this is report about summer intern in NFL Nangal

1. NATIONAL FERTILIZERS
LIMITED , NANGAL

2. NFL
 NFL has five gas based Urea plants viz Nangal & Bathinda in Punjab, Panipat in
Haryana and two plants at Vijaipur in District Guna, 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

3. FEATURES OF NANGAL UNIT
 Installed Capacity: 478500 MTPA
 Capital Investment: 229.19 Crores
 Commencement of Production: November 1, 1978
 Commercial production after revamping started on Feb 1st,2001.

4. NFL Nangal plant
 NFL Nangal plant can be divided into 4 parts-
1.Steam Generation Plant
2.Ammonia Production Plant
3.Urea synthesis Plant
4.Nitric Acid Generation Plant

5. UREA PROCESS
 BRIEF DESCRIPTION :
 It is a Montedison total recycle process.
 Before revamping its capacity was 1000 T/day
 But today its capacity is 1650 TPD
 Ammonia: KBR SMR(Steam Methane Reforming) with Purifier Technology
 Urea: Technimont Total Recycle Process
 Raw material: Coal , LNG/ RLNG, Power, Water

6. UREA PRODUCTION
 CO2 Compressor & H.P.Pumps
 Urea synthesis.
 Urea separation.
 Recovery section.
 Vacuum section.
 Prilling section.
 Waste water section.

7. Specific Consumption
 Ammonia 0.574 T/T of urea
 Carbon dioxide 0.745 T/T of urea
 Steam 30ata 1.23 T/T of urea
 Power 135 kwh

8. Reactor feed
 The expected best operating condition are:
New sec. Old sec.
Capacity (TPD) 600 1050
 Pr (ata) 220 220
 Temp (ºc) 196 196
 N/C 2.9 2.75
 H/C 0 0.7
 Conversion (%) 69 55
0
200
400
600
800
1000
1200
Chart Title
new section old section Column1

9. Reactions
 The principal raw materials required for this purpose are NH3 &
CO2 .Two reactions are involved in the manufacture of urea.
First, ammonium carbamate is formed under pressure by
reaction between CO2 & NH3.

 CO2 + 2NH3 <-→ NH2COONH4 ∆H= -37.4 Kcal

 This highly exothermic reaction is followed by an endothermic
decomposition of the ammonium carbamate.

 NH2COONH4 ↔ NH2CONH2 + H2O ∆H= + 6.3 Kcal

11. Feed:-
 Ammonia : 20C and 20-30 ata
 Demethanolated CO2 : 40C and 11 ata
sulfer content <1mg/m3

12. Urea Separation
 1st stage
Pressure 70 Kg/cm2
Temperature 185 C
Urea conc. 54.5%
 2nd stage
Pressure 12 Kg/cm2
Temperature 150 C
Urea conc. 65%
 3rd stage
Pressure 3 Kg/cm2
Temperature 130 C
Urea conc. 72%

13. Vacuum Section
 1st stage vacuum system
Pressure 0.75 ata
Temperature 128 C
Urea conc. 95%
 2nd stage vacuum system
Pressure 0.35 ata
Temperature 138 C
Urea conc. 99.6%

14. Prilling section
 The 99.5% urea melt having a temp of 140 C from 2nd stage
saparator is then pumped and fed to spray nozzles of the prilling
tower
 Therer are 4 sprayer boxes each having 16 sprayers.
 It is natural draft rectangular prilling tower
 height 75 meters
 free fall height 53 meters
 Urea dust loss 84 kg/Hr
 scrapper type conical
 Air flow 8,00,000 Nm3/h

15. Product Quality
 Total Nitrogen 46.5%
 Moisture 0.35%
 Biuret 0.8-0.9%
 Mean prill dia 1.75mm
 Sieve analysis
Over size nil
Proper size 98.5%
Under size 1.5%

16. Specification of Urea being
produced at Nangal
 Total Nitrogen 46.5%
 Moisture 0.5%
 Biuret 0.8-0.9%
 Mean prill dia 1.75mm
 Sieve analysis
Over size nil
Proper size 98.5%
Under size 1.5%

17. Disadvantages
 When applied to a bare soil surface, urea hydrolyzes rapidly result
into loss of significant quantity of ammonia by volatilization. Such
losses vary from soil to soil and are greater for urea in a pellet form
rather than in solution form.
 It is phytotoxic due to rapid hydrolysis of urea in soils can cause injury
to the seedlings by ammonia,
 The fertilizer grade urea may contain toxic biuret which is formed
during urea manufacture by an excessive temperature rise. Above
2% concentration of biuret in urea is harmful to plant

18. Conclusion
 For the development and upgradation of urea technology. Indian industry
depends on the already established international process licensors and design and
companies. There is hardly any R & D effort towards development of process
technologies for urea except for development of modified total recycle process by
PDIL which has been utilised in Namrup-III plant.
 R&D unit should be set up to deal with the development of fertilizer technologies.

19. Thank You!!!