ANI.

M O'IA PLAN 'rs

Ammonia Plants
SUMMARY

The approximately 44 ammonia plants in the U.S. have a capacity to produce approximately 17 million tans of ammonia annually; this ammonia is used primarily for fertilizer and secondarily for chemical manufacture. The catalytic steam reformer, which is heated with natural gas or fuel oil, is the primary source of NO, from t he ammonia production process. Uncontrolled NO, emissions from these sources, mainly from process heaters, could reach 46,000 tons annually. NO, emissions from ammonia plants are largely uncontrolled. Even though reformers require a high temperature flame (2200'F 2400'F), low NO, burner technology, such as that utilized in ethylene cracking, could be employed.
DESCRIPTION OF SOURCE

naphtha, or the electrolysis of brine at chlorine plants. In the U. S., about 98 percent of synthetic ammonia is produced by catalytic steam reforming of natural gas. Figure I depicts the general process undertaken at a typical ammonia plant. Seven process steps are required to produce synthetic ammonia by the catalytic steam reforming method: 1. Natural gas desulfurization 2. Primary reforming with steam 3. Secondary reforming with air 4. Carbon monoxide shift 5. Carbon dioxide removal 6. Methanatton 7. Ammonia synthesis

Anhydrous ammonia is synthesized by reacting hydrogen with nitrogen at a molar ratio of 3:1, then compressing the gas and cooling it to -27T.. Nitrogen is obtained from the air, while hydrogen is obtained from either the catalytic steam reforming of natural gas (methane) or 1 13

The first, fourth, fifth and sixth steps are to remove impurities such as sulfur. CO, CO2 and water from the feedstock. hydrogen and synthesis gas streams. In the second step, hydrogen is manufactured, and in the third step. additional hydrogen is manufactured and nitrogen is introduced into the process. The seventh step, ammonia synthesis, produces anhydrous ammonia from the synthetic gas. While all ammonia plants use this basic

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OXIDES UNDER In (I III AI7 ACT. A ME) L OF 0r[ PINS

STAPPA/ALAPCO' - Recommendation 0- Little has been done to regulate NO,

STATE AND LOCAL CONTROL EFFORTS

There are no existing state or Iocal regulations addressing NO, emissions from ammonia plants.

emissions from ammonia plants. Agencies seeking reductions could impose controls comparable to those for process heaters and industrial boilers.
process, details such as pressures. temperatures and quantities of feedstock will vary from plant 1, plant. The second step in the process, primary reforming with steam. is the source of NO, emissions. The process heater, which is heated with natural gas or fuel oil, emits combustion products, including NO,.

REFERENCES
I. International Fertilizer Development Center. January 1 994. North American Fertilizer Capacity Data. 2. U.S Environmental Protection Agency. September 1985. Compilation of Air Pollutant Emission Factors. holume I: Stationary Point ,,d Area Sources. 3. U.S. Environmental Protection Agency. July 1993. AIRS Faei/in' Subsystem.

EMISSIONS PER UNIT OUTPUT

EPA has estimated the emission factor for heater fuel combustion (using either natural gas or distillate oil) to be 5.4lb/tan of ammonia produced.

NATIONAL EMISSIONS ESTIMATE

According to the EPA's AIRS Facility Subsystem, 44 ammonia plants emit approximately 25,700 tons of NO, per year.

GEOGRAPHIC DISTRIBUTION OF SOURCES AND EMISSIONS

The vast majority of the approximately 44 ammonia manufacturing facilities are located in the southwest and midwest, with 11 plants located in Louisiana.

AVAILABLE CONTROL STRATEGIES

The process heater used in the primary reforming process operates at a high temperature (in the range of 2200'F2400'F). The NO, control considerations are similar to other process heaters operated at high temperatures, such as ethylene cracking. The chapters on industrial boilers and process heaters describe applicable control strategies and costs.

FEDERAL RULEMANING ANO/OR GUIDANCE DOCUMENTS

There are no existing federal, state or local regulations governing NO, emissions from ammonia manufacturing plants.

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AMMO6i9 P_ANIS

Figure 1 General Process Flow Diagram of a Typical Ammonia Plant EMISSIONS DURING REGENERATION t FUEL COMBUSTION EMISSIONS

NATURAL GAS& ~ FUEL.'

FEEDSTOCK DESULFURIZATION PRIMARY REFORMER SECONDARY REFORMER HIGH TEMPERATURE SHIFT

F-

STEAM AIR

4 4

EMISSIONS i 4

PROCESS CONDENSATE

LOW TEMPERATURE SHIFT 1 CO, ABSORBER 1 METHANATION AMMONIA SYNTHESIS NH, 4

EMISSIONS CO 2 SOLUTION REGENERATION STEAM PURGE GAS VENTED TO PRIMARY REFORMER FOR FUEL

STEAM STRIPPER

STEAM

EFFLUENT