This document provides an overview of the key components and processes in an ammonia plant. It describes the desulphurization process to remove sulfur from natural gas and naphtha feeds. It then explains the multi-step reforming process used to produce hydrogen and other gases from these feeds, including pre-reforming, primary reforming, and secondary reforming. The shift reaction process is also summarized, which converts carbon monoxide into carbon dioxide. Overall temperatures, pressures, catalysts and reactions for each major unit are outlined to concisely explain the production of ammonia.
Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
Other suppliers are Linde (LAC) & Ammonia Casale.
This is great Presentation with 3D effects which is all about production of ammonia from natural gas.
I am damn sure you will be getting everything here searching for.
its better to download it and then run in powerpoint 2013.
This slides shows vocational training which i've done at ammonia-4 plant at GSFC LTD.
There are some tasks that given by our university that we have done here.
Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
Other suppliers are Linde (LAC) & Ammonia Casale.
This is great Presentation with 3D effects which is all about production of ammonia from natural gas.
I am damn sure you will be getting everything here searching for.
its better to download it and then run in powerpoint 2013.
This slides shows vocational training which i've done at ammonia-4 plant at GSFC LTD.
There are some tasks that given by our university that we have done here.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Installation of S-50 ammonia synthesis converter along with waste heat boiler in downstream of existing S-200 ammonia synthesis converter is one of the major schemes of Energy Saving Project of Ammonia plant. The energy saving reported 0.18 G.Cal/T of Ammonia. Several ammonia plants have installed an additional ammonia synthesis converter in combination with a HP steam waste heat boiler, downstream of the existing ammonia converter. The result is increased conversion per pass, reduced compression requirements due to the smaller recycle gas stream, and improved waste heat recovery. Among the methodologies aimed at finding energy saving opportunities, pinch analysis linked to power and steam modeling has proved to be a powerful way for determining projects to improve the overall energy efficiency of industrial sites. This procedure has been applied successfully in many industrial facilities, allowing optimal energy recovery in the process and hence reduction of fuel consumption.
Why have a Secondary Reformer ?
Need nitrogen to make ammonia
Wish to make primary as small as possible
Wish to minimise methane slip since methane is an inert in the ammonia synthesis loop
Other methods of achieving this
Braun Purifier process
Can address all these with an air blown secondary
In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H2 is demineralized water and the hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The present article intended the description of ammonia plant for natural gas based plants and the possible material balance of some section.
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
Energy saving in urea plant by modification in heat exchanger and processPrem Baboo
Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Improvement in energy
efficiency reduces cost of production & results in environmental benefits, e.g. mitigation of global warming by way of less emission of
Green house gases in the atmosphere. Over the years several energy conservation measures have been taken towards reduction in
specific energy consumption and improvement in energy efficiency. The efforts’ resulted in reduction in specific energy consumption
from 6.27G. Cal/tone of Urea to 5.421 G.Cal/tone of Urea in 2015-16 as shown in the Graph No 1 & 2 with energy & down time.
Further a major modification of all plants is under way. Most of the schemes have been implemented in 2012 and the further
modifications expected to result again reduction of energy consumption for ammonia and Urea plants. This paper described some of
the modification in urea plants implemented recently in May/June 2016.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Installation of S-50 ammonia synthesis converter along with waste heat boiler in downstream of existing S-200 ammonia synthesis converter is one of the major schemes of Energy Saving Project of Ammonia plant. The energy saving reported 0.18 G.Cal/T of Ammonia. Several ammonia plants have installed an additional ammonia synthesis converter in combination with a HP steam waste heat boiler, downstream of the existing ammonia converter. The result is increased conversion per pass, reduced compression requirements due to the smaller recycle gas stream, and improved waste heat recovery. Among the methodologies aimed at finding energy saving opportunities, pinch analysis linked to power and steam modeling has proved to be a powerful way for determining projects to improve the overall energy efficiency of industrial sites. This procedure has been applied successfully in many industrial facilities, allowing optimal energy recovery in the process and hence reduction of fuel consumption.
Why have a Secondary Reformer ?
Need nitrogen to make ammonia
Wish to make primary as small as possible
Wish to minimise methane slip since methane is an inert in the ammonia synthesis loop
Other methods of achieving this
Braun Purifier process
Can address all these with an air blown secondary
In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H2 is demineralized water and the hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The present article intended the description of ammonia plant for natural gas based plants and the possible material balance of some section.
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
Energy saving in urea plant by modification in heat exchanger and processPrem Baboo
Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Improvement in energy
efficiency reduces cost of production & results in environmental benefits, e.g. mitigation of global warming by way of less emission of
Green house gases in the atmosphere. Over the years several energy conservation measures have been taken towards reduction in
specific energy consumption and improvement in energy efficiency. The efforts’ resulted in reduction in specific energy consumption
from 6.27G. Cal/tone of Urea to 5.421 G.Cal/tone of Urea in 2015-16 as shown in the Graph No 1 & 2 with energy & down time.
Further a major modification of all plants is under way. Most of the schemes have been implemented in 2012 and the further
modifications expected to result again reduction of energy consumption for ammonia and Urea plants. This paper described some of
the modification in urea plants implemented recently in May/June 2016.
Pre-reforming
Flow-schemes
Feed-stocks
Catalyst handling, loading & start-up
Benefits of a pre-reformer
Case studies
Effects upon primary reformer
Data analysis
Reactor temperature profiles
Catalyst management
Summary
Study 5: Pre-commissioning Safety Review
CONTENTS
5.0 PURPOSE
5.0.1 Team
5.0.2 Timing
5.0.3 Preparation
5.0.4 Documentation
HAZARD STUDY 5: APPLICATION
5.1 TOUR OF THE PROJECT
5.2 REVIEW OF HAZARD STUDY 5
Calculation of an Ammonia Plant Energy Consumption: Gerard B. Hawkins
Calculation of an Ammonia Plant Energy Consumption:
Case Study: #06023300
Plant Note Book Series: PNBS-0602
CONTENTS
0 SCOPE
1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION
2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION
3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT BURNERS OF FLARES
4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT
5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS
6 CALCULATION OF MP STEAM EXPORT
7 CALCULATION OF LP STEAM IMPORT
8 DETERMINATION OF ELECTRIC POWER CONSUMPTION
9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT ISBL
10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST RUN CONDITIONS
11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION IN UTILITIES
12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER CONSUMPTION IN UTILITIES
13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL
14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT
This gives the full specification and working of a generator in a 500 MW power plant in which you will get a clear idea about how a generator works in a power plant.This was used in NTPC power plants all over INDIA according to their power generation capacity.
High speed technology is a boon in fpd /orthodontic courses by Indian dental ...Indian dental academy
The Indian Dental Academy is the Leader in continuing dental education , training dentists in all aspects of dentistry and
offering a wide range of dental certified courses in different formats.for more details please visit
www.indiandentalacademy.com
Solar Or Waste Heat Absorption Cooling System
DRAMATIC INCREASE OF AIR CONDITIONING SINCE THE EARLY 80’S
• COST OF ENERGY
• ISSUES RELATED TO ENVIRONMENTAL POLLUTION
DUE TO ENERGY PRODUCTION
DUE TO THE USE OF CFC’S AND HCFC’S
• MATCHES DEMAND WITH SOURCE AVAILABILITY
• CRUCIAL FOR IMPROVING LIFE STANDARDS IN DEVELOPING COUNTRIES
PRIMARY TAR CRACKING METHODS - Various materials usedAyisha586983
Primary tar cracking methods are essential in gasification and pyrolysis processes to convert tar (a complex mixture of hydrocarbons and other organic compounds) into more useful gases, liquids, or solid products. Tar cracking helps improve gas quality, reduce equipment fouling, and enhance overall process efficiency.
Silent, warm breath, autonomy, increase bottom time, quality decompression, sofnolime, sensors, electronics, breathing loops, head up displays, solenoid, manual injections, radial and axial canisters and so much magnificence.
If you are at least Advanced Open Water or Basics of Exploration certified, click the icon above or the link that you can find to the description and I will see you to the other side.
http://bit.ly/1puOsWd
India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP Flyash and Bag House Filter Dust. Now as this Flyash contains considerable unburned carbon ( 10% and above), it cannot be utilized in cement manufacturing. Likewise the Bag Filter dust contains upto 25% unburned carbon and above 70% ash which again doesn't allow it to be reused viably as a fuel. Meanwhile, reducing the carbon content by the Carbon-burnout method is too expensive and polluting just to convert the wastes into usable Flyash.
As a result most of these wastes go into landfill, where they again contribute to ground and water pollution.
Surprisingly there are technologies which can not only effectively convert these wastes into usable items like recovered fuel and low carbon Flyash, but at the same time clean up the environment and save the companies great expenses. Its is called Carbon-Ash Separation and there are several ways of doing the same.
The explosion hazard in urea process (1)Prem Baboo
In Urea plant passivation air is used in reactor, stripper and downstream of the all equipments. The reactor liner material used Titanium, Zirconium, SS 316L (urea grade), 2RE-69 and duplex material .except Titanium and Zirconium all stainless steel required more passivation air. In CO2 some quantity of Hydrogen is present about 0.14% to 0.2% . The passivation oxygen and Hydrogen makes explosive mixture. To avoid a fire or explosion in a process vessel is to introduce inert (noncombustible) gases in such a way that there is never a mixture with a combustible concentration in exit of MP vent. Mixtures of fuel, oxygen, and inert gases are not combustible over the entire range of composition. In CO2 stripping process the HP scrubber is the risky vessel and this vessel consisting blanketing sphere, Heat exchanger part and a scrubbing part. With help of triangular diagram that shows the shape of the combustible/noncombustible regions for a typical gaseous mixture of fuel, oxygen, and inert at specified temperature and pressure. Present article how to avoid that combustible rang and how to tackle that gases in CO2 & ammonia stripping process.
Over the past two decades, the ammonia and urea industry have witnessed spectacular metallurgical developments for process equipment. For example, stainless steels, modified with special materials, can improve high temperature creep rupture resistance. Using duplex stainless steels and modern corrosion abatement techniques are other methods that improve plant-operating performance.
Ever since the declaration of 100% neem coated urea by India Government, the number of neem trees is increasing continuously in India Neem coated urea requires neem oil, more urea more oil and trees also required more. When it comes to oil, neem plants are rather promising. Probably no other plant yields as many exploitable by-products and benefits. Earlier, 100% Neem Coated Urea was made mandatory in 2015.
Prills /granular urea are not only costly for the producer but may be harmful to humans and the environment. Furthermore, nano Urea may also be used for enhancing abiotic stress tolerance. Nano-Urea prevents environmental pollution and improves physiological traits of wheat grown under drought stress conditions. The nano urea consist of higher surface area because lesser in size of the nano particle and have high reactivity, solubility in water. Nano Urea are the important tools in agriculture to improve crop efficiency, yield and quality parameters with increase nutrient use efficiency, reduce wastage of fertilizers and cost of cultivation. Nano-urea is very effective for precise nutrient management in precision agriculture with matching the crop growth stage for nutrient and may provide nutrient throughout the crop growth period. Nano-Urea increase crop growth up to optimum concentrations further increase in concentration may inhibit the crop growth due to the toxicity of nutrient. Nano-Urea provide more surface area for different metabolic reactions in the plant which increase rate of photosynthesis and produce more dry matter and yield of the crop. It is also prevent plant from different biotic and abiotic stress.
Super conversion in urea reactors with super cup high efficiency traysPrem Baboo
In Urea Conversion gas/liquid mixing in urea reactor with application of high efficiency trays homogeneous and heterogeneous phases’ iquilibria and kinetics is very important. The efficiency of Urea Reactors can be improved by the application of the latest generation of internals .Generally Fluid dynamics phenomenon are created by the concurrent gas liquid flow through the simple perforated trays which generates irregular bubbles now this problem has been solved by new generation high efficiency device super cup patented by M/S. Saipem. Present article intended how conversion increases by super cup with geometry of the shape of super cup etc. The increase in the efficiency has permitted direct benefits to the overall production and energy of the units, thus allowing lower energy consumption and a reduced environmental impact emission of greenhouse gases. The Super Cups can be applied to design a new generation of urea reactors as well as to improve the performance of existing equipment in a revamp design.
Sweet and sour experience of commissioning 1Prem Baboo
The paper describes a successful of plant start-up despite the pandemic difficulties and introduces a set of first considerations about the possible future application of available digital technologies for remote and distributed control system from central control room commissioning of complex Dangote Fertilizer Plants. The numbers of problem were faced during commissioning stage ultimately the 17th march 2021 was the historical date for achieved plant production of line-1 plant .The major problem was pandemic due to which scarcity of staff availability. However numbers of problems faced in Ammonia and urea plants. About 4 time’s unsuccessful attempt were done and finally we got historical success. In this paper we described the failure attempt and types of problems faced in ammonia and urea plants and each time problems were differ from previous.
How to improve safety and reliability of the high pressure section of urea pl...Prem Baboo
This paper elaborates the most critical safety hazards: Ruptures and toxic ammonia leaks. The paper also provides the Top 10 prevention and mitigation measures. To minimize / avoid that incidents do repeat, we recommend to make use of the Center for Chemical Process Safety: Risk Based Process Safety Management approach. Pay proper attention to avoid ruptures, to handle leaks and to apply the right and state-of-the-art leak detection systems.
Experience of material in fertilizers industriesPrem Baboo
Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty 2 RE-69 materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study Material in urea plant in different vessels and equipment design. In Primary reformer numbers of materials are modified such as micro alloy are also used in tubes.
This book covers design of high Pressure equipment and developments, Process flow diagram of different section of Ammonia, Urea and others fertilizers .Fundamentals of ammonia urea plant trouble shooting risk assessment corrosion in different vessels and remedies. This book is useful for Engineers and Sr. Managers for plant commissioning and trouble shooting and Engineering Students. This book contains about 51 tables and 144 useful diagram and chart graphics etc. Detail description of ammonia/CO2 stripping process and new developments. Design Parameters of High pressure vessel and comparison. Study of corrosion for various equipments and control. How to control corrosion by changing of equipments material.
High pressure vessel_leakage_in_urea_plants (1)Prem Baboo
In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.
High pressure vessel leakage in urea plantsPrem Baboo
In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.
If the material of liner changed with 2RE 69 or Duplex material instead of SS316(urea grade), then passivation air can be reduced, resulting the energy saving because the inerts vented from M.P section and loss of ammonia and problem of pollution. To enhance capacity and energy of the existing plant the internals like vortex mixture and HET may be changed the capacity may increase up to 10-15%.HET, you can changed with super cup.The CO2 and feed top of the vortex mixture nozzle and Ammonia plus carbamate feed from side of the vortex mixture. In the mixing area the initial dispersion of gas and formation of liquid – gas mixture are performed.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
1. SIMPLE WAY TOSIMPLE WAY TO
UNDERSTAND AMMONIAUNDERSTAND AMMONIA
PLANTPLANT
BYBY
PREM BABOOPREM BABOO
SR. MANAGER(PROD)SR. MANAGER(PROD)
NATIONAL FERTILIZERS LTD,VIJAIPUR, INDIANATIONAL FERTILIZERS LTD,VIJAIPUR, INDIA
2. SIMPLE WAY TO UNDERSTANDSIMPLE WAY TO UNDERSTAND
AMMONIA PLANTAMMONIA PLANT
TECHNOLOGY HALDOR TOPSOETECHNOLOGY HALDOR TOPSOE
CAPACITY 1750/1864 TPDCAPACITY 1750/1864 TPD
FEED NG AND NEPTHAFEED NG AND NEPTHA
ENERGY 7.2GCAL/TON OF AMMONIAENERGY 7.2GCAL/TON OF AMMONIA
ON NGON NG
7.36 GCAL/TON OFAMMONIA IN7.36 GCAL/TON OFAMMONIA IN
CASE OF MIXED FEEDCASE OF MIXED FEED
3.
4. INGREDIENT FOR AMMONIAINGREDIENT FOR AMMONIA
TO PRODUCE AMMONIA WE REQUIRETO PRODUCE AMMONIA WE REQUIRE
HH22 AND NAND N22
HH22 WE GET FROM NG AND WATERWE GET FROM NG AND WATER
NN22 WE GET FROM AIRWE GET FROM AIR
NG CONTAINS ABOUT 92%CHNG CONTAINS ABOUT 92%CH44
NEPTHA CONTAINS HIGHERNEPTHA CONTAINS HIGHER
HYDROCAREBONHYDROCAREBON
5. BLOCK DIGRAM OF AMOONIABLOCK DIGRAM OF AMOONIA
PLANTPLANT
DESULPHERISATION REFORMING
SHIFT REACTION CO2 REMOVAL AREA
SYNTHESIS
COMP HOUSE
CO2 TO UREA
AMM TO UREA
AND METHNATION
6. DESULPHERISATIONDESULPHERISATION
AIMAIM
TO REMOVE ALL SULPHERTO REMOVE ALL SULPHER
COMING WITH NG AND NEPTHACOMING WITH NG AND NEPTHA
SULPHER IS POISIONOUS FOR THESULPHER IS POISIONOUS FOR THE
DOWNSTREAM CATALAYSTDOWNSTREAM CATALAYST
IT CONSISTS OF TWO STEPSIT CONSISTS OF TWO STEPS
7. HYDROGENATIONHYDROGENATION
IN THIS VESSLE NG AND NEPTHA AREIN THIS VESSLE NG AND NEPTHA ARE
BROUGHT IN CONTACT WITHBROUGHT IN CONTACT WITH
HYDROGEN SO THAT ORGANICHYDROGEN SO THAT ORGANIC
SULPHER GETS CONVERTED INTOSULPHER GETS CONVERTED INTO
INORGANIC SULPHER WHICH ISINORGANIC SULPHER WHICH IS
SUBSEQUENTLY REMOVED IN ZNOSUBSEQUENTLY REMOVED IN ZNO
ABSORBERABSORBER
CATALYST NIMO –FOR NGCATALYST NIMO –FOR NG
COMO -FOR NAPHTHACOMO -FOR NAPHTHA
9. ZnO ABSORBERZnO ABSORBER
TWO BEDS ARE INSTALLED IN SERIESTWO BEDS ARE INSTALLED IN SERIES
CATALYST USED IS = ZnOCATALYST USED IS = ZnO
ZnO+HZnO+H22S = ZnS + HS = ZnS + H22OO
SULPHER AT THE OUTLET OF THESE VESSLE ARESULPHER AT THE OUTLET OF THESE VESSLE ARE
LESS THAN .01PPMLESS THAN .01PPM
INCREASING SULPHER CONTENT GIVE THEINCREASING SULPHER CONTENT GIVE THE
INDICATION THAT BEDS ARE GETTING EXHUSTEDINDICATION THAT BEDS ARE GETTING EXHUSTED
AND THEY REQUIRE CHANGEAND THEY REQUIRE CHANGE
FIRST BED CAN BE BYPASSED AND CATALYST CANFIRST BED CAN BE BYPASSED AND CATALYST CAN
BE CHANGED ON LINE A SPECIAL BED OF CopperBE CHANGED ON LINE A SPECIAL BED OF Copper
BASEDCATALYST IS INSTALLED AT THE BOTTOM OFBASEDCATALYST IS INSTALLED AT THE BOTTOM OF
THE FIRST BED TO ADSORB ANY ORGANIC SULPHERTHE FIRST BED TO ADSORB ANY ORGANIC SULPHER
IF IT SLIPS FROM HYDROGEATION BEDIF IT SLIPS FROM HYDROGEATION BED
11. REFORMINGREFORMING
AIMAIM
TO REFORM NG AND NEPTHA IN TO HTO REFORM NG AND NEPTHA IN TO H22
CO AND COCO AND CO22 REFORMING IS DONE WITHREFORMING IS DONE WITH
THE HELP OF STEAM THATIS WHY IT ISTHE HELP OF STEAM THATIS WHY IT IS
CALLED STEAM REFORMING ITCALLED STEAM REFORMING IT
CONSIST OF THREE STEPSCONSIST OF THREE STEPS
12. STEPS OF REFORMINGSTEPS OF REFORMING
PREREFORMERPREREFORMER
PRIMARY REFORMERPRIMARY REFORMER
SECONDRY REFORMERSECONDRY REFORMER
13. CONDITION OF REFORMINGCONDITION OF REFORMING
REFORMING IS AN ENDOTHERMIC REACTIONREFORMING IS AN ENDOTHERMIC REACTION
IT MEANS THAT HEAT WILL HAVE TO BEIT MEANS THAT HEAT WILL HAVE TO BE
SUPPLIED TO MOVE THE REACTION INSUPPLIED TO MOVE THE REACTION IN
FORWARD DIRECTIONFORWARD DIRECTION
MAJOR PORTION OF REFORMING IS DONE INMAJOR PORTION OF REFORMING IS DONE IN
PRIMARY REFORMER THIS REACTION ISPRIMARY REFORMER THIS REACTION IS
CARRIED OUT IN A FURNACE OPERATINGCARRIED OUT IN A FURNACE OPERATING
CONDITIONS ARE VERY INTENCECONDITIONS ARE VERY INTENCE
15. HOW OPERATING CONDIONSHOW OPERATING CONDIONS
ARE DECIDEDARE DECIDED
AS PER LE CHATERLIERS PRINCIPLE THEAS PER LE CHATERLIERS PRINCIPLE THE
REACTION OF REFORMING REQUIRESREACTION OF REFORMING REQUIRES
HIGH TEMERATUTRE CONDITIONSHIGH TEMERATUTRE CONDITIONS
LOW PRESSURE CONDITIONSLOW PRESSURE CONDITIONS
OPTIMUM PRESSURE IS SET ARROUNDOPTIMUM PRESSURE IS SET ARROUND
34KGCM34KGCM22
PRESSURE BELOW THIS SUITS REFORMIGPRESSURE BELOW THIS SUITS REFORMIG
REACTION BUT THIS IS NOT SUITABLE FORREACTION BUT THIS IS NOT SUITABLE FOR
DOWNSREAM REACTIONSDOWNSREAM REACTIONS
16. CATALYST USED INCATALYST USED IN
REFORMINGREFORMING
CATALYST USED IS NICKLECATALYST USED IS NICKLE
IN VARIOUS REFORMING STEPS ONLYIN VARIOUS REFORMING STEPS ONLY
THE CONTENT OF NICKLE VARRIESTHE CONTENT OF NICKLE VARRIES
BESIDES THIS BASE OF THE CATALYSTBESIDES THIS BASE OF THE CATALYST
ALSO VARRIESALSO VARRIES
CONDENSATION OF STEAM IS TO BECONDENSATION OF STEAM IS TO BE
AVOIDED IN CATALYST BEDAVOIDED IN CATALYST BED
BECAUUSE IT MAY SPOIL THE ENTIREBECAUUSE IT MAY SPOIL THE ENTIRE
CATALYSTCATALYST
17. PRE REFORMERPRE REFORMER
PRE REFORMER IS ISTALLED IN AMMONIAPRE REFORMER IS ISTALLED IN AMMONIA
EXPANSIONEXPANSION
ITS PURPOSE IS TO REFORM HIGER HYDROCARBONITS PURPOSE IS TO REFORM HIGER HYDROCARBON
TO LOWER HYDROCARBONTO LOWER HYDROCARBON
TO BE KEPT IN LINE WHEN NEPTHA IS BEING USEDTO BE KEPT IN LINE WHEN NEPTHA IS BEING USED
IN FEEDIN FEED
WITHOUT PREREFORMER NEPTHA CAN NOT BEWITHOUT PREREFORMER NEPTHA CAN NOT BE
USED IN FEEDUSED IN FEED
IT CAN BE KEPT IN LINE WITH NG ALSO BUT NOTIT CAN BE KEPT IN LINE WITH NG ALSO BUT NOT
WITH GREAT DEAL OF ADVANTAGEWITH GREAT DEAL OF ADVANTAGE
ITS CATALYST IS ONE OF THE COSLIEST INITS CATALYST IS ONE OF THE COSLIEST IN
AMMONIA PLANTAMMONIA PLANT
19. PRIMARY REFORMERPRIMARY REFORMER
IT IS THE MOST IMPORTANT STEP INIT IS THE MOST IMPORTANT STEP IN
THE REFORMING PROCESSTHE REFORMING PROCESS
IT COSIST OF A FURNACEIT COSIST OF A FURNACE
FURNACE IS SIDE FIREDFURNACE IS SIDE FIRED
IT CONTAINS 288 TUBES AND 576IT CONTAINS 288 TUBES AND 576
BURNERSBURNERS
CATALYST IS FILLED INSIDE THE TUBECATALYST IS FILLED INSIDE THE TUBE
FIRING IS DONE ON BOTH THE SIDESFIRING IS DONE ON BOTH THE SIDES
OF THE TUBEOF THE TUBE
21. IMPORTANT PARAMETER OFIMPORTANT PARAMETER OF
PRIMARY REFORMERPRIMARY REFORMER
FURNACE INSIDE PRESSURE SHOULD BEFURNACE INSIDE PRESSURE SHOULD BE
SLIHTLY BELOW ATMOSPHERIC PRESSURESLIHTLY BELOW ATMOSPHERIC PRESSURE
ARROND -5MMWCARROND -5MMWC
TUBES SKIN TEMP SHOULD NOT EXCEEDTUBES SKIN TEMP SHOULD NOT EXCEED
905DEGREE CENTRIGADE OTHRWISE TUBE905DEGREE CENTRIGADE OTHRWISE TUBE
LIFE WOULD BE SHORTENEDLIFE WOULD BE SHORTENED
S/C RATIO IS ONE OF THE MOST IMPS/C RATIO IS ONE OF THE MOST IMP
PARAMETE ITS KEPT ARROUND 3.3 LOWERPARAMETE ITS KEPT ARROUND 3.3 LOWER
S/C RATIO MAY RESULT IN CARBONS/C RATIO MAY RESULT IN CARBON
FORMATIONFORMATION
22. SECONDRY REFORMINGSECONDRY REFORMING
AIMAIM
TO COMLETE THE REMAININGTO COMLETE THE REMAINING
REFORMINGREFORMING
TO INTRODUCE AIR SO THAT WE CANTO INTRODUCE AIR SO THAT WE CAN
GET N2 REQUIRED FOR THE AMMONIAGET N2 REQUIRED FOR THE AMMONIA
PRODUCTIONPRODUCTION
24. WHAT HAPPENS IN SECONDRYWHAT HAPPENS IN SECONDRY
REFORMERREFORMER
PRIMARY REFORMER OUTLET GASPRIMARY REFORMER OUTLET GAS
WHICH CONTAINS ABOUTWHICH CONTAINS ABOUT
11%METHANE AT ATEMP OF ABOUT11%METHANE AT ATEMP OF ABOUT
765DEGREE IS BROGHT IN CONTACT765DEGREE IS BROGHT IN CONTACT
WITH AIR AT A TEMP OF 575 DEGREEWITH AIR AT A TEMP OF 575 DEGREE
FIRST REACTION IN SR IS EXOTHERMICFIRST REACTION IN SR IS EXOTHERMIC
REACTION IN WHICH APART OF GASREACTION IN WHICH APART OF GAS
BURNS WITH AIR O2 GETS CONSUMEDBURNS WITH AIR O2 GETS CONSUMED
25. WHAT HAPPENS IN SECONDRYWHAT HAPPENS IN SECONDRY
REFORMERREFORMER
TEMERATURE OF GAS IN TOP PAERT OFTEMERATURE OF GAS IN TOP PAERT OF
REFORMER REACHES TO ARROUNDREFORMER REACHES TO ARROUND
1200 DEGREE1200 DEGREE
THIS HEAT IS USED FOR FURTHERTHIS HEAT IS USED FOR FURTHER
REFORMINGREFORMING
METHANE AT OUTLET OF SR BECOMESMETHANE AT OUTLET OF SR BECOMES
ABOUT .3%ABOUT .3%
SR OUTLET TEMP BECOMES 940SR OUTLET TEMP BECOMES 940
DEGREEDEGREE
26. SHIFT REACTIONSHIFT REACTION
AIMAIM
GAS AT THE OUTLET OF SR CONTAINSGAS AT THE OUTLET OF SR CONTAINS
BOTH CO AND CO2BOTH CO AND CO2
CO IS OF NO USECO IS OF NO USE
CO2 IS REQUIRED FOR THECO2 IS REQUIRED FOR THE
PRODUCTION OF UREAPRODUCTION OF UREA
IN SHIFT REACTORS ALL CO ISIN SHIFT REACTORS ALL CO IS
CONVERTED IN TO CO2CONVERTED IN TO CO2
27. SHIFT REACTIONSHIFT REACTION
SHIFT REACTION IS TWO STEPSHIFT REACTION IS TWO STEP
PROCESSPROCESS
FIRST STEP IS CARRIED OUT AT HIGHFIRST STEP IS CARRIED OUT AT HIGH
TEMP IT IS CALLED HT SHIFTTEMP IT IS CALLED HT SHIFT
REACTION TO INCREASE THE RATE OFREACTION TO INCREASE THE RATE OF
REACTIONREACTION
SECOND STEP IS CARRIED OUT AT LOWSECOND STEP IS CARRIED OUT AT LOW
TEMP CALLED LT SHIFT REACTION ITTEMP CALLED LT SHIFT REACTION IT
IS TO ACHIVE HIGH EQULIBIRIUMIS TO ACHIVE HIGH EQULIBIRIUM
CONVERSIONCONVERSION
28. HT SHIFT CONVERTORHT SHIFT CONVERTOR
CATALYST USED IRON OXIDECATALYST USED IRON OXIDE
INLETTEMP 355 DEGREEINLETTEMP 355 DEGREE
OUTLET TEMP 423DEGREEOUTLET TEMP 423DEGREE
OUTLET CO 2.8%OUTLET CO 2.8%
CO+HCO+H22O = COO = CO22 +H+H22
29. HT SHIFT CONVERTORHT SHIFT CONVERTOR
HT SHIFT
CATALYST
IRON OXIDE
SR OULET GAS
GAS TO LT
355
423
CO 2.8%
CO 12.77
30. LT CONVERTORLT CONVERTOR
CATALEST USED MIANLY CUCATALEST USED MIANLY CU
INLET TEMP 195 DEGREEINLET TEMP 195 DEGREE
OUTLET 212 DEGREEOUTLET 212 DEGREE
OUTLET CO .17%OUTLET CO .17%
CO +HCO +H22O = COO = CO22 + H+ H22
POISON FOR THE CATALYST AREPOISON FOR THE CATALYST ARE
S AND CHLORIDES AND CHLORIDE
31. LT SHIFT CONVERTORLT SHIFT CONVERTOR
LT CONVERTOR
HT OUUTLET
LT OUTLET
CO .17%
CO 2.8%
32. CO2 REMOVALCO2 REMOVAL
TWO MAIN PROCESS FOR THIS ARETWO MAIN PROCESS FOR THIS ARE
BENFIELD PROCESS USED IN LINE 1BENFIELD PROCESS USED IN LINE 1
GV PROCESS USED IN LINE 2GV PROCESS USED IN LINE 2
GV PROCESS USED IN LINE 2 HAS SOMEGV PROCESS USED IN LINE 2 HAS SOME
ADVANTAGE OVER BENFIELD PROCESSADVANTAGE OVER BENFIELD PROCESS
33. GV PROCESSGV PROCESS
AIMAIM
TO REMOVE ALL CO2 FROM THETO REMOVE ALL CO2 FROM THE
PROCESS GAS BY ABSORBING IN HOTPROCESS GAS BY ABSORBING IN HOT
POTTASIUM CARBONATE SOLUTIONPOTTASIUM CARBONATE SOLUTION
AND THEN REGENERATING THEAND THEN REGENERATING THE
SOLUTIONSOLUTION
CO2 PRODUCED IS SENT TO UREACO2 PRODUCED IS SENT TO UREA
PLANTPLANT
34. GV PROCESSGV PROCESS
SOLUTION IS MADE OF POTTASSIUMSOLUTION IS MADE OF POTTASSIUM
CARBONATECARBONATE
TWO ACTIVATORS USED ARETWO ACTIVATORS USED ARE
GLYCENE AND DEAGLYCENE AND DEA
COMPOSITIONCOMPOSITION
KK22COCO33 27%27%
GLYCENE 1.2%GLYCENE 1.2%
DEA 1.0%DEA 1.0%
VANADIUM .4%VANADIUM .4%
36. TWO STAGE REGENERATION & USE OF FLASH STEAM OF HP IN LPTWO STAGE REGENERATION & USE OF FLASH STEAM OF HP IN LP
REGENERATOR & REDUCTION IN LP STEAMREGENERATOR & REDUCTION IN LP STEAM
REDUCTION CO2 SLIP by 1000PPMREDUCTION CO2 SLIP by 1000PPM
IMPROVED HEAT RECOVERYIMPROVED HEAT RECOVERY
38. BLOCK DIGRAMBLOCK DIGRAM
CO2 FREE GASCO2 FREE GAS
ABSORBER
GAS
SOLUTION
LOADED SOL
REGENERATOR
CO2
REGENERATED SOL
LOADED SOL
STEAM
39. METHNATIONMETHNATION
AIMAIM
TO CONVERT ALL CO AND COTO CONVERT ALL CO AND CO22 TOTO
METHANEMETHANE
OUTLET GAS FROM COOUTLET GAS FROM CO22 REMOVALREMOVAL
AREA CONTAINS BOTH C0 AND C0AREA CONTAINS BOTH C0 AND C022
BOTH THESE GAS ARE NOT REQUIREDBOTH THESE GAS ARE NOT REQUIRED
AS THESE ARE POISON FOR THE SYNAS THESE ARE POISON FOR THE SYN
CATALYSTCATALYST
40. METHNATIONMETHNATION
CATALYST USED NICKLECATALYST USED NICKLE
C0 + HC0 + H22 = CH= CH44 + HEAT+ HEAT
COCO22 +H+H22 =CH=CH44 + HEAT+ HEAT
METHANE FORMED ACTS AS A INERTMETHANE FORMED ACTS AS A INERT
GAS IN SYN REACTION AND IT ISGAS IN SYN REACTION AND IT IS
REMOVED IN PURGE TAKEN OUT FROMREMOVED IN PURGE TAKEN OUT FROM
THE SYN LOOPTHE SYN LOOP
42. COMP HOUSECOMP HOUSE
COMP HOUSE CONTAINS THREE COMPCOMP HOUSE CONTAINS THREE COMP
AIR COMPAIR COMP
REFRIGRATION COMPREFRIGRATION COMP
SYNTHESIS COMPSYNTHESIS COMP
43. AIR COMPAIR COMP
AIMAIM
AIR COMPRESSOR COMPRESSES AIR UPAIR COMPRESSOR COMPRESSES AIR UP
TO 34KGCM2 PRESSURETO 34KGCM2 PRESSURE
AIR IS USED IN SECONDRY REFORMERAIR IS USED IN SECONDRY REFORMER
H2/N2 RATIO DETERMINES FLOW OFH2/N2 RATIO DETERMINES FLOW OF
AIR TO SECONDRY REFORMERAIR TO SECONDRY REFORMER
45. REFRIGRATION COMPRESSORREFRIGRATION COMPRESSOR
AIMAIM
IT IS USED TO COMPRESS AMMONIAIT IS USED TO COMPRESS AMMONIA
WHICH IS USED AS A REFRIGRENT INWHICH IS USED AS A REFRIGRENT IN
SYNTHESIS LOOPSYNTHESIS LOOP
REFIGRATION IS DONE AT THREEREFIGRATION IS DONE AT THREE
PRESSURE LEVELPRESSURE LEVEL
ITS FINAL DISCHARGE PRESSURE ISITS FINAL DISCHARGE PRESSURE IS
14KG CM214KG CM2
46. SYNTHESIS COMPSYNTHESIS COMP
AIMAIM
AMMONIA SYNTHESIS REACTION ISAMMONIA SYNTHESIS REACTION IS
CARRIED OUT AT HIGH PRESSURECARRIED OUT AT HIGH PRESSURE
CONDITIONS AT ABOUT 180KGCM2CONDITIONS AT ABOUT 180KGCM2
SYN COMP IS USED TO COMPRESS GASSYN COMP IS USED TO COMPRESS GAS
UP TO THAT PRESSUREUP TO THAT PRESSURE
48. AMMONIA SYNTHESISAMMONIA SYNTHESIS
AIMAIM
TO PRODUCE AMMONIA WITH THETO PRODUCE AMMONIA WITH THE
HELP OF SYN GAS COMING FROMHELP OF SYN GAS COMING FROM
METHNATORMETHNATOR
SYN GAS CONTAINS MAINLY HSYN GAS CONTAINS MAINLY H22 AND NAND N22
49. AMMONIA SYN REACTIONAMMONIA SYN REACTION
3H3H22 +N+N22 = 2NH= 2NH33 +HEAT+HEAT
CATALYST USED IRONCATALYST USED IRON
REACTION CONDITIONREACTION CONDITION
HIGH PRESSURE AND LOW TEMPHIGH PRESSURE AND LOW TEMP
50. AMMONA SYN REACTIONAMMONA SYN REACTION
AMMONIA SYN REACTION IS A REVERSIBILEAMMONIA SYN REACTION IS A REVERSIBILE
REACTION AND EQULIBIRIUM CONDITION ISREACTION AND EQULIBIRIUM CONDITION IS
DETERMINED BY TEMP AND PRESSUREDETERMINED BY TEMP AND PRESSURE
CONDITIONSCONDITIONS
IN ONE PASS THROUGH THE CONVERTORIN ONE PASS THROUGH THE CONVERTOR
ONLY 30% OF THE REACTANTS GETSONLY 30% OF THE REACTANTS GETS
CONVERTED TO THE PRODUCT SOCONVERTED TO THE PRODUCT SO
REMAINING GAS KEEPS ON CIRCULATINGREMAINING GAS KEEPS ON CIRCULATING
53. BLOCK DIGRAM OF SYNBLOCK DIGRAM OF SYN
SECTIONSECTION
AMM CONVERTOR BFW HEATER
GAS GAS EX WATER COOLER GAS GAS EX
PRI CHIL SEC CHILL AMM SEP LET DOWNVESSLE
LOOP BOILER
STEAM
PURGE GAS
AMM TO UREA
TO
STORAGE
SYN GAS
54.
55. What is purgeWhat is purge
AS AMMONIA SYN REACTION IS NOTAS AMMONIA SYN REACTION IS NOT
COMPLETED IN ONE STEP AND GAS IS KEPTCOMPLETED IN ONE STEP AND GAS IS KEPT
ON CIRCULATING INERTS BUILDS UP IN THEON CIRCULATING INERTS BUILDS UP IN THE
LOOPLOOP
INERT MEANS CH4, Ar NH3 AT INLET OFINERT MEANS CH4, Ar NH3 AT INLET OF
CONV THEIR CONCENTRATION SHALL NOTCONV THEIR CONCENTRATION SHALL NOT
INCREASE BEYOND 14%INCREASE BEYOND 14%
SO A SMALL AMMOUNT OF GAS ISSO A SMALL AMMOUNT OF GAS IS
CONTTIOUSLY WITHDRAWN FROM THECONTTIOUSLY WITHDRAWN FROM THE
LOOP THIS STREAM OF THE GAS IS CALLEDLOOP THIS STREAM OF THE GAS IS CALLED
PUGE GASPUGE GAS
56. PURGE GAS RECOVERYPURGE GAS RECOVERY
PURGE GAS CONTAINS HPURGE GAS CONTAINS H22, CH, CH44 ANDAND
AMMONIAAMMONIA
AMMONIA IS RECOVERED BYAMMONIA IS RECOVERED BY
WASHING THE GAS WITH WATER ANDWASHING THE GAS WITH WATER AND
REMAINING GAS WHICH CONTAINS CHREMAINING GAS WHICH CONTAINS CH44
AND HAND H22 IS USED IN REFORMER FIRINGIS USED IN REFORMER FIRING
SYSTEMSYSTEM
57. PURGE GAS RECOVERYPURGE GAS RECOVERY
ABSORBER REGENERATIONR
PUURGE
WATER
STEAM
GAS TO REF
LOADED SOL
AM TO STORAGE
58. Installation of Plate type Combustion airInstallation of Plate type Combustion air
preheaterpreheater
Facilitate reduction in reformer stack temperature toFacilitate reduction in reformer stack temperature to
125125°C°C
Energy saving: 0.055 Gcal /MT NH3Energy saving: 0.055 Gcal /MT NH3
Energy saving due toEnergy saving due to
a) NG saving due to increase in combustion aira) NG saving due to increase in combustion air
temperaturetemperature
B) Reduction in steam consumption in ID FanB) Reduction in steam consumption in ID Fan
59. Conversion of Benfield process to GVConversion of Benfield process to GV
processprocess
To increase capacity and improve energyTo increase capacity and improve energy
effciencyeffciency
GV 2 stage process has a lower specificGV 2 stage process has a lower specific
regeneration heat requirement and henceregeneration heat requirement and hence
reduction in low pressure steam consumption byreduction in low pressure steam consumption by
utilizing flash steam of HP regenerator &utilizing flash steam of HP regenerator &
utilization heat by LP steam reboiler instead ofutilization heat by LP steam reboiler instead of
loosing to atmosphere through air coolerloosing to atmosphere through air cooler
Energy savings: 0.18 Gcal/MT NH3Energy savings: 0.18 Gcal/MT NH3
Existing Amm-II is based on GV ProcessExisting Amm-II is based on GV Process
60. New equipment in conversion from Benfield to GVNew equipment in conversion from Benfield to GV
sectionsection
Separator OH 2Separator OH 2ndnd
regenerator (B-1307)regenerator (B-1307)
LP steam boiler (E-1301)LP steam boiler (E-1301)
DMW pre-heater (E-1305 A/B)DMW pre-heater (E-1305 A/B)
Condenser OH 2Condenser OH 2ndnd
regenerator (E-1309)regenerator (E-1309)
22ndnd
Regenerator (F-1303)Regenerator (F-1303)
Steam Ejector (X-1301)Steam Ejector (X-1301)
Aeration Injection tank (T-1305)Aeration Injection tank (T-1305)
Sealing water heater (E-1315)Sealing water heater (E-1315)
Cooler for Aeration tank (E-1324)Cooler for Aeration tank (E-1324)
Activated carbon filter and 2Activated carbon filter and 2ndnd
Mechanical filterMechanical filter
61. New machinery in conversion from Benfield to GVNew machinery in conversion from Benfield to GV
sectionsection
CO2 blower (K-1301)CO2 blower (K-1301)
Semi-lean solution pump (P-1301D)Semi-lean solution pump (P-1301D)
Lean solution pump (P-1302 A/B)Lean solution pump (P-1302 A/B)
22ndnd
condensate pump (P-1308 A/B)condensate pump (P-1308 A/B)
Aeration Injection pump (P-1309 A/B)Aeration Injection pump (P-1309 A/B)
Sealing water pump (P-1310 A/B)Sealing water pump (P-1310 A/B)
62. Modifications in 1Modifications in 1stst
regeneratorregenerator
New take off trays are installed below bed 2New take off trays are installed below bed 2
and above bed 3and above bed 3
New liquid re-distributors above bed 1 and 3New liquid re-distributors above bed 1 and 3
Bed limiters over beds 1 and 3Bed limiters over beds 1 and 3
11stst
bed height reduced by 2195 mmbed height reduced by 2195 mm
DemisterDemister
New nozzles and instrumentation for newNew nozzles and instrumentation for new
take-off traystake-off trays
63. Modification in CO2 absorberModification in CO2 absorber
Liquid distributor over Bed 2 and 4Liquid distributor over Bed 2 and 4
Liquid redistributor over beds 1,2,3 & 4Liquid redistributor over beds 1,2,3 & 4
Gas distributor under bed 1Gas distributor under bed 1
Packing : Bed 1: IMTP 50 Bed 4: IMTP25Packing : Bed 1: IMTP 50 Bed 4: IMTP25
64. Installation of S-50 converterInstallation of S-50 converter
To increase the energy efficiency of the ammoniaTo increase the energy efficiency of the ammonia
synthesis loop, an S-50 converter R-1502 is installedsynthesis loop, an S-50 converter R-1502 is installed
downstream of the existing converter.downstream of the existing converter.
The increase in ammonia concentration exit the newThe increase in ammonia concentration exit the new
converter results in a decrease in loop pressure and aconverter results in a decrease in loop pressure and a
lower circulation rate, which gives savings on thelower circulation rate, which gives savings on the
synthesis gas compressor and the refrigerationsynthesis gas compressor and the refrigeration
compressor.compressor.
Energy saving: 0.18 Gcal/MT NH3Energy saving: 0.18 Gcal/MT NH3
65. Advantages of addition of S-50 LoopAdvantages of addition of S-50 Loop
Ammonia concentration at the outlet of S-50 =Ammonia concentration at the outlet of S-50 =
24.35% as compared to 20.02% in S-20024.35% as compared to 20.02% in S-200
Higher conversion 35.5 % as compared to 28.3% in S-200Higher conversion 35.5 % as compared to 28.3% in S-200
Lower circulation rate as compared to S-200 for sameLower circulation rate as compared to S-200 for same
loadload
Higher steam generation 82 T/hr as compared to 70 T/hr in S-Higher steam generation 82 T/hr as compared to 70 T/hr in S-
200200
Lower synthesis loop pressureLower synthesis loop pressure
Lower compressor power due to less circulation and lowLower compressor power due to less circulation and low
pressurepressure
Possible to achieve higher plant load with same equipmentsPossible to achieve higher plant load with same equipments
68. Parallel Air compressorParallel Air compressor
Addition of Parallel air compressorAddition of Parallel air compressor
(reciprocating type) to meet the additional(reciprocating type) to meet the additional
process air requirementprocess air requirement
Process air from Existing PAC: 59152Process air from Existing PAC: 59152
Nm3/hrNm3/hr
Process air from New Compressor: 6030Process air from New Compressor: 6030
Nm3/hrNm3/hr
Total air requirement for 1750 MTPDTotal air requirement for 1750 MTPD
ammonia as per PFD: 65181 Nm3/hrammonia as per PFD: 65181 Nm3/hr
69. Ammonia-II CEP: Process airAmmonia-II CEP: Process air
As per PFD of Ammonia-II CEP, the totalAs per PFD of Ammonia-II CEP, the total
requirement of process air from PAC ofrequirement of process air from PAC of
Ammonia-II shall be 75683 Nm3/hr withAmmonia-II shall be 75683 Nm3/hr with
distribution as follows:distribution as follows:
Process air for Ammonia-II CEP : 69234Process air for Ammonia-II CEP : 69234
Nm3/hrNm3/hr
Instrument air : 3924 Nm3/hrInstrument air : 3924 Nm3/hr
Export to Ammonia-I : 2525 Nm3/hrExport to Ammonia-I : 2525 Nm3/hr
6969
70. Ammonia-II CEP: HTAS report & OEM reviewAmmonia-II CEP: HTAS report & OEM review
The capacity of existing PAC in Ammonia-II is : Normal:The capacity of existing PAC in Ammonia-II is : Normal:
59275 Nm³/h , Rated : 64900 Nm³/h59275 Nm³/h , Rated : 64900 Nm³/h
Based on overall performance curve of PAC, HTAS hasBased on overall performance curve of PAC, HTAS has
confirmed that the desired load shall remain within theconfirmed that the desired load shall remain within the
operating range of the compressor.operating range of the compressor.
OEM of PAC of Ammonia-II has confirmed that it shouldOEM of PAC of Ammonia-II has confirmed that it should
be possible to operate the machine with 75372 Nm³/hbe possible to operate the machine with 75372 Nm³/h
without modifications.without modifications.
It was practically observed that the machine is in positionIt was practically observed that the machine is in position
to deliver the desired load with no limitation on driverto deliver the desired load with no limitation on driver
side.side.
7070
71. LINE1 AND LINE2 DIFFERENCELINE1 AND LINE2 DIFFERENCE
LINE 1 DOES NOT HAVE MIXED FEEDLINE 1 DOES NOT HAVE MIXED FEED
CAPABILITY ONLY NG CAN BE USEDCAPABILITY ONLY NG CAN BE USED
AS FEEDAS FEED
IN LINE1 AIR COMP IS RUN BY STEAMIN LINE1 AIR COMP IS RUN BY STEAM
TURBINE IN LINE 2 GT IS USED FORTURBINE IN LINE 2 GT IS USED FOR
RUNNING AIR COMPRUNNING AIR COMP
72. LINE1 AND LINE2 DIFFERENCELINE1 AND LINE2 DIFFERENCE
IN LINE 1 STRIPPING OF CONDENSATEIN LINE 1 STRIPPING OF CONDENSATE
IS DONE BY LOW PREESURE STEAMIS DONE BY LOW PREESURE STEAM
AND ALL THE STEAM IS VENTED TOAND ALL THE STEAM IS VENTED TO
ATMOSPHEREATMOSPHERE
IN LINE 2 STRIIPING IS DONE BY MPIN LINE 2 STRIIPING IS DONE BY MP
STEAM AND STEAM IS REUSED INSTEAM AND STEAM IS REUSED IN
REFORMER THUS SAVING THE ENERGYREFORMER THUS SAVING THE ENERGY
73. LINE1 AND LINE2 DIFFERENCELINE1 AND LINE2 DIFFERENCE
IN LINE 1 BENFIELD PROCESS IS USEDIN LINE 1 BENFIELD PROCESS IS USED
FOR CO2 STRIPPINGFOR CO2 STRIPPING
IN LINE 2 GV PROCESS IS USED FORIN LINE 2 GV PROCESS IS USED FOR
CO2 REMOVALCO2 REMOVAL
LINE 1 DOES NOT HAVE PRELINE 1 DOES NOT HAVE PRE
REFORMERREFORMER
74. LINE1 AND LINE2 DIFFERENCELINE1 AND LINE2 DIFFERENCE
IN LINE 1 BENFIELD PROCESS IS USEDIN LINE 1 BENFIELD PROCESS IS USED
FOR CO2 STRIPPINGFOR CO2 STRIPPING
IN LINE 2 GV PROCESS IS USED FORIN LINE 2 GV PROCESS IS USED FOR
CO2 REMOVALCO2 REMOVAL
LINE 1 DOES NOT HAVE PRELINE 1 DOES NOT HAVE PRE
REFORMERREFORMER