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1. Fertilizer industries-
Chapter -6
 6.1 Types of Fertilizer and manufacturing processes.

 6.2 Flow chart and safety aspects of machinery in use.

 6.3 Hazards due to bulk storages, processes, transfer
and transportation of chemicals, dust, noise etc. and
their control measures.

2. Fertilizer industries-
 Fertilizers are natural (manure) or artificial
:-
 Artificial fertilizers are produced in
chemical plants and they may be organic or
inorganic, nitrogenous, phosphatic, potash
and trace element fertilizers.
 (Fluorine compounds, H2SO4, NO, HCI,
CO and NH3 gases

3.  How are Fertilizers made in industry?
 When ammonia is used as the nitrogen source in
a fertilizer, one method of synthetic production
requires the use of natural gas and air.
 The phosphorus component is made using sulfur,
coal, and phosphate rock.
 The potassium source comes from potassium chloride,
a primary component of potash.

Fertilizer industries-

4. .
 How urea fertilizer is manufactured?
 Urea was first produced industrially by the hydration
of calcium cyanamide but the easy availability of
ammonia led to the development of ammonia/carbon
dioxide technology. This is a two step process where
the ammonia and carbon dioxide react to form
ammonium carbamate which is then dehydrated
to urea.


5. .
 1. Ammonia pumping:-- Liquid ammonia is pumped from
the multistage pump which maintains the reaction
pressure in the vertical stainless steel vessel

2. Carbon dioxide compression:- ammonia plant directly
boost the carbon dioxide from the compression section as it
readily forms at the CO2 section of the ammonia
production plant.

3. Urea synthesis tower:-- It is lined with a film of oxides to
protect from corrosion. Catalyst bed is placed on the inner
side of the autoclave structure and 180- 200 atm pressure at
a temperature about 180-200 deg centigrade is maintained.
Plug flow operation takes places and molten urea is
removed from the top of the tower.

6. .
 4. Distillation tower and Flash drum: This high-pressure
slurry is flashed to pressure and distilled to remove excess
ammonia and decomposed ammonia carbamate salts are
removed and recycled.

5. Vacuum Evaporator: The solution is fed to vacuum
evaporator for concentrating the slurry.

6. Prilling Tower: It is dryer where the molten slurry is
passed from the top of the tower into a bucket which
rotates and sprinkles the slurry and air is passed from the
bottom. All the moisture is removed as the urea form into
granules during its journey to the bottom of the tower.
These granules are sent by conveyor to the bagging section.


7. UREA -FERTILIZER

8. .
 Now we enjoy video of manufacturing process of urea
Fertilizer

9. Fertilizer Industry
The fertilizer industry deals with some chemicals which
are hazardous and injurious to health if proper
precautions are not taken.
The hazardous chemicals are handled and transported
in a closed system thereby
minimizing the exposure of an individual.
However the following are the sources of health hazard
in any fertilizer industry

10. Fertilizer Industry
 Chemical which is handled stored and
transported by fertilizer industry :-
- Ammonia
-Urea dust
- Oxides of sulphur and nitrogen
-Other chemicals
Particular matter other than urea dust.
The feed stock for the production of nitrogeneous
fertilizer is Natural Gas, Naptha, Fuel Oil and Coal.
Ammonia is an intermediate product in the
production of urea

11. Fertilizer Industry
Characteristics of ammonia and its effect on
personnel:-
(1) The pungent order of ammonia gives advance warning
when released to atmosphere. Concentration as low as 5 to
10 ppm can be perceived by some persons.
(2) The ammonia vapour is lighter than air and will move
up and dissipate.
(3) It is extremely hard to ignite and under normal
conditions it is very stable compound.
(4) Flammable limits at atmospheric pressure are 16% -25%
by volume in air.
(5) Ammonia is highly soluble in water.

12. Fertilizer Industry

Protective measures:
The various protective measures taken against effect of
liquid and vapour ammonia on personnel working in
the plant are illustrated below:

13. Protective measures:-
 (1) Eye protection:-
 Goggles are worn while
working in areas where leak
may occur from pump glands,
seals etc.

14. Protective measures:-
 (2) Head protection:-
Hard hats/ Halmet are
worn even though there
is no danger from falling
objects. They will offer
protection from liquid
splash if any.

15. Protective measures:-
 (3) Foot protection:-
 PVC or rubber boots give
complete foot protection
against liquid ammonia

16. Protective measures:-
 (4) Full body protection-
 Depending up on the
degree of hazard and
nature of exposure PVC
combination suit
comprising of full sleeve
coat, trousers, hood
gives complete body
protection.

17. Protective measures:-
 (5) Respiratory protection:-
Exposure to ammonia may occur during
decontamination of area after spillages or due to
failure of the equipment.

18. are used.
 - Ammonia gas mask:-
 These masks give
protection up to three
percent ammonia
concentration in the
environment. These are
not suitable in oxygen
deficient atmosphere. The
gas masks have been
provided in all control
rooms and other storage
areas

19. Protective measures:-
 -Plus pressure suit for Air
Fed Mask:- These masks
are connected with the
plant air supply line and
keep the wearer under
positive air pressure. The
air supply should be free
from oil or water vapours.
However the mobility of
the wearer is restricted
because of limited length
of air line hose.

20. Protective measures:-
- Self contained breathing
apparatus:-
- The set allows the wearer
to carry a supply of normal
air cylinder on his back
and does not
restrict his mobility.
However the limitation is
imposed by the air cylinder
which is to be replaced
after every half an hour.

21. Protective measures:-
 First Aid:-
After severe exposure to
ammonia gas or liquid, it
is important to move the
victim from the
contaminated area
promptly. Speed is
important

22. Safety measure after Ammoina
leakage
 We first see one video

23. . -- Contact with the skin : -
 Flushing with large quantities of water should be
continued for at least 15 minutes.
 Contaminated clothing should be removed. Ointment,
oil or solution application on the burns is prohibited as
it prevents the neutralizing effect of the water.
Subsequent treatment is the same as for thermal
burns.
 Contact with the eyes:
 Eyes that have been contacted with ammonia will close
involuntarily and must be forced open to be flushed
with copious quantities of water. Failure to irritate eyes
contacted by ammonia can result in serious and
irreparable damage.

24. .
 - Taken Internally (Swallowing): The victim is to be
given plenty of water if the patient is conscious. Do not
induce vomiting if the patient is in shock, extreme
pain or unconscious. If vomiting begins, keep the
patient's face downwards, head lower than the hips, as
this prevents vomiting entering the lungs and causing
further injury.
-- Inhalation: Exposed persons should be removed to
fresh air immediately. No treatment is required for low
concentrations except this.

25. .
 Severe exposure to high concentrations requires
Oxygen administration by authorized persons or a
doctor. If respiration has
stopped, apply an effective method of artificial
respiration
 The patient should be kept comfortable warm and get
him to a physician.
 Remember: The right aid is the best aid. The wrong aid
can do more harm than good.

26. .
 Urea dust:-
Besides ammonia, urea dust is another health hazard.
 Dust extraction systems are installed at Bagging and
Material Handling unit to keep the
operating and surrounding areas free of urea dust.
Further improvement of the environment, a prill
cooler unit is being installed so that prills at a lower
temperature can be transferred resulting in a further
curtailment of urea dust.
The dust extracted is recycled back into the systems
after dilution.

27. .
 The concentration of urea dust measured at various
places is less than 200 mg/Nm only.
Oxides of sulphur and nitrogen:-

In order to improve the quality of air and there by
reducing the health hazard of the people working
around the plant, boiler stack emissions are brought
down well below the limits set by the Pollution
Control Board.


28. .
 The firing media for boiler is changed over from fuel
oil to efficient boiler operation resulted in the
reduction of air borne contaminants. The
concentration of sulphur dioxide and oxides of
Nitrogen is only 13 ppm and 0.02 ppm as against
permissible limits of 100 ppm and 50 ppm respectively

29. .
 Other Chemicals:-
The other chemicals handled by the fertilizer unit are
Hydrochloric acid, sulphuric acid for maintaining
quality of Boiler feed water, effluent water.
 Monthly requirement is given to the supplier and
supplies are made in such a way that minimum
inventories are maintained. This planning has
eliminated the possibility of maintaining high levels of
inventory of the hazardous chemicals

30. .
 Pressure unloading of Hydrochloric and sulphuric acid
tankers is strictly prohibited.
 A sample from the tanker is taken, analysed and then
only unloading operations are carried out. This
procedure is strictly followed
so as to eliminate accidental unloading of another
product into the HCL tanks.
 Unloading is done by the pump installed at site.
 Scrubbers have been provided for fumes coming out
from the vent and breather lines.

31. .
 Safety shower and eye wash fountains are provided
nearby so as to flush, the affected area in case of
accidental contact with the acid.

Particulate matter other than urea dust:
Emission of particulate matter depends upon the type
of feed and fuel used in the manufacture of fertilizer
and source of fuel in the furnace
respectively. Gas can be used for burning in the boiler
and naphtha can be used as a fuel in reformer. The
complete system is fully controlled

32. .
 No particulate emission from boiler as well as reformer
chimney. Such a control has enabled around 89%
boiler efficiency.

The good housing measures and the greenery-
gardening maintained inside the plant has further
helped in maintaining the particulate matter level
within the limits fixed by State Pollution Control
Board.

33. .
The end