Prem Baboo

The Institution of Engineers (India) | IEI · Chemical Engineering

People of the world, take care, reduce carbon emissions, otherwise the coming generations will not be able to see this world. Today human has fallen into a trap of his own making spider web. In the race to progress, we have spoiled both our present and our future, the ongoing human-induced emission of carbon dioxide (CO2) threatens to change the ea...

Green hydrogen is a hope for the future. Green hydrogen is a pollution-free fuel that can be used to transport fertilizers and as a fuel in furnace. Although hydrogen is being used a lot in the world, yet we still have to do a lot more. whenever someone is good The electrolyser and Proton Exchange Membrane) Electrolyzer units, by electrolysis of wa...

The possibility of formulating nitrogen, phosphorus and potassium (NPK) biofertilizer from ashes of waste organic materials such as chicken feathers, bone and banana peels is investigated in this study by first subjecting the agricultural waste to 80-250℃ heat in a muffle furnace to produce ash. Kjeldatherm block digestion unit, UV spectrophotomete...

A type of treatment that uses substances made from living organisms to treat waste and waste water. These substances may occur naturally in the body or may be made in the laboratory. Biological treatment is the sustainable treatment of waste. Biological treatment is an attractive and useful technology that results in the complete conversion of orga...

NOx, SOx & CO2 emission are the serious problem in any fertilizers plant. The urea production and use of nitrogen fertilizers lead to the release of SOx, CO2, N2O and CH4, which are among the most important global GHGs. The synthesis of ammonia, from which all synthetic fertilizers are produced, accounts alone for about 0.8% of the global GHG emiss...

The description of Granulation Process and comparison of Prilling and granulation . benifits against prilling.

If we talk about the costly and biggest heat exchanger in urea plants, then the name of the stripper comes first. Nowadays the competition of stripper is running for more and more capacity. In this regards some urea plant licensers have gone ahead some are left behind some are very much behind and some are dragging.Urea stripper is a vertical in tu...

In any centrifugal compressor the Antisurge protection in action interlock is given for compressor safety. This logic is very typical and related to much input. Each input is very important for compressor life and internals. This paper intended how to work this logic. paper explains surge protection in action phenomena and explains why the anti pro...

Catalyst is the heart of ammonia plants. A catalyst accelerates reaction by providing alternate paths to products, the activation energy of each catalytic step being less than that of no catalytic reaction, in the reaction cycle, active centers of catalysis first combine with at least one reactant and then is reproduced with the appearance of produ...

A trouble shooting case study in Fertilizers unit, India.Solving the problem of Feed/Effluent Exchanger E-3321A/B in Process Condensate stripping section of Ammonia plant by Analytical approach. The problem solved by in house experts without changing the heat exchangers while others plant change the heat exchangers.Number of modification done and h...

The efficiency of stripper is the key factor of decomposition. The stripper is the heart of urea plants either ammonia stripping process or CO 2 stripping process. The sample of reactor outlet and stripper outlet liquid is done daily or when required but vapour is not possible it is to be calculated by difference. How much vapour decomposed? The st...

Operation of the plant is mainly supervised by the operators in the control room, who monitor the various instruments and adjust operating conditions in order to obtain satisfactory operation. They should also react when an alarm is activated. In some cases they can re-establish normal conditions by adjusting the controls in the control room; in ot...

This paper intended general questions and their answers on Ammonia Plant ,trouble shooting questions, design of ammonia plant and very suitable for Engineering students who are making projects on "Topic Ammonia Production " vessel detail practical data .This paper including Green Hydrogen, How to differ from Gas fired in primary reformer, electrica...

The centrifugal Compressor is designed for gas and vapour if the separation efficiency goes down then the water carryover in next stage and this is very dangerous for compressor internals because the gas & vapours are compressible fluid while the liquid is incompressible fluids. As a result a rapid and exponential rise in hydraulic pressure will be...

The operation of Urea reactor with scientific way is also an art. Work with guess is rough way guess is always guessed. In empty urea reactor feed in or operation with interruption N/C ratio in urea reactor is very difficult to guess. But in case of interruption there is very difficult to judge N/C ratio. The N/C ratio is the function of pressure a...

78-80 % energy of Urea process depends upon ammonia process and rest on power & steam. If the energy of ammonia plants is improved then the urea plant energy automatically improves. The specific consumption of urea stoichiometrically is 0.566 but due to losses it generally found 0.569-0.574 depends upon loses of urea/ammonia in the process etc. ste...

G.Cal/ton of Ammonia, G.Cal/ton of urea is the most important data in fertilizers industries for performance evaluation. The energy of the fertilizers is depends upon Reformer feed & fuel. Earlier thinking Fertilizers should be produced at any cost we have nothing to do with energy & pollution and what environment we don’t know? But today time has...

Dear friends today we will discuss on urea product quality. What are the factors on which urea product quality depends? How to improve urea product quality. Urea produced by prilling and granulation rout. In India Prilling is very popular and other countries Granulation rout is adopted. There are some merits and demerits are prilling and granulatio...

There are numbers of Fertilizers are used for improve productivity of grain, N; P &K are important fertilizers among them. Commercially Urea is more produced because the Nitrogen percentage is higher than all fertilizers. These three NPK are primary nutrient. There are some question arises about these industries, present paper intended to attempt t...

After the success of Vol-1, now here is Vol-2, Vol-1 is very much liked by people. There was a time when people did not share their knowledge in public and his knowledge used to be buried with him but he did not tell anything throughout his life.

Fire network & Fire prevention device with fire station is essential for all industries. The fire Industries have very dangerous substances and gases that can catch fire at any time. Most of the accidents/injuries are caused by human errors. Industry says, human error accounts for 96% of accidents. The rest takes place due to external conditions an...

In Urea Process corrosion/Erosion also observed in LP and vacuum section. The paper indeed how to tackle this type of problem? Root cause of corrosion in LP & vacuum section. Construction of material used in these sections. Operation of LP section with trouble shooting How to balance water in the process, Distillation Tower Versus LP carbonate solu...

In M/S. Saipem process the HP loop operation is very typical including HP stripper and Reactor N/C ratio, H/C ratio and conversion of the reactor. The MP loop also very typical in operation point of view in which the level of Medium pressure absorber is fluctuating frequently when plant starts up /shut down or any process disturbances/upset. This a...

There are numbers of Fertilizers are used for improve productivity of grain, N; P &K are important fertilizers among them. Commercially Urea is more produced because the Nitrogen percentage is higher than all fertilizers. These three NPK are primary nutrient. There are some question arises about these industries, present paper intended to attempt t...

In Ammonia plant numbers unwanted products are formed such as CO2 & methanol, Methanol is the by-product and it is very dangerous for environment and cations and anion resin also, which is used treated waste water through urea plant. Methanol is also dangerous for Ozone layers.CO2 is also by-product in ammonia process but it is used for production...

Technology licensors in the fertiliser industry compete to design ever�larger urea plants with increased capacity. These plants require materials capable of withstanding the production capacity conditions while reducing the incidence of shutdowns due to material failure.

Detail revamp of Existing Prilling tower to control the dust & ammonia.

In Fertilizers industries the material plays a very important role. Right material can save energy as well as plant life and wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In urea plant very corrosive chemicals are used for urea...

Risk Management is the Identification, Analysis and Economic Control of those Risks which can Threaten the Assets (Property, Human) or the Earning Capacity of an Enterprise” Risk management is the process of identifying, assessing and controlling threats to an organization's capital and earnings. These risks stem from a variety of sources including...

In Urea plant passivation air is used in reactor, stripper and downstream of the all equipments. The reactor liner material used Titanium, Zirconium, SS 316L (urea grade), 2RE-69 and duplex material .except Titanium and Zirconium all stainless steel required more passivation air. In CO 2 some quantity of Hydrogen is present about 0.14% to 0.2%. The...

Over the past two decades, the ammonia and urea industry have witnessed spectacular metallurgical developments for process equipment. For example, stainless steels, modified with special materials, can improve high temperature creep rupture resistance. Using duplex stainless steels and modern corrosion abatement techniques are other methods that im...

Ever since the declaration of 100% neem coated urea by India Government, the number of neem trees is increasing continuously in India Neem coated urea requires neem oil, more urea more oil and trees also required more. When it comes to oil, neem plants are rather promising. Probably no other plant yields as many exploitable by-products and benefits...

Prills /granular urea are not only costly for the producer but may be harmful to humans and the environment. Furthermore, nano Urea may also be used for enhancing abiotic stress tolerance. Nano-Urea prevents environmental pollution and improves physiological traits of wheat grown under drought stress conditions. The nano urea consist of higher surf...

Installation of S-50 ammonia synthesis converter along with waste heat boiler in downstream of existing S-200 ammonia synthesis converter is one of the major schemes of Energy Saving Project of Ammonia plant. The energy saving reported 0.18 G.Cal/T of Ammonia. Several ammonia plants have installed an additional ammonia synthesis converter in combin...

In Urea Conversion gas/liquid mixing in urea reactor with application of high efficiency trays homogeneous and heterogeneous phases' iquilibria and kinetics is very important. The efficiency of Urea Reactors can be improved by the application of the latest generation of internals .Generally Fluid dynamics phenomenon are created by the concurrent ga...

Purpose of Boron Removal and Remineralization is to produce drinking water by removing boron from a permeate water stream. . It cannot be removed by conventional water treatments and its separation still remains an issue. Boron is a naturally occurring element most often found as boric acid or boric acid salts Boron is an essential micronutrient th...

In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H 2 is demineralized water and the hydrocarbons in the natural gas. The source of N 2 is the atmospheri...

The paper describes a successful of plant start-up despite the pandemic difficulties and introduces a set of first considerations about the possible future application of available digital technologies for remote and distributed control system from central control room commissioning of complex Dangote Fertilizer Plants. The numbers of problem were...

Raised and educated in India, Prem Baboo has dedicated his professional career to the fertilizer industry. With experience within India as well as abroad, Mr. Baboo’s knowledge of alloys and their applications is encyclopaedic. Looking to help others, he freely shares this knowledge by writing technical papers, authoring books and leading on-line i...

On January 1, 2021, the UreaKnowHow.com Urea Incident Database contained already more than 135 serious incidents. Detailed analyses concludes that the majority of these incidents did occur in the high pressure synthesis section. This paper elaborates the most critical safety hazards: Ruptures and toxic ammonia leaks. The paper also provides the Top...

Prilling and Granulation are finishing sections of urea production process. Prilling is defined as distribution of molten droplets into a column of rising air which removes the heat of fusion and yield a solid product. Two most important aspect of prilling are droplet formation and distribution of droplets over maximum cross-section area of prillin...

Materials plays Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty 2 RE-69 materials are used...

In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Ure...

There are many equipment's in urea plant which have very important for holding time, partition plate passing, weep holes monitoring, medium pressure absorber, high pressure carbamate condenser, etc.Startup of medium pressure absorber, is one of the most difficult operations of chemical processes in urea plants. In the last few years we have accompl...

P & I Description

If the material of liner changed with 2RE 69 or Duplex material instead of SS316(urea grade), then passivation air can be reduced, resulting the energy saving because the inerts vented from M.P section and loss of ammonia and problem of pollution. To enhance capacity and energy of the existing plant the internals like vortex mixture and HET may be...

The Design of 5000 TPD Mega urea plant Prilling as well as Granulation.

The objective of this study is to investigate experimentally and theoretically heat and mass transfer characteristics of the common cooling tower for world largest Fertilizers complex and Induced cooling system is also world largest cooling Tower. This theory is universally adopted for calculations of cooling tower performance. Detail of these desi...

The microwave level meter can carry out measurement not only with corrosive/high pressure but also in a high temperature or under an environment with corrosive liquid/gases. Accurate measurement has been achieved even under adverse environment conditions. The microwave level meter contains the self-diagnostic function and informs you of a measureme...

Environmental protection is the practice of protecting the natural environment by individuals, organizations and governments. Wastewaters from chemical fertilizer industry mainly contain organics, alcohols, ammonia, nitrates, phosphorous, heavy metals such as cadmium and suspended solids. The nature of effluent streams varies in terms of its consti...

This paper discusses how to tackle water treatment process with variable TDS. Concentration and high organic strength. The effects of TDS concentration changes when treating combined high TDS and high organic strength wastewater. The process design for a biological treatment system depends on the wastewater characteristics and equalization capacity...

The aim of Chemical Cleaning is to is to safely remove all deposits from the inside of the boiler tubes. mill scale, oil, paint, preservatives, rust, welding slag’s that would have entered during the assembly of new tubes. Steam piping must be cleaned by chemicals when either the product can react with oil left inside of the piping or in case it ca...

- In Fertilizers Industries surplus ammonia is stored in a large capacity tank. For efficient discharge and storage of hazard chemicals such as ammonia, special processes must be developed, and several related parameters must be checked and evaluated. The Nitrogen purging is the very important activities before taking ammonia in the storage tank an...

- Secondary reformer refractory baking and dry out cycle requires very slow and controlled heating of refractory. Thermal stresses will be produced if heating rate is too rapid. Longer period of low temperature drying causes more even heat distribution resulting better refractory dry out. It is very much important that proper dry out of secondary r...

In Urea Plant third stage intercooler of CO2 compressor heat exchanger made of type SS-304L stainless steel at a National Fertilizer plant about 50 numbers of tubes developed cracks due to stress corrosion cracking. In this articles described how to developed SCC in austenite steel in Chloride contents more than 50 ppm at 50 0 C. Stress corrosion c...

Operation of CO2 Compressor & Turbine

In high Pressure Urea reactor, sudden pressure drop by any reason can cause bulging of liner. In any reason (heavy leakage in HP section of urea plant, PSV popped etc.) the HP loop pressure goes to zero, then how to drain out urea /carbamate solution from HP loop without pressure to take shut down. At gravity, it is very difficult to drain out urea...

The success of any industries lies its efficient working which in turn depends not only on equally and quantity of the service or product but also much on safe working. NFL is totally committed to conduct all its activities in harmony with society and nature without compromising on the health and safety of the employees as well as the people living...

In 2017, AmmoniaKnowHow.com and UreaKnowHow.com introduced global open source risk registers for ammonia and urea plants. On January 1, 2018, the Risk Register Safety Hazards in Urea Plants contained its first 100 safety hazards. This paper provides the detailed analysis of these hazards: In which plant sections and during which project phase do th...

The energy of H.P. loop directly proportional to the pressure of h.p loop. The H.P loop is the heart of urea plants. Conversion of urea depends upon N/C & H/C ratio, reactor internal construction, i.e. configuration of trays, reactants mixing phenomenon, flow pattern etc. other than pressure. In conventional plants there was too much pressure of th...

In India the ambient temperature goes to 46-48 0 C in peak summer. The prills temperature goes to higher i.e.in our plants, line-1-prills temperature is 70-72 0 C and sometime reached 78 0 C at higher plant load with recovery of urea solution and that of line-2-prills temperature is 64-66 0 C without Bulk Flow cooling. The caking of urea fertilizer...

Relation between Bulk Flow Cooler dew Point Vs Urea In/Out Temperature

In this article includes many studies and investigation reporting on the effect of various parameters to the prills quality like crushing strength, size distribution, abrasion and impact resistance, humidity factors urea moisture absorption, vacuum studies etc. The Nitrogen, moisture, Prill strength &Biuret contents and the size distribution of pri...

This article entails the chronic problem of Fertilizer Industry regarding leakage in Urea Stripper. A critical leak incident that occurred in one of the most critical piece of equipment (stripper) in Urea plant resulted to emergency shutdown and losses in production and how the situation can be analyzed to prevent re- occurrence of similar incident...

Specific Heat of Ammonium Carbamate Vs Temperature

This paper intended how to recover useful urea dust to control air pollution and that of saving energy. Lot of urea dust is emitted during product handling like falling from one conveyor to another, screening, de-lumping, bagging, etc. To recover the dust, wet de-dusting systems are installed. In the dust recovery system urea particles suspended in...

This paper provides the basis for identifying and correcting turbine problem describes turbine front and rear journal bearing vibration problem and rectified in running plant by some modifications. The 31 CO2 compressor turbine tripped on dated 01/01/2018 & 9/01/18 on rear journal bearing RJB (406 A/B) vibration high. The event analysed and prevent...

The paper intended how to decommissioning of ammonia storage tank, Inspection and maintenance , a detail procedure.

This paper covers background information on the 30 years old revamped plant; problems experienced at the plant after many years of continuous operation, e.g., leaks in the SS 316 L (mod) lining due to the combined action of erosion and corrosion; basis of the revamp work on the design information provided by M/S. Saipem a leader in urea production...

The paper intended to enhancement of energy and product quality by installing Vortex mixture in urea Reactor. This is the new approaches to convert reactant to useful product. In urea plant Carbon dioxide & ammonia are the reactants, in which the ammonia in liquid form and carbon dioxide is in gas form. The Carbon Dioxide is the limiting reactant....

The comparison of M/S Saipem Ammonia Stripping process and M/S Stamicarbon CO2 stripping process part 2, mainly focus on material of construction.New development by both the process.

This is the second part of a series of technical papers comparing Stamicarbon and Saipem Urea Stripping Technologies as per today (April 2017). This part focuses on the applied materials of construction and typical failure modes of its latest references. Mr. Friedrich Wöhler discovered in the 18th century that it was possible to make from NH3 and...

This is the first part of a series of technical papers comparing Stamicarbon and Saipem Urea Stripping Technologies as per today (October 2016). With urea stripping technologies we mean urea melt technologies producing a urea melt suitable for prilling or granulation. This paper mainly discusses the latest process schemes applied in the high pressu...

The paper intended a case study of pollution control through prilling tower and other equipment, in urea plant the prilling tower is main pollution contributors .In India urea production through prilling rout is 100 % no granulation is used.A mathematical hydrodynamics,heat, and mass transfer between the urea and the cooling air aredeveloped in nat...

Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Improvement in energy efficiency reduces cost of production & results in environmental benefits, e.g. mitigation of global warming by way of less emission of Green house gases in the atmosphere. Over the years several energy conservation measures have b...

Coating particles or granules of urea with sulphur and a sealant results in the formation of a membrane that regulates the availability of nitrogen for plant growth.Sulphur Coated Urea (SCU) fertilizer is a slow-release fertilizer that is made by coating urea with sulphur and wax that increases nitrogen efficiency, improves plant growth and reduces...

In order to achieve optimum conversion in synthesis convertor, it is necessary to purge a certain quantity of gas from synthesis loop so as to as to reduce inerts concentration in the loop. Purge gas stream from ammonia process contains ammonia, hydrogen, nitrogen and other inert gases. Among them, ammonia itself is the valuable product lost with t...

The electrostatic oil cleaner is designed and developed to super clean hydraulic oil and other non-detergent type oil, being used in various industrial applications like compressor pumps oil system

The paper intended to the standpoint of harmful emissions typical nitrogen-based fertilizer plants producing ammonia and urea plants using the advanced available technologies. The critical emission points are established and analyzed. Several possible actions have been taken in order to minimize the emissions are presented.The method is low cost an...

This paper describes a process of preparation of neem oil water emulsion & coating of urea in fertilizer plants, at site of urea production. The neem tree found in Asia and basically Indian sub continent. The basic part for neem oil used is seed of the neem known as kernels .Different method are available to obtain neem oil including one new method...

In urea plant Medium pressure Inerts gases recover HRU burner in Captive Power Plant. The inserts containing useful fuel in the form of Hydrogen & Methane about 40-45% volume percentage of total inerts. This inerts also containing Oxygen because the passivation air is given in carbon Dioxide compressor suction line for passivation of Reactor vessel...

The paper intended to deposition of wang scaling/deposition & corrosion on turbine blades. How to deposit these scales? Prevention and control the deposits. Major steam turbine problems causes and effects. Practical examples of our shut down experience of 40 ata & 100 ata steam turbines. Lab analysis detail report of wet steam cleaning and sand bla...

Density Vs temperature Chart of Ammonia at the constant pressure 15.72 bar and temperature range -32 degree cent to 40 degree cent.

This paper intended to the damage of cooling tower of our plant a detail case study of the incident. East side of Urea Cooling Tower of Line-II suddenly collapsed at 7.30 PM on 18.06.2007As per an eye witness middle portion of the tower collapsed first and within seconds the entire extended portion of the tower along with the return header collapse...

This paper intended to remove neem oil in spill urea, this spill urea creates problem when it recovers in urea plant, foaming observed in distillation tower also the fouling/scaling also occurs on heat exchanges.For removing this neem oil activated carbon filter is installed, I have written the experience for this process.

The papers intended to brief description of Ammonia & Urea Plant with energy saving scheme implemented now. The lot of benefits energy wise & Production wise recorded.The energy of line-I now running 5.603 G. Cal/MT of Urea and line -II 5.302 G.Cal/MT of Urea.Now further the line -I turbine will be changed with 40 bar to 100 bar turbine.this will g...

This article describes the failure of second bed outlet pipe in Synthesis converter, problem associated with catalyst carry over and subsequent repair by installing Johnson screen in the converter. There are incidences of failure of Johnson screen also in Ammonia Converters but action taken timely and save major damaged after sufficient strengtheni...

This paper intended to detail incident report analysis and troubleshooting How to save the atmospheric tank from vacuum? How to take safety measures? Design of overflow line with siphon breaker. Brief description of other pressure vessel.

This paper intended how to more beneficial Neem coated urea than ordinary urea,There is a lot of difference in Neem coated urea and the Plain one. In Neem coated urea, they put a layer of Neem over the plain urea that increases the land fertility capacity that leads to the higher production of crops."Slow release of Nitrogen."just like baby milk fe...

The DCS is very efficient now a days, it can save energy time for quick operation.The trouble shooting is very fast.All control application backup and HMI graphics backup can be stored in a CSV file. Very easy to restore and reuse. HMI Graphics page can be easily downloaded from engineering station to particular operator station. Manual steps are r...

“Energy is an essential part of our daily lives. It is the lifeblood of modern life. It is the single most important resource harnessed by man. Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy.”

This paper intended how to measure direct mass without converting from volume and this is the independent from temperature.How mass flow meter better than volumetric flow meters

Energy Saving scheme implemented in Ammonia Plant, like S-50 converter along with S-200 converter. and CO2 absorption benfield changed with GV section.

This paper intended how to reduce the problem of control valves. The control valve is an important component of the total process control loop, and proper valve sizing is essential for this final control element to fulfil its role. The correct process data and accurate knowledge of maximum and minimum flow conditions can reduce the problems of cont...

There has been a "seven-fold increase" in Delhi's air pollution level since October 2015, a Centre for Science and Environment (CSE) expert said today even as real-time exposure readings of nearly all monitoring stations put PM 2.5 and PM 10 figures above the 'severe' threshold. The current air pollution levels in the national capital have reached...

This paper intended to GM crops contribute to a reduction in fuel use from less frequent herbicide or insecticide applications and a reduction in the energy use in soil cultivation. The GM food is ecofriendly approaches.GM crops can actually help keep agricultural soils healthy and productive. Healthy soils are the foundation of a healthy agricultu...

The paper intended how to reduce noise pollution,by installing turbine in industrial let down station and It is often impractical to plant enough vegetation along a road to achieve such reductions; however, if dense vegetation already exists, it could be saved. If it does not exist, roadside vegetation can be planted to create psychological relief,...