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    Ammonia Plant Description

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    hussainbeds
    This document provides an overview of the ammonia production process. It discusses the key raw materials used, including natural gas and air. The major steps of the process are described, including desulphurization of the natural gas, reforming reactions in the tubular and auto-thermal reformers, shift conversion reactions, CO2 removal, methanation, and ammonia synthesis. Details are provided on process equipment, operating parameters, and catalysts used at each step. The refrigeration system for condensing ammonia product is also summarized. Process flow diagrams and comparisons of different ammonia plant configurations are presented. Finally, the document outlines the production department hierarchy and job responsibilities of shift engineers.

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    © All Rights Reserved
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    Ammonia Plant Description

    Uploaded by

    hussainbeds
    1K views41 pages
    This document provides an overview of the ammonia production process. It discusses the key raw materials used, including natural gas and air. The major steps of the process are described, including desulphurization of the natural gas, reforming reactions in the tubular and auto-thermal reformers, shift conversion reactions, CO2 removal, methanation, and ammonia synthesis. Details are provided on process equipment, operating parameters, and catalysts used at each step. The refrigeration system for condensing ammonia product is also summarized. Process flow diagrams and comparisons of different ammonia plant configurations are presented. Finally, the document outlines the production department hierarchy and job responsibilities of shift engineers.

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    This document provides an overview of the ammonia production process. It discusses the key raw materials used, including natural gas and air. The major steps of the process are described, including desulphurization of the natural gas, reforming reactions in the tubular and auto-thermal reformers, shift conversion reactions, CO2 removal, methanation, and ammonia synthesis. Details are provided on process equipment, operating parameters, and catalysts used at each step. The refrigeration system for condensing ammonia product is also summarized. Process flow diagrams and comparisons of different ammonia plant configurations are presented. Finally, the document outlines the production department hierarchy and job responsibilities of shift engineers.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    1K views41 pages

    Ammonia Plant Description

    Uploaded by

    hussainbeds
    This document provides an overview of the ammonia production process. It discusses the key raw materials used, including natural gas and air. The major steps of the process are described, including desulphurization of the natural gas, reforming reactions in the tubular and auto-thermal reformers, shift conversion reactions, CO2 removal, methanation, and ammonia synthesis. Details are provided on process equipment, operating parameters, and catalysts used at each step. The refrigeration system for condensing ammonia product is also summarized. Process flow diagrams and comparisons of different ammonia plant configurations are presented. Finally, the document outlines the production department hierarchy and job responsibilities of shift engineers.

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    At a glance
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    The key takeaways are that ammonia plants produce ammonia using natural gas as a feedstock and the ammonia is used to produce fertilizers. The document discusses the components, process, and responsibilities involved.

    The main components of an ammonia plant include desulfurization units, reformers, shift converters, methanators, CO2 removal units, ammonia synthesis units, refrigeration circuits, and ammonia recovery units.

    The main steps involved in the ammonia production process are desulfurization, reforming, shift conversion, methanation, CO2 removal, ammonia synthesis, and ammonia separation.

    AMMONIA

    PLANT
    INTRODUCTION

    PRESENTED BY:

    FERTILIZERS
    Provide essential nutrients (N,P,K ) to crops
    Nitrogen is required to promote protein formation which helps
    healthy growth, high yields and keep plants green.

    (Urea, CAN, AN)


    Phosphorus accelerates seeding and fruit formation (SSP, DAP)

    Potassium is essential for the development of starch/


    sugar/fibers of plants (Potassium phosphate, NPK blended)

    PROPERTIES OF AMMONIA

    Colorless
    Strong pungent and irritating odors
    Mol. Wt: 17.03
    Boiling Point: -33.3 C at atmospheric pressure
    Gas at ambient conditions
    Flammability Range: 16-25 %
    2500 ppm: fatal in 30 minutes

    FFC AMMONIA PLANTS


    FFC-I

    FFC-II

    *FFC-III

    Commercial
    Production

    June 1982

    March 1993

    June 1980

    Nameplate
    Production
    Capacity

    1000 MTPD

    1100 MTPD

    1000 MTPD

    Process Licenser

    Haldore Topsoe Denmark

    * Previously Pak Saudi (Acquired by FFC in 2003)

    RAW MATERIALS

    Natural gas
    Raw water
    Air
    Electric Power

    Ammonia
    AMMONIA
    PLANT
    CO2

    NATURAL GAS
    Feedstock : Natural Gas
    Fuel : Natural Gas
    Typical Analysis of Natural Gas

    Methane
    Ethane
    Carbon Dioxide
    Nitrogen
    Sulphur

    72.8%
    0.2%
    9.0%
    18.0%
    1-2 ppm

    NATURAL GAS
    Feed Gas
    16

    14
    Fuel Gas
    Mari Gas Fields

    Distance: 52 Km

    FFC

    AMMONIA PROCESS
    AIR

    NATURAL
    GAS CH4, N2,
    CO2, H2S

    SULPHUR
    REMOVAL

    (3)

    (2)

    PRIMARY
    REFORMING
    (TUBULAR)
    PURGE GAS
    CH4, H2, N2

    AMMONIA

    STEAM

    N2

    (9)

    AMMONIA
    REFRIG.

    SECONDARY
    REFORMING
    (AUTHO
    THERMAL)

    AMMONIA
    SYNTHESIS

    H2, N2, NH3,


    CH4

    (5)

    WASTE HEAT
    RECOVERY

    SHIFT
    CONVERSION

    H2, N2, CO,


    CO2,

    RECYCLE
    GAS
    H2, N2, CH4

    AMMONIA
    SEPERATION

    (4)

    (8)

    CO2 TO
    UREA

    METHANATION

    H2, N2, CH4

    (7)

    CARBON
    DIOXIDE
    REMOVAL

    H2, N2,
    (6)
    TRACES OF
    CO, CO2

    H2, N2, CO2

    (1)

    STEAM

    AMMONIA PROCESS
    Desulphurization
    -Removal of sulphur from natural gas feed
    -Predesulphurization
    Remove bulk of sulphur
    -Desulphurization
    Hydrogenation [ 360 380 oC, > 2% H2]
    Active state is sulphided
    Sulphur Absorption

    AMMONIA PROCESS
    Desulphurization
    Natural gas is purified in the desulphurization unit
    to eliminate traces of sulphur which is a poison to
    several catalysts in the process. This is achieved in
    zinc oxide beds.
    ZnO + H2S

    ZnS + H2O

    ZnO + COS

    ZnS + CO2

    Diff between P-I and P-II

    Sulphur slip: < 0.1 PPM AT 360 oC

    AMMONIA PROCESS (contd.)


    Reforming (tubular reformer)
    The steam reforming section consists of a
    primary tubular reformer and a secondary
    auto-thermal reformer. The first reaction
    between natural gas and steam takes place in
    the catalyst filled tubes of the primary
    reformer, producing H2, CO and CO2
    CH4 + H2O

    H2, CO, CO2 & (un-reacted


    H2O, CH4)

    AMMONIA PROCESS (contd.)


    Reforming (tubular reformer)
    Steam reforming

    Side-fired furnace Reactor


    Tubular reformer Operating Parameters:
    Inlet temperature: 520 oC
    Outlet temperature: 890 oC
    Steam/Carbon ratio: 2.65-3.0
    CH4 slip: 12 mole% dry
    Catalyst poisons: Sulphur, Silica, Chlorine
    Difference in P-I and P-II Furnaces

    AMMONIA PROCESS (contd.)


    Tubular Reformer Waste Heat Recovery:
    Flue gas temp. from radiant chamber: 1040C
    Preheating tubular reformer feed to 520C
    Preheating process air to 550C
    Steam superheating to 515C
    Preheating feed for desulphurisation to 365C
    Preheating BFW and DMW
    Flue gas outlet temperature ~150C

    AMMONIA PROCESS (contd.)


    Reforming (Auto thermal reformer)
    Residual methane is reduced in the secondary
    reformer where air is mixed with the exit gas
    from the primary reformer. A partial combustion

    produces the necessary heat for the reforming


    reaction to occur.
    CH4 + 2O2

    CO2 + 2H2O & N2, H2, CO

    CH4 + H2O

    H2, CO2, CO2, & (un-reacted

    H2O, CH4)

    AMMONIA PROCESS (contd.)


    Reforming (Auto thermal reformer)
    Partial combustion with air
    H2/N2 ratio to be 2.7 - 3.0 during normal operation
    RKS-2-7H catalyst and alumina lumps and tiles
    Final methane at outlet of reforming
    Outlet temperature: 950 -1000 oC

    AMMONIA PROCESS (contd.)


    High Pressure Steam Generation
    Process gas temperature is then lowered by the production of steam
    Steam at a pressure as high as 110 Kgcm2 in a waste heat boiler.
    BFW and steam circuit

    AMMONIA PROCESS (contd.)


    Shift Conversion
    The shift conversion section comprises medium
    and low temperature catalytic reactors where the
    CO content is reduced by the production of H2 and
    CO2
    CO + H2O

    CO2 + H2

    High and low temperature shift converters


    Optimum temperature?
    Age/activity
    Poisons:
    Chlorine, Silica, Sulphure
    Activated catalyst is pyrophoric

    AMMONIA PROCESS (contd.)


    Medium temp. Shift converter
    Copper based catalyst

    Operating temp: 240 oC


    Higher activity at higher temperature but lower equilibrium
    conversion

    Low temp. Shift converter


    Copper based catalyst
    Operating temp: 195- 205 oC
    Higher activity at higher temperature but lower equilibrium
    conversion
    Catalyst can be changed on-line

    AMMONIA PROCESS (contd.)


    CO2 Removal
    Carbon Dioxide removed in the CO2
    removal section. The CO2 is sent to the
    CO2 compressor at urea plant.
    aMDEA solution is used for CO2
    absorption.

    AMMONIA PROCESS (contd.)


    CO2 Removal
    BASF aMDEA (activated Methlyl
    DiEthanol Amine).O2 absorption in
    aMDEA solution in C-4302.
    CO2 flash of in V-4302 and V-4301
    Regenration of aMDEA solution in C4301.
    MDEA is a tertiary amine
    Activator is a secondary amine
    Solution contains 40 wt% aMDEA
    (balance: water)

    AMMONIA PROCESS (contd.)


    CO2 absorption
    Absorption in two stages
    Bulk absorption in bottom part with
    semi lean solution
    Final absorption in top part (scrubbing)
    with lean solution
    Rich MDEA solution at bottom outlet
    Depressurization through reverse pump

    AMMONIA PROCESS (contd.)


    Solution regeneration
    Regeneration in two stage flashing:
    HP flash vessel
    LP flash vessel
    Stripping in CO2 stripper

    AMMONIA PROCESS (contd.)


    Methanation
    Final gas purification
    Converts, residual CO and CO2 are
    reduced to a few ppm in a catalytic
    methanation unit
    Ni based catalyst (PK-7R)
    To prevent poisoning of the ammonia
    synthesis catalyst
    CO2 + 4H2
    CH4 + 2H2O+Q
    CO + 3H2
    CH4 + H2O+Q

    AMMONIA PROCESS (contd.)


    Methanation Operating parameters
    Recommended operating range 280- 420 oC
    Equilibrium favoured by:
    low temperature
    High pressure
    Low water content

    Catalyst operation
    higher temp higher activity but thermal aging

    Poisons: sulphur and chlorine


    Steam without H2 oxidises catalyst
    Condensing steam; disintegration of catalyst

    AMMONIA PROCESS (contd.)


    Ammonia Synthesis
    The ammonia synthesis loop features a
    radial flow type ammonia converter. The
    remaining part of the loop comprises
    equipment for heat recovery,
    condensation and ammonia separation.
    3H2 + N2

    380 C - 500 C

    2NH3

    AMMONIA PROCESS (contd.)


    Ammonia Synthesis
    Conversion of N2 and H2 into NH3
    Synthesis loop with app. 30% conversion per pass
    Make up synthesis gas from preparation section
    Amm product separation by condensation
    Inert level kept by purging

    AMMONIA PROCESS (contd.)


    Ammonia Synthesis
    Synthesis make up gas;
    Normal operating pressure 150 Kg/cm2.

    Addition point; between the two ammonia chillers, just downstream


    of purge point

    Water in MU gas absorbed in Amm. (liquid)

    CO2 in MU gas absorbed in Amm. (liquid)


    CO only slightly soluble in Amm

    AMMONIA PROCESS (contd.)


    Ammonia Synthesis
    Synthesis make up gas;
    H2/N2 ratio inlet converter should be 3.0

    H2/N2 ratio in MU gas to loop should be 2.97

    Adjusted by: Ratio in raw synthesis gas outlet methanator by adjusting


    air to secondary reformer and purge rate
    Dependant on flow and composition of H2 recycle from Purge gas
    recovery unit

    AMMONIA PROCESS (contd.)


    Ammonia Converter operation
    Temporary catalyst poisons:
    Oxygen

    containing compounds; H2O, CO, CO2

    Permanent catalyst poisons:


    Sulphur, chlorine etc.

    1st bed recommended inlet temperature: 380 oC


    Outlet:

    510 oC

    2nd bed recommended inlet temperature: 381 oC


    Outlet: 436 oC

    AMMONIA PROCESS (contd.)


    Ammonia Refrigeration circuit:
    Performs the cooling tasks connected to synthesis loop:
    Condensation of product Ammonia
    Recovering Ammonia from purge gas

    Recovering Ammonia from letdown gas

    AMMONIA PROCESS (contd.)


    Refrigeration circuit operation:
    Two chillers levels:
    1st chiller at 10 oC at pressure 1.87 Kg/cm2
    2nd chiller at -4 oC at pressure 5.9 Kg/cm2

    Chiller levels correspond to 1st and 2nd stages on refrigeration


    compressor
    Ammonia booster compressor used for Ammonia to storgae at -33 oC

    AMMONIA PROCESS (contd.)


    Ammonia Recovery:
    Recovery of residual amm. From purge gas and low pressure off-gas
    Absorption in water; from 4% Amm to < 0.01%
    Regeneration by distillation

    Section comprises:
    Purge gas absorber
    Off-gas absorber
    Distillation column

    AMMONIA PROCESS (contd.)


    Process Condensate:
    Remove ammonia, methanol and CO2 from process condensate
    Reduce consumption of demineralisation chemicals
    Avoid environmental pollution

    PROCESS FLOW DIAGRAM

    CATALYSTS
    Desulphurization

    Reforming

    MTS
    Conversion

    Zinc Oxide

    Nickel Oxide

    Copper Oxide

    Ammonia
    Synthesis

    Methanation

    LTS
    Conversion

    Iron Oxide

    Nickel Oxide

    Copper Oxide

    COMPARISON OF AMMONIA PLANTS


    FFC-1

    PARAMETERS

    FFC-2

    FFC-3

    Steam Super heater

    Fuel

    Waste Heat

    Fuel

    Shift Converter

    HTSC

    MTSC

    HTSC

    CO2 Removal

    Benfield

    aMDEA

    Benfield

    Ammonia Synthesis
    Pressure Kg/cm2

    250

    145

    250

    Synthesis Reaction
    Heat

    BFW
    Preheating

    Steam
    Production

    BFW
    Preheating

    NH3 Recovery

    No

    Yes

    Yes

    Hydrogen Recovery

    No

    Yes

    No

    PRODUCTION DEPARTMENT
    HIERARCHY
    HOP

    PM1

    PM2

    DM-AMM I

    DM
    UTILITY

    DM-UREA I

    DM-AMM II

    DM-UREA II

    DM
    BAGGING

    Shift Engr
    Amm

    Shift Engr
    Uty

    Shift Engr
    Urea

    Shift Engr
    Amm

    Shift Engr
    Urea

    Shift Engr
    Bagging

    JOB DESCRIPTION OF SHIFT


    ENGINEER
    Shift Engineer is the overall incharge of his shift
    group. He is responsible to ensure safe, smooth and

    efficient operation of assigned unit. He actively


    participates in trouble shooting plant problems,

    smooth startup, shutdowns & emergency handling.

    JOB RESPONSIBITES OF
    SHIFT ENGINEER
    Supervision of his team for smooth, effective and safe
    Plant Operations.
    Ensure implementation of work permit procedures for
    safe handing/taking over of equipments and machines.
    Optimization of plant parameters to ensure minimum
    specific energy and chemicals consumption.
    Any other task assigned by the supervisor

    THANK YOU

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