Indian Aluminium Company Limited, Alupuram Smelter Eloor.

More documents

Recommendations

Info

82 11 Free Ammonia Nil Nil Nil Nil Nil 12 Ammoniacal Nitrogen 0.44 ND ND ND 0.6 13 Hexavalent Chromium ND ND ND ND ND 14 Total Chromium ND ND ND ND ND 15 Oil&Grease ND ND ND ND ND FACT, UYOGMANDAL. DIVISION Name of Industry :FACT, Uyogmandal. Division Date of inspection :01/06/05,08/07/05,30/07/05 23/08/05,24/08/05 Raw material :Naphtha 673 t/day :Rock Phosphate :Furnace oil Sulphur 325 t/day 135 t/day 194 t/day Products : Sulphuric Acid - 600t/day Sulphuric acid and 550tonnes/day combined capacity SO 2 /acid : Ammonia -900t/day : Phosphoric acid -100t/day : Ammonium Sulphate -682t/day : Ammonium Phosphate - 450 t/day : Carbon dioxide -1007t/day : Gypsum - 500 t/day Production Process: 1.Sulphuric Acid. The process consists of Sulphur melting, Combustion of sulphur-to-sulphur dioxide, Catalytic conversion of sulphur dioxide to get sulphur trioxide, Intermediate absorption of Sulphur tri oxide in concentrated Sulphuric acid to produce Sulphuric Acid, Final conversion of unreacted Sulphur dioxide to Sulphur trioxide and final absorption of Sulphur trioxide in concentrated Sulphuric Acid. The converter consists of four beds of vanadium pentoxide catalyst. The gas from the furnace after passing through the waste heat boilers enters the first bed at 430 o C.In the first layer about 57% of SO 2 is converted and the gas leaving the first bed is cooled from 594 o C to 440 o C in the waste heat boiler, and then enters the second bed where the conversion reaches 85% and the temperature raises to 520 o C which is brought down to 450 o C in Intermediate
83 Heat Exchangers. The gas then goes to 3 rd bed where conversion reaches 94% and temperature to 475 o C.The gas goes to the final heat exchanger and then to the Intermediate Absorption Tower where SO 3 is absorbed and gas leaving the absorber at 65 o C enters the fourth bed at 420 o C after passing through the Final Heat Exchanger and then the Intermediate Heat Exchanger. The conversion reaches 99.5% and temperature 445 o C.The gas then goes to the final absorption tower through an economizer where the temp is brought down to 180 o C.Gas from the final absorption tower is released to the atmosphere through the stack. Process water is admitted to the tower bottom to maintain the acid concentration at 98.4%. The acid drawn off from the final absorber is cooled to 40 o C and stored. 2.Ammonia Process involved in the production of ammonia are : a. Predesulphurisation of the raw naphtha. The bulk part of sulphur is removed in this section. b. Final desulphurisation of the hydrocarbon feed in one step: Removal of remaining sulphur compounds. c. Reforming of the desulphurised hydrocarbon feed in two steps by steam and air. The process gas from these steps contains hydrogen and nitrogen as well as carbon monoxide (CO), carbon dioxide (CO 2 ), methane and argone. The reforming takes place at pressure of about 35kg/cm 2 d. In the gas purification section, CO is first converted to CO 2 and H 2 yield. CO2 is then removed in the CO 2 -removal section, and afterwards the remaining CO and CO 2 in the converted gas are removed in the methanator. e. The purified synthesis gas is compressed to a pressure of about 135kg/cm 2 and converted into ammonia by a catalytic reaction. f. The plant is designed to a nominal production of 900 MTPD ammonia and 10,800 Nm3/H of synthesis gas. The ammonia produced in the plant is sent to the caprolactam plant and to atmospheric storage. Synthesis gas is consumed in the caprolactam plant as well, and in combination with part of the CO 2 produced. 3.Phosphoric Acid Phosphoric acid is manufactured by wet process by the reaction of rock phosphate with sulphuric acid. The principal steps in the production of Phosphoric acid by this method are the following: Grinding of rock phosphate, Reaction of the ground rock with sulphuric acid, and Separation of phosphoric acid from the gypsum. (a) Grinding of rock phosphate: The phosphate rock is ground dry in mills after drying if necessary. There are three grinding mills with a total capacity of 40 tonnes/hr of ground ore. The rock is ground so that 95 per cent will pass through a 100-mesh screen. (b) Reaction of rock phosphate and sulphuric acid: The main aim of this step is to get the rock reacted with sulphuric acid in such a manner as to (1) produce the highest possible concentration of phosphoric acid, (2) give good coarse gypsum crystals which could be easily filtered and washed with minimum of water to give a washed gypsum almost free of soluble phosphoric acid and (3) give the maximum yield of P 2 O5 from the rock.
Page 1 and 2: 77 INDIAN ALUMINIUM COMPANY LIMITED
Page 3 and 4: 79 8. The industrial plant was not
Page 5: 81 5. Industry has obtained consent
Page 9 and 10: 85 1. Concentration and crystalliza
Page 11 and 12: 87 Petro chemical Division is conce
Page 13 and 14: 89 7. The scrubber stack for IVth a
Page 15: 91 the faulty nature of manual anal
Page 18 and 19: 94 Source : FACT - UD Date of sampl
Page 20 and 21: 96 FACT- PETROCHEMICAL DIVISION Nam
Page 22 and 23: 98 scrubbing with ammonia water whe
Page 24 and 25: 100 5. Delay ponds shall be provide
Page 26 and 27: 102 Products : Rare Earths Chloride
Page 28 and 29: 104 recovered. Ammonium di uranate
Page 30 and 31: 106 M/S KEMO GRAVURES , EDAYAR Name
Page 32 and 33: 108 Raw materials : Name Quantity (
Page 34 and 35: 110 The Effluent treatment system c
Page 36 and 37: 112 Date of Sampling 08/06/05. Sl.
Page 38 and 39: 114 Waste: Sources of liquid waste
Page 40 and 41: 116 Date of Sampling 29-11-04 N o D
Page 42 and 43: 118 Raw Materials: Name of material
Page 44 and 45: 120 Findings 1. The factory situate
Page 46 and 47: 122 Consented Parameters and limits
Page 48: 124 Source : Sud Chemie India Pvt.

Indian Aluminium Company Limited, Alupuram Smelter Eloor.

Create successful ePaper yourself

Delete template?

Save as template?