The document provides information about the various sections of an ammonia plant, including the desulfurization, reforming, shift, CO2 removal, methanation, and ammonia synthesis sections. It details the processes that occur in each section, including catalysts used and operating parameters. The goal is to produce 99.73% pure ammonia from natural gas feedstock using a high-pressure synthesis process.
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.
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.
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
Steam Reforming - The Basics of reforming, shapes and carbon:
Steam Reforming Catalysis :
Chemical reactions
Catalyst shape design
Catalyst chemistry
Carbon formation and removal
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.
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.
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
Steam Reforming - The Basics of reforming, shapes and carbon:
Steam Reforming Catalysis :
Chemical reactions
Catalyst shape design
Catalyst chemistry
Carbon formation and removal
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.
Catalytic Reactions in Catalytic Reforming
Catalytic Reforming Reactions
Sulfur Related Problems
Effects of Sulfur in Catalytic Reforming
Reactions in Catalytic Reforming
Catalytic Reforming Catalysts
Effect of Sulfur on Catalytic Reforming Catalysts
Catalytic Reformer Efficiency
VULCAN Sulfur Guards
VULCAN Sulfur Guards for Catalytic Reformers
VULCAN Guard Installation Protects Isomerization Catalysts
Liquid Phase vs Gas Phase: Relative Advantages
Liquid Phase Treating
Which active metal is best?
Thiophenes and Nickel Sulfur Guards
Sulfiding mechanisms with reduced metals
Thiophene adsorption on nickel
Advantages of Cu/Zn Over Nickel Sulfur Guards
Copper oxide vs Nickel
Nickel Sulfur Guards
Manganese Sulfur Guards
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
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
(HTS) High Temperature Shift Catalyst (VSG-F101) - Comprehensiev OverviewGerard B. Hawkins
The high temperature shift duty introduction and theory
HTS catalyst characteristics
developments over time
Typical HTS operational problems
Improved catalysts
VULCAN Series VSG-F101 Series
Summary
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
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
High level introduction
Mainstream syngas = steam reforming processes
Ammonia; methanol; hydrogen/HyCO
Town gas
Steam reforming; low pressure cyclic
Direct reduction iron (DRI)
HYL type processes; Midrex type processes
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
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.
Catalytic Reactions in Catalytic Reforming
Catalytic Reforming Reactions
Sulfur Related Problems
Effects of Sulfur in Catalytic Reforming
Reactions in Catalytic Reforming
Catalytic Reforming Catalysts
Effect of Sulfur on Catalytic Reforming Catalysts
Catalytic Reformer Efficiency
VULCAN Sulfur Guards
VULCAN Sulfur Guards for Catalytic Reformers
VULCAN Guard Installation Protects Isomerization Catalysts
Liquid Phase vs Gas Phase: Relative Advantages
Liquid Phase Treating
Which active metal is best?
Thiophenes and Nickel Sulfur Guards
Sulfiding mechanisms with reduced metals
Thiophene adsorption on nickel
Advantages of Cu/Zn Over Nickel Sulfur Guards
Copper oxide vs Nickel
Nickel Sulfur Guards
Manganese Sulfur Guards
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
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
(HTS) High Temperature Shift Catalyst (VSG-F101) - Comprehensiev OverviewGerard B. Hawkins
The high temperature shift duty introduction and theory
HTS catalyst characteristics
developments over time
Typical HTS operational problems
Improved catalysts
VULCAN Series VSG-F101 Series
Summary
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
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
High level introduction
Mainstream syngas = steam reforming processes
Ammonia; methanol; hydrogen/HyCO
Town gas
Steam reforming; low pressure cyclic
Direct reduction iron (DRI)
HYL type processes; Midrex type processes
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
Manufacturing of ammonia using haber's processrita martin
Ammonia is a colourless pungent smelling gas used mostly in production of fertilizers. It is widely manufactured by Haber process from nitrogen (N2) and hydrogen (H2)
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
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Presentation given by Richard T. J. Porter from ETII, University of Leeds, on "CO2QUEST Typical Impurities in Captured CO2 Streams" at the EC FP7 Projects: Leading the way in CCS implementation event, London, 14-15 April 2014
Processing of Hydrogen Sulfide & Carbon Dioxide From Natural Gas StreamsMohamed Almoalem
This poster was presented in GPA (Gas Processors Association) 23rd technical conference in November 2015. It is the outcome of an individual research that was done voluntarily by me during my internship in Tatweer Petroleum.
Production of Syngas from biomass and its purificationAwais Chaudhary
This project includes production of syngas from biomass and its purification. Firstly we discuss feasibility and availability of raw material. Then we have literature survey. A lot of techniques are there to produce syngas, we have discuss process selection. Environmental considerations are also have been discussed. Piping and instrumentation (P&ID) diagrams also have been attached. At the end we've our conclusion and our recommendations.
Sweetening and sulfur recovery of sour associated gas in the middle eastFrames
Effective and efficient removal of hydrogen sulfide (H2S) is an essential step when sweetening gas for downstream processes. By simultaneously turning the captured hydrogen sulfide into elemental sulfur, a Frames THIOPAQ O&G system improves gas value, while creating a saleable chemical widely sought after in the agricultural and bulk chemical industry.
Accelerate your Kubernetes clusters with Varnish CachingThijs Feryn
A presentation about the usage and availability of Varnish on Kubernetes. This talk explores the capabilities of Varnish caching and shows how to use the Varnish Helm chart to deploy it to Kubernetes.
This presentation was delivered at K8SUG Singapore. See https://feryn.eu/presentations/accelerate-your-kubernetes-clusters-with-varnish-caching-k8sug-singapore-28-2024 for more details.
Search and Society: Reimagining Information Access for Radical FuturesBhaskar Mitra
The field of Information retrieval (IR) is currently undergoing a transformative shift, at least partly due to the emerging applications of generative AI to information access. In this talk, we will deliberate on the sociotechnical implications of generative AI for information access. We will argue that there is both a critical necessity and an exciting opportunity for the IR community to re-center our research agendas on societal needs while dismantling the artificial separation between the work on fairness, accountability, transparency, and ethics in IR and the rest of IR research. Instead of adopting a reactionary strategy of trying to mitigate potential social harms from emerging technologies, the community should aim to proactively set the research agenda for the kinds of systems we should build inspired by diverse explicitly stated sociotechnical imaginaries. The sociotechnical imaginaries that underpin the design and development of information access technologies needs to be explicitly articulated, and we need to develop theories of change in context of these diverse perspectives. Our guiding future imaginaries must be informed by other academic fields, such as democratic theory and critical theory, and should be co-developed with social science scholars, legal scholars, civil rights and social justice activists, and artists, among others.
The Art of the Pitch: WordPress Relationships and SalesLaura Byrne
Clients don’t know what they don’t know. What web solutions are right for them? How does WordPress come into the picture? How do you make sure you understand scope and timeline? What do you do if sometime changes?
All these questions and more will be explored as we talk about matching clients’ needs with what your agency offers without pulling teeth or pulling your hair out. Practical tips, and strategies for successful relationship building that leads to closing the deal.
Essentials of Automations: Optimizing FME Workflows with ParametersSafe Software
Are you looking to streamline your workflows and boost your projects’ efficiency? Do you find yourself searching for ways to add flexibility and control over your FME workflows? If so, you’re in the right place.
Join us for an insightful dive into the world of FME parameters, a critical element in optimizing workflow efficiency. This webinar marks the beginning of our three-part “Essentials of Automation” series. This first webinar is designed to equip you with the knowledge and skills to utilize parameters effectively: enhancing the flexibility, maintainability, and user control of your FME projects.
Here’s what you’ll gain:
- Essentials of FME Parameters: Understand the pivotal role of parameters, including Reader/Writer, Transformer, User, and FME Flow categories. Discover how they are the key to unlocking automation and optimization within your workflows.
- Practical Applications in FME Form: Delve into key user parameter types including choice, connections, and file URLs. Allow users to control how a workflow runs, making your workflows more reusable. Learn to import values and deliver the best user experience for your workflows while enhancing accuracy.
- Optimization Strategies in FME Flow: Explore the creation and strategic deployment of parameters in FME Flow, including the use of deployment and geometry parameters, to maximize workflow efficiency.
- Pro Tips for Success: Gain insights on parameterizing connections and leveraging new features like Conditional Visibility for clarity and simplicity.
We’ll wrap up with a glimpse into future webinars, followed by a Q&A session to address your specific questions surrounding this topic.
Don’t miss this opportunity to elevate your FME expertise and drive your projects to new heights of efficiency.
Kubernetes & AI - Beauty and the Beast !?! @KCD Istanbul 2024Tobias Schneck
As AI technology is pushing into IT I was wondering myself, as an “infrastructure container kubernetes guy”, how get this fancy AI technology get managed from an infrastructure operational view? Is it possible to apply our lovely cloud native principals as well? What benefit’s both technologies could bring to each other?
Let me take this questions and provide you a short journey through existing deployment models and use cases for AI software. On practical examples, we discuss what cloud/on-premise strategy we may need for applying it to our own infrastructure to get it to work from an enterprise perspective. I want to give an overview about infrastructure requirements and technologies, what could be beneficial or limiting your AI use cases in an enterprise environment. An interactive Demo will give you some insides, what approaches I got already working for real.
PHP Frameworks: I want to break free (IPC Berlin 2024)Ralf Eggert
In this presentation, we examine the challenges and limitations of relying too heavily on PHP frameworks in web development. We discuss the history of PHP and its frameworks to understand how this dependence has evolved. The focus will be on providing concrete tips and strategies to reduce reliance on these frameworks, based on real-world examples and practical considerations. The goal is to equip developers with the skills and knowledge to create more flexible and future-proof web applications. We'll explore the importance of maintaining autonomy in a rapidly changing tech landscape and how to make informed decisions in PHP development.
This talk is aimed at encouraging a more independent approach to using PHP frameworks, moving towards a more flexible and future-proof approach to PHP development.
Smart TV Buyer Insights Survey 2024 by 91mobiles.pdf91mobiles
91mobiles recently conducted a Smart TV Buyer Insights Survey in which we asked over 3,000 respondents about the TV they own, aspects they look at on a new TV, and their TV buying preferences.
State of ICS and IoT Cyber Threat Landscape Report 2024 previewPrayukth K V
The IoT and OT threat landscape report has been prepared by the Threat Research Team at Sectrio using data from Sectrio, cyber threat intelligence farming facilities spread across over 85 cities around the world. In addition, Sectrio also runs AI-based advanced threat and payload engagement facilities that serve as sinks to attract and engage sophisticated threat actors, and newer malware including new variants and latent threats that are at an earlier stage of development.
The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
Download the full report from here:
https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
UiPath Test Automation using UiPath Test Suite series, part 3DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 3. In this session, we will cover desktop automation along with UI automation.
Topics covered:
UI automation Introduction,
UI automation Sample
Desktop automation flow
Pradeep Chinnala, Senior Consultant Automation Developer @WonderBotz and UiPath MVP
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Neuro-symbolic is not enough, we need neuro-*semantic*Frank van Harmelen
Neuro-symbolic (NeSy) AI is on the rise. However, simply machine learning on just any symbolic structure is not sufficient to really harvest the gains of NeSy. These will only be gained when the symbolic structures have an actual semantics. I give an operational definition of semantics as “predictable inference”.
All of this illustrated with link prediction over knowledge graphs, but the argument is general.
4. Desulphurization Section
General Information:
• Natural gas contains up to 10
vol ppm sulphur compounds.
• Gas contains both H₂S and
organic sulphur compounds.
• Desulphurization takes place
in two stages.
1. Hydrogenation
2. H₂S absorption
TK- 250
HTZ – 5 catalyst
5. TK- 250
HTZ – 51 catalyst
Hydrogenation
In case if Natural gas containing CO and
CO₂ is fed to the hydrogenator, the
following reactons will take place
CO₂ + H₂ ↔ CO + H₂O
CO₂ + H₂ ↔ COS + H₂O
(400˚C)
(38 Kg/cm2)
35˚C
(39 Kg/cm2)
(395˚C)
(351˚C)
C2H6- 9
C3H8- 3
C4H10- 2
C6H12- 0.25
CH4 – 84.50
N2 – 1.25
TK-250 must not get into
contact with HC’s without
presence of hydrogen.
This will increase sulphur
slip to reforming section.
CoMo or
NiMo based
catalyst.
(Pyrophoric)
6. TK- 250
HTZ – 51 catalyst
H₂S absorption
• The hydrogenated natural gas is fed to
the Sulphur Absorbers ( R 202 A/B).
• Zinc oxide catalyst is in the form of 4
mm extrudates.
• Operating temperature is approx.
395˚C.
ZnO + H₂S ↔ ZnS + H₂O
ZnO + COS ↔ ZnS + CO₂
• Sulphur content in the natural gas =
less than 0.1 ppm by weight
(351˚C)
Ar – 0.02, CH4 – 79.68, CO – 2 ppm,
CO2 – 0.24, H2 – 4.09, N2 – 2.54,
C2H6 – 6.48, C3H8 – 2.63, C4H10 –
1.88, C6H12 - 0.24
C2H6- 9
C3H8- 3
C4H10- 2
C6H12- 0.25
CH4 – 84.50
N2 – 1.25
TK- 250
(400˚C)
(38 Kg/cm2)
35˚C
(39 Kg/cm2)
(395˚C)
Does not react with Oxygen and
hydrogen, Not pyrophoric. Steam
operation should not be carried out.
Operating temp – 350-400’C
ZnO = More than 95%
Al2O3 = Less than 5%
Shape- Cylindrical Extrudates
7. Reforming Section
General Information:
Desulphurized gas is converted into synthesis
gas by catalytic reforming of the hydrocarbon
mixture with steam and the addition of air.
CnH2n+2 + 2H₂O ↔ Cn-1H2n + CO₂ + 3H₂ - heat
CH₄ + 2H₂O ↔ CO₂ + 4H₂ - heat
CO₂ + H₂ ↔ CO + H₂O - heat
Reactions take place in two steps
1. Primary reforming
2. Secondary reforming
8. Primary Reforming
• Heat is transferred by radiation from a number of
wall burners to the catalyst tubes.
• Hydrocarbon in the feed converted to CO₂ and
H₂ with 13.3 mole% of methane(dry)
• Reformer tubes is loaded with catalyst RK-211
(prereduced) followed by a layer of RK-201,
while the bottom part of the reformer tubes is
loaded with catalyst R-67_7H.
520˚C
791˚C
Operating parameter
1. Inlet temperature : 520 ºC
2. Exit temperature : 785 - 795 ºC
3. Pressure: 34 - 31 kg/cm2 g
4. Steam/carbon ratio: 3.0 mole/mole
RK-211
RK-201
R-67_7H
Contents
Nickel(Ni)
Calcium Oxide(CaO)
Potassium oxide(K2O)
Aluminum Oxide(Al2O3 )
Nickel Monoxide(NiO)
Calcium Oxide(CaO
Potassium oxide(K2O)
Aluminum Oxide(Al2O3 )
Nickel Monoxide(NiO)
Calcium Oxide(CaO
Aluminum Oxide(Al2O3 ) Ni-S + H2O = NiO + H2S
C+O2 = CO2
9. Composition : (Mole %)
(At Inlet of Catalyst
Tubes)
Ar – 0.02
CH4 – 79.68
CO – 2 ppm
CO2 – 0.24
H2 – 4.09
N2 – 2.54
C2H6 – 6.48
C3H8 – 2.63
C4H10 – 1.88
C6H12 - 0.24
Composition: (Mole %)
(At Outlet of Catalyst
Tubes)
Ar – 47 ppm
CH4 – 12.86
CO – 9.5
CO2 – 10.70
H2 – 66.20
N2 – 0.74
Higher HC - Neglegible
Primary Reformer Inlet & Outlet
10.
11. Secondary Reforming
520˚C
791˚C
• The process gas is mixed with air.
• Partial combustion takes place in the top
of R 203.
• Methane concentration is 0.60
mole%(dry).
• Outlet gas contains about 13.05mole%
(dry) CO and 7.24mole% (dry) CO₂.
• Loaded with RKS-2-7H, and RKS-2 catalyst.
H2+O2=H2O
CH4+O2= CO2+2H2O
958˚C
(550 ˚C)
(1100-1200˚C )
Operating Pressure: 30 kg/cm2 g
H2/N2 Ratio: 3.0
Ar – 0.27
CH4 – 0.60
CO – 13.37
CO2 – 7.65
H2 – 55.61
N2 – 22.47
Ar – 47 ppm
CH4 – 12.86
CO – 9.5
CO2 – 10.70
H2 – 66.20
N2 – 0.74
NiO = 8 – 10%
Al2O3 = 87 – 90 %
Cao = < 0.05
RKS-2
RKS-2-7H
RKS-2
12. CO Shift Section
General Information:
CO + H2O ↔ H2 + CO2 + heat
• Shift reaction takes place in the two CO
converters:
• HT CO-Converter( R 204)
• LT CO- converter (R 205) with process gas
cooling after each converter
13. HT CO-Converter(R 204)
• Contains SK-201-2 catalyst installed.
• The catalyst is Cu promoted
iron/chromium based, in the form of
pellets.
• Can operate continuously in the range of
320-480˚C.
• Chlorine and inorganic salts are poisons to
the catalyst. (Below 1ppm)
360˚C
432˚C
340˚C
205˚C
(29.6 kg/cm2)
(SK-201-2)
1. Mechanical stability
2. Low Steam to Carbon ratio
3. Low byproduct formation
Fe2O3 - 85- 95 %
Cr2O3 - 7-9 %
CuO - 1-2%
Al2O3 - 1.0%
Ar – 0.27, CH4 – 0.60,
CO – 13.37, CO2 – 7.65,
H2 – 55.61, N2 – 22.47
Ar – 0.24
CH4 – 0.55
CO – 3.22
CO2 – 15.94
H2 – 59.59
N2 – 20.48
14. LT CO-Converter(R 205)
360˚C
432˚C
340˚C
205˚C
(29.6 kg/cm2)
(28.6 kg/cm2)
227˚C 160˚C
• Loaded with a top layer of LSK and a bottom
layer of LK-821-2.
• Can be operated within a temperature range
of 170-250˚C.
• The activity of the catalyst increases with
increasing temperature, but the life of the
catalyst shortened
• LSK is installed to catch possible chlorine in
the gas.
• Amount of CO (3.22 – 0.30), CO2 (15.94 –
17.72)
205˚C
(LSK)
(LK-821-2)
(SK-201-2)
Ar – 0.24
CH4 – 0.53
CO – 0.30
CO2 – 18.32
H2 – 60.73
N2 – 19.88
Ar – 0.24
CH4 – 0.55
CO – 3.22
CO2 – 15.94
H2 – 59.59
N2 – 20.48
Ar – 0.27, CH4 – 0.60,
CO – 13.37, CO2 – 7.65,
H2 – 55.61, N2 – 22.47
• Consist of oxides of copper,
zinc, chromium or
aluminium
• Temperature range - 170-
250˚C.
• Top layer catches possible
chlorine in the gas and also
preventsliqvid droplets from
reaching bottom
layer.(Disintegration may
takes place)
15. CO2 Removal Section
General Information:
• Based on two stage activated
MDEA process
• The solvent used for CO2
absorption is aMDEA(40%)
• Consists of a two stage CO2
absorber, a CO2 stripper and
two flesh vessels.
• Outlet gas from CO converter
contain 17.7 mole% CO2.
R3N + CO2 + H2O ↔ R3NH+ + HCO3
-
2R2NH + CO2 ↔ R2NH2
+ + R2N-COO-
17. Methanation Section
General Information:
• Methanation, a process in which the residual
corbon oxides are converted into methane.
• Methane acts as an inert in the ammonia
synthesis section
CO + 3H2 ↔ CH4 + H2O + heat
CO2 + 4H2 ↔ CH4 + 2H2O + heat
• Low temperature, high pressure and a low
water vapour content favours the
methanation equilibrium.
• Methanator (R 301) has one catalyst bed
loaded with PK-7R catalyst
18. (300˚C)
(322˚C)
PK-7R
(90˚C)
(285˚C)
(100˚C)
26.7 Kg/cm2
(60˚C)
• Temperature range of
methanator- (280˚C - 420
˚C )
• Catalyst sensitive to sulphur,
chlorine compounds.
• PK-7R is Nikel based
catalyst.
Deactivation of catalyst can be
caused by:
• Thermal ageing
• Gradual poisoning by
impurities in the feed gas
such as potassium, sulphur
or arsenic.• CO & CO2 conc. Should be
below 1 mole% to minimize
temperature increment.
• Now pressure of gas
is increased from 25
to 187 Kg/cm2 in
various stages with
Synthesis gas
compressor, gas
booster.
• At every stage
temperature gets
increases, to
maintain low
temperature Syngas
compressor chillers
are installed in
between.
25 Kg/cm2
Ar- 0.29, CH4- 1.08,
H2- 73.95, N2- 24.88
Ar- 0.29, CH4- 0.65,
CO2-0.05,CO-0.36,
H2- 74.29,N2- 24.36
19. Ammonia Synthesis Section
General Information
• In ammonia converter R-501:
3H2 + N2 = 2NH3 + heat
• High pressure and low
temperature favours
equilibrium conc. of ammonia.
• About 20% of N2 and H2 is
converted to ammonia.
• Unconverted remainder is
recycled back.
187 Kg/cm2
(130˚C)
(354˚C)
183.6 Kg/cm2
• Ammonia Synthesis catalyst -
KM1/KM1R
• High concentration of oxygen
compounds at the converter
inlet, even for short periods of
time, should be
avoided.(permanent deactivation
takesplace).
Features of the catalyst
1. Stable pressure drop
2. Long operating life
3. High resistance to poison
• Normal operating temperature for
First bed : 370-510
Second bed: 425-480
Third bed: 420-460
KM1/KM1R
Non pyrophoric upto 90-100’C
Temperature range – 530-550’C
Features of the catalyst :
1.Stable pressure drop
2. Long operating life
3.High resistance to poison
Iron based catalyst with some
non reducible oxides.
23. • Urea is produced by the highly
exothermic reaction of Ammonia and
carbon dioxide to form ammonium
Carbamate with slightly endothermic
dehydration of ammonium Carbamate
to form urea.
The reactor temperature is controlled by the
combination of the following factors:
1. Excess ammonia to the reactor
2. Recycle solution rate to the reactor
3. Pre-heat temperature of liquid ammonia
to the reactor.
Synthesis Section
24. Decomposition Section
1. Here Carbamate is decomposed to
ammonia and carbon dioxide gasses.
NH2COONH4 = CO2 + 2NH3
2. Decomposition is usually achieved at
temperature of 1200C to 165oC
Decreasing pressure favors
decomposition as dose increasing
temperature.
3. During decomposition, hydrolysis of
urea becomes an important factor.
Hydrolysis proceeds as per the
following reaction:
NH2 CONH2 +H2O = CO2 + 2NH3
At low partial pressure of ammonia and temp. Above 900C
Urea converts to form ammonia and biurate as in the overall reaction
below:
2 NH2CO NH2 = NH2 CONHCO NH2 +NH3
25. Recovery Section
1. The unreacted ammonia and CO2 can
not be compressed in practical instead
of this we do
1. Separate and recycle as gasses.
2. Recycle in a solution or slurry
form.
NFL Bathinda uses second one.
1. The mixture of ammonia CO2 gasses
from the decomposers are absorbed in
water and urea solution in the
respective absorbers and recycle back
to the urea synthesis reactor.
2. The excess ammonia is purified in
high-pressure absorber and recycled
separately to the reactor through
ammonia condensers
26. Crystallization Section
1. The urea solution leaving the
Carbamate decomposes is vacuum
crystallized and urea crystals are
separated by centrifuge.
2. Crystals formed in the vacuum
crystallizer are centrifuged and then
dried to less than 0.3% moisture by hot
air.
3. The biurate is converted back to urea in
presence of excess ammonia.
NH2 CONHCONH2 +NH3 = 2NH2CONH2
4. Dry crystals are conveyed to the top of
prilling tower passing through
Fluidizing dryer
27. Prilling Section
• Dry crystals of urea collected in
the air dryer in which it is dried by
passing dry air from F.D. fan.
• Attain a temperature less than
melting point of urea i.e. 1200C.
• Dry crystals are conveyed to the
top of prilling tower passing
through pneumatic duct and send
to the melter via cyclone and
screw conveyor to melter.
• In melter dry urea crystals are
melted by using 7K steam and
finally reaches to the Head tank .
In melter temperature of molten
urea control up to 1370C to avoid
the biuret formation.
28. Prilling Section
• Molten urea solution comes from
head tank to acoustic granulator
and then sprayed in the form of
prills form a rising column of
prilling tower.
• These prills get cooled down by
F.D. fan air which take suction from
atmosphere and send it through
continuous fluidized dryer.
• After cooling of prills not less than
450C, it is conveyed to bagging
plant via passing through trommel
and belts and finally stored in the
silos.