Another Prilling Session…

Finally my on-job training at PT Pupuk Kujang (Kujang Fertilizer) is done.. Well, that was an awesome experience and boring in the same way… Getting closer with the chemical processes there becomes a special experience, but I’m fed up with my field supervisor, whom – if only I could – I intend to kick out…

Hm… PT Pupuk Kujang built its first ammonia and urea plant in 1975. The first plant was then called Kujang I-A. It was the plant in which I had my on-job training. Since it was f

ounded many many years ago, it seems to be an old-fashioned plant. Computer monitor? You’ll find only one in each control room, for typing, not controlling. Computerized panel? you wish.. The panels in the control room are analog. There’s only one panel man, accompanied by one foreman. All the operators stand by on field.

The old-fashioned plant seems to be efficient no more. Well, leakage is everywhere. Ammonia release is everywhere. The plant has been operated over its lifetime. It was designed to operate for 20 years, so the corrosion allowance is only prepared for 20 years operation. That’s why, leakage everywhere…

Kujang has its new reactor in 2003. It was the second hand reactor from PUSRI (PT Pupuk Sriwijaya – Sriwijaya Fertilizer, Sumatera). Before installed, it was re-lined with stainless steel and completed with 12 trays. Thus it became a gas-liquid contactor in form of tray column. The former reactor was titanium-lined (Wow..!). It had no tray. With the new reactor, the conversion increased 3%.

The special thing in every urea plant is prilling tower. Yes, it is a 76 metres-high tower (see picture), in which top the melted urea is sprayed and -with the forced convection and other transport phenomena through the tower- become prilled urea when it reach the bottom of prilling tower. It’s really a high tower, and I’ve climbed it two times!! amazing…

With Prilling Tower as the background

Well, those two prilling sessions are unforgettable experiences… I was totally nervous when climbing it up. Enough, no more third prilling session… hahaha…

Me (rightmost) and Friends at PT Pupuk Kujang

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