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PRODUCTION PROCESS

IN
AMMONIA PLANT
PT PUSRI PALEMBANG

PUSRIS PRODUCTION FACILITY

Ammonia & Urea Plants


Life time

: More than 30 Yrs

Urea Plant

: 2.090.000 ton

UREA STORAGE
Amount : 4 Unit
Capacity : 85.000 TON

Amonia Plant: 1.324.000 Ton


Gas consumption

Plant

: 225 MMSCFD

Ammonia

Urea

P-1B (1993)

1.350 TPD

1725 TPD

P-II (1972)

726 TPD

1725 TPD

P-III (1977)

1.100 TPD

1725 TPD

P-IV (1978)

1.100 TPD

1725 TPD

4.276 TPD

6.900 TPD

TOTAL

AMMONIA STORAGE
Amount : 4 Unit
Capacity : 3 x @5000 MT
1 x @10000 MT

AMMONIA SHIP
Amount : 1 Unit
Capacity : 5.700 Ton

UREA SHIP
Amount
Capacity

: 8 Unit
: 7 x 8.500 Ton
1 x 11.000 Ton
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PRODUCTION PROCESS

Natural gas
Air

NH3
CO2

Ammonia Plant

UREA

Urea Plant

Electricity
Water
Steam
Instr.Air

Electricity
Water
Steam
Instr.Air

Utility Plant

Natural gas
Air
River water
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PRODUCTION PROCESS | Ammonia


Steam
Treated
natural gas

Natural gas
CxHy
CO2
H2S

H2O

Air

N2
O2

Steam
Syn.gas

FEED
TREATING

REFORMING

Hot Ammonia
REFRIGERATION

Cold Ammonia

LP Purge Gas

Tail Gas

PGRU

H2
N2
NH3 (g)

NH3 SYNTHESIS

HP Purge Gas

NH3 Recovery
Hydrogen (H2)

H2
N2
CH4
CO, CO2

H2
N2

WHB

BFW

Syn.Gas
Purification

CO2 (98%min.)
CO2 to Urea Plant

PRODUCTION PROCESS | Ammonia

1. FEED TREATING

Remove solid particle, heavy hydrocarbon and sulphur


from natural gas.
Feed preparation for Reforming section.

FILTRATION :
Clean up natural gas from solid particle
DESULPHURISATION Unit :
Remove Hydrogen Sulfide (H2S) by ZnO Adsorben.
ZnO + H2S ZnS + H2O + Q
DEHYDRATION UNIT :
Absorb water (H2O) in the body of natural gas by
Triethylene Glycol.
CO2 REMOVAL :
Absorb CO2 from natural gas body in the Absorber and
stripped it out in the CO2 Stripper with Benfield solution.
K2CO3 + H2O + CO2 2 KHCO3
HYDRO DESULPHURISATION:
React organic sulphur and hydrogen by CoMo Catalyst
and Adsorb H2S by ZnO.
RSR+2H2 2 RH+H2S (@ CoMo)
H2S+ZnO ZnS+H2O (@ adsorben ZnO)
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PRODUCTION PROCESS | Ammonia

2. REFORMING

Consists of Primary Reformer & Secondary Reformer


Produce synthesis gas : H2 & N2.
CH4 + H2O CO +3 H2 -49.3 kcal/gmol CH4
CO + H2O CO2 + H2
-9.8 kcal/gmol CO
Form CO and CO2 as side product.
The highest operating temperature in the plant

PRIMARY REFORMER :
Tubular fired reactor with Nickel catalyst
SECONDARY REFORMER :
Initially natural gas is mixed with air with the purpose to :
introduce proper amount of Nitrogen into system and
provide heat required for additional reforming.
2ND Reformer is equipped with combustion zone at the top
of reactor where combustion is occured.
2H2 + O2 2H2O

+ 115.6 kcal/gmol H2

CH4 + 2O2 CO2 + 2H2O + 173.9 kcal/gmol CH4


2CO + 2O2 CO2 + 2H2O

+ 135.3 kcal/gmol CO
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PRODUCTION PROCESS | Ammonia

3. SYN. GAS PURIFICATION

Purify syn.gas from CO and CO2


Consists of HT and LT Shift Converter, CO2 AbsorberStripper, and Methanator.
Separate CO2 and deliver it to as a feed of urea plant.

HT & LT SHIFT CONVERTER:


use iron (HTSC) and Cu (LTSC) based catalyst:
+ 9.8 kcal/gmol
CO + H2O <===> CO2 + H2
350 500 oC in the HTSC and 190 270 oC in the LTSC.
CO2 ABSORBER - STRIPPER:
Use benfield solution as absorbent.
Vanadium (V2O5) is added for anti corrosion, UCON for foam
inhibittor.
METHANATOR:
Nickel catalyst
Reconvert CO and CO2 under the reaction as follows:
+49.3 kcal/gmol CO
CO + 3H2 <===> CH4 + H2O
+39.5 kcal/gmol CO2
CO2 + 4H2 <===> CH4 + 2H2O
o
Operation range temp. : 260 500 C.

PRODUCTION PROCESS | Ammonia

4. NH3 SYNTHESIS

Produce NH3 under the reaction as follows:


N2 + 3H2 <===> 2NH3
-45.9 kJ/gmol NH3

Ammonia in the vapor state is condensed at -25 oC and


separated from syn.gas in the KO drum.
inert gas (CH4, Ar, still contain H2, N2, NH3) is purged to
PGRU.

NH3 CONVERTER:
Vertical or horizontal type reactor with Fe promoted catalyst
284 500 oC under pressure 140 165 kg/cm2.

PRODUCTION PROCESS | Ammonia

5. PGRU

Recover hydrogen and ammonia from purge gas.


Consists of NH3 Absorber-Stripper and Membran
Separator

NH3 ABSORBER - STRIPPER:


Absorb and strip out NH3 from purge gas.
Deliver NH3 back to the plant
SEPARATOR:
Semipermeable membrane
Separate hydrogen from gas
Deliver H2 back to the plant
Tail gas as side product is used for fuel into fuel system.

CLOSING STATEMENT

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