Post on 08-Apr-2018
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 1/10
1
REPORT
Visit to Fuji fertilizers Bin Qasim
Limited
SUBMITTED BY: SHEIKH ABDUL MALIK
ROLL# PP-034
TO: SIR ADEEL-UR-REHMAN
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 2/10
2
Table of contents
Serial no. CONTENTS Page no.
1 Introduction
2 Plant architecture of FFBL
3 1. Site information
4 2. Storage capacity
5 3. Plant production rate
6 4. Parts of plant7 I- Utility plant
8 1. Power production
9 2. Water and steam
10 3. Cooling towers
11 4. Nitrogen supply
12 5. Other utilities
13 II- Ammonia production area
14 III- Urea and DAP production area
15 y Urea production
16 Specification of urea produced by FFBL
17 Properties of Sona urea
18 y DAP production
19 Properties of DAP produced in FFBL
20 IV- Storage and market supply of urea and DAP
21 Financial results
22 Backwardness of FFBL
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 3/10
3
INTRODUCTION
FFBL was developed in 1993 near port Qasim. And now a bold fertilizer company
in Pakistan. This industry manufacturing urea and Di-ammonium phosphate
(DAP). The property that make this industry unique from others fertilizers
manufacturers like ENGRO, etc. is the production of DAP. Because this is the only
industry which is producing DAP in Pakistan. About 31%-40% of DAP consumption
of Pakistan are fulfilled by the industry. ENGRO and other fertilizer companies are
only licensed supplier of DAP by the government of Pakistan in order to meet the
demand.
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 4/10
4
Plant architectures of FFBL
1. Site information
The total plant area of FFBL is about 350 acres in which complex areas are about 120 acres. The plant
has also 8 acres in port Qasim.
2. Storage capacity
Items Capacity in MeT
ammonia 5,000urea 35,000
DAP 35,000
Phosphoric acid 45,000
3. Plant production rate
Products Production per day in
metric tons (when
designed)
Production per day in
metric tons (current)
ammonia 1,270 1,570
Urea 1,670 1,920
DAP 1,350 2,230
4. Parts of plant
The FFBL plant is can be divided into four major categories:
I-Utilities plant
II-Ammonia production area
III-Urea and DAP production area
IV- Storage and market supply of urea and DAP
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 5/10
5
I-Utilities plant
No industry can be run without utilities. Deferent industries may have deferent type of utilities but they
are necessary for a continuous operation in an industry. If supply of any utility disturbs it will effect very
badly to the production and may cause the entire plant shut down. We have an example of electricity. A
power failure can cause entire plant close. And in Pakistan such type of accident are in routine. So
everyone who has a thought of establishing an industry must first consider about utilities. FFBL have also
some prospective thought thats why they have arranged utilities by their selves. Their utility plant
contains:
1. power production
For independency from KESC, FFBL is producing their own electricity of 52 mega watt by two gas
turbines at 60 Hz. This power is enough for the entire plant. In case of any failure in any gas turbine they
have also emergency diesel generators as stand by.
2. Water and steam
FFBL has water storage reservoirs and ponds for usage of water. For steam generation they have two
boilers producing 100 metric ton of steam per hour.
3. Cooling towersFor cooling purposes in the plant, 11 cooling towers are available. The distributions of cooling towers in
the entire plant are as under:
ammonia 06
DAP 02
Urea 02
Spare* 01
*use when damage or repairing.
4. Nitrogen supply
Storage tanks and supply facilities of nitrogen to the plant are available in utility department.
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 6/10
6
5. Other utilities
Other utilities are instrument air and waste water treatment plants.
II-Ammonia production area
Ammonia is the major component for the production of urea and DAP. For making continuousproduction of urea and Dap it is necessary to produce ammonia simultaneously. The signification of this
plant is that this is a relocated plant. Actually this plant was first installed in America in 1965. But due to
some problems it was shut down in early 1990s. Then this plant was uninstalled, taken to port Qasim
and re installed in the location where it is actually now.
Note: The frequency of power is 60Hz because of this plant.
The general reaction of producing ammonia in FFBL is as under:
Natural gas + steam + air (nitrogen) ammonia
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 7/10
7
III-Urea and DAP production area
Here we come to the main purpose of making all the plant the production of urea and DAP.
y Production of urea:
Just for the information urea was the first organic compound which was made in the laboratory. In FFLBurea is produce by ammonia and carbon di oxide under the catalyst of UF-85.
Ammonia + CO2 UF-85 Urea
Specification of urea produced by FFBL:
Brand name Sona urea
Nitrogen (amide) 46%
Fulfill country demand 10% approximate
Properties of Sona urea:
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 8/10
8
a. Cheapest among all nitrogenous fertilizers based on per unit cost of nutrient
b. Less acidifying than many other nitrogenous fertilizers hence most suited for high pH soils
c. High concentration of nutrients makes packing, storage and transport cost cheaper
d. Larger granular size
e. Greater granules strength
f. Minimum fines, dust and powder
g. Minimum losses in the air
h. Least caking property
i. Easy to spread in the fields
j. No settling on crops
*very large grain produced in the packing.
Application:
y Production of DAP:
As discussed before that FFBL is the only manufacture of DAP in Pakistan. It is a phosphorous based
fertilizer. The basic raw material for DAP manufacturing is phosphoric acid. The industry fulfills the
demand of about 31%-40% of the country. The general reaction for producing DAP in FFBL is as under:
Phosphoric acid + Sulphuric acid + Sand + coating oil + ammonia
DAP
Properties of DAP produce in FFBL:
a. Completely soluble in water
b. Good storage properties
c. Total water soluble phosphoric acid helps plants to utilize moisture better and let roots grow
stronger and deeper even in acidic soilsd. Being non- hygroscopic, DAP stores well even in high rainfall areas
e. High concentration of nutrients makes packing, storage and transport per unit cost of nutrient
very low
f. Nitrogen is present in an easily absorbed ammonical form, loss due to leaching is thus minimum
Application:
a. Can be applied to soil. Also suitable in solution form as spray
b. Application is recommended in split doses for better use efficiency
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 9/10
9
a. DAP is suitable for all crops and soils
b. Recommended for initial application
Note: in 2001-2002 the DAP plant in FFBL was remained closed due to economical reasons.
IV- Storage and market supply of urea and DAP
The storage facilities in FFBL have discussed before. The market supply of urea and DAP performed
through transport (truck, trawlers). For loading the trucks they use moving channels on which the
unpacked product move to the packing and then to trucks.
Financial results
2009 Rs 2008 Rs
Sales-net 5,856,387 2,004,831
Cost of sales (5,036,921) (1,402,213)
Gross Profit / (loss) 819,466 602,618
Administrative (93,439) (50,368)
8/7/2019 REPORT of FFBL
http://slidepdf.com/reader/full/report-of-ffbl 10/10
10
Backwardness in FFBL:
Along with qualities FFBL has a medium type of drawback like ENGRO. This
industry is producing electricity through natural gas turbines. As we all know that
our natural gas reservoirs in Sui are drying day by day very quickly, because the
consumption and unnecessary uses like power generation through gas. Our
appeal is that if an industry is considering safety, environmental issues, spending
millions to increase their production, also change their gas turbine into stream,
and wind turbine that are better than gas and also give the same power
production if good technology is used.
Expenses
Other Income 247,657 157,606
Taxation 3,350 (62,293)
Profit after Tax 12,577 162,090
Earnings per Share
(Rs.)0.01 0.17