REPORT ON INTERNSHIP IN AMMONIA PLANT AT NFL PANIPAT

SUBMITTED BYNEHA MALIK 1209535

ACKNOWLEDGEMENT
I am glad to inform that I have been provided with a golden oppurtunity to get my practical training in National Fertilizers Limited, Panipat, Haryana and I express my deep sense of indebtness to Dr. Bodhraj (Head of chemical department, JMIT, RADAUR (Yamunanagar)), training and placement cell and to all officers who made me to get imparted with valuable knowledge during the training period from 08 july 2011 to 23 august 2011. I am very thankful to P.D.Batra ( manager- production of ammonia plant) D.P.Kohli(Manager-production of ammonia plant) and Ashok bansal (Senior manager- production of ammonia plant), D.C.Naik (Chief manager- production of ammonia plant) and to all officers of ammonia plant who helped me directly and indirectly during my training at NFL, Panipat. Thanking you all, Yours faithfully Neha malik Roll no- 1209535 Chemical engg. Department, JMIT, radaur (yamunanagar)

PREFACE
The object of industrial training in B.Tech course imparted to students is to provide them an insight into the methods both culture and the ground realities of chemical industry.i undertook my training at the NATIONAL FERTILIZERS LIMITED (NFL) PANIPAT from 08 july, 2011 to 23 aug. 2011 for the period of six weeks. I was alloted AMMONIA PLANT. I have tried to grasp the basics of various processes involved in the plant. This report is the reflection of what I have assimilated during the training period at NFL, PANIPAT. I have also discussed about all the processes, their basic principles, their working and about the safety aspects in the plant. I hope that my experience at NFL will not only help me in future as a chemical engineer but also in my current studies. NEHA MALIK JMIT, RADAUR

NFL- A PROFILE
National fertilizers limited (NFL) is a fully owned government of India undertaking and was established on 23rd August, 1974 to setup two fuel oil based plants at Bhatinda (Punjab) and Panipat (Haryana). NFL is a multi unit and multi product company and is one of the Indias largest producers of nitrogenous fertilizer with a market share of 15%. Both of them were commissioned in 1979. the Nangal fertilizer plant of fertilizer corporation of India (FCI) was established in 1978 on the recognisation of FCI and NFL group of companies. Later, NFL executed the countrys first inland gas based plant at vijaipur (MP) on HBJ gas pipeline. Vijaipur plant had gone in commercial production in july, 1988. subsequently, expansion was undertaken in 1997 for doubling the capacity of vijaipur unit. NFL is a mini ratna category-1 company and has distinction of being profitable public sector undertaking. This company is now operating three fuel oil based plants located at nangal, bhatinda, panipat and gas based plant at vijaipur.

PLANT CAPACITY
LOCATION AMMONIA (TDP) UREA (TDP)

Nangal Bhatinda Panipat Vijaipur

900 900 900 2700

1000 1550 1550 4800

The company thus occupies the position of largest producer of nitrogenous fertilizers in the country. NFL produced two popular brand of chemical fertilizer namely Kisan Khad (calcium ammonium nitrate- CAN) and Kisan Urea beside the fertilizers, it manufacture some by products like S, liquid O2, N2, HNO, Ar, methanol.

COMPANY OVERVIEW
NFL panipat was incorporated on 23rd August 1974.

1974 NFL Panipat NFL Bhatinda 1978 NFL Nangal 1988 NFL Vijaipur

THE PANIPAT UNIT

Panipat project was approved by the govt. of INDIA in 1975. the prime consultants for design, engeeniering and commissioning of the plant wereM/S TOYO ENGG. Corporation of JAPAN and M/S ENGINEERS INDIA ltd. Starting from dates 30/04/1975, and was completed on 01/09/1978. the total cost of the project was 221.33 crore. The company also considers its employees as its greatest assets and takes care of the training needs of the indivisual employees, a separate HRD department is established for this purpose. To improve their skills part time classes are conducted in advance.

PLANT AND CAPACITY

Besides ammonia and urea plants, the plant consists of various other off site utilities. Ammonia plant 900MT/day Urea plant 1550 MT/day Sulphur recovery plant 26.5MT/day Steam generation plant 3*150MT/hr Captive power plant boiler 210T/hr Turbine 2*15MWh Coal handling plant 150&250 MT/hr DM water plant 400m/hr Raw water plant 240m/hr Bagging plant 4000MT/day Effluent treatment plant 200m/hr For production of 900MT/day of urea and 30MWh of power the following raw material are requiredFuel oil 1050MT/day Coal 1600MT/day Water 12.5MG/day

AMMONIA PLANT
The plant has a capacity of 900 metric tons per stream day of liquid ammonia by one train based on the SHELL gasificatiuon process for gasification of heavy oil and carbon recovery, LURGI-RECTISOL Process for desulphurisation and carbon dioxide removal and TOPSOE ammonia synthesis process starting with heavy oil feed stock and consists of following section:1. Air seperation section 2. Shell gasification and carbon recovery section 3. Desulphurisation section (rectisol process) 4. Shift conversion section 5. CO2 removal section (rectisol process) 6. Nitrogen washing section 7. Ammonia synthesis section including refrigeration section Basic engeeniering for the SHELL gasification and LURGI-RECTISOL Section is performed by LURGI and basic engeeniering for TOPSOE performed by TOPSOE.

BLOCK DIAGRAM OF AMMONIA PLANT

AIR SEPERATION UNIT A-BE001

Air separation unit is provided for getting oxygen gas and nitrogen gas from air. Produced oxygen gas is led to the reactors in shell gasification processes, where it contributes to partial oxidation of feed oil. On the other hand, nitrogen gas after being liquefied is mainly sent to nitrogen washing unit to purify synthesis gas. Some of the nitrogen gas is also used as utility, for example, as compressor sealing gas, degassing medium of lube oil and so on. The air is fed from atmosphere at a pressure of 140,000 Nm/M. The atmospheric air contain many gases like CO2, CO,H2S,CH4 and moisture except the main gases N2 abd O2. here we separate N2 and O2 by distillation process by cooling down the air upto its liquefication temp or we can say its boiling point. The boiling point of N2 and O2 are: N2: -196C O2: -183C The feed air first cooled by refrigeration unit upto temperature of 6C. Then, the air passes through air dryers filled with molecular sieves and alumina gel for adsorption of CO2 and water respectively. The main need of these air dryer bottles is because if we do not adsorb the water and CO2 at this point then they will choke all the pipes bec. Of higer freezing point i.e. 0C for water and -75C for CO2. Then the gas is sent to a filteration unit from which molecular sieves contained in gas are filtered and sent back to adsorber. The adsorbors are alternatively used one at a time with the other going through a desorption process. After removal of CO2 and water by the adsorbers, the air is fed to heat exchangers. The cold air gets liquefied in heat exchangers by getting cooled after exchanging heat with the pure N2 and O2 gas purified by rectifying column and going to nitrogen wash unit and gasification unit respectively and then is led to the lower rectifying column. The air is extracted by expansion turbine from heat exchangers to cool it by 33C (approx.)

Before combined with the air from air heat exchanger the air from rectifying column is warmed by heat exchanger with pure N2 gas from the nitrogen washing unit. Because the turbine can be operated at rather higher temperature, the expansion turbine work effectively and provide necessary refrigeration for the unit. The exhaust air from the expansion turbine is led to the middle part of upper rectifying column. The rectifying column comprises a lower column working at about 6 kg/cmG and upper column working at about 0.8 kg/cmG and a main condenser. Air from the air heat exchanger first enters the bottom of lower rectifying the column and reaches the main condenser after rising up through the lower column. At the lower column, air is preliminarily separated to the N2 and O2 rich liquid air. The main condenser N2 is liquefied by heat exchanger with the liquid O2. As a result, liquid air of about 40% O2 purity is obtained at the bottom of the lower column, while gaseous N2 and liquefied N2 are obtained at the top and middle of the lower column. The liquefied air and N2 thus, obtained by preliminary separation in the lower column, are sent respectively at the liquid state to the upper column. The liquefied air withdrawn from the bottom of lower column passes through one of the two alternately operating hydrocarbon absorbers and liquid air filters to remove any possible contamination of hydrocarbon. It is, then super cooled against waste N2 from the upper column in the liquid air super cooler before being expanded to the pressure of the upper column through the expansion valve which automatically

controls the liquid level at the bottom of the lower column and fed to the upper column Liquid N2 withdrawn from the middle of lower column is fed to the upper column through the expansion valve. Liquid N2 withdrawn from the top of lower column is super cooled in the N2 super cooler and fed to the upper column through the expansion valve. These liquid air and liquid N2, which are fed to the upper column, are rectified further by repeated rectifying operations. Finally, liquefied O2 of a specified purity is obtained in the main condenser. A part of the liquid O2 continuously circulated by liquid O2 pump in order to remove remaining hydrocarbons in circulating adsorber. The waste N2 is withdrawn from the middle part of upper column and warmed in the liquid air super cooler and air heat exchanger then extracted from cold box. This waste N2 gas is used for the cold gas air pre cooler and also for the regeneration liquid of the air dryers. 1. Oxygen producing line Product O2 gas is extracted from the main condensor and warmed to maximum 19C in the air heat exchanger and then goes to the O2 compressor (A-GB002). 2. Nitrogen producing lines Pure N2 gas is withdrawn from the top of upper column and warmed in the

Liquid N2 super cooler, and air heat exchanger, and the greatest part of N 2 gas goes to the N2 compressor (A-GB004). Part of N2 gas is sent to the rectisol section via no. 3 air cooler, N2 blower and the N2 chiller. 3. Nitrogen liquefying line The pure N2 gas, which has a pressure of 41 kg/cmG from the N2 wash unit is liquefied in the N2 liquifier by heat exchanging with the cold air from the lower rectifying column and is further cooled down in coil embedded in the main condenser. Then, the liquified N2 is subcooled against the pure N2 from the top of upper column in the liquid N2 supercooled and fed back to the N2 wash unit. 4. 5.3 kg/cmG nitrogen line to NWU adso0rber. The N2 gas from the top of lower column is warmed in the air heat exchanger and the air precooler and then goes to the absorber for N2 wash unit. The air seperation unit is based on following design considerations:

Feed air condition

Quantity 140,ooo Nm/M as dry basis

pressure
Temperature Relative humidity

7kg/cmG
45C 100% or less

Maximun restriction of contaminants in feed air:

CO2
C2H2 CmHn NO+NO2CmHn

500 ppm max.

0.45 mg/Nm max. 7 mg/Nm max. 1.25 mg/Nmmax.

Dust

1 mg/Nm max.

production
Quantity Purity Pressure Temperature Max. 25,920 Nm/Hr Normal 22,615 Nm/Hr MIN. 98 vol.% moisture and co2 free 500 mm H2O 19C

Nitrogen 1) Nitrogen to nitrogen compressor Quantity Purity Pressure Max. 30,000 Nm/H Min. 99.99 voi.% CO2and moisture free O2 content: less than 8 ppm 500 mm H2O

Temperature
2). Nitrogen to rectisol etc. Quantity Purity Pressure Temperature

19C max.

Max. 19,000 Nm/H Normal 17,000 Nm/H Min. 99.99 voi.% CO2 and moisture free O2 content: less than 8 ppm. 2.5 kg/cmA 25C

3) Nitrogen for other utilities Quantity Purity Pressure Temperature Max. 800 Nm/H Min.99.99vol.% CO2 and moisture free. O2 content: less than 8 ppm 500mm H2O 19C

SHELL GASIFICATION AND CARBON RECOVERY PROCESS

The raw synthesis gas is produced by gasification of the heavy oil with O2 and steam in three parallel oil gasification reactors A-DC101A-C, using the shell partial oxidation process. Now fuel oil is used to produce H2 in gasification unit which is low sulphur heavy stock (LSHS) comes from IOCL PANIPAT , MATHURA. Carbon oil Before feeding in gasifier the fuel oil is mixed with carbon and then the homogeneous mixture is called CARBON OIL stored in carbon oil tank. The carbon oil coming from carbon oil tank has the following composition Component wt % C 84.92 H 09.99 S 04.20 N 0.40 O 0.44 ASH 0.05

And the rate of c. oil fed in gasifier is 30600 kg/hr c.oil is fed in the gasifier by gun O2 and steam oxygen from air separation unit is heated in O2 preheater and mixed with steam and fed into gasifier. O2 reacts with c. oil and the reaction is highly exothermic .H2O reacts with c. oil in an endothermic manner and works as moderator. With the help of this endothermic reaction the temp is maintained at 1350 0C. N2 Nitrogen is used to wash whole the gasification section. Its used only at time of shutdown and starting and takes away the explosive gases and material to avoid explosion and escapes to atmosphere. Flushing steam Flushing steam is used only at the time of shutdown of the plant to wash c.oil in the gun to avoid choking. When all these reactants enter in gasifier DC-101 partial oxidation of the hydrocarbons under pressure and high temp in the presence of O2 and steam takes place. The reactions are better described by three individual phase
Chemical reactions:The process consist essentially of partial oxidation of hydrocarbons under pressure in the presence of O2 and steam, this reaction proceeds as a flame. The gaseous products of combustion contain mainly H2 and CO, a mixture called Water gas. The overall reaction can be formulated:

CnHm + n/2 O2 nCO + m/2 H2 . (1). CnHm + nH2O nCO + (m/2+n) H2 ...(2). The process can be better understand by three individual phases which are described below Heating and cracking phase: In this phase cracking takes place in the reactor at high temperature resulting in the formation of various hydrocarbons.

CnHmSr (m/4-r/2)CH4 + (n-m/4+r/2)C + r H2S. Reaction phase: As soon as the ignition temperature is reached, part of the hydrocarbon will react with O2 acc. to the highly exothermic reaction. CnHm + (n+m/4) O2 nCO2 + m/2 H2O As the equilibrium is far to the right practically all the available O2 is consumed in this phase. The rest of hydrocarbon, which have not been oxidized, react with the combustion products from rxn. Above and steam acc. to the endothermic rxn. CnHm + nCO2 2nCO + m/2 H2 CnHm + nH2O nCO + (m/2+n) H2 In order to, prevent excessive local temp., it is essentially that all reactants of equation above are mixed so that the endothermic rxn. Balance the exothermic rxn. In this way it results in the equilibrium temp. of 1300 to 1400C. Soaking phase: This takes place in the rest of the reactor where the gas is still at a high temp.. The gas composition changes only slightly owing to sec. Reactions of methane and carbon and the water gas shift reaction.

CH4 + H2O CO + 3H2 CH4 + CO2 2CO + 2H2 As the reaction rate is slow, the methane content is higher than would be expected from equilibrium. If sufficient residence time work provided, the carbon formed should theoretically disappear under the condition prevailing in the reactor to C + CO2 2CO C + H2O CO + H2 The reaction takes place without the presence of catalyst. The endothermic gasification reaction process in the refractory-lined reactors at about 55.5 kg/cm2G and 1350C. Now the gases from gasifier enters into waste heat boiler (WHB) AEC101 A-C. where temp of the gases decreases to 318C,the steam from the top of the tower goes to superheater FA-101 where it is superheated to 490C at a pressure of 105 atm which is used to rotate the turbine.and the gases further cooled to 200C. by boiling feed water (BFW) in economizer EA102. Here we are decreasing the temp to remove carbon formed in gasifier otherwise it will corode the calalyst used in next unit. The carbon slurry does not form at high temp. Gases from WHB goes to FA-104 enters from top where water is added from ten quench pipes which form slurry mixture with the carbon. Now the gases enters into the carbon separator from the top, the carbon slurry is settles down and removed from the bottom rest of gases exits from the top most at 144C. The carbon is removed with ash and goes to carbon recovery plant.

After that the gases again cooled by BFW and the temp is reduced to 120C and the gases are taken to carbon scrubber in which the carbon present in traces is removed. The carbon scrubber contains two beds of raschig rings which increases the contact area. The two beds are used just to increase the efficiency. From the bottom of the carbon scrubber impure water is removed containig carbon particles which is used earlier in quench pipes. And the raw gases almost free of the carbon exits from the top at 45C. and taken to 200 (rectisol desulphurisation) unit.

RECTISOL-DESULPHURISATION
desulphurisation The crude gases to be purified in the H2S removal stage of the rectisol unit has a pressure Of 48 kg/cm at a temp of 45C and is water saturated. Water present in gases is condensed in FA-204 and FA-202 . H2S absorbtion in methanol takes place at -28C. So the crude gas feed is cooled in three steps from +45C to 18.5C in heat exchanger EA-201 A to -10.5C in heat exchanger EA 201 B heat is exchanged with cold desulphurized gas and to -22C in ammonia chiller EA-202 using vapourising NH3. After removing water in the condencer FA-204 and 202 water is still left in gas in a very littlle amount here we are dealing with temp below 0C .In order to avoid ice formation on cooling methanol is injected into the crude gas stream before it enters the heat exchanger EA-201 B. In the starting we dont have desulphurised cold gas for cooling in EA 201 A & B so NH3 chiller EA 202 alone cool the gas until sufficient desulphurised cold gas is available. Condensation of gas also takes place in heat exchangers EA 201 A& B and the condensate being a mixture of water and injected methanol is passed to reflux tank FA 201 from LIC 204. The crude gas enters H2S absorber DA-201 at a temp of about -22C and a pressure Of 47 kg/cm. In the bottom portion of the absorber the crude gas is washed with a small amount of cold methanol (-31C ) to remove the cyanogen compounds.

The cold methanol taken from the main stream to the top portion of absorber DA 201 and sprayed. The gas to be purified reaches the upper portioin of H2S absorber 201 via a chimney tray and than from trays. Here H2S and all other sulphur compounds are removed to a total sulphur content of .4 ppm or less by cold methonol supplied from CO2 regenerator DA 402 in decarbonation section. After passing over the valve trays the sulphur loaded methanol is withdrawn on level control above the chimney tray. The desulphurized cold gas leaves H2S absorber DA 201. A demister installed in the top prevents methanol droplets from being entrained. The cold desulphurized gas is used for cooling the crude gas in heat exchanger EA 201 and it leaves the H2S removal stage at about +35 0C and 45 kg/cm2. The sulphur free gas is supplied to CO shift conversion. During startup the gas is discharged to the flare via a separate pressure controller untill the final sulphur content is reached. The loaded methanol in chimney tray also contain little amount of valuable gases like H2 and CO. Methanol purification The loaded methanol is comes to DA-202 in the bottom part where pre. Is decreased to 12kg/cm2 and temp is -18 0C at this pre. H2 and CO are removed. H2 and CO taken to FA203 and again mixed with raw gas after FA-202. In the top of the DA-202 the pre is decreased to .5 kg/cm2 due to this pre difference methanol rises to the top part of the tower without using any pump. Here desorbtion of CO2 takes place and the rate of desorption is increased by nitrogen. Nitrogen enters in the middle of the tower at -15 0C which rises up taking CO2. and due to that partial pre of CO2 decreases and more desorbtion takes place. Here H2S is also removed in a very amount. Methanol from DA-402 at -58 0C is added at the top which condenses the upgoing methanol with gas. Now nitrogen containing CO2 with 1000 ppm of H2S at -55 0C are sent to the sulphur recovery incinerator after heating in heat exchanger EA-209 to -39 0C and in EA-207 to +30 0C.

From the middle of the tower DA-202 the pump GA-201 transfers the solvent on level control to hot regenerator DA- 203 after heating to 88 0C in lean/ semi lean methanol heat exchangers EA-205. In the upper section of hot regenerator (DA-203) the methanol is heated to boiling point and H2S and COS gases are completely stripped off at +86 0C by rinsing methanol vapours from the top of tower. In the tower pure methanol is also added from DA-204. In the chimney tray the methanol is in pure form at temp 93 0C. from the chimney tower, part of the methanol through pump GA202 is used in heat exchanger and supplied to EA-404 small amount is sent to DA-204 left is sprayed in bottom part of the tower. From the bottom, part of methanol is passed through heat exchanger EA-206 which is again fed in the tank this is used to recover the heat loses and maintain the temp in the tower. The crude gas and the converted gas carry a certain quantity of water into the H2S and CO2 removal stages. To keep the water level in the methanol below maximum 2.0% by wt. a methanol stream is withdrawn continuously for dehydration. To keep this quantity as low as possible the methanol in the bottom of hot regenerator DA-203 is concentrated with water and methanol vapours moves up through chimney tray by heating in EA-206. The methanol concentrated with water from the bottom at 96 0C is taken to DA-204 through GA-203. In DA204 the temp is maintained as earlier by EA-211 upto the boiling point of methanol so that methanol vapours withdrawn from the top and impure water is drain from the bottom containing 50-500 ppm of methanol. The methanol from GA-202 is sprayed from the top to condence the water so that pure methanol goes to DA-203. And the methanol added in the middle of the tower is coming from DA-205 is supplied from EA-403 ( Decarbonation section) .

The claus gas with small amount of methanol vapour at 1.7 kg/cm2 and +86 0C is withdrawn overhead from DA-203. The methanol vapours must be almost completely removed from this mixture by condensation . the methanol containing claus gas is cooled with off gas coming from DA-202 in EA-207 from 86 0C to 84 0C and with cooling water in claus gas condenser EA-208 from 84 0C to 40 0C. The methanol is condensed and the clauss gas pass through reflux drum FA-201 for seperation of condenced methanol. The methanol condensate from H2S absorber (DA-201) bottom section and H2S absorber feed gas heat exchanger (EA-201 B) and also from clauss gas seperator (FA-403) are discharged into reflux drum FA-201 which is then refluxed in DA-203 through reflux pump GA-204.

CO SHIFT CONVERSION SECTION

About reaction In the shift conversion section sulphur free gas reacts with steam to form H2 and CO2 the reaction occurs at proper pre and temp (350-500 0C) condition with a suitable catalyst (iron-chromium). CO + H2O H2 + CO2 The reaction is reversible and endothermic so H2 formation is favoured by low temp but the reaction rate constant is favoured by high temp so the temp is adjusted to maximum conversion. Excess steam is used to achieve higher conversion and to prevent carbon deposition. But too much excess steam reduces the contact time between gases and catalyst which reduces the conversion rate. The sulphur free raw gas from the desulphurization section at 35 0C enters the humidifier DA-301 where it is warmed and humidified by hot water coming from dehumidifier at 221 0C. Humidifier contains two bed of pall rings for efficient counter current contact of gas with hot water. The heated and humidified gas leaves the humidifier from the top at 211 0C which is further heated by EA-301 to 229 0C and EA-302 to 430. To get proper steam to dry gas ratio and temp (360 0C), a superheated steam through FIC-304 at 430 0C and process condensate through TIC-301 coming from economizer EA-306 at 173 0C is added.

The raw gas with steam enter in shift converter DC-301 at 360 0C0 and the CO composition is 48.47 by volume. At the outlet of the first bed the temp is 500 0C and CO composition in gas is reduced to 12.6 % on dry basis. Converted gas from outlet of the upper bed is sent to EA-302 and is cooled by shift converter feed gas to 360 0C and enters into lower bed. At the outlet of the second bed the CO content reduses to 3.5% and the temp is increased to 392 0C. The gas from the lower bed enters shift converter feed gas heater EA-301 where it heats up shift converter feed gas the temp decreases to 378 0C and is fed to EA-303 where temp decreases to 212 0C. In the outlet gas from DC-301 steam is also present so to remove water it is fed to dehumidifier DA-302. Dehumidifier is packing tower loaded with pall ring for direct counter current contact of gas with water. where excess steam condenses by the condensate feeded above the bed at 176 0C. the pressure in the bed is sufficiently high so that steam at this temp condenses. The condensed steam from bottom ( 202 0C) is used in humidifier after increasing the temp in EA-303 to 221 0C. The outlet gas from the top of dehumidifier sent to absorption regrigeration BE-401. Further the shift converted gas is used to generate low pre steam in the low pre boiler EA-307 and to heat up boiler feed water in the economizer EA-306 and finally cooled till 45 0C by the cooling water in EA-304 and then in condenser to condense the water left in gas. The condensed water is sent to dehumidifier as a condensate. and gases at 45 0C and 41.5 kg/cm2 sent to the rectisol decarbonation process.

Rectisol decabonation section

Entering gas in decabonation section is water saturated so water is condensed and separated in separators FA-406 and FA-404 and discharged to sewer through level indicator controllers. The gas to be decorbonated is cooled in three steps. After FA406 the gas is cooled in EA-401 A from 45 0C to 27 0C again condensate is removed in FA-404 and then the gas is further cooled upto -16 0C in EA-401 B with cold synthesis gas from liquid N2 scrubbing,and in ammonia chiller EA-402 where the temp is decreased to -25 0C. like desulphurisation section here also working temp is below 0 0C. To prevent ice formation on cooling methanol is injected into the gas before it enters into FA-404. On starting up ammonia chiller alone cool the converted gas untill cold pure gas from CO2 absorber DA-401 is available.By lowering the pressure on the NH3 side the temp is decreased. Now the gas at -25 0C and 40.4 kg/cm2 enters the bottom section of CO2 absorber ( DA-401). The gases from the bottom rises up through chimney tray. Where almost all CO2 is removed from the gas by washing with cold methanol supplied at -70 0C from DA-402 in the middle of the tower. Another cold methanol stream is sprayed to the top of the tower at -58 0C just to condense the vapourising methanol.

The cold pure gas withdrawn overhead from absorber (DA-401) has a residual CO2 content of maximum 10 ppm. The methanol flowing down from the top is combined with the methanol added in the middle gathered at the bottom of the tower via chimney tray. From where highly CO2 loaded solvent is transferred into ammonia chiller by circulation pump GA401. The absorption heat released during CO2 absorption is carried off by vapourising NH3 and temp inside the tower is maintained by this ammonia chiller. A condenser FA-402 is installed at the outlet of the gas which condenses methanol going with the gases. The pure gas at a pre of 39.5 kg/cm2 and a temp of -55 0C is supplied direct to liquid N2 scrubbing. The gas from N2 scrubbing (BE-501) is used to cool down the feed gas in EA-401 A and B. regenerated CO2 from FA-410 is also used to cool down the feed gas in EA-401B A CO2 analyzer in the pure stream analyzes the concentration of CO2 gas. During startup the pure gas is to be discharged to the flare untill the required purity is reached.

NH3 SYNTHESIS SECTION

Synthesis gas ratio is maintained of the gases before coming to synthesis section. Synthesis section is compressed from 37.0 kg/cm2 to 231 kg/cm2 in the centrifugal type synthesis gas compressor. After compression to about 218kg/cm2 the total make up gas is mixed with recirculation gas from the ammonia separator FA-601 and the mixture is added before the 4th stage of compressure . The feed gases then heated in the EA-602 to 134 0C by heat exchange with the hot effluent gas. At the outlet of the synthesis converter DC-601 the gas contains approximately 16.2 vol% of NH3 and the temp is about 317 0C. the heat of gas is utilized in the synthesis economizer EA-601 A,B in which the gas is cooled to 169 0C. after the synthesis economizer the gas is further cooled to about 71 0C in the heat xchanger EA-602. The cooling of the gas continues in the water cooler EA-603 in which a large amount of ammonia is condenced at the outlet of EA-603 the temp is 40 0C. the gas then passes through cold xchanger EA-604 in which it is cooled to 33 0C by heat xchange with the recirculation gas coming from the ammonia separator FA-601. Finally the gas is cooled to 10 0C in the ammonia chiller EB-601. The mixture of synthesis gas and liquid ammonia is passed on to the ammonia separator FA-601 in which the liquid ammonia separated. And the synthesis gas from the top of FA-601 at pre of 219 kg/cm2 and temp 10 0C is passed through EA604 where temp is increased to 30 0C and then mixed with inlet synthesis gas after 3rd stage of compressure. The liquid ammonia separated in the ammonia separator FA-601 is depressurized

to 45 kg/cm2 in the flash drum FA-602. The gases dissolved in liquid ammonia are flashed off in this flash drum and the gases are recycled to the inlet of the synthesis gas compressure GB-601 and reused in the synthesis loop. The liquid ammonia is delivered to storage tank at a pre of 20 kg/cm2. Ammonia synthesis converter (DC-601) The ammonia converter DC-601 is a radial flow converter which contains a heat xchanger section in the lower part and a catalyst section in the upper part enclosed in a high pressure shell. The catalyst consist of two catalyst beds with quench between the beds. The total catalyst volume installed is 23.36 m3 of which 7.05 m3 is installed in the 1st bed. The startup heater BA-601 is placed outside the pressure shell of the converter. The main flow of synthesis gas is introduced through the main inlets in the top flange the flow is regulated by HC-601. The gas flows down through the outer annular space between the pressure shell and the insulated basket in order to keep the temp of the pre shell at about 130140 0C. from the bottom of the converter, gas flows up through the shell side of the lower heat xchanger where it is heated to about 390 0C by heat xchanger with hot converted synthesis gas which has passed 2nd catalyst bed. The temp at the outlet of the heat xchanger is controlled by introducing some cold shot gas (gas introduced through the lower heat xchanger by pass). The amount of cold shot gas is regulated by TRC-602 keeping a constant temp inlet 1st bed. The gas stream to 1st bed which is about 390 0C flows upwards through the transfer tube to the perforated center tube in 1st catalyst bed which is surrounded by two layers of wire mesh. From the center tube the gas passes radially out through the catalyst bed and through the outer catalyst bed wall which consists of two layers of wire mesh a perforated wall and finally a well equiped with a number of nozzles designed so as to ensure satisfactory distribution of flow in the catalyst bed.

The partly converted gas leaves the 1st catalyst bed at a temp of about 520 0C and enters the inner annular space in which the gas is mixed with the quench gas (about 30% of total feed) introduced in the top of the same annular. The flow of quench gas is regulated by HC602. The temp of the mixed gases is about 405 0C. and the gas is introduced into the 2nd catalyst bed through a catalyst bed wall equipped with nozzles perforated wall and wire mesh as described above. The gas flows radially through the 2nd bed and leaves this bed at a temp of about 505 0C containig 16.2 % ammonia. After leaving the 2nd catalyst bed the gas flows down through the central annular space to the lower heat xchanger which is passed on the tube side before the converted synthesis gas leaves the converter through the exit pipe in the bottom of the pressure shell at a temp of about 320 0C. the temp is recorded by TR-601 which gives the alarm at high temp. The catalyst temp are indicated by means of thermocouples placed in four thermocouple pipes going through the catalyst beds and the inlet and outlet temp of the catalyst section is indicated by means of thermocouples placed in a thermocouple pipe going through the center tube. In each thermocouple pipes six thermocouple are placed which gives in total 30 thermocouples. The temp of the pre shell is indicated by TPA-605-1 to 605-12 The outlet gas from the converter has the following composition Ammonia 16.24 % Hydrogen 61.77 % Nitrogen 20.59 % Argon 1.26 % Methane 0. 14 %

ASSIGNMENT
QUES-1. how much H2 is required to produce 1 tonn ammonia? SOLUTIONN2 + 3H2 2NH3 28 tonn 6 tonn 34 tonn 34 tonn ammonia requires = 6 tonn of H2 1 tonn of ammonia requires= 6/34 tonn of H2 =6/34 X 1000 kg. of H2 = 6000/34 kg. of H2 = 6000/34 x moles of H2 =6000/34x1/2x22.4 Nm H2 = 1976.47 Nm H2

Ques-2. If 0.1% CH4 get increase in 86000 Nm NH3. what will be its effect on NH3 production? SOLUTIONCH4 + H2O CO+ 3H2 CH4 + CO2 2CO+2H2 In CO shift reaction CO + H2O CO2 + H2 This implies that 1 mole of CO is equivalent to 1 mole of H2. Thus, 1 mole of methane is equivalent to 4 moles of hydrogen. 0.3% of methane in 86,000 Nm NH3= 86000 x 0.3/100 = 258 Nm methane 0.4% of methane in 86000 Nm NH3= 86000 x 0.4/100 = 344 Nm methane Change in amount of methane= 86 Nm methane

Amount of H2 lost= 86 x 4= 344 Nm H2

If 2000 Nm H2 produces= 1 ton NH3 1 Nm H2 produces= 1/2000 ton NH3 344 Nm produces= 1/2000 x 344 ton NH3 Ammonia lost per hour= 1/2000x 344x 24 = 4.128 ton NH3 per day

QUES-3. convert 1 kgf/ cm into N/m . SOLUTION 1 kgf = 9.80665 N 1 kgf/cm = 9.80665 N/cm = 9.80665x 10000 N/m = 98066.5 N/m