads to include:

 Safety and automation systems;

 Controls;

 Emergency lighting (plant and buildings);

 Lube oil pumps and ventilation fans in turbines, generators & other

major plant loads;

 Jockey pump;

 Communication systems;

 Process control systems;

 Shutdown systems; and

 Portable water pumps;

 Instrument Air Compressor

The emergency generator system is self-contained and located away from

the main power generator building. The diesel engine will start automatically
on loss of main power and the generator connected to the bus through a
transfer switch on failure of main power. Arrangements for black start will
also be provided.

7.9 Fuel &Steam:

One START UP Coal fired service boiler of 60 T/hr. shall be installed to generate
steam at 61 bar pressure and 450 deg C temperatures with turn down capacity of
25% of normal capacity. The capacity of boiler has been derived based on start-
up case of Nitric Acid Plant.

34
The entire requirement of steam in the complex will be met by this boiler.
Suitable let down station with de-superheating facilities shall be provided to cater
the steam pressure and temperature as per the requirement of downstream
process.

The start-up requirements of Nitric Acid plant require further investigation at

the next phase of work. But during the normal operation of all plant, there
will be hardly any additional requirement of steam in the process plants
other than the waste steam. However, to keep the boiler in operating
condition at minimum turndown ratio of 25 % continuously to make the

steam available readily in case of shutdown/ eventuality

in WNA or in any other plant, some of the drives like BFW and FD fan of boiler,
CW pump etc shall operate on condensing type turbine. This will also ensure
continuous operation of WNA plant during the power failure.

At peak load, Coal requirement will be around 120 TPD which will be required
only during the start-up of Nitric acid plant. Normal requirement will be 50 TPD.
Hence, eight days Coal storage capacity (1000 MT) on peak load basis shall be
installed. (FO fired Boiler is also being considered as an alternative possibility )

Steam and Condensate System & Process Description

Boiler feed water to the plant is produced from two sources, one from the
demineralization plant and the other from condensate water polishing unit. The
filtered water from Raw Water Treatment unit is sent to the demineralization plant
whereas return condensate water from the plant is routed to condensate
polishing unit to remove the dissolved solids.

The demineralization plant is designed to 25 m3/h capacity. The condensate

polishing unit will be designed in the later stage.

Low pressure steam from LP header would be used for stripping the dissolved
oxygen from the condensate water in the de-aerator. Oxygen scavenger dosing

35
 is required to remove any residual oxygen present in the condensate water at the
outlet of the de- aerators. The condensate from the de-aerator would be
approximately 100 deg C, and routed to the Boiler Feed Water (BFW) pumps.
Since the BFW is at boiling point, the de- aerators will be elevated to avoid pump
cavitation.

The BFW pump suction piping design will also take in to account the pump
NPSH requirements, frictional losses in the suction piping, vapor pressure, high
fluid temperature and other similar requirements.

Condensate from the surface condenser in Nitric Acid plants will be recycled
back to the Waste heat boilers in those plants. Any shortfall in condensate will be
made up by DM Water

General Steam Piping Design

 All steam lines shall be insulated with hot insulation material and cladding.

 The steam header shall be designed with slight gradient towards the
steam trap.

 The steam header shall be provided with steam traps at suitable location.

 Pocketing of the steam line shall be avoided. Steam trap shall be

provided at the low point of the pocketed section.

 Provision of a by-pass around the trap as required for a start-

up shall be provided.

 Proper line rating shall be considered once the P&ID’s are developed.

7.10 Cooling Water System

The cooling tower provides indirect cooling to the heat exchangers to remove the
heat duty from the circulating water. The circulating cooling (cooling medium)

36
 water would be used as a close loop circulating water to cool the coolers/heat
exchangers in ammonia, nitric acid and ammonium nitrate plants. The circulated
water from the outlet of the individual plant would return via a circulating water
return header back to the cooling tower.

An induced draft, cross flow type cooling tower will be used for supply of cooling
water to different section of the plant. Maximum temperature difference of 10°C is
desirable in the cooling tower. This will be associated with CW circulating pumps,
side stream filtration, chemical dosing system etc. Three cooling water pumps
(electric motor driven) will be running to meet the process requirements.

The water losses calculated from the cooling tower includes drift and
evaporation loss as well as blow down loss. The blow down rate from the
cooling tower would vary, and depend on the water quality being maintained.

Circulating Cooling Water Flow in m3/h

Plan Actual Flow Design Flow

t
Nitric Acid Plant (m3/h)
---- mmmmm(m3/h)
7079
ANS Plant ----- 968
Ammonia plant --------- 6800
AN Prill Plant ----- 648
Utilities area ----- 500
Total ----- 15995

Pumps Design

The main pumps shall be designed with a discharge pressure required to

overcome the highest static head of the downstream process in the Complex
and associated frictional losses. This requires further investigation based on the
plant layout and will be considered in the next phase of work. The discharge
pressure requirements need to be reviewed once the header piping and
equipment layouts are finalized.

Design Considerations

 The pump sizing is based on very preliminary information. The sizing

shall be reviewed later when the equipment layout and piping layouts
are available.
37
  The cooling water header should have high point vents and low point
drains

 To check the cooling water pumps performance, provision for flow

measurement is advantageous at the individual pump discharge header.

 Proper chemical and hypochlorite treatment would be required to keep

the Legionaries bacteria under control.

Cooling Water Chemistry

Actual cooling water chemistry and quality will be determined upon site
selection and water source and treatment. Cooling water chemistry requires
some amounts of free chlorine, phosphate and dispersant to prevent corrosion,
scaling by keeping the impurities in suspended form.

Free chlorine also keeps bacterial and organic growth under control. Provision
of descale chemical injection point would be required in cooling water circuit.

7.11 Air Systems (Compressed Air)

The facilities shall have 2x 1,500 Nm3/hr. oil free compressors which shall cater
the requirement of instrument and Plant Air of the complex. One compressor
will be in line and another shall be kept as standby. A 1,200 Nm3/hr. of drying
unit shall be installed to necessary conditioning of the air to be used as
instrument air.

Detail requirement of complex instrument& plant air will be freeze during detail
engineering stage of project.

System will comprise one plant air receiver and one instrument air receiver.

Instrument Air

The consumption rate for instrument air is based on all instruments operating
plus the design margin. Since P&ID’s are not available or the instrument loop
diagram, an assumption has been made to arrive at the capacity requirement.
It is important that once the details are available the capacity requirement need

38
 to be revisited after detail engineering.

Plant Air

No specific information is available and a small continuous requirement is

considered (assumed) for design purpose. The plant air would be typically
about 800 kPag, but will be confirmed after detail engineering.

Design Parameters for Compressed Air System

The instrument air pressure is set by the instrument specification. Typically, it is

700 kPag measured immediately downstream of the final driers.

Description Operating Design Remarks

Plant air condition
8 bar g condition
10 bar g
header
pressure air
Instrument 7 bar g 10 bar g
header pressure
Temperature Ambient 65 dig C
Instrument air - 40 deg C At 7 bar g
dew point

Compressor and Air Drier, Receiver Sizing

The system design is based on the following:

 The compressor is sized to 1500 Nm3/h flow considering 300

instrument components for the whole plant and considering 5 Nm3/h
consumption per instrument. Detail requirement of instrument air will be
estimated and freeze during detail engineering.

 Dry running oil free reciprocating compressor type is preferred.

 Inter-cooler and after cooler should be part of the compressor vendor skid.

 Instrument air driers have a design dew point of – 40 deg C at the

operating pressure

39
  Driers will be reactivated by desorption which is a package item

 Two Filters of 100% capacity are provided upstream and downstream of

the driers to provide dust free air supply.

Instrument Controls

The compressed air system shall include the following controls:

 Operation and control of the compressors within the package (by the
vendor)

 Control of the driers within the package (by the vendor)

 Start and stop of the duty compressor with the air demand (low/high
instrument air header pressure)

 Failure of the duty compressor, and further fall in instrument air header
pressure, the control system should start the stand-by compressor
automatically.

 Due to criticality, preference would be given to instrument air header

pressure over the plant air. Therefore, in the event of fall in instrument air
header pressure, plant air supply will be shut. As discussed, the stand-by
compressor would come online to cope with the additional demand.

 One of the two instrument air compressors would be connected to the

emergency power system for black start scenario.

7.12 Fire Water System

Fire water system will be provided as per the regulation.
The firewater system should be designed to the following criteria:

 The main firewater pumps (both diesel and electric drive) designed to

40
 have waterwhich will be finalized during detail engineering stage of
project. The sizing of the pumps and the firewater headers assumethat at
any given time five monitors each of 55 m3/h would be required to
firefight

 A minimum of two main independent power 100% for firewater pump

systems are available. One Electric motor and one diesel engine driven
ump shall be provided.

 The main pumps shall can operate for 24 hrs.continuously

 The main pump shall be capable of developing pressure of 9 bar g at the

discharge flange

 Firewater pumps shall be located within a safe area if possible, such that
a fire in one area will not put both the fire pumps out of action

 The electrical jockey pump capacity of 10 m3/h shall be provided.

 The jockey pump should can maintain the firewater system pressure at 8
barg

Firewater tank would be designed to 3 hrs. capacity at the water flow rate of 275
m3/h

 Diesel driven firewater pump will be a package item. The package should
includethe following:

1. Start-up – Cranking (battery / Air receiver /Hydraulic)

2. Diesel day tank should have capacity for 8 hrs.continuous

operations

3. Auxiliary system

4. Local control panel

 The firewater ring main sized to 350m3/h

 The firewater piping design to 16 bar g and the firewater pump shutoff
head not to exceed the FW header design pressure
41
  Firewater pumps should be designed to applicable NFPA / APIcodes

 A provision of a spill back line is provided back to the FW storage to

bleed-off the excessive pressure from the firewater header

7.13 Product Handling

Ammonium Nitrate melt shall be dispatched through road Tankers. Tanker
loading system will be provided for handling product evacuation.
Prilled Ammonium Nitrate (TAN)shall be bagged in bags in Bagging Plant. Filled
bags shall be loaded in trucks and then dispatched by road. Truck loader shall be
provided for loading the bags in truck. All precautions as per latest AN rule shall
be taken during storage and delivery stages.

7.14 Manpower
The manpower required for the operation of the proposed facility will be met by
deployment of personnel with requisite experience and skill. The manpower will
beadequately trained before start of operation. Focus shall be training and
employing locals to the extent possible and based on availability of workforce
with required skill sets.

7.15 Laboratory
Adequate laboratory facility will be provided to check the all the raw materials,
products, by products, water and steam system, effluent system parameters
during day to day operation.

8. PROCESS FLOW BLOCK DIAGRAM OF NITRIC ACIDPLANT

See Annexure-1 for Ammonia, A, ANS & TAN Process Flow Block Diagram

42
 9. RAW MATERIAL & PRODUCTSPECIFICATION

9.1. Feedstock – Raw Materials – Liquid Ammonia

Descriptio Min Avg. Max Unit

n
Ammonia content 99.5 Balanc % wt
Water e
0.5 % wt
Oil 10 ppm wt
Organics Not ppm wt
detectabl
Iron e 2 ppm wt.
Storage Temperature - 34 20 Deg C
Liquid Ammonia Density 674.4 670.3 kg/m3

Ammonia Storage

Imported ammonia shall be brought by ships while domestic ammonia if available

shall be brought by road tankers. The Ammonia shall be stored in atmospheric
storage tanks existing in the neighboring plant. Ammonia at – 33 Deg C shall be
pumped directly to DFPCL’s TAN process plants through a pipe line Only a small
Ammonia bullets (2) of 250-300 MT capacity shall be provided at DFPCL site to
meet the demand in case of interruption from supplier and due to power failure
etc.

More information can be furnished after carrying out the Detail Engineering.

9.2. Products Specifications

9.2.1 Weak Nitric Acid

Descriptio Min Max Unit

HNO3 n 58 62 % wt.
NOx (as NO2) 0.005 % wt.
Chloride (as HCI) 1 Ppm
Silica (as SiO2) 1 w/w
Ppm
Storage temperature 40 45 w/wC
Deg

43
9.2.2 Technical Ammonium Nitrate Prills(LDAN)

Descriptio Value Unit

n
Total Nitrogen by mass 34 % wt. min
Ammonium Nitrate 99 % wt. min
Humidity (H2O) 0.20 % wt.max
Acidic Nature (pH) 4.8 – 5.2 - min
Oil Absorption 6 % wt. min
Free Flow Bulk Density 0.72 – g/cm3
Total Organic Carbon 0.78
0.2 % max

9.2.3 Technical Ammonium Nitrate Prills(HDAN)

Descriptio Value Unit

Ammonium Nitraten 99 % wt. min
Humidity (H2O) 0.50 % wt.max
Acidic Nature (pH) 4.8 - min
Chloride as Cl 10 ppm max
Iron as Fe 10 ppm max
Sulphates as H2SO4 15 ppm max

9.2.4 Ammonium Nitrate Melt

Descriptio Value Unit

Ammonium Nitraten 84 - 86 % wt. min
Humidity (H2O) 14 - 16 % wt.max
Acidic Nature (pH) 5 - Min

10. ENVIRONMENTALCONSIDERATIONS
Climate and Meteorology
Meteorology plays a vital role in affecting the dispersion of pollutants into
the environment after their discharge into the atmosphere. Jagatsinghpur
District enjoys a temperate climate. Winters are cold, while summers are hot
and humid. The District is prone to cyclonic rainfalls during the monsoons.
The maximum temperature of the District is 38°C and minimum temperature
is 12°C. The average rainfall measured in the District is 1765.1-mm.
The state experiences four seasons, these are:
Winter ( December to February), Pre-monsoon (March to May), Monsoon
(June to September), Post-monsoon (October to November).
Winter Season: Occasional rains with average 40-mm rainfall is received
during this period, the average minimum temperature goes to 5°C or below
in interior districts and in coastal areas it remains around 12-15°C. Normally

44
 the winter brings a clear sky, light winds and abundant sunrays during the
daytime.
Summer Season: The average temperature in the coastal districts remains
30-35°C and in interior districts remained around 35-42°C. There are some
hot pockets in the western belt, where the temperature goes as high as 45-
50°C. During March to May often a high-pressure area created over the Bay
of Bengal, forcing moisture-laden wind to the coastal districts of the State.
This situation brings thunderstorm, hail storm, dust storm and light rains to
the area.
Monsoon Season: The period mid-June to end of September or early
October is considered as monsoon season. Southwest monsoon sets in
over the State by the mid-June brining rain. About 80% of the total rainfall
(average more than 1480.0-mm) occurs during this period.
Post-monsoon Season: The monsoon usually continues up to the end of
September and to the early part of October. Then the sky becomes clear
and the day temperature starts decreasing and the night temperature drops
sharply. During the post-monsoon period, the interior parts of the State
receive about 75.0-150.0-mm rainfall and the coastal districts receive about
200 to 220-mm rainfall. Another feature of this period is occurrence of
intense low-pressure system over the Bay of Bengal creating cyclonic
storm, often striking Orissa coast.
Following waste shall be generated during the process

Environmental Sensitivity
1 Areas protected under
international conventions,
There is a Protected Forest at 5.20km,
national or local legislation for Yes
their ecological, landscape, SSW
cultural or other related value
2 Areas which are important or There is a river called Mahanadi at
sensitive for ecological 5.40km, N and Santra Nallah 1.84km,
reasons -Wetlands, SW, Antrabanki,4.18 km, SE, Mahanga
watercourses or other water Yes
Nallah,4.89km, SW
bodies, coastal zone,
biospheres, mountains, forests Bay of Bengal,6 km SE
3 Areas used by protected, There is a Protected forest present in the
important or sensitive species study area but it is an open forest and
of flora or fauna for breeding, there are no protected, important or
No
nesting, foraging, resting, over sensitive species of flora or fauna for
wintering, migration breeding, nesting, foraging, resting, over
wintering, migration
45
4 Inland, coastal, marine or There is a river called Mahanadi at
underground waters 5.40km, N and Santra Nallah 1.84km,
SW, Antrabanki,4.18 km, SE, Mahanga
Yes
Nallah,4.89km, SW

Bay of Bengal,6 km, SE

5 State, National boundaries There are no state State, National
No
boundaries
6 Routes or facilities used by the
NH-5A,5.26 km, E and Ranigarh RD,0.23
public for access to recreation Yes
or other tourist, pilgrim areas km, E
7 Defense installations No There are no Defense installations.
8 Densely populated or built-up
Yes Paradip,2.78km, NE
area
9 Areas occupied by sensitive
DAV Public School,2.08 km, SE
man-made land uses
Yes
(hospitals, schools, places of
Port Trust Hospital,6.41km, SE
worship, community facilities)
10 Areas containing important,
high quality or scarce
resources (ground water
No
resources, surface resources,
forestry, agriculture, fisheries,
tourism, minerals)
11 Areas already subjected to
pollution or environmental
damage. (Those where No -
existing legal environmental
standards are exceeded)
12 Areas susceptible to natural
hazard which could cause the
project to present
environmental problems
(earthquakes, subsidence, Project area falls in the seismic zone-III(Moderate
landslides, erosion, flooding or damage Zone)
extreme or adverse climatic
conditions)

11. Environmental Management Provision

Solid Waste Management:Proposed project does not generate solid wastes
on continuous basis. However solid waste generated because of the
following
 Spent Ion exchange resins

46
  Oily cotton rags from maintenance activities

 Filter media used for filtration of air / water / cutting or lubricating oil

Empty chemical containers, drumsInclude NOx abator used catalyst &

Ammonia plant used catalyst.

The wastes indicated above are of special concern since theycould be eco-
toxic or hazardous and special attention needs to be given to their
handling, treatment and disposal.

Spent Filter Cartridge:

After analysis under hazardous waste these wastes will be disposed off at their
hazardous waste site in sealed containers after obtaining requisite approvals.

The other generated waste is municipal solid waste, scrap –metal, paper,
plastics, waste packaging material etc. These miscellaneous wastes will also be
disposed of through local / federal approved vendors.

10.2 Liquid Effluent:

During the normal operation of the plant there will be no liquid effluent from
WNA plant but a smallquantity of Nitrate bearing effluent will generate from AN
wet plant. Some quantity of Nitrate and Nitric acid containing effluent from
WNA and AN wet plant will also generate during the plant upset or
startup/shutdown condition. In addition to this process effluent, blow down
water from cooling tower, boilers, backwash of DM plant resins and side
stream filters of cooling tower, domestic waste from canteen etcwillalso be
part ofmain effluent.

47
 A suitable effluent treatment plant shall be installed to take care of all the
effluents. Following will be the characteristics and quantity of the liquid
effluent.

Plant Source Qty pH TSS O&G BOD COD

Nitric Acid Plant Floor Washing 9 2-7 50 5 80 200
Nitric Acid Plant Boiler Blow down 53 11-12 NIL NIL NIL NIL
Ammonia Plant Synthesis loop NH3 50 7-8 NIL NIL NIL NIL
recovery section &
floor washing
Ammonia plant Blowdown and
cooling water filter Backwash 600 7-9 20 <10 20 30

AN Solution Plant Floor Washing 9 3-9 50 5 80 200

AN Solution Plant Clean/ 222 5-8 5 NIL 20 50
Proces
TAN s Condensate
Plant washings 17 3-9 50 5 100 250
AN Storage Spillage and 5 2-7 50 5 20 50
and Plant
Handlingarea
Nitric Acid Storage washings
Spillages and 5 2-7 50 5 80 200
Area plant
Boiler Area + DM washings
Boiler Blow Down 20 11-12 Nil Nil Nil Nil
Water Plant +
Sulphuric Acid
and caustic
storage area
Boiler Area + DM Plant 79 7-8 10 5 20 50
Water Plant + washing
Steam Network s, regeneration
CoolingWater effluent
Blowdown and 1104 7-9 20 <10 20 30
Tower filter
Domestic effluent Backwash
Domestic Effluent 48 5.5-7 160- 20-30 250- 400
200 300

The total amount of industrial effluent that is envisaged to be generated Based

on Ammonia plantcapacity, shall be 2221 m3/Day.

Liquid effluent from process plants / ancillary units shall be collectedthrough

drain channels and taken to a centralized effluent treatment plant for Primary
andSecondary bio-treatment consisting of astripper, equalization
tank,aeration basin, clarifier etcto further reduce the COD and Nitrate contents
to the levels wellbelow the specified limits. In addition to the above, a guard
pond shall also be provided to collect the initial washings from the storm water
drains during the first monsoon shower. The washings shall be routed though

48
the effluent treatment plant.

49
Special Civil Works

 The open drain lining shall be resistant to acid and alkali.

 Underground neutralizing pit may be considered for mixing the acid

and alkali before discharging to effluent treatment plant.

Effluents Plant Design Basis

The process water effluents from the Ammonia, AN, NA and Utilities area are
effluents included in the effluent plant design. The effluent water from the plant
would be segregated and routed to a holding pond or evaporation pit prior to
treatment and disposal. The holding pond or evaporation pit should be lined to
prevent soil contamination/pollution.

The composition of the pond water may change drastically during turn-around
due to the discharge of large amounts of acid or other product effluent from the
plant.

The following are important while designing and segregation.

1. Determination of composition and amount of each stream entering the

holding pond.
2. Determination of cyclic change, discharge period and frequency.
3. Determination of corrosively, suspended solids, and compatibility of the
various streams.

Effluent treatment plant design is based on the constituents present and the
quality of water to be achieved at the outlet of the treatment plant. The options are
a batch or continuous process.

Provision of RO system for near zero discharge:

To conserve the water and achieve minimum discharge from the complex, we
may plan to install RO system to remove majority of dissolved salts, organics,
bacteria and suspended solids from aqueous liquid effluent and recover pure
water which willbe suitable for make up as cooling towers and other process
50
 use. Around 70% recycle of ETP treated water will be targeted.

Requirement of an RO unit shall be separately studied and a unit shall be

provided if the need so arises.

In case RO becomes essential the reject stream from the RO unit will be further
concentrated and used as landfill unless the reject or the solid concentrate can
be suitable used for alternate application.

10.3 Gaseous Emission:

The major source of air emissions from Process area during the
operational phase oftheAmmonia plant reformer, gas engines, CO2 stacks as
mentioned.
Ammonia Plant gaseous emissions stacks:
1) Reformer stack.
2) Gas engine.
3) CO2 scrubber.
More details of emissions will be included based on existing Ammonia facility
of Taloja plant.

 NOx in Tail gas from the Nitric Acid Plant: Before venting the tail gas in to
atmosphere, NOx level in the tail gas shall be reducedto the
acceptablelimit byselective catalytic reduction with ammonia in presence
of Vanadium pentoxide, platinum or iron/chromium oxides catalysts
 Ammonia and ammonium nitrate laden air from the prilling scrubber: This
air is cooled and scrubbed to remove most of the ammonia and
Ammonium Nitrate from them.
 Air emission from utility area is through boiler stack which will operate on
fuel oil. Dedicated stack will be attached for the service boilers.

51
 The approximate quantity and quality of gaseous emission from Spent Air
and boilerstack are furnished below:

Sl. Particulars Tail Gas Service Waste air

from Nitric Boiler from prilling
No.
Acid Plant scrubber
1 Stack gas temp (oC) 130 150- 40-45
2 Stack gas velocity (m/sec) 30-35 160
Later 20-25
3 Stack gas volume m /hr.
3 155500 Vendor’ About
scope 1,10,000
4 Stack height (m) Will be Will be Will be
furnished furnished furnished
5 Stack diameter (m)
after detail after detail after detail
engineering engineerin engineerin
g g
6. Emission rate (mg/Nm3)

- SOx NIL NIL

- CO NIL NIL
- NOx As per norm NIL
7 SPM NIL <150 <150
mg/m3 mg/m3

The other non-specific sources of gaseous emissions are from vents of

storage tanks, Vessels and other process equipment.

12. PROJECT IMPLEMENTATION PLAN & TIMESCHEDULE

11.1 Scope of Project

The proposed project would include site development, main process plants
along with Offsites&Utilites, Raw material and product storages, Electrical
substation, Covered Ware houses, Plant and non-plant buildings etc. The
project scope shall also include the construction of cross country facilities for
bringing Ammonia, fuel, Raw material, and Power to the site.

11.2 Location

TAN Plant will be in the eastern part of India at “Kujang (Tehsil),

52
 Jagatsinghpur(dist), Paradeep”, East coast, Odisha State, India.

11.3 Implementation Modalities

Implementation of project would involve several activities, of which some are
pre- project activities and others are related to physical execution of the project.
The total project including offsite facilities will be executed by DFPCL on EPCM
basis with the help of reputed consultant who will provide services for detailed
engineering, procurement, construction supervision and supervision of pre-
commissioning & commissioning activities (EPCM) and multiple site contractors

working in parallel and interfacing where appropriate. License, know-how and

basic engineering is being obtained by DFPCL from reputed process licensors.

Site contractors will have additional project management personnel. A

Project Management Plan, which defines scope and responsibilities
and details theprocedures and practices to be used to deliver the complete
ammonium nitrate complex has been developed by the Contractor

11.4 Pre-project Activities

The pre-project activities to be completed before the physical execution of the

project are briefly enumerated below:

a) Approval of the project by competent authority.

b) Preparation of Environment Impact Assessment (EIA) study and/ or

clearance by State and Central Pollution Control Boards, as may be
required.

c) Soil investigation work for ascertaining soil characteristics of the area

identified within the present boundary for location of the new facilities.

d) Selection of Technologies –completed

e) Selection of Detailed Engineering Consultant.

f) Mobilization of resources for construction facilities.

g) Appointment of Owner's Project Management team.

h) Firming up of arrangement for supply of raw materials from concerned
agency – in progress.
53
 i) Finalization of contracts with process licensors for grant of license and
supply of know-how and basic engineering – under finalization

All the pre-project activities mentioned above should be completed before the
zero date of the project. It is envisaged to implement the Project through
spending equity first and then to use loans thereafter.

11.5 Project Execution

Based on the above philosophy, DFPCL plans to implement the project by

entering an agreement with a reputed Process licensor to provide Know-how and
Basic engineering of the plant. DEC's scope of work shall be on EPCM basis to
include detailed engineering, Assistance during procurement, inspection and
expediting of all equipment and materials, construction supervision and
commissioning of plant, including Offsite and Utilities facilities.

To perform the above activities, DFPCL has a project management group

consisting of highly competent, dedicated and qualified team of professionals
with wide experience in the field to co-ordinate and follow-up to ensure
completion of the project within projected time schedule.

11.6 Project Management

The project will be managed by DFPCL’s in-house PMC team to utilize the
experience obtained over 30 years and building 5 Nitric Acid and 4 Ammonium
Nitrate units. The learning from previous projects and operations over years have
been incorporated during basic and detailed design of the plants.

DFPCL has a formidable and highly dedicated project team of qualified engineers
of various disciplines and a very skilled and experienced workforce. The team
has recently executed a Rs. 600 cr brown field AN-complex at Taloja. A team
comprising of Operation group and Project group will be constituted to implement
the project and will be responsible for Overall Project Management. This team will
be composite with Engineers from various disciplines including Finance and
Accounts and Materials Management personnel.

54
11.7 Engineering:

Basic Process Engineering

The basic engineering is carried out by a reputed process licensor and will be
issued to the Detail Engineering Contractor to carry out the detail engineering.

Detail Engineering & Process Equipment Procurement

Detail engineering work will follow from basic process engineering.

The selected Detailed Engineering Contractor (DEC) shall carry out the detailed
engineering of plants and off-sites, which will form the basis for plant
construction. It will comprise all discipline design services necessary for the
procurement, construction and commissioning of the plant and associated
infrastructure including:

 Prepare calculations and design/construction drawings in a suitable

format for fabrication and construction;

 Prepare data sheets, standards and technical specifications and for all
materials and equipment;

 Develop scope of work documentation for supply and construction

contracts; undertake constructability reviews;

 Prepare the process control philosophy and manage control

system programming

 Participate in HAZOPstudies;

 Perform technical evaluation of all supply and construction tenders;

 Provide technical clarification and support during the

construction and commissioning phases;

 Prepare Operations and Maintenance manuals;

 Prepare As-built drawings.

The data provided will cover all the activities necessary for procurement of
equipment’s, plans, elevations and isometrics of different sections for civil design

55
 and equipment erection etc. The Detail Engineering Contractor will require the
vendor design information from the process equipment vendors and the utilities
equipment vendors. The procurement group will expedite this vendor information
for the detail design contractor.

11.8 Procurement

The EPCM Contractor’s procurement team will provide services for the
procurement, expediting, inspection and delivery of all mechanical equipment
except for the Propriety Equipment. Orders will be placed with qualified vendors
based on technical compliance, quality, price and delivery.

Principle activities undertaken in the procurement phase will include:

 Prepare tender lists for all packages and submit for Deepak approval;
 Prepare and issue tender documentation, perform evaluations and
submit recommendations for award to Deepak;

 Deepak shall award the purchase orders and Carry out all
management requirements, inclusive of financial guarantees,
vendor data, spares and maintenance documentation, during the
term of the order;
 Review all suppliers Inspection and Test Plans (ITPs) and perform all
necessary inspection and expediting activities to ensure the specified
quality and delivery schedule requirements are met;
 Receive and review all vendors invoices and prepare
recommendations for payment;

 Close out all purchase orders upon completion;

 Provide support to the construction group as required.

11.9 Contracts –Construction Contractors

The Contractor will be required to tender and administer construction contracts

on Deepak’s behalf. Key activities will be of similar nature to those described
above. It is anticipated that contracts will be a mix of schedule of rates and lump
sum.

56
11.10 Project Control

An accurate project controls system is critical to manage the Project. The

principal function of the controls system will be the monitoring and reporting of
actual progress and cost against the baselines established at the commencement
of project implementation. Secondary functions of control will provide progress
reports, establish quality standards and maintain a comprehensive document
control system. The EPC Contractor’s PMMP will include the basis for these
control and reporting systems.

11.11 Quality

It is a fundamental requirement that all aspects of the Project are executed in

accordance with specified technical requirements, be they performance,
compliance with technical specification or manufacturing and fabrication
standards. The EPC Contractor will develop a Quality Management Plan (QMP)
defining quality objectives, identifying all standards applicable to the Project and
practices, such as design reviews, vendor inspections and audits etc.to be
performed to ensure the quality objectives are met.

11.12 Document Control

It is critical that all Project documentation is clearly identified and traceable to the
end user. There will be an agreed document and drawings numbering system,
document registers maintained, protocol for revision management of drawings
and a drawing transmittal system for all external document issue.

11.13 Construction:

Construction activities for the main plants and off-sites will be grouped per the
nature of the jobs and bids invited from pre-qualified contractors. The bids will be
evaluated based on the experience of the contractors, their background, cost and
time schedule. The overall responsibility for the construction would be that of the

57
 DFPCL. The chief of the construction group shall look after the co-ordination of
all the construction activities. He will be assisted by a group of Engineers,
managers and other staff.

11.14 Construction Management

Project construction will be carried out by suitably experienced discipline

contractors operating under the management of Deepak and the Local EPCM
Contractor’s site team.

The EPCM team will have the following key responsibilities:

 Safety;

 Contract management;

 Verification of contractor’s quality compliance;

 Interface management;

 Resolution of technical queries;

 Progress monitoring and reporting;

 Contractor progress and claim certification;

 Survey control;

 Materials management.

11.15 Materials Management

As each consignment reaches the site, it will be unloaded and inventoried.

Material receipt reports and report of overages, shortages and damaged
goods will be generated and distributed to appropriate management and
accounting groups. Everything receiving information will be entered the
materials tracking system. After inventory, equipment and materials will be
stored either in the construction warehouse or in a secure, fenced area.
Equipment designated as free issue to contractors will be issued upon written
request.

58
11.16 Construction Contractor’responsibilities

 Construction Equipment

Construction contractors will provide their own equipment, tools, construction

power, fuel, supplies and facilities. Contractors will be expected to furnish all
materials and equipment required to complete their contract works in accordance
with their contract requirements.

 Quality Control/Quality Assurance

Contractors will furnish their own Quality Control program in accordance with
contract documents. This will include all testing requirements including
compaction, concrete strength, weld and electrical installation testing.

 Construction Personnel

Contractors will be responsible for provision of all supervisory and trades

personnel. The contractor shall follow all statutory rules & regulations for labor
working / deployed at site.

11.17 Commissioning

The pre-commissioning and commissioning activities will be carried out by the

commissioning team with assistance from vendor’s representatives plus the
construction contractor’s resources as required. With detailed planning, systems
can be handed over to the commissioning team progressively to facilitate the
commissioning process.

Commissioning, sustained load run and guarantee test will be under the total
responsibility of the licensor for the main plants. The owners must make
arrangement for the supply of raw materials in adequate quantities. The utility
requirements like power, water etc. would be kept ready to be supplied whenever
necessary. The owner will also supply the necessary operators, engineers and
skilled and non-skilled worker, who will be involved in the commissioning

59
 activities. Commissioning spares also must be procured before the
commissioning activities start.

11.18 Scheduling &Monitoring

Scheduling and monitoring of the main plants and overall scheduling and
monitoring of entire Project will be the responsibility DFPCL project group.
PERT/CPM chart will be prepared incorporating main activities in each section
discipline wise. The activities will cover design, engineering, procurement,
transportation, civil construction etc.

Cost Control

Following confirmation of the Project capital cost estimate, the estimate will then
become the Project budget. The budget for the project will then be entered in to
database cost control system utilizing a coding structure that identifies all
equipment, materials and discipline activities. Throughout the course of the
Project all commitments and expenditure will be entered in the cost control
system. Forecasts to complete and variances will be updated monthly and
contingency drawdown will be managed. Efficient and accurate cost control will
be critical to ensure the Project is completed within budget.

Reporting

During the Project, there will be the need for on-going communication of project
status to Deepak from all parties involved. The monthly progress reports shall be
prepared and shall be circulated by DFPCL project group.

Key issues to be reported will include:

 Safety;

 Environmental;

60
  Progress in all discipline (measurement and narrative);

 Procurement and contract status;

 Costs;

 Quality;

 Project issues and

concerns; The principal reporting

forums will be;

 Weekly progress meeting;

 Formal monthly report including narrative and updated project

controls reports and forecasts.

11.19 Schedules

The project will be monitored with the help of the following schedules.
a) Overall project schedule
b) Engineering schedule
c) Procurement schedule
d) Construction Schedule.

The physical progress of the project will be monitored based on schedules S-

curves as follows.

 Overalls-curve

 S-curve for engineering, procurement and construction.

All the networks/CPM will be computerized for working out the earliest/latest start
and finish dates and floats/slacks available in each activity.

61
11.20 Time Schedule

The overall time schedule for the proposed project including pre-project activities
is 36 months. There shall be overlap in procurement to reduce the overall time
schedule.

A preliminary bar chart showing the details of activities and their completion time is
provided on the next page.

62
52
 13. PROJECT COST &FINANCIALS

Cost Estimate

The estimate has been built up from the following inputs:

Base Equipment List

The base equipment list reflects current technology offer by Grande Paroisse, France
and as presented in Section 4 of this report. Prices of proprietary equipment reflect data
base prices prepared by our internal team out of our project and operating exposure to
the relevant manufacturing set-up. For the current study, it is assumed that the balance
of the ISBL/ OSBL equipment’sis procured in India and our internal team has prepared
this pricing based on current data base pricing for Indian supply as well as capital
committed on previous projects of similar nature.

Plant Layout

The plant layout has been developed about information from previous geotechnical
investigations on this site as well as from our experience. The plant layout has been
stepped in two levels to minimize the site earthworks. The minimum elevation of the
plant is 3.2 m AMSL to remain above to the tide and storm surge water level. Refer
Infrastructure & Plant Layout (preliminary) at the end of this section.

Item UOM Base Case

Project Cost Rs Cr 1750

Project IRR % 18.3%

Equity IRR % 24.8%

Simple Payback Yrs 4.8

DSCR-Avg % 2.05

Cash Breakeven capacity % 14%

Avg cap utilization % 96%

CORM Rs/(MT 12283

of
AN+NA)
53
Infrastructure & Plant Layouts

The building of the Ammonium Nitrate plants being a grass root project shall
consist of the following process and non-process units/facilities:

Inside Battery limit process units:

1) Main Battery limit plant for Weak NitricAcid

2) Main Battery limit plants for Ammonium Nitrate Solution –melt

3) Main Battery limit plants for Ammonium Nitrate Solution – TAN

prills Outside Battery limit units /facilities:

4) Power receiving switch yard and sub-station

5) DG set

6) Complete firefighting system

7) Fire and smoke / gas detectors

8) Intake pipeline for water

9) Water treatment plant

10) Water reservoir

11) DM Water plant

12) DM Water tank

13) Condensate tank

14) Process water tank

15) Cooling Tower including pumps, motors / turbine and dosing system

16) Boilers and stack

17) Instrument air compressors, receivers and dryer

18) Effluent treatment plant including Reunite

19) Storage tanks including pumps for;

54
 a) Nitric Acid

b) Ammonia

c) Diesel

d) Furnace oil

e) Caustic soda

f) Sophoricoside

20) Ammonia& Natural gastransfer pipeline

21) Weighbridges

22) Bagging facility

23) Tanker loading bay

24) Buildings to house

a) Control system, Electrical switchgears, MCCs

b) Plant offices

c) Laboratory

d) Administrative offices &canteen

e) Workshop

f) Engineering &chemical stores

g) Security/Fire &safety

h) First aid/Medical Centre

i) Restrooms

25) Pipe racks &cable racks

The preliminary & conceptual lay out is displayed below. The detailed layout
shall be finalized during engineering stage incorporating all statutory
regulations/ guidelines.

55
56
ANNEXURE 1:PROCESS FLOW

DIAGRAMS NITRIC ACID UNIT

PFD: AMMONIA PLANT

PDF:NITRIC ACID

57
PDF TAN UNIT AN SOLUTION AND TAN

58