JULY, 1973 » THE M. W. KELLOGG COMPANY. $ OPERATING INSTRUCTIONS MANUAL 1000 SHORT TONS PER STREAM DAY AMMONIA PLANT THE M, W, KELLOGG COMPANY (A DIVISION OF PULLMAN, INCORPORATED)THE M. W. KELLOGG COMPANY . TABLE OF CONTENTS INTRODUCTION SECTION I - THE PROCESS A. DESCRIPTION OF THE FLOW 1 Process Flows a. Raw Synthesis Gas Preparation System (1) Primary Reformer Preheat Coils and Zine Oxide Guard Chamber (2) Primary Reforming (3) Process Air (4) Secondary Reforming (5) Shift Converter (High and Low Temperature) b. Synthesis Gas Purification System (1) Carbon Dioxide (CO2) Removal (2) Methanator (CO Conversion) c. Ammonia Production System (1) Compression of Purified Synthesis Gas (2) Synthesis (Conversion) of Gas to Ammonia (3) Refrigeration and Ammonia Product Purification Utility Flows a. Steam Systems (1) 105 Kg/cm2 (1500 psig) Steam System (HS) (2) 38.4 Kg/cm2 (545 psig) Steam System (MS) (3) 11.3 Kg/cm2 (160 psig) Steam System (S) (4) 7 Kg/cm? (100 psig) Steam System (SS) (5) 3.5 Kg/cm@ (50 psig) Steam System (LS) (6) Import Steam (7) Steam Condensate Systems (8) Steam Drum 101-F b. Feed Water Deaeration Deaerator ¢. Reformer Cooling Water Jackets d. Cooling Water and Raw Water (1) Cooling Water (2) Raw Water e. Utility Air (1) Plant Air (2) Instrument Air f. Inert Gas g- Fuel Gas» THE M. W. KELLOGG-COMPANY TABLE OF CONTENTS B. PROCESS AND OPERATING PRINCIPLES T Raw Synthesis Gas Preparation System a. Feed Gas Desulfurization (1) Guard Chamber and Catalyst (2) Guard Chamber Operation b. Primary Reforming (1) Reforming Reactions (2) Reforming Conditions (3) Primary Reformer Catalyst (4) Farnace Operation ¢. Secondary Reforming (1) Secondary Reformer Catalyst (2) Secondary Reformer Operation 4. Waste Heat Boilers 101-CA, 101-CB and 102-C e. Shift Converter 104-D (High and Low Temperature) (1) High Temperature Sbift Converter Operation High Temperature Shift Catalyst Precautions (2) Low Temperature Shift Catalyst Section (a) Low Temperature Shift Converter Operation {b) Low Temperature Shift Catalyst Precautions {, Recovery from Shift Effluent Synthesis Gas Purification System a. COz Removal (1) Flow of Gas and Catacarb Solution (2) Chemietry of Catacarb Process (a) Summary of Important Points (b) Water Quality (c) Air Addition (d) Solution Characteristics - Foaminess and Color {e) Solution Strength b. Methanation (106-D) Ammonia Production System a. Compression of Synthesis Gas and Water Removal b, Synthesis (Conversion) of Synthesis Gas to Ammonia (1) Conditions Influencing the Converter Reaction (2) Control of the Synthesis Reaction Operation (3) Converter Catalyst Characteristics c. Separation of Anhydrous Liquid Ammonia from Synthesis Gas Loop 4, Ammonia Product Purification (Removal of Uncondensibles) (1) Primary Ammonia Separator 107-F (2) Third Stage Refrigerant Flash Drum 112-F 62, 62 63 63“Index 7 THE M. W. KELLOGG COMPANY TABLE OF CONTENTS (3) Refrigerant Receiver 109-F (4) First Stage Refrigerant Flash Drum 110-F (5) Second Stage Refrigerant Flash Drurn 111-F (6) Refrigerant Compressor 105-3 . Boiler Feed Water Deaeration 101-U SECTION Il - UNIT CONDITIONING, CATALYST LOADING B. c. PROCEDURES AND SPECIAL EQUIPMENT UNIT CONDITIONING Introduction 1, Inspection of Vessels 2. Flushing Lines 3, Instruments 4, Running-in Pumps 5. Running-in Compressors (101-J, 103-3 & 105-J) 6 Drying Furnace Masonry (101-B, 102-B & 103-B) 7. Drying Linings of 103-D 8. Preparation of the Catacarb COz Removal System a. Construction Phase b. Initial Circulation and Degreasing c. Passivation CATALYST LOADING PROCEDURES SPECIAL EQUIPMENT 1, Mechanical Equipment a. Air Compressor (101-J) b. Synthesis Gas Compressor (103-J) Precautions Relative to Synthesis Gas Compressor c. Refrigeration Compressor (105-J) d. Hydraulic Power Recovery Turbine (1107-JHT) 2, Auxiliary Equipment a. Catacarb Injection System (1105-L) b. Hydrazine Injection System (2001-L) c. Phosphate Injection System (2002-L) 4. Instrument Air Dryer (2003-L) e. Ammonia Injection System (2004-L) f, Catacarb Solution Filters 3, Special Instrumentation Introduction a. Complex Instrumentation (1) Steam Drum (101-F) Level Control (2) C02 Absorber (1101-E) Level Control 69 69 69 70 70 3 14 5 16 16 7 17 8 80 81 83 83 83 84 87 89 90 90 90 a 1 92 92, 93 93 93 94 94 96~Tndexs THE M. W. KELLOGG COMPANY son ive TABLE OF CONTENTS Page (a) Low Level in the COz Absorber 96 (b) Overspeed Trip 96 (c) Manual Bypass 97 (3) 105 Kg/cm? (1500 psig) and 38.4 Kg/em? (545 psig) Steam System Controls 100 I. PIG-13 and MIC-22 101 I, Hydraulic Valve Operation 102 ll, 103-5 Trip Checks 103 IV. Hydraulic Oil Package 104 (4) Auxiliary Boiler Damper Controller 106 (5) Analyzers 108 (6) Instrumentation on the Synthesis Gas Compressor 108 (7) Purged Thermowells 109 b. Shutdown Devices 109 (1) Low Feed Gas and Process Steam Flows to the Primary Reformer 109 (2) Fuel Gas Burners Safety Control 110 (3) Low Temperature Shift Catalyst Section Bypass 112, (4) Methanator (106-D) Emergency Vent 113 , (5) Furnace (101-B) Emergency Draft Induction 113 SECTION Ill - STARTUP PROCEDURE 14 INTRODUCTION 114 A. PRELIMINARY STARTUP PROCEDURES 115 UNIT STARTUP PROCEDURES 129 1, Air Heating 129 2, Steam Heating 131 3, Heat the Zinc Oxide Guard Chamber 132 4, Raise Reformer Rates and Temperature and Establish 101-CA and CB Circulation 133 a. Formula for Calculating Downcomer Density 135, b. Sketch of 101-CA and CB Instrumentation 137 c. Density of Water 138 d, Thermal Properties of Water 140 Start Feed Gas to Primary Reformer 144 a. Catalyst Reduction 144 b. High Temperature Shift Converter Catalyst Reduction Procedures 144 c. Reformer Reduction Precautions a a, Reformer and High Temperature Shift Catalyst Desulfurization 145, €. Precautions for Air Injection During Desulfurization 145,¢. 10, il 12, THE M. W. KELLOGG COMPANY : TABLE OF CONTENTS Start.COz Removal a. Start Solution Circulation b, Start COz Absorption Place Methanator (106-D) on Stream a, Activate Methanation Catalyst b. Place Synthesis Gas Analyzers in Service Reduce the Low Temperature Shift Converter Catalyst and Commission the Low Temperature Shift Converter a. Reduce the Low Temperature Shift Converter Catalyst b. Commission the Low Temperature Shift Converter c. Dilution Natural Gas for the Low Temperature Shift Converter Catalyst Increase Primary Reformer Rates Start Refrigeration Compressor (105-J) Synthesis Section Starting Procedures a. Start Synthesis Gas Compressor (103-J) b. Warm-up Procedures c. Conduct Operator Leak Test of Synthesis Gas Loop Synthesis Converter Catalyst Reduction a, Alignment of the Synthesis Gas Loop for Reduction b, Start Converter Catalyst Reduction (1) Phase 1: Inlet Temperature to 343°C (650°F) Start up Heater (102-B) Precautions (2) Phase 2: Hot Spot from 343 to 410°C (650 to 70°F) (3) Phase 3: Continuing Reduction to 449°C (840°F) and Decreasing Heater Load (4) Phase 4: Moving Toward Full Production STARTUP WITH ACTIVATED CATALYST 1 2 Primary and Secondary Reformers (101-B and 103-D) High Temperature and Low Temperature Shift Converters (104-D) a. High Temperature Shift Converter b. ‘Low Temperature Shift Converter (1) After Brief Shutdown (2) After Protonged Shutdown Methanator Startup with Activated Ammonia Converter Catalyst (105-D) a. After Brief Shutdown b. After Prolonged Shutdown 172 172 172 172 173 173 473 173 173 173 174Index THE M. W. KELLOGG COMPANY * TABLE OF CONTENTS SECTION IV - SHUTDOWN PROCEDURES B. c. NORMAL SHUTDOWN Introduction 6 Ammonia Synthesi b. a. Section Shutdown Reduce Unit Feed Rate Reduce Synthesis Section Feed Rate Stop Synthesis Compressor (103-J) Pump Out and Stop Refrigeration Section Depressure and Nitrogen Purge Synthesis Converter (105-D) Methanator Shutdown Divert Methanator Feed Gas to Upstream Vent (PIC-5) Oz Removal System Shutdown a b. Preliminary Divert the High Temperature Shift Converter Effluent to 103-C vent (SP-71) The Reforming Section Shutdown a. by Reduce Secondary Reformer Temperatures Stop Natural Gas Feed to Reforming: Zinc Oxide Guard Chamber Shutdown Shutdown Auxiliary Boiler and Secure 105 Kg/em” (1500 psig) Steam System Offsite Facilities SPECIAL PROCEDURES Steam Oxidizing of Reformer Catalysts EMERGENCY PROCEDURES Introduction Shift Converter (104-D) Methanator (106-D) General Emergencies Loss of Boiler Feed Water to Steam Drum (101-F) Loss of Process Air Electric Power Failure Natural Gas Failure (1) Total Failure (2) Loss of Feed Gas to the Primary Reformer Cooling Water Failure Catacarb Solution Circulation Failure Precautions to be Observed to Protect Steam Generating Equipment 184 185 186 186 186 187 187 188 189 190 191 192 194 194 196 196 196 197‘THE M. W. KELLOGG COMPANY TABLE OF CONTENTS h, Water Treatment System Failure i. Lose of Steam Pressure j- Instrument Air Failure SE! INTRODUCTION, ‘TION V - OFFSITE FACILITIES COOLING WATER SYSTEM T. Cooling Tower 2. Cooling Water Pumps 3. Surface Condenser (2202-JE) 4. Chromate Inhibitor Injection System (2005-L) DEMINERALIZER T, Description of the Flow and Equipment a, Normal Flow b. Filters and Exchangers {1) Demineralizer Water Feed Filters (2) Cation Exchangers (3) Anion Exchangers {4) Mixed Bed Polishers c. Regenerative Flow (1) Cation (2) Anion (3) Mixed Bed 4. . Operating Principles Introduction (1) Cation (2) Anion (3) Mixed Bed . Automation and Instrumentation Conductivity Analyzers SECTION VI - APPENDIX Material Balance Operating Temperature Limits for Reformer Tubes 1, Normal Tubes (Radiant Rate 16,800 BTU/hr/tt?) 2. Abnormal Tubes (No Heat Flux - Plugged Tubes or Hot Spots) 102-8 Startup Heater Operating Limitations Standards OD-215 Standard Classifications OD-208 Instrument Symbol List OD-209 201 201 201 202 202 203 203 204 205 205 205 206 206 206 206 207 208 210 210 aul 213 215 216 217 219 219 225 225 226 227 228 229 230THE M. W. KELLOGG COMPANY TABLE OF CONTENTS Furnace Refractory Dryout Procedure OD-241 Steam to Carbon Ratio Calculations OD-224M Secondary Reformer Burner Steam Rate at Reduced Air Rates OD-210M Procedure for Gradual Heatup of Steam Drums OD-211M Steam Generator Operation OD-216M ‘Temperature Conversion Tables OD-206 Pressure Conversion Table OD-219M Conversion Factors OD-218 Purge Type Thermowell OD-177 Excess Air from Furnace Flue Gas Analysis OD-204 Inert Purge Cycles vs Oxygen Concentration OD-213M Specific Gravity of Aqueous Ammonia Solution OD-242M Vapor Pressure of Aqueous Water Solutions OD-202M. Vapor Pressure of Ammonia OD-244M Determination of Water Vapor in Gas at Ammonia Synthesis Converter Outlet OD-220 Dilution of Caustic Soda Solutions OD-235 CATALYST UNLOADING PROCEDURES Catalyst Removal from Primary Reformer Tubes OD-245 Catalyst Removal from Secondary Reformer OD-238 Catalyst Unloading from High or Low Temperature Shift Converters OD-239 Catalyst Unloading from Methanator OD-240 Catalyst Unloading of Ammonia Synthesis Converter (Fixed Basket Type) OD-236 CATALYST LOADING PROCEDURES Catalyst Loading of Primary Reformer Furnace Tubes (Dry Loading Method) Catalyst Loading of Secondary Reformers Catalyst Loading of Shift Converters Catalyst Loading of Methanators Gatalyst Loading of Ammonia Synthesis Converters (Fixed Basket Type) Alarm Summary Sheets Relief Valve Summary Sheets DRAWINGS Operating Flagsheets with Anticipated Operating Conditions Normal Plant Stearn Balance Process Flow Diagram Page aan 234 240 243 253 271 274 275 277 278 279 280 281 282 283 286 295 295 301 304 308 311 BAl-2P72 D43-1P-T D44-1P-T D46-1P-T D45-2P-TR-2 H-94 thru H-97 550-C P-3642-DTHE M. W. KELLOGG COMPANY TABLE OF CONTENTS Plot Plan Offsites Plot Plan Site Location Drawing and Equipment List Process Piping and Instrumentation Flow Sheets Auxiliary Piping and Instrumentation Flow Sheets Utility Piping and Instrumentation Flow Sheets Electric One Line Diagram FURNACE DATA SHEETS AND DRAWINGS 101-B Furnace Data Sheets (4) 101-B Arch Burner Data Sheet (1) 101-B Tunnel Burner Data Sheet (1) 101-B Auxiliary Burner Data Sheet (1) 101-B Induced Draft Fan Data Sheet (1) 101-B Induced Draft Fan Turbine Driver Data Sheet (1) Primary Reformer Furnace Drawings 102-B Startup Heater Data Sheets (2) 102-B Burner Data Sheet (1) 102-B Startup Heater Drawing 103-B Guard Chamber Heater Drawing 103-B Guard Chamber Burner Data Sheet (1) 103-B Guard Chamber Furnace Data Sheets (2) Primary Reformer Furnace General Arrangement Drawings VESSEL DRAWINGS 103-D Secondary Reformer Secondary Reformer Nozzle Details Secondary Reformer Water Jacket Details Secondary Reformer Lining Details Secondary Reformer Air Mixer 104-D Shift Converter Location of Connections 105-D Ammonia Converter Ammonia Converter Details Ammonia Converter Details Ammonia Converter Details 106-D Methanator Location of Connections 107-D Primary Reformer Effluent Chamber Assembly and Details 108-D Zinc Oxide Guard Chamber Location of Connections ix. 61-D1 61-n2 61-D3 62-D1 thru 62-D5 63-Di thru 63-D5 64-D1 thru 64-D7 703-D1 5912-Bl-2-3 3907-8 5908-A 210-D1, D2, D3 405-D1 405-D2 405-D3 405-D4 405-D5 404-D1 404-Bi 402-D1 402-D2 402-D3 403-D4 403-D1 403-B1 407-D2, 408-B1 408- B2“Index THE M. W. KELLOGG COMPANY TABLE OF CONTENTS 1101-E COz Absorber Location of Connections 1102-E COz Stripper 101-F 105-F 106-F 107-F 108-F 109-F 110-F 1ll-F 112-F Location of Connections Steam Drum Synthesis Gas. Gompressor First Stage Separator Ammonia Separator Primary Ammonia Separator Purge Separator Refrigerant Receiver First Stage Refrigerant Flash Drum Second Stage Refrigerant Flash Drum ‘Third Stage Refrigerant Flash Drum )450-DL )~“Tntroduction THE M. W. KELLOGG COMPANY vo INTRODUCTION ‘This Operating Instructions Manual has been prepared to assist the operating personnel with the initial startup and subsequent operation of the 1900 short ton per standard day Ammonia Plant 2 irene aoc ea 7 Its primary objective is to provide flow descriptions and discussions of the process and related Operating Principles, suggested procedures for the initial commissioning and startup and shutdown of the unit. The manual should be regarded as a source of reference for information in resolving operating problems. Because it is not possible to anticipate and present all potential circum- stances beforehand which may be confronted during commissioning, startup and shutdowns of the plant, the operating manual must be recognized essentially as a guide, and unless specifically noted as such, conditions which are stipulate need not necessarily be regarded as rigid standards. ‘The best operating techniques will evalve from operating experience of the plant and optimum operating conditions will be found for the most advantageous and economic utilization of the unit. Under no circumstances should operators deviate from safety regulations and practices followed throughout the industry. The unit design is based on a high pressure catalytic reforming method to produce 1000 short tons per stream day of anhydrous liquid ammonia from primary raw materials comprising natural gas (chiefly methane), steam and air, Included, as an integral part of the design, are items of equipment with sufficient steam generating capacity to satisfy the process and equipment requirements of the plant. This is accomplished with an auxiliary gas fired boiler and waste heat exchangers that utilize a common steam separatér drum and steam superheater system. The water treating and boiler ieed water systems are common to the auxiliary boiler and waste heat steam exchangers. ‘The production of the liquid anhydrous ammonia is accomplished in the following processing steps: Raw Synthesis Gas Preparations a. Desulfurization (by adsorption) b. Reforming (primary) c. Secondary Reforming plus Nitrogen Addition @. Carbon Monoxide (CO) Shift and Carbon Dioxide (CO?) Synthesis Gas Purification a. Carbon Dioxide (CO) removal by absorption. b, Conversion of CO and trace amounts of COz (total oxides) by Methanation"Introduction THE M. W. KELLOGG-COMPANY . - 2, 3. Liquid Ammonia Synthesis (Production) a, Compression of synthesis feed gas b, Synthesis (conversion) of synthesis gas to ammonia c. Separation of liquid ammonia from the synthesis gas (chilling) 4, Removal of Uncondensibles (Methane and Argon) Approximately 1,140 tons per day of carbon dioxide (CO2) plus water is released from the COz stripper in the purification section and vented to atmosphere as 4 waste by-product of the process. Purge and flash gases from the synthesis loop and refrigeration systems are routed to the fuel gas system for use in the arch, tunnel and 193-B burners. Ammonia produced at 1000 short tons per stream day is delivered to battery limits from the first stage,refrigerant flash drum (110-F) and from the third stage refrigerant flash drum (112-F) at a combined temperature of -2°C (28°F). Section I of the manual contains a detailed description of the process flaw through the unit. It also contains a description of the process and operating principles. References to drawing numbers 62-D! through 62-D5, 63-D1 through 63-D5 and 64-D1 through 64-Dé will be necessary to understand the systems being described in this section. Section Il contains a suggested procedure for conditioning all process equipment in preparation for the initial startup. It also contains a detailed description of special equipment and complex instrumentation within the unit. Reference to the "Job Specification Books", vendor instruction books and vessel drawings are an additional source of information while the unit is being conditioned for the initial start-up. Section III contains a recommended starting procedure for the initial start-up and subsequent operation of the unit. Reference to the operating flagsheets with anticipated operating conditions and process flow diagram P-3642-D will assist in bringing the unit on stream and producing an "on spec" product. Section IV contains a recommended shutdown procedure which includes special procedures for various items of equipment. Certain emergency pro- cedures are also discussed in this section. Section V will describe the equipment located in the Offsite plot of the plant. Process principles and operations will be outlined on equipment when applicable.Yntroduction ° THE M.W4KELLOGG-COMPANY 3. Section VI contains all drawings, graphs and other information which may be of interest or assistance in getting the unit successfully conditioned and started up. It cannot be stressed too strongly that this operating manual is, at best, only a guide to assist the operators in understanding the process and equipment operation of the unit, The successful operation of the unit will depend on each operator having a thorough understanding of the process con- ditions, and how to adjust them to give the desired product specification. During upset or emergency conditions it is necessary to take corrective action quickly, which can be done only when an operator knows his unit well.“section T* THE M. W. KELLOGG COMPANY 4 SECTION I - THE PROCESS. DESCRIPTION OF THE FLOW Process Flows This section of the manual will give the reader a clearer understanding of the operations and process principles of the unit. The description of the process flows through the unit can be more readily understood if the Process Piping, Auxiliary and Utility Instrumentation Flow Sheets are referred to during study of this section. These are drawing numbers 62-D1 through 62-D5, 63-D1 through 63-D5, 64-D1 through 64-D7 located in Section VI of the manual. ‘The ensuing discussions will describe in detail the main process flow through the unit. All auxiliary systems that are pertinent to the process will be described separately under a separate subsection. The auxiliary flows will include all systems that are required in the operation of the plant such as steam, boiler feed water and fuel gas. The Process and Operating Principles are discussed in detail in the portion of this section. Complex instrumentation is subsequently described under a separate subsection "C. Special Equipment" in Section II of the manual. a. Raw Synthesis Gas Preparation a Primary Reformer Preheat Coils and ‘Zinc Oxide Guard Chamber The natural gas feed is delivered to the battery limits and enters the feed gas knockout drum 116-F for elimination of entrained liquids. The gas flows through a demisting pad and out the top of the drum. Analyzer AR-4 is provided at this point to measure the sulfur content of the natural gas. From the outlet of the knockout drum, the raw feed gas enters the feed prebeat coil in the convection section of the primary reformer furnace 101-B. This gas flow is under control of flow recorder ratio controller FRRCa-) in the line to the feed preheat coil. A low flow alarm (FA-83) is associated with the flow controller. At a preset low flow, this alarm, when actuated, closes the motor operated valve (SP-3) shutting off air to the Secondary Reformer.—seatiea THE M. W. KELLOGG COMPANY Undesulphurized natural gas leaving the preheat coils is routed through the guard chamber preheater (103-B) to operating temperature controlled by TRGa-l. The preheater effluent then passes downflow through the zinc oxide guard chamber 108-D. Here trace sulphur compounds are effectively removed passing through the hot zinc oxide beds. Leaving the.zinc oxide guard chamber the feed gas is joined and mixed with process steam, ‘flow controlled by FRCa-2. The steam flow controller is furnished with a low flow alarm (FA-81) which, whem actuated, will sound an alarm and trip solenoid valve VS-19. This action vents the control air to FRRCa-1 feed gas control valve. All feed gas to the primary reformer is then discontinued. The combined stream (gas and steam) flows into the mixed feed preheat coil to the primary reformer via a 12-inch distributor header. @ Primary Reforminy From the main twelve-inch inlet header, the process flow is distributed to nine six-inch sub-headers, Each of the sub-headers distributes the flow downward through 42 parallel (catalyst packed) tubes in the radiant section of the primary reformer 101-B, The six-inch sub-headers are arranged in nine parallel rows over the top of the heaters, distributing the flow through a total of 378 catalyst packed tubes, These catalyst packed tubes are, in fact, the "Primary Reforming Reactor", ‘The bottom of each row of 42 catalyst packed tubes terminates in collector headers located near the floor of the primary reformer. There are nine risers (centrally located) on each of these collection headers that retarn the flow to a water jacketed transfer line located over the top of the reformer. The transfer line directs the flow from the primary reformer to the process inlet of the Secondary Reformer, 103-D. ‘The primary reformer has various pressure gauges, temperature indicators and temperature recorders (TR) to observe pracess conditions. There is also pressure differential indicator (Pdla-55) for observing the pressure drop across the tubes and an analyzer recorder (AR-1, Stream #4) recording the methane (CH) content of the process flow leaving the primary reformer. (3)___ Process Air Process air for the secondary reforming operation is delivered by the air compressor, 101-5. This compressor, its auxiliaries and its operations are fully described under "Special Equipment" in Section II of this manual. Description here is limited to that equipment through which the process air flows.: Section I + THE M.W. KELLOGG COMPANY 6 ‘The compressor takes suction through the air filter, 102-L, which removes dust, etc. from the air stream. The air is compressed in two cases, low pressure and high pressure, of the compressor. It is then cooled in the intercooler following the first, second and third stages of compression. Entrained water, which is condensed, is automatically removed to sewer from moisture separators provided with each intercooler. These intercoolers are equipped with level gauges and high level alarms, LA-127, LA-123, and LA-128, respectively. These alarms are located on the local compressor board panel. The anti-surge controller, FICa-4, is provided to maintain the com- pressor flow above its minimum value (surge point) by venting air to atmos- phere. A side stream from downstream of the third stage discharge intercooler is used to supply instrument air via line IA-1. A branch line (A-22) from the final discharge line (A-80) is provided to supply air for dusting of the down- stream equipment containing catalyst during the initial phases of commissioning. The intercase vent for the 101-J can be operated manually by MIC-24 or opened automatically if the shutdown circuit is activated closing motor operated valve (SP-3). Local pressure and thermometer indicators are provided wherever necessary for the checking of process air conditions throughout the compressor system. The last discharge is provided with a high temperature alarm (TA-71) located on the instrument panel. Process air flow to the secondary reformer leaves the compressor and is controlled by FRCa-3. Process air flow may be closed off to the secondary reformer by the operation of motor operated valve (SP-3) which is part of the reformer feed shutdown circuit. A two inch bypass is provided around SP-3 for use during initial startup of the secondary reformer. The compressor speed is manually controlled by board mounted MICa-20 which governs the turbine driver steam. Downstream of MOV SP-3, the process air is joined by a flow of medium level steam, Thé combined stream flows through the steam and air preheat coil in the convection section of the primary reformer furnace. The steam flow is metered by FI-51 and controlled manually by MIC-18. This steam flow is necessary for the protection of the preheat coil in the event of process air failure. Startup bypass line A-28 is provided around the steam/ air preheat coil to avoid overheating the process air during the air heating of the secondary reformer catalyst.“Section 1 THE M. W. KELLOGG COMPANY ~ 4. 4 Secondary Reforming The process flow enters a chamber at the top of the secondary reformer (103-D) and is directed downward through a diffuser ring to enter the com- bustion zone of the reformer. Preheated air is introduced to the process through a nozzle located just below the diffuser ring. Leaving the combustion zone of the reformer, the flow passes through the catalyst bed to enter a chamber at the bottom of the reformer. From the outlet chamber of the reformer the flow is split to pass through the shell sides of two “bayonet type" waste heat boilers (101-CA and 101-CB). The flow through the tube side of these waste heat boileze is boiler water from 101-F. From the shell side outlet of the primary waste heat boilers the flow recombines to enter the tube side of a secondary waste heat boiler (102-C). The flow through the shell side of this waste heat boiler is also boiler water from 101-F. From the tube side outlet of the secondary waste heat boiler the flow combines with a bypass flow around 102-C via a “mixing tee" and continues on to the high temperature shift converter (104-D). The secondary reformer and waste heat boilers described above are supplied with pressure gauges, temperature indicators, temperature recorders and temperature alarms. There is a pressure differential PdI-53 which measures the pressure differential from the transfer line inlet to the secondary reformer outlet and an analyzer for CH4 (AR-1, Stream #4) to observe process conditions through the system. A hot line bypass around 102-C controls the process inlet temperature to the high temperature shift converter, temperature controled by TRCa-10. A small flow of medium steam is piped to the valve stem of the TRCa-10 valve for cooling purposes. A butterfly valve (SP-39) installed on the outlet of 102-C (line PG-2) permits effective control of the TRCa-10 instrument by keeping its throttling value in good control range. High temperature alarms are installed in the Secondary Reformer catalyst bed and outlet of 102-C (TA-74 and TA-75 respectively). The Primary and Secondary Reformer systems including the waste heat boilers are protected against overpressuring by RV-104-CT-I at the outlet of the 102-C, The secondary reformer is furnished with metal temperature indicating points to permit checking metal temperatures at the top and bottom of the vessel. These will be indicated on TI-1-122 through 129 by means of a special selector switch. r Shift Converter (High and Low Temperature) The shift converter (104-D) is in reality two shift converter systems (high and low temperature), so constructed with internal dished heads to separate one from the other. The upper section being the high temperature converter and first in the process flow from the secondary reformer.“Section 1 THE M. W. KELLOGG COMPANY . - ‘The flow enters the top of the high temperature shift converter, through a distributor and down through the shift catalyst and out the bottom of the converter. The flow then enters the tube side of the primary shift effluent waste heat boiler 103-C to give up heat to the boiler water from 101-F. This exchanger is equipped with a hot line by-pass to give flexibility of temperature control to the inlet of the low temperature shift converter. ‘The temperature is automatically controlled by TRCa-11 located in the hot line process by-pass of the primary shift effluent waste heat boiler whose sensing element for this control is installed at the inlet to the L.T. shift converter. The control valve stem of TRCa-11 is cooled by medium pressure steam. The process gas is further cooled in methanator feed preheater 104-C, before entering the low temperature shift converter. ‘The gas from the high temperature shift converter enters the low temperature section and passes through the catalyst bed, the top 650 cu. ft. acting as a guard to the catalyst bed where any sulfur that may have evolved from the high temperature shift converter will be picked up, the gas then flows through the remaining low temperature shift converter catalyst and out the bottom of the shift converter. ‘The low temperature shift converter may be by-passed during start-up or upset via PG-20. This operation is controlled by push button PB-2 which closes MOV-SP4 in the }ow temperature shift inlet line while opening MOV-SP5 in the by-pass line or vice-versa. By “inching" the PB-2 instrument, the two converter operated valves may be adjusted for partial bypass operation. ‘The high and low temperature shift converters are provided with tem- perature indicating and recording points. A high temperature alarm TA-77 is associated with TRCa-11 on the low temperature shift converter inlet line. Pressure drop through the catalyst beds is obtained on locally mounted PdIA-54 for the high and low temperature shift converters. The hot "'shifted" gas from the bottom of the iow temperature shift converter passes through a reactor effluent desuperheater station. ‘The desuperheater outlet temperature is quenched to its dew point by injecting process condensate from the raw gas separator 102-F, supplied by the quench water pump 106-J with the flow controlled by MICa-11. A high temperature alarm, TA-82, is provided at a point downstream of the desuperheater, From the desuperheater outlet the process stream is first cooled in the tube side of the converter effluent-Catacarb solution exchanger (1105-C) while furnishing reboiler heat for the CO2 stripper (1102-E). Next the partially condensed process stream flows through the tube side of the COp stripper con- densate reboiler (1113-C) where further cooling takes place. At this temperatur. most of the water vapor is condensed with the latter being disengaged from the Process gas stream in the raw gas separator (102-F).Section I THE M. W. KELLOGG COMPANY 9 ‘The raw synthesis gas passes overhead from the separator and is directed to the COz absorber for the initial synthesis gas purification step. The condensed process stream is withdrawn from the bottom of the separator. Provisions are made so that boiler feed water can be used as a quenching ‘medium for the shift converter effluent during start-up or emergencies. A portion of the raw gas separator water is used to maintain the water balance in the COz system controlled by FRCa-12, ‘The balance of the net condensate is level controlled as export condensate and sent outside battery limits via PW-6. ‘The systems described above are instrumented as required to observe and control operating conditions. Pressure protection on the circuit is provided by relief valve RV-102-F located on the raw gas separator vapor outlet line. Synthesis Gas Purification System (1) ___Carbon Dioxide (CO2) Removal Removal of carbon dioxide from the raw synthesis gas is accomplished by absorption using a catalyzed solution of potassium carbonate. This process is known as the Catacarb System. Catacarb solution consists of an aqueous solution of potassium carbonate which combines chemically with carbon dioxide. In addition the treating solution contains additives which improve COz absorption, inhibit corrosion and control foaming of the solution. ‘The raw synthesis gas flows directly from the top of the raw gas separator to a distributor in the bottom of CO absorber 1101-E, The upflowing process gas passes through four beds of packing. The top two beds contain 1" carbon steel pall or flexirings topped off with 1" stainless steel pall or flexirings. The two lower beds contain 1 1/2" carbon steel pall or flexirings topped off with 1 1/2" stainless steel pall or flexirings. As the gas flows up through the packing it contacts downflowing semi-lean and lean Catacarb solution which absorbs the COz. The process gas passing out the absorber top, essentially free of COz, flows to the COz absorber knockout drum 1113-F for removal of entrained Catacarb solution, ‘This solution is returned to the system under level control (LC-5) entering the Catacarb sewer and sump system via a steam traced line. A high level alarm is provided on the knock-out drummeray THE M. W. KELLOGG COMPANY ao to warn of an abnormal level condition. Process gas leaving the absorber top then passes through the shell side of 136-C (synthesis gas - methanator feed exchanger) and the shell side of 104-C (methanator feed heater) before flowing to the methanator (106-D) top inlet. Catacarb solution enters the COz absorber at two levels. In the lower (larger diameter) section semi-lean Catacarb solution affects bulk removal of COz from the upflowing gas. This partially regenerated solution is taken {rom an intermediate point of the CO2 stripper (1102-E) by the semi-lean Catacarb circulating pump 1107-J, entering over the bottom two beds of the absorber via a distributor. The semi-lean solution Slow is controlled by FRCa-5 and a low flow alarm (FA-84) warns of a pre-set low flow condition. Lean Catacarb solution is withdrawn from the COz stripper bottom by lean Catacarb circulating pump 1110-J and is directed through a distributor over the two top beds of the absorber. The flow rate of this stream is controlled by FRCa-14 and a low flow alarm (FA-91) also warns of a preset low flow con- dition. An adjunct of the lean Catacarb circulating stream is the carbon filter 1118-F. A small slip stream of the regenerated solution passes through the carbon type filtering medium for the continuous removal of entrained solids that may have been picked up. This slip stream is manually controlled by a globe valve, with a forcing globe valve in the main line, and is metered by Fi-67. A pressure differential indicator (Pdl-23) is provided to indicate the need of cleaning the filter, The filter inlet and outlet lines (CAT-35 and CAT-36) are steam traced to prevent crystalization of the lean Catacarb solution. ‘The combined "rich" Catacarb solution collecting in the absorber bottom is level controlled by LRCa-4 to the top of the stripper. The higher pressure on the absorber is used as a driving medium for the hydraulic turbine to affect a forward flow of rich Catacarb solution, The hydraulic turbine is integrated with 1107-J, semi-lean Catacar’ circulating pump. The instrumentation relating to the control of this system is separately discussed under "Complex Instrumentation" in Section II of this manual. A low level alarm (LA-107) and appropriate switches and solenoid operated valves are an integral part of the system, The differential pressure across the absorber is measured by Pdla-19. An increase in pressure drop is indicative of foaming in the absorber, or an excessive Liquid loading. As described above, rich Catacarb solution flows to the CO2 stripper via the hydraulic turbine. .A metered stream of air (FIr-46) is injected into the rich solution upstream of the stripper. This air is required to assist the corrosion inhibitor in the stripper overhead circuit. A solenoid actuated valve (V-21) will automatically stop the flow of air on loss of "rich" Catacarb sdlution flow. The air is supplied from the process air compressor discharge (101-J).» » THE M, W.KELLOGG COMPANY a. Flashing of the "rich" solution in the upper section of the CO2 stripper releases some of the absorbed. As with the absorber, the stripper design. is based on operating at two Catacarb solution levels. The upper (larger diameter) section is provided with twenty-six (26) four flow trays where the downflowing "rich" Catacarb solution is partially stripped of COz by the upflowing vapors. A portion of this semi-lean Catacarb solution is withdrawn by circulating pump 1107-J and is returned to the absorber mid-section as previously described. The balance of semi-lean Catacarb solution continues downward through seventeen (17) two flow trays to the bottom of the stripper, where it accumulates on a trap-out pan flowing into the COz stripper gas reboilers 1105-C and 1111-C. The stripped (lean) Catacarb solution collects in the bottom of the stripper and is withdrawn by the lean Catacarb circulating pump 1110-J for return to the absorber top as previously described. The stream from the stripper to 1110-J is cooled in Jean Catacarb-BFW exchanger 1107-C. Directly above the "rich" solution inlet of the stripper is a demister pad to reduce entrainment of Gatacarb solution droplets in the upflowing vapors. Above the demister pad are three (3) two flow trays to wash the effluent vapors for further reduction of Catacarb solution entrainment. The wash material is composed of condensate withdrawn from stripper reflux drum 1103-F by pump 1108-J, The flow is on level control (LRCa-7) and is metered by FRa-16. Additional wash material is the condensate from the raw gas separator con- trolled by FRCa-12. ‘The bottom tray in the "wash" section is provided with a total drawoif routing the recovered Catacarb solution bearing condensate to the condensate reboiler 1113-C. This reboiler, along with CO? stripper gas reboiler 1105-C and CO; stripper steam reboiler 1111-C, provides the stripping medium for 1102-E, Considerable uncondensed steam is included with the raw synthesis gas entering the COz absorber. About 90% of this steam is condensed leaving the absorber bottoms with the "rich" Catacarb solution. This material, along with the condensate from the raw gas separator used as wash in the upper cection of the stripper is entrained in the COz and vents to atmosphere under pressure control of PiCa-24 to atmospheric vent through silencer (SP-100). The overhead is divided into two streams. One stream of carbon dioxide is cooled in the CO2 stripper condenser 1110-C, The condensate resulting from“ * THE M:W. KELLOGG COMPANY 13, Temperature recorder TR-6, points 1, 2, 3, 4, 5.and 6, also monitors the temperature of the catalyst bed, High temperature alarms are associated with each of these points; these are TA-95, 79, 96, 97 and 78 respectively. These alarms and their functions will be described more fally in Section Il under the heading “Complex Instrumentation’ ‘The methanator. section is also equipped with all instruments necessary to control and observe progess conditions. The methanator part of the system is pressure protected by RV-104-F located on the effluent of the synthesis gas suction drum 104-F, ce Ammonia Production System Synthesis feed gas leaving suction drum 104-F is analyzed for CHq (AR-1 Stream #1), CO and COz (AR-2 Stream #2) and Hz (AR-3). (1) ____Compression of the Purified Synthesis Gas The synthesis gas compressor (103-J) is the first step in the ammonia production part of the system. The compressor takes suction from the synthesis gas compressor suction drum (104-F) and increases the pressure im the first case of the compressor and discharges into the second case of the compressor via a series of intercoolers and the synthesis gas compressor first stage separator (105-F). The synthesis gas compressor (103-J) is fully described undér "Special Equipment" in Section Il of thie manual. A pressure controller PRCa-6 senses the 104-F compressor suction drum pressure and adjusts the compressor speed to maintain the pressure constant in the drum. A high level alarm LA-108 on 104-F is also provided to warn of such a condition and a compressor shutdown switch LS-109 will protect the machine by shutting it down when an abnormally high level actuates the device. Liquid is removed from 104-F via level control LC-8. PICa-4 will maintain pressure on the suction drum by venting the stream when the compressor is slowed down or out of service. The flow of synthesis is progressively cooled by passing through the tube side of the synthesis feed gas compressor intercooolers (136-C, 116-C and 129-C), In the 129-C, the synthesis gas is cooled in exchange with feed to the methanator, followed by exchange with cooling water in 116-C and finally chilled to 8° (46°F) in 129-G in exchange with ammonia from the 110-F re- frigerant flash down, The process gas outlet temperature of 129-C is controlled by PIC-10 which maintain the necessary pressure on the refrigerant side.Section F THE M. W. KELLOGG COMPANY 14, From the last inter-cooler (129-C) the flow enters the inter-cooler separator (105-F) where all condensed liquid (mainly water) is drained'to sewer level contro} (LC-10). The dry synthesis feed gas leaves the top of the separator, after passing through a demisting pad and flows to the suction of the second case of the synthesis gas compressor where'the pressure is further increased to the necessary pressure level to enter the synthesis gas loop. A low case kickback from 105-F to the suction of the first case inlet regulated by FICa-7 is provided to maintain the flow through this case and keep it out of surge. The synthesis feed gas compressor is equipped with pressure recording controls, flow controls, pressure gauges, temperature indicators and level alarms to provide proper control, and to observe process conditions through the compressor. ‘The first case discharge of the synthesis feed gas compressor is pressure protected by RV 105-F located at the outlet of the inter-cooler separator (105-F) and on the second case discharge by RV-103-J. A high liquid level in 105-F will activate high level alarm LA-110 and a compressor shutdown switch LS-111 will protect the machine by shutting it down when an abnormally high level actuates the device. ‘The first stage discharge of the compressor is provided with special by-pass piping where a portion of the discharge flow may be sent directly to 116-C inter-cooler. This arrangement permits some flexibility to enable control of the temperature of the inlet gas to the low temperature shift con- verter. With by-passing part of the compressor discharge from 136-C, heat input is reduced resulting in a lower process gas outlet temperature (ThI-33) with subsequent loss of heat exchange in the 104-C, methanator feed heater. The effect is a temperature decrease of the low temperature shift converter feed gas (TI-I-11) from 104-C. Control of the stream is by a mechanical inter-connection of butterfly valves SP-79 and SP-80. When the by-pass SP-80 is opened, the mechanical linkage provided closes SP-79 a corresponding amount "forcing" the flow through the by-pass to 116-C. (2) ___ Synthesis (Conversion) of Gas to Ammonia Gas from 105-F passes through a check valve into the suction of the second compressor case. There is a small bypass line around the check valve with 2 13/32" restriction orifice. This bypass serves to equalize the pressure in both cases in case of compressor shutdown. The gas flow is metered by FiCa-8 which sets the quantity of gas, when necessary being recycled back to suction to keep the second case of the compressor out of surge.Section I THE M. W. KELLOGG COMPANY Sob ‘The synthesis gas is compressed in the second case and is then joined by a large stream of recycle synthesis gas containing ammonia, for final com- pression by the last wheel of the case. This stream is cooled in the tubes of the synthesis gas compressor after-cooler 124-C. The high case anti-eurge controller FICa-8, routes a kickback flow from the downstream of the after- cooler to the high case suction via line SG-42 when necessary to maintain the high case suction flow above its minimum valve. SG-42 bypass line will be steam traced to prevent condensation in 103-J compressor suction line, for its entire length to SG-11. In addition, a second kickback stream may be routed to the recycle suction to prevent surge in the recycle wheel of the second case, regulated by FICa-15 in line SG-51 and is only used when the normal recycle flow has been shut off closing valve SP-70 or during start-up. Low flow FA-87 is associated with FICa-15, The discharges of the low and high cases are provided with high tem- perature alarms, TA-83 and TA-80 respectively. These alarms are mounted locally but also activate common compressor alarm CA-3 in the control room. ‘The synthesis recycle suction is provided with low temperature alarm, TA-87. Motor-operated valves SP-70 and SP-1 are provided in the high case cooled discharge and synthesis gas recycle lines respectively. They are closed by operation of a trip circuit on shutdown of compressor PS-92. The MOV's SP-70 and SP-1 can be manually opened or closed by push button PB-5. The three-inch bypass valve around MOV SP-1 will be used for con- trolling the flow to the start-up heater at startup. The high pressure synthesis gas is further cooled in two parallel streams, The first stream is cooled in series flow through the tubes of the feed and recycle gas first stage chiller, (117-C), and the feed and recycle gas second stage chiller, (118-C). Cooling mediums for 117-C and 118-C are ammonia refrigerants. The second stream is throttled by local HCV-10 and is cooled in the shell of the ammonia converter feed effluent and recycle exchanger 120-C before joining the first stream for further chilling in the tubes of the feed and recycle third stage chiller 119-C with ammonia refrigerant. The chilled stream enters the secondary ammonia separator 106-F via a horizontal distributor. Ammonia from the recycle stream condenses out in the chillers and disengages in the 106-F. The liquid, under pressure, leaves the ammonia separator under control of LC-13 to the primary ammonia separatorTHE M. W. KELLOGG COMPANY 7 16. “Section I 107-F. The secondary separator level shows on Lla-80 and the presence of liquid can be checked locally by tricocks. The synthesis recycle gas passes through demisting pads at the top of the ammonia separator going to the ammonia synthesis system as a continuation of the synthesis recycle gas loop and comprises feed to the ammonia converter. High and low level alarm LA-112 is provided to warn when either extreme condition exists, Leaving the ammonia separator drum the recycle gas flow enters the tube side inlet of the ammonia converter feed and recycle gas exchanger (120-C) to take up heat from the process flow in the shell side, From the tube side outlet of this exchanger the flow enters the tube side inlet of the ammonia converter feed /effluent exchanger (121-C) and continued on to the inlet of the ammonia converter (105-D) being controlled by HCV-11. At the effluent of the tube side of 121-C, the synthesis gas is analyzed for methane (CH4) on stream #1 of AR-1 and for hydrogen (Hz) on stream #1 of AR-3. SP-35, a special two-way rupture disc assembly is located on the by-pass line around HCV-11 in the effluent line from 121-C to the inlet of the 105-D ammonia converter. This rupture disc is to protect 121-C exchanger against excessive differential pressure if one side of the exchanger is depressured. ‘The synthesis gas feed inlet to the ammonia converter is at the bottom of the converter 105-D. The flow of gas is upward through an annular space between the outer shell and the wall of the. catalyst section into an interchanger shell 122-C located at the top of-the converter where the gas is preheated against hot converter effluent. Leaving the shell side of 122-C, the flow passes downward through four catalyst beds in a "catalyst basket." There is a space between each of the catalyst beds where quench is introduced above the first and succeeding beds of catalyst to control the temperatures for maximum yield. ‘The quench used is a part of the synthesis gas feed that bypasses the 122-C interchanger. After leaving the bottom catalyst bed, the flow enters a centrally located stand pipe that carries the gas up through the converter to the tube side of the converter effluent/converter feed exchanger 122-C. The flow passes through the interchanger tubes giving up heat to the converter feed and leaves via an outlet nozzle at the top of the converter 105-D. Before the synthesis gas enters the converter, part of the flow may be by-passed around the inter-changer (122-C), and routed directly to the number one bed inlet via MICa-13 for temperature control at this point. This inter- changer by-passing is extended to include three quench gas flows to control the inlet temperatures to beds two, three and four, these quench flows are regulated as necessary by MICa-14, 15 and 16 respectively.Section I THE M.W. KELLOGG COMPANY - ro ‘The converter effluent enters the tube side inlet of the ammonia converter/boiler feed water exchanger 123-C to give up heat to the boiler feed water. The converter effluent undergoes further cooling with heat exchange against the feed to the converter in 121-C. The flow from the shell side outlet of this cooler returns to the last wheel suction of the synthesis gas compressor (103-J) second stage to complete the synthesis Bas loop. : A part of the converter effluent can be routed via FICa-13 and line SG-39 to 101-B as fuel gas or removed by MIC-12 to the SP-75 vent at the top of the CO2 strippers from the purge gas separator 108-F to contro) the concentration of inerts (methane and argon). A build up of these components is reflected in lower ammonia conversion. The purge gas is chilled in chiller 125-C before entering the purge gas separator 108-F. Liquid from the separator, predominately ammonia, is routed to the primary ammonia separator for recovery, Pressure on the fuel gas system to which the purge gas flows is controlled by PICa-1. The ammonia synthesis converter is equipped with a start-up heater (102-B). This heater is used to heat the converter to reaction temperatare during the start-up. ‘The converter feed flow is indicated on Fla-62. A low flow alarm FA-89 is associated with the MIC-17 which controls the fuel gas to the 102-B burners. The synthesis loop has all the temperature indicators (and recorders), pressure differential indicators and hand control valves (HCV and MIC's) to observe and control process conditions within the "loop". There are also special emergency motor valves that isolate the recycle compressor from the syn, gas loop under certain conditions. These will be discussed under sub- section "C, SPECIAL EQUIPMENT", located in Section II of this manual, The entire synthesis gas loop {including converter 105-D) is pressure protected by RV-105-D located in line SG-35 at the outlet of 121-C. (3)___ Refrigeration and Ammonia Product Purification The ammonia product that is separated from the synthesis loop in the secondary separator drum (106-F) is sub-cooled fot maximum ammonia condensation. This sub-cooling at the high pressure level of the synthesis loop will cause a degree of inerts (hydrogen/nitrogen) to be absorbed by the liquid and results in a contaminated ammonia product.Section 1 THE M. W. KELLOGG COMPAN' 18, ‘To remove the absorbed gases from the ammonia product it is first flashed in the primary ammonia separator (107-F) at low pressure. The glash gas that leaves the primary flash drum is released to the fuel gas system for disposal via PiG-8 that is set to hold design back-pressure on 107-F to prevent over-flash. Separator 107-F is provided with level indicator Lla-81 and LA-113, high and low level alarm. The liquid leaving the primary ammonia separator 107-F is routed to two points in the refrigeration system. One stream is let-down to the second stage refrigerant flash drum I11-F by flow controller FRCa-21 in line NH-59-2"" The remaining stream is let-down to the third stage refrigerant flash drum 112-F by level control LC-12. With the two controls constant for 107-F and 112-F the refrigerant requirements of I11-F (118-C, 125-C) and 1)2-¥F (119-C) will be satisfied. ‘The ammonia product is made up of two streams to give the desired temperature level. One stream or the hot product comes from the first stage refrigerant flash drum. It is pumped by the hot ammonia product pump 121-J with the rate controlled by FRCa-17. The other stream of cold product comes from the third stage refrigerant flash drum where it is pumped by the cold ammonia pump (109-J) with the rate controlled by LICa-19 which senses the level in the flash drum, the rate recorded on FRa-35. The two product streams combine and flow to the product storage or pipeline whichever the case may be. TA-98 is provided to alarm on a high temperature level as recorded on TR-7-11. The ammonia product receiver (109-F) receives all condensed ammonia from the discharge of the refrigeration compressor (105-J). The level is controlled by LICa-15 which controls the amount of excess liquid delivered to the first stage refrigerant flash drum, Ammonia from the 109-F is also used as a cooling medium or quench for the compressor kickback flows recycling to each of the refrigerant flash drums, the rate controlled by a 5/16" restriction orifice located in each of the kickback lines. This quench is used mainly during startup and is also provided with a globe valve in each service to hand control refrigerant when under low heat control conditions. A small flow of ammonia is taken from the ammonia receiver via line NH-90 for use in 2004-LF the ammonia chemical injection tank. Flash gas chiller 126-C is used to condense ammonia flash vapors liberated from the ammonia product receiver. The pressure is controlled by PIC-7 which releases the excess to the plant fuel gas system via line NH-120. Condensed arnmonia flows by gravity and joins the ammonia flow from 109-F.Section TE THE M. W. KELLOGG COMPANY ». Refrigerant ammonia used 126-C comes from the first stage refrigerant flash drum (110-F) with the flow restricted by a°ll/31" orifice and the vapors recovered in the second stage refrigerant flash drum (u-F). ‘The first stage refrigerant flash drum is used to supply refrigerant at the necessary temperature level for the thermosyphon feed and recycle first stage chiller (117-C) and through a 3/4" restriction orifice feeding the synthesis gas compressor interstage chiller (129-C), the temperature of the compressed gas is controlled by PIC-10 located on the refrigerant outlet side. As noted earlier, the warm ammonia used for the tempering of the cold product stream comes from this drum. A sidestream is taken from the pump suction line furnishing the ammonia injection pump (120-J) with ammonia. ‘This pump delivers liquid ammonia to the ammonia vaporizer (147-C) where the vapors enter the suction of the synthesis gas compressor via line NH-77. ‘The first stage refrigerant level is controlled by LC-16 routing the excess liquid ammonia to the next pressure /temperature level flash drum. LA-1L5 is provided to alarm on a high level with LS-116 provided to shut down the refrigeration compressor on extreme high level. ‘The second stage refrigerant flash drum (311-F) receives its ammonia from 110-F and also a set rate from the primary ammonia separator (107-F) controlled by FRC-21. The excess level of this drum is level controlled by LG-18 to the third stage refrigerant flash drum. Liquid ammonia from 111-F is circulated by thermosiphon effect through the feed and recycle second stage chiller 118-C, Refrigerant from 111-F also supplies duty for the purge gas chiller 125-C through a 7/16" restriction orifice. LA-117 is provided to alarm on a high drum level with LS-118 shutting down the compressor on extreme high level conditions. ‘The third stage refrigerant flash drum (112-F) receives excess ammonia from 111-F and also the remaining major portion of product from the primary ammonia separator. Ammonia from 112-F is circulated by thermosyphon effect through the feed and recycle third stage chiller (119-C). Ammonia product removed from the 112-F is pumped by the 109-J product pumps and recorded on FR-35 before joining the hot product stream, LA-119 is provided to alarm on a high level with LS-120 shutting down the refrigeration compressor on extreme high level conditions.