PROCESS OF AMMONIA PRODUCTION AT NATIONAL FERTILIZERS LIMITED NANGAL UNIT

LALIT PRASAD SR.Manager (Production), AMMONIA

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WHAT IS AMMONIA WHY AMMONIA

TECHNOLOGICAL ROUTES TO MANUFACTURE AMMONIA

FEEDSTOCK OPTIONS

MANUFACTURING AMMONIA

HABER PROCESS

N2 + 3 H2

2 NH3

FEEDSTOCK OPTIONS

TECHNOLOGY SELECTION

NAPHTHA NATURAL GAS/LNG/RLNG

COAL

FUEL OIL/LSHS

TECHNOLOGY ROUTES SMR (STEAM METHANE REFORMING) POX ATR

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ENERGY CONSUMPTION
Feedstock Coal Fuel Oil Naphtha Naphtha Natural Gas Technological Option Gasification Gasification Gasification Steam Reforming Steam Reforming Energy Gcal /MT Ammonia 19-20 11-13 10-11 8-9 6-7.5
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Basic Steps For Ammonia Production

Feedstock Purification Production of Raw/Reformed Gas Purification of Gases Ammonia Synthesis

AMMONIA PLANT
900 MTPD AMMONIA PRODUCTION CAPABILTY (100%) COMBINATION OF BEST TECHNOLOGIES TECHNOLOGY FOR RAW GAS GENERATION: SHELL GASIFICATION-POX PROCESS

LURGI RECTISOL PROCESS FOR GAS PURIFICATION

CRYOPLANTS DESIGNED AIR SEPARATION UNIT AND LIQUID

NITROGEN WASH(LNW)
HTAS DESIGNED BASKET S-200 COMMISSIONED IN THE YEAR 1978
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BASIC REQUIREMENTS
FEEDSTOCK POWER COAL RAW WATER

INFRASTRUCTURAL FACILITIES
MANUFACTURING FACILITIES RELIABLE AND ENERGY EFFICIENT TECHNOLOGY CONTROL SYSTEM
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BLOCK DIAGRAM AMMONIA PRODUCTION FACILITY

IP/BYPRODUCTS OF AMMONIA MANUFACURE

PRODUCT SULPHUR, MTPD LIQUID NITROGEN , Lit/day (approx.) LIQUID OXYGEN,Nm3/day METHANOL, MTPD WASTE METHANOL,MTPD CARBON SLURRY ANHYDROUS AMMONIA GASEOUS CARBON DIOXIDE ,MTPD LIQUID CARBN DIOXIDE,MTPD

PRODUCTION CAPACITY 20 10000 10,000 94 5 -----------------60 24

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STEPS IN AMMONIA PRODUCTION

STEP-1 AIR SEPARATION to produce oxygen & Nitrogen Feedstock Purification No special purification methods used but quality control with respect to metal salts, ash, water content.

STEP-2 Production of Raw/Reformed Gas Gasification of Fuel Oil with limited quantity of oxygen. The Raw Gas comprising of Hydrogen (45.8%) ,Carbon Monoxide (46.8%), Carbon dioxide (5.5 %), Methane (0,5%),Inerts (0.6%)AND Hydrogen Sulfide(0.75% is produced at High Temperature of 1350 deg C in three refractory lined reactors (GASIFIERS). The cooled and Washed Raw Gas is then sent to RECTISOL-I
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AIR SEPARATION UNIT

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SHELL GASIFICATION
GASIFICATION REACTIONS

Cn Hm + n/2 O2------ n CO +m/2 H2

Cn Hm +n H2O -------- n CO + (m/2+n) H2

Cn Hm + (n+m/4) O2------- n CO+ m/2 H2 O

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GASIFICATION PROCESS

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STEP-3: RECTISOL GAS PURIFICATION

The desired gas is Hydrogen for manufacturing Ammonia. RECTISOL process utilizes Methanol as solvent (Physical Solvent). Due to selective absorption capabilities of methanol ,it removes selectively H2S and Carbon Dioxide. At low temperature levels and high pressure firstly H2S is absorbed. Then at high temperature and low pressure gases are flashed thus regenerating methanol. The Flashed H2S is sent to Sulphur Recovery Unit.The Raw gas is now termed as DESUPHURIZED GAS (DSG)

STEP-4: CO SHIFT CONVERSION

The gases mainly unaffected by methanol wash are Carbon Monoxide,CO2 and Hydrogen. As the desired gas is Hydrogen , Firstly CO is Converted into Hydrogen and CO using WATER GAS SHIFT REACTION. The DSG is now termed as CONVERTED GAS (CNG)
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CO SHIFT CONVERSION
CO + H2O = CO2 + H2 + Heat

Iron Based Catalysts are used to reduce CO content of Gas, CO being a poison for synthesis catalyst is removed and equal amount of hydrogen is generated. LEVELS OF CONVERSION HT Shift Converter : Iron Chromium Based Catalysts MT Converters Cu, Cr, Zn Based Catalysts LT Shift Converter - Cu, Zn, Alumina based catalysts

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64 460 29.3 HP STEAM

64 460

43 350 216
214

370
360
348

107 75 RW 43 45
43 30

65 550 419
395

D-1403 173 E-1403 A/B 216 225 388 384 D-1404

72

515
D-1401 46 35 85090 93000 D-1402 E-1401

CONVERTED GAS TO UNIT - 15

167 163 GAS 'C' TO METH. PLANT BFW MAKE UP

DSG FROM UNIT 13

227 227 G-1401 G-1402 201 203

AMMONICAL WATER

529 167

E-1901

E-1405

PRESSURE DROP ACROSS D-1401 1800 mm D-1402 95*0.025 D-1403 85*0.025 D-1404 20*50 UNIT-14

AMMONIA WATER

BOILER FEED WATER FROM UNIT-12

Flow (NM3/hr) Temperature (0C) Pressure (Kg/cm2)

CO-SHIFT CONVERSION SECTION (UNIT-14)

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STEP-5: RECTISOL GAS PURIFICATION (CO2 REMOVAL)

The desired gas is Hydrogen for manufacturing Ammonia. The CNG is now washed again with methanol at temperature of (-) 56 deg C, all CO2 is absorbed in Methanol. At low pressure CO2 is desorbed thus regenerating methanol. The flashed CO2 is sent to UREA Plant and Raw Gas is now Termed as DECARBONATED GAS (DCG).

STEP-6: LIQUID NITROGEN WASH

DCG contains mostly hydrogen, CO, small amount of inert gases and trace impurities like CO2, Methanol etc(in ppm range). These trace impurities are ADSORBED over molecular Sieves and final impurity CO is removed in NWU . The DCG is washed with liquid nitrogen serving two purposes a) Removal of CO b) Addition of Nitrogen The DCG is now termed as PURIFIED GAS.
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GAS 'A' TO METHANOL PLANT

47

34

46.3

35

85098

Ar+O2 = 1.96 % CH4 = 0.17 CO = 47.45 CO2 = 6.09 H2 = 43.57

DESULPHURISED GAS UNIT-14

-29

51. 52

46

93000 85750

E-1301A

50

45

RAW GAS FROM UNIT-11

-37 F-1301 18 115

-31 112

Ar+O2 2= 1.98% CH4 0.0016 CO= 47.2 CO2 = 6.31 H2 = 43.5 H2S = 0.7 G-1345

-26 methanol E-1301B -22 E-1302 Ammonia D-1370

-31 3

PRESSURE DROP ACROSS E-1301 A (Shell Side) 1.92 E-1301 A (Tube Side) D-1370 0.96

-20 112

TO D-1376 TO F-1372 CO2 LOADED METHANOL FROM E-1543 (Tube side)

RECTISOL (DESULPHURISATION) UNIT - 13

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LP N2

OFF GAS TO INCINERATOR IN UNIT 21 E-1373 E-1374

CLAUS GAS TO E-1548

h2s = 50 %

2500

2000
25
43

72

from E-1301B and F-1547

CW RW F-1372 FRESH METHANOL and from F-1547

E-1375

E-1372

-58

-62 132 131 FROM E-1503

-34

20 132 131

93
TO D-1541

-20 112 115 G-1376

E-1376 A~G

H2S LOADED METHANOL FROM D-1370

-43 130 E-1371 E-1331

striping n2 D-1332

D-1376

-18

D-1371

D-1331

G-1373

IMPURE WATER TO DRAIN

FROM E-1542 (D-1541 BOTTOM)

LEAN METHANOL TO E-1541

PRESSURE DROP ACROSS D-1376 UNIT-13

Flow (M3/hr) Flow (NM3/hr) Temperature (0C) Pressure (Kg/cm2)

RECTISOL (DESULPHURISATION) UNIT - 13

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SYN GAS FROM UNIT-16

SYN GAS TO UNIT-18 CONVERTED GAS FROM UNIT -14

CO2 FROM D-1541

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CO2 TO UNIT-22 DCG (GASB) TO METH. PLANT 79905 DECARBONATED GAS TO UNIT-16

F-1503
43

40

88000 -55

46

121000 F-1502 -58 135 -54 120

43

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H2 = 94 % CO = 4% CH4 = 0.55% N2+Ar = 0.66%

CO2 =33.43 % H2 = 62.7 % CO = 3% CH4 AND Ar+N2 = 1%

E-1503 -14 -17

-69 185

-69 220

G-1374

NH3 E-1504

-69 -27 396 -26 -31 -33 E-1543A~D G-1570 METHANOL FROM D-1541 (MIDDLE)

-26

-25

D-1540

NH3
E-1540 A/B

PRESSURE DROP ACROSS D-1540

METHANOL TO D-1541

E-1541 -15

TO D-1370

FROM E-1376 (SHELL)

RECTISOL (DECARBONATION) UNIT - 15

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1200 CLAUS GAS FROM F-1372 E-1548 A/B 25 NITROGEN OFF GAS TO STACK E-1548 C 4 E-1544
1.85

1308

H2S = 50 % CO2 = 43.8% N2+Ar = 2.93% CO = 2 %

36% 56%

CLAUS GAS TO UNIT-21

3238 OFF GAS TO STACK

-40 22500
-48 20217

CO2 TO E-1503

NH3 E-1547 -35 -10

0.68 -59

D-1541

-60
0.65 -59

NH3 LIQ. NH3 FROM E-1547 U/S -58 -71

-69

LIQ. NH3 TO E-1547 D/S 15000

30877 4
1.4

350
1.3 -50

1.85

-48

E-8003

320
8700 8296

40
40

TO G-1570 FROM D-1540

-18 -23

1.35

320 350 CR-1 P-01A/B TO SLOP C.W. TO NEW CO2 COMP.

NH3 TO D-1376 (T)

E-1542

PRESSURE DROP ACROSS D-1540 UNIT-15

RECTISOL (DECARBONATION) UNIT-15

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LIQUID NITROGEN WASH

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STEP-7: MAKE-Up Gas Preparation and Ammonia Synthesis

Nitrogen is now added in PURIFIED GAS so as to make gas fit for Ammonia Synthesis. The PURIFIED GAS is now called as MAKE-UP SYNTHESIS GAS having H2:N2 in Ratio 3:1 In a S-200 series converter at high pressure and Temperature , Ammonia is formed and condensed at low temperatures. The unconverted gases are again recycled back .

STEP-8: AMMONIA STORAGE FACILITIES

The Liquid ammonia is then stored in a storage vessel called HORTON SPHERE . Liquid ammonia is supplied to Urea Plant.

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AMMONIA SYNTHESIS N2 + 3H2 = 2NH3 + Heat

HTAS S-200 CONVERTER DESIGN CAPACITY 925 MTPD CONVENTIONAL IRON BASED HTAS CATALYST

LOOP PRESSURE 190 barg

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S-200 SERIES AMMONIA SYNTHESIS CONVERTER

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TURBO MACHINERY
To compress the gases like Air,Carbon Dioxide, Oxygen ,Nitrogen and Synthesis Gas , High speed centrifugal machines are used to raise pressure matching the process requirement

State of the art Instrumentation is being used to control various operating parameters. Vibro Control/Bently Nevada Machine monitoring systems are used to track the machine performance
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NANGAL UNIT
BACK PRESSURE TURBINES
BFW PUMP 2.5 MW

CONDENSING TURBINES
CO2 COMPRESSOR OXYGEN COMPRESSOR 3.0 MW 6.5 MW

EXTRACTION -CUM -CONDENSING TURBINES AIR COMPRESSOR 15 MW NITROGEN COMPRESSOR 7 MW SYNTHESIS GAS COMPRESSOR 13 MW
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REFRIGERATION UNIT 19 A&B

TYPES OF REFRIGERATION SCHEME

1. COMPRESSION REFRIGENERATION.
2. ABSORPTION REFRIGERATION. ABSORPTION REGRIGENARATION SYSTEM ADOPTED AT NANGAL FOR AMMONIA SYNTHESIS AND RECTISOL UNIT
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PROCESS SCHEME FOR ABSORPTION REFRIGENERATION COMPRISES OF CHILLER, ABSORBER,SOLUTION RECEIVER, SOLUTION PUMP, SOLUTION HEATER, RECTIFICATOR, REBOILER AND AMMONIA RECEIVER.
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INSTRUMENT AIR FACILITY

INSTRUMENT AIR FACILITY COMPRISES OF 1. INSTRUMENT AIR COMPRESSOR 2. AIR DRYER BASED ON SILICA GEL AS DESICANT. 3. INSTRUMENT AIR RECEIVER AND DUST FILTER. 4. DISTRIBUTION NETWORK.
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CARBON DIOXIDE PURIFICATION

1. PURPOSE TO REMOVE METHANOL AND HYDROGEN SULFIDE FROM COMPRESSED CARBON DI OXIDE STREAM TO UREA PLANT. 2. PROCESS SCHEME TWO ADSORBER LOADED WITH MOLECULAR SIEVE (ABOUT SIX TON), ASSOCIATED STEAM HEATER AND COOLER FOR REGENERATION OF MOLECULAR SIEVE.
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BFW PREPARATION
GENERATION OF HIGH PRESSURE STEAM REQUIRES HIGH QUALITY FEED WATER. 1. DMW AS RECEIVED FROM BFW PLANT IS DEAERATED TO REMOVE DISSOLVED GASES. 2. AMMONIA AND HELAMINE ARE DOSED TO MAINTAIN pH AND CONTROL CORROSION & SCALING.
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STEAM NETWORK
DIFFERENT LEVEL OF STEAM USED 1. 91 ATA AND 510o C, 2. 65 ATA AND 460o C 3. 65 ATA SATURATED STEAM 4. 33 ATA AND 380o C 5. 11 ATA AND 300o C 6. 11 ATA AND 180o C 7. 3.5 ATA AND 140o C
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AMMONIA STORAGE AND DISTRIBUTIN FACILITY

PRODUCT AMMONIA IS STORED IN HORTON SPHERE CAPACITY 1500 MT OPERATING PRESSURE 3.35 ATA (G)

DISTRIBUTION NETWORK
1. TO UREA PLANT.
2. TO UNIT GROUP OF PLANTS 3. TO LP AMMONIA STORAGE 4. TO RAIL WAGON AND ROAD TANKER FOR OUTSIDE CUSTOMER 5. INTERNAL CONSUMPTION.
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ON STREAM DAYS
ON STREAM DAYS

360 340 320 300 280

DAYS

260 240 220 200 180 160 140 120

1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 Ammonia Urea 337.20 337.82 320.90 319.80 349.90 340.45 305.83 279.64 324.27 321.59 327.09 320.95 334.56 323.76 340.47 334.08 312.35 310.03 323.45 321.45
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ENERGY PROFILE
ENERGY CONSUMPTION

17 16
ENERGY (MKCal/Te)

15 14 13 12 11 10 9 8
Ammonia Urea

1997-98 14.657 9.935

1998-99 14.731 10.021

1999-00 14.439 9.921

2000-01 14.604 9.965

2001-02 14.648 9.892

2002-03 14.461 9.791

2003-04 14.004 9.639

2004-05 13.693 9.579

2005-06 13.723 9.631

2006-07 13.680 9.563

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AMMONIA + METHANOL PRODUCTION

AMMONIA+METHANOL PRODUCTION 400000 350000 100 120

80 250000 200000 150000 40 100000 20 50000 0 Prod. C.U.% 0 60

1997-98 318656 107.29

1998-99 315407 106.20

1999-00 298273 100.43

2000-01 268548 90.42

2001-02 299783 100.94

2002-03 308962 104.03

2003-04 332263 111.87

2004-05 338354 113.92

2005-06 299770 100.93

2006-07 309844 104.32

CAPACITY UTILISATION (%)

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300000

FEEDSTOCK CHANGEOVER AT NFL NGL

Invitation to Bid (ITB) for proposed Feedstock Changeover from FUEL OIL to RLNG floated on 31.07.07

COMPETING TECHNOLOGIES HTAS (HALDOR TOPSOE) STEAM METHANE REFORMING ROUTE KBR STEAM METHANE REFORMING ROUTE

ALL OF THE AMMONIA PLANT EXCEPT SYNTHESIS SECTION, UTILITIES, AMMONIA STORAGE AND DISTRIBUTION WILL BE NEW BASED ON ONE OF THE ABOVE MENTIONED LATEST TECHNOLOGIES
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THANK YOU

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