Capacity Enhancement of Ammonia Production By The Revamping of Ammonia. In this project, we find conversion and temperature profile of a two catalyst bed with one interbed heat exchanger ammonia converter and a three catalyst bed with two interbed heat exchanger ammonia converter both have radial flow by using a pseudo homogeneous two dimensional mathematical model on the basis of principle of conservation of mass and energy balance with the help of MATLAB pde solver.We conclude that a three catalyst bed ammonia converter give a higher conversion and lower pressure drop compare to the two catalyst bed ammonia converter for the same volume of catalyst bed and same amount of feed stock.

2. Capacity Enhancement of Ammonia Production By
optimizing the performance of Ammonia Convertor
GROUP MEMBERS
DANYAL KHAN
ZEESHAN ZAHID
FAWAD AHMED
ABDUL RAFAY
ZULFIQAR ALI SADIQ
SAQIB KHAN

3. CONTENTS
 Introduction
 Background
 Problem statement
 Scope of study
 Literature review
 Methodology
 Results
 Conclusion

4. INTRODUCTION
 From the last few decades there is an exponential increase in the world population
which cause:
“Continuous decrease in land and increase in food demand”
 Here ammonia comes into the matter because:
“Ammonia — synthetic fertilizer requires less land for more food production”
 With this ammonia can further be used in:
1. Explosives
2. Fermentation.
3. Refrigeration.
4. Cleaning agents.

5. BACKGROUND
AIR METHANE
REFORMING
NITROGEN HYDROGEN
AMMONIA
 How ammonia is produced?
AMMONIA
CONVERTER
FERTILIZER
CARBON DIOXIDE
UREA

6. BACKGROUND
 why ammonia production is
important?
 Ammonia act as a refrigerant
replaced CFCs that cause ozone
depletion.
 It is a source of nitrogen for
growing plants in the form of
fertilizer.
 In nature NH3 is produced by
biological process thus naturally
decomposed and does not
contribute in green house effect.
HABER
BOSCH

7. PROBLEM STATEMENT
 World apparent consumption of
ammonia increased by 22%
during 2004–2013.
 Growth is forecast at 2.7%
annually during 2013–2018 .
 In Pakistan apparent consumption
of ammonia increased by 6%
during 2003–2013.
 Growth is forecast at 1 %
annually during 2013–2018
2.35 2.1 2.25 2.35 2.45 2.5
0
1
2
3
2003 2005 2007 2009 2011 2013
Millionton
Year
Ammonia Production
Production

8. SCOPE OF STUDY
 This study aims to increase the production of ammonia by:
“Revamping of 2 radial bed ammonia converter (currently installed at FFBL)
with 3 radial bed ammonia converter using same amount of feed stock.”

9. OBJECTIVES
 FOR REVAMPING FOLLOWING OBJECTIVES HAVE TO BE FULFILLED:
 Literature survey
 Mathematical modelling of ammonia converter.
 Comparative study of results.
 Mass balance.
 Energy balance.
 Hazard and operability study.
 Economic analysis.

10. Types of ammonia converters
Axial flow Radial flow Axial radial
Conversion Low conversion per pass More conversion per pass Maximum conversion per
pass
Pressure drop Maximum pressure drop Minimum pressure drop Low than axial but more
than radial flow
Temperature Exothermic heat release is
small
Exothermic heat release is
more
Exothermic heat release is
maximum
Name Flow type Heat exchange Number of
converters
Numer of catalyst
beds
Uhde Radial flow Intercooled Two Three
Kellog(kbr) Axial flow Intercooled or
quench
One Two or four
Topsoe Radial flow Intercooled or
quench
One or two Two or three
Casale Axial radial flow intercooled One Three
ICI Axial flow Intercooled and
quench
One Three beds
Types of ammonia converters

11. LITERATURE SURVEY (Contd.)
Catalyst bed 1
Catalyst bed 2
Catalyst bed 3
Interbed exchanger 1
Interbed exchanger 2
Inlet gas interbed
heat exchanger
Main gas inlet Gas outlet
 Arrangement of three catalyst bed ammonia converter
Cold shot

12. LITERATURE SURVEY (Contd.)
 WHY HALDOR TOPSOE
AMMONIA CONVERTOR IS
BEING PREFERRED?
 100% radial flow gives
higher conversion
 Indirect cooling of the gas
in inter-bed heat exchanger
avoid dilution of converted
gas.
 Inlet gas passes through all
beds fully utilizing the total
installed catalyst volume.

13. ADVANTAGES OF TWO CATALYST BED OVER THREE CATALYST BED
 Higher conversion because contact area is increased in three catalyst bed
 Since ammonia formation is an exothermic reaction installation of
second inter-bed heat exchanger exchange more heat and shift
equilibrium in forward direction.
 More utilization of total installed catalyst volume.

14. METHODOLOGY
To date, most of the ammonia converters are operating as a black box and simulation
and modelling was performed by provider.
Therefore, a two dimensional mathematical model was developed for the simulation
of a radial flow Ammonia converter using MATLAB.
Simulation of two as well as three catalyst bed ammonia converter is carried out.

15. METHODOLOGY
 MATHEMATICAL MODEL:
 In this model mass and energy balance equations are solved simultaneously for a
cylindrical differential element to obtain:
I. Final fractional conversion
II. Temperature profile.

16.  ASSUMPTIONS:
 Steady state operation.
 External transport resistances between catalyst particles and gas are
negligible.
 Interfacial gradients inside catalyst are negligible.
 Tempertaure of the gas flowing through the catalyst bed is the same as the
catalyst particle at each position.
METHODOLOGY

17. METHODOLOGY
 MASS BALANCE EQUATION:

18. METHODOLOGY
 ENERGY BALANCE EQUATION:

19. METHODOLOGY
 OPERATING CONDITIONS AND DATA USED IN THE SIMULATION OF RADIAL
AMMONIA SYNTHESIS CONVERTER

20. RESULTS
 Fractional conversion along the reactor beds.

21. RESULTS
 Reactants/product concentration across each catalyst bed.

22. RESULTS
 Temperature profile along each catalyst bed.

23. CONCLUSION
 A three radial bed Ammonia Convertor like haldor topsoe
S300, is an attractive option for increasing the capacity of
the production of ammonia.