HBTU

TRAINING REPORT ON

Ammonia Production
IN
Partial fulfillment for the summer training program of
BACHLOR OF TECHNOLOGY
In
CHEMICAL ENGINEERING
Submitted by: Submitted to:
Utkarsh Tripathi Dr. Rajesh Katiyar
663/15
1504551043
 CERTIFICATE

DEPARTMENT OF CHEMICAL ENGINEERING

HARCOURT BUTLER TECHNICAL UNIVERSITY
KANPUR – 208002
BONAFIDE CERTIFICATE

Certificate that this project report is “INDUSTRIALTRAINING AT NATIONAL

FERTILIZERS LIMITED (AN ISO -14001 UNIT), NANGAL” is the bonafide work of
Utkarsh Tripathi who carried out the project work under my supervision. This is
to further to the best of my knowledge, that this project has not been carried
out earlier in this vocational training at NATIONAL FERTILIZERS LIMITED.

SIGNATURE AND SEAL

NAME OF SUPERVISOR

Certified that the above mention project has been duly carried out as per the
norms of the college and training.

SIGNATURE AND SEAL

HEAD OF DEPARTMENT
 PREFACE

As per the requirement of B.TECH degree course in Chemical Engineering industrial

training has to be undertaken after third year. To full-fill this requirement I took my
training from NFL NANGAL. During this period (2/07/2018 to 30/07/2018), I learned
about the functioning and processes involved in the AMMONIA PRODUCTION PLANT.

This report contains all the necessary information about the AMMONIA
PRODUCTION PLANT. It also contains an overview of NFL. The information has been
prepared to best of data available at my knowledge and time.

It was pleasure to face the industrial life that helped me to convey my theoretical
concepts into practical knowledge at this esteemed organization.
 ACKNOWLEDGEMENT
The success and final outcome of this report required a lot of guidance and
assistance from many people and I am extremely privileged to have got this all
along the completion of my report. All that I have done is only due to such
supervision and assistance and I would not forget to thank them.

I am very grateful to Mr. SHUBHANKAR MITRA (ASSISTANT MANAGER - HRD) ,

Mr. I.P. SINGH ( CHIEF MANAGER PRODUCTION ), Mr. PRAVEEN KUMAR
(ASSISTANT SHIFT MANAGER) & Mr. VIVEK SHARMA (MANAGER PRODUCTION)
who deputed me with senior engineers and provided me knowledge of various
chemical process and equipments in detail that are used in industry . I pay my
sincere thanks to all supervisors and other official of the plant for providing me
the details of the respective plant. I am very thankful to PROF. S.K. GUPTA
(HEAD OF CHEMICAL DEPARTMENT, HBTU KANPUR), PROF.RAJESH KATIYAR
and all the professors of Chemical Engineering Department who guided and
supported me from time to time.
CONTENT
TOPIC PAGE

Preface

Acknowledgement

1)Abstract 1

2) About Organization
2.1) History 2
2.2) Business operations 2
2.3) Products 3
2.4) Marketing 3
2.5) Future Projects 3

3) NFL,Nangal Unit 4

4) Ammonia Manufacturing 5
4.1) Process Description 5
4.2) Steps involved 6

5)Project 19

6)References 31
 1) Abstract

Company’s profile and brief synopsis of the history of company is also penned.

This report comprises of detailed process description of manufacturing of ammonia

process based on plant designed on KBR technology.

Process comprises of following steps :-

• Feed gas compression, Preheating and Desulfurization

• Primary Reforming
• Process air Compression

• Secondary Reforming
• Shift Conversion

• Carbon Dioxide Removal

• Methanation
• Drying

• Cryogenic Purification
• Synthesis-Gas compression

• Ammonia Synthesis

• Water Cooling

1
2.1)History ofOrganization
NFL was established in 1974, as a public-sector undertaking of the Government of
India. NFL initially operated two plants in Bathinda and Panipat. In 1978, the
ownership and operations of the Nangal plant of FCI was transferred to NFL.

The Govt. of India, in 1984, entrusted the Company to execute the country's first
inland gas based fertiliser project of 726,000 tonnes Urea capacity in District Guna of
Madhya Pradesh and commercial production started rom 1 July 1988.The company
built and commissioned its Vijaipur plant in Guna district of Madhya capacity was
doubled to 1.45 million tonnes in 1997.NFL was granted the Mini-Navratna status
with additional autonomy due to its profitable operations.

In 2001, the company went public company, with listings on the Bombay Stock
Exchange and the National Stock Exchange.

NFL has five gas based Urea plants viz Nangal & Bathinda in Punjab,Panipat in
Haryana and two at Vijaipur (Madhya Pradesh). The plants at Panipat, Bathinda &
Nangal have recently been converted from fuel oil feedstock to natural gas. Vijaipur
plants have also been revamped for energy saving & capacity enhancement.

The percentage share of NFL in Urea production in the country was 14.2% during
2012–13.The Company produced 3211,000 tonnes of Urea which includes 10.83 LMT
of Neem coated Urea. 448 MT of Bio-fertilizers (solid & liquid) was produced during
the year.

2.2) Business Operations

NFL has five gas based Urea plants viz Nangal & Bathinda in Punjab,Panipat in
Haryana and two at Vijaipur (Madhya Pradesh). The plants at Panipat, Bathinda &
Nangal have recently been converted from fuel oil feedstock to natural gas. Vijaipur
plants have also been revamped for energy saving & capacity enhancement.

2
2.3) Products
NFL is engaged in manufacturing and marketing of Urea, Neem Coated Urea, Bio-
Fertilizers (solid & liquid) and other allied Industrial products like Ammonia, Nitric
Acid, Ammonium Nitrate, Sodium Nitrite, Sodium Nitrate etc.
The value-added Neem Coated Urea developed by NFL & widely recognized for its
effectiveness is being produced at its three units at Panipat, Bathinda & Vijaipur. NFL
is the first company in India to be permitted by the Government of India to produce
and market Neem Coated Urea.
It also manufactures Rhizobium, Phosphate Solubilizing Bacteria (PSB)
and Azotobacter. Starting with a mere 23 MT production in 1995–96, the production
has risen to 231 MT (Approx) in 2010–11.

2.4) Marketing
The Company's Marketing Network comprises Central Marketing Office at NOIDA,
three Zonal Offices at Bhopal, Lucknow & Chandigarh, 13 State Offices and 39 Area
Offices spread across the country.

2.5) Future Projects

An agreement for a Joint Venture Company "Ramagundam Fertilizers And Chemicals
Limited" has been signed on 14 January 2015 between National Fertilizers
Limited, Engineers India Limited(EIL) and FCIL for setting up new Ammonia and Urea
plants of 2200 MT per day & 3850 MT per day capacity respectively at the existing
site of Ramagundam Fertilizer Plant in Distt. Karim Nagar in Telangana.As per this
joint venture agreement, NFL shall provide commissioning,operation,maintenance
and marketing services to the Joint Venture Company and EIL shall provide
Engineering, Procurement and Construction Management (EPCM) Consultancy
Services for the project. The total capital expenditure of 50 billion is being funded in
Debt:Equity of 70:30 percentage.NFL and EIL are contributing equity of 26% each and
11% is from FCIL. The balance equity is in the process of being tied up. [5] The
Company also has a Joint Venture (33.33% share) “Urvarak Videsh Limited” with M/s.
KRIBHCO and RCF as promoters. The main objective of the joint venture company is
to explore investment opportunity abroad and within the country in nitrogenous,
phosphatic and potassic sectors and to render consultancy services for setting up
projects in India and abroad.
3
3) NFL, Nangal Unit

Consequent upon the reorganization of FCI group of plants, Nangal Plant was
transferred to NFL & subsequently expansion plant of Nangal Unit was
commissioned with an installed capacity of 3.30 LMT. Further in order to sustain and
enhance the company’s growth, NFL successfully revamped Urea Plant of the Nangal
Unit & Commercial Production was commissioned after revamp w.e.f. 1st Feb 2001
thus enhances the Annual installed Capacity from 3.30 LMT to 4.785 LMT . As per
guidelines of GOI, in order to reduce subsidy burden & Carbon footprint, NFL
revamped the Nangal Unit on LSTK basis for changeover of Feedstock from LSHS/FO
to Natural Gas and commercial production on Gas was commenced during April
2013.

Installed Capacity: 478500 MTPA

Capital Investment Rupees 229.19 Crores
Commencement of Production: November 1, 1978

• PROCESS:

Ammonia: KBR SMR (Steam Methane Reforming) with purifier technology

Urea: Technimont Total Recycle Process
Raw materials: Coal, LNG/RLNG, Power, Water

• BY PRODUCTS:

 NITRIC ACID
 SULPHUR
 AMMONIUM NITRATE
 SODIUM NITRITE
 SODIUM NITRATE
 CARBON DI-OXIDE

PRODUCTS:

 KISAN KHAD
 KISAN UREA

4
4) Ammonia Manufacturing
4.1) PROCESS DESCRIPTION:

The front end of Ammonia Plant is based on KBR purifier TM technology which is a
low energy Natural Gas steam reforming process i.e offered and licensed by the KBR.
The New front end is combined with the existing synthesis loop to produce 950
MTPD of Ammonia. The Plant design and performance is based on the lean Natural
Gas composition which is controlling case. However, the plant will also operate and
achieve the name plate capacity with the rich Natural Gas composition.

Block Diagram of Ammonia Plant

5
4.2.1) FEED GAS COMPRESSION
Natural gas for feed and fuel is supplied at the plant battery limit at 300 0C and 40.5
kg /cm2 natural gas is initially directed to a Feed Gas Knockout Drum , where any
entrained liquid are removed. Part of the natural gas from the outlet of Feed gas
knockout drum is sent to the primary reformer furnace as fuel.

The remaining natural gas is compressed to 57.3 kg/cm2 in the Feed Gas compressor,
which is driven by an electric motor. To allow the compressor to operate over a wide
range of operating conditions without going into surge, it is provided with Kickback
line with a Kickback cooler. This allows some of the compressor discharge gas to be
recycled back to the compressor suction through Feed gas knockout drum. This is
typically required during plant start-up and turn down conditions when the feed gas
flow is much lower than normal.

After compression in feed gas compressor , natural gas feed is mixed with a small
amount of syngas recycled from the synthesis loop which provides the required
hydrogen for the downstream hydrotreater. If the synthesis loop is not in operation,
the hydrogen recycle stream can be taken from the Methanator Effluent Separator
overhead, and added at the suction to Feed gas compressor. There is also a provision
to generate hydrogen via ammonia cracking in the primary reformer during initial
plant start-up.

4.2.2) Pre-heating
The mixture of natural gas and hydrogen is heated to 3710C, first using condensing LP
steam in the LP steam/Feed Gas Preheater , and then in the Feed Gas Coil located in
the convection section of the primary reformer .

4.2.3) Desulfurization
The hot gas then enters a two-step desulfurization system. In the first step, the hot
gas passes through Hydrotreater , which contains cobalt/molybdenum(CoMo)
catalyst. The catalyst ensures hydrogenation of organic sulphur compounds, if
present in the feed gas, such as mercaptans (RSH), carbonyl sulfide (COS), to
hydrogen sulfide.

6
COS + H2 CO + H2S

RSH + H2 RH + H2S

In the second step, hydrogen sulfide in the feed gas is removed in two desulfurizers.
Each desulfurizer contains a bed of zinc oxide. Hydrogen sulfide reacts with the zinc
oxide and is retained as zinc sulfide, thereby producing an effluent stream containing
less than 0.1 ppmv of sulphur.

H2S + ZnO ZnS + H2O

The two desulfurizer vessels are arranged in series, in a lead-lag configuration such
that either vessel can be taken out of service to replace the zinc oxide while the
other vessel remains in service and plant operation is not interrupted. Each vessel
contains enough zinc oxide to last for at least one year of continuous service at the
design inlet sulfur concentration of 10 ppmv hydrogen sulfide in the feed gas.

4.2.4) PRIMARY REFORMING

Desulfurized feed gas is mixed with process steam from the overhead of the Process
Condensate Stripper to give a steam to organic carbon molar ratio of 2.7:1. The feed
gas flow is controlled by ratio to the process steam flow. This feature protects the
reforming catalysts in case of loss of process steam. The mixture is preheated to
about 495 0 C in the convection section of the Primary Reformer . The preheated
mixed feed is distributed over tubes packed with reforming catalyst and suspended
in the radiant section of Primary reformer. Steam Reforming reactions takes place
over the Nickel based reforming catalyst in the radiant tubes to form carbon
monoxide, carbon dioxide and hydrogen. Steam reforming reaction for any
hydrocarbon can be written as

CnHm + nH2O nCO + (2n+m)/2 H2

For methane the above reaction becomes:

CH4 + H2O CO + 3H 2

7
The water gas shift reaction converts carbon monoxide to carbon dioxide and
additional hydrogen:

CO + H2O CO2 + H2

The Primary reformer effluent gas at 48.0kg/cm2 (a) and 72loC contains about 29.9
mole% (dry basis) of unreacted methane. The Primary reformer effluent is sent to
the Secondary Reformer via the Primary Reformer Effluent Transfer line .

Heat for the endothermic steam reforming reactions in Primary reformer is supplied
by the combustion of fuel gas in burners located at the top of the furnace. The
burners are located between rows of catalyst tubes and operate with downward
firing. Thus, the heat flux is highest at the top of tubes, where the process
temperatures are the lowest and most of the reforming reaction is being done.

8
 The outlet manifolds and riser tubes are located inside the radiant box, for heat
conservation. The primary reformer uses the latest refractory and insulation
technology.

Ceramic fiber lining in the radiant section provides rapid thermal response due to
low heat storage. Super duty hard factory is used where flames may contact the
sidewalls. The reformer is designed with 2% oxygen (dry basis) in the flue gas at the
outlet of the radiant section. This ensures complete combustion of the fuel in the
burners. The Purifier process uses excess air in the secondary reformer. This feature
reduces the size of the primary reformer furnace by about one third, and lowers the
process gas outlet temperature from the reformer substantially, as compared to a
conventional ammonia plant. The lower outlet temperature results in longer tube
and catalyst life.

The primary reformer is designed to obtain maximum thermal efficiency by

recovering heat from the flue gas in the convection section. The heat recovered is
used for the following services:

 Mixed Feed Preheating

 Process Air Preheating
 Steam Superheating
 Feed Gas Preheating
 Combustion Air Preheating

4.2.5) PROCESS AIR COMPRESSION

Process air is drawn in through an Air Filter which removes any dust particles.
Process air is then compressed in an integrally geared Process Air Compressor to a
pressure of 50.8kg/cm2 (a). Inter Stage cooling and condensate separation is
provided in process air compressor. Process air compressor is controlled to maintain
a constant pressure drop across the downstream process air control valve. During
plant startup or turndown operation, enough compressed air is vented to maintain
the minimum load on the compressor to prevent it from going into surge.
Compressed process air is then preheated to about 5100C in Air preheat Coil located
in the convection section of Primary reformer, and sent to the secondary reformer.
Steam is continuously added to the process air to the inlet of the coil.

9
 This feature prevents backflow of hot gas from the secondary Reformer in the event
of Process air compressor trip. Process air compressor also provides plant and
instrument air which is required for the entire plant from one of the intermediate
stages of the compressor.

4.2.6) SECONDARY REFORMING

Hot compressed process air and primary reformer effluent are sent to the top
section of the Secondary Reformer where spontaneous combustion occurs. The
resulting hot gas mixture then flows down through a bed of Nickel based reforming
catalyst in the lower section of Secondary reformer. The heat released from the
combustion reactions in the upper section supplies the heat for the steam reforming
reactions in the lower section, converting methane to more carbon oxides and
hydrogen. The unreacted methane content in the gas leaving Secondary reformer is
about 1.8mole% (dry basis).

In a conventional ammonia plant, the amount of process air introduced in the

secondary reformer is controlled carefully to produce a stoichiometric 3:1 molar
ratio of hydrogen to nitrogen at the inlet to the ammonia converter.

In the Purifier process, about 50 percent excess air is used in the secondary reformer
with the excess nitrogen being removed in the Purifier Cold box. The excess air
produces additional combustion heat for the reforming reactions in the Secondary
reformer. Thus the reforming load is shifted from the primary reformer to the
secondary reformer.

In addition, the methane leakage from the reforming section is relaxed as the
unreacted methane is removed in the Purifier Cold box. This reduces the overall
reforming severity and lowers the secondary outlet temperature to about 906 0C.
The lower reformer results in milder conditions for the downstream waste heat
boiler as compared to conventional plants.

The heat in the Secondary reformer effluent is recovered by generating HP steam

(104kg/cm2 (g)) in the Secondary Reformer Waste Heat Boiler is a KBR proprietary
design. It is vertical water tube, themosyphon boiler.

10
For safety reasons, Secondary reformer, Primary Reformer Effluent Transfer line
and waste heat boiler are provided with water jackets. The water jackets keep the
metal walls cooler, and provide an early warning system against any possible
refractory failure which allows an orderly shutdown of the plant in such a scenario.

4.2.7) SHIFT CONVERSION

The cooled secondary reformer effluent is sent to high Temperature shifter (HTS)
Converter reactor. Here , the gas flows over a bed of HTS catalyst (Fe based catalyst )
and carbon monoxide reacts with steam to form carbon dioxide and hydrogen via the
water gas shift reaction.

CO + H2O ---- CO2 + H2

About 72% of the carbon monoxide is shifted to carbon dioxide in HTS converter. The
carbon monoxide content in the HTS effluent is about 2.9% (dry basis). The water gas
shift reaction is exothermic. The gas leaving the HTS converter is cooled by
generating high pressure steam in the HTS effluent and by heating high pressure
boiler feed water in the HTS effluent.

The gas then passes through a LTS guard bed which is packed with LTS catalyst.
Catalyst volume is based on 2.5 years of catalyst life. LTS guard effluent is cooled by
the BFW in the LTS guard bed effluent and is then sent to LTS shift converter at about
208 degree celcius. Most of the remaining carbon monoxide is carbon dioxide in LTS,
leaving a residual carbon monoxide content about .25 mole% (dry basis) in the LTS
effluent.

LTS effluent is cooled against BFW in the LTS effluent and by raising low pressure
steam in the LTS effluent low pressure steam generator. The gas is then sent to CO2
stripper and further cooled in LTS effluent to about 70 degree celcius. The overhead
of raw gas separator is sent to carbon dioxide removal unit.

11
4.2.8) CARBONDIOXIDE REMOVAL
The carbon dioxide removal unit uses two stage aMDEA process licensed BASF. The
process gas enters the bottom of CO2 absorber at 70 degree celcius. It is contacted
counter-currently with the semi-lean aMDEA solution. The gas then flows upward
into top section of CO2 absorber tower where it is contacted with lean aMDEA
solution. The gas is then passed through a water wash section,a demister pad and is
sent to CO2 absorber overhead knockout drum to remove traces of entertained
aMDEA solution.

12
Rich aMDEA solution from the bottom of CO2 absorber is first Passed through a
power recovery hydraulic turbine. The power recovered in the hydraulic turbine is
used to drive one of the semi-lean solution pump. The rich aMDEA solution is then
sent to high pressure flash where most of the dissolved inert are flashed out from
the rich solution.

As the flash gas from the high pressure flash contain a fair amount of the carbon
dioxide .this gas is further scrubbed with the slipstream of lean aMDEA solution in
the high pressure gas scrubber to recover almost all of the carbon dioxide.

The high pressure gas scrubber bottoms are mixed with the high pressure flash
bottom and sent to the CO2 low pressure flash. The low pressure flash operates
about 1.8kg/cm2 .at this low pressure most of the carbon dioxide from the rich
aMDEA solution is flashed. The solution flows down through the packed bed where it
is contacted with rising vapor from CO2 stripper.condensate is separated from the
CO2 low pressure flash overhead knockout drum and pumped by the CO2 low
pressure reflux pump to provide wash water for CO2 absorber. CO2 low pressure
flash and high pressure flash gas scrubber . the makeup water required for the CO2
removal unit is also added to the suction of reflux pump.

Semi lean aMDEA solution is drawn from the bottom of the low pressure flash. Most
of the semi-lean solution is pumped by the pumps to the bottom section of CO2
absorber about 17% of the semi-lean solution is pumped by the semi lean solution
circulating pump heated to about 111 degree celcius in the lean/semi-lean solution
exchanger and then sent to CO2 stripper. LTS effluent gas supplied heat to the CO2
stripper which is used to strip carbon dioxide from the aMDEA solution. The stripped
carbon dioxide flows up to the stripper and is then sent to low pressure flash. Lean
aMDEA solution is drawn from the bottom of CO2 stripper .the lean solution is
cooled by the exchanging heat with the semi-lean solution is then pumped by the
lean solution pump to the top section of CO2 absorber.

The carbon dioxide removal unit is designed with a slightly negative water balance to
maintain the concentration of aMDEA solution in the system , a continuous make-up
of about 220kg/hr of demineralized water is required. This design eliminate the
discharge of any aMDEA solution loss. Given the composition of natural gas , the
steam reforming front end does not produce sufficient amount of carbon dioxide
,when producing syn-gas sufficient for 950 MTPD of ammonia.

13
Hence additional feed gas to be reformed and passed through to meet requirement
of the carbon dioxide.

Will result in the more production of the syn-gas as we required for 950 MTPD of
ammonia surplus syn-gas is produced about 3% of total syn-gas produced, is sent to
fuel system

4.2.9) METHANATION
The vapor CO2 absorber Overheated Knockout Drum is preheated to methanation
reaction temperature .using the methanator effluent in the Feed/Effluent ex-changer
and using condensing high pressure start-up heater. The preheated gas then flows
through the methanator where carbon dioxides converted to methane by reaction
with hydrogen over Ni catalyst .Residual carbon oxides leaving the methanator are
less than 5ppmv(dry basis)

14
 CO2 +4H2 ------------- CH4 + 2H2O

CO + 3H2 -------------- CH4 + H2O

The methanation reactions above are slightly exothermic and could potentially over
heated in methanator. This could occur if an upset in the shift (LTS/HTS) or carbon
dioxide to methanator an automatic shutdown system is provided to prevent
overheating.

4.2.10) DRYING
In prepration for drying the methanator effluent is cooled by heat exchange with
methanator feed ex-changer to 79C and against cooling water in methanator effluent
cooled to 38C the methanator effluent then combines with recycle synthesis loop
purge gasfrom high pressure ammonia scrubber and the mixture is chilled using
ammonia refrigerant in the methanator effluent chiller to about 4C .The chilled gas is
sent to methanator effluent separator where the process condensate is separated
out

The overhead fromMethanator effluent separator is then sent to Molecular sieve

dryers

.Then two dryersthe packed with zeolites based dessicant and operate cyclically
.Each dryer sized to remove traces of ammonia. Residual carbon dioxide and the
water in 24-hours drying cycle

The dryer regeneration facilities are designed for a ammonial 20hrs heating and
cooling cycle to provide a comfortablesafely margin of 4 hours ofstand-by time
.Regeneration and cooling of driers are done using waste gas from the purifier
.During dryer regeneration the waste gas is heated to 265C in the molecular sieve
Regeneration heater by condensing steam from the 63kg/cm2 steam heater

15
4.2.11) CRYOGENIC PURIFICATION
Dried raw synthesis gas is then sent to cryogenic purification section. The gas is
cooled by heat exchange with make-up synthesis gas and with purifier waste gas is
the top section of the purifier Feed/Effluent ex-changer.

The gas then flows through the purifier expander where work is remove to provide
net refrigeration duty required for purifier.

The expander effluent is further cooled and partially condensed in bottom section of
effluent ex-changer and enter the purifier rectifier at 171C .Liquid from the bottom
of rectifier is partially evaporated at reduced pressure in the shell side of purifier
rectifier condenser and provides cooling for condenser and re-flux for the column.the
rectifier contain nitrogen ,methane and some of hydrogen.

The partially evaporated liquid leaving the shell side of purifier rectifier condenser is
reheated and the vaporiseineffluent exchanger and leave as purified waste gas, the
waste gas is used as carrier gas to regenerate the molecular sieve drier and then sent
to fuel system, the makeup syn-gas from the top of purifier rectifier is heated
ineffluent exchanger and send to the synthesis gas compressor at 1.8 degree celcius,
the operation of purifier to maintain and control the exact molar ratio of hydrogen
and nitrogen of 3:1 the other impurities in make-up gas is 32% argon and less then
50ppmv of methane .

4.2.12) SYNGAS COMPRESSION

The process for syn-gas compression and ammonia synthesis section of the plant are
identical, except for new mechanical refrigeration system and purge gas ammonia
recovery system all the existing equipment in the syn-gas compression and ammonia
synthesis sections will be reused.

16
The purified syn-gas is compressed in four stages, steam turbine driven synthesis gas
compressor, recycle gas is added to the syn-gas before the fourth stagesuction , and
the combined flow leaves the compressor at about 197.2kg/cm2.

The syn-gas compressor is driven by turbine that is rotated with the help of 91 ata
steam pressure.

4.2.13) AMMONIA SYNTHESIS

Ammonia is produced in fixed – bed , vertical converter. Effluent in the hot
exchanger. It then flow to the ammonia converter. Ammonia concentration in the
feed to the converter is about 2.7 mole %. Ammonia is synthesized in two adiabatic
beds provided with an inter cooler and after cooloer.

The converter effluent containing about 17.70 mole% ammonia at 726 K. It is cooled
by generating high pressure steam in the syn – loop Waste heat Boiler and by heating
boiler feed water in the converter effluent BFW Preheater. After recovery of heat,
the converter effluent is cooled to 311 K by cooling water in the converter effluent
cooler. The converter effluent is then sent to the cold Ex – changer where it is chilled
by heat exchanger with the recycle gas. The gas is finally chilled to 269 K against the
ammonia refrigerant in the ammonia chiller.

Liquid ammonia is separated out from the converter by the separator while the
vapor is recycled to the last stage of compression by line. A small fraction of the
vapor stream from purged from the synthesis loop is control the inerts (methane or
argon) concentration inlet to the ammonia converter at 3.20 mole% liquid ammonia
is depressurized to about 37.0kg/cm2 in a flash drum. This reduction in pressure
dissolves most of the gas in liquid ammonia. Than this recovery ammonia is sent to
the Horton Sphere as product of capacity 2500m3. The expected purity of the
ammonia is 99.85wt% ammonia. The Horton Sphere is operate about 4.2kg/cm2
pressure and it is used to pump ammonia to Urea Plant at 283 K which passes
through the ex-changer.

17
4.2.14) Water Cooling
The cooling water supply is at 33deg C. The overall mixed return temperature is
limited to 43deg C. The combined surface condenser is in series with ammonia
refrigerant condenser. All other exchanger are in parallel.

18
5) Project
ABSTRACT

This report comprises of study of Ammonia Manufacturing Unit of National

Fertilizers Limited (Nangal Unit). The primary reformer is core of the report
and motive of the report is to balance heat and mass at inlet and outlet of
Primary reformer.

A brief note on Heat Losses, Heat duty of the coils used and reforming process
is also penned for better insight.

19
Material Balance on Primary Reformer
The primary reformer is a gas fired, processing furnace containing radiant and
convection sections. The desulfurized feed is mixed with 406 deg. medium
pressure steam. The steam is added in a ratio of 2.7moles of steam per mole of
organic carbon and 2.98 steam to gas weight ratio.

The desulfurized natural gas flow rate to the radiant section of primary reformer
is 21464 kg/hr.

Feed :

Natural gas = 21464 kg/hr or 1321.9 kmol /hr

Steam = 3445.2 kmol/hr

Carbon: steam (molar ratio) = 1:2.7

CH4 + H2O → CO + 3H2

(1270-x) (3445.2-x) x 3x

C2H6 + 2H2O → 2CO + 5H2

(23.17) (46.34) (46.34) (115.85)

C3H6 + 3H2O → 3CO + 7H2

(1.864) (5.592) (5.592) (13.04)

CO + H2O → CO2 + H2
(51.9+x-y) (3395-x-y) (y) (y)

Mole balance for CH4 :

(1270 - x) / (1450.8 + 3x + y) = 0.299

1.897x + 0.299y = 836.21 ….. 1

Mole balance for CO :

20
(51.9 + x - y)/ (1450.8 + 3x + y)

0.871x – 1.043y = 10.48 …... 2

Solving both equations :

x = 391 moles ; y = 316 moles

Inlet (kmol/hr) Outlet( kmol/hr )

CH4 : 1270.2 879 (29.9%)

CO2 : 0 316(10.74%)

H2 : 25.88 1617.8(55%)

CO : 0 126.9(4.31%)

Steam : 3445.2 2738.2

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Energy Balance on Primary Reformer :
Basically, we provide fuel in the form of natural gas to the burners which
creates a large amount of heat which is utilized in reforming reaction and
is recovered in convection section of primary reformer , and remaining
are the heat losses in the form of radiation losses, insulation losses and
most importantly energy lost in terms of flue gases.

Fuel used for SR reaction

Recovered in conv.sec

Losses

Energy fed in form of fuel :

5.1Primary fuel(NG)
Flow rate = 3135kg/hr

Net calorific value for N.G. = 11000 kcal/kg

Heat generated = 34.49 Gcal/hr

5.2 Secondary fuel composition:

H2(kg/hr) CH4(kg/hr)

HP flash gas fuel 31.54 9.216

Purifier rectifier 131.2992 2058.88

Purge gas 24.22 0.46848

Total 187.06 2068.53

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N.C.V. of H2 =28555 kcal/kg

Heat generated by H2 = N.C.V. of H2 * flow rate = 28555*187.0592 =

5.34 Gcal/hr

Heat generated by CH4 = 24.71 Gcal/hr

Total heat generated by primary and secondary fuel = 34.49+5.34+24.71

= 64.54 Gcal/hr

To calculate the heat of reforming reaction at 768k

CH4 + H2O → CO + H2 …..∆Hf = 206 KJ/mol

Moles of CH4 reacted = 442.9 kmol

∆H1 = (442.9*103*206*103)/4.18

=21.83 Gcal/hr

CO + H2O → CO2 + H2 …..∆Hf = -41 KJ/mol

∆H2 = -2.41 Gcal/hr

We know that:

Heat absorbed during = Heat released by reactant + Heat absorbed to

reaction at 768k to change temp. to 298k bring product to

.
. inlet temp.

+ (Heat added to product to bring them to

. . 768k)

∆H3 = Heat released to bring down the reactants (CH4 and steam) to
298k

= 3445.2*103*38.34(298-768) +1321.9*58.2*(298-768)*103 /4.18

= -20.29 Gcal/h

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∆H4 = Heat absorbed to bring the product to inlet temperature

= 126.9*103*(768-298)*103 + 316*103*50.8*(768-298) +
3*391*29.3*103 *(768-298) + 316*103*29.34*(768-298)

∆H4 = 7.15Gcal/hr

∆H5 = Heat required to raise the temperature from 768k to 994k

= 103 *(994-768)[879*71.6 + 1617*28.96 + 126.9*33.18 +

316*55.176 + 2738*41.184]

∆H5 = 17.12 Gcal/hr

Hence, Heat of reforming reaction can be calculated by summing all

five enthalpies:

∆H = ∑i=1 to 5 ∆Hi = 21.83+(-2.41)+(-20.29)+7.15+17.12

∆H = 23.40 Gcal/hr

5.3 Heat recovered from the convection section

There are six heat coils installed in the convective section of the primary
reformer, which are used to as a tool for exchange of heat from fluid/gas with
coil.

Also there heat duties can be defined as the specific heat absorbed by the stream
during rise of temperature and here no term of latent heat is used in calculating
the heat duty because no phase change is taking place.

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Also the heat generated is not spent as a waste and is used in BFW, DMW,
waste heat re-boiler, and is sent to heat recovery section for maximum
optimality condition and in order to ensure the process is viable.

In total there are six coils which are in order as:-

1. Mixed Feed Coil

2. Hot Process Air Coil
3. Hot HP Steam Superheat Coil
4. Cold HP Steam Superheat Coil
5. Cold Process Air Coil
6. Feed Preheat Coil

Coil -1 : Mixed Feed Coil

Tin = 657K

Tout = 768.6K

Tavg = (Tin + Tout) / 2 = (757 +768.6) / 2 = 712.8K

Cp value for CH4 at Tavg = 3.65 kJ/kg. K

Cp value for C2H6 at Tavg = 3.34 kJ/kg. K

Cp value for H2O at Tavg = 2.10 kJ/kg. K

Mass Flow rate = 85426 kg/hr

Cpmix of feed gas = (m1Cp1 + m2Cp2) /( m1 + m2 )

= 3.645 kJ/kg. K

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Now, as we know that Heat Duty (Q) is mCp∆T.

Q = 85426*2.53*(768.6 – 657 ) = 85426*2.53*111.6

= 24.0245 GJ /hr

= 6.11 Gcal / hr (1 cal = 4.196 J)

Coil-2: Hot Process Air Coil

Tin = 641.1K

Tout = 783K

Mass Flow rate = 74156 kg/hr

Q = 74156*1.98*640.52*28.97 ( R = 1.98 cal/mol.K)

= 2.93 Gcal/hr

Coil -3: Hot HP Steam (Superheat Coil)

Tin = 647.7 K

Tout = 778 K

Mass Flow Rate = 94124 kg/hr

Tavg = (647.7 + 778 ) / 2 = 712.85 K

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Cp for steam at Tavg and Pdesign = 2.77 kJ/kg.K

Q = mCp∆T

Q = 94124*2.77*130.3

= 8.39 Gcal/hr

Coil – 4 : Cold HP Steam (Superheat Coil)

Tin = 586.1 K

Tout = 652.4 K

Mass Flow Rate = 93852 kg/hr

Tavg = (586.1 + 652.4) / 2 = 619.25 K

Cp for steam at Tavg and Pdesign = 2.45 kJ/kg.K

Q = mCp∆T

Q = 93852*4.55*66

= 7.01 Gcal/hr

Coil -5: Cold Process Air Coil

Tin = 450 K

Tout = 641.1 K

Tavg = (Tin + Tout ) / 2 = (450 + 641.1) / 2 = 545.55K

Mass Flow rate = 74156 kg/hr

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Q = m*R [650.1405 + 59.9]

= m*R*[710.04]

Q = 74156*1.98*701.04*28.97 (R = 1.98 cal/mol.K)

= 3.78 Gcal/hr

Coil -6: Feed Preheat Coil

Tin = 393.5 K

Tout = 644.1 K

Mass Flow Rate = 21442 kg/hr

Tavg = (Tin + Tout ) / 2 = (393.5 + 641.1) / 2 = 518.75K

Cp value for CH4 at Tavg = 2.95 kJ/kg. K

Cp value for C2H6 at Tavg = 2.65 kJ/kg. K

Cpmix of feed gas = (m1Cp1 + m2Cp2) /( m1 + m2 )

= (0.9668*2.95 + 0.0331*2.65) /( 0.9668 + 0.0331)

= 2.943 kJ/kg. K

Q = mCp∆T

= 21442*2.943*250.7

= 3.89Gcal/hr

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Hence,

Coil 1 – 6.11 Gcal/hr

Coil 2 – 2.93Gcal/hr

Coil 3 – 8.39 Gcal/hr

Coil 4 – 7.01 Gcal/hr

Coil 5 – 3.78 Gcal/hr

Coil 6 – 3.89 Gcal/hr

Total heat duty of heat coils is 32.11 Gcal/hr.

Heat balance :
Heat generated by fuel=Heat of SMR reaction + Heat recovered in
. convection section
. +Total heat loss

64.54 = 23.40+ 32.11 + losses

Total heat Loss=9.03 Gcal/hr

Heat losses:
In most heat generation equipment, significant sources of heat loss are the
convection and radiation of energy. This heat loss depends on the outside
temperature of the heating equipment and can cause a significant reduction in
process heating efficiency.

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The energy leaving radiant section to convective section for heat recovery is
approximately 8% higher. A reduction of this would mean less fuel needed, but
since the temperature of the flue gases leaving to the atmosphere is similar, it
seems as this heat is needed in the convective section. Finally, when subtract-
ing “heat to tubes" and flue gases" from “fuel", the losses are obtained. By
reducing the losses it should be possible to reduce the fuel consumption. The
reason behind the higher losses is unfortunately unknown.

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6.References
a) Wikipedia
b) Engineerstoolbox.com
c) Tlv.com
d) KBR Module
e) KBR Data of Reformer

31