How to Bring Existing Ammonia

Plants Up-to-Date
Many existing ammonia plants located in areas with high feedstock prices are facing difficulties in today’s
more and more competitive market. In order to survive the competition from new plants coming up in areas
with low gas cost, existing plant owners can revamp their plants to reduce the energy consumption and/or
increase the plant capacity. Capacity revamps often offer a lower cost option to meet increased demand.

This paper will highlight a preferred approach to a revamp project and list a number of revamp features
available for bringing existing ammonia plants up-to-date. Following this a number of revamp projects cur-
rently under implementation will be described. Finally, a novel revamp option, the proprietary and patented
Haldor Topsøe Exchange Reformer (HTER), and the benefits by installing the same will be presented. The
HTER can be applied in existing plants, or may be included in the design of new plants. It offers, when in-
stalled in parallel with an existing reforming unit, the potential for increasing the capacity by up to 25% or
more depending upon specific plant configuration.

Svend Erik Nielsen

Haldor Topsøe A/S, Lyngby, Denmark

Peter Vang Christensen

Haldor Topsøe A/S, Lyngby, Denmark

Introduction with a lower investment compared to erect-

The increasing demand for ammonia and fertil-
isers is widely discussed and well documented. The
world population is constantly growing and the fertil-
iser consumption increases by 2-3% every year.
The increasing demands can in principle be satis-
fied by a number of actions such as:
• Construct new production facilities at loca-
tions where natural gas is cheap, and trans-
port the products to the consumers.
• Revamp existing production facilities for
increased capacity as required in order to
satisfy the increased demand locally. This
additional capacity can often be achieved
ing new facilities. Furthermore, local infra-
structure is available and can be utilised.
If the plant owner consider revamping an existing
plant it is our experience that the best way to structure a
revamp project is to divide the project into a study
phase followed by an engineering and implementation
phase provided that the scheme identified in the study is
attractive to the plant owner.
The target of the study phase is to establish the
most attractive revamp scheme in accordance with the
objective of the project together with a cost estimate for
the implementation of the project. Thus, the main pur-
pose of the study is to establish a solid basis for the

AMMONIA TECHNICAL MANUAL 168 2004

plant owner to evaluate the attractiveness of the revamp
project at a minimum cost.
Which specific revamp features to consider in the
study phase of the revamp project will have to be
evaluated on a case to case basis depending on the ob-
jective and the specific conditions prevailing. Below are
listed a number of the current revamp features which
can be considered when establishing the best possible
revamp scheme:
• Upgrading of feed purification and desul-
phurization section
• Installation of feed gas saturator
• Upgrading of mixed feed preheater and in-
let header system to increase reformer inlet
temperature
• Reduction of the steam to carbon ratio in
the reformer, taking advantage of new
high-activity reforming catalysts
• Change of reformer catalyst tubes with
thinner wall tubes made from new,
stronger alloys
• Introduction of combustion air preheat
• Installation of adiabatic prereformer
• Installation of a “heated prereformer”, a
heat exchange reformer heated by either
flue gas or by process gas
• Installation of an add-on convection re-
forming unit (e.g. the Topsøe HTCR de-
sign) with associated waste heat recovery
in parallel with the existing reformer
• Installation of a primary reformer with as-
sociated waste heat recovery in parallel
with the existing reformer
• Introduction of new high-activity shift
catalysts and re-configuration of shift sec-
tion by e.g. introduction of a LT shift
guard reactor
• Modification of shift reactor outlet system
to reduce pressure drop
• Upgrade of CO2 removal unit to boost ca-
pacity or reduce energy consumption by
introducing improved packing materials
and/or by adding additional flash stages
• Modifications/additions of coils in the re-
former waste heat section
• Replacement/addition of heat exchangers
to handle revised operating conditions
• Addition of more ammonia synthesis ca-
pacity by modifying the existing converter
2004
by installing new internals or by adding
new converter(s)
• Changing make-up gas addition point by
using a make-up drying unit or alterna-
tively an ammonia washing unit
• Introduction of purge gas recovery unit
• Modification/replacement of rotating ma-
chinery to add more capacity or to reduce
energy consumption
The most often used features are introduction of
prereformer, installation of additional ammonia con-
verter capacity, new reformer tubes and reduction of
S/C ratio. However, the choice beween the above op-
tions must of course be made during the study phase on
the basis of a careful analysis of the specific situation,
keeping in mind that an attractive revamp concept will
be characterised by:
• Low investment cost per additional ton of
ammonia product
• Low operating costs
• Short implementation time
• Minimum interference with the existing in-
stallation
The above approach to a revamp project has been
applied in connection with a number of revamp projects
currently under implementation for a plant owner in In-
dia. In the following we will list the selected revamp
options and describe one of the revamp features to be
implemented in more detail. Following this we will
demonstrate that the list of available revamp options is
constantly being extended by the development of new
technology features. In this respect a novel and attrac-
tive revamp feature which is of particular interest when
the reforming capacity of an existing plant is a bottle-
neck will be presented.
Revamp Projects Currently under
Implementation
In India, for a significant period of time, gas short-
age has presented significant restrictions to the ammo-
nia producers. Many plants changed their feedstock
from natural gas to naphtha and some plants have even
been designed for mixed feed operation. These days,
LNG is becoming available in India. In view of this,
many plant owners consider revamping their plants to
be able to operate on LNG and at the same time to re-
169 AMMONIA TECHNICAL MANUAL
duce the specific energy consumption to the lowest pos-
sible level, with reasonable investment cost.
One of the major fertiliser producers in India,
IFFCO (Indian Farmers and Fertilisers Cooperative) has
decided to revamp all their ammonia plants to be able to
meet the future Indian fertiliser scenario and is cur-
rently implementing energy saving revamp projects in
their 5 ammonia plants. The five plants are:
• Kalol, natural gas-based plant started up in
1975 designed by Kellogg
• Phulpur I, naphtha-based plant started up
in 1980 designed by Kellogg
• Aonla I, natural gas-based plant started up
in 1988 designed by Topsøe
• Aonla II, mixed feed-based plant started up
in 1996 designed by Topsøe
• Phulpur II, naphtha-based plant started up
in 1997 designed by Topsøe
The revamp schemes that will be implemented in
each of the five ammonia plants was developed during
the study phase of the project where various alternative
features were considered before arriving at the most at-
tractive schemes. Considering that the plants are of dif-
ferent designs and of very different vintage the revamp
features that were evaluated during the study phase was
carefully considered in each specific case.
As part of the study work a cost estimate was de-
veloped in order to provide the plant owner with a solid
basis for deciding if implementing the schemes would
be an attractive investment.
A number of revamp features that will be imple-
mented in the five ammonia plants are listed below (not
all features will be implemented in all of the plants):
• Final desulphurisation section to handle
the new feedstock
• New coils in cold end of reformer waste
heat section
AMMONIA TECHNICAL MANUAL
• Introduction of LT shift guard
• New outlet systems from HT, LT shifts
and methanator in Kellogg designed plants
• Revamp of the oldest CO2 removal units to
two stage Giammarco Vetrocoke/aMDEA
with two-stage flash
• Introduction of make-up gas chilling
• Retrofit of synthesis gas compressor train
• New make-up gas point along with ammo-
nia wash unit in Kellogg designed plants
• Introduction of radial flow S-50 converter
and new waste heat boiler
The achievable energy savings by implementing the
revamp schemes in the five ammonia plants vary be-
tween 0.3 – 0.9 Gcal/MT NH3 (1.3 – 3.9 MMBtu/ST
NH3). Considering that the introduction of the S-50
converter is the revamp feature that accounts for the
highest contribution to the overall energy savings, this
feature will be described in more detail in the follow-
ing.
S-50 Converter – M.W. Kellogg Plants
In Kellogg plants, the ammonia synthesis loop con-
tains an existing ammonia converter unit with
built-in feed/effluent exchanger. From the existing
converter, the exit gas is sent direct to the new S-50
converter at a temperature of approx. 325° (617°F).
After the S-50 converter a new MP steam boiler is
introduced. See Fig 1.
As the inlet temperature to the S-50 converter
is lower than the required inlet temperature to the
catalyst bed, an S-50 converter with a lower heat
exchanger is applied in the Kellogg plants.
170 2004

BFW
Preheater
New MP
Steam Boiler
Figure 1: Lay-out of Synthesis Loop in M.W. Kellogg-designed Plant with S-50 Converter
The S-50 converter consists of a full closure pres-
sure vessel and a converter basket. The converter basket
consists of a catalyst bed and a feed/effluent heat ex-
changer (lower heat exchanger). See Fig 2 for details.
The main part of the gas is introduced into the con-
verter through the main inlet in the top of the converter
(A) and passes downwards through the outer annulus
between the basket and the pressure shell, keeping the
latter cooled. It passes to the shell side of the feed-
effluent exchanger, where it is heated to reaction tem-
perature by heat exchange with the converter effluent
leaving the catalyst bed.
The remaining part of the gas, the cold shot gas, is
introduced through the inlet in the bottom of the con-
verter (B). It mixes with the main inlet gas having
2004
Purge
Gas
CW NH (l) NH (l) NH (l)
3 3 3
Ammonia
Product
passed the shell side of the heat exchanger, and the
mixed gas stream passes to the top of the converter
through the transfer pipe located in the centre of the
catalyst bed. The amount of cold shot gas determines
the inlet temperature to the catalyst bed.
At the top of the converter the gas passes to the
inlet panels of the catalyst bed. It passes the catalyst
bed in radial inward direction and flows to the annulus
between the bed and the central transfer pipe.
The effluent from the catalyst bed passes the tube
side of the heat exchanger, thereby heating the feed gas
to the reaction temperature, and flows to the converter
outlet (C).
171 AMMONIA TECHNICAL MANUAL
 fore the gas enters the S-50 converter at approx. 370°C
(698°F). See Fig 3 for details.

S-200 S-50
Converter Converter

Purge Gas
NH3 (l)

Preheater
BFW CW

Boiler NH3 (l) NH3 (l)

Product
Ammonia
Make-up Gas

Figure 3: Lay-out of Synthesis Loop in a Topsøe-

designed Plant with S-50 Converter

In the Topsøe designed plants, the S-50 converter is

designed as a hot wall radial flow converter (further de-
tails on the hot wall design are provided in [1]). The
converter lay-out is shown in Fig 4.
In this case, the S-50 converter has no lower heat
exchanger and the optimum inlet temperature to the
ammonia converter is achieved by cooling the effluent
from the first ammonia converter in the intermediate
HP steam boiler. The inlet temperature to the S-50 con-
verter is controlled by means of a by-pass around the
HP steam boiler.
The actual energy saving achieved by installing an
S-50 converter depends upon the lay-out of the synthe-
sis loop, but varies in the IFFCO cases between 0.15 –
0.30 Gcal/MT NH3 (0.65 – 1.30 MMBtu/ST). With the
high feedstock cost in India, this gives very attractive
payback times ranging from 1.5 – 3 years.
The revamp projects in IFFCO’s five ammonia
plants are implemented in a phased manner, and all the
revamp options will be installed from now and up to
3rd quarter 2005.
As stated previously the main objective in the re-
vamp projects for IFFCO has been to reduce the spe-
Figure 2: S-50 Converter with Lower Heat Ex- cific energy consumption, and the revamp options
changer evaluated in this connection has therefore been with the
target to meet this objective.
S-50 Converter – Topsøe Plants

The ammonia synthesis loop in the Topsøe-

designed plants contains an existing converter without a
built-in feed/effluent exchanger. From the existing con-
verter, the exit gas is sent to a new HP steam boiler be-

AMMONIA TECHNICAL MANUAL 172 2004

 However, very often the plant owner has the main
objective to increase the capacity of the plant. In this
connection it will be relevant to evaluate how to in-
crease the capacity of the existing reforming section in
the most attractive way. In the following a new revamp
feature addressing this issue will be presented.

Revamp by Installation of HTER

When significant capacity increase is desired, the
traditional revamp options may be insufficient
because bottlenecks in existing equipment, espe-
cially in the reforming section, restrict a possible in-
crease in production capacity. In such cases the pre-
ferred solution was the introduction of a prereformer [2]
to reduce the load on the primary reformer. In other
cases it has been necessary to construct a new primary
reformer in parallel to the existing one. In addition to
these options, Topsøe offers a new revamp option – in-
stallation of a newly developed proprietary and pat-
ented Haldor Topsøe Exchange Reformer (HTER) in
parallel with the existing reformer. This revamp feature
caters for significant capacity increase, and may repre-
sent an attractive solution especially in cases where the
existing reformer or the steam generation system is a
bottleneck.

This new revamp option will be described in the

following. The basis will be a typical ammonia plant
with a lay-out as illustrated in Fig 5.

Figure 4: Hot Wall Radial Flow S-50 Converter

2004 173 AMMONIA TECHNICAL MANUAL

 Desulphurization Reforming Shift

Natural Gas
Process Air

Flue Gas

Purge Gas

CO2- CO2
Removal
Ammonia Process
Product Condensate

Ammonia Synthesis Methanation

Figure 5: Typical Lay-out of an Ammonia Plant

The HTER is a newly developed proprietary heat
exchange reformer design, which offers a compact and
cost-effective increase of the reforming capacity when
installed in parallel with an existing steam reformer
(SMR). A description of the
HTER concept for revamps of hydrogen plants may be
found in [3].
The installation of a HTER in parallel with the
reforming section in a typical ammonia plant is illus-
trated in Fig 6.

Secondary HTER
Reformer

Process
Steam

Desulp.
Natural
Gas

Process Air

Figure 6: Revamp of an Ammonia Plant by installation of HTER in Parallel with SMR

AMMONIA TECHNICAL MANUAL 174 2004

 The HTER is installed in parallel with the SMR and
fed independently with desulphurized feed mixed with
steam. This allows for individual adjustment of the
feedstocks, e.g. the steam to carbon ratio, to obtain a
desired conversion. The outlet gas from the existing
secondary reformer is transferred to the HTER and
mixed internally with the product gas from the catalyst
bed installed in the HTER. The mixed gas is then sup-
plying heat by heat ex
change to the reforming reaction in the HTER, be-
fore it passes to waste heat recovery and further proc-
essing.
The operating conditions before and after revamp
by installation of a HTER in an ammonia plant are
summarised in Table 1 and compared with the installa-
tion of a prereformer and a fired
heater.

Before After After

Revamp Revamp Revamp
Prereformer HTER
NH3 Production, MTPD 1,500 1,650 1,650
(STPD) (1,654) (1,819) (1,819)
SMR Duty, Gcal/h 78.5 71.2 72.9
(MMBtu/h) (311.5) (282.5) (289.3)
NG Consumption for Feed and Fuel, 57,786 61,683 59,532
Nm3/h (MMSCFD) (2.15) (2.30) (2.21)
HP Steam Prod. (110 kg/cm2g, 510°C), MT/h 283 284 267
(ST/h) (312) (313) (294)
Steam Export (44 kg/cm2g, 390°C), MT/h 91 66 33
(ST/h) (100) (73) (36)
Outlet Temperature SMR, °C 820 816 801
(°F) (1,508) (1,501) (1,474)
Relative Flow through Reformer 1.00 1.10 0.99

Table 1: Operating Conditions Before and After Revamp by Installation of Prereformer or HTER

The operating conditions are unchanged for the
SMR after the revamp with respect to steam to carbon
ratio. Since the duty of the reformer is slightly reduced,
the amount of waste heat available from the flue gas is
reduced. This in combination with the fact that the natu-
ral gas preheat duty along with the process air preheat
duty is increased more or less proportionally to the ca-
pacity increase, gives certain modified operating condi-
tions in the existing flue gas waste heat section and the
revised operating conditions have been taken into ac-
count.
Compared to a revamp including a prereformer, the
inclusion of a HTER offers certain benefits.
Using the HTER, which operates in parallel to the
existing primary reformer, both the load on the combus-
tion side as well as the process side of the primary re-
former are reduced. The overall effect is seen directly
on the steam production, since the HTER utilises part of
the waste heat available after the secondary reformer
normally used for steam production. Furthermore, due
to the parallel operation, the pressure drop across the
reforming unit is minimised.
In most cases, the steam production lost in the proc-
ess unit after the revamp can be substituted by steam
production in already existing installations, e.g. by util-
ising idle capacity in auxiliary boilers. In other cases,
especially in cases with very large capacity increase, it
may be necessary to install additional steam generating
capacity. In both situations, additional steam production
can often be made with cheaper fuel than the fuel nor-
mally used in the tubular reformer.

2004 175 AMMONIA TECHNICAL MANUAL

 A HTER has been in successful industrial operation
in combination with an ATR in a synthesis gas generat-
ing plant at SASOL in South Africa for more than 16
months. The operating conditions in this installation,
which has a capacity corresponding to more than
100,000 Nm3/h (3.7 MMSCFD) of hydrogen, are more
severe than what would be expected in a revamp of an
ammonia plant as described above.
It should be emphasized that the HTER installed in
SASOL was also as a revamp project in an existing
plant, i.e. the tie-in of the HTER in an existing plant has
already been successfully demonstrated.
Regarding the economical attractiveness of install-
ing a HTER in an ammonia plant a cost comparison re-
veals that the expected investment cost for the HTER
concept in most cases will be a very attractive alterna-
tive compared to the cost related to the installation of a
prereformer with a fired heater for the same capacity
increase.
References
1. Dybkjær, I., “Advances in Ammonia Con-
verter Design and Catalyst Loading”, pre-
sented at the NITROGEN ’97 Conference,
Geneva, Switzerland, Feb. 9-11, 1997
2. Nielsen S.E., Dybkjær I., ”Use of Adia-
batic Prereforming in Ammonia Plants”,
Ammonia Plant Safety & Related Facili-
ties, Vol. 37, AIChE, New York (1997)
3. Winter Madsen, S., Dybkjær I., ”Novel
Revamp Solutions for Increased Hydrogen
Demand”, presented at the 8th Europeran
Technology Conference, London, U.K.,
Nov. 17-19, 2003

Conclusions
• In order to arrive at the most attractive re-
vamp scheme it is of paramount impor-
tance that the scheme is optimised based
on the objective and the specific conditions
prevailing.
• As demonstrated with the IFFCO revamps,
various attractive possibilities exist for re-
vamping ammonia plants to save energy or
to increase capacity.
• The novel revamp feature, the Haldor Top-
søe Exchange Reformer (HTER), is an at-
tractive alternative for increasing the ca-
pacity of the reforming section in an
ammonia plant.

AMMONIA TECHNICAL MANUAL 176 2004