Process Description
Jakarta, 27 Oktober 2014
General
Capacity (As 100% ammonia):
2,160 MTPD ammonia with purge gas processing facilities
online
2,000 MTPD ammonia with purge gas processing facilities
off-line.
KBR Purifier™ Process Technology
2000 MTPD 2160 MTPD CO2 max
Natural Gas (Nm3/h) 67,454 72,048 74,439
Process Steam (kg/h) 138,424 145,849 145,849
Air (Nm3/h) 110,903 117,000 118,259
Conventional Process
PURIFIER™ PROCESS
Advantages
101-B Temp outlet
50% extra Air Additional reaction heat 103-D
740oC vs 799oC
CH4 leakage Relaxes severity of 103-D
1.7%-v vs 0.3%-v (902oC vs 990oC)
Enables lower S/C ratio
N2, CH4 and Argon separated in purifier Sent to Fuel Gas
Feed gas compression & Desulfurization
360oC
Hydrogenation & Desulfurization
Catalyst : Cobalt/Molybdenum oxide (CoMox)
RSH + H2 H2S + RH + heat
COS + H2 CO + H2S + heat
Catalyst : Zinc Oxide
H2S + ZnO ZnS + H2O + heat
Primary Reforming
371oC
28.5%-v CH4
497oC
740oC
40.5 kg(g)
80.3%-v CH4
44.2 kg(g)
488oC
360oC
146oC 722oC
Combution Air
FD Fan
101-BJ1/BJ1A
Primary Reforming + Convection NG + Waste Gas
Arch burners
Fuel Gas
Superheat burners
BFW
Fuel Gas
Waste Gas Tunnel burners
• HP flash column
• Purifier waste gas
• ARU (Ammonia scrubber
Primary Reforming
Catalyst : Nickel-based
CnHm + nH2O + heat nCO + ( 2n + m )/2 H2
CH4 + H2O + heat CO + 3 H2
CO + H2O CO2 + H2 + Heat
Steam to Carbon molar ratio : 2.7
Convection section coils
Natural gas preheat prior to 101-D, 108DA/DB
Process air preheat (Hot & Cold)
Combustion air preheat
Mixed feed preheat prior to reformer
HP Steam superheater (Hot & Cold)
Process Air Compression
MP steam
2.7 tph
Secondary Reforming
28.5%-CH4
Combustion
1349oC
section
Reforming
section
898oC
1.7%-CH4
Catalyst : Nickel
CH4 + H2O + heat CO + 3 H2
CO + H2O CO2 + H2 + Heat
Steam Generation & Superheater
20.7% vapor 374oC
ex 103-C1/C2
ex 123-C1/C2
902oC
Carbon Monoxide Shift Conversion
205oC
11.98%-v CO
431oC
0.3%-v CO
3.34%-v CO
103-C1/C2
Catalyst : 131-C
BFW BFW preheater
Iron oxide (Copper-promoted) HTS 166oC
Copper/Zinc LTS
CO + H2O CO2 + H2 + Heat
Carbon Dioxide Removal
500 ppmv CO2
134oC 70oC
CH3N(CH2CH2OH)2 + CO2 + H2O HCO3- + H+CO2N(CH2CH2OH)2
Methanation & Chiller
172-C
115-C
114-C
CO slip : 0.38%-v (EOR)
CO2 slip : 500 ppm-v (EOR)
Catalyst : Nickel
COx outlet < 5 ppm-v (EOR)
CO + 3H2 CH4 + H2O + heat
CH4 outlet < 2.2%-v (EOR)
CO2 + 4H2 CH4 + 2H2O + heat
Drying – Regen (Heating up)
A : online
B : regeneration
245oC
Drying – Regen (Cooling down)
A : online
B : regeneration
Purification
134-C
132-C
131-JX 137-D
Syngas Purification Comparison
Purifier Conventional
Purified Syngas
-Percent Inert < 0.3 >1
-Moisture Dry Wet syngas
-CO2 0 5 – 10 ppm
PG H2 Recovery Integral Separate Unit
H2/N2 Ratio Control Simple & Precise Complex
Catalyst Deactivation Full Production Reduced Production or
Shutdown
Synthesis Loop
3-Bed Horizontal Intercooled
Ammonia Converter
Catalyst : Promoted Iron Synthesis
3H2 + N2 2NH3 + heat
Refrigeration
Unitized Chiller
Ammonia Recovery Unit
25
The Steam System at the Ammonia Plant
1. STEAM GENERATION
2. STEAM USERS
3. STEAM CONDENSATE TREATMENT
Steam Generation HS
P = 123.1 kg/cm2G
Diagram 103-JT
102-C Reforming Furnace
Superheated
HP Steam Superheat Coils
Superheater T=336 OC (101-B) ; T = 510 oC
HS
P = 123.1 kg/cm2G 105-JT
141-D
Steam Drum Heat Recovery 101-C
Secondary
Liquid Reformer WHB
Blowdown
Vap 20.7 %
Vap 20.7 %
123-C1
103-C1 Ammonia Converter Eff./ Steam
HTS Eff. Steam Generator Generator
103-C2 123-C2
HTS Eff. BFW Ammonia Converter Eff./
Preheater BFW Preheater Exch.
130-C
LTS Eff/ BFW
Preheater
101-U
BFW Deaerator
104-J/JA
HP BFW Pump 27
Steam Turbine for
Syngas Compressor
HP Steam ;
269.65 T/h
From HS
Header
103-JT
Exhaust Line
103-JTC;
16 T/h
MP Steam;
253.65 T/h
to MS
Header
28
Steam Turbine for
Ammonia Refrigerant Compressor
High Steam ;
104.90 T/h
From HS
Header
105-JT
Medium Steam;
104.90 T/h
to MS
Header
29
Steam Network
Pressure (kg/cm2G) Temperature (oC)
High Pressure (HP) Steam 123.1 510
Header
Medium Pressure (MP) Steam 46.9 387.9
Header
Low Pressure (LP) Steam 3.5 236
Header
Import MP Steam from OEP Start up only
Import MP Steam from Power Generation internal MP
steam production low
30
High Pressure Steam (HS)
High Pressure Steam (HS)
Control at High Pressure Steam Header
The ammonia plant produces Pressure
high pressure superheated • PIC-1018 and local PG-1018
steam P = 123.1 kg/cm2G; T = monitoring Pressure at HS Steam
510 oC Header.
To Syngas Turbine (103-JT) : • High pressure and Low pressure alarm
combination extraction-condensing will sound on PIC-1018 if either of those
machine conditions are reached.
Capacity: 269.65 T/h (2000 MTPD • PIC-1018 uses split range control
through high selector PN-1013 with PIC-
HOT CASE)
1013:
To Ammonia Refrigerant Turbine - 0-50% through PY-1013 to 103-JT
(105-JT) : extraction machine governor
Capacity: 104.90 T/h (2000 MTPD - 50-100% for letdown to MS by PV-
HOT CASE) 1018.
- Override by PIC-1013
32
High Pressure Steam (HS)
Control at High Pressure Steam HS Header Protection
Header • The steam system piping and the
Temperature superheater coil protection by
TIC-1005 and TIC-1005A The safety relief valve PRV-101B1/B2
superheat temperature out of hot set at 135 and 137 kg/cm²g
coil (101-BCS2). relieving directly to the
atmosphere.
This controls the temperature by
adjusting the firing rate of the • At header: Vent HV-1048 and
superheater burners in the 101-B Silencer SP-152 (shared with the
convection section using TIC-1005 MS Steam) manually operated.
adjusting TV-1005 fuel gas valve.
33
High Pressure Steam (HS)
HS Letdown
When one or both of the turbines 103-JT and or 105-JT are not operating,
the steam flow is passed through letdown valves PV-1018 and HV-
1028 HV-1028 will open on a 103-JT or 105-JT trip, into the MP
steam system.
DCS HIC-1028 controls HV-1028 and receives internal DCS inputs from
the 105-J and 103-J trip circuits through internal block XS-1128. If one or
both of these turbines trip, a corresponding output will be sent to HIC-
1028 to immediately open the letdown valve.
103-J trip HV-1028 opens flowrate : (0.7 x FI1033) – FI1125
105-J trip HV-1028 opens flowrate : FI1125
HIC immediately released to operator
34
Medium Pressure Steam (MS)
Medium Pressure Steam (MS)
MP steam is extracted from the syngas (103-JT) and refrigeration
compressor turbines (105-JT).
MP steam supply to:
1. Process Steam
2. ID Fan Turbine (101-BJ1T/ BJ1AT), FD Fan Turbine(101-BJT/ BJAT), Semi-Lean Oase Solution
Pump Turbine (107-JBT), Lean Oase Solution Pump Turbine (108-JT), and Steam Turbine
for Lube Oil 101-J & 102-J (101-JLOT), and Steam Turbine for Lube Oil 103-J & 105-J (103-
JLOT)
3. Air Compressor Turbine (101-JT)
4. HP BFW Pump Turbine (104-JT)
5. Feed Gas Compressor Turbine (102-JT)
6. Cooling Water Pump for Ammonia and UOA (6209-JAT/JBT)
7. Ammonia Distillation Column Reboiler (160-C), Mol Sieve Regeneration Heater (183-C),
LTS Start-up Heater (175-C)
Excess medium pressure steam from the ammonia plant is
exported to the CO2 compressor turbine of the urea plant.
36
Medium Pressure Steam (MS)
Control at Medium Pressure Steam Header
Pressure
The MP steam header is measured by PT-1013, PT-1014 and PT-1015 to
median select PN-1015 which provides control necessary for the MP
steam system.
PG-1752 can be used to monitor the header pressure locally.
HS Letdown to MS
MP Steam Header pressure becomes too low:
PIC-1013 thru PN-1013 will letdown to MP by PV-1018 header
pressure back to normal.
37
Medium Pressure Steam (MS)
Excessive Steam
PIC-1014 pressure high to atmosphere through
silencer SP-152
MP Steam Header Protection
overpressure by safety relief valve PRV-1314 set at
51.6 kg/cm²g relieve to atmosphere.
38
Medium Pressure Steam (MS)
Exported and Imported MS Header
P&T
Export flow: measured on FI-1350B Totalized on FQI-1350B compensated
Import flow: measured on FI-1350A Totalized on FQI-1350A using PN-1015
and TI-1554
Normal Condition
Exported to Urea and UOA area (Demin Pump)
PV-1075 closed no export to PUSRI II and PUSRI III
Import to Ammonia Plant (in case export flow is not balanced): supplied by
STG boiler
Start-up
Import to Ammonia supplied by PUSRI II or PUSRI III or STG
Alternative Condition
MP steam to PUSRI II or PUSRI III from STG boiler 39
Low Pressure Steam (LS)
Low Pressure Steam (LS)
LP Steam User
P = 3.5 kg/cm2G; T = 236 oC
The main users of the LP steam are 101-JT and 101-U Deaerator.
Other users include:
Turbine gland condenser ejectors (101-JTC,103-JTC, 102-JTC, 6209-JTC)
Utility stations, steam tracings
Control at LS Header and Letdown
Pressure
DCS PIC-1017A senses the pressure in the LS reduces the LP flowrate to 101-JT (admission
steam)
The LP steam header is measured and controlled by PT-1016, PT-1017 and PT-1020 to
median select PN-1017
PIC-1016 control letdown valve PV-1016 by median select PN-1017 (set pressure lower
than PIC-1017A).
PIC-1017A over pressure controller
output signal: to 101-JT governor.
PIC-1017B over pressure control 41
output signal: control PV-1017B to vent through SP-153
Low Pressure Steam (LS)
Control at LS Header and Letdown
Temperature
The letdown steam temperature is sensed and DCS indicated on TIC-1023 with a high and
low alarm.
TIC 1023 command TV-1023 to reduce the steam temperature (condensate line from
119-J/JA ).
Exported and Imported LS Header to Utility
Export flow: measured on FI-1118A
Import flow: measured on FI-1118B
The export flow rate is temperature and pressure corrected using TI-1555 a high and low
alarms.
LS Header Protection
Overpressure protection PRV-2239 (set pressure = 5.3 kg/cm²g to vent the
atmosphere)
42
Steam Condensate
Treatment Diagram
Note:
Turbine Condensate
Treatment
Process Condensate
Treatment
43
Steam Condensate Treatment
Turbine Condensate Treatment
101-JTC Condensate
Condensate Tank
(from 101-JT) Pump 118-J/JA
102-JTC Condensate
(from 102-JT & 104-JT) Pump 119-J/JA
Deaerator
103-JTC Condensate
(from 103-JT) Pump 123-J/JA
6209-JTC Condensate
Condensate Tank
(from 6209-JA/B T) Pump 6000-JA/JB
Vacuum Cond. Condensate
Condensate Tank
Urea unit Pump
Process Condensate Treatment
130-D 188-C1/2/3 174-C Condensate Tank
44
Steam Condensate Treatment
Non-condensable
Steam
Inert and non-condensables from 101-JTC, 102-JTC, and 103-JTC removed by set of LP
Steam Driven Jet Ejectors.
The ejectors typically come in two pairs with each pair capable of 100% of design non-
condensable removal.
The ejectors pull the non-condensables from the surface condenser shell top.
The driving steam from the ejector condensed in condenser against cooling water
trapped back to the hotwell of surface condenser;
The non-condensables vented to the atmosphere.
Surface Condenser
Protection
Overpressure PRV-103-JTC, PRV-102-JTC, and 101-JTC set pressure = 1.1 kg/cm2g
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