PROCESS CONTROL:
Computer Control
Stabilizes Ammonia Operations
Computer control of this and similar plants has saved enough money
to pay for the changeover in only six months or less.
S. Weems, Cominco American, Inc., Borger, Texas
D. H. Ball, and D. E. Griffin, Applied Automation, Inc., Bartlesville, Okla.
In December, 1976, the 907 metric ton/day Kellogg ammo-
nia plant operated by Cominco American, Inc., in Borger,
Texas, was switched over to a computer control system.
Prior to that time, the plant, which started up in October,
1968, had been operated by conventional control. This
article discusses the implementation of that system.
Ammonia production at Cominco American is limited in
that only a certain rate of natural gas usage is permited in a
24-hr period. The objective is to produce as much ammonia
as possible from the gas allotment. Increasing the efficiency
of the plant by 1% would give more than 10 ton/day of
additional ammonia without increasing gas costs. Ammonia
prices fluctuate, but at $120/ton ($109/metric ton) each 1%
increase in efficiency returns $l,200/day or $420,000/yr.
.Experience at Cominco American and similar plants has
shown the savings resulting from computer control of an
ammonia plant will pay for the computer in six months or
less.
Many disturbances affect a modern ammonia plant. Feed
gas rate may be changed several times a day to fully utilize
but not exceed an allowable daily quota of gas. Changes in
primary reformer operation affect the methane leakage into
the synthesis loop. These changes in methane leakage will
require changes in purge rate to hold loop pressure or inerts
level at the desired value. However, the change in purge rate
introduces another disturbance in the primary reformer
where the purge is burned as fuel. The extensive heat
exchange incorporated in modern ammonia plants has the
potential of feeding disturbances throughout the entire
plant. Efficiency of the turbines driving the air, make-up
gas and recycle gas compressors shift due to weather and
day-to-night changes.
Even the best of operators, at times, has difficulty in
knowing when and how much correction to apply to
compensate for a change in feed rate or purge rate. This
plant experienced the upsets and disturbances common to
most ammonia plants. Therefore, a computer was installed
to isolate certain disturbances and prevent them from
echoing through the plant. A number of other inputs were
incorporated in the system to provide information for the
operator and management to monitor plant performance.
By stabilizing the operation and holding the plant at
optimum conditions, increased plant efficiency was
0360-7275/79/2416-0064 $01.00 © 1979 AIChE
expected. This increased efficiency was, in fact, obtained.
The analyzers required for control were installed two
months before the arrival of the computer system in order
to gain operating experience. The chromatographs quickly
revealed that the hydrogen-to-nitrogen ratio varied from
2.8 to 3.1, with the optimum being somewhere between 2.8
to 3.0. In addition, the ratio was constantly varying, some-
thing that was not previously suspected. This variation
emphasized the need for computer control.
Performance criteria
To achieve the improvements in efficiency and stability
that were desired from control, the system has to meet
several performance criteria. These include:
1. The system has to operate reliably with little or no
maintenance.
2. The control system has to control automatically over a
wide range of plant throughputs without retuning or revert-
ing to conventional control.
3. The system has to have a simple, easy-to-understand
operator interface to win operator acceptance.
4. The system has to include checks and alarms to assure
that only valid information is used for control.
5. Analyzers used in the system have to operate reliably
and reproducibly with little or no maintenance.
6. It must be possible to perform normal preventive
maintenance on the analyzers without going off control.
Research, simulation, and plant tests have shown that
increased efficiency can be obtained by closely controlling
the steam-to-hydrocarbon ratio to the primary reformer,
the hydrogen-to-nitrogen ratio in the synthesis loop and the
purge rate from the synthesis loop, and the temperature of
the reformer effluent gas. Computer control can achieve
much closer control of these variables.
Hydrogen-to-nitrogen ratio is probably the most difficult
variable to control. This loop is the most important in
stabilizing downstream operation. A hydrogen-to-nitrogen
ratio controller implemented with software uses both
makeup gas composition and synthesis loop composition to
generate an air-to-gas ratio set point. This controller
includes a patented form of dead-time compensation to
offset the process and analyzer lags.(7,2) The algorithm is
not affected by changes in throughput rate. Normally, the
39
 air rate is adjusted to achieve the desired air-to-gas ratio.
This arrangement provides feed-forward compensation for
changes in gas rate.
The hydrogen-to-nitrogen ratio control loop has an alter-
nate mode of operation to handle the situation where the
plant is air limited. When this occurs, the control mode
switches and the gas rate is adjusted to use all the air
available and maintain the desired air-to-gas ratio.
Control of steam-to-hydrocarbon ratio to the primary
reformer is a second important control function. Volumetric
flows are converted to a mass basis. The computer control
system includes checks to assure the steam flow is adequate
to prevent coking of the catalyst in the reformer tubes. The
accurate material balances produced by the computer aided
process engineers at Cominco American in determining the
optimum steam-to-hydrocarbon ratio for this plant. It was
found that the influence of steam on the conversion of
methane is more important than the cost of producing the
steam.
The third important function is the control of purge flow.
One approach is to set the purge flow to maintain a constant
pressure in the synthesis loop. An alternative approach is to
adjust purge flow to maintain a constant level of inerts as
indicated by the analyzer output.
The fourth important loop is control of primary reformer
effluent gas temperature. Controlling this temperature
minimizes downstream disturbances as well as conserving
fuel. As indicated in Figure 1, the purge gas is used as part
of the fuel to the primary reformer. However, the heat value
of the purge is lower than that of the fuel. The computer
calculates composite volumetric heat content for the
composite fuel to the reformer. The computer adjusts fuel
OTHER
PLANT
USES
FUEL TO
BURNERS ®-
PRIMARY REFORMER
FEED
REFORMER SECONDARY
STEAM —US*-
—cSi-
Figure 1. Simplified process schematic, showing location of chromatographs.
40
as necessary to hold total heat flow per hour at a value
needed to maintain primary reformer gas outlet tempera-
ture at its set point. Tube temperatures are checked to
insure that reasonable measurements are being made. A
model then is used to validate the reasonableness of the
effluent temperature measurement. Control is permitted if
the temperatures pass these validation tests.
The operator of an ammonia plant measures his plant
performance in gas consumption per unit weight of ammo-
nia. This and other operational information is summarized
in the charge and yield log, which is important in alerting
plant management to changes that are occurring. A
decrease of 1 % in the plant efficiency indicates a problem
or a significant shift in operation of the plant. High accu-
racy of the calculated yields is obtained by using quality
instrumentation including turbine meter on product ammo-
nia and pressure-temperature-gravity compensation of key
flows. A customized charge and yield log is shown in Table
1.
Key role of analyzers
Reliable and reproducible measurement of stream
compositions is essential to the success of the control
system. The corrective action cannot be correct if the
measurements are wrong. Gas chromatographs were chosen
because they have demonstrated reliability in thousands of
applications where properly installed and maintained.
Two analyzers were installed at the plant, as shown in
Figure 1. One analyzer samples the makeup gas between the
two compression stages. The second samples the gas in the
synthesis loop as it enters the converter. One analyzer could
PURGE
SAS
SYNTHESIS
CONVERTOR
SHIFT
CONVERTER
AND
PURIFI-
CATION
@i SAWPLE POINT FOR
CHAOMAT06RÂPHÏC ÄNALYZIR
have been used to alternately sample these two streams, but
Cominco American chose to install two analyzers for reli-
ability reasons. Either analyzer can take alternate samples
from the two streams should the other analyzer be out of
service.
In defining their requirements, Cominco American
personnel visited eight plants in which process control
computers were installed. Two of these visits were to an
Applied Automation installation at Hoag, Neb. The first
was in the presence of Applied Automation personnel; the
second was made independently. In these and all other
visits, primary attention was focused on the percentage of
time the system operated on closed loop control, the
number of loops on control, and the benefits achieved.
The significant dates in the project are summarized in
Table 2. From receipt of the purchase order to completion
of the project was just under six months. The original
purchase order included control of hydrogen-to-nitrogen
ratio, steam-to-gas ratio, and purge flow rate. The history
and management of this project was reviewed in detail
previously. (3)
By the time the computer arrived at the plant, Cominco
American personnel had completed all field wiring and
plant preparation. Only two days were required to place the

Table 1. Management report.

Charge and Yield Log
(DATE: 7/6/77 TIME: 18:1: 0)

Average Total
Current Daily for
Rate Rate Day
Charges
Primary Reformer:
Feed Gas XXXX MSCFH XXXXX MSCF
Reformer Steam XXX MLBHR XXXX MLB
Fuel Gas XXX MSCFH XXXX MSCF
Total Gas XXXX MSCF .. XX MMSCF
Boiler Feed Water XXX MLBHR XXXX MLB
Steam/Gas Ratio 3.72 3.71.
Secondary Reformer:
Secondary Air 1320 MSCFH 16105 MSCF

Synthesis Converters:
H2/N2 Ratio 2.96 2.96.
Purge to Burners 183 MSCFH 1979 MSCF
Purge Temperature — 12.96°F
Inerts 14.12 13.94...

Compressor Speeds:
101J XXXX RPM
103J XXXX RPM
105J XXXX RPM
Yields
Ammonia Produced. XXX tons
Calculated Data
Production Rate XXXX tons/day
Feed Gas/Ammonia XX MSCF/ton
Total Gas/Ammonia XX MSCF/ton

Chromatograph Analysis Log

(DATE: 7/6/77 TIME: 18: 2: 0)
Chromatograph No. 1

Stream 1 Mol% Stream 2 Mol%

Helium 0. Helium 2.02
Hydrogen 74.03 Hydrogen 63.16
Argon 0.25 Argon 3.67
Nitrogen 25.01 Nitrogen 21.34
Methane 0.69 Methane 8.42
MSCFH (1,000 std cu ft/hr) = 28 mVh MLBHR (1,000 Ib/hr) = 454 kg/h °C = 5/9(°F—32) ton/day = 907 kg/d = 0.907 metric ton/d
MSCF/ton (1,000 std cu ft/ton) = 30.87 mVmetric ton
41
computer and attach the field wiring. After the system was
Started up in a stand-alone mode, customer engineers spent
one week training the operators so that they would be
familiar with the system. Commissioning of the loops
required less than two weeks. The few software and plant
instrumentation problems that appeared were solved on-
site during the two-week start-up period.
The primary reformer control was added a year later. The
customer and supplier jointly developed an approach for
controlling the reformer. In a period of two and one half
months, the application was defined, software written and
checked out, hardware installed and checked, and the
control loops closed and tuned. The necessary plant work
proceeded concurrently.
Project management
Careful project management by both customer and
supplier avoided the delays and cost overruns that have
plagued many computer control projects. Listed below are
actions that materially contribute to the timely implemen-
tation of any computer control system. An important objec-
tive of these actions is to maintain functional lines of
communication between the purchaser and the supplier.
1. The supplier must know what the customer wants,
and the customer must know what he is buying. Much of
the groundwork for the project's success is laid in the
exchange of information leading to a proposal, before the
purchase order is issued.
2. Customer and supplier should each designate one
Individual as project manager.
3. A kick-off meeting should be scheduled early in the
project. This conference between purchaser and supplier
personnel has several objectives:
a. Set up lines of communication between purchaser
and supplier.
b. Review what has been purchased.
c. Make additions and deletions as desired or
required.
d. Discuss schedules (both supplier's and customer's).
e. Be certain both parties know what must be done.
4. The vendor and the supplier must respond promptly
to requests for information.
5. Supplier should keep customer informed on progress
of project.
6. Plant preparation should be completed on schedule.
1. Engineering and operations personnel should be
trained. The objectives of the training depend somewhat on
the orientation of the purchaser. As a minimum, the
customer's engineers must know how to use the system.
Although the supplier may include training at the plant
site, better experience results when the customer engineers
train the supervisors who, in turn, train the operators. This
helps to assure that customer personnel are familiar with
the system, and gives them a better image in the view of the
operators. It also provides an in-plant resource for training
of new operators.
8. Customer should budget an amount for contingen-
cies. Ten percent of the system cost is recommended.
From a financial point of view, the computer control
system has been a success. The analyzers and computer
have been used as a part of a continuing plant improvement
program to identify the best steam-to-gas and hydrogen-
to-nitrogen ratios. This program has resulted in a signifi-
cant increase in ammonia production from the same raw
materials as consumed previously.
The computer system has produced a marked improve-
ment in plant stability. When the final loop was closed (the
primary reformer effluent temperature control), the small
variations that had been present were eliminated. The
hydrogen-to-nitrogen ratio is held within a few hundredths
42
Table 2. Project history.
November, 1975—Proposal and quotation submitted
February 11,1976—First trip to Hoag plant
February 19,1976—Second trip to Hoag plant
March 11,1976—Revised proposal and quotation
June 17,1976—Purchase order for Chromatograph
June 20,1976—Purchase order number for control
system
June 23,1976—Kick-off meeting
July 8,1976—Purchase order received
September 10,1976—Chromatographs delivered
September-November, 1976—Customer engineers
attended training sessions
October, 1976—Plant turnaround
November 17,1976—System shipped on expedited
basis
November 19,1976—Field wiring completed
November 22-24,1976—Stand-alone start-up
November 29-December 3,1976—Operators trained
by customer personnel
December 6-17,1976—Application commissioning
May 12,1977—Purchase order received to add
reformer control
July 27,1977—Reformer control loop closed
of the set point. Primary reformer temperature is held
within ±0.5°C normally, and to ±2.8°C with feed gas
decreases of 0.5 root. Pressure variations in the synthesis
loop have been eliminated, allowing operation at higher
pressure which increased ammonia production. The system
has operated as low as 55% of the normal feed rate without
retuning control loops or reverting to conventional control.
Stabilization of hydrogen-to-nitrogen ratio and loop pres-
sure have made the NH3 converter operate at very stable
bed temperatures, so converter "tuning" by operators is
now viable, further enhancing operations.
The system provides early warning of impending prob-
lems. The rate-of-change alarm on inputs, rather than the
high or low alarms, usually provides the first warning.
These alarms have led to the identification of reformer tube
problems and feed gas problems.
The improvement in stability of process conditions in the
plant will enhance catalyst life and conditions, yielding
improved efficiency and a better on-stream factor for the
plant. This is most important as catalysts damaged or
artificially aged by unstable or erratic plant conditions will
have shorter or less productive life cycles. This can cause a
loss in cash flow ranging from $l,000/day up to an unsche-
duled shutdown at a $100,000/day rate.
A most important aspect of any application is its avail-
ability for use. This system has remained on-line without
problems other than power failure related causes. When
these power dips occur, the computer is restarted immedi-
ately with no ill effects. Operator acceptance has been
excellent since it makes their job easier. They are reluctant
to have the system taken off control.
The analyzers are calibrated once per week. When a
Chromatograph is taken out of service for calibration, the
second Chromatograph becomes the controlling instrument.
The chromatographs have been very reliable, with only one
backflush column having been replaced at this time. #
Literature cited
1. Giles, R. F., and L. D. Gaines, Instrum. Techn., 24 (10) 41 (1977).
2. Ball, D. H., R. W. Rutledge and J. D. Voelkers, U.S. Patent 4,094,959, to
Phillips Petroleum Co. (June 13,1978).
3. Weems, S., D. Ball and W. S. Stewart, Processing, pp. 23-24 (March,
1978).
 DISCUSSION
PHIL RUZISKA, Exxon Chemical: I think you said
that you measure tube metal temperatures and use
those to check that you are ot overheating the fur-
nace. How is that done?
DONALD BALL, Applied Automation, Inc.: It's not
really the tube temperatures themselves. Stan
Weems from Cominco can give you answers for
most of the instrumentation questions about the
plant and the operation.
STAN WEEMS, Cominco: We don't measure the
metal temperatures. We measure effluent.
JOHN LAWRENCE, CF Industries: I've probably
been in the overhead building too long but some of
these things intrigue me. One is, you're controlling 5
psi in the synloop and 1$F. There must be a lot of
good instruments developed lately. My qustion is:
How does the instrument package here compare
with computer costs? I have one other question:
Why do you control the pressure in the synloop
rather than the purge flow? Wouldn't it be better to
control the purge flow, and let the pressure fluctu-
ate? A increased pressure would give you a little
more leeway on reaction rate.
WEEMS: First of all, we have a pressure limit on the
loop, due to piping in vessels. The relief valve limit
determines our settings. We run as close as possible
to this pressure limit. As far as instrumentation lim-
its, we are controlling to the measured values. As to
the accuracy of these values—of course, they are
only as good as thermocouples or the transducers,
and we realize that. But we are measuring, and we
are controlling, to these limits.
BALL: The other thing is that we use a 14-bit A to D
converter in the computer. This allows you to get
down to this resolution and look at temperatures of
one degree and so forth on K-type thermocouples.
LAWRENCE: The last part of my question was the
relative cost to the instrument package aside from
the computer itself. Did you include that in your
numbers?
WEEMS: Yes, our plant originally had electronic
implementation, so the interface instrumentation
cost was really relatively small.
JIM GERDES, Chevron Chemical: Did you consider
looking at the methane leakage, either of the prim-
ary or the secondary as the control point, as
opposed to temperature, and then perhaps going to
high constraint?
BALL: I know that function has been done several
times, but no, we did not do that in this plant. We
worked with the plant to decide what functions they
particularly wanted.
JOHN ARMSTRONG, Chevron Chemical: Could
you elaborate a little bit more on how you decide
what is the proper steam to gas ratio to run?
WEEMS: Originally we thought that probably the
most efficent way to run was to use as little steam as
possible for energy consumption. But we are rate-
limited, and we found through operation, trial and
error more or less, that as you increase the steam to
gas ratio, production goes up, to a point. At some
point there is a balance between production and
fuel costs; we found it by trial and error. We don't
really have any hard rules on that, and we still do this
periodically.
RON MULHOLLAND, El Paso Products Co.: Is the
capital cost of your system that is, the cost of equip-
ment, essentially independent of plant size?
WEEMS: Yes, that's relatively independent of plant
size.
MULHOLLAND: Have you done recent economics
basded on the current price of ammonia? One
hundred and twenty dollars is a little high, right now.
WEEMS: No, I havent't.
CARNELL, Imperial Chemicals Industries: You
mentioned an increase in efficiency of 1%. Was that
what you actually achieved, or did you achieve
more?
WEEMS: More.
CARNELL: Would you care to give a figure?
WEEMS: No.
CARNELL:Second question: Could you tell me what
makes chromatographs you used in the computer
system?
WEEMS: They were Applied Automation's also. We
selected them because we felt they were more
compatible with the computer and because of the
good performance we saw in the chromatographs.
43