AMMONIA PLANT

TECHNOLOGY HALDOR TOPSOE

CAPACITY

FEED
ENERGY

1750/1864 TPD
NG AND NEPTHA
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 90%CH4
NEPTHA CONTAINS HIGHER
HYDROCAREBON

BLOCK DIGRAM OF AMOONIA

PLANT
DESULPHERISATION

SHIFT REACTION

COMP HOUSE

REFORMING

CO2 REMOVAL AREA

AND METHNATION

SYNTHESIS

CO2 TO UREA

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
H2
NIMO

RSH +H2 =RH +H2S

R1SSR2 +H2 = R1H +R2H +H2S

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 FURNACE
OPERATING CONDITIONS ARE VERY INTENCE

REACTIONS OF REFORMING

CnH2n+2 +2H20 = Cn-1H2n +Co2 +3H2HEAT

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

NI

CH4 90%
450---500

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
CH4 11%

1200

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

CO 12.77

HT SHIFT
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 = KHCO3
REGENERATION REACTION
KHCO3 +HEAT = K2CO3 +H20+CO2

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

26kg/cm2

175

180kg/cm2
Gas to conv

172kg/cm2

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
AMM CONVERTOR

GAS GAS EX

PRI CHIL

STEAM
LOOP BOILER

BFW HEATER

WATER COOLERE

GAS GAS EX

SEC CHILL
PURGE GAS

AMM SEP

LET DOWNVESSLETO
STO
RAG
AMMTO UREA E

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 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

GAS TO REF

ABSORBER

WATER

LOADED SOL

AM TO STORAGE

REGENERATIONR
STEAM

PUURGE

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