Revamping Ammonia Plants to Follow Feedstock Situation and Market Demands

by Peter Vang Christensen Haldor Topse A/S, Lyngby, Denmark

Presented at the FAI symposium on Improving Productivity of Ammonia and Urea Plants April 19-20, 2001 New Delhi, India

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Introduction
The present paper deals with the changeover of feedstock from naphtha to LNG or dual feedstock in ammonia plants. Furthermore the paper will describe various options to be considered in connection with revamping of ammonia plants in general. Finally, the approach applied by Topse when carrying out a revamp study will be described.

Changeover of Feedstock
The changeover of feedstock from naphtha to LNG or a mixture of the two feedstocks in general requires limited changes to the existing process equipment. Typically, the modifications required are limited to upstream the reforming section. In Figure 1 a typical lay-out of the desulphurization and reforming sections of a pure naphthabased plant is illustrated.

Figure 1: Desulphurization and Reforming Section When revamping existing naphtha-based plants to handle LNG as supplementary feedstock, it is normally proposed to mix the two feedstocks upstream of the fired heater and then preheat the mixture to the inlet temperature of the desulphurization unit. The performance of the existing fired heater of course need to be checked at the new operating conditions to ensure that the required duty can be transferred, and that the pressure drop on the process side does not get prohibitive. In case it turns out that the existing heater cannot handle the new operating conditions, it is investigated if the existing fired heater can be modified to meet the new conditions, or if a completely new heater will be required. In

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case a new fired heater is required, it is normally recommended to install a new heater preheating the LNG in parallel with the existing heater preheating the naphtha. The two preheated feed streams are then mixed upstream the desulphurization section. In case LNG completely substitutes naphtha as feed and fuel, the naphtha deaeration (and predesulphurization if present) can be taken out of operation. The existing final desulphurization section will typically be able to handle the sulphur content in the LNG. However, in case the sulphur content in the LNG is on the high side, additional sulphur removal equipment can be installed. With regard to the naphtha fuel system this needs to be checked for operation on LNG. Normally, it will be required to replace the burner nozzles, since the Wobbe number of the fuel is significantly changed. The operation of the prereformer (if present), the primary reformer as well as the flue gas waste heat section need careful checking for the new operating conditions. Typically no modifications to these sections will be required in connection with the conversion of feedstock to LNG. Downstream the reforming section the influence on the operation due to the change in feedstock will be limited. The process section mostly affected is the CO2 removal section. As the carbon content of LNG is lower than that of naphtha, the load on the CO2 removal section will go down for the same production rate of ammonia, and less CO2 will be vented from the CO2 removal section. As can be seen from the above the required changes in connection with the conversion of feedstock from naphtha to LNG are normally rather limited. However, in order to establish the most favorable solution for a specific plant a detailed study will be required.

Topses Experience with Designing for Dual Feedstock Operation

In connection with design of ammonia plants operating on dual feedstocks the following Topse-designed Indian ammonia plants shall be highlighted. TATA, Babrala This ammonia plant designed by Topse was designed for full flexibility in feed and fuel. This means that the plant has been designed to operate on 100 % naphtha, 100% natural gas or any mixture of these. The plant was successfully started up in 1994.

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IFFCO, Aonla II NFL Vijaipur II These two ammonia plants were designed to operate as mixed feed plants, meaning that up to 40% of the feedstock can be natural gas, and the balance feedstock is naphtha. For these plants a mixed feed control strategy was developed by Topse. The fuel for the primary reformer burners is natural gas. The plants were started up in 1996/1997. IFFCO, Kalol Revamp This plant was originally a natural gas-based plant. Due to shortage of gas it was decided to install a naphtha add-on unit based on prereforming to be able to operate the plant as a dual feedstock unit. The add-on unit was started up in 1997. As can be recognised from the above examples Topse is well acquainted with feedstock changeovers, and the experience even covers the ability to design full flexible units like the TATA, Babrala plant.

Revamp Options in General

In the following a few of the revamp options to be considered in connection with revamp of ammonia plants will be highlighted. It is realized that the listed options are a small selection only of the numerous revamp options available with Topse. Considering the current situation in India, focus will be on revamp options resulting in energy savings: Flue Gas Waste Heat Section Steam to Carbon Ratio Secondary Reformer Burner Condensate Stripping with MP Steam S-300 Ammonia Converter

Flue Gas Waste Heat Section One way of improving the energy efficiency of a plant is to decrease the stack temperature to as low a level as possible. In a revamp situation this typically can be accomplished in one of the following ways, provided that the required space is available in the reformer area. Introduction of combustion air preheat Introduction of low pressure steam production Introduction of BFW or DMW preheat

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All these modifications require that a new heat exchanger coil is installed in the flue gas channel just upstream the flue gas fan. Introduction of combustion air preheat requires installation of combustion air blower, air preheater, air ducting and new burners. The flame temperature will increase and therefore the reformer tubes should be checked at the new operating conditions. The energy saving is obtained due to reduced consumption in fuel to the primary reformer. In connection with conversion from naphtha to LNG this revamp option is often advantageous, as modification to the primary reformer burners will be required anyway. Introduction of low pressure steam production or preheating of BFW or DMW is a more simple solution as it will only require installation of a coil connected to the relevant parts of the steam/water system. The energy saving is in low level heat. By reducing the stack temperature by approximately 100C the energy saving will be approximately 0.10 Gcal/MT of NH3. Steam to Carbon (S/C) Ratio Reduction of the S/C ratio will result in energy savings in the form of reduced heat input to the primary reformer and in savings in process steam. Also a lower front-end pressure drop will be obtained, resulting in energy savings in the synthesis gas compressor. The minimum allowable S/C ratio is typically determined by requirements set by the downstream shift section. With todays Cu-promoted high-temperature shift catalysts the S/C ratio can be reduced to approximately 2.8 without any problems. Also the heat requirement of the CO2 removal process can be a hindrance for reducing the S/C ratio. Based on the actual CO2 removal process various possibilities exist to reduce the energy consumption. In this connection the following revamp features should be mentioned: Introduction of solvent flash at regenerator exit Change of packing materials in the towers Change of activator in the existing solution Change to another type of solution (solution swap). This modification often requires some changes to the existing process lay-out as well

The energy savings obtained in connection with improvements in the CO2 removal section will typically be in the range of 0.10-0.35 Gcal/MT of NH3. The energy savings obtained in connection with reducing the S/C ratio from, say 4 to 3, will be approximately 0.20 Gcal/MT of NH3.

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Secondary Reformer Burner Design of the secondary reformer has been improved by introduction of a new Topse designed nozzle burner as shown in Figure 2. This type of burner has proved to be maintenance-free compared to older types of burners, and has added to the plant reliability. Therefore, even though installation of this burner will not directly result in energy savings, it will add to savings in the form of a higher on-stream factor and reduced maintenance cost.

. Figure 2: Nozzle Burner Process Condensate Stripping with MP Steam In case the existing condensate stripping system is based on stripping with LP steam, this system can be improved by the introduction of condensate stripping with MP steam. Process condensate will be stripped by the process steam and no gaseous effluents from the unit will be present. A very pure condensate stream going to the DMW will be the result. Figure 3: Process Condensate Stripping using MP Steam

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A typical energy saving by the introduction of MP condensate stripping will be approximately 0.10 Gcal/MT of NH3. S-300 Ammonia Converter The Topse S-300 converter three bed radial flow converter - being a further development of the S-200 converter is another candidate in a revamp job, whether it is a converter revamp job only or a more general revamp project. Almost ten years ago the first S-300 converter was started-up as a result of an in-situ modification of a MWK three-bed converter. The modification comprised changes from axial flow to radial flow for all three beds and installation of an internal heat exchanger between 2nd and 3rd catalyst bed. Today, a total of 13 S-300 converters are in operation or under construction. As a further development and in particular interest to the existing S-200 converters with a full-open pressure shell is the possibility to install a new S-300 converter basket with interbed heat exchangers between both 1st and 2nd catalyst bed and 2nd and 3rd catalyst bed in the existing pressure shell. Figure 4: S-300 Converter An important advantage with the newest design is that no modifications to piping, valves etc. outside the pressure shell is required. Furthermore, the simplicity in operation of an S-200 converter, which is highly appreciated by the industry, is still maintained with the new S-300 converter.

Execution of a Revamp Project

In the following the Topse approach to a revamp project is described. The first phase will be to carry out a revamp study to establish the most favorable revamp scheme in accordance with the objective of the revamp. Revamp Study Based on the objective of the revamp, which is defined in collaboration with the client, the target is to establish with reasonable accuracy the possible capacity increase and/or energy savings obtainable, and the capital expenditures required for materializing these benefits. In order to have a sound basis for arriving at the most favorable solution, the study work will include the following activities.

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Site visit to the plant by Topse engineers (about one week) for data collection and preliminary identification of revamp possibilities. In order to have the best basis for evaluating any additional capacity of the equipment and identify possible bottlenecks, the data collected should be at the highest obtainable production rate. During this site visit the actual plant operation is discussed with the operating personnel. As they possess key knowledge about the behavior of the specific plant, it is very valuable to have their view on the equipment capabilities and comments on any peculiarities in the plant operation. Based on the data collected during the site visit, a base case reflecting the actual plant operation in the form of flowsheets with consistent heat and mass balances will be established. These flowsheets are discussed thoroughly with the client, as they form the basis for the further revamp study. Based on the operation reflected in the base case the performance of the equipment is evaluated. As an example, the performance of a heat exchanger is determined by a process simulation of the existing exchanger based on the actual geometry of this equipment. The present performance of the exchanger is calculated at the base case operating conditions and used when simulating the performance of the exchanger at the revamp conditions. Based on the equipment evaluations carried out at the base case conditions, the bottlenecks in the various sections of the plant can be identified and the relevant revamp options can be pinpointed. In this phase various options are studied to come up with the best solution in order to arrive at the possible capacity increase and/or energy savings and the related investment. This phase of the study will comprise process engineering of the required modifications to the existing equipment as well as specification of new equipment. Also mechanical engineering will be employed for check of critical items as required. The engineering will be sufficiently detailed for developing a cost estimate based on installed cost for the revamp project. In this phase of the study, the existing plot plan is studied carefully to utilize possible available space for any new equipment foreseen as part of the revamp. The study will also contain a proposed time schedule for implementation of the proposed revamp scheme and emphasis will be put on the detailed logistic arrangements required to interfere as little as possible with the existing operation in order to minimize the required down time. Tie-in philosophy is proposed to make minimum impact on the plant operation, and normally the target is to be able to implement the required modifications during a normal turn around.

When the proposed revamp scheme has been arrived at, this is jointly discussed with the client before the final study report is issued. The study report will typically comprise the following: Description and flowsheets for the base case Description and flowsheets for the revamp case(s) Production and consumption figures for the base case and revamp case(s) List of new equipment and modifications to existing equipment Specification of new equipment and modifications to existing equipment Cost estimate for the revamp case(s) Identification of possible tie-in points Preliminary time schedule

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Revamp Project If the revamp scheme identified and described in the revamp study is attractive to the client, the next phase will often be to implement the revamp scheme in the plant. During this project phase Topse can undertake the complete revamp project on a main contractor basis or, if desired, our involvement can be less comprehensive, e.g. in collaboration with a local contractor or direct involvement of the client.