KRIBHCO SHYAM FERTILISERS LTD AMMONIA PLANT

INSTALLED CAPACITY PROCESS LICENSOR

- 1520 MTPD - HALDOR TOPSOE, DENMARK

PROCESS TECHNOLOGY - NG STEAM REFORMING RAW MATERIAL - FEED-NG FUEL NG AND/OR NAPHTHA

F
Natural gas 98% CH4 387 Deg C 32Kg/Cm2

HP Stea Stack Process air m 10.95% 0.3%CH4 CH4 991 Deg C Primary Reformer 801 Deg CSec. Reformer RG Boiler

Desulphurizer R-1201/1202

360 Deg C 12.96% CO

T
HT Shift

427 Deg C 3.09% CO

CG boiler

Trim heater Recycle Hydrogen Steam Comb. Air Natural gas From 2d Stage Purge gas Boiler feed water

Surplus syn gas

BFW Pre heater BFW from E1502 200 Deg C LT Shift T CO2 TO URE A 221 Deg C 0.25% CO BFW Pre heater 17.75% CO2 BF W

Syn gas compressor

Make up gas chiller

Make up syn gas 210 Kg/cm2 & 23 Deg C

26 Kg/Cm2 38 Deg C 74.2% H2 & 24.77% N2 1.03% CH4/Ar Separator Final gas cooler 338 Deg C E1311 Methanator 0.1%CO2

CO2 Removal

SEP Separator L

FPT

320 Deg C Lean and Semi Lean GV Solution

RAW MATERIAL CONSUMPTION

NG (MSM3/DAY) FEED TO REFORMER FUEL TO REFORMER 1.008 0.273 OR* 0.137 NIL OR* 0.017
(* IN CASE OF MIX-FUEL FIRING)

NAPHTHA (MT/DAY) NA NIL OR* 110 OR* 45

FUEL TO SUPER HEATER0.068

MAJOR PROCESS STEPS

HYDRO-DESULPHURISATION PRIMARY & SECONDARY REFORMING CO SHIFT CONVERSION CO2 REMOVAL-GV GLYCINE SYSTEM METHANATION COMPRESSION AMMONIA SYNTHESIS PROCESS CONDENSATE TREATMENT PURGE GAS RECOVERY

DESULPHURISATION

Natural Gas mainly containing methane (98%) and higher hydrocarbon has 10-50 ppm of sulphur. In desulphurization process sulphur content is reduced to 0.05 ppm.

Type of catalyst TK-251 Volume of catalyst 8.9 M3

After hydrogenation the process gas is passed through the absorption vessels where the H2S is absorbed on ZNO

Type of catalyst HTZ-3 of HTAS Volume of catalyst 13.8 M3

There are two ZNO absorbers in series and one can be isolated in running for replacement of catalyst.

PRIMARY REFORMER
It is a side fired tubular primary reformer with flue gas heat recovery section. Natural gas is reformed with steam to produce a mixture of hydrogen, carbon monoxide, carbon dioxide and methane. There are two chambers and each chamber contains 144 tubes. There are 576 radiant burners are provided. Catalyst volume in Primary reformer is 44 M3 Primary reformer outlet Methane is approx. 11 %.

PRIMARY REFORMER

ID Fan

Stack

FD Fan

SECONDARY REFORMER

Function of secondary Reformer is to reform the Primary Reformer exit residual methane and to add Nitrogen to the process gas. This is achieved by mixing a stoichiometric quantity of process air to the primary reformer exit gases in Secondary Reformer. Secondary Reformer outlet gas mixture contains hydrogen, nitrogen, carbon monoxide, carbon dioxide and methane (0.3%).

WASTE HEAT RECOVERY

High temperature process gas exit secondary Reformer at 950 deg C is cooled down in Waste Heat Boiler to 360 deg C and in turn high pressure steam (115 Kg/cm2g) is produced. Steam produced is super heated to 510 deg C and utilized as driving force for Syn gas turbine which in turn generate Medium Pressure steam.

SHIFT CONVERSION
Carbon monoxide is converted to carbon dioxide in two stage shift conversion bringing down the carbon-monoxide content from 12.95% to 0.3 % in the process gas. High temperature Shift converter Catalyst volume 100 M3 Type of Catalyst SK-201 of HTAS CO Content reduced to 3.09% from 12.96%. Low temperature Shift converter Catalyst volume 116 M3 Type of Catalyst C-18 G/7 of Sud-Cheme CO Content reduced to 0.25% from 3.09%.

CARBON DIOXIDE REMOVAL

Giammarco Vetrocoke (GV) solution is used to absorb carbon dioxide from the process gas thus reducing carbon dioxide content from 17.72% to 0.05% in gas mixture in CO2 absorber. GV solution contains

Potassium Carbonate Glycine Di Ethanol Amine & Vanadium penta oxide

GV solution rich in Carbon dioxide is regenerated in HP & LP regenerators by giving heat & Carbon dioxide is sent to Urea Plant.

METHANATION

Oxides are harmful for synthesis converter catalyst, 0.25 % Carbon monoxide from LTS outlet and 0.05% Carbon dioxide from CO2 Absorber are converted into methane in this step. Catalyst Volume 30 M3 Catalyst type PK-5 of HTAS. The exit process gas (Synthesis Gas) contains mainly a mixture of hydrogen and nitrogen in the ratio of 3:1.

SYNTHESIS GAS COMPRESSION

Synthesis gas is compressed to 220 Kg/cm2g in synthesis gas compressor. This compressor has four stages and one recycle stage. This compressor was supplied by BHEL.

AMMONIA SYNTHESIS

AMMONIA SYNTHESIS

Conversion of this gas mixture into ammonia takes place in TOPSOE-S200 radial flow converter. Gas inlet temperature is 244 deg C. Converter has two beds with inter-bed heat exchanger. Catalyst volume is 100 M3. Type of catalyst KM1R/KM1 of HTAS. Converter outlet gas at 455 deg C is cooled in various heat exchangers and finally separated at 12 deg C in Ammonia Separator.

REFRIGERATION SYSTEM

Gas mixture containing ammonia is cooled down to separate liquid ammonia from the gases by providing ammonia refrigeration. Separated liquid ammonia is sent to Urea Plant at 12 deg C temperature. In case Urea Plant is not in operation, product Ammonia can be sent to Ammonia Storage. The operating pressure of chillers

0.05 Kg/cm2g 3.5 Kg/cm2g 6.5 Kg/cm2g

STEAM SYSTEM
Steam Type

Pressure Temperature

SH Superheated 110 Kg/cm2g 510 C

SM Superheated 38 Kg/cm2g 381 C

SL Superheated 3.5 Kg/cm2g 260 C

There are two service boilers and two HRSG boilers in offsite which can generate 100te/hr each at 112Kg/cm2 and 510 DegC. Normally one service boiler and one HRSG boiler are in service. High pressure steam from boiler is distributed to Ammonia plant and Urea plant. In KSFL SH steam pressure is maintained by Offsite. The HP steam is used in running Syn gas turbine and CO2 turbines.

MEDIUM PRESSURE STEAM

Extraction

from Syn gas turbine and Let down from SH steam to SM steam joins SM steam header. This steam is used in Primary Reformer, all backpressure and condensing turbines. This SM steam header is connected to Offsite SM Steam header. Normally SM steam header pressure is maintained by Ammonia Plant.

LOW PRESSURE STEAM

Low pressure steam generated from backpressure turbines is used in Process Condensate stripper, GV system, Deaerator and ejectors of Compressors. The balance SL steam can be fed in Process Air Compressor to avoid venting of SL steam. Here also Offsite, Urea and Ammonia Plant headers are interconnected. SL header pressure is also maintained by Ammonia Plant.

SH STEAM NET WORK

NG FEED STOCK SPECIFICATION

Ammonia plant can be fed with one of the feed/fuel gas having the following characteristics at battery limits:

CASE A Lean gas

CASE B Rich Gas

CASE C After LPG extraction

Methane Ethane Propane I-Butane N-Butane I-Pentane N-Pentane Hexane Carbon Dioxide Oxygen Nitrogen Total Sulfur content as H2S Normal Design Pressure Temperature

78.84 7.23 4.59 0.88 1.10 0.26 0.24 0.26 6.49 0.10 0.01 10ppm 50ppm 43 Kg/cm2g 30 C

83.29 7.60 2.10 6.9 0.10 0.01

98.39 1.40 0.10 0.10 0.01

DM WATER NETWORK

Quality of DM water Conductivity Silica (reactive) Fe TDS Total Hardness Oil Ph Total Cation Total Anion

0.30 s/cm 0.1 ppm NT 0.10 ppm 0.10 ppm 7 + 0.5 0.1 ppm 0.1 ppm

As (CaCO3)

DM WATER NETWORK
DM

water supplied from DM plant at a rate of 500 M3/hr and 5-6 kg/cm2 is preheated in different pre heaters of CO2 removal section ie.E-1303, E-1308, E1313, E-1306, and E1325. The heated DM water is distributed to Offsite/Ammonia Deaerator. Around 150 M3/hr is returned back to Offsite and 350 M3/hr fed to ammonia Deaerator.

DM WATER NETWORK

BFW DISTRIBUTION

BFW pumps P-1601A/B/C takes suction from Deaerator. BFW from pump discharge goes to BFW pre heater E-1211 and BFW heated to 176 DegC. From BFW pre heater E-1211,BFW goes to E-1210 and E-1502 pre heaters in parallel and heated up to 273 DegC. From E-1210 and E-1502 BFW is fed to RG boiler and Syn Loop boiler for steam generation.

BFW DISTRIBUTION

SERVICE AIR AND INSTRUMENT AIR

Service Air Moisture Pressure Temperature Instrument Air Pressure

Saturated 6-7 Kg/cm2g abs 40 C

Max. Min. Nor.

Temperature Type Dew point

9 Kg/cm2g 6 Kg/cm2g 8 Kg/cm2g 40 C dry and oil free -20 C at 7 Kg/cm2g

SERVICE AIR AND INSTRUMENT AIR

Air

required for Service air, Instrument air and PSA unit is supplied from 3rd stage of Process air compressor at a rate of 5500 NM3/hr. Air from HP air receiver also joins this header after pressure reduction. This hold up volume maintains header pressure in case of tripping of Process air compressor

PROCESS AIR COMPRESSOR AND INSTRUMENT AIR SYSTEM

ELECTRIC POWER

Alternating Current

11000 V 3300 V 415 V 240 V

3 phase 3 phase 3 phase 1 phase

50 Hz 50 Hz 50 Hz 50 Hz

Instrumentation and Control

115 V 1 phase 50 Hz

COOLING WATER

Inlet temperature to the unit Outlet temperature from the unit Fouling factor for shell side m2hC/Kcal Fouling factor for tube side

34C 44C 0.0006

0.0006 m2hC/Kcal

COOLING WATER

Ammonia cooling tower was designed by Paharpur. There are six cells and each cell is provided with an induced draft fan. There are three cooling water pumps out of which one is motor driven and two are condensing turbine driven. The normal cooling water flow is 20,000 M3/hr and CW header pressure is 3 Kg/cm2g.

PURE NITROGEN

In KSFL Nitrogen generation plant is not available. So Pure Nitrogen is purchased as per requirement from outside agencies Quality of Nitrogen Nitrogen plus noble gases 99.99 % vol (min.) Carbon dioxide NT Carbon monoxide NT Water NT Oxygen 10 ppm (max.) Pressure 6 Kg/cm2g Temperature 40 C

PRODUCT SPECIFICATION

Ammonia Quality Ammonia Moisture Oil Temperature Pressure

99.5 wt % max. 0.5 wt % max. 10 ppm max. 12/-33 C 25/5 Kg/cm2g

PRODUCT SPECIFICATION

Carbon Dioxide: Composition, dry: CO2 H2 N2 Temperature Pressure Water

98.7 % vol 0.8 % vol 0.5 % vol 40 C 0.8Kg/cm2g saturated

DESULPHURISATION SECTION

The desulphurization section consists of three vessels, one containing the hydrogenation (Ni-Mo) catalyst and two vessels containing ZnO catalyst for absorbing H2S. Over the hydrogenation catalyst the sulphur containing compounds are converted into Hydrogen sulphide at a temperature of about 390 deg C. This Hydrogen sulphide is absorbed in the ZnO absorption vessels. Sulphur outlet of ZnO absorbers will be below 0.05 ppm sulphur.

HYDROGENATION

The Natural gas with recycle gas is preheated to 390-400 deg C in the waste heat section of the primary reformer before entering the hydrogenation vessel R-1201. The Hydrogenation catalyst is TOPSOE TK-251 (Ni Mo). The catalyst volume is 8.9 M3 Normally hydrogen for the hydrogenation is obtained by recycling of synthesis gas after the 1st stage of Syn gas compressor but following alternative sources of hydrogen are also available: In case of methanator trip the recycle gas can be taken at the outlet of the CO2 removal. If the CO2 removal is not in operation either, the recycle gas can be taken upstream of theCO2 removal or if the synthesis unit is under pressure recycle gas may be taken from the synthesis loop.

NG DESULPHURISATION

GV FILTARATION AND AERATION

REFORMER NAPTHA FIRING

PRIMARY AND SECONDARY REFORMER

HT AND LT SHIFT CONVERTER

CO2 REMOVAL SYSTEM

CO2 REMOVAL OH SYSTEM

METHANATION SECTION

SYN GAS COMPRESSOR

AMMONIA SYNTHESIS

AMMONIA REFREGERATION

PURGE GAS RECOVERY UNIT

PROCESS CONDENSATE STRIPPER

AMMONIA BOOSTER COMPRESSOR