Commissioning of a urea bulk handling system for Train-2 of a mega fertilizer plant being established in Nigeria has been completed. This project builds upon the success and client satisfaction of a previous handling system also supplied by TAKRAF for Train-1 of the project.
The contract for the design, supply, supervision of erection/commissioning and performance testing of the handling system for Train-2 was awarded in 2018 and covered the handling of urea from receipt of the material from the granulation plant through to a storage yard, from where it is reclaimed for feeding a truck loading station.
System specifications include;
Material: Urea granules
Capacity of conveyors (incl. overhead tripper, feeding storage yard) 200 t/h
Belt width 800 mm
Capacity of reclaiming circuit conveyors 400 t/h
Portal scraper (main and auxiliary boom) 400 t/h
Storage capacity (building by others) 60,000 t
Handling urea in bulk storage poses unique challenges requiring special design considerations, such as completely sealing all conveyor galleries and transfer towers to avoid any moisture entry or exposure of the product to the outside environment. In addition, the portal scraper is provided with a “de-lumper” to break the lumps that are formed during storage. To avoid material degradation and dust generation, the truck loading station, which can handle up to four trucks at once, is equipped with special cascading chutes, a pit-less weighing bridge and de-dusting bag-filters. Importantly, in order to protect worker health and safety, fresh air supply is provided to the operator cabin and E-house via a separate hose reeler.
With a view to aiding transportation and site assembly, the conveyor galleries and transfer towers were designed for modular transportation through the use of containers and special packing requirements. Strict attention was also paid to painting specifications for corrosion resistance and to the manner in which items were packed so as to avoid paint damage during transport.
GOPAL Kalyanakrishnan, Managing Director: TAKRAF India, had this to say upon successful commissioning: “The demanding design and engineering required for this complex bulk handling application, as well as stringent requirements in terms of manufacturing, packing and transportation, were addressed to the full satisfaction of the client. The TAKRAF India team must be congratulated on their expertise, commitment and teamwork in meeting these challenging requirements within a tight project schedule. Supervision of site erection and commissioning by TAKRAF ensured that the rigorous acceptance criteria required by both the client and TAKRAF itself, due to the demanding nature of urea handling, were fully met. With successful commissioning and operation of the system, we’re proud to add another world-class reference to our growing global track record.”