Ammonia

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August 1998

TABLE OF CONTENTS
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SUMMARY
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CHEMISTRY AND TECHNOLOGY

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INTRODUCTION
COMMERCIALLY AVAILABLE AMMONIA PROCESS TECHNOLOGY
1.
Brown & Root Braun Purifier Process
2.
Haldor Topsoe Low Energy Ammonia Process
3.
ICI Katalco
(a) ICI-AMV Process
(b) ICI-LCA Process
4.
Linde Ammonia Concept (LACTM)
5.
M.W. Kellogg Kres-KAAP Process
6.
UHDE Low Energy Technology
COST OF PRODUCTION
GLOBAL MARKET OVERVIEW
1.
Demand
2.
Supply
3.
Trade

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AMMONIA PROPERTIES
OVERALL PROCESS DESCRIPTION
1.
Feedstocks for Ammonia Synthesis
2.
Hydrogen Production
3.
Synthesis Gas Purification
4.
Ammonia Synthesis
GENERIC PROCESS REVIEW
1.
Natural Gas Purification
2.
Syngas Production
(a) Steam Reforming
(b) Partial Oxidation
(c) Byproduct Hydrogen Rich Streams

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COMMERCIAL AVAILABLE PROCESS TECHNOLOGY

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Syngas Purification
(a) Shift Conversion
(b) Removal of Carbon Dioxide
(1) Methyldiethanolamine (MDEA)
(2) Potassium Carbonate
(c) Removal of Residual Carbon Oxides by Methanation
(d) Dehydration
(e) Cryogenic Separation
4.
Ammonia Synthesis and Separation
(a) Catalyst and Reaction Heat
(b) Kinetics and Equilibrium Considerations
(c) Operating Pressure
(d) Synthesis Converters and Loop
(e) Purge Gas
THERMAL EFFICIENCY AND ENERGY BALANCE
1.
Thermal Efficiency of Ammonia Plants
2.
Energy Consumption and Recovery in Ammonia Plants

BROWN & ROOT BRAUN PURIFIER PROCESS

1.
Technology Features
(a) Mild Primary Reforming
(b) Secondary Reforming with Excess Air
(c) Cryogenic Purification Unit
2.
Process Description
(a) Feed Desulfurization
(b) Primary Reforming
(c) Secondary Reforming
(d) Shift Conversion
(e) Carbon Dioxide Removal and Methanation

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(f) Drying and Cryogenic Purification

(g) Ammonia Synthesis and Recovery
HALDOR TOPSOE LOW ENERGY AMMONIA PROCESS
1.
Technology Features
2.
Process Description
(a) Reforming
(b) Shift Conversion
(c) Gas Purification
(d) Synthesis
(e) Ammonia Plant Optimization
ICI KATALCO
1.
ICI-AMV Process
(a) Technology Features
(b) Process Description
(1) Excess Air to the Secondary Reformer
(2) Lower Synthesis Loop Pressure
(3) Purge Gas Hydrogen Recovery
2.
ICI-LCA Process
(a) Technology Features
(b) Process Description
LINDE AMMONIA CONCEPT (LACTM)
1.
Technology Features
2.
Process Description
(a) Desulfurization
(b) Primary Reformer
(c) Isothermal Shift
(d) Pressure Swing Adsorption (PSA)
(e) Nitrogen Production
(f) Ammonia Synthesis

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PROCESS ECONOMICS
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M.W. KELLOGG KRES-KAAP PROCESS

1.
Technology Process
(a) KRES Front End
(b) KAAP Ammonia Synthesis
2.
Process Description
(a) Raw Synthesis Gas Preparation and KRES Front End
(b) Synthesis Gas Purification
(c) Ammonia Synthesis and KAAP Catalyst
(d) Ammonia Refrigeration System
UHDE LOW ENERGY TECHNOLOGY
1.
Technology Features
2.
Process Description
(a) Steam Reforming and Carbon Monoxide Shift
(b) Carbon Dioxide Removal and Methanation
(c) Ammonia Synthesis and Hydrogen Recovery
RECENT LICENSOR EXPERIENCE

COST OF PRODUCTION METHODOLOGY

1.
Battery Limits
2.
Production Costs
(a) Variable Costs
(b) Direct Fixed Costs
(c) Allocated Fixed Costs
(d) Financing
AMMONIA COST OF PRODUCTION
1.
Capital Cost Data
2.
Cost of Production
3.
Sensitivity Analysis
HISTORICAL AMMONIA PRICING

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NEW DEVELOPMENTS AND PLANT MODERNIZATION

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COMMERCIAL ANALYSIS
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NEW DEVELOPMENTS AND INDUSTRY TRENDS

1.
Heat Exchange Reforming
2.
Pre-reforming
3.
Shift Catalysts for Low Steam to Carbon Ratios
4.
Low Temperature Ammonia Synthesis Catalyst
5.
Carbon Dioxide Removal
6.
Advanced Process Control
7.
Trends in Ammonia Plant Size and Costs
REVAMP AND PLANT MODERNIZATION
1.
Higher Efficiency Converters
2.
Reformer Design
(a) Reformer Tubes
(b) Steam to Carbon Ratio
3.
Modification of Shift Unit
4.
Molecular Sieve Dryer
5.
Combustion Air Preheat
6.
Process Feed Saturator
7.
Improved Carbon Dioxide Removal
8.
Purge Gas Recovery
9.
Methanolation

INDUSTRIAL APPLICATIONS
1.
Fertilizer Uses and Industrial Applications
2.
Nitrogen Fixation - The Nitrogen Cycle
3.
Handling, Transportation, and Storage
GLOBAL MARKET OVERVIEW
1.
Demand
2.
Supply
3.
Trade

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NORTH AMERICA
1.
United States
(a) Demand
(b) Supply
(c) Trade
2.
Canada
(a) Demand
(b) Supply
(c) Trade
WESTERN EUROPE
1.
Demand
2.
Supply
3.
Trade
EASTERN EUROPE AND THE FORMER SOVIET UNION (FSU)
1.
Demand
2.
Supply
3
Trade
SOUTH AND EAST ASIA
1.
China
(a) Demand
(b) Supply
(c) Trade
2.
India
(a) Demand
(b) Supply
(c) Trade
3.
Indonesia
(a) Demand
(b) Supply
(c) Trade

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Japan
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Other
LATIN AMERICA
1.
Demand
2.
Supply
3.
Trade
PRODUCING COMPANIES

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ACKNOWLEDGMENTS

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REFERENCES

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PERP TITLE INDEX

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TABLES
Page
Table I.A.1
Table I.D.1
Table I.D.2
Table I.D.3

Typical Properties of Ammonia

Ammonia Demand Summary, 1997-2010
Ammonia Capacity Summary, 1997-2010
Ammonia Net Trade, 1997-2010

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10
12
15

Table II.A.1
Table II.C.1

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Table II.D.1
Table II.D.2
Table II.D.3

Typical Properties of Ammonia

Typical Compositions of Byproduction Hydrogen Rich
Streams
Major Carbon Dioxide Removal Processes
Relative Energy Requirements for Bulk Carbon Dioxide
Removal
Definition of Thermal Input and Credits for Ammonia Plants
Cost and Thermal Efficiencies of Ammonia Plants
Developments of Ammonia Plant Energy Consumption

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Table III.C.1
Table III.G.1

Typical Reforming Conditions for the ICI AMV Process

Ammonia Licensor Experience Data (By Country)

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Table IV.B.1

Cost Estimate of Ammonia Production

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Table V.B.2

Approximate Energy Savings in Revamping Options

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Table VI.B.1
Table VI.B.2
Table VI.B.3
Table VI.C.1
Table VI.F.1
Table VI.F.2

Ammonia Demand Summary, 1997-2010

Ammonia Capacity Summary, 1997-2010
Ammonia Net Trade, 1997-2010
U.S. Ammonia End Use Breakdown, 1997
Fertilizer Application Rates - China
Indias and Chinas Fertilizer Contribution to Food
Production
Ammonia Capacity Producing Companies, 1998

Table II.C.2
Table II.C.3

Table VI.H.1

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FIGURES
Page
Figure I.A.1
Figure I.A.2
Figure I.D.1
Figure I.D.2
Figure I.D.3
Figure I.D.4
Figure II.B.1
Figure II.B.2
Figure II.C.1
Figure III.A.1
Figure III.D.1
Figure III.E.1
Figure III.E.2
Figure III.F.1
Figure III.F.2

Schematic Diagram of Ammonia Plant Based on Natural

Gas Feedstock
Global Capacity by Feedstock, 1998
World Ammonia Balance, 1995-2010
Global Ammonia Demand, 1995-2010
Global Ammonia Capacity, 1997
Estimated Global Ammonia Net Trade, 1997

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Schematic Diagram of Ammonia Plant Based on Natural

Gas Feedstock
Global Ammonia Capacity by Feedstock, 1998
Equilibrium Concentration on NH3 in Synthesis

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Brown & Root Braun Purifier - Process Flow Diagram

Process Flow Diagram of Lindes Ammonia Concept (LAC)
M.W. Kellogg Integrated KAAP/KRES Process Flow Diagram
Open Tube Reforming Exchanger
UHDEs Low Energy Technology Steam Reformer and Co Shift
UHDEs Low Energy Technology CO2 Removal and
Methanantion
UHDEs Low Energy Technology Ammonia Synthesis and
Hydrogen Recovery

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Figure IV.B.1
Figure IV.B.2
Figure IV.C.1

Net Cost of Ammonia Production

Ammonia Prices Compared to Base Case
Ammonia Price History, 1987-1997

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Figure V.B.1

Development of Ammonia Plant Energy Consumption,

1960s-1990s

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Figure III.F.3

Figure VI.B.1
Figure VI.B.2
Figure VI.B.3
Figure VI.B.4

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World Ammonia Balance, 1995-2010

Global Ammonia Demand, 1995-2010
Global Ammonia Capacity, 1997
Estimated Global Ammonia Net Trade, 1997

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