O/s/o )5,7,5,l0, 12,13, 15,16,1,18,29, 219;25

Haldor-Topsoe Ammonia Process 26,1,3),3A,333,9641,43,44,B5, 46,51,s2,5hs,I

To produce ammonia from a variety of
gas to heavy naphtha, the hydrocarbon feedstocks ranging from natural
Topsoe low energy ammonia technology is used.

Desutfurization Reforming Shift

Process steam
Process atr

Natural gas
Prereforming (optiona)
Purge gas S-50 (optlonal)
Stack

removal
Methanation
Ammonia Ammonia synthesis CO,
product

Fig.: Process flow diagram for Holder - Topsoe ammonia synthesis

Naturalgas or another hydrocarbon feedstock is compressed (ifrequired), desulfurized,
mixed with steam and then converted into synthesis gas. The reforming section
comprises a pre-reformer (optional, but gives particular benefits when the feedstock is
higher hydrocarbons or naphtha), a fired tubular reformer and a secondary reformer,
where process air is added. The amount of air is adjusted to obtain an H, / N ratio of
3as required by the ammonia synthesis reaction. The tubular steam reformer is Topsoe
proprietary side-wall-fired design. After the reforming section, the synthesis gas
undergoes high- and low-temperature shift conversion, carbon dioxide removal and
methanation process.

Synthesis gas is compressed to the synthesis pressure, typically ranging from 140 to
220 kg/cm'g and converted into ammonia in a synthesis loop using radial flow
synthesis converters followed by a boiler or steam super heater, and a one-bed S-50
 convertet Ammonia produet Is condensed und
layout is flexible, and euch ammonia nlant willseparated Iby refrigeration. This process
be optimized for the local co
0y ajustment of various process
purameters. Top80e supplics all catalysts used in tne
catalytic process steps for ammonia
production.
eatures, such as theinclusion of a pre-reformer, installation of a ring-type
burner wi
nOZzles for the secondary reformer and upgrading to ammonia converter, are a
Teatures that can be applied for existing ammonia plants. These features will casy to
maintenance and improve plant efficiency.
1,2.2 STORAGE AND TRANSPORTATION OF AMMONIA

Liquefied ammonia from production plants is either used directly in downstream plants
or transferred to storage tanks. From these the ammonia can be transferred to road
tankers, rail tank cars or ships.

Ammonia Storage: Ammonia is usuallystored by usingone or other of three methods

() Fully refrigerated storage in large tanks with a typical capacity of 10,000 to 30,000
tons (up to 50,000) (ii) Pressurized storage spheres or cylinders up to about 1,700 tons
(iii) Semi-refrigerated tanks.

A well designed, constructed, operated and maintained installation has a very low
probability of an ammonia leak of hazardous proportions. However, even though the
residual risk is small, the effects of a major leak on areas of high population density
could be very serious. It is therefore good practice to build ammonia storage and
handling installations at a sufficient distance from domestic housing, schools, hospitals
or any area where substantial numbers of people may assemble,In some countries there
are planning procedures or regulations which control the siting of ammonia storage
installations and similar establishments. Where there are no formal controls, the siting
of ammonia storage facilities should be given serious consideration at the design stage.
Itis undesirable for ammonia storage tanks to be sited close to installations where there
is a risk of fire or explosion, since these could increase the possibility of a release of
ammonia.
 Transportation: Liquid or gas pipelines should he ftted with ísolation valves.ne
main isolation valves should be backed un by remotely operated valves. The
remo8
Systems should be of such a type that closure is automatic in case of a
power 1aiUre.
Liquid ammonia has a high thermal coefficient of expansion and, therefore, sorme
means of safeventing should be provided on pipelines in which any significant
quantiy
Can be trapped between valves, etc, Ligujd ammonia pipelines should be fitted with
remotely operated valves at suitable intervals to minimize the loss in the event ofa line
Tailure. Ammonia is transported in road tankers, rail tank çars (both pressurized) and
ships (pressurized or refrigerated).

Railroad and road loading: Loading and unloading of rail tank cars and road tankers
is usually done by loading arms. During (un)loading both the liquid supply and vapour
return lines must be conneçted to the transport medium. Th¹ ammonia vapors can be
transferred during (un)loading to a storage tank, an ammonia vapour network of the
siteor to a scrubber/absorber, to prevent emissions to the
atmosphere.
Before disconnection of equipment after (un)loading the liquid ammonia in these parts
must be removed to one of the reservoirs. Preferably, this should be done by using a
pressurized inert gas such as nitrogen or ammonia vapour. If inert gas is used, attention
should be paid to avoid getting inert gas into tankersand storage tanks. There should
be a scrubbing system or a flare in the event of venting inert gas.
A weigh check must be carried out after the loading, to ensure that
the maximum
allowable content has not been exceeded. Modern road and rail car loading stations are
equipped with a safeguard against overfilling.

Ships: Loading and unloading of ships is only permittd at sites which are authorized
for this purpose. During (un)loading a minimum safety distance to other ships must
always be maintained around the ship(eg. 30m). Both liquid and vapour return lines
should be present for import and export terminals. A vapour return line is not
necessary
when the ship has sufficient refrigeration capacity or for the import of
ammonia only.
 Dou iqdandvapour
the
ship as possible. connections mustbe eauinned with
Itmust be possible to close these isolation valves asunder
eat to
conditions and the connection between valves quickly all

isolation valve. The ends of tank and liquid line must be equipped with an
break couplings. The loading and unloading arms should be equipped with dry
isolation valves must be closed automatically, when these
cOuplings are disconnected or when the
(un)loading arms are too far out of position.
After each
loading-unloading operation, liquid ammonia contained within loading
arms must be collected in a suitable
evaporation tank connected to the storage tank
through the vapour line. Loading arms are then purged by
inert gas or ammoniavapour.
If nert gas is used, attention should be paid to
avoid getting the inert gas into tankers
and storage tanks. There should be a scrubbing system or
flare in case the inert gas has
to be vented.