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Flowsheet
Operator Training
By
Gerard B. Hawkins
Managing Director, CEO
Introduction
Most modern ammonia processes are
based on steam-reforming of natural
gas or naphtha.
The 3 main technology suppliers are
Uhde (Uhde/JM Partnership), Topsoe
& KBR.
The process steps are very similar in all
cases.
Other suppliers are Linde (LAC) &
Ammonia Casale.
H2O SimplifiedAir
- NH3 Plant
Ammonia
Purification NH3
synthesis
Cooling
Steam 550o C
400o C 350o C
200o C
H2
Steam
Natural superheater
Gas
30 o
220 C
bar 1000o C 420 C o
o Steam Steam Heat
o 790 C Recovery
390 C raising raising
Preheater o Process
150 C
290o C Condensate
Dissociative adsorption of H2
Dissociative adsorption of N2 -
Believed to be the Rate Determining
Step (RDS)
Multi-step hydrogenation of
adsorbed N2
Desorption of NH3
Typical Uhde Synthesis Loop
Uhde Dual-Pressure Process
Once
through
converter
Steam
Purge
1 2 3 R
Synthesis
Loop
Make up gas C.W. C.W. NH3 NH3
from frontend NH3
Effect of Pressure on Ammonia
Equilibrium Concentration
60
NH3 concentration %
50
40 380 C
30 400 C
20 420 C
10
0
50 75 100 125 150 175 200 225 250 275 300
Pressure bara
Ammonia Equilibrium Diagram
40
Ammonia content %
Equilibrium
30 Max Rate
20
10
0
300 350 400 450 500 550 600 650
(572) (662) (752) (842) (932) (1022) (1112) (1202)
Temperature C (F)
Effect of Catchpot Temperature on
Ammonia VLE
12.0
10.0
NH3 concentration %
8.0
6.0 0C
minus 20 C
4.0
2.0
0.0
50 75 100 125 150 175 200 225 250 275 300
Pressure bara
Synthesis Loop Principles:
Mass Balance
Overall Loop Mass Balance
On a mass basis:
NH3 = MUG Purge
On a molar basis:
NH3 = (MUG Purge) / 2
because 4 mol -> 2 mol in the NH3
reaction.
Converter balance, on a molar basis:
NH3 = Inlet gas Outlet gas
Synthesis Loop Principles:
Mass Balance
Converter Molar balance:
NH3 = Circ Flow x (NH3out- NH3in)
1 + NH3out
Multi-bed design :
2, 3, or 4 catalyst beds with
intermediate cooling.
Synthesis Loop Principles :
Converter Heat Balance
Older converter designs usually had an
interchanger after the final bed to contain
high temperatures within the converter.
Modern designs typically have no overall
interchanger because this gives better
heat recovery (heat available at a higher
temperature)
Split converter designs further increase
the heat recovery temperature.
3 Bed Converter Example
410 C
1. Optimum Catalyst
Temperatures 520 C
415 C
480 C
410 C
450
3 i/c design
410 C
520 C
Cold Converter
415 C
480 C
410 C
450 C
120 C
335 C
2 i/c design
410 C
520 C
Hot Converter
415 C
480 C
235 C
410 C
450 C
1 i/c design
410 C
520 C
Split Converter 305 C
415 C
480 C
410 C
450 C
Converter Heat Recovery Example
80
70
60
50
40
30
0 2 4 6 8 10 12 14
Time on line (years)
Effect of Size on Activity
120
100
Relative Activity
80
60
40
20
0
0 2 4 6 8 10 12 14
Particle Diameter (mm)
Effect of Size on Activity
Smaller pellets = high activity
Therefore high production rate or
smaller catalyst volume
But pressure drop will rise
Either axial-radial or radial flow
beds are used to minimise
pressure drop
Radial flow is the basis of many
converter internal retrofits
Deactivation
Clean Gas
Thermal sintering
Contaminated Gas
Both Temporary and Permanent
Poisoning
Oxygen induced sintering
By water, CO and CO2
Site blocking/Sintering
Typical Operating Conditions
Grade Size
A 1.5-3.0 mm
B 3.0-4.5 mm
C 3.0-6.0 mm
D/E 6.0-10.0 mm
G 14.0-20.0 mm
Catalyst Reduction
Pre-reduced Oxidized
Max water in outlet gas during 1000 3000
reduction (ppm)
Formation of water during
reduction of 1te of Catalyst (kg) 25 280
End
Ammonia Converter
Designs
Converter Designs
Objectives for modern designs are;
- low pressure drop with small catalyst
particles.
- high conversion per pass with high grade
heat recovery.
Principal types are designed by:
Uhde
Kellogg (KBR) - conventional, Braun,
KAAP
Topsoe
Ammonia Casale
JM (I C I)
Uhde
Uhde design a range of converters:
Modern designs use radial flow
with inter-cooling & 'split
converters' with heat recovery
between,
- Converter 1 : 2-bed, 1
interchanger
- Heat recovery (boiler)
- Converter 2 : 3rd bed.
Uhde 3 bed
NH3 Converter
M W Kellogg Converter Types
Inlet
Kellogg Horizontal Converter
Inlet
Outlet
KBR KAAP
Cold
Bypass
Outlet
Ammonia Casale
Ammonia Casale - 'axial-radial'
concept
- radial flow without a top cover on
the beds
- simpler mechanical design
Equilibrium
30 Max Rate
Converter Profile
20
10
0
300 350 400 450 500 550 600 650
(572) (662) (752) (842) (932) (1022) (1112) (1202)
Temperature C (F)