LATEST TECNIQUES
ADOPTED IN AMMONIA
PLANT TO IMPROVE
ENERGY
BY
PREM BABOO
SR. MANAGER(PROD)
NATIONAL FERTILIZERS LTD,VIJAIPUR, INDIA
SIMPLE WAY TO UNDERSTAND
AMMONIA PLANT
TECHNOLOGY HALDOR TOPSOE
CAPACITY 1750/1864 TPD
FEED NG AND NEPTHA
ENERGY 7.2GCAL/TON OF AMMONIA
ON NG
7.36 GCAL/TON OFAMMONIA IN
CASE OF MIXED FEED
INGREDIENT FOR AMMONIA
TO PRODUCE AMMONIA WE REQUIRE
H2 AND N2
H2 WE GET FROM NG AND WATER
N2 WE GET FROM AIR
NG CONTAINS ABOUT 92%CH4
NEPTHA CONTAINS HIGHER
HYDROCAREBON
BLOCK DIGRAM OF AMOONIA
PLANT
DESULPHERISATION REFORMING
SHIFT REACTION CO2 REMOVAL AREA
AND METHNATION CO2 TO UREA
COMP HOUSE
SYNTHESIS AMM TO UREA
DESULPHERISATION
AIM
TO REMOVE ALL SULPHER
COMING WITH NG AND NEPTHA
SULPHER IS POISIONOUS FOR THE
DOWNSTREAM CATALAYST
IT CONSISTS OF TWO STEPS
HYDROGENATION
IN THIS VESSLE NG AND NEPTHA ARE
BROUGHT IN CONTACT WITH
HYDROGEN SO THAT ORGANIC
SULPHER GETS CONVERTED INTO
INORGANIC SULPHER WHICH IS
SUBSEQUENTLY REMOVED IN ZNO
ABSORBER
CATALYST NIMO –FOR NG
COMO -FOR NAPHTHA
HYDRODE-SULPHERISATION
ALL ORGANIC SULPHER GETS
CONVERTED IN H2S
NG
HDS
RSH +H2 =RH +H2S
H2
R1SSR2 +H2 = R1H +R2H +H2S
NIMO
OUTLET
ZnO ABSORBER
TWO BEDS ARE INSTALLED IN SERIES
CATALYST USED IS = ZnO
ZnO+H2S = ZnS + H2O
SULPHER AT THE OUTLET OF THESE VESSLE ARE
LESS THAN .01PPM
INCREASING SULPHER CONTENT GIVE THE
INDICATION THAT BEDS ARE GETTING EXHUSTED
AND THEY REQUIRE CHANGE
FIRST BED CAN BE BYPASSED AND CATALYST CAN
BE CHANGED ON LINE A SPECIAL BED OF Copper
BASEDCATALYST IS INSTALLED AT THE BOTTOM OF
THE FIRST BED TO ADSORB ANY ORGANIC SULPHER
IF IT SLIPS FROM HYDROGEATION BED
DESULPHERISATION
ZnO +H2S = ZnS +H2
FROM HDS
ZnO ZnO
TO REFORMER
REFORMING
AIM
TO REFORM NG AND NEPTHA IN TO H2
CO AND CO2 REFORMING IS DONE WITH
THE HELP OF STEAM THATIS WHY IT IS
CALLED STEAM REFORMING IT
CONSIST OF THREE STEPS
STEPS OF REFORMING
PREREFORMER
PRIMARY REFORMER
SECONDRY REFORMER
CONDITION OF REFORMING
REFORMING IS AN ENDOTHERMIC REACTION
IT MEANS THAT HEAT WILL HAVE TO BE
SUPPLIED TO MOVE THE REACTION IN
FORWARD DIRECTION
MAJOR PORTION OF REFORMING IS DONE IN
PRIMARY REFORMER THIS REACTION IS
CARRIED OUT IN A FURNACE OPERATING
CONDITIONS ARE VERY INTENCE
REACTIONS OF REFORMING
CnH2n+2 +2H20 = Cn-1H2n +CO2 +3H2-
HEAT
CH4 +2H2O = CO2 +4H2 –HEAT
CO2 + H2 = CO + H20 - HEAT
HOW OPERATING CONDIONS
ARE DECIDED
AS PER LE CHATERLIERS PRINCIPLE THE
REACTION OF REFORMING REQUIRES
HIGH TEMERATUTRE CONDITIONS
LOW PRESSURE CONDITIONS
OPTIMUM PRESSURE IS SET ARROUND
34KG\CM2
PRESSURE BELOW THIS SUITS REFORMIG
REACTION BUT THIS IS NOT SUITABLE FOR
DOWNSREAM REACTIONS
CATALYST USED IN
REFORMING
CATALYST USED IS NICKLE
IN VARIOUS REFORMING STEPS ONLY
THE CONTENT OF NICKLE VARRIES
BESIDES THIS BASE OF THE CATALYST
ALSO VARRIES
CONDENSATION OF STEAM IS TO BE
AVOIDED IN CATALYST BED
BECAUUSE IT MAY SPOIL THE ENTIRE
CATALYST
PRE REFORMER
PRE REFORMER IS ISTALLED IN AMMONIA
EXPANSION
ITS PURPOSE IS TO REFORM HIGER HYDROCARBON
TO LOWER HYDROCARBON
TO BE KEPT IN LINE WHEN NEPTHA IS BEING USED
IN FEED
WITHOUT PREREFORMER NEPTHA CAN NOT BE
USED IN FEED
IT CAN BE KEPT IN LINE WITH NG ALSO BUT NOT
WITH GREAT DEAL OF ADVANTAGE
ITS CATALYST IS ONE OF THE COSLIEST IN
AMMONIA PLANT
PRE REFORMER
490 ----510
PRE
REFORMER
NG+NEPTHA+STEAM
NI
440----470
REFORMED GAS TO P R
PRIMARY REFORMER
IT IS THE MOST IMPORTANT STEP IN
THE REFORMING PROCESS
IT COSIST OF A FURNACE
FURNACE IS SIDE FIRED
IT CONTAINS 288 TUBES AND 576
BURNERS
CATALYST IS FILLED INSIDE THE TUBE
FIRING IS DONE ON BOTH THE SIDES OF
THE TUBE
REFORMER FURNACE
TUBES CH4 90%
450---500
NI
765
CH4 11%
IMPORTANT PARAMETER OF
PRIMARY REFORMER
FURNACE INSIDE PRESSURE SHOULD BE
SLIHTLY BELOW ATMOSPHERIC PRESSURE
ARROND -5MMWC
TUBES SKIN TEMP SHOULD NOT EXCEED
905DEGREE CENTRIGADE OTHRWISE TUBE
LIFE WOULD BE SHORTENED
S/C RATIO IS ONE OF THE MOST IMP
PARAMETE ITS KEPT ARROUND 3.3 LOWER
S/C RATIO MAY RESULT IN CARBON
FORMATION
SECONDRY REFORMING
AIM
TO COMLETE THE REMAINING
REFORMING
TO INTRODUCE AIR SO THAT WE CAN
GET N2 REQUIRED FOR THE AMMONIA
PRODUCTION
SECONDRY REFORMING
AIR
P REF O/L
765
1200
CH4 11%
SECONDRY REFORMER
S R O/L
940
CH4 .3%
WHAT HAPPENS IN SECONDRY
REFORMER
PRIMARY REFORMER OUTLET GAS
WHICH CONTAINS ABOUT
11%METHANE AT ATEMP OF ABOUT
765DEGREE IS BROGHT IN CONTACT
WITH AIR AT A TEMP OF 575 DEGREE
FIRST REACTION IN SR IS EXOTHERMIC
REACTION IN WHICH APART OF GAS
BURNS WITH AIR O2 GETS CONSUMED
WHAT HAPPENS IN SECONDRY
REFORMER
TEMERATURE OF GAS IN TOP PAERT OF
REFORMER REACHES TO ARROUND
1200 DEGREE
THIS HEAT IS USED FOR FURTHER
REFORMING
METHANE AT OUTLET OF SR BECOMES
ABOUT .3%
SR OUTLET TEMP BECOMES 940
DEGREE
SHIFT REACTION
AIM
GAS AT THE OUTLET OF SR CONTAINS
BOTH CO AND CO2
CO IS OF NO USE
CO2 IS REQUIRED FOR THE
PRODUCTION OF UREA
IN SHIFT REACTORS ALL CO IS
CONVERTED IN TO CO2
SHIFT REACTION
SHIFT REACTION IS TWO STEP PROCESS
FIRST STEP IS CARRIED OUT AT HIGH
TEMP IT IS CALLED HT SHIFT
REACTION TO INCREASE THE RATE OF
REACTION
SECOND STEP IS CARRIED OUT AT LOW
TEMP CALLED LT SHIFT REACTION IT
IS TO ACHIVE HIGH EQULIBIRIUM
CONVERSION
HT SHIFT CONVERTOR
CATALYST USED IRON OXIDE
INLETTEMP 355 DEGREE
OUTLET TEMP 423DEGREE
OUTLET CO 2.8%
CO+H2O = CO2 +H2
HT SHIFT CONVERTOR
355
SR OULET GAS
HT SHIFT
CO 12.77
CATALYST GAS TO LT
IRON OXIDE
423
CO 2.8%
LT CONVERTOR
CATALEST USED MIANLY CU
INLET TEMP 195 DEGREE
OUTLET 212 DEGREE
OUTLET CO .17%
CO +H2O = CO2 + H2
POISON FOR THE CATALYST ARE
S AND CHLORIDE
LT SHIFT CONVERTOR
HT OUUTLET
CO 2.8%
LT CONVERTOR
LT OUTLET
CO .17%
CO2 REMOVAL
TWO MAIN PROCESS FOR THIS ARE
BENFIELD PROCESS USED IN LINE 1
GV PROCESS USED IN LINE 2
GV PROCESS USED IN LINE 2 HAS SOME
ADVANTAGE OVER BENFIELD PROCESS
GV PROCESS
AIM
TO REMOVE ALL CO2 FROM THE
PROCESS GAS BY ABSORBING IN HOT
POTTASIUM CARBONATE SOLUTION
AND THEN REGENERATING THE
SOLUTION
CO2 PRODUCED IS SENT TO UREA
PLANT
GV PROCESS
SOLUTION IS MADE OF POTTASSIUM
CARBONATE
TWO ACTIVATORS USED ARE
GLYCENE AND DEA
COMPOSITION
K2CO3 27%
GLYCENE 1.2%
DEA 1.0%
VANADIUM .4%
GV PROCESS
CHEMISTRY INVOLVED
ABSORBTION REACTION
K2CO3+H20+CO2 =2 KHCO3
REGENERATION REACTION
2KHCO3 +HEAT = K2CO3 +H20+CO2
TWO STAGE REGENERATION & USE OF FLASH STEAM OF HP IN LP
REGENERATOR & REDUCTION IN LP STEAM
REDUCTION CO2 SLIP by 1000PPM
IMPROVED HEAT RECOVERY
Heat loss to
atmosphere via
air cooler-12.68
Gcal/h
BLOCK DIGRAM
CO2 FREE GAS
CO2
SOLUTION
LOADED SOL
ABSORBER REGENERATOR
GAS
STEAM
LOADED SOL REGENERATED SOL
METHNATION
AIM
TO CONVERT ALL CO AND CO2 TO
METHANE
OUTLET GAS FROM CO2 REMOVAL
AREA CONTAINS BOTH C0 AND C02
BOTH THESE GAS ARE NOT REQUIRED
AS THESE ARE POISON FOR THE SYN
CATALYST
METHNATION
CATALYST USED NICKLE
C0 + H2 = CH4 + HEAT
CO2 +H2 =CH4 + HEAT
METHANE FORMED ACTS AS A INERT
GAS IN SYN REACTION AND IT IS
REMOVED IN PURGE TAKEN OUT FROM
THE SYN LOOP
METHNATION
GAS FROM GV
290
CO .17% CO2 300 PPM
METHNATOR
NICKLE COANDCO2<1PPM
306
GAS TO COMP
COMP HOUSE
COMP HOUSE CONTAINS THREE COMP
AIR COMP
REFRIGRATION COMP
SYNTHESIS COMP
AIR COMP
AIM
AIR COMPRESSOR COMPRESSES AIR UP
TO 34KG\CM2 PRESSURE
AIR IS USED IN SECONDRY REFORMER
H2/N2 RATIO DETERMINES FLOW OF
AIR TO SECONDRY REFORMER
AIR COMP
AIR COMP
AIR TO SECONDRY REFORMER
ATMOS AIR 34KG /CM2 170
REFRIGRATION COMPRESSOR
AIM
IT IS USED TO COMPRESS AMMONIA
WHICH IS USED AS A REFRIGRENT IN
SYNTHESIS LOOP
REFIGRATION IS DONE AT THREE
PRESSURE LEVEL
ITS FINAL DISCHARGE PRESSURE IS
14KG \CM2
SYNTHESIS COMP
AIM
AMMONIA SYNTHESIS REACTION IS
CARRIED OUT AT HIGH PRESSURE
CONDITIONS AT ABOUT 180KG\CM2
SYN COMP IS USED TO COMPRESS GAS
UP TO THAT PRESSURE
Syn compressor
Gas to comp Gas from loop
Gas to loop 180kg/cm2
26kg/cm2 172kg/cm2
175 Gas to conv
AMMONIA SYNTHESIS
AIM
TO PRODUCE AMMONIA WITH THE
HELP OF SYN GAS COMING FROM
METHNATOR
SYN GAS CONTAINS MAINLY H2 AND N2
AMMONIA SYN REACTION
3H2 +N2 = 2NH3 +HEAT
CATALYST USED IRON
REACTION CONDITION
HIGH PRESSURE AND LOW TEMP
AMMONA SYN REACTION
AMMONIA SYN REACTION IS A REVERSIBILE
REACTION AND EQULIBIRIUM CONDITION IS
DETERMINED BY TEMP AND PRESSURE
CONDITIONS
IN ONE PASS THROUGH THE CONVERTOR
ONLY 30% OF THE REACTANTS GETS
CONVERTED TO THE PRODUCT SO
REMAINING GAS KEEPS ON CIRCULATING
BLOCK DIGRAM
GAS TO CONV
H2 AND N2
H2 N2 AND NH3
OUT LET GAS
BLOCK DIGRAM OF SYN
SECTION
SYN GAS STEAM
AMM CONVERTOR LOOP BOILER BFW HEATER
GAS GAS EX WATER COOLER GAS GAS EX
PRI CHIL SEC CHILL AMM SEP LET DOWNVESSLETO
PURGE GAS STORAGE
AMM TO UREA
What is purge
AS AMMONIA SYN REACTION IS NOT
COMPLETED IN ONE STEP AND GAS IS KEPT
ON CIRCULATING INERTS BUILDS UP IN THE
LOOP
INERT MEANS CH4, Ar NH3 AT INLET OF
CONV THEIR CONCENTRATION SHALL NOT
INCREASE BEYOND 14%
SO A SMALL AMMOUNT OF GAS IS
CONTTIOUSLY WITHDRAWN FROM THE
LOOP THIS STREAM OF THE GAS IS CALLED
PUGE GAS
PURGE GAS RECOVERY
PURGE GAS CONTAINS H2, CH4 AND
AMMONIA
AMMONIA IS RECOVERED BY
WASHING THE GAS WITH WATER AND
REMAINING GAS WHICH CONTAINS CH4
AND H2 IS USED IN REFORMER FIRING
SYSTEM
PURGE GAS RECOVERY
AM TO STORAGE
GAS TO REF WATER
ABSORBER LOADED SOL REGENERATIONR
STEAM
PUURGE
Installation of Plate type Combustion air
preheater
Facilitate reduction in reformer stack temperature to
125°C
Energy saving: 0.055 Gcal /MT NH3
Energy saving due to
a) NG saving due to increase in combustion air
temperature
B) Reduction in steam consumption in ID Fan
Conversion of Benfield process to GV
process
To increase capacity and improve energy
effciency
GV 2 stage process has a lower specific
regeneration heat requirement and hence
reduction in low pressure steam consumption by
utilizing flash steam of HP regenerator &
utilization heat by LP steam reboiler instead of
loosing to atmosphere through air cooler
Energy savings: 0.18 Gcal/MT NH3
Existing Amm-II is based on GV Process
New equipment in conversion from Benfield to GV
section
Separator OH 2nd regenerator (B-1307)
LP steam boiler (E-1301)
DMW pre-heater (E-1305 A/B)
Condenser OH 2nd regenerator (E-1309)
2nd Regenerator (F-1303)
Steam Ejector (X-1301)
Aeration Injection tank (T-1305)
Sealing water heater (E-1315)
Cooler for Aeration tank (E-1324)
Activated carbon filter and 2nd Mechanical filter
New machinery in conversion from Benfield to GV
section
CO2 blower (K-1301)
Semi-lean solution pump (P-1301D)
Lean solution pump (P-1302 A/B)
2nd condensate pump (P-1308 A/B)
Aeration Injection pump (P-1309 A/B)
Sealing water pump (P-1310 A/B)
Modifications in 1st regenerator
New take off trays are installed below bed 2
and above bed 3
New liquid re-distributors above bed 1 and 3
Bed limiters over beds 1 and 3
1st bed height reduced by 2195 mm
Demister
New nozzles and instrumentation for new take-
off trays
Modification in CO2 absorber
Liquid distributor over Bed 2 and 4
Liquid redistributor over beds 1,2,3 & 4
Gas distributor under bed 1
Packing : Bed 1: IMTP 50 Bed 4: IMTP25
Installation of S-50 converter
To increase the energy efficiency of the ammonia
synthesis loop, an S-50 converter R-1502 is installed
downstream of the existing converter.
The increase in ammonia concentration exit the new
converter results in a decrease in loop pressure and a
lower circulation rate, which gives savings on the
synthesis gas compressor and the refrigeration
compressor.
Energy saving: 0.18 Gcal/MT NH3
Advantages of addition of S-50 Loop
Ammonia concentration at the outlet of S-50 =
24.35% as compared to 20.02% in S-200
Higher conversion 35.5 % as compared to 28.3% in S-200
Lower circulation rate as compared to S-200 for same
load
Higher steam generation 82 T/hr as compared to 70 T/hr in S-
200
Lower synthesis loop pressure
Lower compressor power due to less circulation and low
pressure
Possible to achieve higher plant load with same equipments
S-50 Integration in synthesis loop
Parallel Air compressor
Addition of Parallel air compressor
(reciprocating type) to meet the additional
process air requirement
Process air from Existing PAC: 59152
Nm3/hr
Process air from New Compressor: 6030
Nm3/hr
Total air requirement for 1750 MTPD
ammonia as per PFD: 65181 Nm3/hr
Ammonia-II CEP: Process air
As per PFD of Ammonia-II CEP, the total
requirement of process air from PAC of
Ammonia-II shall be 75683 Nm3/hr with
distribution as follows:
Process air for Ammonia-II CEP : 69234
Nm3/hr
Instrument air : 3924 Nm3/hr
Export to Ammonia-I : 2525 Nm3/hr
69
Ammonia-II CEP: HTAS report & OEM review
The capacity of existing PAC in Ammonia-II is : Normal:
59275 Nm³/h , Rated : 64900 Nm³/h
Based on overall performance curve of PAC, HTAS has
confirmed that the desired load shall remain within the
operating range of the compressor.
OEM of PAC of Ammonia-II has confirmed that it should
be possible to operate the machine with 75372 Nm³/h
without modifications.
It was practically observed that the machine is in position
to deliver the desired load with no limitation on driver
side.
70
LINE1 AND LINE2 DIFFERENCE
LINE 1 DOES NOT HAVE MIXED FEED
CAPABILITY ONLY NG CAN BE USED AS
FEED
IN LINE1 AIR COMP IS RUN BY STEAM
TURBINE IN LINE 2 GT IS USED FOR
RUNNING AIR COMP
LINE1 AND LINE2 DIFFERENCE
IN LINE 1 STRIPPING OF CONDENSATE
IS DONE BY LOW PREESURE STEAM
AND ALL THE STEAM IS VENTED TO
ATMOSPHERE
IN LINE 2 STRIIPING IS DONE BY MP
STEAM AND STEAM IS REUSED IN
REFORMER THUS SAVING THE ENERGY
LINE1 AND LINE2 DIFFERENCE
IN LINE 1 BENFIELD PROCESS IS USED
FOR CO2 STRIPPING
IN LINE 2 GV PROCESS IS USED FOR CO2
REMOVAL
LINE 1 DOES NOT HAVE PRE REFORMER
LINE1 AND LINE2 DIFFERENCE
IN LINE 1 BENFIELD PROCESS IS USED
FOR CO2 STRIPPING
IN LINE 2 GV PROCESS IS USED FOR CO2
REMOVAL
LINE 1 DOES NOT HAVE PRE REFORMER
