Spare Secondary Reformer at IFFCO Aonla

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Disposal of spare secondary reformer at Aonla Unit

Spare Secondary Reformer At IFFCO Aonla

Old Secondary Reformer of Ammonia plant in IFFCO Aonla-I was replaced with new Secondary Reformer
in April 2004.. IFFCO Aonla intends to dispose off the old Secondary Reformer which is lying as spare in
the plant, to interested parties on as is where is basis. Details of old Secondary Reformer are as given
below:-

The Secondary Reformer forms an integral part of the reforming and synthesis gas generation section of
the Ammonia Plant. Its aim is to reform the unconverted methane coming out of the primary reformer as
well as to introduce the necessary quantity of nitrogen to the process stream. Air is introduced in
secondary reformer with the help of Air Mixer Gun which consists of a central pipe with holes at the top
and an outer ring around the central pipe. The outer ring also has holes to disperse air in combustion
zone. In Secondary Reformer oxygen content in the air is burnt with process gas and the heat of
combustion is utilised for the endothermic methane reforming reaction. Nitrogen present in air is utilised
to make a synthesis gas containing mainly H2 and N2.

The Secondary Reformer operates at 32 kg/cm2g and temperature up to 1200 0C. The normal shell
temperature is about 150 0C with design temperature of 350 0C. The shell of the reformer is made of low
alloy steel SA 204 Gr B (C-1/2 Mo) having thickness of around 80 mm. The Secondary Reformer is lined
from inside with two layers of refractory with total thickness of around 300mm. To warn against any
possible refractory failure and high shell temperature, the shell is coated with Thermo Indicative Paint
which changes colour at different shell temperature.

The Secondary Reformer for IFFCO Aonla-I plant was supplied by M/s Hyundai Heavy Industries, South
Korea in the year 1986 and was in service from July 1988 to March 2004.

In October 2001, gas leakage was observed from one of longitudinal weld joints in the conical portion of
the Secondary Reformer. During inspection cracks were noticed in the longitudinal and circumferential
weld seams also. Plant was shut down immediately and restarted in Jan 2002 after completion of repairs
in Secondary Reformer. The Secondary Reformer remained in service up to March 2004 and its
performance was satisfactory.

The specifications of the old Secondary Reformer are as given below:

Design and operating conditions:

Sl. No. Parameter Unit Value

1 Pressure (operating) Kg/cm2g 32.0

Pressure (design) Kg/cm2g 38.0

2 Temperature (gas inlet) 0C 800

Temperature (air inlet) 0C 550

Temperature (top) 0C 1200

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 Spare Secondary Reformer at IFFCO Aonla

Temperature (bottom) 0C 990

3 Shell operating temperature 0C 160

Shell design temperature 0C 350

4 Shell I.D. mm 4800

Shell thickness mm 80

Height between top and bottom flange mm 12550

Insulated I.D. mm 4200

Top head shell I.D. mm 1650

Open space mm 1100

5 Insulation (total thickness of refractory in the mm 300

main shell)
High alumina castable refractory (Firecrete 95) % 94 (Al2O3)
0.1 (SiO2)
0.21 (Fe2O3)
Insulation castable (Firelite 2600 LI) between % 40-60 (Al2O3)
refractory and shell 30 (SiO2)
0.7 (Fe2O3)

Material of construction:

Shell, heads and skirt : SA-204 Gr-B

External plates and brackets : SA-283
Forged nozzles and nozzle neck : SA-182

Details of Air Mixer Burner:

Air distribution :Through holes

Air inlet pipe material :ASTMA 312 Type 321H and INCOLOY 800
Burner ring material including shroud : INCOLOY 800
Length of mixer : 4630 mm
Length of insulated portion : 1500 mm
Deflector O.D. : 900 mm
Thickness : 10 mm
Guide ring : 1056 mm
Sleeve thickness : 5 mm
Central air pipe dia : 323 mm
Dia of each of Three distributors of air : 168 mm to external air distributor ring
Diameter of external ring : 918 mm
Thickness of air distributor pipe and external ring connecting pipes : 7 mm

Interested parties may contact at following address for further details:

CM(Purchase)
IFFCO Aonla Unit
Bareilly(U.P) - 243 403
Phones : 0581-2404001,2404036

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 Spare Secondary Reformer at IFFCO Aonla

Fax : 0581-2404227,05823-234890
Email : dsrao@iffco.nic.in

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