Prem Baboo - Academia.edu (original) (raw)

Papers by Prem Baboo

Global Scintific Joirnal(GSJ), 2021

Prilling and Granulation are finishing sections of urea production process. Prilling is defined a... more 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 prilling tower. The paper intended how the mathematical hydrodynamics, heat, and mass transfer between the urea and the cooling air are developed in natural prilling tower. The height of the prilling tower is about 80 meter to 140 meter according to plant load and weather condition. Granules are larger, harder and more resistant to moisture as compare with prills urea. The aim of this study is to build a mathematical model for a prilling process at in National fertilizers Ltd, Vijaipur (Guna (M.P.). with productivity of 3500 tons/ day, located in India with a schematic diagram shown in Fig. 1. A numerical technique is used to solve the mathematical model in order to calculate the following parameters within the prilling tower.

Global Scintific Journal(GSJ), 2021

Materials plays very important role in any industry. Selection of material is vital at design sta... more 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 for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study Material in urea plant in different vessels and equipment design. In Primary reformer numbers of materials are modified such as micro alloy are also used in tubes.

Global Scintific Journal, 2021

In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems w... more 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 Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. 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 duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.

Global Science Journal, 2021

In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems w... more 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 Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. 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 duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.

This article entails the chronic problem of Fertilizer Industry regarding leakage in Urea Strippe... more 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 incidents in chemical Industry.On dated 19/01/2018 at 05.30 hrs. Suddenly 31 stream urea stripper got heavy leakage and carbamate came out through pressure safety valve in shell side of heat exchanger (stripper). A rupture in old plug of the tube of a high pressure caused leakage of high pressure urea solution and ammonium carbamate to the atmosphere which results to emergency shutdown and losses in production for three days. Leakage was so big that Shell became pressurized up to PSV setting value i.e. 26.0 bar. Immediately shut down was taken to control the situation. The intent of this article is to highlight the issues faced in identification of Urea Stripper leakage during plant operation and rectification of the problems.

The paper intended to enhancement of energy and product quality by installing Vortex mixture in u... more 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 percentage conversion calculated how much carbon dioxide converted to urea. The ammonia is excess reactant. For enhancement of conversion different process technique are used e.g. high efficiency trays etc. The Vortex mixture also the same function like CSTR. Efficiency enhancement of the synthesis section not only improves process parameters, but also increases final product output. The contact surface is increased by 1.5-2.0 times compared to conventional mixing arrangements. Efficient operation of synthesis section greatly depends on the amount of ammonia and Carbon Dioxide recycle. The worldwide Russian company M/S. NIIK is supplied the Vortex mixture at reasonable cost. The energy saving reported 0.03 to 0.08 G.cal. /ton of Urea as depends upon plant capacity and process.

The paper intended a case study of pollution control through prilling tower and other equipment, ... more 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 natural prilling tower. The height of the prilling tower is about 80 meter to 110 meter according to plant load and weather condition. The formation of biuret & triuret is the loss of ammonia is the source of pollution in this process.The prilling tower is the source of pollution in form of dust and ammonia and that can be control by simple technic also energy saving in terms of ammonia saving, ammonia is the harmful pollutant if you vent and useful product if you recovers. The company developed many techniques to reduced pollution after establishment of these modifications and techniques, prilling tower emission are safer than the local environment requirements and company were received many environmental awards.

Coating particles or granules of urea with sulphur and a sealant results in the formation of a me... more 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 water pollution, compared with water soluble fast-release urea. Sulphur Coated Urea Avoid soil compaction; reduce frequency of application and reducing total cost; effectively reduce salt index, improving quality of crops; sulphur is a middle element, to provide nutrition for crops. As a hi-tech controlled/slow release fertilizer, Sulphur coated urea (SCU) has both effects of nitrogen and sulphur fertilizers.

In order to achieve optimum conversion in synthesis convertor, it is necessary to purge a certai... more 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 the purge stream. Moreover it has a serious adverse effect on the environment.This purge gas containing about 60% Hydrogen was fully utilised as primary reformer fuel. The recovered hydrogen is sent back to the synthesis loop to increase production or save energy, as the quantity of hydrogen produced by steam reforming can be reduced.

The electrostatic oil cleaner is designed and developed to super clean hydraulic oil and other no... more 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 right from simple power pack up to most sophisticated aircraft hydraulic oil system.

This paper describes a process of preparation of neem oil water emulsion & coating of urea in fer... more 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 Supercritical method for extraction of neem oil from kernels.Now a days the main demand of neem oil in fertilizers Industries for coating of Urea and other fertilizers. “Government of India has done away with the cap on neem- coated urea and now it can be produced 100%. It is a win-win situation for both industry and farmers. It has been noted that farmer’s income would increase with the help of neem-coated urea as productivity would increase with less usage of urea.”Consequently the demand of Neem oil drastically increasing. In this paper some description of oil preparation method. Using carbon dioxide: methanol for supercritical fluid extraction is the maximum yield eco friendly process but slightly economical.

In urea plant Medium pressure Inerts gases recover HRU burner in Captive Power Plant. The inserts... more 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 and all downstream Stainless Steel vessel. In the presence of Oxygen there are chances of explosive mixture of Hydrogen and Oxygen in exit of MP section final vent line, to overcome this dangerous situation natural gases are added in the MP section before MP condenser so that the range of explosive can be avoided. These gases Hydrogen & Methane come with carbon Dioxide gas from Ammonia plant, carbon Dioxide about 0.5-0.7 % and Methane about 0.08 to0.1%. But we have seen after implementation of this scheme, frequent leakage was observed from inlet flange as well as heavy erosion was noticed in the inside surface of vapour inlet line and flange. Erosion was noticed from NG injection point and extended downstream up to nozzle flange in elliptical pattern. Material of construction of the process piping is A312 TP -316 L (Cr-18%, Ni-12%, Mo-2.0%, N-0.2%, and C-0.03%) which is compliable as per basic licenser. Hence frequent thinning of the pipe wall nearing injection point is due to sudden expansion of natural gas. In order to minimize pipe wall erosion phenomenon near NG injection point an alternative arrangement of NG injection extending the 1” NG line up to center of the vapour inlet line has been implemented and location of injection also changed as fig.-3.

The paper intended to deposition of wang scaling/deposition & corrosion on turbine blades. How to... more 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 blasting cleaning of the blades.

Density Vs Temperature of Ammonia at constant pressure -32 degree cent to 40 degree cent at const... more Density Vs Temperature of Ammonia at constant pressure -32 degree cent to 40 degree cent at constant pressure 15.72 bar.

This paper intended to the damage of cooling tower of our plant a detail case study of the incide... more 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 collapsed. All the five fans were running after the collapse and were stopped manually. Some of the pictures of Urea Cooling Tower taken after the failure as shown in the main front page and figure No.6.The one side of cooling water collapse with totally return header of urea cooling tower of urea-II , resulted in huge production and financial loss.”What was the reason of failure behind it?” National Fertilizers Limited has reviewed the practices followed in operation and maintenance to avoid any catastrophe in future. Some possible causes behind this collapse, like heavy vibration of return header, water hammering, failure of wooden column, failure of wood due to biological attack, failure of structure due to non-conformity standard, shifting of support column from RCC support, etc. Previously the return header was placed on deck. “Later it has been modified & down to ground floor.” To avoid vibration & additional load on deck.

This papaer intended how to remove neem oil from spill neem coated urea, this neem oil creates pr... more This papaer intended how to remove neem oil from spill neem coated urea, this neem oil creates problem in Heat exchangers and foaming problem in distillation tower,The neem oil removing description by Activated carbon Filter adsorption.

This paper intended to damaged of ammonical waste atmospheric Tank in Urea Plant due to Vacuum wa... more This paper intended to damaged of ammonical waste atmospheric Tank in Urea Plant due to Vacuum was created inside the vessel.A case study, What was the reason behind this accident and modification done for future.Brief description of Pressure Vessel and its Classification.

This Paper intended to brief description of Ammonia & Urea Plant Process description and recently... more This Paper intended to brief description of Ammonia & Urea Plant Process description and recently energy saving Scheme.Minor modification resulted High Production & Energy saving.Installation of S-50 along with S-200 converter. Benfiel section changed into GV section in line-I plant and in Urea Plant Pre concentration with Pre decomposer installation.CO2 Compressor modification etc.

This article describes the failure of second bed outlet pipe in Synthesis converter, problem asso... more 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 strengthening in design by Haldor Topsoe these are expected to perform well. Converter basket repair was completed in 25 days and catalysts carry over successfully arrested thereafter.

This paper intended how to more beneficial Neem coated urea than ordinary urea, there is a lot of... more 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 feed in with nipple rather than glass. The oil coating of Neem in Neem coated urea mixes up slowly with the land and the crops soaks it according to the need

Global Scintific Joirnal(GSJ), 2021

Prilling and Granulation are finishing sections of urea production process. Prilling is defined a... more 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 prilling tower. The paper intended how the mathematical hydrodynamics, heat, and mass transfer between the urea and the cooling air are developed in natural prilling tower. The height of the prilling tower is about 80 meter to 140 meter according to plant load and weather condition. Granules are larger, harder and more resistant to moisture as compare with prills urea. The aim of this study is to build a mathematical model for a prilling process at in National fertilizers Ltd, Vijaipur (Guna (M.P.). with productivity of 3500 tons/ day, located in India with a schematic diagram shown in Fig. 1. A numerical technique is used to solve the mathematical model in order to calculate the following parameters within the prilling tower.

Global Scintific Journal(GSJ), 2021

Materials plays very important role in any industry. Selection of material is vital at design sta... more 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 for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study Material in urea plant in different vessels and equipment design. In Primary reformer numbers of materials are modified such as micro alloy are also used in tubes.

Global Scintific Journal, 2021

In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems w... more 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 Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. 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 duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.

Global Science Journal, 2021

In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems w... more 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 Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. 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 duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.

This article entails the chronic problem of Fertilizer Industry regarding leakage in Urea Strippe... more 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 incidents in chemical Industry.On dated 19/01/2018 at 05.30 hrs. Suddenly 31 stream urea stripper got heavy leakage and carbamate came out through pressure safety valve in shell side of heat exchanger (stripper). A rupture in old plug of the tube of a high pressure caused leakage of high pressure urea solution and ammonium carbamate to the atmosphere which results to emergency shutdown and losses in production for three days. Leakage was so big that Shell became pressurized up to PSV setting value i.e. 26.0 bar. Immediately shut down was taken to control the situation. The intent of this article is to highlight the issues faced in identification of Urea Stripper leakage during plant operation and rectification of the problems.

The paper intended to enhancement of energy and product quality by installing Vortex mixture in u... more 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 percentage conversion calculated how much carbon dioxide converted to urea. The ammonia is excess reactant. For enhancement of conversion different process technique are used e.g. high efficiency trays etc. The Vortex mixture also the same function like CSTR. Efficiency enhancement of the synthesis section not only improves process parameters, but also increases final product output. The contact surface is increased by 1.5-2.0 times compared to conventional mixing arrangements. Efficient operation of synthesis section greatly depends on the amount of ammonia and Carbon Dioxide recycle. The worldwide Russian company M/S. NIIK is supplied the Vortex mixture at reasonable cost. The energy saving reported 0.03 to 0.08 G.cal. /ton of Urea as depends upon plant capacity and process.

The paper intended a case study of pollution control through prilling tower and other equipment, ... more 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 natural prilling tower. The height of the prilling tower is about 80 meter to 110 meter according to plant load and weather condition. The formation of biuret & triuret is the loss of ammonia is the source of pollution in this process.The prilling tower is the source of pollution in form of dust and ammonia and that can be control by simple technic also energy saving in terms of ammonia saving, ammonia is the harmful pollutant if you vent and useful product if you recovers. The company developed many techniques to reduced pollution after establishment of these modifications and techniques, prilling tower emission are safer than the local environment requirements and company were received many environmental awards.

Coating particles or granules of urea with sulphur and a sealant results in the formation of a me... more 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 water pollution, compared with water soluble fast-release urea. Sulphur Coated Urea Avoid soil compaction; reduce frequency of application and reducing total cost; effectively reduce salt index, improving quality of crops; sulphur is a middle element, to provide nutrition for crops. As a hi-tech controlled/slow release fertilizer, Sulphur coated urea (SCU) has both effects of nitrogen and sulphur fertilizers.

In order to achieve optimum conversion in synthesis convertor, it is necessary to purge a certai... more 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 the purge stream. Moreover it has a serious adverse effect on the environment.This purge gas containing about 60% Hydrogen was fully utilised as primary reformer fuel. The recovered hydrogen is sent back to the synthesis loop to increase production or save energy, as the quantity of hydrogen produced by steam reforming can be reduced.

The electrostatic oil cleaner is designed and developed to super clean hydraulic oil and other no... more 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 right from simple power pack up to most sophisticated aircraft hydraulic oil system.

This paper describes a process of preparation of neem oil water emulsion & coating of urea in fer... more 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 Supercritical method for extraction of neem oil from kernels.Now a days the main demand of neem oil in fertilizers Industries for coating of Urea and other fertilizers. “Government of India has done away with the cap on neem- coated urea and now it can be produced 100%. It is a win-win situation for both industry and farmers. It has been noted that farmer’s income would increase with the help of neem-coated urea as productivity would increase with less usage of urea.”Consequently the demand of Neem oil drastically increasing. In this paper some description of oil preparation method. Using carbon dioxide: methanol for supercritical fluid extraction is the maximum yield eco friendly process but slightly economical.

In urea plant Medium pressure Inerts gases recover HRU burner in Captive Power Plant. The inserts... more 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 and all downstream Stainless Steel vessel. In the presence of Oxygen there are chances of explosive mixture of Hydrogen and Oxygen in exit of MP section final vent line, to overcome this dangerous situation natural gases are added in the MP section before MP condenser so that the range of explosive can be avoided. These gases Hydrogen & Methane come with carbon Dioxide gas from Ammonia plant, carbon Dioxide about 0.5-0.7 % and Methane about 0.08 to0.1%. But we have seen after implementation of this scheme, frequent leakage was observed from inlet flange as well as heavy erosion was noticed in the inside surface of vapour inlet line and flange. Erosion was noticed from NG injection point and extended downstream up to nozzle flange in elliptical pattern. Material of construction of the process piping is A312 TP -316 L (Cr-18%, Ni-12%, Mo-2.0%, N-0.2%, and C-0.03%) which is compliable as per basic licenser. Hence frequent thinning of the pipe wall nearing injection point is due to sudden expansion of natural gas. In order to minimize pipe wall erosion phenomenon near NG injection point an alternative arrangement of NG injection extending the 1” NG line up to center of the vapour inlet line has been implemented and location of injection also changed as fig.-3.

The paper intended to deposition of wang scaling/deposition & corrosion on turbine blades. How to... more 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 blasting cleaning of the blades.

Density Vs Temperature of Ammonia at constant pressure -32 degree cent to 40 degree cent at const... more Density Vs Temperature of Ammonia at constant pressure -32 degree cent to 40 degree cent at constant pressure 15.72 bar.

This paper intended to the damage of cooling tower of our plant a detail case study of the incide... more 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 collapsed. All the five fans were running after the collapse and were stopped manually. Some of the pictures of Urea Cooling Tower taken after the failure as shown in the main front page and figure No.6.The one side of cooling water collapse with totally return header of urea cooling tower of urea-II , resulted in huge production and financial loss.”What was the reason of failure behind it?” National Fertilizers Limited has reviewed the practices followed in operation and maintenance to avoid any catastrophe in future. Some possible causes behind this collapse, like heavy vibration of return header, water hammering, failure of wooden column, failure of wood due to biological attack, failure of structure due to non-conformity standard, shifting of support column from RCC support, etc. Previously the return header was placed on deck. “Later it has been modified & down to ground floor.” To avoid vibration & additional load on deck.

This papaer intended how to remove neem oil from spill neem coated urea, this neem oil creates pr... more This papaer intended how to remove neem oil from spill neem coated urea, this neem oil creates problem in Heat exchangers and foaming problem in distillation tower,The neem oil removing description by Activated carbon Filter adsorption.

This paper intended to damaged of ammonical waste atmospheric Tank in Urea Plant due to Vacuum wa... more This paper intended to damaged of ammonical waste atmospheric Tank in Urea Plant due to Vacuum was created inside the vessel.A case study, What was the reason behind this accident and modification done for future.Brief description of Pressure Vessel and its Classification.

This Paper intended to brief description of Ammonia & Urea Plant Process description and recently... more This Paper intended to brief description of Ammonia & Urea Plant Process description and recently energy saving Scheme.Minor modification resulted High Production & Energy saving.Installation of S-50 along with S-200 converter. Benfiel section changed into GV section in line-I plant and in Urea Plant Pre concentration with Pre decomposer installation.CO2 Compressor modification etc.

This article describes the failure of second bed outlet pipe in Synthesis converter, problem asso... more 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 strengthening in design by Haldor Topsoe these are expected to perform well. Converter basket repair was completed in 25 days and catalysts carry over successfully arrested thereafter.

This paper intended how to more beneficial Neem coated urea than ordinary urea, there is a lot of... more 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 feed in with nipple rather than glass. The oil coating of Neem in Neem coated urea mixes up slowly with the land and the crops soaks it according to the need

The paper intended to the standpoint of harmful emissions typical nitrogen-based fertilizer plant... more 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 and at the same time enhances the fertilizer value of sewage sludge. It therefore has a large potential of competing with more established methods of sanitization.