Internship Report

Duration: 4 Weeks
(1oth June 2024 – 5th July 2024)

Prepared By : Ruba Tarique

Mentor : Aamir Munir

Operation Department , Plant Site

FFBL Karachi

Submitted To: Sir Shoaib Saleem

Table of Contents
ACKNOWLEDGEMENT ................................................................................................................................... 1
EXPERIENCE................................................................................................................................................... 2
ABSTRACT...................................................................................................................................................... 2
INTRODUCTION ............................................................................................................................................. 3
History ....................................................................................................................................................... 3
Performance and Production .................................................................................................................... 3
SAFETY........................................................................................................................................................... 4
Personal Protective Equipments ............................................................................................................... 4
Work Permit in FFBL.................................................................................................................................. 4
AMMONIA PLANT ......................................................................................................................................... 5
Introduction .............................................................................................................................................. 5
Block Flow Diagram of Ammonia Plant .................................................................................................... 6
Natural Gas Compression ......................................................................................................................... 7
Desulphurization ....................................................................................................................................... 7
Steam Methane Reforming ....................................................................................................................... 7
Shift Conversion ........................................................................................................................................ 8
Synthesis Gas Purification ......................................................................................................................... 8
Methanation and Synthesis Loop ............................................................................................................. 9
Ammonia Conversion and Storage ........................................................................................................... 9
UREA PLANT .................................................................................................................................................. 9
Introduction .............................................................................................................................................. 9
Wet Process of Urea Production ............................................................................................................. 10
CO2 and NH3 Compression ................................................................................................................. 10
Synthesis ............................................................................................................................................. 10
Low-Pressure (LP) Recirculation.......................................................................................................... 10
Evaporation and Condensation........................................................................................................... 11
Desorption and Hydrolization ............................................................................................................. 11
Dry Process of Urea Production .............................................................................................................. 11
Urea Granulation ................................................................................................................................ 11
Screening and Cooling......................................................................................................................... 11
Dust Scrubbing .................................................................................................................................... 12
Product Storage and Distribution ....................................................................................................... 12
 Block flow diagram of Urea Plant............................................................................................................ 12
CONCLUSION............................................................................................................................................... 13
 ACKNOWLEDGEMENT

I would like to express my heartfelt gratitude to FFBL for providing me with a valuable
internship opportunity. I am thankful for the experience and knowledge gained while working
with the esteemed organization.
I appreciate the support and guidance received from the unit managers, shift engineers, and
management associates, who shared their expertise and time with me. Their contributions
significantly enhanced my learning experience.
I am particularly grateful to my mentor, Aamir Munir, and the operational department team for
their encouragement, guidance, and mentorship throughout my internship. Their leadership and
expertise played a significant role in my professional growth.
Lastly, I thank the management of FFBL for providing a conducive environment to apply my
theoretical knowledge in a practical setting, and for their commitment to developing future
professionals like myself.

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 EXPERIENCE
During my internship at FFBL, I gained valuable insights into the ammonia and urea
manufacturing processes. I observed the synthesis of ammonia and the subsequent conversion to
urea, including the detailed granulation process. FFBL's commitment to safety was evident
through their provision of PPE, rigorous safety protocols, and mandatory safety tests for
employees. The working environment was exceptional, with well-mannered and friendly
employees, and a clean, well-maintained plant. This experience significantly enhanced my
knowledge and provided me with substantial industrial exposure, particularly in understanding
the importance of safety and advanced machinery in the chemical industry.

ABSTRACT

This report showcases my enriching internship experience at Fauji Fertilizer Bin Qasim Limited
(FFBL), a premier chemical company in Pakistan. As a third-year chemical engineering student, I
had the privilege of immersing myself in the inner workings of FFBL's ammonia and urea plants.
Through hands-on exposure and mentorship, I gained a deeper understanding of the intricacies of
chemical processing and production. This report distills the key takeaways from my internship,
highlighting the practical knowledge and industry insights I acquired during my time at FFBL.

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 INTRODUCTION

Since its inception in 1993, Fauji Fertilizer Bin Qasim Limited (FFBL) has played a crucial role
in Pakistan's agricultural sector as a subsidiary of Fauji Fertilizer Company Limited (FFC).
Renowned for its advanced facilities and adherence to top-tier industry standards, FFBL ensures
high-quality products and environmental sustainability. This dedication to excellence has
established FFBL as a vital contributor to the nation's economic development.
FFBL is unique in Pakistan as the only producer of Di-Ammonium Phosphate (DAP) and
Granular Urea, fulfilling 45% of the domestic DAP demand and 13% of Urea. Situated in the
Eastern Zone of Bin Qasim, about 45 km southeast of Karachi, the plant was built with an
investment of USD 469 million and commenced operations in November 1993. Its strategic
location and connection to the National Highway enable efficient distribution across the country.

History

Initially known as FFC-Jordan Fertilizer Company (EIFC), FFBL was established on November
17, 1993, with FFC, FF, and JPMC as key sponsors. The company was listed on the stock
exchanges in May 1996, and commercial production began in January 2000. Despite facing
significant technical, financial, and managerial issues that led to a suspension of the DAP plant
in 2001 due to a Rs. 6.5 billion loss, FFBL managed a successful turnaround by September 2003.
The company was renamed Fauji Fertilizer Bin Qasim Limited (FFBL) in 2003 following the
exit of Jordan Phosphate Mines Company (JPMC) from the partnership, which also resulted in
the termination of a Phosphoric Acid supply agreement with Jordan. By 2004, FFBL had
regained profitability and declared its first dividend. The company has continued to see
increasing profitability, with 2007 marking its most profitable year to date.
FFBL, in collaboration with FFC, holds a dominant position in Pakistan's fertilizer market,
commanding 63% of the Urea market and 51% of the DAP market. Its ability to surpass
designed production capacities highlights its significant and distinctive role in the country's
fertilizer industry.

Performance and Production

The FFBL fertilizer complex is equipped with a modern manufacturing facility that utilizes an
advanced Distributed Control System (DCS) to ensure both safety and efficiency in its
operations. For the production of Di-Ammonium Phosphate (DAP), the complex sources
phosphoric acid from Morocco and stores it in tanks located at Port Qasim. The following
section provides a comparison between the designed production capacities and the actual output
achieved by the plants.

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 Manufacturing Plant Production (metric ton/day)
Original Actual
Ammonia 1270 1570
Urea (granular) 1670 1920
DAP 1350 2230

SAFETY
At FFBL, safety is of paramount importance and is regarded as a crucial indicator of success
across all operations. This involves the continuous assessment of tasks and the methods used to
perform them, ensuring the protection of employees and the safeguarding of company assets.
Equipment is regularly monitored to reduce the risk of accidents.

FFBL's safety priorities include:

 Ensuring the well-being and protection of employees

 Preserving company assets
 Promoting environmental conservation and stewardship

Personal Protective Equipments

FFBL provides the following Personal Protective Equipment (PPE) to maintain safety standards:

 Safety helmets and shoes for use during work and other activities at the plant
 Goggles to protect against exposure to liquids and gases
 Gloves designed to guard against acids, alkaline solutions, and heat
 Respiratory masks with filters to protect against dust and toxic gases such as H2S, NH3,
and natural gas
 Compressed air masks to protect against carbon monoxide (CO)
 Earplugs to defend against high noise levels
 Dragger equipment (Tubes and Sniffer) for detecting poisonous gases like CO, H2S,
NH3, and natural gas

Work Permit in FFBL

The FFBL is controlled by operation Department and no work carried out by an

unauthorized person or department. Any work which is related to concern
department is carried by its permission.
The permission is sought on a prescribed format is known as permit.

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1. Cold work permit: This is requiring when urgent and routine / inspection is to be carried out
and job doesn’t involve a flame or Spark.
2. Hot work permit: It is required for job as lighting all naked flame-fires exposed material
including
electric aces and spark, electronic and gas welding / cutting, blow lamps and tar
heating.

3. Vessel entry permit: This is requiring when one or more persons to enter in to any confined
space such
as tower/vessel/storage tank excavation more than 1.5 deep column, reactor
piping will 1m sewer etc.

4. Vehicle entry permit: This permit is required before any vehicle can enter to work area.

5. Radiography work permit: This permit is required to do any sort of radiography testing
anywhere in the plant.

AMMONIA PLANT
Introduction

As an intern at Fauji Fertilizer Bin Qasim Limited (FFBL), I had the opportunity to observe and
understand the intricate processes involved in ammonia synthesis, which plays a crucial role in the
production of fertilizers like urea and diammonium phosphate (DAP). The ammonia plant at FFBL
is a sophisticated facility where natural gas is transformed into ammonia and carbon dioxide,
essential raw materials for fertilizer manufacturing. This report provides a detailed overview of
the ammonia synthesis process, highlighting each step from the compression of natural gas to the
storage of liquefied ammonia.

Ammonia synthesis, fundamentally carried out through the Haber-Bosch process, involves the
reaction of nitrogen and hydrogen under high pressure and temperature in the presence of a
catalyst. This process not only produces ammonia, a vital component for fertilizer manufacturing,
but also generates carbon dioxide as a byproduct, which is utilized in the production of urea.
Originally the production of ammonia was 1270 MTPD but after revamp it increased to about 1570
MTPD in 2007. The primary steps of ammonia manufacturing process are listed below.

Hydrogen and Nitrogen Sourcing: Hydrogen is obtained from natural gas. Nitrogen is extracted
from the air.

Ammonia Synthesis: Hydrogen and nitrogen are combined under high pressure and temperature
in the presence of a catalyst to form ammonia (NH₃).

Ammonia Purification: The produced ammonia is purified to meet quality standards and obtain
the final product.

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 Storage and Distribution: The purified ammonia is stored in tanks. It is then distributed to the
urea and DAP plants for further processing.

Block Flow Diagram of Ammonia Plant

Natural gas from SSGC Air from Atmosphere

Natural gas
Air Compressor
Compression
Steam

Sulphur Primary Secondary

Removal Reformer Reformer

Benfield Solution

Carbon dioxide Carbon dioxide Secondary Shift Primary Shift

Regenration Absorber Converter Converter

Synthesis Gas Recycle

Synthesis gas Synthesis Ammonia

Compression Converter Separator

Carbon dioxide Ammonia

Methanation Storage

Synthesis gas Synthesis Ammonia

Compression Converter Separator

Synthesis Gas Recycle

Carbon Dioxide to Urea Ammonia to

Plant Urea and DAP
Plant

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Natural Gas Compression

The process begins with the natural gas booster compressor, which compresses natural gas
supplied by Sui Southern Gas Company (SSGC). This step is essential for increasing the pressure
of the gas, making it suitable for subsequent processing stages. The compressed natural gas is then
directed to the desulphurization unit.

Desulphurization

In the desulphurization unit, sulfur compounds are removed from the natural gas. This step is
critical to prevent catalyst poisoning in the downstream processes. The feed gas is heated in heat
exchanger to about 325 ⁰C, further heating is carried out in furnace to 380 ⁰C. After heating hot
gas enters a cobalt bed reactor, in this hydrogenation of heavy organic Sulphur compounds of feed
gas is done giving hydrogen sulphide. The hydrogenated gas then enters into the double bed reactor
containing zinc oxide catalyst. The desulfurized gas, primarily consisting of methane, is now ready
for the steam reforming process.

𝑅 − 𝐶2𝐻2 − 𝑆𝐻 + 𝐻2 → 𝑅 − 𝐶𝐻3 + 𝐻2𝑆

𝑍𝑛𝑂2 + 𝐻2𝑆 → 𝑍𝑛𝑆 + 𝐻2𝑂

Steam Methane Reforming

Primary Reforming

The desulfurized methane enters the primary reformer, a double terrace furnace equipped with 224
burners and 432 catalytic tubes filled with nickel catalyst. Here, methane reacts with steam to
produce hydrogen, carbon monoxide, and carbon dioxide. The reactions occur under high
temperatures, facilitated by the nickel catalyst.

𝐶𝐻4 + 𝐻2𝑂 → 𝐶𝑂 + 3𝐻2 (endothermic)

𝐶𝐻4 + 2𝐻2𝑂 → 𝐶𝑂2 + 4𝐻2 (endothermic)

𝐶𝑂 + 𝐻2𝑂 → 𝐶𝑂2 + 𝐻2 (endothermic)

Secondary Reforming

The mixture of gases from the primary reformer then flows into the secondary reformer, where
compressed air is introduced which is the source of nitrogen. The oxygen in the air reacts with any
remaining methane and provide energy to complete the reforming reaction. At the bottom of the
secondary reformer an endothermic reaction takes place which further produces hydrogen and
carbon monoxide. This step ensures an adequate supply of nitrogen for the subsequent ammonia
synthesis.

2𝐻2 + 𝑂2 → 2𝐻2𝑂 (exothermic)

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 𝐶𝐻4 + 2𝑂2 → 𝐶𝑂2 + 2𝐻2𝑂 (exothermic)

2𝐶𝑂 + 𝑂2 → 2𝐶𝑂2 (exothermic)

𝐶𝐻4 + 𝐻2𝑂 → 𝐶𝑂 + 3𝐻2 (endothermic)

𝐶𝑂2 + 𝐻2 → 𝐶𝑂 + 𝐻2𝑂 (endothermic)

Shift Conversion

The gas mixture then undergoes shift conversion, which occurs in two steps: high temperature shift
conversion and low temperature shift conversion. This process is essential for converting carbon
monoxide to carbon dioxide, facilitating easier removal and ensuring the purity of the hydrogen-
nitrogen mixture required for ammonia synthesis.

High Temperature Shift Conversion

In the high temperature shift converter, iron and chromium catalysts are used to facilitate the
reaction. At high temperatures, a high rate of reaction is achieved, where carbon monoxide reacts
with steam to form hydrogen and carbon dioxide. The high temperature conditions favor a fast
reaction.

Low Temperature Shift Conversion

Following the high temperature shift conversion, the gas mixture enters the low temperature shift
converter, where copper and chromium catalysts are employed. The lower temperature allows the
reaction to achieve equilibrium, ensuring that the unconverted carbon monoxide is effectively
converted to carbon dioxide. This step maximizes the conversion efficiency, resulting in a gas
mixture ready for carbon dioxide removal.

Synthesis Gas Purification

The synthesis gas is processed for the removal of carbon dioxide and carbon monoxide to yield a
pure hydrogen-nitrogen rich synthesis gas.

Carbon dioxide gas Removal

The Benfield process is employed for the removal of carbon dioxide. The gas mixture enters an
absorber where carbon dioxide is absorbed in the Benfield solution. The absorbed carbon dioxide
is then stripped off in two strippers. In high pressure absorber carbon dioxide is picked up by
carbonate solution through physical absorption. This step results in a mixture free of carbon
dioxide, ready for the final stages of ammonia synthesis.

𝐶𝑂2 + 𝐻2𝑂 → 𝐻2𝐶𝑂3

𝐻2𝐶𝑂3 + 𝐾2𝐶𝑂3 → 2𝐾𝐻𝐶𝑂3

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 Methanation and Synthesis Loop

After carbon dioxide removal, the gas mixture enters the methanator, where any remaining traces
of carbon monoxide and carbon dioxide are converted into methane. The purified mixture of
hydrogen and nitrogen is then compressed in three stages before entering the ammonia converter.

Ammonia Conversion and Storage

In the ammonia converter, hydrogen and nitrogen react under high pressure and temperature,
facilitated by a catalyst, to form ammonia. The formed ammonia is then separated from unreacted
gases, which are recycled back into the compression cycle. The liquefied ammonia is stored in
specially designed storage tanks, ready for use in urea and DAP production.

3𝐻2 + 𝑁2 → 2𝑁𝐻3

UREA PLANT
Introduction

As the only producer of granular urea in Pakistan, Fauji Fertilizer Bin Qasim Limited (FFBL)
plays a vital role in meeting the country's fertilizer demands. With an original capacity of 1670
metric tons per day, FFBL's urea plant is a significant contributor to the nation's agricultural
growth. The basic raw materials used in the urea manufacturing process are ammonia and carbon
dioxide, which are both sourced from the ammonia plant. The ammonia plant produces ammonia
as its primary product, while carbon dioxide is generated as a byproduct. These raw materials are
then converted into urea through a complex process, which I had the opportunity to learn about
during my internship at FFBL. Through this experience, I gained a deeper understanding of the
intricate processes involved in producing high-quality urea.

The Urea Plant at FFBL is divided into two main sections: Urea Wet and Urea Dry. The Urea Wet
section utilizes the CO2 stripping process, a technology developed by Stamicarbon of the
Netherlands. Meanwhile, the Urea Dry section employs the Fluidized Bed Granulation technology
from Hydro Fertilizer Technology (HFT) of Belgium.

The STAMICARBON technology is a advanced method for producing urea, with a daily capacity
of 1670 metric tons. Urea formation is divided into two main parts: Wet Part and Dry Part.

Wet Part

The Wet Part involves the following processes:

 Compression
 Synthesis
 Recirculation

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  Evaporation
 Condensation
 Desorption
 Hydrolization

Dry Part

The Dry Part involves the following processes:

 Granulation
 Screening and cooling
 Scrubbing

These processes work together to transform raw materials such as CO2, NH3, urea formaldehyde,
HP steam, cooling water, and instrument air into high-quality urea granules.

Wet Process of Urea Production

The wet process of urea production at FFBL involves several stages, each crucial for the synthesis
and initial purification of urea.

CO2 and NH3 Compression

 Ammonia Compression: Liquid ammonia, supplied from the ammonia plant, is

compressed to increase its pressure and temperature.
 CO2 Compression: Carbon dioxide, a byproduct from the ammonia plant, is compressed
using four-stage centrifugal compressors.

Synthesis

 High-Pressure CO2 Entry: The compressed CO2 enters the high-pressure (HP) stripper,
a falling film type shell and tube heat exchanger.
 High-Pressure Carbamate Condenser (HPCC): Compressed NH3 enters the HPCC,
where it reacts with CO2 to form ammonium carbamate. This reaction is fast and
exothermic, generating heat.
 Urea Reactor: Both gaseous and liquid products from the HPCC are transferred to the urea
reactor. Here, ammonium carbamate decomposes into urea and water, a slower,
endothermic reaction that utilizes the heat generated in the HPCC. The resulting solution
is 34% concentrated urea mixed with unreacted CO2, NH3, and carbamate.

Low-Pressure (LP) Recirculation

 HP Stripper: The mixture from the urea reactor moves to the HP stripper. Here, fresh CO2
strips away unreacted gases, and MP steam on the shell side decomposes unconverted
carbamate back into NH3 and CO2. This results in a urea solution that is 54-55% pure.

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  LP Recirculation: The solution is expanded to 4.2 kg/cm², causing further decomposition
of carbamate into NH3 and CO2. The urea purity increases to 68%.

Evaporation and Condensation

 Rectifying Column: The urea-carbonate solution is heated in a rectifying column to

135°C, decomposing any remaining carbamate into NH3, CO2, and water. The urea
concentration reaches 71%.
 Flash Separator and Evaporator: The solution passes through a rectifying column and
flash separator to enhance its purity. LP steam is used to remove the water content, and the
solution passes through an evaporator where it comes into contact with LP steam. The final
result is a 96% pure solution that is shifted towards the granulation section.

Desorption and Hydrolization

 Total Recycle Carbon Dioxide Stripping Process (Stamicarbon): Ammonia from a

storage tank and CO2 from a compressor react in the HPCC. The exothermic reaction
generates LP steam, with 60% of the reaction occurring here. The remaining 40% occurs
in the urea reactor, which has 10 sieve trays. The urea solution then moves towards the
stripper, where any unreacted gases are stripped off, resulting in a 34% pure urea solution
that moves to the LP system for further purification.

Dry Process of Urea Production

The dry process involves converting the concentrated urea solution into granules and ensuring its
purity and usability.

Urea Granulation

 Seed Material: Seed materials are fed into the granulator.

 Nozzles: Urea solution and atomization air are introduced through nozzles in the
granulator.
 Chambers: The granulator consists of six chambers. In the first three chambers, accretion
occurs to increase the size of the granules. In the last three chambers, only cooling takes
place, and there are no nozzles to shower the solution.
 Concentration Requirement: For granulation, a 96% concentrated urea solution is
required.

Screening and Cooling

 Screens: The granules are separated into undersized, oversized, and correctly sized
product granules. The undersized and oversized granules are crushed and reused as
seed material in the granulator.
 Fluidized Bed Cooler: The correctly sized granules are further cooled in a fluidized
bed cooler.

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Dust Scrubbing

 Scrubbers: Two scrubbers are used in the process—one for granulator dust and another for fluidized
cooler dust. Condensate is used for scrubbing, and the exhaust gases exit through a common vent from
both scrubbers.

Product Storage and Distribution

 Conveyor Belt: The final granules are transported via conveyor belt to the bagging
area, where they are packaged for distribution to farmers.

By utilizing advanced machinery and a meticulously controlled process, FFBL ensures the
efficient production of high-quality urea for agricultural use.

Block flow diagram of Urea Plant

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 CONCLUSION
My internship at FFBL provided a comprehensive understanding of the ammonia and urea
plants. Observing the intricate processes of ammonia synthesis, including the Haber-Bosch
method, and the transformation of ammonia into urea through various production stages gave me
valuable insights into large-scale industrial operations. This hands-on experience enhanced my
technical knowledge, deepened my understanding of process optimization, and allowed me to
witness the implementation of strict safety protocols and environmental standards, all of which
have significantly broadened my industrial expertise.

This experience has not only enhanced my technical skills but also highlighted the importance of
safety protocols and efficient plant management. The hands-on exposure to advanced machinery
and state-of-the-art technologies will be invaluable as I progress in my future career in the chemical
and manufacturing industries.

I am truly grateful for the opportunity to intern at FFBL. The knowledge and experience gained
here will undoubtedly play a crucial role in shaping my professional development and career path.

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