1

NFL NANGAL TRAINING REPORT

TRAINING REPORT

NATIONAL FERTILIZERS LIMITED(NANGAL)

SUBMITTED TO:
BY:HRD DEPTT.

SUBMITTED
NIHAL KASHYAP

NANGAL UNIT

14BEL8031
BE EE (LEET)
5TH SEM

INDEX

NFL NANGAL TRAINING REPORT

S.NO.

TOPIC

1.
2.
3.

PREFACE
ACKNOWLEDGMENT
INTRODUCTION
NANGAL PLANT

3.1.
3.1.1.

ABOUT NFL PLANT

3.1.2. SALIENT FEATURES OF NANGAL PLANT

4.
5.
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
6.
6.1.
6.2.

7.
7.1
7.2
7.3
7.4
7.5
8.

PAGE NO.
3
4
5
6
-DO-DO-

3.1.3.

VARIOUS PLANTS OF N.F.L.

3.1.4.

PRODUCTS MANUFACTURED

-DO-

3.1.5.

BI PRODUCTS

-DO-

3.1.6.

NATIONAL FERTILIZER LT. AT GLANCE

TRAINING SCHEDULE
AMMONIA PLANT
TECHNICAL DETAIL
TURBINE DATA
PROCESS
MAJOR EQUIPMENT
POWER DISTRIBUTION IN AMMONIA PLANT
LINE DIAGRAM OF NANGAL PLANT
UREA PLANT
FEATURES
DIFFERENT SECTIONS OF PLANT
6.2.1.
SYNTHESIS SECTION
6.2.2.
UREA SYNTHESIS
6.2.3.
DECOMPOSITION SECTION
6.2.4. CRYSTALLIZATION AND PRILLING SECTION
6.2.5.
RECOVERY SECTION
ELECTRICAL WORKSHOP
VARIOUS TYPES OF MOTORS
CLASSIFICATION OR TYPES OF MOTOR
DC MOTOR
AC MOTOR
DG SETS AT NFL NANGAL

-DO9
10
-DO11
-DO12
14
15
16
-DO17
-DO18
19
21
22
24
-DO26
27
28
30

REFERENCE

1. PREFACE
Electrical engineering is a field of engineering that generally deals with the study and
application of electricity, electronics, and electromagnetism.

31

NFL NANGAL TRAINING REPORT

Working in an industry provides us a practical approach to our theoretical basis of knowledge

acquired in our class room. It has been a great pleasure; training at NATIONAL
FERTILIZERS LIMITED, NAYA NANGAL. This industry helped me to boost up my
practical skills correlating the theories of book into actual work environment. The following
implants training report presents all my observation, analysis made during my training period
of 6 weeks. The report concerns with the workshops, ammonia plant, steam generation plant,
urea and begging plant and section where I have been deputed in the training.
The information and data furnished in the context are on the basis of my information
collected through interaction with the Engineers, Technocrats, Technicians, and Workers
working in the firm. Despite taking every effort to procedure an error free report, I apologize
for any mistake in the context on my part.
The main objective of industrial training is to enable the students to apply the theoretical
knowledge to practical situations &to expose themselves to the industrial environment. It
helps the students to understand the importance of discipline, punctuality & teamwork & also
cultivates a sense of responsibility in them. With the help of training students get exposed to
the current technological developments & also understand the psychology of the workers.

2. ACKNOWLEDGEMENT
Out of deep sense of gratitude I express my sincere thanks to Mr SHUBHANKAR MITRA
(Sr. manager, HRD deptt.), Mr R.K. SHARMA (Ammonia II electrical deptt.), Mr SUSHIL

NFL NANGAL TRAINING REPORT

KUMAR (Urea electrical deptt.) and Mr KESHAV KUMAR (Electrical workshop) for timely
helping me in the technical and operational aspect.
I sincerely express my thanks to Training and placement incharge, Chandigarh University for
providing me this opportunity.
This project would not have been a success without my dear friends in this department. I am
grateful to each and every one of them for their love and affection extended to me.
Without the support and wishes of my parents, I could have never completed my project
work. From depth of my heart, I acknowledge them with regared and affection.
NIHAL KASHYAP
14BEL8031

3. INTRODUCTION

NFL NANGAL TRAINING REPORT

National

Fertilizers Limited (NFL) company is a major Indian producer of

chemical fertilizers, organic fertilizers and industrial chemicals.
NFL,
incorporated in 1974 is India's largest Central Public Sector
Enterprise (Government of India Undertaking) in Fertilizer Sector
with a turnover of over Rs. 8000 crores. Coming under the
administrative control of Ministry of Chemicals and
Fertilizers, it is the second largest producer of the key fertilizer
Urea in India. NFL has five gas based Ammonia-Urea plants viz Nangal & Bathinda in
Punjab, Panipat in Haryana and two at Vijaipur (Madhya Pradesh). The company has a total
annual installed capacity of 35.68 LMT and is the 2nd largest producer of Urea in the country
with a share of about 16% of total Urea production in the country.
The products being manufactured and sold by NFL under brand name KISAN' include Urea,
Neem Coated Urea, Bio-Fertilizers (solid & liquid). Besides manufacturing of fertilizers, the
company is also producing allied Industrial products like Nitric Acid, Ammonium Nitrate &
Ammonium Nitrite, Sodium Nitrite, Sodium Nitrate etc. The Company is also in the process
of setting up a Bentonite Sulphur plant at its Panipat Unit to cater the requirement sulphur
deficient soil.During 2014-15, the company has achieved the ever best Urea production of
36.39 LMT and Urea sale of 36.79 LMT. This includes ever best Neem Coated Urea (NCU)
production / sale of 13.65 LMT. During 2013-14, Company achieved a total sales turnover of
8520 crore.
NFL has taken various initiatives in adopting best practices for environment management,
energy conservation and social upliftment. Some of them include conversion of its three Fuel
Oil based plants on natural gas which is a cleaner and greener fuel, switch over of coal fired
boilers on gas, installation of 100 KW & 90 KW Solar Power Plant at Corporate Office and
Bathinda unit. The company is also envisaging bigger capacity Solar Power Plants at its Units
over the next couple of years.Presently, company has a total manpower of 3843
employees. Presently, 5 world scale fertilizer plants and a bio-fertilizer plant are under the
ambit of NFL operating in different parts of the country.
They are:
NFL Nangal unit(Punjab)
NFL Bathinda unit(Punjab)
NFL Panipat unit(Haryana)
NFL Vijaypur 2 units(Madhya Pradesh)
Bio-fertilizers Indore unit(Madhya Pradesh)

3.1 NANGAL PLANT

NFL NANGAL TRAINING REPORT

With the coming up of Bhakra Dam and surplus power available from the hydel project,
Govt. of India decided to set up Fertilizer Factory at Naya Nangal, which went on stream in
1961.

3.1.1 About NFL Plant

Consequent upon the reorganization of FCI group of plants, Nangal Plant was transferred to
NFL & subsequently expansion plant of Nangal Unit was commissioned with an installed
capacity of 3.30 LMT. Further in order to sustain and enhance the companys growth, NFL
successfully revamped Urea Plant of the Nangal Unit & Commercial Production was
commissioned after revamp w.e.f. 1st Feb 2001 thus enhances the Annual installed Capacity
from 3.30 LMT to 4.785 LMT . As per guidelines of GOI, in order to reduce subsidy burden
& Carbon footprint, NFL revamped the Nangal Unit on LSTK basis for changeover of
Feedstock from LSHS/FO to Natural Gas and commercial production on Gas was
commenced during April 2013.
Reasons for Setting up Fertilizer Plant (i.e. Calcium Ammonium Nitrate (CAN) Fertiliser)
and Heavy Water Plant at Nangal: The main factors responsible for setting up these plants at
Nangal were:
1) The availability of cheap and abundant power from nearby Bhakra Dam
2) Inter-dependence of the process for the production of Heavy Water (a key material used in
the production of nuclear power) & CAN Fertilizer
3) Suitability of CAN fertilizer to the northern zone
4) Good rail & road communication facilities and
5) Availability of cold water from Sutlej River near the factory.

3.1.2 SALIENT FEATURES OF NANGAL UNIT

Installed Capacity:

478500 MTPA

Capital Investment:

229.19 Crores

Commencement of Production:

November 1, 1978

ProcessAmmonia:

KBR SMR (Steam Methane Reforming) with Purifier Technology

NFL NANGAL TRAINING REPORT

Urea: Technimont Total Recycle Process

Raw material: Coal, LNG/ RLNG, Power, Water

Fig.3(a)

Fig.3(b)

3.1.3 VARIOUS PLANTS OF N.F.L.

Ammonia Plant
Steam Generation Plant

NFL NANGAL TRAINING REPORT

Urea Plant
Bagging Plant
Nitric acid Plant
Methanol Plant

3.1.4 PRODUCTS MANUFACTURED

Nangal unit offers following industrial products:

Nitric acid (54%)

Anhydrous Ammonia
Ammonium nitrate Liquid & Solid
Methanol
Urea
Mill Rejected Coal
Carbon Slurry
Ash Slurry
Element Sulpher
Nitrogen Liquid
Hydrogen Liquid
Oxygen Liquid
Carbon Dioxide Liquid (98%)

3.1.5 BI-PRODUCTS

Sodium Nitrate
Sodium Nitrite

3.1.6 NATIONAL FERTILIZERS LIMITED AT A GLANCE

Cost (in crores):Urea plant

Industrial Capacity (in tons)

Urea plant

330000.00

Raw Material Requirement

Electricity
40 MW
Water 80 M Gallon/day
Fuel oil
720 tons/day
Coal 900 tons/day
Naphtha
180 tons/day

Total Production

Urea 1450metric tones/day

Methanol
67 tons/day

132.00

NFL NANGAL TRAINING REPORT

Ammonia

900 tons/day

4. TRAINING SCHEDULE

S.No.
1.
2.
3.

Plant Name
Ammonia II
Urea
Electrical workshop

Time Period
10/06/15-22/06/15
23/06/15-05/07/15
06/07/15-18/07/15

5. AMMONIA PLANT
5.1 TECHNICAL DATA

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NFL NANGAL TRAINING REPORT

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Liquid
Pumping Temp.
No. of Stages
Impeller Type
Dia
Wearing dia
Clearance
Brg. Radial
Thrust Bearing
Lube oil
Coupling
Rotation
Capacity (Nor.)
Capacity (Des.)
Suction Pr.
Discharge Pr.
Total Head
RPM
Power
Des. Eff.
Min. Cont. Flow
Cooling Water

Boiler Feed Water

131C
6
Closed
420mm
224mm
0.38mm
Journal
Kingsbury Type
Turbine Oil 90 forced
Gear type
CW (when viewed from coupling end)
382m3/hr
473m3/hr
3 Kg /Cm2
138.0 Kg /Cm2
1477.5m
3230
2310 kW
76.8%
100m3/hr.
33C

5.2 TURBINE DATA

1.

Rated Output

2541

2.

RPM

5366

3.

Inlet Steam Pr.

39.6 Kg/cm

4.

Inlet Steam Temp.

370C

5.

Exhaust Pr.

0.126 Kg/cm

5.3 PROCESS:The ammonia plant has the following processing units:Sl no.

Unit/section

Features

11

NFL NANGAL TRAINING REPORT

1.

Air separation unit

Mol. Sieve and activated

alumina gel bed for CO2&
moisture removal, cold
recovery from the products
in plate and fin type heaty
exchangers and
conventional double

2.

Gasification

column for distillation.

3 refractory gasifiers of

3.

Rectisol (de-sulfurisation)

series 700.
Selective absorption of
H2S and CO2by low

4.

Rectisol(decarbonation)

temperature methanol
Total regenration of partial

5.

CO shift

steam only.
Double bed high
temperature CO shift

6.

Absorption refrigeration

converter.
Part of heat duty is
supplied by the converted

7.

Nitrogen wash unit

gas from shift convertor.

Mol.sieveadsorbers for
removal of methanol and

8.

Ammonia synthesis

CO2
Topsoe S-100 radial flow
basket, waste haet
recovery of the converter
exit gases in BFW
economizers.

5.4 MAJOR EQUIPMENTS: The compressor house of ammonia plant has the
following major equipments:Sl no.

Section

Features

12

NFL NANGAL TRAINING REPORT

1.

Air compressor

1,40,000NM3/hr capacity
15.45 MW turbine

2.

Nitrogen compressor

30,000 NM3/hr capacity 6.9

MW turbine

3.

24,970 NM3/hr capacity

Oxygen compressor

6.59MW turbine

4.

Synthesis compressor

1,10,000 NM3/hr for 1st ,2nd

and 3rd stages recycle stage
15.983MW turbine

5.

Refrigeration compressor

41,330 NM3/hr capacity

2.8MW turbine

Against the rated capacity of 900Te/day, plant has produced a record production of 1011Te
and has been constantly running above 105% for the past few years.
The basic chemistry for production of ammonia is based on the HABERSS BOSCH
PROCESS for ammonia synthesis. The reactants in the ammonia plant are nitrogen and
hydrogen. Nitrogen is obtained from its abundant source i.e. atmosphere and hydrogen is
obtained from fuel oil which is hydrocarbon with C/H ratio of approximately 8.
As will be evident from above, the constituents in the synthesis gas other than
nitrogen and hydrogen does not play any part in the ammonia synthesis reaction, rather they
exercise undesirable effects like exerting their own partial pressure, poisoning the catalysts
etc.as such, the ammonia plant process is laid down such that the undesirable constituents in
the raw gas are removed in the process of purification before the synthesis gas mixture,

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NFL NANGAL TRAINING REPORT

containing hydrogen and nitrogen in the ratio of 3:1 at the required pressure is sent to
ammonia synthesis converter for synthesis reaction.
The plant has been provided with a fail safety system to take care of all eventualities.
The periodical review of the safety system is also done and incorporations whenever
necessary are done.
The plant is also equipped with a flare system with 80M height flare stack provide with pilot
and main burners capable of burning around 90,000 NM 3/hrof process gas at a time and also
mol. Seal to prevent flow of gas into the flare gas system. The pilot burner is of automatic
ignition system.
The harmless gases like CO2 and nitrogen are vented through a cold flare outlet also at
80M height. The flare system has been designed so that the toxic gases are burnt so that their
combustion products are not harmful to the environment.
Adequate measures have been taken to contain the air and water pollutants with in the
MINAS standard. As in this process of ammonia manufacturing, the gases,CO and H 2S are
extremely toxic. Monitors have been provided in the control room with sensors installed at
sensitive locations of plant for continuous monitoring of the environment.

5.5POWER DISTRIBUTION IN AMMONIA PLANT

Two feeders from MRS incomer A and incomer B feed the 11kV bus at ammonia
control panels for 11kV are provided by L&T. each panel is provided with circuit breaker of
630A, 300MVA which are activated by the relay in case of fault. Panels 1-5 and 12-17 are fed
to 415V panel through 11kV/415V, 2MVA transformer and panels 6 and 11 feed the 3.3kV
panel through transformer of rating 11/3.3kV, 10MVA. Bus coupling is provided between
buses A&B from ammonia there are two feeders to coal handling (1.6MVA), boilers (2MVA),
and D.M plant (2MVA). If one of the feeders fails or there is any abnormality then the total
load is transferred on the other feeder by using bus coupler. The 11kV supply is then further
stepped down to 3.3kV and 415V using step down transformers, 3.3kV is used for H.T.
motors and 415V is used for L.T. motors. This plant also has the facility of battery room.

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NFL NANGAL TRAINING REPORT

5.6 LINE DIAGRAM OF NANGAL PROJECT

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NFL NANGAL TRAINING REPORT

Fig. 5(a)

6. UREA PLANT
Urea plant has a rated capacity of 1550Te/day of prilled urea produced in a single
stream plant employing MITSUI TOATSU TOTAL RECYCLE C IMPROVED PROCESS.

6.1 Features of the plant are as under:Sl no.

1.
2.

3.
4.

5.
6.
7.
8.

Features
Type of process
Molecular ratio

MTC-C-IMPROVED
Conventional

NH3 : CO2

4:1

H2O : CO2
Conversion percentage
Reactor conditions

0.544:1
70%

Pressure kg/cm2

250

Temperature 0C
Reactor lining
Reactor features
Excess NH3 recycle
Decomposition stages

200
Titanium
Hollow
As liquid NH3
1st: 17.5kg/cm2
2nd : 2.5 kg/cm2 ( 5% CO2
fed to 2nd decomposer)

9.

Heat recovery in carbonate

3rd: 0.3 kg/cm2

For supplying heat to

condenser

crystallization to urea slurry

and heating hot water.

10.

11.
12.
13.
14.

Sp. Cons.
Te NH3/Te urea

0.58

Te CO2/Te urea

0.76

Power /Te urea KWH

86.4

Steam /Te urea

No. of conc. Stages
Type of prilling tower
Approx. prilling height
Salient features

1.24
One
Induced draft
40M
a.) power saving as 5%
CO2 is fed to LD
b.) P.T. height is less

16

NFL NANGAL TRAINING REPORT

cause of cooler at
bottom.
c.) Low biuret
d.) Because of Ti lining
in reactor corrosion
rate is less and
thinner liner.
e.) Water recycle is less
due to counter
current flow of
liquid and vapour in
decomposers.

6.2The plant is divided into four sections:

1. Synthesis section.
2. Decomposition section.
3. Crystallization and prilling.
4. Recovery.
The brief description of various sections is given as under:
6.2.1 SYNTHESIS SECTION
In MITSUI TOATSU TOTAL RECYCLE C IMPROVED PROCESS liquid ammonia
is recycled since it is easier to handle but require equipments like rectification column storage
tanks etc. and higher capacity liquid ammonia pumps.
Recycling of carbamate requires higher capacity carbamate pumps.
CO2 is received from ammonia plant at a pressure of 0.2 kg/cm 2 and 200C and is compressed
in a centrifugal booster compresser,UGB-101 to 32 kg/cm2 in 3 stage unit. The compressor
supplied by M/S BHEL has a normal capacity of 25256NM 3/hr and has 2 barrels 2 M.C.L.
805 and MCL 455. The drive of the compressor is an extraction and condensing type by
steam turbine supplied by M/S BHEL. The turbine is driven by 40K super heated steam and
has a rated output of 5792KW.

17

NFL NANGAL TRAINING REPORT

6.2.2 UREA SYNTHESIS

2NH3 +

CO2

NH2CONH4

NH2CONH4, H = -37.64Kcals
NH2CONH2+ H2O, H = 6.32Kcals

1
2

Where as reaction 1 is an exothermic and rapidly goes to completion of 2 and is

endothermic and is always incomplete. The overall reaction is exothermic and hence heat has
to be removed continuously for the equilibrium reaction to proceed. The conversion of
ammonium carbamate to urea depends upon:
1. Reaction temperature.
2. Mol. Ration of NH3/CO2, H2O/CO2 of the feed reactants.
3. Residence time.
The conversion increases with the increase in temperature, NH3/CO2 ratio and residence time
and decreases with H2O/CO2 ratio since the presence of water tends to shift reaction 2 in the
backward direction. The pressure employed depends on the reaction temperature and has to
be kept higher than the dissociation pressure of ammonium carbamate at that temperature.
Further since the dehydration of ammonium carbamate to urea takes place in liquid phase
only. The pressure employed must also be higher than the vapour pressure of ammonium
carbamate which is rather high.
High ratio of NH3/CO2 increases conversion and helps to minimize corrosion. As this
ratio increases the load on recovery section increases since excess NH 3 over stoichiometric
requirement has to be recovered and recycled back to reactor. This excess ammonia can either
be recycled as liquid NH3 or carbamate. In each case it becomes necessary to inject CO 2 into
carbamate condensers.
The compressed CO2 is washed with water in a packed bed tower called methanol
absorber for removal of entrained methanol in CO 2 which is normally 100ppm. The washed
CO2 is further compressed to a pressure of 260kg/cm 2 in a two stage compressor, UGB-102
supplied by M/S KOBE STEEL, JAPAN. This reciprocating compressor has a normal
capacity of 26260NM3/hr and is driven by a 2.2MW synchronous motor. Anti corrosion air at
the rate of 120NM3/hr is fed to CO2 at the suction of centrifugal CO2 booster compressor.

18

NFL NANGAL TRAINING REPORT

Liquid ammonia at 110C and 18kg/cm2 pressure is received in the ammonia reservoir,
UFA-401 from the Horton sphere. Ammonia booster pump UGA-404A&B boost the pressure
of the feed ammonia to 24kg/cm2 and feeds at the suction of plunger type ammonia feed
pumps UGA-101A-D. the ammonia feed pumps are of URACA MAKE driven by
3.3kV/450KW and have capacity of 53.2M 3/hr, 178RPM and 89% efficiency. The ammonia
preheater UEA-101 and 102. The preheated ammonia at 85.30C is fed to the urea reactor at
bottom.
The recycled carbamate solution of CO2 concentration, 7.5 lit per 25ml, at 1050C and
260kg/cm2 pressure is delivered to the urea reactor at bottom by recycle carbamate solution
pumps UGA-102A&B. these pumps are centrifugal type and are driven by back pressure
steam turbine, supplied by M/S EBARA,JAPAN and have a capacity of 81M3/hr.
The three feeds i.e. CO2 liquid ammonia and recycled pump solution are fed to a Ti
lining multi layer urea reactor. The reactor is a 12 layered C.S vessel with Ti liner thickness
of 5mm, 4mm and 3mm for the 1/6th, 1/6th and 2/3rd of total height of the reactor from bottom.
The reactor top temperature is maintained at 2000C maximum. The effluents from urea
reactor from top are let down to 17.5kg/cm2 pressure through a pressure control valve PCV101 and fed to the high pressure decomposer at 1240C.

6.2.3 DECOMPOSITION SECTION

MITSUI TOATSU TOTAL RECYCLE C IMPROVED PROCESS is a conventional
process.
The decomposition reaction
NH4COONH2

2NH3 +

CO2

Is favored by lower pressure of system or by low partial pressure of one of the reaction
products i.e. NH3 and CO2. Conventional process means the process where the decomposition
is affected by lowering in pressure in successive stages followed by indirect heating whereas
the processes where decomposition takes place by lowering the partial pressure of either NH 3
or CO2 followed by indirect heating are called STRIPPING PROCESSES.

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NFL NANGAL TRAINING REPORT

The reactor effluents at 17.5kg/cm2 and 1240C enters the part of high pressure
decomposer U-DA-201 having sieve trays at upper and falling film heater at lower section.
The flashed gases go up and liquid flows down through sieve trays. On trays the high
temperature gas from reboiler,U-EA-201 and falling film heater contacts with the liquid
flowing down. The sensible heat of gas and heat of condensation of water vapour are used to
evaporate the excess ammonia and to decompose the carbamate.
This helps in minimizing water evaporation and thus reducing water recycle to
reactor. The reboiler further heats the liquid by 12kg/cm2 steam to release excess ammonia
and carbamate gases. The temperature at middle is maintained at 151 0C by a temperature
control valve TCV-201. The temperature at bottom is maintained at 1650C through TCV-202.
The falling film heater is used to minimize residence time in order to reduce biuret formation
and hydrolysis of urea.
Anti corrosive air is fed to high pressure decomposer and reboiler through air
compressor UGB-201@ 2500ppm as air. Overhead gases from HD are absorbed in HAC(high
pressure absorber cooler). The bottom liquid flows to L.D. (low pressure decomposer) at
2.5K, 1450C,upper part, having 4 sieve trays. A similar phenomenon occurs in the low
pressure decomposer. The reboiler U-EA-202 provides heat using 7kg/cm 2 steam for
decomposition and hot stream from H.D heats up the solution from L.D in an exchanger
before entering the upper part. The temperature is maintained at 130 0C at middle by TCV203. Small amount of CO2 is fed below packed bed for improved stripping of decomposed
gases. The overhead gases from low pressure decomposer are absorbed in low pressure
absorber U-EA-402. Bottom liquid flows to 3 rd stage of decomposer called gas separator UDA-203. The upper part of gas separator operates at 1060C, 0.3K and lower part with packed
bed operates at 1000C and atmospheric pressure. The sensible heat of solution from low
pressure decomposer is enough for evaporating the overhead gases. In the lower part, air
containing trace amounts of NH3 and CO2, is blown under the packed bed, by off gas recycle
blower UGB-401. The urea solution is concentrated to 70-75% and sent to crystallization
section.

6.2.4CRYSTALLIZATION AND PRILLING SECTION

20

NFL NANGAL TRAINING REPORT

The urea solution obtained from the last decomposition stage i.e. gas separator
contains 25% H2O since every mole of urea one mole of H 2O is formed. Urea has to be
concentrated to 99.5% before prilling.
MTC-C-IMPROVED PROCESS employs crystallization-remeltprilling route and
uses spray nozzles for prilling. The prilling tower is of induced raft type.
The solution from gas separator enters lower part of crystallizer, U-FA-201. The upper
part is vaccum concentrator with two stage ejectors and barometric condenser.
In vaccum concentrator. Operating at 75mm of Hg and 60 0C, water is evaporated and
supersaturated urea solution comes down through barometric low into the crystallizer, where
urea crystals grow. The heat required for water evaporation comes from:
1. Sensible held of feed urea solution.
2. The heat of urea crystallization.
3. Heat recovered by urea slurry circulated through high pressure absorber.
The crystallizer is operated at 600C and atmospheric pressure, so the slurry leaving the
bottom contains 30-35% urea crystal by weight.
Hot water from hot water pump is used in jackets of crystallizer and pipe to avoid
crystal build up on vessels walls which may cause choking otherwise.
The urea slurry is pumped from crystallizer bottom to centrifuges U-CF-201A-E
(1000RPM, 43Te/hr of slurry) maintaining minimum recirculation to crystallizer to prevent
choking of lines.
Biuret remains with mother liquor, which after separation from urea crystals in the
centrifuges is recycled back to the system. Because of excess ammonia in reactor biuret, thus
recycled is converted back to urea.

NH2CONHCONH2 +NH3

2NH2CONH2

Urea crystals separated from slurry with 2-4% moisture are discharged to fluididsing dryer
UFF-301 at 1100C. The mother liquor flows down to mother liquor tank, provided with steam

21

NFL NANGAL TRAINING REPORT

coils. Mother liquor is pumped back to crystallizer via LCV-207. a part of mother liquor
going to low pressure absorber has been cutoff and instead dust chamber overflow solution
has been lined up.
Air is blown from blower U-GB-301(82360NM3/hr) and heated to 1000C in air heater.
This hot air droes the crystals to 0.1% to 0.3% moisture content. Dried crystals are conveyed
by a pneumatic duct to cyclones at the prilling tower top. The collected crystals are melted in
melter (1370C) and urea melt is sprayed through 12 nos. acoustic granulators. Prills are
cooled in fluidizing bed called CFD,installed at the prilling tower bottom. Air/cyclone
scrubbed for urea dust separators. Air containing urea dust from P.T column is scrubbed with
water and passed through 144 sets of poly urethane filters before exhaust to atmosphere to
reduce air pollution.

6.2.5 RECOVERY SECTION

The gases from gas separator are condensed in off gas condenser UEA-406 to 62 0C
and enter the bottom of off gas absorber DA-402(OGA). Condensed liquid flows down to off
gas absorber tank UFA-203. After cooling to 360C, liquid is sent to top portion of OGA as
absorbent. OGA bottom fluid is recycled as absorbent at OGA middle position (2nd bed).
Air from top of OGA is blown to gas separator by GB-401 blower. The gases from
low pressure decomposer are absorbed in low pressure absorber (EA-402) bubbling a sparger.
Dust chamber over flow solution (10-15% urea) is used as absorbent. Low pressure absorber
temperature is controlled at 450C and CO2 concentration 2.2 lit/2.5ml.
Solution from LA is pumped by GA-402A/B to high pressure absorber (DA-401)
middle through mixing cooler where liquid ammonia is mixed and serves as medium in the
absorber.
The gases from HD top are bubbled through a sparger in high pressure absorber
cooler EA-401, where 65% of CO2 is absorbed. Remaining gases from HAC go to HA and
are cooled down to 800C max. in middle cooler at the bottom of HA 35% of CO 2 is absorbed
in packed bed by a mixture of lean carbamate from low pressure absorber through FCV-401
and liquid ammonia from GA-404A/B( temp. max 600C) through FCV-402. the scrubbed gas
then passes through five nos. of condensers(EA-404A-E) and purge condenser EA-403.

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Liquid ammonia flows down to ammonia reservoir FA-401. Non-condensable gases flow to
ammonia recovery absorber. Recovery loop pressure is controlled by PCV-405 at top of EA405 lV. Cold steam condensate is fed for absorption. Aqueous ammonia is with drawn from
recovery absorber bottom by GA-405A/B.

7. ELECTRICAL WORKSHOP

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7.1 VARIOUS ELECTRICAL MACHINES(MOTORS):

MOTORS:
An electrical motor is an electric machine that converts electrical energy into mechanical
energy

.
Fig.7(a)

Operation-

In normal motoring mode,most electric motors operate through the interaction between an
electric motors magnetic field and winding currents to generate force within the motor.

ConstructionRotor: In an electrical motor the moving part is the rotor which turns the shaft to
deliver the mechanical power. The rotor usually has conductors laid into it which
carry currents that interact with the magnetic field of the stator to generate that force
turns the shaft. However, some rotor carry permanent magnets and the stator holds the
conductors.
Stator: The stationary part is the stator, usually has either windings or permanent
magnets.
Air gap: In between the rotor and stator is the air gap.The air gap has important effects
and is generally as small as possible.

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Fig.:7(b) Construction of motor

7.2 Classification or Types of Motor:

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The primary classification of motor or types of motor can be tabulated as shown below:

7.3 DC MOTOR: A DC motor is any of a class of electrical machines that converts direct
current electrical power into mechanical power. The most common types rely on the forces
produced by magnetic fields. Nearly all types of DC motors have some internal mechanism,
either electromechanical or electronic, to periodically change the direction of current flow in
part of the motor. Most types produce rotary motion; a linear motor directly produces force
and motion in a straight line.
DC motors were the first type widely used, since they could be powered from existing directcurrent lighting power distribution systems. A DC motor's speed can be controlled over a
wide range, using either a variable supply voltage or by changing the strength of current in its
field windings. Small DC motors are used in tools, toys, and appliances. The universal
motor can operate on direct current but is a lightweight motor used for portable power tools
and appliances. Larger DC motors are used in propulsion of electric vehicles, elevator and
hoists, or in drives for steel rolling mills. The advent of power electronics has made
replacement of DC motors with AC motors possible in many applications.

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TYPES OF DC MOTOR:
1. Separately excited motor.
2. Self excitedmotor :it is further categorised as SHUNT ,SERIES & COMPOUND
MOTORS.

7.4 AC MOTOR:
An AC motor is an electric motor driven by an alternating current (AC). The AC motor
commonly consists of two basic parts, an outside stationary stator having coils supplied with
alternating current to produce a rotating magnetic field, and an inside rotor attached to the
output shaft producing a second rotating magnetic field. The rotor magnetic field may be
produced by permanent magnets, reluctance saliency, or DC or AC electrical windings.
Less commonly, linear AC motors operate on similar principles as rotating motors but have
their stationary and moving parts arranged in a straight line configuration, producing linear
motion instead of rotation

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NFL NANGAL TRAINING REPORT

INDUCTION MOTOR:
An induction or asynchronous motor is an AC electric motor in which the electric current in
the rotor needed to produce torque is obtained by electromagnetic induction from the
magnetic field of the stator winding.

SYNCHRONOUS MOTOR :
A synchronous electric motor is an ACmotor in which, at steady state, the rotation of the shaft
is synchronized with the frequency of the supply current; the rotation period is exactly equal
to an integral number of AC cycles.

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7.5 DG SETS AT NFL NANGAL:

A Diesel Generator (DG) is a combination of diesel engine with electrical generator (often
called an alternator) to generate electricity. DG sets are used in places that have no
connection to power grid, and as emergency power-supply if the grid fails.

DG SETS AT NFL NANGAL:

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NFL NANGAL TRAINING REPORT

937 KVA :at expansion, feeding expansion load.

375 KVA : at expansion,feeding expansion load.
240 KVA : at R&S feeding critical load of R&S, WTP, NMP-1 and telephone
exchange.
100 KVA : at nitric acid feeding critical load of nitric acid, NOX,ANP & UREA
BAGGING.
187 KVA : at water works (township) feeding critical load of hospital, clubs, school &
GM bunglow. All DG sets are rated to supply 415 volt at rated rpm.

REFERENCE
1. www.nfl.com
2. www.nflnangal.com
3. www.wikipedia.com

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4. www.electrical4u.com
5. www.interfacebus.com