Technology Assessment Air Pollution Control Fertilizer Industry (Use of CP/CT Technique)

Abstract

This project discusses the study of the Urea plant of IFFCO Kalol plant based stamicarbon CO2 stripping process for energy saving and air pollution abatement. It also discusses the parameters, which needs to be controlled during the operation. It also covers some analytical calculation, which shows the amount of the wasted energy utilized from different stream of urea process and control of air pollution with proper recovery and reuse with the economic viability. For above purpose, the cleaner production and cleaner technology technique is applied to the urea plant which reduces the ammonia losses to atmosphere around 1.1 ton per day. Here the experiment and calculation is carried out for CP/CT tools in different section of urea plant that is synthesis section, CO2 compressor section, low pressure section, evaporation and waste water section and prilling section.. Results show that 28.5 Lakhs /annum of waste energy is utilized from high pressure section offgas which is let down through pressure control valve. The tail gas of HP section is vent to atmosphere containing ammonia and hydrogen gas is used in boiler as fuel which saved around 85.6 lakhs/ annum and also reduces the air pollution. In CO2 compressor section, the interstage heat of CO2 from compressor is thrown into cooling water which can be utilized to heat DM water and process liquid. This scheme will save 1.95 crores/ annum. With help of CP/CT technique , the saving from low pressure section, waste water section comes around 64 lakhs/annum and saving of resource as ammonia is 550 kg/hr. From Prilling tower and prill cooling system the total urea dust generated is around 3.2 Kg/ te of urea produce which is loss of resource as well as air pollution to atmosphere. After use of cleaner technique, the dust generation can be reduced to 1.7 Kg/te of urea production. The total saving may be of the tune of @42.7 lakhs/annum.