Advanced Process Control Systems

Improve Ammonia Plant Safety

The application of an MVC has improved overall plant safety and achieved smoother plant
operations. Operators from the plant have accepted the advanced process control system with
enthusiasm while improving their knowledge of operating the plant.

Brent Frahm
Farmland Industries Inc., Beatrice, NE 68310

Robert Lin and William A. Poe

GE Continental Controls, Houston, TX 77042

Introduction tubes.
• Control primary reformer exit temperature to

T
he ammonia plant was built in 1964 with a
capacity of 600 short tons per day (TPD). In
1980, the plant underwent debottlenecking to
increase the production rate to 750 TPD. In 1993, the
plant revamped and improved the operation to a capac-
ity of 850 TPD. In July 1997, the plant management
contacted GE Continental Controls (GE CCI) to study
the possibility of implementing an advanced process
control (APC) system.
The main objective of the multivariable control sys-
tem implementation was to achieve safer and smoother
operations, while achieving the plant economic opti-
mization. To realize this objective, the following oper-
ation considerations must be taken into account:
• Monitor primary reformer tube temperature to
assure there are no "hot spots" among the reforming
achieve stable operations and optimum methane leak-
age.
• Properly control the primary reformer furnace pres-
sure to a certain level (vacuum pressure) to assure that
no flue gases are released to the atmosphere through
the furnace or convection section.
• Stabilize and optimize the H/N ratio at the ammo-
nia converter inlet to improve energy efficiency.
• Tightly control the primary reformer excess oxygen
to save fuel gas firing in the primary reformer.
• Optimize the shift converter temperatures to obtain
maximum CO shift conversions, while avoiding steam
condensation in the shifts units.
• Maximize the methanator exit temperature for bet-
ter heat recovery while preventing carbon oxide leak-
age.

AMMONIA TECHNICAL MANUAL 1 2001

 • Better control the CO2 absorber overhead CO2 com-
position in the CO2 removal unit and optimize the
MDEA circulation rate.
• Monitor the three major compressor speeds, name-
ly, refrigeration compressor, air compressor and syn-
thesis gas compressor, to assure safe operations by
avoiding the compressors over speed limits.
• Control the synloop pressure to achieve smoother
operation.
• Optimize the ammonia converter temperature pro-
file to realize optimum ammonia conversion per syn-
thesis gas pass.
• Optimize the steam system to obtain maximum
power outputs while satisfying process requirements.
• Maximize plant throughput while satisfying all
process and equipment constraints.
• Reduce process alarms through future constraint
violation prediction and automatically taking appropri-
ate action for alarm avoidance.
• Maintain closed-loop supervisory control to reduce
operator set point changes.
Based on each process unit's specific needs, a ten
module MVC system was set up and implemented for
this ammonia plant. The system and the control strate-
gies for each of the ten modules are discussed.
The MVC System
The multivariable control system (MVC) is GE
Continental Control's (GE CCI) patented, online, real-
time, nonlinear multivariable control, and optimization
technology. The technology is a marriage of process
dynamics, thermodynamics, physico-chemical models,
and operating economics that handles complex
processes experiencing wide variability and unsteady-
state operation. It is unique in that it can be run as a
"constraint pushing" multivariable controller or as a
true economic optimization driven multivariable con-
troller. The optimization can take place on a per unit
basis or on multiple units with several controller mod-
ules under the overall optimization strategy.
Because of its predictive and adaptive capabilities,
the system is unique in advanced process control for an
ammonia plant due to the highly interactive nature of
the ammonia plant operation.
The APC system designed for this plant resides with-
AMMONIA TECHNICAL MANUAL
in a personal computer (ALR) containing an operating
system and the MVC control modules (CM). A second
personal computer includes the man-machine interface
with real-time graphics, trending, and data retrieval
capabilities. A plant information (PI) system from OSI
Software Company was used for the real-time data-
base. Pi-Process Book is the graphical interface that
provides real-time graphics and trending. The database
resides within the Pi-Archive software. The Windows-
NT computer is considered the server to the application
specific programs. Data travels back and forth through
TCP/IP communications.
SCI interface (Pl-IN-FR-SCI-NT) provides the com-
munications between the Windows NT System and the
plant's SCI computer. The SCI computer provides the
PI database with real-time measurements, and this
information is relayed to the MVC control modules
designed for specific process units.
The MVC system structure is shown in Figure 1.
MVC Control Strategy
All APC is one control level above the plant basic
regulatory control system. The MVC system controlled
approximately 45 variables throughout most of the
process sections of the ammonia plant.
Two modules were set up for the primary reformer,
namely a primary reformer furnace exit temperature
control module and a primary reformer riser tempera-
ture balance control module.
A secondary reformer module was executed for the
secondary reformer.
A shift/methanator module was applied for the HTS
converter, short shift converter, LTS converter, and
methanator.
For the CO2 removal section, a CO2 removal module
was used.
Four ammonia converter modules were used for the
three ammonia converters, three of them dealt with the
optimization of the temperature profiles of each of the
ammonia converters, while the fourth controlled the
flow optimization to each of the three converters.
An integrated module was designed for the manage-
ment of interactions and constraint control between
modules to control the front-end pressure of the plant.
2001
 Rösemount System 3
Regylatory PHO
& Logic Control
Controller
Figure 1. MVC computer system architecture.
Primary reformer furnace exit temperature control
module
This module controls the primary reformer outlet
temperature by adjusting the fuel gas header pressure,
while honoring reforming tube high temperature limit.
In this module, the variations of the inlet feed-gas flow,
feed-gas BTU, mixed fuel gas BTU, and the mixed
feed-gas inlet temperature to the primary reformer
were active variables for the real time outlet tempera-
ture set points.
Primary reformer riser temperature balance con-
trol module
This module balanced the temperature distribution
among the reformer tubes. In this plant, there are 210
reforming tubes divided into five rows. There are six
rows of burners controlled by MIC valves to supply the
required fuel to the primary reformer. The module min-
imized the temperature differences between the adja-
cent tube rows by adjusting the controller output of the
MIC valves. More weight was given to temperature
differences between the first row and the third row, and
between the first row and the fifth row of the reforming
tubes to prevent temperature drifting.
AMMONIA TECHNICAL MANUAL
Computer Computer
Rant i/o
Secondary reformer module
The secondary reformer module controls the hydro-
gen to nitrogen ratio at the inlet of ammonia converters
by manipulating the process air-flow rate of the sec-
ondary reformer based on the purge gas flow, and inlet
gas flow fluctuations subject to the secondary reformer
maximum outlet temperature constraint. In this mod-
ule, the feed-gas flow, feed-gas BTU, steam-to-gas
ratio, and purge gas flow from the synthesis loop are
considered as disturbance variables.
There are two air compressors in this plant; one is
steam turbine driven and the other is electric motor
driven. The control strategy for these compressor con-
trols is to maximize the speed of the electric motor
driven compressor, while minimizing the speed of the
steam turbine driven compressor subject to the mini-
mum anti-surge requirements.
Shift Module
The shift module was set up to control the CO con-
version in HTS, guard shift converter, and LTS by
adjusting their outlet temperatures through manipulat-
ing their inlet temperatures subject to maximum outlet
temperature constraints.
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 The methanator outlet temperature is also controlled
by this module by manipulating the methanator inlet
temperature.
CO2 removal module
In this module, the absorber overhead CO2 compo-
sition in CÛ2 removal unit is controlled by manipulat-
ing MDEA circulation flow rate subject to the mini-
mum MDEA pump suction pressure constraint. The
fluctuations of feed-gas flow, feed-gas BTU and the
steam-to-gas ratio are taken into account.
Ammonia converter module
There are three ammonia converters in the plant.
Each converter has its own module to control its tem-
perature profile. The individual ammonia converter
module is designed to control the bed outlet tempera-
tures by adjusting the corresponding bed inlet temper-
atures through manipulating the quench flows to the
converter. The feed-gas flow, feed-gas BTU, synthesis
loop H/N ratio, inert composition, and total synthesis
gas flow were used as disturbance variables so as to
reject their effects.
Ammonia flow optimization module
Because of the differences in catalyst age, quench
flow control scheme, and operation conditions among
the three ammonia converters, the ammonia conversion
out of each ammonia converter is different between the
converters. This module is set up to minimize the
ammonia conversion differences between the ammonia
converters by adjusting the main synthesis flow to each
of the three converters subject to the maximum flow
controller output constraints.
The total synthesis gas flow to converters was con-
sidered as disturbance variables.
Integrator module
The main purpose of this module is to control the
front-end pressure of the plant and obtain maximum
throughput, while honoring process or equipment con-
straints.
AMMONIA TECHNICAL MANUAL
Maximum throughput is achieved by maximizing the
feed flow, while honoring the following known con-
straints:
• Maximum feed flow controller output;
• Maximum primary reformer draft pressure;
• Maximum process steam flow to the primary refor-
mer controller output;
• Maximum air compressor speed;
• Maximum refrigeration compressor speed; and
• Maximum air flow to secondary reformer control-
ler output.
If one of the constraints becomes active, the feed
flow will be lowered only enough to satisfy that con-
straint. Thus, the feed flow is always kept at its highest
allowable point.
In this module, the synloop pressure is controlled by
adjusting the purge gas flow, while honoring the maxi-
mum synthesis gas compressor speed and maximum
inert gas composition constraints.
The primary reformer excess O2 is controlled by
adjusting the forced draft fan controller output subject
to the minimum combustion air pressure constraint.
Operator Training
Two operator training sessions have been conducted
with the objective of improving each operator's under-
standing of the operation and the basic functionality of
the advanced process control system. On-site training
was also carried out to help the operators gain hands-
on experiences with this system. Through the training,
the operators have a better knowledge in both process
and process control.
Operation Results
Integrate module
Since the implementation of the MVC system, the
synthesis loop pressure variation from the set point has
been reduced from ±25 psi to ±10 psi.
A higher desired set point has been set by the MVC
system for the inlet gas flow to the primary reformer.
The system drives the inlet gas flow toward its desired
set point as soon as the opportunity exists. By doing
this, more feed gas has been put to the primary
2001
reformer, which results in greater ammonia production
(about 10 tons more ammonia has been produced each
day in this module alone).
Primary reformer furnace temperature control
module
By controlling the mixed fuel gas pressure to the pri-
mary reformer and considering the fluctuation of
mixed fuel gas heating value and the mixed feed inlet
temperature to the primary reformer, the temperature at
the primary reformer outlet is controlled with reduced
variation from ±10°F to ±2°F.
Primary reformer riser temperature balance con-
trol module
Primary reformer riser temperature is the reflection
of the reforming tube temperature. Large temperature
differences in the risers are the result of the arch burn-
er's firing, wind direction, and so on. Using this mod-
ule, the reforming tubes have been operated under
more moderate conditions and the expected lifetime
will be extended. Operating results are shown in Table
1 and Figures 2 and 3.
From Table 1, it is apparent that, although the aver-
age primary reformer riser tube temperature has
remained the same, the average maximum temperature
has dropped about 7°F and the average minimum tem-
perature increased 15°F.
Figures 2 and 3 show that the maximum temperature
between the riser tubes has been significantly reduced,
and the minimum temperature between the rise tubes
has increased drastically because of the MVC system
operation. The temperature differences have been
reduced from ±25°F to current ±5°F. It is estimated that
the reforming tubes lifetime can be lengthened about
10,000 h. Lower temperatures allow lower steam-to-
carbon ratio thus reducing the energy consumption,
while preventing carbon deposition in the reforming
tubes that is a big concern in the primary reformer
operations.

Table 1. Comparison Results of Riser Temperature

Reforming Tube Temperature Pre-MVC Operation MVC in Operation

North South Average North South Average

Side Side Temp. Side Side Temp.
Riser Riser Riser Riser

Row No. 1 1482.9 1472.7 1478.9 1476.1 1462.9 1469.5

Row No. 2 1472.1 1471.7 1471.9 1469.5 1469.5 1469.5

Row No. 3 1459.3 1473.3 1469.5 1467.1 1471.9 1469.5

Row No. 4 1447.8 1472.8 1460.3 1465.1 1473.8 1469.5

Row No. 5 1470.6 1472.9 1471.7 1468.0 1470.9 1469.4

Minimum Temp. 1447.8 1472.7 1460.3 1465.1 1462.9 1469.4

Average Temp. 1466.5 1472.6 1469.6 1469.2 1469.8 1469.5

Maximum Temp. 1482.9 1473.3 1478.9 1476.1 1473.8 1469.5

AMMONIA TECHNICAL MANUAL 2001

 Figure 2. Primary reformer operation results: (1) riser temperature distribution.

15 minute snapshot
10 Days

Figure 3. Primary reformer operation results: (2) riser temperature difference between adjacent rows.

AMMONIA TECHNICAL MANUAL 2001

Secondary reformer module CO2 removal module

The H/N ratio at the ammonia converter inlet has The CO2 concentration at the absorber overhead has
been well controlled at the desired set point by manip- been controlled quite well. The variation of the CO2
ulating the air flow to the secondary reformer. To save
concentration was reduced from 100 ppm to 10 ppm.
energy, the electric motor driven air compressor speed
was maximized, while the steam turbine driven air
Ammonia converter module
compressor speed was minimized.
The operating results are shown in Figure 4. From
The inlet temperature of each catalyst bed in the
this figure, it is apparent that before the MVC was in
ammonia converter was better controlled by manipu-
operation, the operators had difficulty controlling the
lating the quench flow, and the temperature profile
hydrogen to nitrogen. The deviation of the H/N ratio at
inside the ammonia converter was much closer to the
the ammonia converter inlet from its set point was
optimum profile. The variations of the converter out
reduced greatly from ±0.4 to ±0.05.
temperature were reduced from ±1°F to ±2°F. The opti-
mum temperature profile enables more ammonia con-
Shift/methanator module
version per pass of the synthesis gas to the ammonia
converter.
By using the optimization and predictive capabilities
of the system, the CO concentration at the low temper-
Conclusion and Discussion
ature shift outlet (LTS) was reduced. The reduction of
CO composition at the LTS outlet results in less metha- Because of the frequent revamps to the ammonia
nation reaction in the methanator, less hydrogen con- plant, most equipment is operated near its limit.
sumption during methanation and, finally, less purge Different constraints arise in different seasons. With all
flow to maintain the same inert gas composition in the of the key process constraints considered in the control
synthesis loop. modules in the MVC system, all the constraints were

2.7

2.5
15 minute snapshot
10 Days
Figure 4. H/N ratio at ammonia converter inlet.

AMMONIA TECHNICAL MANUAL 2001

handled adequately. Less alarms were generated and
less operator interventions are required during upset
periods. The regulatory controllers were properly tuned
and operated more smoothly and stably.
The operators are better trained to be able to under-
stand the overall process and how the new control solu-
tions maintain smoother plant operation. Areas of con-
cern such as the primary reformer tube temperatures
are managed to avoid "hot spots" on the reformer
tubes, thus reducing the chances of tube rupture.
Primary reformer exit temperature control stabilized
the primary reformer operation and further prevented
overheating of the reformer tubes. The reformer tube
lifetime is projected to increase, while the average tem-
perature is held higher. The methane conversion is also
significantly improved. Predictive control of the H/N
ratio to the ammonia converter stabilizes and optimizes
overall ammonia plant operations.
The MVC system has stabilized the plant operation
QUESTIONS AND ANSWERS
Khalid S. Subhani, Engro Chemical Pakistan Ltd.:
(1) How much variation do you have in feed/fuel gas
composition on a routine basis and how much plant
rate is varied on a daily basis. I believe that "APC"
will not yield a significant benefit on energy consump-
tion/production increase for a plant which does not
have any variation in gas composition and runs flat out
with no rate change (2) What was the total cost of
implementing APC?
AMMONIA TECHNICAL MANUAL
and improved the safety of ammonia operations.
Several problems were incurred during the project.
First, was a lack of time to accomplish satisfactory ana-
lyzer performance for CO2 measurement. This delayed
the implementation of the CO2 module by three
months. Another problem was the need for repairs of
the ammonia converter quench valves. They were stuck
due to infrequent stroking and, as a result, the commis-
sioning of these ammonia converter modules was
delayed about six months. Finally, an upgrade of the
OSI database software was required to solve the day-
light time change, so that MVC would operate with
valid data. Otherwise, it appeared that there was a loss
of one hour's data that forced the system off-line until
the new-time stamped operation data was available.
A benefit analysis was performed to confirm the col-
lected data. At this time, it appears that the potential for
operating the plant with the MVC system will provide
even greater energy savings and ammonia production
increases.
Brent Frahm, Farmland Industries Inc.: (1) About
2% variation in both. The goal of MVC is not only to
minimize effect of variations, it is also to push con-
straints. Often, a plant running very stable may be
away from its maximum capacity. Running closer to
the limiting constraint could result in greater variations
and the operations could respond by running slightly
away from the maximum. (2) The cost is confidential
information. It is typical for MVC projects to have less
than a one year payback.
2001