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   1 PROJECT REPORT ON 1. Calculation of specific energy of Ammonia 1 plant by considering each equipment separately 2. Calculation of efficiency of all major heat exchangers in Ammonia 1 AT CHAMBAL FERTILISER AND CHEMICALS LIMITED BY BABU LAL KUMAWAT 2011CH70150 INDIAN INSTITUTE OF TECHNOLOGY, DELHI 110016   2 Acknowledgement   Firstly, I would like to express my deepest gratitude to Mr. A.K. Saxena (Manager, HR)  and Mr. Koushik Kumar (Deputy Manager, HR)  for providing me valuable opportunity to pursue my training at Chambal Fertilizer & Chemicals Limited, Gadepan. This training has been a constant learning experience and I look forward to undertake more such stimulating training in the future.   I would like to thank my mentor KK PUNJ  and who assigned me this project and it is solely due to him that I achieved what I achieved. I would never have finished my project without their excellent guidance, caring, patience, and providing me with an excellent atmosphere for learning new things.   Also I am really grateful to Mr. Atul Jain (Documentation)  who provided me with all the technical and plant data manuals I required for my project. I would also like to thank various departmental heads, whose names I can’t encapsulate in one breadth of space, for their support and guidance. Also I really appreciate the staff of the Gadepan 1 and 2 plants who were directly or indirectly involved in making this training program a success and who gave me the chance to develop my project in detail.   I would also like to thank my Instructor Dr. Munawar shaik  for providing me valuable guidance and constant encouragement in making this project report. He has been very accommodating throughout and ensured my welfare at every point of time.   In project part I learnt many things and experience many things. So this is very great for me. I will take back a lot of knowledge, hands - on experience and a glimpse of industry environment with me, which will help me in developing my selves in good professional.   Date: July 18, 2014   Thank you   Place: Gadepan, Kota *Rajasthan+     3 Abstract   Chemical process technology is widely used in almost all chemical industries for basic designing and simulation of a process. For designing & operation purpose companies uses some or other simulation software. In this project I used Aspen Plus as my simulation software for purpose of calculating the specific energy consumption in Ammonia production plant. Simulating a process after inserting required data into the chosen model will give me the results. These results are helpful in comparing the theoretical values with the actual values, this will give me the deviation of actual data from theoretical data. In this manner I can operate the plant at certain values which will give the optimum operating conditions Energy Requirement of the plant can be calculated theoretically by using the simulation software. Aspen plus chooses a thermodynamic model which will give me the best results in certain range of temperature, pressure and other properties that are required to run the process model.   A heat exchanger  is a piece of equipment built for efficient heat transfer from one medium to another. They are also used to minimize the heat lost to the atmosphere by recovering some of the heat contained in process discharge streams. Other heat exchangers are used to recover the heat contained in a process stream recycled from a late stage in the process and use it to preheat a stream entering an earlier stage in the process.   In industry complicated problems are often not solved by hand for two reasons: human error and time constraints. Thus, Chemical engineers use process simulation to perform a variety of important work. This work ranges from calculations of mass and energy balances of large flow - sheets to predict the performance of process alternatives that can save millions of dollars. All unit operation models need property calculations to generate results.   When building a simulation, it is important to ensure that the properties of pure components and mixtures are being estimated appropriately. In fact, selecting the proper method for estimating properties is one of the most important steps that will affect the   4 rest of the simulation. Therefore, it is important to carefully consider my choice of methods to estimate the different properties.   1. Introduction   1.1 About the company   Chambal Fertilizers and Chemicals Limited is one of the largest private sector fertilizer producers in India. It was promoted by Zuari Industries Limited in the year 1985. Its two hi - tech nitrogenous fertilizer (urea) plants are located at Gadepan in Kota district of Rajasthan. Built at a price of over Rs. 25 billion (USD 500 million), the two plants produce about 2 million tons of Urea per annum. The first plant was commissioned in 1993 and second plant in 1999. These plants use state - of  - the - art technology including that from Denmark, Italy, United States and Japan.   The company is a flagship company of Dr K.K. Birla group involved in the business of producing high quality urea. With huge manpower strength of around 850, the company produces urea under the brand name Uttam Veer Urea”. The company is divided into two sections -  Gadepan -  I and Gadepan – II. Each plant is further divided into Ammonia and urea plants. The technology in various plants of CFCL is as follows:   Ammonia 1: Haldor Topsoe, Denmark   Urea 1: Snamprogetti, Italy   Ammonia 2: Kellogg, Brown and Root (KBR), USA   Urea 2: Toyo Engineering Corporation, Japan   Natural gas /naphtha are used to run steam and power generation plants. The ammonia plant capacity was 1560 MTPD for each of the plants which has now increased after the implementation of Revamp project in Mar -  April 2009. The urea 1 plant capacity is up to 3400 MTPD and urea 2 plant capacity is up to 3100 MTPD. The total power consumption is 20 MW. The average De -  

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