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Modeling the Performance and Emissions of Integrated Gasification Combined Cycle Based Lurgi Ammonia Synthesis System

Modeling the Performance and Emissions of Integrated Gasification Combined Cycle Based Lurgi Ammonia Synthesis System

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03/18/2014

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If there exists appreciable amount of inerts such as argon, helium or methane in

the makeup gas, the purge gas generated from synthesis loop should be removed

continuously, otherwise those inerts will concentrate in the synthesis loop and break the

mass balance. However, “if the inerts concentration in the makeup gas is low enough, i.e.,

under 0.2 vol%, dissolution in the product ammonia suffices to remove the inerts from

the synthesis loop.” (Appl, 1998) Typically, for a Lurig ammonia synthesis system, the

Rectisol process can remove most of the impurities in the syngas to very low

concentration, for example, 0.1 ppm total sulfur, 2ppm CO2, close to zero amount of

moisture, so if further treated in the liquid nitrogen wash process, the high pure make up

gas will make the purge gas recovery unnecessary (Lurgi, 2001a, b).

Several possibilities are available for reducing the losses associated with the

purge gas. The most expensive method consists of feeding the purge gas to a second

synthesis loop at lower operating pressure. Other methods include Hydrogen Recovery by

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Cryogenic Units, Membrane Separation and Pressure Swing Adsorption, Hydrogen

Recovery using Mixed Metal Hydrides, etc.

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3.0DOCUMENTATION OF THE PLANT PERFORMANCE AND EMISSION

MODEL IN ASPEN PLUS OF THE LURGI AMMONIA SYNTHESIS

PROCESS

This chapter presents the performance model of the Lurgi ammonia system. The

performance model, which calculates mass and energy balances for the entire Lurgi

ammonia synthesis system, is implemented in ASPEN PLUS. The ASPEN PLUS model

unit operation blocks, FORTRAN blocks and design specifications are described for each

process area. The convergence sequences for each process area and for the entire model

is explained in details.

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