Ammonia Production Background The proposed Ammonia Plant is based on the Kellogg Brown & Root (KBR) Purifier

ammonia process. The plant is a single continuous train using natural gas as feedstock. The plant has a capacity of 464 tonnes per day (tpd), which is exported to atmospheric ammonia storage at -330C. A description of the ammonia process is provided below with references to Figure 1. Desulphuriser Natural gas feedstock is initially compressed and preheated in the heat recovery section of the primary reformer. The hot gas is passed to the catalytic Desulphuriser Reactor which reduces the sulphur content of the natural gas. Primary and Secondary Reformers Desulphurised natural gas is mixed with process steam, preheated and reacted over a nickel catalyst in the Primary Reformer to convert the methane (CH4) to produce a gas containing hydrogen (H2), carbon dioxide (CO2), carbon monoxide (CO) and methane (CH4). The reactions occurring in the Reformer are shown below: CH4 + H20 CO + H20 CO + 3H2 CO2 + H2 - Heat + Heat

The gas then passes directly to the Secondary Reformer into which preheated excess process air is introduced to complete the reactions. Shift Conversion The gas leaving the Secondary Reformer passes directly to a waste heat recovery boiler. The gas then passes to the High Temperature Shift (HTS) converter then the Low Temperature Shift (LTS) converter in which the carbon monoxide is converted to carbon dioxide and hydrogen as shown below: CO + H20 CO2 + H2 + Heat

Carbon Dioxide Removal Carbon dioxide is removed by a two stage process licensed to BASF. Process condensate is recovered, stripped with medium pressure (MP) steam in the Condensate Stripper for recycle as process steam for the reforming section. Carbon dioxide in the gas stream is then removed in a two step process: an absorption step in amine solution (MDEA) at low temperature and high pressure, and the regeneration of the amine solution at low pressure and high temperature. The carbon dioxide is vented to atmosphere.

Methanation

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In the final stage of synthesis gas purification the concentrations of carbon monoxide and carbon dioxide are reduced to very low levels by catalytic methanation over a nickel based catalyst where CO and CO2 reacted with hydrogen to form methane as shown below: CO + CO2 + 7H2 Drying and Purification In preparation for drying, the methanator effluent is cooled by methanator feed and cooling water then further cooled with ammonia refrigerant. The synthesis gas is then dried in molecular sieve desiccant dryers. The final purification occurs in a cryogenic Purifier. All the methane, excess nitrogen and some argon are removed a rectifier bottoms. Ammonia Synthesis The purified synthesis gas is from the Purifier is compressed in a large centrifugal compressor while combining the un-reacted recycle gas. The compressed gas is heated before passing through a horizontal iron magnetite catalyst, where hydrogen and nitrogen are reacted to form ammonia: 3 H2 + N2 2 NH3 - Heat 2CH4 + 3H2O + Heat

The converter effluent is cooled by generating high pressure steam and finally in the Unitized chiller. The liquid ammonia is exported to the atmospheric storage at - 330C.

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COOLING

EXCESS AIR HTS AIR COMPRESSOR HEAT RECOVER Y

TO PROCESS STEAM CONDENSATE STRIPPER

NG FEED FEED GAS COMPRESSOR SULFUR REMOVAL HEAT RECOVERY SECONDARY REFORMER LTS

PRIMARY REFORMER

HEAT RECOVERY HEAT RECOVERY

MP STEAM

PROCESS STEAM

TO BFW SYSTEM

METHANATOR SYNTHESIS GAS COMPRESSOR

REFRIGERATION COMPRESSOR

CO2 CO2 STRIPPER DRYER WASTE GAS TO FUEL HEAT RECOVERY

UNITIZED CHILLER CONDENSER AMMONIA PRODUC T

CO2 ABSORBE R HORIZONTAL MAGNETITE CONVERTER EXPANDER FEED/EFFLUENT EXCHANGER

RECTIFIER COLUMN

Purifier
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Figure 1. Ammonia Process

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Nitric Acid Production The proposed Nitric Acid Plant is based on the Weatherly nitric acid process. The plant is a single continuous train using ammonia as feedstock. The plant has a capacity of 764 tonnes per day (tpd) of 60% nitric acid (on 100% basis). A description of the nitric acid process is provided below with references to Figure 2. Feed Preparation The ammonia feedstock can be sourced as a liquid from ammonia storage at - 330C or directly from the ammonia plant as a vapour. Liquid ammonia is vaporised using steam and superheated to prevent any liquid carryover. The ammonia vapour is fed to a mixer where it is combined with preheated air in a ratio of 10.2 : 1 ammonia : air. Ammonia Converter The ammonia-air mixture is reacted on a platninum/rhodium alloy catalayst in an Ammonia Converter. Nitric oxide (NO) and water are formed in this process according to the desired reaction: 4NH3 + 5O2 4NO + 6H2O + Heat

Simultaneously, unwanted by-products of nitrous oxide (N2O), nitrogen and water are also formed in small quantities. 4NH3 + 3O2 4NH3 + 4O2 2N2 + 6H2O + Heat 2N2O + 6H2O + Heat

A nitrous oxide abatement catalyst in the converter is used to reduce the levels of nitrous oxide and greenhouse emissions in the tail gas vent. 2N2O 2N2 + O2

The hot reaction gases are then cooled by passing through a series of heat exchangers including the Expander Gas Heater, Waste Heat Boiler, Steam Superheater, Air Heater and Condenser. The nitric oxide (NO) in the hot reaction gases is then oxidised to nitrogen dioxide (NO2) as the gases are cooled: 2NO + O2 Absorption Column The resulting gas/liquid mixture from the condenser is a weak nitric acid and NOx gas is fed to the Absorber. Process water is fed to the top of the column. The non-dissolved nitrogen oxide gases (NOx) are absorbed into the weak acid to form nitric acid at a concentration of approximately 60% w/w. 3NO2 + H2O 2HNO3 + NO + Heat 2NO2

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Cooling water coils provide cooling on the absorber trays. The nitric acid produced in the absorber conatins dissolved nitrogen oxides which are physicall stripped off and returned to the absorber using bleaching air. The acid is pumped from the bottom of the Absorber to the nitric acid storage tank. Tail Gas The heated tail gas is released to the atmosphere through a gas turbine for energy recovery. The NOx concentration in the tail gas is reduced using selective catalytic reduction (SCR) in the NOx abator.

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EXHAUST STACK TO ABATOR TAIL GAS BLOWER AIR

BFW

BFW

ECONOMISER AIR/TAIL GAS INTERCHANGER NOx ABATOR

STEAM

COND

STARTUP HEATER

STEAM TURBINE

COMPRESSOR

EXPANDER CWR

CONVERTER STEAM

PLATINUM FILTER ELEMENT

DISCHARGE AIR FILTER CW

AIR HEATER

COOLER CONDENSER

ABSORBER

EXPANDER GAS HEATER AUXILLIARY AMMONIA VAPORISER SUPERHEATER AMMONIA VAPORISER WASTE HEAT BOILER STEAM CWR CW STEAM DRUM

STEAM
AMMONIA VAPOUR

STEAM
BFW COND STEAM SUPERHEATER FROM ECONOMISER OUTLET ABATOR TAIL GAS BLOWER SUPERHEATED STEAM TAIL GAS HEATER/ PLATINUM FILTER SHELL

LIQUID AMMONIA

WEAK ACID PUMPS

60% NITRIC ACID

PROCESS CONDENSATE

Figure 2. Nitric Acid Production

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Ammonium Nitrate Production The proposed Ammonium Nitrate Plant is based on the CIFe ammonium nitrate process. The plant is a single continuous train using ammonia and nitric acid as feedstocks. The plant has a capacity of 1,000 tonnes per day (tpd) of 84% ammonium nitrate solution (on 100% basis) and prill. A description of the ammonium nitrate process is provided below with references to Figure 3. Neutralisation Liquid ammonia is pumped from the ammonia storage tank where it is vaporised in the Ammonia Vessel and then superheated to remove any liquid droplets before being fed into the Neutraliser. In the Neutraliser ammonia and nitric acid are reacted together to form AN solution. HNO3 + NH3 NH4NO3 + Heat

The exothermic reaction provides sufficient energy to produce process steam. Evaporation The AN solution flows under pressure to the Flash Drum in the top section of the Evaporator where the solution is concentrated to 85%. The 85% solution is heated in the falling film Evaporator using process steam and further concentrates the solution under vacuum to 97%. The solution is transferred to the remelt tank. The solution is combined with condensate and sent to storage as an 85% solution and also pumped to the prilling tower head tank. Prilling and Drying Prilling is the formation of round solid porous spheres by allowing molten droplets to fall through air. In the Head Tank an additive is added to the AN solution to assist crystallisation. Liquid AN is passed through spray nozzles with suitable sized holes through which the solution flows. The counter current flow of air up through the prilling tower cools and solidifies the prills during their fall. The prills are then dried in a series of driers, screened and cooled in the Fluidised Bed Cooler using air that has been chilled by the incoming liquid ammonia. The prills are then coated with an anti-caking additive and transferred by conveyors to a bulk store.

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Figure 3. Ammonium nitrate process

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Ammonium Nitrate Emulsion Manufacture The proposed Ammonium Nitrate Emulsion (ANE) Plant is based on the Dyno Nobel process. The plant is a single train using ammonium nitrate solution and fuel blend as feed stocks. The batch plant has a capacity of 300 tonnes per day (tpd) of emulsion. A number of different grades of emulsion are manufactured. A description of the ammonium nitrate process is provided below with references to Figure 4. Oxidiser Solution Preparation Ammonium nitrate solution is transferred batch wise from the ANSol storage tank to the Oxidiser Tank. Depending on the grade of emulsion to be manufactured, the concentration and pH of the solution is adjusted and other chemicals added. Fuel Blend Storage Fuel blend is a mixture of diesel, mineral oils and emulsifiers. Fuel blend is supplied in bulk tankers and transferred into storage tanks. ANE Manufacture and Storage ANE is manufactured by blending oxidiser solution and fuel blend together in a mixer then pumping and cooling the product during transfer to bulk ANE storage tanks. ANE is distributed to customer sites in bulk tankers.

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Figure 4. Ammonium nitrate emulsion

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