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VOCATIONAL TRAINING REPORT

of

Gujarat Narmada Valley Fertilizers and Chemicals Limited

Bharuch Plant

Duration
23rd May,2016 to 18th June,2016

Prepared by:

Modi Ankitkumar Kamleshbhai

Final Year Undergraduate Student,
Chemical Engineering Department.
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ACKNOWLEDGEMENT

It give me pleasure in submitting this training report at the end of the training period
from 23/05/2016 to 18/06/2016 at GNFC, Bharuch. This training report is prepared not only by
a solo effort. A great deal of effort and time has been involved in preparing training report.
Many people are involved in it directly or indirectly. It is my sincere desire to express heedful
thanks for their guidance and support.

I would like to express my sincere gratitude to Mr. I. P. Bhatt (Chief Manager),

Mr. V. C. Shah (Senior Manager), Mr. H. K. Parekh (Training Officer) and
Mr. A. M. Dalwadi(Chief Manager of Methanol-2 Plant) to give me this opportunity for better
Industrial knowledge. I would also like to thank all the Shift Engineers, Plant & Panel
Operators For their kind Guidance.

Last but not the least I would like to thank Dr. B.R. Sengupta (HOD of Chemical
Engineering Department, Faculty of Technology And Engineering, The M.S. University of
Baroda, Vadodara ) for providing me with immense support and encouragement to undergo the
training.

Ankitkumar K. Modi
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INDEX

No Topic Page
. No.
1 Company Profile 4

2 Introduction of Methanol 9

3 Manufacturing Process of Methanol 14

4 Condensate System of Methanol 25

5 Utility Section 27

6 Conclusion 32
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Chapter:-1

Company
Profile

1) Mission Statement
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We shall be the leading providers of the Chemicals and Agricultural inputs through adoption of
the Art Technologies and Business Processes;
1]Have a firm commitment to qualify, environment, health and safety;
2]Enrich human resources and promote teamwork, innovativeness and integrity.

2) Starting Point
Gujarat Narmada Valley Fertilizer Company Limited (GNFC) was incorporated on 10 th
MAY 1976 as a joint sector company by Government of Gujarat and Gujarat State Fertilizer
Company Limited.
GNFC went to public in 1981 with the largest shareholder base of the time for GNFCs
first project, a single-stream Ammonia-Urea plant.
In 1985 onwards, GNFC has been active in major diversification into industrial
chemicals-Methanol, Formic Acid ,Acetic Acid, and Weak Nitric Acid (WNA) ,Concentrated
Nitric Acid(CAN),etc., revamp of expansion of capacities for high demand chemicals like
Methanol, CAN and Acetic Acid consolidation in GNFCs flagship concern, fertilizers with new
plants for Ammonium Nitro phosphate(ANP)And Calcium Ammonium Nitrate (CAN), and a
foray into IT infrastructure.

3) Achievements Benchmark
GNFC has set up the worlds largest single stream, fuel oil based Ammonia- Urea plant.
All fertilizers under the brand name of Narmada, along with extensive support activities,
have been well accepted by the countrys farmer community.
Indias largest producer of Formic Acid, Acetic Acid and Methanol.
Indias only manufacturer of Glacial Acetic Acid through the cutting-edge Methanol
route.
High to record capacity utilizations in all plants, defying the vintage through ingeniously
innovative maintenance measures.
A 50MW captive power plant enhances self-sufficiency of all units.
Development of the first indigenous, eco-friendly technology for H2S removal.
GNFC Info tower is 14000 sq. meter Facility, set up to provide ready to use
infrastructure required by IT companies under one roof.

5) Business area
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Fertilizer: Urea, Ammonium Nitro Phosphate (ANP) and Calcium Ammonium Nitrate
(CAN).
Chemicals: Ammonia, Methanol, Acetic Acid, Formic Acid, Methyl Formate, Weak Nitric
Acid (WNA), Concentrated Nitric Acid (CNA), Aniline, Toluene Di-Isocynate (TDI),
Nitrobenzene (NB).
Imports/Trading: Single Super Phosphate, Muriate of Potash, Urea, Di-Ammonium
Phosphate, Water Soluble Fertilizer, Methanol.

6) Technology Partners

Technology partners with GNFC Ltd. are as given below:

SNAMPROGETTI, ITALY

DU PONT, USA

UHDE, GERMANY

BP CHEMICAL, UK

LINDE AG, GERMANY

TEXACO, USA

BASF, GERMANY

7) Product Profile

NO. PRODUCT CAPACITY

1 AMMONIA 4,45,500 MTPA
2 METHANOL 1,50,000MTPA,
The countrys Largest capacity
3 FORMIC ACID 10,000MTPA,
The countrys Largest capacity

4 ACETIC ACID 1,00,000 MTPA,

The countrys Largest capacity
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5 CONCENTRATED NITRIC ACID 66,000 MTPA,

The countrys Largest product
6 WEAK NITRIC ACID 2,47,500 MTPA
7 UREA 6,36,000 MTPA
8 AMMONIUM NITROPHOSPHATE 1,42,500 MTPA
9 CALCIUM AMMONIUM NITRATE 1,42,500 MTPA

8) Awards

National Safety Council, USA: Good Safety Performance

National Productivity Council: Best Productivity - First, Second & Third Prizes, Best
Productivity for Nitrogenous Fertilizers
Ministry of Labour, GOI: Good Safety Performance (Thrice)
Federation of Indian Chamber of Commerce & Industry (FICCI) : Best
Environment Preservation & Pollution Control
Indian Chemicals Manufacturers Association (ICMA) : Environmental Control &
Safety
Fertilizer Association of India (FAI) : For research paper
Best Technical Innovation - pure CO2 enhancement scheme in Ammonia plant
Best Technical Innovation implemented in fertilizer industry (twice)
Best Overall Performance of an operating unit for P2O5 in complex fertilizers
All India Organization of Employers: Outstanding Contribution in the field of
Industrial Relations

National Energy Conservation Award, Depts. of Energy, Government of India:

Energy Conservation Award, Second Prize
Government of India: Award for Energy Conservation
Jawaharlal Nehru Memorial National Award: Effective Energy Conservation Award
National Suggestion Scheme: Two awards for the company, one for the employee

Indian National Suggestion Scheme (INSAAN) : Prizes in different years (thrice),

Excellence in Suggestion Scheme for the Company, Second Prize to the employee
(twice)
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Texaco Development Corporation (TDC), USA : Licensee of the year for operating
gasifier on more than rated capacity for over a decade
Labour & Employment Depts. Government of Gujarat: Shram Bhushan Award &
Rajya Shram Ratna Award to the employees

Indian Institute of Chemical Engineers (IICE): ICI Award for Excellence in Process
/ Product Development
Dept. of Scientific & Industrial Research, Ministry of Science & Technology, GOI
FICCI: National Award for R&D efforts
World Environment Foundation: Golden Peacock Eco Innovation Award
Fertilizers Association of India: Transfer of Improved Farm Technology Award at the
national level
Corporate Society of India: CSI-Nihilent e-Governance Award for the best
technology implementation for e-Governance projects

Chapter:-2
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Introduction
Of
Methanol

Methanol, also known as methyl alcohol, wood alcohol, wood naphtha or wood
spirits, is a chemical with the formula CH3OH (often abbreviated MeOH). It is the simplest
alcohol and is a light, volatile, colour less, flammable liquid with a distinctive odour very
similar to, but slightly sweeter than ,ethanol (drinking alcohol). At room temperature, it is a
polar and is used as an antifreeze, solvent, fuel.
1)Total capacity & overall capacity in the world
 P a g e | 10

The production capacity of GNFC Methanol-2 plant is 570 MTPD. The

methanol industry spans the entire globe with production in Asia, North and South America ,
Europe, Africa and the Middle East. Worldwide over 90 methanol plants have a combined
capacity of over 100 million metric tonnes, with China producing nearly half of the total. Each
day more than 1 lakh tons of methanol is used a feedstock or as a transportation fuel.

2) Market value

Market value is the price at which the chemical or product would trade in
competitive Market. Methanol has a market price of Rs. 15000-20,000/MT.
3) Uses
The main applications for methanol are the production of formaldehyde (used in
construction and wooden boarding), acetic acid, MTBE (fuel component and
replacement for the very volatile diethyl ether) and more recently for the formation of
methyl esters in the production of bio-diesel. Methanol can also be used to produce
gasoline.
The use of methanol is receiving attention due to its availability, low cost, and
environmental benefits as a motor fuel.
Methanol is a widely used industrial solvent and also finds application as an antifreeze in
pipelines and windshield washer fluid.

Applications of Methanol

1] To make the wood adhesives, plastics, dyes and paints.

2] It is used in petrochemicals.
3] It is used as denaturant for ethyl alcohol.
4] It is used as antifreeze in pipelines.

Chemical Properties:
1] Combustion of Methanol: Methanol burns with a pale-blue, non-luminous flame to form
carbon dioxide and steam.
2CH3OH + 302 ===> 2CO2 + 4H2O

2] Oxidation of Methanol: Methanol is oxidized with acidified Potassium or Sodium

Dichromate K2Cr2O7 or Na2Cr2O7 or Potassium Permanganate, KMnO4 to form formaldehyde.
 P a g e | 11

CH3OH ===> HCHO + H2

If the oxidizing agent is in excess, the formaldehyde is further oxidized to formic acid and then
to carbon dioxide and water.
HCHO ===> HCOOH ===> CO2+ H2O

3] Dehydrogenation of Methanol: Methanol can also be oxidized to formaldehyde by passing

its vapor over copper heated to 300 & this process is termed dehydrogenation.
300C
CH3OH ===> HCHO + H2

4] Dehydration of Methanol: Methanol does not undergo dehydration reactions. Instead, in

reaction with sulphuric acid the ester, di methyl sulphate is formed.
2 CH3OH ===> (CH3)2SO4 + H2O
Methanol Dimethyl Sulphate Water

5] Esterification of Methanol: Methanol reacts with organic acids to form esters.

CH3OH + HCOOH ===> HCOOCH3 + H2O

Methanol Formic Acid Methyl Formate Water

Material Safety Data Sheet

Synonym: Methyl alcohol, Wood alcohol, Carbinol

CAS Number: 67-56-1 Mixture: 100% Weight

[1] SAFETY PRECAUTIONS:

Eye Contact: Rinse immediately with plenty of water, also under the eyelids, for at least 15
minutes. Call a physician immediately.
Skin Contact: Wash off immediately with soap and plenty of water. Take off contaminated
clothing and shoes immediately.Wash contaminated clothing before re-use. Call a physician
immediately.
Inhalation: Move to fresh air in case of accidental inhalation of vapours. If not breathing, give
artificial respiration. If breathing is difficult, give oxygen, provided a qualified operator is
available. Call a physician immediately.
Ingestion: Do Not induce vomiting. Immediate medical attention is required.

[2] FIRE CLASSIFICATION:

Flammability of the Product: Class 1B Flammable Liquid From USHA Flammability Class.
 P a g e | 12

[3] ACCIDENTAL RELEASE MEASURES:

In Case Of Spill OR Other Release,
Containment Procedures: Use personal protective equipment. Ensure adequate ventilation.
Remove all sources of ignition. Stop flow of material, if this is without risk.
Cleanup Procedures: Soak up with inert absorbent material (e.g. sand, silica gel, acid binder,
universal binder, sawdust).Shovel into suitable container for disposal. Do not use sparking
tools. Do not allow product to enter sewer or waterways.
Evacuation Procedures: Keep unnecessary people away. Isolate area. Special Procedures: Use
personal protective equipment. Remove all sources of ignition.

[4] HANDLING AND STORAGE:

Normal Handling: Ensure all equipment is electrically grounded before beginning transfer
operations. Ensure adequate ventilation. Do not allow product to contact skin, eyes and
clothing. Do not breathe vapours.
Storage Recommendations: Keep in a well-ventilated place. Empty containers may retain
product residue including Flammable or Explosive vapours. Do not cut, drill, grind, or weld
near full, partially full, or empty product containers.

[5] PERSONAL PROTECTION:

Skin Protection: Wear impervious gloves and impervious flame retardant antistatic protective
clothing. Gloves must be inspected prior to use. For leak, spills, or other emergency, use full
protective equipment.
Eye Protection: Wear chemical goggles and face shield. Remove contact lenses.
Respiratory Protection: When workers are facing concentrations above the exposure limit
they must use certified respirators.

[6] PHYSICAL AND CHEMICAL PROPERTIES:

Molecular Formula: CH3OH
Boiling Point: 65 deg C
-1
Molecular Weight: 32.04 g mol
Density: 0.7928 g cm-3
IUPAC name: Methanol
Chemical Name : Methyl Alcohol
Melting Point : -98 deg C
Vapour Pressure: 13.02 KPa at 20 deg C
Appearance: colourless Liquid
Odour: Alcoholic Odour
Other name: Hydroxy methane

7] STABILITY AND REACTIVITY:

Stable Conditions: Stable under recommended storage conditions.
Avoid: Heat, flames and sparks. Incompatible products.
Incompatibilities: Avoid oxidizers, plastics, rubber and coatings. May react with metallic
Aland generate Hydrogen.
Hazardous Decomposition Products: Hazardous decomposition products include CO,
formaldehyde and (CO2).
Hazardous Polymerization: Hazardous polymerization does not occur.
 P a g e | 13

[8] TOXICOLOGICAL INFORMATION:

Immediate(Acute) Effects: The product causes irritation of eyes, skin and mucous membranes.
Toxic by inhalation, incontact with skin and if swallowed. Methanol can cause blindness.
Causes headache, drowsiness to the central nervous system.
Deleyed (Subchronic & Chronic) Effects: In human methanol poisoning, the transformation
of methanol to formaldehyde and formic acid can cause metabolic acidosis and ocular injury.
Repeated exposure to airborne concentrations in the range of 200 - 375 ppm have been
associated with headaches, and at 1200 to 8300 ppm with damaged vision and occurs
Neurological damage.
Other Data: This material is not known or reported to be carcinogenic by any reference source
including (NTP = National Toxicology Program; OSHA = Occupational Safety and Health
Administration, IARC = International Agency for Research on Cancer).

[9] ECOLOGICAL INFORMATION:

Prevent from entering sewer or waterway. This material may be slightly toxic to aquatic life.
When released into the soil, water or Air, this material is expected to readily biodegrade.
Methanol is not expected to bio accumulate.
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Chapter:-3

Manufacturing Proces
Of
Methanol
 P a g e | 15

The process description is for the production of 570 MTPD of specified

purified Methanol based on natural gas as feedstock with addition by means of well
established ICI Low Pressure Methanol Technology.

Raw Material Specification: Raw material is the Natural Gas in G.N.F.C. Natural gas is
obtained from GAIL, GSPL and GSPC via pipelines.

(1) Natural gas is obtained from GAIL, GSPL, RLNG and GSPC via pipelines. They
generally have the following compositions.

CH4 = 97.2% vol

Pressure = 3.7 bar

(2) Consumption Pattern: To produce 1 MT of methanol , nearly 0.97 MT of natural gas is

required.

(3) Cost of N.G. is Rs. 13 / kg

Major steps involved in Methanol production:

1] Desulphurization of Natural Gas.

2] Preparation of Methanol Synthesis Gas.
3] Compression and Methanol synthesis.
4] Methanol Distillation.
Supporting Utilities are:
1] Steam System.
2] Methanol storage tank yard facility.
3] Flare system.
4] Electric Power and Emergency Power System.
Basic Engineering
1) Steam Reforming & Methanol Distillation Unit: M/s. Toyo, Japan
2) Methanol Synthesis Unit: M/s. Linde, Germany
 P a g e | 16

Process Block Diagram of Methanol 2 Plant

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1) Desulphurization of Process Natural Gas

The natural gas is divided into the process natural gas and fuel gas. In the process
natural gas enters the Natural Gas K.O. drum, where heavy hydrocarbons are separated out.
The process natural gas is compressed to 26 kg/cm 2g. by the N.G. compressor which is
electric motor driven, one stage, reciprocating machine with the N.G. compressor kick
back cooler. The compressed process natural gas is mixed with recycle hydrogen from the
synthesis loop section, the ratio of which is adjusted to maintain 2 volume% of natural gas.
 P a g e | 18

The compressed process natural gas contains organic S and H2S, which are
poison for the reformer catalyst and synthesis catalyst. These are removed by two steps of
catalytic reactions. The mixture of Natural Gas and recycle hydrogen are heated to about
370 C in the feedstock heater located in the convection section of the reformer and then
enter the desulphurizer to decompose organic Sulphur (S) to Hydrogen Sulphide (H 2S) on
cobalt- molybdenum catalyst as the first step and to remove all Sulphur by reaction with
packed Zinc Oxide , forming Zinc Sulphide as the second step.

The reactions are as under: R 2 S + H2 H2S + R2

H2S + ZnO ZnS + H20

The each catalyst volume in desulphuriser contains 2.24 ton of Ni-Mo catalyst and 7.5
ton of ZnO catalyst. This catalyst volume are selected to provide a nominal 12 months of
service period assuming total Sulphur content of 20 ppm in Natural Gas.

2) Preparation of Methanol Synthesis Gas

The desulphurized process natural gas is mixed with middle pressure steam at a
total steam to carbon ratio of 3.4. The middle pressure steam for mixing are fed at two
injection points, the first is upstream of the MRG heater and the other is upstream of the
Mixed gas heater, which are located in the convection section of the reformer. The mixture
of process gas and steam are heated to 510C at the MRG Heater and heated to 585C at
the mixed gas heater.
The heated mixed gas is distributed to the catalyst filled tubes in the radiant
section of the reformer where it flows downward through the nickel deposited catalyst. The
quantity of catalyst provided in the reformer tubes is about 11.07 TON. The upper half of
reformer tubes filled with (Potash-nickel base catalyst) and lower half are filled with
(Nickel base catalyst) catalyst. The material of reformer tube is 25 % Cr, 33 % Ni and a
small amount of Nb.
A total of 96 catalyst filled tubes are provided in the radiant section arranged in 4
rows. A total of 45 arch burners are provided on the top of the furnace for normal operation
in the radiant section and a total of 4 SSH burner for controlling the high- pressure steam
temperature. Further, 1 burner is provide at upstream of feedstock heater in the convection
section to control the process natural gas temperature. The arch burners are operated with
down-firing using a mixture of fuel natural gas; purge gas and waste gas. The SSH burners
 P a g e | 19

are operated with upward firing using fuel natural gas, waste gas and fusel oil from
Methanol in distillation section.

The reformed gas leaves the catalyst filled tubes at about 19 kg/cm 2g and
8600C and contains about 2.2 vol. % methane on a dry gas basis. Most of the hydrocarbons
in the process natural gas are converted to H2, CO and CO2 by passing through the reformer
catalyst. The reaction is endothermic and the required heat for reforming reaction is
supplied from burner firing. The reactions are as under:

CH4 + H20 CO + 3H2 H = -49.3 Kcal / Kgmol

CO + H20 CO2 + H2 H = 9.8 Kcal / Kgmol
Overall CH4 + 2H20 CO2 + 4H2 H = -39.5 Kcal / Kgmol

The reformer furnace is designed to attain maximum thermal efficiency by

recovering heat from the flue gas at 990C. Waste heat is first recovered by preheating the
process natural gas and steam mixture to 585C in the mixed gas heat. The second coil in
 P a g e | 20

the flue gas waste heat recovery system is the steam super-heater where high-pressure
steam used to drive a steam turbine of the synthesis gas compressor is superheated to
505C. The third coil is the MRG heater which preheats process natural gas and steam
mixture to 510C. Finally the flue gas is vented by the included draft fan through the
chimney stack to atmosphere at 175C.
The reformed gas waste heat recovery train consists of a
series of steps where the reformer gas waste heat is
efficiently recovered from a level of 860C to 85C.
The reformed gas is first cooled from 860C to 401C
in the reformed gas waste heat boiler to generate high-
pressure steam (104.4 kg / cm2 g).
The reformed gas is next cooled to 371C in the
process steam super-heater to superheat the high
pressure steam and cooled to 267C in the
reformed gas economizer to preheat the boiler
feed water. In the final stage of the waste heat
recovery train the reformed gas is cooled to
61C in the B.F.W. heater to preheat feed water.
The B.F.W. heater exit gas enters the process
condensate K.O. drum in which process
condensate is removed.

Reformer
Furnace Then the reformed gas is mixed with the
compressed CO2 gas from CO2 compressor at the exit of the process condensate K.O. drum.
The CO2 compressor is a two stage reciprocating machine with inter stage cooling, driven
by electric motor. The first stage of the compressor raises the temperature to 126C and 5.4
kg/cmg, CO2 compressor intercooler reduces the gas temperature to 400C and condensed
methanol is separated in the CO2 compressor inter stage K.O. Drum.
The second stage delivery condition is at about 140 0C and 19.2 kg/cm2g and
the CO2 compressor after heater heat the CO2 gas temperature to 220C, then CO2 gas enter
the CO2 gas desulphuriser to remove Hydrogen Sulphide in CO 2 gas. The CO2 gas
desulphuriser contains 10.2 ton (10.2 m3) of Zinc oxide catalyst and the catalyst volume is
selected to provide a nominal 12 months of service period assuming a hydrogen sulphide
content of 48 ppm (vol.) in CO2 gas.
 P a g e | 21

The reformed gas after mixing with CO 2 gas flow to the synthesis gas
compressor suction cooler and the synthesis gas compressor suction cooler and the
synthesis gas compressor suction K.O. drum, which reduce the reformed gas temperature
to 400C and remove the condensate water. The mixture of reformed gas and CO 2 gas flows
as the synthesis make-up gas.

3) Compression and Methanol Synthesis

The synthesis gas containing near stoicheometric quantity of H 2 , CO and

CO2 for the production of methanol along with some residual methane and inert N 2 is
delivered to the suction of the synthesis gas compressor at about 17.9 kg/cm2g. The
synthesis gas compressor is two stages centrifugal machine with inter stage cooling
combined with synthesis gas circulator, driven by one steam turbine.
The reactor top flow gas is heated to 240 C and introduced catalyst bed in
the methanol reactor. The quantity of catalyst provided in the methanol reactor is 53.4 Ton
(42.7 m3). The reactor feed at 215-220C / 240C enters the top of the catalyst bed and the
two main reactions that occur are as follows:

CO + 2H2 CH3OH H = 21.6 Kcal / Kgmol

CO2 + H2 CO + H20 H = -9.8 Kcal / Kgmol
Overall CO2 + 3H2 CH3OH + H20 H = 11.8 Kcal / Kgmol

The reactor effluent is subsequently cooled down in the reactor effluent final water
cooler to 40 C to condense out the crude methanol. The condensed crude methanol
product contains mainly methanol and water with trace quantity of side reaction products
and dissolved gases. The recycle gas is separated from the crude methanol in the crude
methanol catch pot. The recycle gas leaving the catch pot is recycle gas from the synthesis
gas circulator joins the synthesis make-up gas.
Prior to entering the synthesis gas circulator, a part of the recycle gas is purged
from the loop to maintain the desired inert level in the loop. The purged gas is used as
supplemental fuel in the reformer furnace and as recycle hydrogen in the natural gas
desulphuriser. The crude Methanol from the catch pot is flashed to remove most of the
 P a g e | 22

dissolved gases in the let down vessel and then the liquid is sent to the crude Methanol
tank. The flashed gases are also used as supplemental fuel in the reformer furnace.

4) Methanol Distillation
The crude Methanol containing 21% W/W. Water and about 0.4% W/W of other
impurities is purified in a two distillation tower system consisting of the topping column
and refining column.
 P a g e | 23

TOPPING COLUMN:
The crude Methanol is pumped by the crude Methanol pump from the crude
Methanol tank via the crude Methanol heater which preheats the feed to about 58 C, the
topping column which contains 48 sieve trays. The selection of feed tray depends on the
composition of the crude Methanol.
A small quantity of caustic solution is pumped by the caustic injection pump
located in the Methanol storage facilities and injected in to the crude Methanol stream to
inhibit corrosion of the carbon steel heat exchangers and the towers etc. in system.
The topping column removes the light ends, which are principally DME,
Methylformate, aldehydes, ketones, lower paraffinic Hydrocarbons and iron carbonyl. To
improve the removal of some of the above components, some amount of water is required
to the column. This has the effect of increasing the components relative volatility to
Methanol. This technique is known as water Extractive distillation.
Since the topping column serves only to remove light ends and dissolved gases,
the concentration of Methanol in the topped crude is essentially same as that of incoming
feed. The topping column over head vapour is first cooled to 35-70C in topping column
condenser.
The condensed Methanol flows to topping column reflux drum where the
condensed Methanol is also fed to the reflux drum. The Methanol condensate from the
reflux drum is fed back to the top tray of the topping column to private reflux for the
column by the topping reflux pump.
 P a g e | 24

REFINING COLUMN:
The topped Methanol is pumped from the bottom of the topping column by the
topping column bottoms pump in the lower section of the refining column which contains
93 sieve trays. Selection of the feed tray depends on the composition of the crude
Methanol.

The purpose of the refining column is to remove water and organic heavy ends.
The heavy ends are predominantly alcohols such as iso-butanol and are known as fusel oil.
The refining column splits the crude Methanol into the sacrificed Methanol product and a
bottoms water stream. The product Methanol is cooled to 40C in the product Methanol
cooler and is sent to the product Methanol test tank.
The refining overhead stream is condensed in the refining column condenser at
about 70C. The condensed Methanol flows under gravity to the refining column reflux
drum. Unless the product Methanol is being removed as stream from the reflux pump.
The refining column is operated at a bottom temperature of 125C a top
temperature of 75C Respectively. Fusel oil and Ethanol are withdrawn at an intermediate
tray located in the stripping section of the column. The fusel oil thus withdrawn us used as
supplemental fuel in the reformer furnace.
 P a g e | 25

Chapter:-4

Condensate System
Of
Methanol-2 Plant
 P a g e | 26

DMW is received from DM plant at 8 kg /cm2g and ambient temperature. The major
use of DM water is as a BFW but there is a provision to supply DM Water to other
equipment like Heat Exchangers, reformed gas transfer line jacket and BFW chemical
injection system. DMW is preheated to 103C in DMW pre-heater and then fed to top of
deaerator stripper, which is having 3 numbers of perforated trays. In deaerator, condensate
from (turbine condensate), and Exchangers are also received. Low- pressure steam is
introduced through to strip out dissolved oxygen from DMW.
The Deaerator pressure is maintained at 1.33kg /cm 2g (125C). The hydrazine
hydrate solution is dosed to deaerator to maintain residual dissolved oxygen of 0.007 ppm
in BFW pH of BFW is adjusted to 8.5-9.5 at the outlet of the deaerator by dozing morph
line in MP BFW pumps suction line. Two numbers of BFW pumps are provided in series,
one is MP BFW pumps up to 20.1 kg /cm2g and other is HP BFW pump which pumps up
to 125.5 kg /cm2 g.
HP BFW is supplied to Reformed Gas Boiler through BFW exchanger and
economizer. HP BFW is also distributed to super-heaters as quench water for controlling
high and middle pressure steam temperature. Phosphate solution is pumped to WHBs by
respective phosphate dozing pumps to maintain PO4 in the range of 1 to 5 ppm in boiler
drum. The describable pH range of boiler drum water is 9.8 to 10.2.
The generated steam from the reformed gas WHB is superheated to 510C by
passing through the steam super heaters 4 number of SSH burners are given in convection
section of reformer to finally achieve high pressure superheated steam (100kg /cm 2g,
510C) which is utilized to drive turbine of the synthesis gas compressor. The synthesis
gas compressor gas turbine is a combined type of extraction and condensing.
The superheated high pressure steam is let down by extraction to the middle
pressure steam header (28 kg/cm2g, 345C). In case of rising pressure of HP steam same
can be let down through MP steam header. During the start-up and shut-down and to
maintain MP steam pressure during normal running same can be let down from HP import
steam (95 kg/cmg, 500C).
HP import steam is (95 kg /cmg, 500C) used during synthesis catalyst heating in
start- up heater and in coil during initial reformer heating up for coil protection. The
turbine condensate is pumped to drain or deaerator or to transfer line water jacket.
 P a g e | 27

Chapter:-5

Utility Section
 P a g e | 28

Cooling Tower
It is a familiar sight in all industries. A tower through which water is circulated to
remove the heat generated from various heats generating operations and the hot water
comes back to the Cooling Tower. This water is cooled in the Cooling Tower collected in
the Sump and re circulated, the cycle continues. This is basic definition of Cooling Tower.

There are four cells in the cooling tower unit. All cells are of counter flow induced
draft type. The major advantage of this flow configuration, This ensures maximum driving
force for heat and mass transfer.

At the top of each cell big ID fan is installed which draws air from the beneath
of fan and discards it from top. Water is fed up just below the fan. The mass transfer takes
place over wooden grids and fibre screens. Water enters the tower at 43 0C and leaves it at
330C. Outlet temp. of air is 38 0C. It has capacity to cool 7000m3/ hr water from 43C to
33C.

After passing through the tower, cooled water passes through sand filters which
are provided to eliminate dust and waste from water. 2 side stream Sand filters are also
provided to remove Suspended Solid from 100ppm to 10ppm. The pH of Cooling water is
maintained 7 to 7.5 with the help of H2SO4.
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Flare System
The flare system is designed to burn safety the
explosive gases and inflammable gases discharged from
the methanol process unit at emergency as well as normal
start up & shut down. Two flare headers connecting with
the flare stack are installed, one for explosive gases and
inflammable gases discharge and the other for methanol
vapor discharge.
The flare stack has 55 mt. Height and has three
no. of pilot burners which are always fired. A molecular
Sieve is provided on the top of the flare stack to prevent
the back fire.

Pressure Swing Adsorption

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The PSA Unit has been designed to recover pure Hydrogen from hydrogen rich feed
gas. PSA Unit work on the principle of adsorption and desorption process based on pressure
swing operation.

Adsorption is the binding of molecules to a solid surface, the releasing of the

adsorbed molecules is the opposite of absorption called desorption, the reason for the
binding are physical interaction between the molecules of a gas and the adsorbent.

The degree of interaction is given by the adsorption forces basically depending on:-

Physical condition like pressure and temperature. Adsorption is directly proportional to

pressure and inversely proportional to temperature.

The kind and size of molecules to be adsorbed. Means smaller molecule will escape easily
from adsorbent material.

The pore size distribution and the surface properties of the solid adsorbent material.
Proper size and type of adsorbent are to be selected for the better product.

It consists of three sections:

1) Activated Alumina
2) Activated Carbon
3) Molecular Sieves
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Methanol Storage Facilities

Because of flammability of Methanol, the storage tanks are located at
some distance from the plants and are surrounded by a dyke wall. Storage area is
provided with following facilities:

1)Foam type fire extinguishing system.

2)Water spray system for cooling the tanks in case of fire occurring in the nearby area.
3)Eye showers.

Personnel who handle Methanol should wear chemical safety goggles and a full-face
shield for protection of the face and eyes. If the concentration of Methanol vapors in the
area is high or unknown, a respirator should be worn to avoid inhalation. Furthermore,
protective clothing and hand gloves are advisable to avoid skin contact.

First Aid Measures

In case of methanol contact with the skin, remove contaminated clothing. Wash
with soap and water for 15 minutes. Seek medical attention if irritation occurs.
In case of methanol contact with the eyes, flush immediately with gently running
water for a minimum of 15 minutes, ensuring all surfaces and crevices are flushed by
lifting lower and upper lids. Obtain medical attention.
In case of inhalation of methanol vapors, remove the individual to fresh air.
Asphyxiation from vapors may require artificial respiration. Due to the possibility of
delayed onset of more serious illness, it is important to obtain medical attention.
Ingestion of methanol is life threatening. Onset of symptoms may be delayed for 18
to 24 hours after ingestion. Do not induce vomiting. Transport to medical attention. The
individual should remain under close medical care and observation for several days.
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Conclusion
It is One of the rare privileges for anyone to see a Plant inside area.
It was one of the great opportunities to observe the DCS controlled plant.

I learned design of equipments like Reactor, heat exchanger, pump, Reformer, PSA etc. by
practical means.
By industrial training, I came to know how to minimize difference between theoretical
thing that we learn in collage and practical thing.
I learned various type of problems can be occur while operating the plant and various
safety measures which are taken in the industry.
Finally, my wishes for GNFC-
Prosperous it was, it is & always will Be !