Ammonia Plant Description

Presenter: Sohail Raza

Deputy Manager - Ammonia Plant
 Overview

FFC-Goth Machhi

Plant-I Plant-II
Commercial Production June 1982 March 1993

Design Production Capacity

Ammonia (Tons/day) 1220 1100

Urea (Tons/day) 2105 1925
Control System DCS DCS
(Invensys) (Honeywell/
Yokogawa)
 Ammonia & Urea Complex

AMMONIA PLANT
Ref &
CO2
SC Syn
Rem
Loop

CARBON DIOXIDE

AMMONIA
AMMONIA
POWER STORAGE
STEAM TANK
COOLING WATER
DEMIN WATER
INSTT AIR UREA PLANT
BULK
UTILITIES Urea STORAGE
Syn Purif.
Prill

BAGGING
WASTE WATER PLANT
 Process Technology

Ammonia-I
PROCESS LICENSERS
HALDOR TOPSOE
(DENMARK)
 Gas Route

Natural Gas supply

Feed Gas 24 ” Feed Gas 16 ”

MPCL DSP FFC GM

Fuel Gas 20 ” Fuel Gas 14 ”

Distance: 52 Km
 NG Supply Source

Mari
Petroleum
Company
Limited
 Mari Gas Field
Natural Gas Supply
• Mari Gas Production 650 MMSCFD
• Mari Gas Consumers
FFC – Plant-I 100 MMSCFD
FFC – Plant-II 75 MMSCFD
Total FFC – GM 175 MMSCFD
FFC - MM 90 MMSCFD
Total FFC (GM+MM) 265 MMSCFD
Engro Chemicals 175 MMSCFD
Fatima Fertilizer 100 MMSCFD
Guddu Power Station 110 MMSCFD
 NG Compression Station

Deh Shahbaz Pur

 NG Compression Station

Phase-III
 NG Compression Station

Phase - I & II
 FFC–GM NG Receiving Station

Natural Gas As Feed Gas & Fuel Gas

 Natural Gas Composition

Components Composition

Methane 72%

Ethane 0.2%

Carbon Dioxide 9.8%

Nitrogen 18.0%

Sulphur 1-2 mg/Nmc

Process Description
 Process Description
Natural Gas (CH4 N2)
Water (Steam)
From MPCL
Air

H2, H2O,
Shift H2, H2O,
Desulphurization Reforming N2, CO,
N2, CO2
CO2 Conversion

Ammonia H2 H2
N2, Methanation N2,
CO2 Removal
Synthesis
NH3, H2, N2
H2 O

Ammonia
Urea Plant Water
Condensation & H2 Storage CO2 Treatment
Separation N2, Section

NH3
end
 Process Description

Operating Conditions
Adsorbent: ZnO Catalyst: Ni Catalyst: Ni Catalyst: Fe3O4

Desulphurization Steam Reforming Secondary

HT Shift Conversion
Reformer
400 °C 38 kg/cm2 777 °C 33 kg/cm2 360 °C 29 kg/cm2
902 °C 31 kg/cm2

Catalyst: Ni Catalyst: Cu

Methanation CO2 Removal LT Shift Conversion

300 °C 27.5 kg/cm2 72 °C 28 kg/cm2 200 °C 28.5 kg/cm2

Catalyst: Fe
Ammonia Condensation &
Ammonia Synthesis
Compression Separation
550 °C 240 kg/cm2
46 °C 26 kg/cm2 - 6 °C 16 kg/cm2
 Desulphurizer

 Sulphur is a poison to catalyst

used in the process & must be
removed
 This is achieved in zinc oxide
beds at 410 °C & 37 Atm
ZnO + H2S ZnS + H2O
 Sulphur is reduced from 2 ppm
to < 5 ppb
 Primary Reformer
Tubular Reformer [Catalyst (Ni) filled tubes]
Inlet Outlet
CH4 H2
H2 O CO2
N2 CO
C2H6 CH4
H2O
N2

780 °C & 32.5 Atm ∆H = + 206 kJ/Kmol

CH4 + H2O CO + 3H2
Ni
∆H = - 41 kJ/Kmol
CO + H2O CO2 + H2
∆H = + 165 kJ/Kmol
CH4+ 2H2O CO2 + 4H2
A high kinetic rate for methane-steam reforming is favored by high
pressures and high temperatures whereas a good equilibrium position is
favored by low pressure and high temperature.
 Secondary Reformer

 Air is introduced at this stage as source

of N2.
 Combustion takes place in upper
portion while methane reforming takes
place in lower portion
 Combustion reaction increase temp up to
1350 °C
CH4 + 2O2 CO2 + 2H2O

H2 + O 2 2H2O

 Reforming reaction over Nickel catalyst at

1350 - 915 °C & 31 Atm
CH4 + H2O H2 , CO2 , CO

Methane is reduced up to 0.6 – 0.7 %

 Process Description

Steam generation

Waste heat recovery:

Production of high pressure steam at 110 kg/cm2

Primary reformer flue gases temp. reduction from
1050 to 200 °C
 Shift Conversion

 Comprises high/medium and low temperature Converters

 Conversion of CO to CO2 over Iron & copper catalysts.

CO + H2O CO2+H2
(355- 415 / 200 - 220 °C & 30 Atm)
∆H = - 41 kJ/Kmol
CO at exit is reduced up to 0.12 – 0.15 %

The reaction is moderately exothermic and is reversible, hence the higher the
temperature the lower the equilibrium conversion. Pressure has no influence on the
equilibrium position, as equal moles of gases are present on each side of the
equilibrium. Increasing the steam level to the reactor will push the equilibrium
position in the forward direction. Hence excess steam and low temperatures give
maximum equilibrium conversion.
Shift Conversion
High & Low Temp. Shift Converters
 CO2 Removal System

Absorption Column

Stripping column

Circulation pump
 CO2 Removal System

 Potassium carbonate solution is used for CO2 removal.

 Absorption is favored at high pressure and low temp.
K2CO3 + CO2 + H2O 2KHCO3
 CO2 stripping is favored at low pressure & high
temp.
2KHCO3  K2CO3 + CO2 + H2O
 CO2 produced gas is sent to urea plant.
 CO2 slip with process gas is up to 1300 to 1500
PPM.
 Methanator

 CO and CO2 are poisonous for

the ammonia synthesis catalyst.

 CO and CO2 are converted to

methane over Nickel catalyst at 295
°C & 27.5 Atm

CO2 + 4H2 CH4 + 2H2O

∆H = - 165 kJ/Kmol
CO + 3H2 CH4 + H2O
∆H = - 206 kJ/Kmol
 Syn Gas Compressor

 04 – Stage Compressor

 Speed :13,200 rpm

 Press. Increase from

26 to 245 kg/cm2
 Ammonia Synthesis

 Ammonia conversion is achieved at 370 °C - 540 °C &

245 kg/cm2 over Fe catalyst
3H2 + N2 2NH3 +Heat ∆H = - 46.2 kJ/mol
 H2 & N2 ratio is set at 2.7 at Reactor inlet
 Heat recovery
 Ammonia Condensation and separation.

Since there is a large volume decrease associated with the synthesis of

ammonia (4 volumes to 2 volumes), the synthesis reaction is favored
by high pressures.
S-300 Basket

Flow Pattern of
Topsoe S-300
 Plants Comparison

Ammonia-I Ammonia-II Ammonia-III

Primary reformer CH4 (%) 8.2 12 7.3
Steam / carbon ratio 3.7 2.7 3.7
Shift conversion HTS / LTS MTS / LTS HTS / LTS
CO2 removal system Benfield(K2CO3) aMDEA Benfield(K2CO3)

Loop Pressure ( kg/cm2) 244 150 252

Purge rate (NMC/Hr) 6,000 20,000 9000
Purge recovery NH3 H2 & NH3 NH3
THANK YOU