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A PLANT
There are two streams of ammonia plant, each of 1350 MTD capacity based on the
renowned KELLOGG High Pressure Reforming Technology. The gas obtain from Bombay
High/South Basin, will be desulphurised, mixed with steam and passed on to the battery of tubes in
a furnace called primary reformer where in the gas steam mixture passed to through the bed of
nickel catalyst as well as heated externally to a temp. Of 818oC to reform the Hydrocarbons in to
CO, CO2 and H2. This partially reformed gas mixture is passed on to the secondary reformer where
in air is added in stochiometric proportion to supply the N2 as well as to complete the reforming
.The reformed gas pass through the high temp. and low temp. shift converters wherein the CO is
converted into CO2. The CO2 is then removed from the gas mixture in the CO2 Removal Section
employing the latest “Modified Ben filed” process. The gas mixture is then Methanated to remove
the final traces of CO, CO2. The gas mixture contains N2 and H2 in the ratio 1: 3 is then compressed
in sys. Gas compressor to a pressure of 220 atm and passed over the catalyst filled Ammonia
Converter to Synthesize Ammonia.
The Ammonia formed is refrigerated to –30oC and stored in the Atmospheric Storage Tank.
The waste heat generated at the various stages of exothermic reactions utilized to produce
steam at 105-ata pressures. This steam coupled with that from an Auxiliary Boiler situated in the
Main Reformer furnace provide power for all the drives in the Ammonia Plants as well as satisfied
the process steam requirement, making the plant self-sufficient, independent, and reliable and
energy efficient.
PROCESS DESCRIPTION
The Hazira Ammonia plant uses the “Kellogg Process” and has many features in common
with the other Kellogg plants even though the feed stock used is Nature gas.
The manufacture of the Ammonia involves the following basic steps namely,
2. REFORMING: - Reforming of the desulphurised Natural gas mixture of Hydrogen and Carbon
Oxides and addition of air in-between two stages of reforming.
PRIMARY REFORMER: The primary reformer consists of 504 tubes suspended in 12 rows of
42 parallel tubes each, in the radiant section. Each row of tubes terminates in a manifold placed
within the radiant section of furnace. There are twelve centrally located risers on each of these
manifolds. These risers lea the gas flow to a water jacketed transfer line located over the top of
primary reformer furnace. As the reforming reaction is endothermic heat is supplied externally to
the tubes.
The furnace operates with a down firing of natural gas between the rows of tubes to
develop a process gas temperature of 818°C at the catalyst tube outlet.
There are 234 arch burners arranged in 13 rows of 18 burners each. Natural gas, purge and flash
gases from ammonia synthesis loop and absorber K.O. drum are used as fuel for the reformer
furnace.
Inside the catalyst tunes the natural gas-Steam Reforming reaction takes place. the transfer
line directs the reformed gas into the secondary reformer at the following conditions:
Pr. : 33.1 Kg/cm² Temp. : 824°C
REFORMING REACTIONS:
The following reactions take place producing a mixture of H2, CO, CO2, CH4 and excess
H2O when hydrocarbons undergo steam reforming over nickel catalyst:
CnH2n + 2nH2O = nCO + (2n+1) H2
CH2 + H2O + heat=CO + 3H2
CO + H2O = CO2 + H2 + heat
Carbon formation is a serious problem in catalyst tubes when higher hydrocarbons are used as a
feed stock. Carbon deposition will hinder reforming and reduce heat transfer so that the tube wall
temperature will rise in that zone producing “hot bands” and “hot tubes”. Carbon formation also
causes disintegration of catalyst resulting in higher pressure drop in reformer tubes, loss of catalyst
activity, low steam/ carbon ratio contribute to carbon formation. Precautions should be taken to
prevent carbon formation on reforming catalyst for successful performance of reformer operations.
SECONDARY REFORMING:
Partially reformed gases from the water jacketed transfer line (107-D) are directed to refractory
lined and water jacketed secondary reformer (103-D) tangentially. Once it enters the secondary
reformer the flow is downward around a centrally located Air inlet pipe of an air burner and passes
through a diffuser to enter a mixing zone where the gas and air are mixed before entering a catalyst
bed of secondary reform.
Preheated air steam mixture from the coil enters the secondary reformer vertically
through the centrally located Air burner. Instantaneous mixing and rapid combustion of the
air reformed gas take place at the burner tip as per the following equation at a temperature of
1238°C.
2H2 + O2 +Air 3.8 N2 = 2H2O + 3.8N2 + heat
CH4 + O2 + air3.8 N2 = CO2 + CO + H2O + N2 + heat
After combustion the gas mixture flows through a bed of secondary reforming
catalyst. The catalyst in the secondary reforming comprises of a layer of high temperature
chromia at the op and nickel reforming catalyst at bottom. The shallow layer of chromia has a
high fusion temperature and protects the lower layer of nickel catalyst against excessive
temperature.
A layer of alumina target bricks is laid over the chromia catalyst for protection of
catalyst and also proper distribution of gas in the catalyst bed Methane reforming reaction in
secondary reformer is as follows:
2CH4 + 3H2O + heat = CO + CO2 + 7H2
The reformed gas leaves the reactor at 996°C.
Both these reactions are highly exothermic, and hence,extreme care is to be taken
while operating methanator.
The design temperature of the methanator (vessel) is 454°C which provides a large
margin of safety in the event carbon oxides in feed gas to methanator are momentarily above
normal conditions. The unit is properly protected with high temperature alarms and shut off
systems. Methanator vessel, filled with a single bed of nickel catalyst operates at a temp of
around 315°C inlet.