Yara Fertilizers India Pvt. Ltd.

Yara Fertilizers India Pvt. Ltd., a subsidiary of Yara International, operates one of the largest fertilizer plants in India, located in Babrala, Uttar Pradesh. The plant specializes in producing ammonia and urea, key components in fertilizer manufacturing. Due to an increasing plant capacity, the existing ammonia cooling tower (ACT) pumps and urea cooling tower (UCT) pumps were found to be inadequate for the required flow range. The system, originally designed for a flow range of 6000-8000 m³/h, had to be upgraded to handle an enhanced capacity of approximately 11,000 m³/h.

Wilo was selected after a thorough evaluation process, despite the lack of prior Wilo pump installations at the plant. The primary customer requirement was to ensure high hydraulic capacity, reliability, operational stability, and long service life. Through proactive technical support, multiple site visits, and detailed engineering assessments, Wilo was able to gain customer confidence and successfully replace the existing pumps.

The pumping systems supplied for Yara Fertilizers are designed to handle high-capacity cooling requirements efficiently. The ACT and UCT pumps were engineered to provide reliable cooling for both ammonia and urea processes, which are critical to the fertilizer production process.

The 36/36 DV Lono and 24/30 DV Lono pumps were specifically designed to fit into the existing foundation and piping layout, ensuring no alterations were needed, which was a key requirement from the customer. These pumps, coupled with ABB 1250KW HT motors, ensure optimal performance while minimizing power consumption.

The pumps' design was based on customer-specific requirements, including considerations for shut-off head, impeller diameter, and efficiency. The engineering team evaluated approximately ten design options to ensure the most suitable and reliable solution for the plant’s cooling needs. The system was also designed in accordance with HIS standards, ensuring top-tier performance.