ENERGY SAVING OPPORTUNITIES IN AMMONIA

AND UREA PLANT : KRIBHCOs EXPERIENCE

OPPORTUNITY FOR ENERGY SAVINGS
OPPORTUNITIES RELATED WITH TECHNOLOGICAL
INNOVATIONS / IMPROVEMENTS
OPPORTUNITIES RELATED WITH IMPROVEMENTS IN
EQUIPMENT & MACHINERY INCLUDING MATERIALS
OPPORTUNITIES BY BETTER OPERATION & ENERGY
MANAGEMENT

OPPORTUNITY FOR ENERGY SAVINGS
Peluang dari segi Inovasi Teknologi Proses (Improvements)
Peluang yang berkaitan dengan Inovasi Teknologi Peralatan
dan Mesin-Mesin termasuk Materialnya
Peluang yang berkaitan dengan perbaikan Manajemen
Opersai dan Energi

MODERN LOW ENERGY AMMONIA PLANT
PROCESS TECHNOLOGY
KELLOGG BROWN & ROOT (KBR)

HALDOR TOPSOE

UHDE

AMMONIA CASALE
ENERGY LOSS AREA IN AMMONIA PLANT
SURFACE CONDENSERS

CO2 REMOVAL SECTION

PRIMARY REFORMER FURNACE STACK

HEAT LOSS IN CW EXCHANGERS

OTHER LOSSES
- PURGE GAS
- FURNACE STACK OTHER THAN PRIMARY REFORMER
- STEAM LOSS THROUGH VENTS
- ENERGY LOSS THROUGH STEAM TRAPS
- LOSSES THROUGH FLASH GASES
ADVANCES IN REFORMING AREA
PROCESS TECHNOLOGY

OPERATION AT INCREASED PRESSURE
DECREASE OF STEAM ADDITION
INCREASING EXIT TEMP FROM P/R AND S/R
INCREASING PREHEAT TEMP FOR FEED, PROCESS AIR,
COMBUSTION AIR
PART LOAD SHIFTING FROM P/R TO S/R
NEW CONCEPT OF GHR AND KRES

EQUIPMENT OR METALLURGY

USE OF MORE SOPHISTICATED ALLOY FOR TUBES

ADVANCES IN SHIFT CONVERSION AREA
PROCESS TECHNOLOGY

DEVELOPMENT OF MORE ACTIVE LT SHIFT CATALYST
NEW COPPER PROMOTED HT SHIFT CATALYST
ISOTHERMAL SHIFT (LINDE CONCEPT)


EQUIPMENT OR METALLURGY

CHANGE IN FLOW PATTERN WITHIN HT & LT SHIFT
REACTORS
ADVANCES IN CO2 REMOVAL AREA
PROCESS TECHNOLOGY

USE OF IMPROVED SOLVENT BASED SYSTEMS
USE OF IMPROVED ACTIVATORS, CORROSION INHIBITORS
USE OF INTERNAL HEAT RECOVERY SCHEMES USING
EJECTOR, HEAT PUMPS, SECOND REGENERATORS
USE OF ADSORPTION BASED PROCESS
USE OF MEMBRANE BASED PROCESS (FUTURISTIC)

EQUIPMENT OR METALLURGY

USE OF IMPROVED PACKING/TRAYS
USE OF IMPROVED TOWER INTERNALS

COMPARISON OF ENERGY FOR DIFFERENT CO2 REMOVAL PROCESS
(KCal/NM3)
PROCESS

SOLVENT ENERGY
MEA H2N(CH2CH2OH) 2230
MEA H2N(CH2CH2OH) +
Activators -1
1490
MEA H2N(CH2CH2OH) +
Activators -2
1240
Benfield(1 stage regenerator) K2CO3 + Activators 1140
MEA H2N(CH2CH2OH) +
Activators -3
940
Benfield(1 stage regenerator, lean soln, flash, steam ejectors)

K2CO3 + Activators 940
Benfield(2 stage regenerator, lean soln, flash, steam ejectors)

K2CO3 + Activators 810
Benfield(2stage regenerator, lean soln, flash, mechanical heat
pump)

K2CO3 + Activators 672
GV(HP & LP regenerators, lean soln, flash, steam ejectors)

K2CO3 + Activators 630
MDEA(2 stage regenerators H3CN(CH2CH2OH)2 +
Activators
450-530
MDEA (with vacuum flash) H3CN(CH2CH2OH)2 +
Activators
385


ADVANCES IN SYNTHESIS GAS PURIFICATION
PROCESS TECHNOLOGY

USE OF METHANATION CATALYST

USE OF MOLECULAR SIEVE

USE OF INTER-STAGE CHILLERS IN THE SYN GAS
COMPRESSOR

USE OF CRYOGENIC SYSTEM FOR REMOVING ALL IMPURITIES

DE HYDRATOR CONCEPT
ADVANCES IN AMMONIA SYNTHESIS
PROCESS TECHNOLOGY

LOWER PR. OPERATION OF SYNTHESIS LOOP
HIGHER CONVERSION OF AMMONIA
INDIRECT COOLING
LOW INERT LEVEL
NEW TYPE OF CATALYST

EQUIPMENT OR METALLURGY

LOWER PR. DROP IN THE LOOP OR CONVERTER, REDUCING
POWER REQUIREMENT IN RECYCLE GAS COMPRESSOR
FACTORS AFFECTING AMMONIA PRODUCTION
1. OPERATING PR.- AFFECTS CONVERSION, COMPRESSION COST, PRODUCT NH3
REMOVAL, LOOP CAPITAL COST

2. OPERATING TEMP.- AFFECTS REACTION RATE, CATALYST VOLUME

3. DEGREE OF CONVERSION-AFFECTS RECYCLE FLOW,PRODUCT NH3 REMOVAL

4. INERT LEVEL - AFFECTS PURGE FLOW, DEGREE OF CONVERSION

5. LEVEL OF REMOVAL OF PRODUCT NH3 - AFFECTS REFRIGERATION LOAD, CW
LOAD, NH3 YIELD

6. CONVERTER FLOW PATTERN - AFFECTS CONVERTER PRESSURE DROP

7. METHOD USED FOR MID STREAM REMOVAL OF HEAT - AFFECTS DEGREE OF
CONVERSION, CATALYST VOLUME

8. PRESSURE DROP IN CONVERTER & LOOP - AFFECTS RECYCLE COMPRESSION
POWER

OPTIONS FOR ENERGY SAVING IN STEAM &
POWER SYSTEM

REDUCING POWER REQUIREMENT AT PROCESS LEVEL

REDUCING POWER REQUIREMENT AT MACHINE LEVEL

INCREASING THE EFFICIENCY OF CONVERSION TO PRODUCE
POWER

INTRODUCING FEATURES TO RECOVER LOW LEVEL HEAT
AVAILABLE IN THE SYSTEM
ADVANCES IN STEAM & POWER SYSTEM
PROCESS TECHNOLOGY

RECOVERY OF HEAT BY GENERATION OF HP STEAM IN SYN
LOOP
STEAM PRODUCTION & SUPERHEATING DOWN STREAM OF
S/R
PRODUCTION OF PROCESS STEAM FOR LOW LEVEL HEAT BY
FEED GAS SATURATOR

STRIPPING OF PROCESS CONDENSATE WITH LP OR MP STEAM
FOR RE-USE AS BFW

CONTD..
CONTD.

USE OF COMBINATION OF BACK PR., CONDENSING TURBINES
AND MOTOR DRIVES TO OPTIMISE THE SYSTEM

EQUIPMENT OR METALLURGY

IMPROVED DESIGN OF COMPRESSOR AND TURBINE WITH
HIGH EFFICIENCY

USE OF GT AS DIRECT DRIVE OR PART OF COGENERATION
UNITS PRODUCING STEAM & POWER

BETTER OPERATION & ENERGY MANAGEMENT
PROCESS CONTROL SYSTEMS

KEY PARAMETERS TO BE CONTROLLED ARE :
STEAM TO CARBON RATIO

METHANE LEAKAGE

H2 TO N2 RATIO OF SYNTHESIS GAS

CONVERTER TEMP CONTROL

SYNTHESIS LOOP PURGE

REFRIGERATION PURGE

ADD-ON UNITS
PGR UNIT

DEMETHANIZATION

METHANOLATION

MODERN UREA TECHNOLOGIES
Stamicarbon CO2 STRIPPING PROCESS

Snamprogetti NH3 STRIPPING PROCESS

ACES-21 CO2 STRIPPING PROCESS

UREA CASALE SPLIT FLOW LOOP

ADVANCES IN UREA PLANT
PROCESS TECHNOLOGY

PRILLING - FORCED DRAFT PRILLING TOWER REPLACED BY
NATURAL DRAFT

UREA CONCENTRATION - OLD ROUTE OF CRYSTALIZATION,
SEPARATION, DRYING AND THEN RE-MELTING REPLACED
WITH VACUUM CONCENTRATION AND DIRECT PRILLING

IMPROVEMENTS IN STRIPPING CYCLE TO MINIMUM USE OF
STEAM

CONTD.


CONTD..
VAPOUR RECYCLE SYSTEM(VRS)

EQUIPMENT OR METALLURGY

INCREASED CONVERSION THROUGH SPECIALLY DESIGNED
TRAYS

SAFUREX ALLOY

CONSUMPTION OF DIFFERENT UREA PROCESSES
(CONSUMPTION PER MT UREA)
COMPONENTS

ACES STAMICARBON SNAMPROGETTI
CO2 740-750 KG 740-750 KG 740-750 KG
COLLING WATER 90 M3 81 M3 94 M3
STEAM HP
LP
771 KG
-
814 KG
-
814 KG
759 KG

POWER 25 KWH 17 KWH 26 KWH
ENERGY TERMS 0.699 GCal/MT 0.710 GCal/MT 0.748 GCal/MT
AMMONIA 567 KG 567 KG 567 KG


BETTER OPERATION & ENERGY MANAGEMENT IN
UREA PLANT
PROCESS CONTROL SYSTEMS

KEY PARAMETERS TO BE CONTROLLED ARE
HP NH3 FEED TO REACTOR
N/C MOLAR RATIO
REACTOR CONVERSION PER PASS
SPECIFIC STEAM CONSUMPTION
1ST DECOMPOSER STEAM CONSUMPTION
1ST SEPARATOR TOP TRAY TEMP
CARBAMATE CONCENTRATION ANALYSER SCALE READING
INTERNAL WATER BALANCE CONTROL
HYDROLYSER STRIPPER TOP TRAY TEMP
HYDROLYSER STRIPPER FEED TRAY TEMP
UREA RECYCLE

KRIBHCOs EXPERIENCE
ENERGY LOSS AREA IN AMMONIA PLANT
GCAL/MT AMMONIA
SURFACE CONDENSERS 1.367
CO2 REMOVAL SECTION 0.577

PRIMARY REFORMER FURNACE STACK 0.292

HEAT LOSS IN CW EXCHANGERS 1.054
(Excluding Surface Condensers)

OTHER LOSSES 0.180
-Purge Gas
-Furnace Stack Other Than Primary Reformer
-Steam Loss Through Vents
-Energy Loss Through Steam Traps
-Losses Through Flash Gases
TOTAL 3.470

PRIMARY REFORMER OF KRIBHCO
NO. OF TUBES 504 (12x42)
TUBES OD 101.92 mm
TUBES ID/THICKNESS 71.12 / 15.4 mm
TUBE MATERIAL A 351-HK-40
TUBE PITCH 260 mm
INLET CONDITIONS:
- PR. OF PROCESS STREAM
- TEMP. OF PROCESS STREAM
38.1 kgA
510 C
S/C RATIO 3.5
OUTLET
- PR OF PROCESS STREAM
- TEMP. OF PROCESS STREAM
34.1 kgA
819 C
CH4 SLIP IN DRY % 10.38
NO. OF BURNERS 234 (18x13)
HEAT RELEASE/ABSORBED 173.4 / 80.24 Gcal/hr
CATALYST VOLUME 20.4 m3
PRIMARY REFORMER OF KRIBHCO(After Tube Change)
NO. OF TUBES 504 (12x42)
TUBES OD 106.42 mm
TUBES ID/THICKNESS 85.06/10.68 mm
TUBE MATERIAL Manurite 36 X
TUBE PITCH 260 mm
INLET CONDITIONS:
-PR. OF PROCESS STREAM
-TEMP. OF PROCESS STREAM
OUTLET CONDITIONS:
-PR. OF PROCESS STREAM
-TEMP. OF PROCESS STREAM
38.0 kgA
506 C
35.8 kgA
821 C
S/C RATIO 3.4
CH4 SLIP IN DRY %
NO. OF BURNERS
-
234(13x18)
HEAT RELEASE/ABSORBED 215.83 / 103.66
Gcal/hr
CATALYST VOLUME 28.26 m3
RESULTS OF P/R RETROFIT

PRESSURE DROP ACROSS THE TUBES REDUCED FROM 3.5 Kg/Cm2 TO 2.2
Kg/Cm2

S/C COULD BE REDUCED MARGINALLY

THE REVAMED REFORMER PERFORMANCE RESULTED IN LOWER CH4
SLIP FROM THE P/R EFFLEUENT

EXISTING BOILERS 101-C, 102-C, 103-C, AND THE BFW PREHEATER 123-C
ABSORBED MORE HEAT

CAPACITY OF PRIMARY REFORMER INCREASED PROVIDING POTENTIAL
FOR MORE PRODUCTION

PROCESS CONDITION OF KRIBHCO AMMONIA
CONVERTER
CONVERTER INLET
PRESSURE / TEMP 215 kgA / 140 C
NH3 1.74 %
INERTS 13.6 %
CONVERTER OUTLET
PRESSURE / TEMP 212 kgA / 326.1 C
NH3 14.5 %
INERTS 15.31 %
PURGE GAS FLOW 411 Kg Mole/Hr
TEMP
AMMONIA CONVERTER RETROFIT
MAIN FEATURES

GAS FLOW IS CHANGED FROM AXIAL TO AXIAL-RADIAL.
REDUCING THE PATH FOR GAS TO TRAVEL FROM 9 M TO 0.6
M.
REDUCING THE PR. DROP.
1.5 MM CATALYST IS USED INSTEAD OF 6-10 MM.
HIGHER NH3 CONCENTATION ARE ACHIEVED UPON USE OF
SMALL CATALYST.
INTRODUCTION OF GAS/GAS EXCHANGER BETN. 2ND AND
3RD BED ELIMINATES THE QUENCH
PROVIDES THERMODYNAMIC ADVANTAGES IN IMPROVING
THE CONVERSION FURTHER.



BENEFITS

INCREASE IN NH3 CONC. AND THEREBY REDUCTION IN
RECIRCULATION RATE. POWER CONSUMPTION IN SYN GAS
COMPR.IS REDUCED
REDUCTION IN CONVERTER AND SYN LOOP PR. DROP
INCREASE IN SYN GAS TEMP EXIT
INCREASED NH3 CONC FACILITATES MORE NH3
CONDENSATION IN WATER COOLED CONDENSER AND
REDUCING POWER CONSUMPTION IN REFRIG. COMPR.
HIGHER SYN GAS EXIT TEMP FROM CONVERTER IMPROVES
HEAT RECOVERY IN BFW PREHEATER
OVERALL BENEFIT IS ENERGY SAVING OF 0.257 GCAL/MT NH3
DURING GTR
COSTS
Cost Of License Fee , Design& Basic Engg., Detailed Engg.
Services For Construction, Erection,Engineering, And
Commissioning Rs. 2.90 Cr

Cost of off shore Material, procurement,
inspection Rs. 1.63 Cr.

Cost of catalyst unloading Rs. 0.36 Cr.

Cost of catalyst (three charges) Rs. 5.79 Cr.

Cost of Indian material procurement Rs. 4.25 Cr.

Cost of civil work, erection, custom duty
and other expenses Rs. 10.54 Cr.
TOTAL Rs. 25.47 Cr.
Energy savings in money terms Rs. 10.57 Cr.
Pay back period 2.5 Years

ENERGY SAVING DURING COLD START UP
AND LT REDUCTION
AS PER ORIGINAL DESIGN:
NG USED FOR HEATING CATALYSTS OF THE DESULPHURISER,
LT SHIFT CONVERTERS (BOTH LT GUARD AND MAIN) WAS
BEING VENTED

NG USED AS CARRIER GAS FOR LT GUARD CATALYST
REDUCTION WAS BEING VENTED

NG USED AS CARRIER GAS FOR LT MAIN CATALYST WAS BEING
VENTED.
ENERGY SAVING DURING COLD START UP AND LT
REDUCTION

NG USEDFOR HEATING SAVING IN EACH STARTUP DESULPHURISATION
CATALYST
DURING COLD START UP 90,000 NM3

NG USED FOR HEATING LT GUARD
&LT MAIN CATALYST 60,000 NM3
150,000 NM3
NG USED AS CARRIER GAS DURING
LT GUARD CATALYST REDUCTION 240,000 NM3

ANNUAL SAVINGS WITH 3 COLD
START UP AND 1 LT GUARD
REDUCTION Rs. 21 LAKHS

INVESTMENT ON THE SCHEME Rs. 14 LAKHS

PAYBACK PERIOD 8 MONTHS

OTHER IMPROVEMENTS DONE IN PLANT
IMPROVED NH3 CONVERSION BY ADJUSTING OPERATING
PARAMETERS OF SYNTHESIS CONVERTER

ADJUSTMENT OF AIR FLOW TO AUXILIARY BOILER

INCREASING THE CONCENTRATION OF BENFIELD SOLUTION

CLOSING OF MP STEAM VENT

PROVISION OF BAFFLES IN P/R CONVECTION

USE OF SEAL OIL FLASH GAS AS FUEL

FEED PREHEAT COIL IN LT COVECTION ZONE OF PR

ENERGY SAVING GCAL/MT NH3
IMPROVED NH3 CONVERSION BY
ADJUSTING OPERATING PARA-
METERS OF SYN. CONVERTER 0.011

ADJUSTMENT OF AIR FLOW TO
AUXILIARY BOILER 0.006

INCREASING THE CONCENTRATION OF
BENFIELD SOLUTION 0.002

CLOSING OF MP STEAM VENT 0.057

PROVISION OF BAFFLES IN P/R
CONVECTION SECTION 0.017

USE OF SEAL OIL FLASH GAS AS FUEL 0.004

FEED PREHEAT COIL IN LT CONVECTION ZONE OF PR 0.035


IMPROVEMENT IN UREA PLANT
SCHEME ENERGY SAVED
Gcal/MT of UREA


UREA MODERNISATION SCHEME 0.10

CO2 COMPRESSOR ROTOR CHANGE 0.02
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