At
KANPUR FERTILIZERS AND CEMENT LIMITED
on
Ammonia Production
BY
RINKU PRASAD
B.TECH. (CHEMICAL ENGINEERING)
ROLL NO. 1304551024
HBTI, KANPUR
Contents
Company profile
Introduction
Hydro desulphurisation
Secondary reforming
CO Conversion
CO2 Removal
Methanation
Ammonia Synthesis
Company Profile
Process description
3 . Ammonia synthesis
Natural
gas desulphurization
Compression
Primary
steam-natural gas
Catalytic
reforming
Secondary
combustion
2 . Synthesis gas Purification
CO
shift conversion
CO2
removal
Methanation
conversion of
synthesis gas to ammonia
Condensation
ammonia
of
DESULPHERISATION
SHIFT REACTION
COMP HOUSE
REFORMING
SYNTHESIS
CO2 TO UREA
AMM TO UREA
Desulphurization Section
Natural
Gas Feed
380oC
38 Kg/cm2
395oC
Recycle
Hydrogen
Sulphur
Absorber
No. 1
Sulphur
Absorber
No. 2
Hydrogenator
351oC
Hydrogenation
In this NG is brought in contact with Hydrogen at
about 3800C and passing over a cobaltmolybdenum catalyst , the reactive sulphur
compounds are transformed into H2S.
RSH + H2
RH + H2S
Absorption of H2S
Followings the hydrogenation
of sulphur compounds the
formed H2S is absorbed by
the zinc oxide according to
the following reaction :
Reforming Section
CO + 4H - heat
CO + H
CO + HO heat
1.
Primary reforming
2.
Secondary reforming
Primary Reformer
Primary Reformer
3H2 + CO
+ H2O
H2
+ CO2
Primary Reformer
Process Air
Desulphurized Gas
Composition :
Preheater
(Mole %)
Process Steam
(At Inlet of
520 C
Catalyst Tubes)
Ar 0.02
34 - 31 kg/cm2 g
CH4 79.68
Composition
CO 2 ppm of catalyst (% w/w)
1.Nickel Monoxide, NiO (17)
Primary CO2 0.24
Reformer 2.Calcium Oxide, CaO (7)
H2 4.09
3.Potassium
N2 2.54 oxide, K2O (4)
4.Aluminum
C2H6 6.48 Oxide, Al2O3 (Balance)
C3H8 2.63
C4H10 1.88
C6H12 - 0.24
Steam Carbon Mole Ratio=3/1
Secondary
Reformer
785-795oC
Composition:
(Mole %)
(At Outlet of
Catalyst Tubes)
Ar 47 ppm
CH4 12.86
CO 9.5
CO2 10.70
H2 66.20
N2 0.74
Higher HC
Neglegible
Process Gas
Primary Reformer
Composition :
Process Air
Preheater
(Mole %)
Composition:
Desulphurized
Gas
(At Inlet of
(Mole %)
Catalyst
Secondary
Steam Carbon Mole Ratio=3/1
(At Outlet of
Tubes)
Composition
of catalyst (% w/w)
Reformer
Catalyst
Process Ar
Steam
520oC
0.02
1.Nickel Monoxide, NiO (17)
Tubes)
CH4 79.68
Ar 47 ppm
2.Calcium
Oxide, CaO (7)
Primary
CO 2 ppm
34 - 31 kg/cm2 g
CH4 12.86
3.Potassium
CO2 0.24 oxide, K2O (4)
Reformer
CO 9.5
4.Aluminum
Oxide, Al2O3 (Balance)
H2 4.09
CO2 10.70
N2 2.54
H2 66.20
C2H6 6.48
N2 0.74
C3H8 2.63
Higher HC
C4H10 1.88
Neglegible
C6H12 - 0.24
785-795oC
Process Gas
Important Parameter Of
Primary Reformer
*s/c=steam/carbon
Secondary Reforming
Secondary Reformer
550oC
Gas inlet
composition (mole%)
Ar 47 ppm
CH4 12.86
CO 9.5
CO2 10.70
H2 66.20
N2 0.74
791oC
1100-1200oC
30 kg/cm2 g
Catalyst
composition(%mole):
NiO = 8 10%
Al2O3 = 87 90 %
Cao = < 0.05 %
958oC
Gas outlet
composition (mole%)
Ar 0.27
CH4 0.60
CO 13.37
CO2 7.65
H2 55.61
N2 22.47
What Happens in
Secondry Reformer
CO CONVERSION
HT/LT CO Convertors
Composition (mole%)
Composition (mole%) of
of outlet stream of HT
inlet stream of HT CO
CO Converter is:
Converter is:
Ar 0.24, CH4 0.55
Ar 0.27, CH4 0.60,
CO 3.22, CO2 15.94
CO 13.37, CO2 7.65,
H2 59.59, N2 20.48
360oC
H2 55.61, N2 22.47
29.6kg/cm2
Process gas from
205oC
Reformer Section
28.6kg/cm2
HT CO
Convertor
Catalysts
composition
(mole%) which
is available in
pellet form.
Fe2O3 - 85- 95 %
Cr2O3 - 7-9 %
CuO - 1-2%
Al2O3 - 1.0%
432oC
Catalyst consist
the oxides of Cu,
Cr and Al,
Which is most
active in between
170-250oC.
Composition (mole%)
of outlet stream of LT
CO Converter is:
LT COAr 0.24, CH4 0.53
Conver
CO 0.30, CO2 18.32
tor H2 60.73, N2 19.88
Methanator trim
heater
340oC
Waste heat
boiler
205oC 227 C
BFW Preheater 1
o
160oC
BFW Preheater 2
CO2 Removal
Methanation
Methanation
Normally
the
above
reactions
proceed
essentially to completion. Both Methanation
reactions are exothermic, the Methanation of
CO2 causing a temperature rise of 61C for each
volume % in the feed gas, and of CO causing a
temperature rise of approximately 74 C for each
vol. %. If too high concentrations of carbon
oxides are fed to the methanator, excessive
temperatures and possibly runways will occur.
The reactions shown will tend to be reversed if a
high steam concentration is present.
300C
Methanator
Nickel based catalyst
is used here in methanator
which consist around 27%
wt Nickel. (280-420C)
Composition(%mole)
at inlet is:
Ar- 0.29, CH4- 1.08,
H2- 73.95, N2- 24.88
Synthesis gas to loop
Trim
heater
Synthesis Gas
From CO2
Gas/Gas 60C Removal Section
26.8 Kg/cm2
HE
322C
285C
90C
25 Kg/cm2
Composition(%mole)
at inlet is:
Ar- 0.29, CH4- 0.65,
CO2-0.05,CO-0.36,
H2- 74.29,N2- 24.36
Ammonia Synthesis
Composition(mole%) at
Outlet of Ammonia
Converter
Ar- 2.11, CH4- 7.14
H2- 52.84, N2- 17.61
NH3- 20.30
Composition(mole%)
at
Startup
nlet of Ammonia
Heater
Converter
Ar- 1.82,130C
CH4- 6.18,
H2- 65.95, N2- 21.99,2
187Kg/cm
NH3- 4.06
Ammonia
Converter Synthesis
Hot
Heat
Steam
Exchanger
Boiler HE
Makeup Synthesis
Gas
Compressors
10C
178.9Kg/cm2
Composition(mole%) of
Purge Gas of Ammonia
Converter
Ar- 2.49, CH4- 8.38
Purge
H282.48,Gas
N2- 20.82
NH3- 5.82
Composition(mole%)
Ammonia
of Let Down Gas of
Separator
10C
Chiller
Ammonia Converter
Ar- 3.16, CH4- 16.12
H2- 38.06, N2- 15.76
11C NH3- 26.88