The Uhde Ammonia

Processes
The Uhde process and design for ammonia plants is
based on reliable and proven process steps. The main
features are a top-fired primary reformer with a cold outlet
manifold, a secondary reformer with a circumferential
vortex burner and a magnetite-based three-bed radial heat
exchange synthesis with one or two synthesis converters.
The feedstock (natural gas for example) is desulphurized, mixed with steam and
converted to synthesis gas over nickel catalysts at approximately 40 bar and 800C in
the primary reformer. The Uhde steam reformer is a top-fired reformer which has tubes
made of centrifugally-cast alloy steel and a proprietary cold outlet manifold system to
enhance reliability.

Efficient, reliable, durable

The process gas leaving the primary reformer enters the secondary reformer, where
process air is admitted to the syngas via a special nozzle system that provides a perfect
mixture of air and gas. Subsequent high pressure steam generation and superheating
permit maximum process heat exploitation to achieve optimized energy efficiency. Since
its introduction in 1968, the Uhde secondary reformer has proved to be a reliable item of
equipment with a long service life.

Emission reduction

Carbon monoxide is converted to carbon dioxide in the HT and LT shift over standard
catalysts. Carbon dioxide is removed in a scrubbing unit, which normally uses the
BASF-OASE or the UOP-Benfield process. Remaining carbon oxides are reconverted to
methane by catalytic methanation at trace ppm levels.

The flowsheet diagram of an Uhde ammonia plant shows the conventional sequence of
process steps that form the basis of most present-day ammonia processes. However, a
more detailed scrutiny of the facts and figures shows that what appears to be a
conventional set-up is in fact a most up-to-date ammonia plant concept. The total
consumption figure (feed + fuel + electric power) per metric ton of ammonia produced is
in the range of 6.6 to 7.2 Gcal (27.6 - 30.1 GJ), depending on local conditions (e.g.
cooling water temperature) and project-specific requirements (such as the natural gas
price, etc.).

The following process areas have undergone major modifications in order to achieve
these figures:

the steam reforming section including its waste heat recovery system;

the CO2 removal unit;

the ammonia synthesis unit.