3rd SNAMPROGETTI WORLDWIDE UREA USERS

SYMPOSIUM

SORRENTO - ITALY - JUNE 18+22,1996

Paper No. 2

G.N.F.C.

BHARUCH - INDIA

FIVE FACETS
OF A SUCCESS STORY :
G.N.F.C. UREA PLANT

AUTHORS : B.M. SHARMA

AX. AGRAWAL

ABSTRACT

The largest SP plant is running since 1981.

The Authors, e m p h a s i i the excellent perfonnances of the plant, indicate the five
facets of this success achieved by G.N.F.C.:
1) debottlenecking measures
2) modiications
3) improvement regarding safety and environmental aspects
4) energy conservation
5) future technological improvements.
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Contents

A. Introduction

C. Tbe Urea Story

1. Debottlenecking Measures
1.1 Stripper
1.2 Replacement of Carbamate Condensers
1.3 Increase in CO, Machine Throughput
1.4 replacement of H.P. Ammonia Pump Block
1.5 Increase in Motor Capacity
1.6 Descaling of M.P. Decomposer / L.P. Decomposer
1.7 Ejector Capacity Increase
1.8 New Urea Solution (V-4) Tank
1.9 Change in Material of Construction

2. Modification
2.1 5 ata Scheme
2.2 Improvements in Anti-Surge System (CO, Machine)
2.3 Partial Bypassimg of H.P. Vent Gases
2.4 Reactor Weephole Monitoring System
2.5 Suction Line Modification of Melt Urea Pump (?-8)
2.6 Improvement in Cooling Water System

3. Improvement Regarding Safely and Environmental Aspects

3.1 Safety Aspect
3.2 Environmental Aspect

4. Energy Conservation
4.1 Increase in Reactor Pressure
4.2 Flash Steam to Deaerator
4.3 Saving Through Passivation Air Compressor (K-2)
4.4 Additional Ammonia Recovery fiom Waste Water Vent Gas Stream
4.5 Increase in C02Suction Pressure
4.6 Utilization of Hydrolyzer Effluent

5. Future Technological Improvements

5.1 Additional Ammonia Recovery from L.P. Section
5.2 Bimetallic Stripper
5.3 DM Water Sealing for High Pressure Ammonia Pump
5.4 CO, Machine Revamp'mg
5.5 Structural Packings for M.P. I L.P. Decomposer
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1. INTRODUCTION

Gujarat Nannada Valley Fertilizers Company Limited (GNFC) was incorporated as

a joint sector in May 1976, promoted by the Government Of Gujarat (GOG) and
Gujarat State Fertilizers Company Limited (GSFC).
GNFC created a history in 1981 by issuing a share capital of Rs.436.1 million to
489,000 shareholders, out of which 100,000 shareholders are farmers and co-
operative societies.

In the first phase, the Company established its Ammonia-Urea plants alongwith
important facilities l i e Boilers, Water Treatment Plant, Effluent Treatment Plant,
Off-site Plants, etc.

GNFC has in its command the most sophisticated fertilizer technology in the world,
availing internationally aclcnowledged technical expertise.
As the FUEL OIL GASIFIERS in GNFC's world's largest single stream
Ammonia/Urea plant was lit on 23rd July 1981, it heralded a new generation of
fertilizer plants in the country.
The plant design has taken care of a total energy concept and thereby ensures
minimum energy consumption.
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B. THE LEGEND '

Incorporation 10th May, 1976

Share Capital Rs.1464.7 million

Shareholders 344,000

Ammonia Plant on stream December, 1981

Urea Plant on stream December, 1981

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A c E n C ACID (Glacial) MIS.BP CHEMICALS, UK

BYPRODUCTS: Liquid Ammonia, Liquid Nifmgen, Methyl Formate,

Ammonium Nitrate (Melt)
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I

JOINT VENTURE COMPANIES :

1 . Ws. N.C.P.L.

Aniline 20,000 T Ws. CHEMATUR AB,

SWEDEN

TDI 10,000 T Ws. DUPONT, USA

2. Ws. V.N.E.L.

CTV Glass Shell (20") 1.7 Million Ws. GI-NEG,

USA

B&W TV Glass Bulbs 0.25 Million Ws. GI-NEG,USA

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C. TEE UREA STORY

GNFC is one of the leading fertilizer manufacturers in the country, under the brand
name "NARMADA".
The premium fertilizer product of Narmada family is 'NARMADA UREA'
manufactured through stripping technology of SNAMF'ROGETTI introduced for the
fust time in the country.

GNFC has become the model plant for 'Snamprogetti' in the country.

TEE MARATHON RUN OF 100% PLUS CAPACITY UTILIZATION

CONSISTENTLY FOR TEE LAST 11 YEARS WlTH A PEAK
PERFORMANCE OF 121% ARE JUST TO INDICATE TEE SPLENDID
SUCCESS STORY (Tables 1 & 2).
The secret of this success story lies in the FIVE FACETS described below:

1) DEBOTTIENECKING MEASURES
2) MODIFICATIONS
3) IMPROVEMENT REGARDING SAFETY
AND ENVIRONMENTAL ASPECTS
4) ENERGY CONSERVATION
5) FUTURE TECHNOLOGICAL IMPROVEMENTS
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1. DEBOTnENECKING MEASURES

1.1 Stripper

1.1.1 Replacement of Stripper

Stripper has been the inherent limitation for Urea Plant because of high rate of
corrosion and erosion at high temperature.
The tube thickness reduction is mainly experienced in top portion.
During August 1986, the original stripper was overturned to utilize the better
thickness in bottom portion and hence extract more life.
However, the stripper dciency was not adequate after reversal because it was not
reversible type. So, in April 1990,the new stripper fabricated by MIS. Kobe Steel,
Japan, was installed and taken in line.
The following table indicates salient features of old and new strippers:

1.1.2 Steam Flow L i t a t i o n

After reversal of old stripper during September, 1986,the steam entry got shifted to
bottom thus causing limitation of steam flow and heat transfer.
To overcome this problem, two additional lines (of 2" and 4") were incorporated for
increasing throughput fiom Stripper E l shell side top. With this arrangement, plant
could be operated up to April 1990 when stripper was replaced.
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The new stripper is designed for bottom entry (steam inletlcondensate outlet) in
order to limit the erosion/corrosion in upper zone of tubes. But, due to design
deficiency (baffles spacing problem), maximum throughput was limited to 45 T per
hour.
The amazing part of stripper story is that this problem was also solved by 4" line
which was originally laid to overcome the limitation of old stripper after reversal
(refer figure 1).

1.2 Replacement of Carbarnate Condensers

The original material of construction for old carbamate condenser was SS-3 16 LM.
As both exchangers were in series, load on first carbamate condenser (E-5) was on
higher side and it had resulted in tubes thickness reduction in the inlet zone off
exchanger (from 500 mm).Due to this, during 1984-85 flow path of first carbamate
condenser was reversed.

As tube leakagehbe-to-tubesheet leakage were experienced leading to frequent

shut-downs, both carbamate condensers were interchanged during April 1990.
Also second carbamate condenser (E-6) flow path was reversed during 1990-91.
Even after that, performance of both condensers was inconsistent.
Hence, during April 1992, both exchangers were taken out of service and replaced
by a new condenser (only one) of 2 RE 69 tubes.
Since then, problems of carbamate condenser have disappeared.
The following table indicates salient features of old and new carbamate condensers:
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1.3 Increase in CO, Machine Throughput

C02machine has capacity limitation at design suction conditions.

The problem was overcome by the simple and brilliant idea of raising the suction
pressure from 1.5 kg/cm2to 2.2 kg/cml.
Some alterations were required to be done in Ammonia-Urea plants to
accommodate this change. This modification resulted into a sharp increase in the
capacity of C02machine.

This was the most economical way of debottlenecking and has helped in substantial
steam saving and reducing load on Steam Generation Plant (SGP). (Even at reduced
plant load, we use to operate C02machine at maximum possible suction pressure for
energy economy.)

1.4 Replacement of H.P. Ammonia Pump Block

For pure Ammonia senice, Carbon Steel is suitable material of construction and
hence Carbon Steel blocks were used in high pressure Ammonia pumps right from
inception stage.
Because of the pump block leakage, Ammonia pumps were remaining under
maintenance resulting into production loss.
The main causes for Ammonia pump block leakage were:

1. Stress corrosion cracking due to 'T bore' construction design (obsolete design).

2. COl slippage with Ammonia from M.P. absorber.

3. Thermal shock due to sudden pressurization and depressurization of the pump

block.

Looking at this problem, firstly in one pump, Carbon Steel block was replaced by
SS-304 block during August 1989.
As experience with SS block was successfiS same was implemented in remaining
two pumps during April 1993. This resulted in improving availability of Ammonia
pumps, thus eliminating production loss due to block problems.
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1.5 Increase in Motor Capacity

As Urea plant is normally operated at very high capacity (125-130%), some drive
motors were causing limitations.
There were instances of overload tripping and hence disturbance in operation.

This has also helped in substantial power saving as instances of two motors running
simultaneously have reduced.

1.6 Desding of M.P. Decomposer I L.P. Decomposer

The practice of Hydrojet cleaning of M.P. decomposer (E-2) and L.P. decomposer
(E-3) tubes was started in the year 1987-88, when strange phenomenon of iron scale
deposition on the tube surface was observed.
The hydrojetting has resulted into improved performance of M.P.L.P. decomposers
and thereby minimizing steam consumption and ammonia losses.

Now it has become a regular practice to cany out tube cleaning of E-UE-3 once in a
Year.

1.7 Ejector Capacity Increase

.
EJ-1 is ejector for recycling unconverted carbarnate solution by means of driving
fluid (i.e. high pressure Ammonia). At higher capacity, as Ammonia input through
nozzle was causing limitation, its ID was increased 6om 16.2 mm to 17.1 mm.

1.8 New Urea Solution (V-4)

Tank
Earlier, we had only one V-4 (melt urea solution tank), having capacity of 165 m3.
At the time of disturbance of waporational I prilling section, plant was required to
be shut down after about 2.30 hours (100% plant load basis).

Mter installing new additional V-4 (i.e. V-4 B), having capacity of 359 m, we can
'
sustain running of plant for total 8.30 hours (100% plant load basis) at the time of
disturbance of Evaporational I Prilling sections.
This arrangement has helped in improved continuity and maximizing on-stream
factor.
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1.9 Change in Material of Construction

Following exchangers' tube materials were changed for better reliability and to
reduce the downtime.
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2. MODIFICATIONS

2.1 5 ata Scheme

Urea plant when operated at high load, the requirement of flow pressure steam
increases in second stage preheater.
As this steam is generated in H.P. carbamate condenser (E-5), it results in higher
shell side pressure and hence poor condensation in the carbamate condenser.
This in turn results into:
- Higher gas flow from H.P. carbamate separator (MS-1) to M.P. decomposer
(E-2) aggravating the flooding problem in E-2
- Lower NH3 /C02ratio in reactor
- Frequent diversion of prilling.

To combat all these problems, an INNOVATIVE IDEA (5 ata steam scheme) of

separating the L.P. steam used in second stage vacuum evaporator from the L.P.
steam generated in H.P. carbamate condenser was implemented.

2.1.1 Details of the Scheme (Refer Figure 2)

M.P. decomposer outlet condensate is flashed in a flash drum to generate 5 ata

steam and then remaining condensate is taken to E-5 shell side to generate 4 ata
steam.
With this scheme, we are able to generate 7 T/h steam of 5 ata which is sufficient to
operate second stage vacuum section and also facilitates operation of carbamate
condenser at significantly low pressure of 4 ata, even at 125% capacity, thus
allowing us to extract maximum heat of condensation in carbamate condenser. This
in turn facilitates the excess generation of low pressure steam.

Advantages:

a) Recycle carbamate temperature has reduced by @3 to 4OC. This has helped in

increasing plant capacity by a 1 0 0 TID.
b) Lower corrosion rate of carbamate condenser due to low temperature.
c) Better condensation in carbamate condenser results into less flow of gas from
carbamate separator to M.P. decomposer. This in turn gives more liberty of
keeping higher NH3/C02ratio and thus minimizing the rate of corrosion of H.P.
requirements.
d) It also helps in reducing the problems of flooding at M.P. decomposer.
e) Higher NH3 /C02ratio helps in improving the conversion in reactor.
f) Better condensation in E-5 helps in generating more L.P. steam.
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g) Frequency of diversion of pding has reduced due to more steam pressure

available for 2nd stage vacuum preheater.

2.2 Improvements in Anti-Surge System (CO, Machine)

2.2.1 S i d e Antisurge Control Svstem (Refer Figure 3)

Double antisurge system in Urea plant was provided because of installation of

Sulphur and Methanol removal section between MCL and BCL stages. However,
due to permissible limits of H2S and MeOH content in CO,, this section was not
required for operation.

Additionally, double antisurge system which was provided for MCL & BCL was
very cumbersome and problematic during loading and unloading of the machine and
often the machine used to trip and sometimes subjected to surge condition also. This
in turn used to cause damages to MCL & BCL stages and reduced the efficiency of
individual stages.

In view of above, antisurge system was modiied during September 1986 to single
antisurge system.

Following are the advantages:

. Reliability of the machine has improved substantially, chances of surging are

considerably reduced
. Ease and convenience of operation have been grently improved.

2.2.2 F i e Tuning of Timings

M e r incorporating single antisurge system, we h e the problem of MCL damage

during loaded trip of CO, machine.
M e r every four to five trips (loaded) of the machine, some damage in MCL stage
resulting into capacity decrease (labyrinth seal damage) was noticed.
M e r detailed study and dialogue with M s . BHEL, additional recommendation for
change in timing of vent control valve (HC-1.3: second stage discharge vent) was
incorporated during 1995 and results are quite encouraging in terms of 'no
deterioration' to either MCL or BCL during loaded trip. Earlier, the vent valve
maximum opening was restricted up to 50% and it used to open after 4 seconds of
trip. Instead HC-1.3 has been made quick open and becomes full open in 7 seconds
of trip.

The damage of MCL was mainly due to less capacity of BCL with respect to more
delivery by MCL and thus creating mismatch during trip. This mismatch was
partially overcome by incorporating this modification.
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2.3 Partial Bypassing of H.P. Vent Gases

H.P. carbarnate separator (MS-1) off gases go to M.P. decomposer (E-2) for
passivation of E-2 tubes. In M.P. decomposer, increase of gas flow increases gas
velocity and does not allow the liquid to fall down thus resulting into hold up and
flooding of E-2 tubes and also causes carry-over of liquid. This problem is basically
due to limited cross sectional area of E-2.

During 1992, the problem was partially overcome by installing a 2" bypass line from
PIC-101 VA (MS-1 off gas outlet) to MV 2 (M.P. separator) off gas line which was
subsequently modied to 4" bypass line with a 30 mm orifice based on our
experience. This modiication has almost eliminated the flooding problem of
decomposer.

Befer Figure 41

2.4 Reactor Weephole Monitoring System

Urea reactor is a high pressure vertical cylindrical vessel (2.4 mt dia. x 42 mt. high x
90 mm thick single layer CS shell) having 7 mm SS 3 16 LM liner.
There are 18 segments of liner and each segment is connected to a weephole system
for indicating any liner joint (circumferential or longitudinal) failure.

The conventional system of physical checking of individual weepholes or

arrangement of glass bottles Ued with phenolphtalein solution were not full-proof
system and often misleading. Hence during 1988, an innovative in-house system
utilizing the conductivity probes was developed for detection of liner leakage on
continuous basis. In Urea reactor, each liner segment is connected to 4 weepholes
except the top and bottom dome liners.

2.5 Suction Line Modification of Melt Urea Pump (P-8)

Earlier design of melt urea pump suction h e was flanged type having common
3 way Ball type suction valve. Due to flanged construction, it used to result into air
in-gress problem and cavitation.
After carefil examination of all related aspects, flanged joints were converted into
weld joints and common suction valve was converted to T d i n type individual
suction valves during April 1993.
After this modification, the performance of melt urea pump has improved
remarkably.
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2.6 Improvement in Cooling Water System

Following improvements were made in cooling water system

2.6.1 Channe in Coolin Water Treatment

Due to perennial problem of scaling in M.P.condenser (E-7) tubes (due to high CW

outlet temperature around 70 to 7S°C), the cooling water treatment was changed
over fiom conventional SHMPIZnSO, formulation to glassy phosphate treatment
during May 1992. The new CW system has eliminated the scaling problem
completely.

2.6.2 NRV of Cooline Water Pumos

Due to improper bctioning of original swing type check valve ( 3 4 3 the wafer
type (12") check valves were installed and all the related problems have come to an
end.

2.6.3 CT Deck Covering

In order to reduce bacterial growth in presence of sun light and also to reduce
chlorine demand, CT decks were covered in December, 1995.

2.6.4 Chlorine Dosim Svstem

The original system of chlorine dosing &om absorber was replaced by a modified
system which uses water ejector for chlorine absorption.
With this system, precise control of chlorine dosing is achieved.
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3. IMPROVEMENT REGARDING SAFETY AND ENVIRONMENTAL

ASPECTS

3.1 Safety Aspect

3.1.1 Action Plan

Afier the serious mishap occurred in NFL (Panipat) caused due to ammonia leakage,
the following action plans were implemented:

a) Additional Suction Valve Provision in Hiph Pressure Ammonia Pum~s(April

1994):
Additional suction valve was provided (Block & Bleed arrangement) for
positive isolation.

b) F i e Water Curtain (July 1994):

In the event of sudden ammonidcarbamate leakage, in order to effectively cover
the (AmmonidCarbamate) H.P. pump bay area, provision of fire water curtain
was made which can be operated fiom control room.

c) Emereencv Stop Button for Ammonia Booster P u m ~(February 1995):

In the event of sudden ammonia leakage fiom H.P. ammonia pump, supply of
ammonia can be stopped by stopping Ammonia booster pump (P-5) through
emergency push button in the control room.

3.1.2 H.P. Ammonia PumDs

a) Drain L i e Medication - (February 1994):

There was a perennial problem of small line leakages (CDISY drains) caused
due to vibration of main suction and discharge line of H.P. ammonia pumps.
This was resulting into serious emergency situation due to ammonia leakages
apart fiom causiig production loss due to pump stoppage.
CDISY drain lines were modied fiom small bore piping (112" to bigger bore
piping of 1W) and thereby e l i t i n g the socket welding which was the prime
reason for leakages.

b) Seal Oil L i e Modification:

In the original design, the seal oil outlet line fiom H.P. Ammonia pumps was
common (1") leadiig to ammonidoil separator (MV-8). This line was giving
fiequent problems of choking due to entrainment of packing material with oil.
This in turn led to pressurization and subsequent leakage of fermle joints
causiig ammonia leakages. The problems was rectified by providing 3 separate
lines (1") fiom individual pumps leadiig to MV-8.
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3.1.3 Additional Escape Routes

Urea plant existing structure is vertical and quite a compact design and not
horizontally spread layout.
In the past, emergency situations were faced at various operating floors due to
ammonia/carbarnate leakages. This in turn was causing unsafe condition and even
rescuing the personnel at the time of emergency was a very d i c u l t task.
The total vertical stnrcture was reviewed and based on the past exuerience. four
additional escape routes were designed, engineered and implemented in the year
1990.

3.2 Environmental Aspect

3.2.1 Improving Waste Water Ouality

In the Waste Water Section of Urea plant, there is a hydrolyzer with normal
operating pressure at 17 kg/cm2pressure and 190°C.
As hydrolysis is favourable at high pressure and high temperature, the operating
pressure was increased to 21 kg/cma after suitably revised PSV setting.
W~ththis modification, Ammonia and Urea content could be reduced to 251100 ppm
&om 1001200 ppm respectively.

3.2.2 Modied Trays for Distillation Column IC-2)

At higher plant capacity of 125% to 130%, the distillation column of Waste Water
Section is causing a limitation and often Waste Water Section gets disturbed
resulting into deterioration of waste water quality.

Due to higher loading, ray &g is often experienced. In order to overcome this
limitation, modified trays are being installed.
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4. ENERGY CONSERVATION

4.1 Increase in Reactor Pressure

In the Urea Reactor the conversion of Urea is greatly dependent on operating

pressure, i.e. the higher the pressure, the higher is the conversion.
The reactor operating pressure was increased 6om 150 kg/cmz to 162 kg/cm2
thereby directly increasing the COZconversion (by @ 2.0%) in the reactor.
With improved conversion of COZ, process steam requirement for decomposing
unconverted carbarnate has reduced accordingly and the saving corresponds to
65,000 T per year of M.P.-saturated steam or 58,000 T per year of H.P.-steam (Eq).

4.2 Flash Steam to Deaerator (Refer Figure 5)

In Urea plant, after using the steam as heating medium, condensate collected in
condensate tank (V-2) is being pumped to DM water plant for polishing.

Originally the flash steam of condensate tank was condensed by removing the heat
by means of Cooling Water. We have removed the Cooling Water condenser from
the S ~ M C ~and flash steam at around 1.5 kglcma abs. pressure is taken to Deaerator
of Ammonia plant. By utilizing this steam in deaerator, energy is conserved.

It is equivalent to saving of 10,000 T per year of H.P.steam (Eq).

4.3 Saving Through Pessivation Air Compressor w-2)

As 'Sulphur and Methanol Removal Section' was not required to be kept in line.
continuous operation of passivation air compressor for r& injection to C O ~stream
was no more required and instead air injection was shifted 6om 3rd stage suction to
1st stage suction. This resulted into substantial power saving to the tune of 800,000
kwh per year.

4.4 Additional Ammonia Recovery from Waste Water Vent Gas Stream

(Refer Figure 6)

An innovative system of recovering additional ammonia 6om Waste Water Section

vent gas stream was implemented during the year 1988.
Originally ammonia content in the waste gases was in the range of 10 to 15% by
volume which was reduced to 2 to 3% by absorption in additional packed column.
This corresponds to an additional ammonia recovery of 300 T annually.
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4.5 Increase in C0,'Suction Pressure

Originally, CO1 was supplied fiom Ammonia plant at 1.5 kg/cmlg pressure which
was increased to 2.2 kg/cm'g.
This apart fiom giving the advantage of increasing plant capacity, has also resulted
into substantial steam savings in terms of reduced steam flow for the same capacity
of the plant.
This corresponds to yearly saving of 5000 T of H.P.-steam (Eq).

4.6 Utilization of H y d r o l p r Emueat

Originally hydrolyzer effluent fiom Waste Water Section containing about 25 ppm
of Ammonia and 100 ppm of Urea was going to Environment Control Unit.
During the year 1990, the system was modified for partial utilization of this
hydrolyzer effluent for saving DM water for the following:

a) Condensate make up in flash drum of Ammonia plant used for quench water
purpose.

b) Packing flushing media for high pressure carbamate pumps.

This has resulted into yearly DM water saving to the tune of 120,000 n3.
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5. FUTURE TECHNOLOGICAL IMPROVEMENTS

5.1 Additional Ammonia Recovery from L.P. Section

In order to reduce the ammonia loss fiom L.P. section vent stream, an additional
absorption column (C-7) has been installed and will be commissioned shortly. This
will correspond to an additional ammonia recovery of 300 T annually.

5.2 Bimetallic Stripper

The present stripper is in operation since 1990 and as per the thickness measurement
data, likely reversal is expected during 1997.
In line with the latest trend, the future stripper shall be B i m d c one.

5.3 DM Water Sealing for High Pressure Ammonia Pump

Each H.P. ammonia pump consumes about 20,000 litres of oil per year.
Looking to the exorbitant cost of lubricating oil, all the 3 H.P. ammonia pumps will
be phase-wise converted to DM water sealing arrangement.

5.4 COZMachine Revamping

To take advantage of technological development, GNFC is actively considering the

C02machine revamping by replacing existing impellers with the 3-D impellers.
This is likely to result into substantial steam saving.

5.5 Structural Packings for M.P.L.P. Decomposer

For better mass and heat transfm at a reduced pressure drop, structural packings are
being planned for M.P.L.P. decomposer in place of the existing random packings
(Pall-rings).
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Table 1- Production Performance o f Urea Plant

1) Financial years (1985 to 1988) were considered &om July to June.

2). Financial year (1988-1989) considered &om July 1988 to March 1989.

3) Subsequent iinancial years (1989 onwards) are 6om April to March.

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Table 2 - Important Achievements of Urea Plant

(Installed Capacity: 1800 TID)

1) Highest Daily Production 241 1 T (134% load)

6th June 1990

2) Highest Monthly Production 71770 T (142% capacity utilization)

January 1992

3) Highest Yearly Production 717454 T (121% capacity utilization)

Year 1991-92

4) Minimum Number of Days 527 days

Required for Fastest Production
of 'One Million Tonne'

5) "Best Technical Innovation Award 5 ata scheme of urea plant

by 'Fertilizer Association of India'
for the Year 1994-95 Won by GNFC
 t - -.
-

3rdSNAMPROGETTl UREA
~~rna~rn~prrog@ikiiii G.N.F.C. - BHARUCH
SYMPOSIUM INDIA
STEAM FLOW LIMITATION OF STRIPPER
- -

................

MV-7 MP STEAM
TO
CONDENSATE
DRUM E-2 MV-12 1 E-5
MP DECOMPOSER
FIG. 1
 S~na~rnplrogexx~~3rdSNAMPROGETTl UREA
JLJL. -
G.N.F.C. BHARUCH
SYMPOSIUM INDIA

5 ATA SCHEME
- -. -
-

TIC - 402
MP
STEAM

TOV-2
(LC HEADER)
TIC - 201
7
1

-
TO
LS - 1 HEADER

- TOE-6 -
FROM LIC - 711
E-13
MV-7
E -2 M V - 12 2ndSTAGE VACUUM
MP DECOMPOSER FLASH DRUM PREHEATER

I FIG. 2 1
L
I
 -
- G -. . - .

& i n a m p ~ i ~ g e ~3rdSNAMPROGETTI UREA

ALAL.
G.N.F.C. - BHARUCH
SYMPOSIUM INDIA
SINGLE ANTISURGE CONTROL OF CO, MACHINE
-

TO .............
S&M
IWVlOVAL 4 . .. .... X
SECTION

CO, FROM NH, PLANT ......... FROM

SBM -
r TO REACTOR REMOVAL
SECTION
-.

FIG. 3
Y
S~nampi~gefii 3rdSNAMPROGETTI UREA -
G.N.F.C. BHARUCH
SYMPOSIUM INDIA
- --
E-5
HP CARBAMATE E-I E-2
MP DECOMPOSER -

MP CONDENSER

CARBAMATE

DIS.
-

PUMP P-2 MV-3

P-I CARBAMATE
AMMONIA PUMP
0 PARTIAL BYPASSING OF
PUMP MP DECOMPOSER

FIG. 4
-
1
SNAMPROGETTl UREA 1 G.N.F.C. - BHARUCH
SYMPOSIUM INDIA

2 STEAM TO DEAERATOR

4 LOCAL
VENT

FLASHED STEAM TO.

M
b DEAERATOR
(AMMONIA PLANT)
. CW
- IN

LOW PR.
CONDENSATE

v-2
STEAM CONDENSATE TANK
FIG. 5
1 Ird
SNAMPROGETTI UREA
fl~~~a~rnrnplmg@~~i
SYMPOSlUM
-
G.N.F.C. BHARUCH
INDIA
RECOVERY OF AMMONIA FROM WW VENT

I C-2 OFFGAS I

I
-
E-17
CONDENSER
V-8
REFLUX DRUM
C-6
VENT GAS SCRUBBER

FIG. 6 -