Welcome to Fatima Group

Designed capacity of this plant is 1500 M. Tons per day Calcium Ammonium Nitrate having 26% Nitrogen contents and 1-2 % Potassium Sulphate as additional nutrient to stabilize the prills & fulfill the soil requirement. It is manufactured by mixing 75% molten Ammonium Nitrate and 25 % Calcium Carbonate in the mixing tank at 170 C. 550-700 M. Tons per day Ammonium Nitrate is produced directly by reacting Ammonia gas and 60% Nitric acid in the Neutralization Reactor. 1050 M. Tons per day Ammonium Nitrate is produced in the CN Section by reacting Calcium Nitrate solution with Ammonia and Carbon dioxide gases in the CN Reactors. 600 M. Tons per day Calcium Carbonate is also produced in the same CN Reactors.

Calcium Ammonium Nitrate is hygroscopic by nature and absorbs moisture from the atmosphere therefore it can be used in the soil with out sufficient water. It contains 13% Nitrate Nitrogen which supplies nutrients immediately to the plants and rest 13% Ammonium Nitrogen gives food slowly till ripe up of the crop.

Process of the plant is designed by Hoescht whereas detail engineering is done by UHDE Germany. This plant is in production since 1979.

The process was based on license from Stamicarbon, Holland, while detailed Engineering was made by Uhde, Germany.

The plant was designed to produce 229.4 MTPD of P2O5 or 1015 MTPD of NP having 22.6% P2O5 with 300 on-stream days/annum. The plant could not produce NP product at its rated capacity both in terms of designed quality as well as quantity at the time of guarantees; Uhde was made to undertake modifications on the plant, which they performed through addition of 2-lines of Crystallizers making total six lines. Similarly 2 centrifuges were added to 4 existing ones and additional refrigeration capacity was provided. However, even after the modifications designed product quality could not be achieved. The plant consumes much higher energy level compared with design.

In view of the fact that plant could not produce 22.6% P2O5, the specs were revised to 20% P2O5 and 22% Nitrogen (originally 22.6% each of Nitrogen and P2O5).

A new Urea unit of 280 MTPD capacity commenced production in April, 1986 based on Snamprogetti design. Old Urea unit, Evaporation unit and Prilling Tower was retained.

The new plant has 330 operating days/annum. Urea unit is a trouble free unit. It has the highest production efficiency. The highest production achieved was 387 MTPD against design of 280 MTPD (38.2% higher). Last year a production capacity of 101,754 MT of Urea as compared to design of 92,420 MT/annum and was 10.12% higher inspite of gas load shedding (+ 13,619 M. Tons).

Based on Kellogg process, steam reforming of the natural gas, the plant commenced production in November 1978. The plant had capacity of 910 MTPD, which was enhanced by 50 MTPD through addition of Purge Gas Recovery Unit in April, 1986.

The plant is designed to operate 330-days per annum (initially 320-days/ annum prior to capacity increase. Present energy consumption at the plant is 9.6 G.Cal /MT of Ammonia (excluding non-productive gas), which was 9.464 G.Cal /MT of Ammonia during guarantee period.

There are two units (three lines) of Nitric Acid production. The old line has a capacity of 180 MTPD of 60% Nitric Acid strength. This line commenced production in 1963. Other two lines have a capacity of 600 MTPD of 60% Nitric Acid. These two lines commenced production in December, 1978.

The old line was modified in 1986 when an additional Absorption Tower was added, which resulted in increase of Nitric Acid concentration to 60% strength and reduced pollution level i.e. NOx Emission from 4000-6000 mg/cubic meter to 800 mg/cubic meter. The plant is operated as and when required.

The two new lines have on stream factor of 330 days (originally 320 days). The old line consumes 0.310 MT Ammonia/ton Nitric Acid (100% basis) while the new lines consume 0.290 MT Ammonia/ton of Nitric Acid (100% basis). Thus old unit of Nitric Acid consumes higher energy.

Approximately 40% of total Ammonia produced is used to produce Nitric Acid.

The Utilities Plant supply's the following utilities required by the production plants of Pakarab.

	Steam by BORSIG boilers three with a capacity of 85 t/hr each and produces 40 bar steam at 395 Celsius.
	Electric power by three turbo generators of BBC with a normal capacity of 7.6 MW/hr each and produces 6KV electric supply.
	De mineralized water by three trains of 120 m3/hr flow and quality of <10 PPB silica water.
	Raw water by deep wells as no surface water is available.
	Cooling water by three cooling towers with total capacity of 38000 m3/hr for total cooling water need of the complex.
	Instrument Air and Plant Air by four air compressors.
	Nitrogen by cryogenic Nitrogen Making Plant made in China with a Capacity of 720 m3/hr and Nitrogen gas purity of 3 ppm Oxygen.
	Effluent treatment, Chromate Removal and Disposal.