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Keyworth Ammonia Project is proposing to construct and operate an ammonia production facility to
manufacture and supply ammonia from natural gas.
The main raw materials of the ammonia product are methane (CH 4), some higher hydrocarbon
molecules and also sulphur content.
Ammonia is produced by a reaction between nitrogen and hydrogen using Haber process. The
nitrogen is obtain from the catalytic steam reforming of the natural gas (CH4)
MANUFACTURING PROCESSES
There are six processes that occur during the production of ammonia:
The first stage of the process is the removal of sulphur compound from the natural gas the feedstock
because sulfur deactivates the Catalyst used in subsequent steps. Sulfur removal requires catalytic
Hydrogenation to convert sulfur compounds in the feedstock to gaseous Hydrogen Sulfide:
There are two different processes that enable us from removing the hydrogen sulphide (H 2S) from
the natural gas feedstock, which are activated carbon and zinc oxide. The gaseous hydrogen sulphide
is then absorbed and removed by passing it through beds of Zinc Oxide where it is converted to solid
Zinc Sulphide:
NB: the Hydrogen Sulphide must be removed before the feed can be used for producing hydrogen;
the sulphur content is reduced to less than 5ppm.
Reforming process
The reformation process is carried out in two stages: primary and secondary reforming
Catalytic Steam Reforming of the sulfur-free feedstock is then used to form hydrogen plus Carbon
Monoxide:
The next step then uses catalytic Shift conversation to convert the carbon monoxide to carbon
dioxide and more hydrogen:
CO + H2O CO2 + H2
In this step, CO2 in the final shift gas is removed. CO2 removal can be done by using 2 methods:
mono-ethanol-amine (C2H4NH2OH) scrubbing and hot potassium scrubbing. Approximately 80
percent of the ammonia plants use mono-ethanol-amine (MEA) to aid in removing CO 2.
Methanation
The final step of producing hydrogen, the use catalytic Methanation to remove any small residual
amounts of carbon monoxide or carbon dioxide as they will act as poison ammonia synthesis:
Exit gas from the Methanation process, which has a 3:1 mole ratio of hydrogen and nitrogen, is then
cooled to 38°C.
Ammonia synthesis
To produce the desired end-product ammonia, the hydrogen is then catalytically reacted with
nitrogen (derived from process air) to form anhydrous liquid ammonia. This step is known as the
ammonia synthesis loop (also referred to as the Haber- Bosch process):
3H2 + N2 → 2NH3