Page 175 - CW E-Magazine (16-7-2024)

Special Report Special Report

Reliability and effi ciency improvement in fertiliser tion of the plant. Further, revamping of more reliable. There has been upgrada- P O also increased from the level of
2
5
civil structures to improve longevity of tion in the instrumentation system from 93% in 1992-93 to 98% at present.
plants the plants are being carried out. PLC-based to DCS-based. Use of ad- The water consumption of ammonia
vance process control systems further
In sulphuric acid plants, opera- help in optimisation of the parameters and urea plants has been reduced by
ertiliser production involves higher mass fl ow. A number of plants detection systems for reactors are avail- tional challenges have been overcome and smooth operation of the plant. about 50%, while complex fertiliser
employment of very sophisti- have implemented this scheme in pro- able from some technology providers. by improving conversion efficiency Technologies like artifi cial intelligence plants have been able to reduce water
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Fcated technologies and process- cess air, carbon dioxide and synthesis Use of such a system during operation and improvement in waste heat and machine learning are now being consumption by 60% over last 26 years.
ing, handling and storage of hazardous gas compressors. Ammonia plants were may help in attending to the very small recovery. adopted to predict the problems in ad- The wastewater discharge has been
chemicals like sulphur, ammonia, sul- revamped for higher conversion by in- defects before they become severe and ChemImpex vance. Electrical systems are also made drastically brought down during the
IndiaChemTrade
phuric acid, nitric acid, phosphoric acid corporating additional converter. Further, affect reliability of the plant. There Complex fertiliser plants are highly more reliable by improving the power same period.
and other hazardous chemicals. Plants effi ciency has been improved by re- have been developments in materials of dependent on imported raw materials factor, transformer, other electrical
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also operate under extreme condition of vamping the compressors, turbines construction (MoC) of stripper, such as and intermediates for production. Raw systems and grid synchronisation. The survey report for downtime
ChemImpex, the trade database, tracks, on a daily
temperature and pressure. Any break- or replacing them with more effi cient bimetallic or proprietary materials that materials account for major part of IndiaChemTrade provides consolidated trade statistics
shows that forced shutdown due to
basis, exports and imports of chemicals and related
of India. The information provided here is based on the
down of the plant can lead to heavy ones. offer better corrosion resistance. Life overall cost of production. Therefore, Improvements in effi ciency and equipment problems in ammonia plants
products through the major ports in India — a vital
losses on account of energy and produc- of the existing strippers were improved improvement in raw material use effi - reliability annual trade data published by the Directorate General
reduced from average of 24.4 down-
of Commercial Intelligence and Statistics, Government
source of commercial intelligence. Find out on-line
tion. Reliability of plant and machinery Urea production by reversal of stripper after a few years ciency is of utmost importance. For These efforts have resulted in signi- time in days per plant per year (DDPY)
of India. The database can be searched by: Chemical
how international markets are moving; where your
is very important for continuous opera- Urea plants have been modifi ed to of operation and shortening of stripper improving the operational effi ciency, fi cant improvement in effi ciency and in 1987-1990 to 6.1 DDPY in 2020-23.
competitors are exporting and at what price; where
tion, effi ciency and safety of the plants. improve the conversion effi ciency of and save capital investment in a new efforts have been made to improve the reliability of fertiliser plants. The The urea plants also reduced forced
Name/Harmonised Code to obtain the consolidated
This assume more signifi cance in view reactor by installing additional trays or equipment. recovery effi ciency of ammonia and Fertiliser Association of India (FAI) is shutdowns due to equipment problems
imports are coming from and how their prices are
trade (import or export) in that item; or by Country to
of the fact that vintage of most of the replacing old trays with improved de- phosphoric acid. These plants have monitoring vital parameters of effi ciency from 11.8 DDPY to 6.1 DDPY during
moving. Download all this data, seamlessly, for a
obtain the trade (import or export) in all chemicals and
urea and complex fertiliser plants in sign ones. A few plants have installed a Production of complex fertilisers undertaken modifi cations in granulator and environment for the last several the corresponding period.
related products between India and that country
small fee — online, anytime, with no hassles.
India is in the range of 20 to 50 years vortex mixer in the reactor to increase Production of NP/NPK complex and pipe reactor systems for precise years. Efforts of the industry are refl ec-
with exception of six urea plants com- the conversion effi ciency and reduce fertilisers involves reactions of sul- control of grade formulation. Modifi ed ted in very signifi cant improvement in There has been continuous em-
ChemXchange
missioned during 2019 to 2022. Being steam consumption. Urea plants have phuric acid with rock phosphate to pro- design of scrubbing system has resulted performance of all fertiliser plants. ployment of new technologies, timely
Open to all registered users — no subscription required
energy- and capital-intensive, effi cient been revamped with additional stages duce phosphoric acid and then reac- in reduced ammonia and particulate replacement of old and ineffi cient
ChemXchange — the chemical exchange with a difference — is where you can identify your buyers and sup-
and reliable operations also play a key such as pre-decomposer and pre- tion of ammonia with phosphoric acid matter losses from stack, besides pro- The energy consumption for the equipment, adoption of high degree of
plyers on-line, any time. This unique platform is free to all advertisers in the print version of Chemical Weekly.
role in ensuring viability of the plants. concentrator for higher raw materials to produce complex fertilisers. Due viding operational fl exibility to the ammonia plants has been reduced from automation, better maintenance prac-
recovery and savings in steam. There to acidic nature of materials handled, plant. 12.48-Gcal/tonne in 1987-88 to 8.07- tices leading to improved effi ciency,
Ammonia production have been efforts to improve the quality these plants are also prone to corrosion For more information contact: 022-24044477. Fax: 022-24044450
Gcal/tonne ammonia in 2022-23 and reliability, safety, and environmental
Email: corporate@chemicalweekly.com or log on to chemicalweekly.com
Ammonia is the key intermediate of fertiliser products. Plants have in- and erosion of material. The equipment More reliable and safe operations for urea plants from 8.87-Gcal/tonne to performance of the plants.
for production of nitrogenous fertilisers. stalled acoustic system, vibro-priller or needing special attention in sulphuric Technological advancement in the 5.71-Gcal/tonne during the same period.
The ammonia production processes specially designed prill buckets to im- acid plant are reactor, intermediate and fi eld of instrumentation and control In case of complex fertiliser plants, the [Indian Journal of Fertilisers, 20 (6):
involve reactions that are both endo- prove the quality of the prills as well as fi nal absorption and drying towers. The have made plant operations safer and raw material effi ciency of Nitrogen and 534-535, June 2024]
thermic and exothermic in nature. reduce dust emissions. critical equipment in phosphoric acid
Effi ciency of the process depends upon plants are digester, fl ash cooler, recycle
utilisation of the endothermic heat Corrosion is one of the critical fac- acid tank, scrubber and vacuum cooler.
supplied by burning of fossil fuels and tors affecting the reliability of equip- These equipments are lined with spe-
waste heat from fl ue gases and exother- ment in urea plant due to handling of cial and rubber materials to improve
mic reactions. Ammonia plants are corrosive materials such as ammonium corrosion resistance. Missed a copy !!!
effectively utilising these heats to gene- carbamate, an intermediate compound
rate either steam or preheat process gas produced during the making of urea. Units making complex fertilisers For Digital Edition of this month’s issue & all other past issues
or air. Older heat exchangers have been Precautions such as maintaining passi- have optimised the process for various
replaced with newer improved designed vation air and use of special materials grades of products and to withstand Visit www.hpicindia.com
heat exch angers for higher heat transfer for reactors, strippers, decomposers, corrosive environment by changing
and waste heat recovery. The low-level pipelines, etc., which come in contact to improved materials of construction
heat, which was earlier wasted in cool- with carbamate solution susceptible to (MoCs) for equipment, and mainte- PDF copies available for download
ing water, is used in vapour absorption corrosion are being undertaken. Repair nance practices to achieve higher pro- Register Now
machines (VAM) to cool the process and maintenance procedures and work- ductivity. As result of aging, timely Mrs. Usha S. - usha@hpicindia.com
gas for compression thus increasing its manship are critical for ensuring reli- replacement of a vessel/equipment is Contact: For Subscription : Mrs. Usha S. - usha@hpicindia.com
effi ciency and also the capacity due to ability of these equipment. Online leak important for safe and reliable opera- For Advertising : Mr. Vijay Raghavan - vijay@hpicindia.com
174 Chemical Weekly July 16, 2024 Chemical Weekly July 16, 2024 175
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