WELCOME

PRESENTATION ON
1350 MTPD
AMMONIA PLANT (A-IV)
PROCESS
Y V N S Suvikram
DY. MANAGER (A-IV PRODUCTION)
 INTRODUCTION TO GSFC
 One of the India’s largest Integrated Fertilizers and
Petrochemical complex located at Fertilizernagar,
Vadodara, India.

 Initiative of Government of Gujarat - First joint sector

Fertilizer unit established in year 1965.

 Started with Ammonia, Urea, Sulphuric Acid, PA and

DAP.

 Diversified to products like Caprolactam, AS, Nylon 6,

Nylon Yarn, Melamine, MEK- Oxime, Argon, Plastics,
Polymers, Nitric Acid etc.
 OUR ORGANISATION

MANUFACTURING UNITS:

 Headquarters – Fertilizernagar, Vadodara

 DAP Unit – Sikka, Jamnagar

 Polymers Unit – Nandesari, Vadodara

 Fibre Unit – Kosamba, Surat.

 AMMONIA USES

Ammonia is one of the most highly produced inorganic

chemicals.

Major uses of ammonia:

 Approx. 80% or more as Fertilizers like Ammonium
Sulfate, Ammonium Phosphates , Urea etc.

 Production of plastics, fibers and intermediates for

dyes and pharmaceuticals.

 As a coolant in Refrigeration and Air conditioning

equipment.

 In the manufacture of commercial explosives.

 IMPORTANCE OF A-IV TO GSFC

AMMO
Natural MOTHER PLANT
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Raw
Naptha Gas rNIA-IV
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 DESIGN CAPACITY
Product Design Capacity Operating Condition
Liquid Ammonia 1350 MTPD 1360 MTPD
Liquid Argon 8,880 NM3/Day 9,300 NM3/Day
CO2 Gas 31500 NM3/Hr 31500 NM3/Hr
Power 20 MW --
Oxygen 5000 Nm3/hr 5000 Nm3/hr
H2 / Syn Gas As Required --

 Commissioned on 16-07-1998
 Max. Continuous Operation Period
• H2 Plant : 484 days (05-05-10 to 31-08-11)
• N2 Plant : 672 days (13-06-17 to 16-04-19)
 NEED FOR 1350 MTPD NH3 PLANT
1350 MTPD Ammonia -IV Plant is set up as a replacement
to Old Ammonia Plants due to:
 High energy consumption in old Ammonia plants. (10-
10.5 Gcal/MT)

 Pollution abatement requirement due to use of

Arsenic based CO2 removal in old plant.

 Old Ammonia plants operating since year 1967-69 &

completed operation for more than 30 years.

 With increased Ammonia demand in the complex,

GSFC opted for setting up new world scale 1350
MTPD Ammonia plant.
 AMMONIA TECHNOLOGY

Following four are leading supplier of Ammonia

process technology

 Linde Ammonia Concept, Germany

 Holder Topsoe, Denmark

 M W Kelloge, USA

 Udhe , Germany
CONVENTIONAL V/S LAC PROCESS

CO2

IInd H L CO2 Methan NH3 Syn Gas

NG
DS RF RF T T Remov ation Synthesi NH3
al s

Air
IG PC PGR
Conventional Plant Unit Polishing Unit

CO2
Syn Gas
NG CO2 NH3
DS RF ISR PSA Synthesi
Removal NH3
s

H2

N2
Air ASU O2
LAC Plant Ar
 CATALYST VOLUME WITH LAC
FOR 1350 MTPD
Reactor Conventional LAC plant
plant (m3) (m3)
Desulphurisation 24.8 28.0
Primary Reformer 36.0 37.0
Sec. Reformer 35.1 --
HT Shift 70.5 --
LT Shift 96.5 52.0
Methanation 27.0 --
Amm. Synthesis 92.3 83.9
Total 382.2 200.9
 SELECTION OF TECHNOLOGY

 GSFC selected Linde Ammonia Concept ( LAC )

of M/s Linde AG, Germany for the first time in the
world.

 LAC is much more direct route to Ammonia - An

overall simplification of classical process route.
Resulting into savings in investment cost ( Less
No. of equipments ) / construction time / site
area / maintenance / spare part cost and catalyst
replacement cost.

 LAC also provides useful additional products like

H2, O2 , N2 and Argon.
 SALIENT FEATURES OF A-IV PLANT

 Self sufficient in terms of Utilities & Power

 Can operate without ISR @ 30 %

 Can operate w/o CO2 removal system @ 50 %

 Any combination of Naphtha & NG for feed

 No pollutant from plant

 SALIENT FEATURES OF A-IV PLANT

 Biggest motor in GSFC (N2 Comp. 6.5 MW)

 Temperature range : (- 195) to 1000 °C

 Pressure Range : Vacuum to 143 Bar

 33 % power consumption of GSFC

 80 % Natural gas consumption of GSFC

 Energy consumption:
7.56 Gcal / MT for NG
7.98 Gcal / MT for Naphtha
 OTHER FEATURES OF A-IV PLANT
A-IV has following features for Plant safe operation & S/D:
 Distributed Control system (DCS) Foxboro - USA.

 Programmable Logic Control system for plant Interlocks,

stationary and rotating equipment, compressor & steam
turbines ; from HIMA Germany, MODICON -
USA,SIEMENS - Germany.
 System consists of 350 No of microprocessors
transmitters, 650 No of temperature sensors, 250 No of
switches, 20 No of analyzers, 350 No of control valves.
 Fire alarm system consisting of smoke detectors, heat
detectors and Manual call points.
 Gas detection system for Hazardous and Toxic gas
leakage sensing and alarming.
HYDROGEN PLANT BLOCK DIAGRAM
CO2
HP NG Product
Flash Gas
Steam

Steam CO Shift MDEA CO2

DS Reforming Conversion Removal
200
100 200 300

Purge Gas PSA

LP NG
400

HYDROGEN
PRODUCT
REFORMER OF AMMONIA-IV
REFORMER OF AMMONIA-IV
Isothermal Shift Reactor ( ISR )
ISOTHERMAL SHIFT REACTOR
CO + H2O  CO2 + H2

CATALYST VOLUME: 52 M3

CATALYST TYPE : ICI-83-5

Cu/Zn catalyst

CAT. SIZE : 5.4 (dia)x3.0(ht)

mm pallets
ISOTHERMAL SHIFT REACTOR
 CO2 REMOVAL SECTION

CO2 Removal Unit :

 Absorbent: Aqueous MDEA solutions

 Licenser: M/s BASF.

 Liquid effluent generation is nil.

 CO2 purity 99.5 % due to two stage regeneration,

 Almost 100 % CO2 recovery from process gas.

CO2 REMOVAL SECTION
CO2 REMOVAL SECTION
CO2 REMOVAL SECTION
 PSA UNIT
Pressure Swing Adsorption ( PSA ) :
 Patented Technology of M/s Linde, Germany

 The pressure swing adsorption process has four basic

process steps:
– Adsorption
– Depressurization
– Regeneration
– Repressurization

 Extremely high purity H2( 99.99 %) with max 9 ppm CO,

1 ppm CO2 and 20 ppmCH4.
 Pressure swing Adsorbers
PSA UNIT

Purge Gas As Fuel

H2 Product

Feed Gas
 PSA UNIT
Pressure Swing Adsorption ( PSA ) :
 H2 production is possible even without operating CO 2
removal unit and with higher leakage of CO from ISR.

 Completely automatic sequences switching through

PLC for adjusting process variations. The faulty
adsorber is taken off line without interrupting H 2
production /quality.

 Entire Purge gas is utilized as Ref. fuel substituting

NG.
PSA UNIT
 HYDROGEN PLANT BLOCK DIAGRAM
H2 : 69.29 %
NG : 100 % NG : 100 % CO : 14.19 %
Sulfur : @10 ppm Sulfur : <0.2 ppm CO2 : 8.54 %
CH4 : 7.96 %
Steam
Steam
DS Ref. ISR
HP NG

H2 : 99.99 % H2 : 90.17 % H2 : 72.93 %

CO : 9 PPM CO : 0.83 % CO : 0.676 %
CO2 : 1 PPM CO2 : 0.3 % CO2 : 19.36 %
CH4 : 20 PPM CH4 : 8.64 % CH4 : 7.02 %

H2 CO2
PSA
PRO. Remo.

CO2 : 99.5%
All calculations are on dry basis
 NITROGEN & NH3 SYNTHESIS

S.G
Air Ammonia
N2
Air Separation Synthesis Amm.
700 500

Oxy.

Refrigeration
Argon 600

H2
 AIR SEPERATION UNIT
ASU :
 Principle: Cryogenic distillation.

 A-IV ASU Process Data:

Stream Flow Product Purity
Air flow 54000 NM3/Hr
LP Nitrogen 38000 NM3/Hr < 5 ppm O2
Gaseous O2 11000 NM3/Hr 99.5 % max
Liquid Argon 370 NM3/Hr 3 ppm O2

 Instrument air from adsorbers to meet process control

requirements.

 Booster cum Expander is source of cold generation.

PFD FOR ASU
LIQUID ARGON STORAGE/LOADING
AMMONIA CONVERTER
 UTILITIES

Pre- CRG Naphtha

Naphtha Desufurization Tank Farm
Sections 1600 900 1800

Turbines & Cooling Emergency Flare

Condensate Water Power
800 1100 1200 1300

Liquid Instrument Fire Water

Effluent Air Unit System
1400 1500 2100
INSIGHT OF SHUT DOWN
THANK YOU