N 2 + 3 H2

2NH3
EFFECTS OF-A.PRESSURE
B.TEMPERATURE
C.CATALYST
D.INERTS
E.GAS COMPOSITION
F.CIRCULATION RATE

H500= -26kcal

Temkin &Pyzhe
w = k2 { kp pN2(pH23 / pNH32)a - (pNH32 / pH23)1-a}
w = rate of reaction
kp=equilibrium constant for ammonia reaction.

K2=k2(0)exp-{ Ek2/R( 1/T - 1/T0)}

a has value between 0 & +1.

Addition of first H2molecule to

the adsorbed nitrogen
Temkin ,Morozov & Shapatina(1963)
W = k*pN21-a{1- pNH32 / KppN2pH23 }
{L/pH2 +1/kp. pNH32/ pN2pH23}{1+ l/pH2}1-a

 Since the reaction is accompanied by

decrease in volume ,so the equilibrium conc
Of ammonia will be favored by high
pressure.
Designed for maximum pressure of 155ksc.

 Since the reaction is exothermic(about 750

kcal/kg of ammonia), equilibrium conc. is
favored by low temp.
However , reaction velocity is very much
enhanced at high temp. operation.
Reaction temp. in the catalyst bed is 360 to
520 0C.

TYPE

KM1

VOLUME

26.9

WEIGHT

59720

COMPOSITION

KM1R
68.4

m3

194940
Fe3O4,oxides of
Ca,Al and K

kg

 Magnetite has a spinel structure, consisting of cubic

packing oxygen ions ,in the interstices of which Fe 2+
and Fe3+ ions are distributed. During reduction all
the oxygen is removed, but no shrinkage occurs.
Catalyst is activated by reducing the iron oxide
surface layer to free iron.This reduction is normally
carried out with circulating syn gas.
Cat. is stable in air below 1000C . Above 100 C it
will react with air and spontaneously heat up.

 Main component has remained iron since the catalyst was first
introduced in1914 by BASF in Germany.(osmium & uranium
have been tried).
Reaction does not take in absence of catalyst because of high
stability of the N2 molecule.
The catalyst function by forming a nitrogen compound on the
catalyst surface which is hydrogenated to ammonia.
Iron chemisorbs nitrogen rapidly, and it is this adsorption which
is generally considered to be the step which controls the rate of
overall synthesis process.

 In the manufacture of catalyst ,some of the alumina and

magnesia promoters dissolve in the magnetite as they
have similar ionic dimensions.
During reduction, the dissolved Al2O3 & MgO comes
out of solution and separates in the pores between the
iron crystallites , hindering their further growth during
the reduction and in subsequent use.
Thus Al2O3 assist in both the formation and
preservation of small iron crystals of high surface area.

 Potash
It increases the intrinsic activity of the iron surface
,but also tends to decrease the iron surface area.
Calcium oxide
it enhances the action of Al2O3 in stabilizing the iron
surface area and preventing sintering.
It also make the catalyst more resistant to poisoning
by sulphur and chlorine.

inlet
H2
N2
NH3
CH4
Ar

outlet

%
Kmol/hr %
Kmol/hr
64.0618 16103.26 51.5264 11303.47
23.6478 5944.36 19.8039 4344.43
3.3805
849.75
18.46 4049.61
6.8845 1730.55
7.8887 1730.55
2.0255
509.16
2.321
509.16
25137.08
21937.22

E-501
E-502
E-503
E-504
E-505
E-506
E-507
E-508

Duty(Gcal/hr)
18.557
11.795
31.459
10.769
6.8945
5.7425
3.9061
5.0359

 Pressure shell
type
I.D.
H2 partial pressure
shell thickness

S-200
2700mm
102ksc
117 mm

Rel
ativ
e

n
e
v
i
t
ela

p re
ssu
r

ed

0
1.5-3

3-6

ry
a
s
ces

6-10

ro p

per

st
y
l
a
cat

un i
t be

um
l
o
v

dh

8-12

eig

ht

1st bed

2nd bed

Diameter

2334/1050

2400/650

Total height

7925

16390

Effective
7015
height
Total volume 26.9m3

15250

Effective
volume

63.7m3

23.8m3

68.4m3

type
1-1 disc and doughnut
no.of tube
667
dimensions of tubes 3/4 BWG 18
effective length
6780mm
baffle distance
565mm
shell length
5765mm
shell I.d.
825mm
disc dimension
569mm
doughnut dimension 823/573mm
material of tubes
inconel600

 OXYGEN COMPOUNDS
SULPHUR
CHLORINE

PPM O EQV. = 2*ppm O2 + ppm H2O +

ppm CO +2*ppm CO2
The rate of sintering increases in presence of
oxygen compound particularly H2O .
SOURCE--poor performance of methanator
-poor performance of secondary ammonia separator
Chlorine-loss of K due to formation of KCL

Effect is mainly irreversible

primarily inner layer of the catalyst is affected.
SOURCE
make up gas
lubricating oil leaking from syn gas compressor

3 bed
2 bed

N
H3
%

TEMP.

 reduced operating
pressure.
reduced circulation flow
rate & pressure drop.
reduced refrigeration
load.
increased heat recovery
from the synthesis loop.

Mechanical characteristics

Multi layer shell.

3layers
inner layer A387 Gr 11 30m thick.(A.S.)
Outer layer A533 Gr B 32mmX2 layers.
(C.S.)
Total thickness 94 mm.
Design Pressure 152.1 KSC

Mechanical characteristics
Vendor L & T.
Other Features being same as of Now.