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PROBLEMS FACED ON GRANULATION AFTER TA - 2007

PROBLEMS FACED ON GRANULATION AFTER TA - 2007. Presented by: MOHSAN MAJEED UREA OPERATIONS. CONTENTS. OBJECTIVE. INTRODUCTION TO GRANULATION. GRANULATOR OPERATION. BACKGRAOUND OF MODIFICATION. MAJOR MODIFICATIONS. PROBLEMS FACED AFTER MODIFICATION. PROPOSED SOLUTION. OBJECTIVE.

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PROBLEMS FACED ON GRANULATION AFTER TA - 2007

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  1. PROBLEMS FACED ON GRANULATION AFTER TA - 2007 Presented by: MOHSAN MAJEED UREA OPERATIONS

  2. CONTENTS OBJECTIVE INTRODUCTION TO GRANULATION GRANULATOR OPERATION BACKGRAOUND OF MODIFICATION MAJOR MODIFICATIONS PROBLEMS FACED AFTER MODIFICATION PROPOSED SOLUTION

  3. OBJECTIVE • Part of my training • To decrease the no. of washing cycles

  4. GRANULATION • Engineering designHydro Agri (Belgium) • Plant capacity1670 MT/Day • Process Fluidized bed • ModeAccretion

  5. Vibrating Screen To Scrubber Crusher Seed Granulator 96 % Solution Seed Storage Safety Screen UF-85 Final Cooler Belt Conveyor Atomization Air Bucket Elevator First Cooler Fluidization Air

  6. GRANULATOR • Lower casing • Injection Headers (09 containing 21 nozzles on each) • Perforated Plate • Upper casing (Six chambers, 03 is for cooling and conditioning)

  7. SCRUBBING SYSTEM GRANULATOR UREA SOL. ATOMIZATION AIR FLUIDIZATION AIR

  8. SPRAY NOZZLE SIGMA ELEMENT ATOMIZATION AIR ATOMIZATION AIR UREA SOLUTION

  9. BACKGROUND OF MODIFICATIONS • Load limitations • High header pressure

  10. MODIFICATION JOBS • TA -2003 • 3rd chamber’s 63 nozzles dia. enlargement (4.02 mm to 4.20 mm) • TA -2007 • 6th header’s 21 nozzles dia. enlargement (4.02 to 4.20 mm )

  11. PROBLEMS AFTER MODIFICATIONS Nozzle’s blockage Fluidization Air flow limitation Choking of perforated plate of granulator High dust generation Suspected mechanical problems

  12. NOZZLE’S BLOCKAGE • Reason : • High bed level • Entrainment of solid particles (Teflon melt and rust particles) • Atomization air low temperature • Falling of dust patch

  13. FLUIDIZATION AIR FLOW LIMITATION • Reason : • Fluidization air heaters blockage • Fluidization air I / L Flap valves fixed / not operative • Insufficient capacity of granulator scrubber fan

  14. CHOKING OF PERFORATED PLATE • Reason : • High dust generation • High moisture contents in urea solution • Poor fluidization at high bed level

  15. HIGH DUST GENERATION • Reason : • High plant load • Poor performance of UF.85 dosing pumps • Ambient high temperature • Tiny particles escaping due to high flow through nozzles

  16. SUSPECTED MECHANICAL PROBLEMS Reason : • Header # 5 nozzles found of larger dia. • Small dia. Nozzles in 3rd chamber • Threads damage due to frequent replacement

  17. WASHING ANALYSIS

  18. PROPOSED SOLUTION Atomization air header inspection Fluidization air heaters replacement Fluidization air Flap valves in operation UK-651 capacity Enhancement Optimization of Formaldehyde dosing System

  19. PROPOSED SOLUTION Regular nozzle’s inspection Efficient strainer system Formaldehyde should be of better quality

  20. THANK YOU WORK SAFELY SMARTLY & HAPPILY

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