Zero Ammonia Gas Emmission Strategy @ Ammonia Urea Complex

Engro Fertilizers limited is 2nd largest Urea Producer in Pakistan. Engro is operating 02 Ammonia, 03 Urea and 03 Utilities plants near a rich natural gas facility in district Ghokti with total capacity of 2.1 Million tons per year. In 2014 Engro achieved land mark DuPont 4.3 ranking in process safety management. High standard of process safety has been achieved through top management commitment and developing a marvelous system of integrated safety management, now Engro is striving for world class safety and Environment performer. Engro commissioned new Ammonia Urea complex in 2010 based on Snamprogetti technology having 2194 MeT/day Liquid Ammonia and 3835 MeT/day Urea capacity.

Engro Fertilizers HSE policy is true depiction of its top management commitment towards Process Safety and Environment Management. One clause of policy says "Continuously improve environmental performance to achieve sustainable development."  In this regard state of the art technology, flare system was procured for new Ammonia Urea complex to ensure zero ammonia gas effluent during normal operation, start up, shutdown and process upset. This initiative eradicated the all possible risks related to ammonia release in environment. Flare system protected workforce at plant, surrounding community and trespassers. It has been designed to burn continuous ammonia effluent as well as to cater abrupt ammonia release in case of process upset. Since commissioning of new Ammonia Urea plant, environment complains have been drastically reduced and one element of environment pollution have been eradicated. Moreover detail PHA studies were conducted to analyze the relevant hazards and their consequences. After commissioning, a key in house design modification was conducted to avoid localized Ammonical water release at Urea plant, which not only avoided ammonia release from Urea plant permissive but also resulted in ammonia recovery through close header, recovered ammonia recycled to Urea process which enhanced Urea yield.