13-09-2012, 12:49 PM
FERTILISERS & CHEMICALS TRAVANCORE LTD (FACT), UDYOGAMANDAL
FACT.docx (Size: 70.48 KB / Downloads: 65)
SAFETY
• Always wear helmet and other safety equipment.
• Inform the employees in the case of an accident.
• In case of gas leakage, move away from the wind stream by moving perpendicular to the direction of wind socks.
• During acid spills, wash thoroughly using water provided at showers.
• In the case of ammonia leakage, cover the face with damp cloth and drink butter milk.
• Heinrich's Law: that in a workplace, for every accident that causes a major injury, there are 29 accidents that cause minor injuries and 300 accidents that cause no injuries.
HABERS PROCESS
a. PRIMARY DESULPHURIZATION (PDS)
Hydrogenation and stripping are the primary process to remove bulk sulphur present in naphtha. The raw naphtha is passed through Deaerater to remove oxygen content. Heat exchanger in series increases the temperature of naphtha from 38 to 380 Celsius. Sulphur present is made to react with hydrogen and form hydrogen sulphide at Hydrogenator. The sulphur content is reduced to 1 to 10 ppm.
b. FINAL DESULPHURIZAION (FDS)
This process is carried out after primary desulphurization process in order to reduce the sulphur content below 0.01 ppm. Here a zinc oxide bed is used as the catalyst, which converts hydrogen sulphide to zinc sulphide.
c. REFORMER
Here the desulphurized naphtha is cracked in a furnace. The naphtha at 493 Celsius is passed through nickel tubes to produce hydrogen gas. To this nitrogen from air is added at 35 bar pressure to produce synthesis gas.
d. SHIFT CONVERTER
Here the carbon monoxide formed by reforming is oxidised to carbon dioxide.
e. CARBON DIOXIDE REMOVER
The carbon dioxide is then removed either by absorption in aqueous ethanolamine solutions or by adsorption in pressure swing adsorbers (PSA) using proprietary solid adsorption media.
f. METHANATOR
The final step in producing the hydrogen is to use catalytic methanation to remove any small residual amounts of carbon monoxide or carbon dioxide from the hydrogen by converting to methane by using nickel as the catalyst.