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ENERGY SAVING BY PURGE GAS RECOVERY UNIT

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 ENERGY SAVING BY PURGE GAS RECOVERY
UNIT

Author
Prem Baboo
Sr. manager (prod)
National Fertilizers Ltd. Vijaipur, India

Abstract
In order to achieve optimum conversion in synthesis convertor, it is necessary to purge
a certain quantity of gas from synthesis loop so as to as to reduce inerts concentration
in the loop. Purge gas stream from ammonia process contains ammonia, hydrogen,
nitrogen and other inert gases. Among them, ammonia itself is the valuable product lost
with the purge stream. Moreover it has a serious adverse effect on the environment.This
purge gas containing about 60% Hydrogen was fully utilised as primary reformer fuel.
The recovered hydrogen is sent back to the synthesis loop to increase production or
save energy, as the quantity of hydrogen produced by steam reforming can be reduced.
A cryogenic purge gas recovery unit, designed by M/s L'Air Liquide, France is available
in order to recover H2 from it which is recycled back convert it to Ammonia while the by
- product tail gas from PGR Unit is burnt as fuel in the primary reformer . The ammonia
recovery unit removes and recovers the major part of the remaining ammonia
contained in the purge gas, let down gas and inerts vent gas from loop and the
refrigeration circuit, respectively. The makeup gas contains small amount of Argon and
Methane. These gases are inerts in the sense that they pass through the ammonia
synthesis converter without undergoing any chemical changes. Because of the
complexity and cost of hydrogen production various processes are employed in the
industry to recover hydrogen from tail gases. Specific industries use specific hydrogen
separation and purification method based upon their requirement and feed conditions .
This process is based on the difference in boiling points of liquid gases in the stream.
The basic principle adopted in our refrigeration circuit is employed.
Introduction
The use of hydrogen is mainly in refineries petrochemical and fertilizer industries.
Because of the complexity and cost of hydrogen production various processes are
employed in the industry to recover hydrogen from tail gases. Specific industries use
specific hydrogen separation and purification method based upon their requirement
and feed conditions.

The purge gas from synthesis loop of ammonia plant is washed with an aqueous
solution of ammonia and then washed gas having low ammonia content is sent to
absorption unit, where remaining ammonia and water is removed completely. The gas
delivered by the purification unit is cooled by exchange with hydrogen and tail gas
steam coming out of exchangers in cold box unit. The cooled gas is let down to sub
cooled gas where it is partially condensed. The gas and liquid are separated in the
vessel. The gaseous fraction, containing the main part of hydrogen is warmed in this
exchanger and recycled back to synloop to convert it to ammonia. The liquid fraction,
after expansion through a valve is vaporised and warmed in a exchanger and used as a
fuel in Primary Reformer. Ammonia solution from the ammonia washing tower is
concentrated in the distillation unit and fed back to the main refrigeration loop. The
purge gas from synthesis loop of ammonia plant is washed with an aq ueous solution of
ammonia and then washed gas having low ammonia content is sent to absorption unit,
where remaining ammonia and water is removed completely. The gas delivered by the
purification unit is cooled by exchange with hydrogen and tail gas steam coming out of
exchangers in cold box unit. The cooled gas is let down to sub cooled gas where it is
partially condensed. The gas and liquid are separated in the vessel.

Description of the Process

Following process are used for recovery of Hydrogen from purge gases.

1. Membrane,
2. Pressure swing adsorption (PSA) processes and,
3. Cryogenics Process

Above all process have all been commercially applied for the recovery of hydrogen
from the purge gas. Purge gas is drawn from the loop after the second cold exchanger
just before addition of the make-up gas. At this point the gas has the maximum content
of inerts. The purge gas is transferred to a purge gas recovery unit for recovery of
hydrogen. Recovered hydrogen is recycled to the process and introduced between first
and second casing of the synthesis gas compressor the choice of separation technology
is driven by the desired purity, degree of recovery, pressure and temperature.
Membrane separators are widely accepted to recover hydrogen from purge gas and
recover typically 85-90% hydrogen, with a hydrogen purity of 87-90%. The cryogenic
process operates at high pressures (7.0 M.Pa) and can achieve a hydrogen recovery of
90-98%. Pre-treatment of the purge gas to remove ammonia and water is required
for the cryogenic process. Pressure swing adsorption has been used for ultra -high-
purity hydrogen from the purge gas and has a somewhat lower hydrogen recovery
(70-85%) than the membrane and cryogenic processes. No pre-treatment is required
and water and ammonia are removed by PSA in addition to argon and methane.

When comparing membrane separators with cryogenic technology it is noted that

recovery based on cryogenic technology is more energy efficient, whereas the recovery
based on membrane technology requires a lower investment. Which technology to
choose will have to be decided on a case-to-case basis? Various manufacturers supply
different types of hydrogen recovery technologies, including Air Products, Air Liquid,
Linde, and UOP. This measure is applicable to both retrofit and new high pressure
synthesis loop steam reforming plants. In 1980, an Indian plant installed a hydrogen
separation and recovery unit based on the cryogenic process. By recycling the hyd rogen
contained in the purge gas, about 60%, to the synthesis loop, the ammonia throughput
increased by about 40-50 TPD; a 5% increase in plant production. In addition to the
increased production, the energy use decreased by 0.96 GJ/T of NH 3. The tail gas from
the purge gas recovery unit containing 30% methane and 15% Hydrogen was used as
fuel in the primary reformer.

1. HYDROGEN RECOVERY WITH MEMBRANE PROCESS

Membrane systems are based on the difference in permeation rates between hydrogen
and impurities across a gas-permeable polymer membrane. Permeation involves two
sequential mechanisms: the gas-phase component must first dissolve into the
membrane and then diffuse through it to the permeate side. Solubility depends
primarily on the chemical composition of the membrane and diffusion on the structure
of the membrane. Gases can have high permeation rates as a result of high solubility,
high diffusivity, or both. The driving force for both solution and diffusion is the partial
pressure difference across the membrane between the feed and permeate sides. Gases
with higher permeability, such as hydrogen, enrich on the permeate side of the
membrane, and gases with lower permeability enrich on the non-permeate side of the
membrane because of the depletion of components with high permeability.
Fig. No-1

The first fraction of the gas to permeate through the membrane consists primarily of the
components with the highest permeability. As a larger fraction of the feed gas is allowed
to permeate, the relative amount of the components with lower permeability increases
in the permeate stream. In hydrogen separations, higher purity product hydrogen is
associated with lower recovery, and lower purity product hydrogen is associated with
higher recovery.

Fig. No.2
The effect of hydrogen purity on recovery is much more dramatic with membrane
systems than with PSA or cryogenics units. A fairly small change in hydrogen purity can
change the recovery significantly.

BENEFITS-
Efficient and economical hydrogen recovery: typically 80% to 98% recovery of feed
H2 with a purity of 90 volume % to 99 volume %

1. Handles high feed pressures up to 170-175 Bar.

2. Reduce flaring and correct refinery fuel balance
3. Proven performance, long membrane life, many references

Fig. No. -3

Higher hydrogen recovery also requires that more membrane area be provided. The
membrane area required when feed composition and system pressure levels are fixed
increases exponentially at high hydrogen recovery. The performance of a specific
membrane system, that is, the recovery versus the product purity for a given feedstock,
is primarily dependent on the ratio of feed to permeate pressure and is largely
independent of the absolute pressure level. However, the area requirement is inversely
proportional to the feed pressure. Hence, compressing the feed gas rather than the
permeate, even though the permeate flow is smaller, is often preferable when the
objective is to achieve the required pressure ratio.

2. PSA PROCESS

POLYBED™ Pressure Swing Adsorption units for hydrogen purification are based on the ability
of adsorbents to absorb more impurities at high gas-phase partial pressure than at low partial
pressure. Impurities are adsorbed in an absorber at high partial pressure and then desorbed at
low partial pressure. The impurity partial pressure is lowered by swinging the absorber
pressure from the feed pressure to the tail gas pressure and by using a high-purity purge gas.
The driving force for the separation is the difference in impurity partial pressure between the
feed and tail gas. A minimum pressure ratio of approximately 4:1 is required. The feed pressure
is usually in the range of 14 to 35 atm. Optimum tail-gas pressure is as low as possible.

Because vacuum is normally avoided, tail-gas pressures less than 1 atm is typically used when
high hydrogen recovery is desired.

The PSA tail-gas is frequently compressed from this low pressure to fuel-gas pressure.

Hydrogen is essentially not adsorbed in the PSA process and is available at close to feed
pressure: the typical pressure drop between the feed and product battery limits is less than 10
psi. The two key advantages of the PSA process are its ability to remove impurities to any level
and to produce a high-purity high-pressure hydrogen product. The purity of the hydrogen
product from a PSA unit is typically in excess of 99 vol-% and frequently 99.999 vol-%. Removal
of CO and CO2 to a volume level of 0.1 to 10 ppm is common and readily achieved.

3. HYDROGEN RECOVERY WITH CRYOGENIC PROCESS

This process is based on the difference in boiling points of liquid gases in the stream.
The basic principle adopted in our refrigeration circuit is employed here. Ammonia line
1 PGR and IGP is based on this process. The Energy saving is 0.11 Gcal/MT ammonia
with purge gas recovery for 1864TPD ammonia plant and correspondingly 0.06Gcal/MT
urea. Annual profit from PGR after payback period is around Rs 15 crore (USD 2238806).

1. Hydrogen gets liquefied at -253°C atm pressure.

2. Nitrogen gets liquefied at -196°C atm pressure.
3. Methane gets liquefied at -161°C atm pressure.
4. Ammonia gets liquefied at -33°C atm pressure.
PURGE GAS RECOVERY DESIGN BASIS

FACTOR THAT AFFECT HYDROGEN RECOVERY

Sr. No. Process Condition Effect of Hydrogen
Recovery
1 Increase no. of separators on-line Increase

2 Increase feed flow rate Decrease

3 Increase the hydrogen purity of Increase

 the feed

4 Increase permeate pressure Decrease

5 Increase feed pressure Increase

FACTOR THAT AFFECT NH 3 SLIP FROM SCRUBBER

Sr. No Process condition Effect on overhead NH 3

1 Increase feed flow rate Increase

2 Increase water flow rate Decrease

3 Increase the ammonia conc. in feed Increase

4 Increase feed pressure Decrease

5 Increase feed or water temperature Increase

ENERGY AND UTILITY CONSUMPTION

Sr. Utility Supply Units Quantity
No. Condition
Normal
1 LP Steam 3.5 Bar,2500C Kg/hr. 60
2 MP Steam 38 bar,3800C Kg/hr. 1008
3 Cooling Water Supply 3.5 bar,330C Kg/hr. 42993
4 Cooling water return 2.0 Bar,430C Kg/hr. 42993
5 Demineralized water 2.0 Bar,400C Kg/hr. 10(recycled
stripper
bottom)1605(10
0%, fresh feed)
6 Electricity Pump 440 V ,50 Hz ---- KW 6.5
7 Electricity Instruments --- KW Minimal
115V,AC,50
Hz(Instruments,110 V
DC(Solenoid valve)
8 Nitrogen, Dry 6.0 Bar,400C Nm3/Event 175
9 Instrument, air 6.5 Bar, Nm3/Hr. 50
ambient, dew
point ≤400C
The refrigeration required for the process is obtained by Joule-Thomson refrigeration,
which is derived from throttling the condensed liquid hydrocarbons. The ammonia
process flow diagram as figure No. 4.

Fig. No.-4

The feed needs to be pretreated to remove water and other components that could
freeze in the system. The pretreated feed at high pressure, 20 to 82 bars, is cooled
against a stream leaving the cryogenic unit to a temperature at which the majority of the
hydrocarbons and ammonia condense.

Fig. No. 5
The two-phase stream is sent to a separator where the hydrogen-methane vapor stream
is taken overhead and further cooled to a temperature low enough to give the desired
hydrogen purity. The cooled stream is fed to another separator, and the hydrogen
product is taken overhead. Thus, the cryogenic unit typically splits the feed into three
products:

1. A high purity hydrogen stream,

2. A methane rich stream at fuel gas pressure, and
3. Ammonia stream. Nitrogen is also recovered. The Process flow diagram as
follows in figure No. 6

Fig. No. 6

The approximate converter inlet gas composition is shown in below-

1. Hydrogen- 64.2 mole %

2. Nitrogen- 21.4 mole %
3. Ammonia -5.6 ole %
4. Methane – 5.9 mole %
5. Argon -2.9 mole %
The contents of ammonia, Hydrogen and Methane are measured and recorded downstream of
the cold heat exchanger as figure No. 7.

The main inlet flow to the converter is introduced through two inlet nozzles at the bottom. The
inlet gas passes through the annular space between the pressure shell and the insulated basket
and thereby the pressure shell is kept relatively cool.
The temperature profile of the shell may be followed by the eleven thermocouples mounted on
the shell. Nine of the thermocouple are installed at three levels each comprising three elements,
and two are mounted just above the inlet gas nozzle.

The ammonia synthesis takes place in the ammonia synthesis converter, R 3501,
according to the following reaction scheme:

Fig. No-7
3H2 + N2 = 2NH3 + heat

Fig. No.8
The reaction is reversible and only a part of the hydrogen and nitrogen is converted into
ammonia by passing through the catalyst bed. The conversion of the equilibrium
concentration of ammonia is favoured by high pressure and low temperature. In R 3501
only about 30% of the nitrogen and the hydrogen are converted into ammonia.

Fig. No-9

To get maximum overall yield of the synthesis gas, the unconverted part will be recycle
to the converter after separation of the liquid ammonia product.

After the synthesis gas has passed through R 3501, the effluent gas will be cooled down
to a temperature which the main part of the ammonia is converted.

The circulation is carried out by means of the recirculation, which is an integrated part
of the synthesis compressor, K 3431.

As the reaction rate is very much enhanced by high temperature, the choice of
temperature is based on a compromise between the theoretical conversion and the
approach to equilibrium.

The ammonia synthesis loop has been designed for a maximum press ure of 245kg/cm2
g. The normal operating pressure will be 220kg/cm 2 g depending on load and catalyst
activity.

The normal operating temperatures will be in range of 360-525°C for the 1st bed and
370-460°C for the 2nd bed.

The heat liberated by the reaction (about 750kcal/kg produced ammonia) is utilized for
high pressure steam production (in the loop waste heat boiler, E 3501) and preheat of
high pressure boiler feed water.
As illustrated in diagram, the converted effluent gas is cooled stepwise, first in the loop
waste heat boiler, E 3501, from 456-350°C. Next step is cooling to about 269°C in the
boiler feed water preheated, E3502. And then the hot heat exchanger, E 3503, where the
synthesis effluent gas is cooled to 61°C by preheating of converter feed gas.

The synthesis gas is cooled to 37C in the water cooler, E 3504 and to 28 C in the heat
exchanger.

The final cooling to 12°C takes place in the ammonia chillers. The condensed ammonia
is separated from the circulated to the ammonia converter through the cold heat
exchanger, the recirculation, and the hot heat exchanger.

The water vapour concentration in the make-up gas is in the range of 200-300 ppm,
depending on the operating pressure in the loop. The water is removed by absorption in
the condensed ammonia. The carbon dioxide in the make-up gas will react with both
gaseous and liquid ammonia, forming ammonium Carbamate:
2NH 3 + CO2 = NH 4 -COO-NH2
Ammonia + Carbon Dioxide = Ammonium Carbamate
The formed Carbamate is dissolved in the condensed ammonia. As the water deactivates
the ammonia synthesis catalyst, the content of carbon monoxide in the make -up
synthesis gas should be kept as low as possible.

INERTS GASES
The make-up gas enters the loop between the two ammonia chillers. This gas contains
small amount of argon and methane. These gases are inert in the sense that they pass
through the synthesis converter without undergoing any chemical changes. The inert
will accumulate in the synthesis loop, and a high inert level, i.e. high concentration of
inert gases will build up in the circulating synthesis gas. The inert level will increase
until the addition of inert gases will make the make-up gas in the same as the amount of
inert removed from the top.

The low temperature outlet of the 1 st ammonia chiller means that the partial pressure of
ammonia in the gas phase is relatively low. Only a minor amount of ammonia will be
removed together with the purge gas. The purge gas is further cooled in the purge gas
chillier, E 3511, and the liquid ammonia is separated in B 3512. The liquid ammonia is
sent to B3501.

HYDROGEN/NITROGEN RATIO

By the synthesis reaction, 3 volumes of hydrogen reacts with 1 volume of nitrogen to

form 2 volumes of ammonia.

The synthesis loop is designed for operating at H 2/N2 ratio of 3.0, but special conditions
may make it favourable to operate at a slightly different ratio in the range of 2.5-3.5.
When the ratio is decreased to 2.5, the reaction rate will increase slightly, but decrease
again for ratios below 2.5. On the other hand the circulating synthesis gas will be
heavier. Therefore, the pressure drop and ammonia concentration at the inlet of the
ammonia synthesis converter will increase.

AMMONIA CONVERTER R 3501

Flow Pattern in R 3501 At the top of the converter, the gas passes the tube side of the
inter bed heat exchanger, where the inlet gas is heated up to the reaction temperature
of the heated up the reaction temperature of the 1st catalyst bed by the heat exchanger
with gas leaving the 1 st catalyst bed. The gas inlet temperature to the 1 st bed is adjusted
by means of the so-called “cold shots” which is cold synthesis gas introduced through
the transfer pipe of the centre tube.

The gas, which leaves the 1 st catalyst bed, is led through the 2 nd bed and into the centre
tube from which it is returned to the ammonia loop.

The two catalyst bed contains a total of 109.3 m 3 of KMIR catalyst, which is a promoted
iron catalyst containing small amounts of non-reducible oxides.

Reaction Temperature
At the inlet of R 3501, 1 st catalyst bed, the minimum temperature of approx. 360°C is
required to ensure a sufficient reaction rate. If the temperature at the catalyst inlet is
below this value, the reaction rate will become so low that the heat liberated by the
reaction becomes too small to maintain the temperature in the converter. The reaction
will quickly extinguish itself if properly adjustments are no t made immediately.

On the other hand, it is desirable to keep the catalyst temperature as low as possible to
prolong the catalyst life. Therefore, it is recommended to keep the catalyst inlet
temperature slightly above the minimum temperature. It is anticipated that the
synthesis gas enters the 1 st catalyst bed at a temperature of max. 400°C. As the gas
passes through the catalyst bed the temperature increases to a maximum temperature
in the outlet from the 1 st bed, which is normally the highest temperature in the
converter, called the “hot spot”. The temperature of the hot spot is up to 510°C, but
should not exceed 520°C.The gas from the 1 st bed is cooled with some of the cold inlet
gas to the 1st bed in order to obtain a temperature of approx. 370°C inlet 2 nd bed. The
gas outlet temperature from the 2 nd bed is about 455°C.

Catalyst
The catalyst is distributed with 29.0 m3 in the first (upper) bed, and 80.3 m3 in the
second (lower) bed. The particle size of the catalyst is 1.5-3 mm. The smallest particle
size causes a very high overall catalyst activity. Further the radial flow design of the
converter allows small particle without causing a prohibitive pressure drop. The pre-
reduced KMIR catalyst has been stabilizes during manufacturing by superficial
oxidation. The partly oxidized catalyst contains about 2 wt% of oxygen. The
stabilization makes the KMIR catalyst non pyrophoric up to 90-100°C, but above 100°C
the catalyst will react with oxygen and heat up spontaneously.
Reducing the iron oxide surface layer to free iron with simultaneous formation of water
activates the catalyst. The reduction is carried out with circulating synthesis gas. The
desired level temperature is obtained by using the start-up heater, H 3501
The use of synthesis gas with hydrogen to nitrogen ratio close to 3:1 for activation of
KMIR has two advantages. The first is production of ammonia starts early, causing a
heat production. The production of heat provides the possibility of circulating more
synthesis gas, which helps in reducing the remaining part of the catalyst.
The second advantage is removal of the formed water from the circulating gas. It will be
dissolved in ammonia and then purify the circulating the synthesis gas. This is
important as water is the catalyst poison. The catalyst activity decreases slowly during
normal operation and the catalyst lifetime, which is normally more than 5 year, its
affected by the actual process conditions, notably the temperature in the catalyst bed
and the concentration of the catalyst poisons in the synthesis gas at the inlet of the
convertor.
Although the KMIR can be used in the range of 530-550°C ,it should be noted that the
lower the catalyst temperature are in operation, the slower the decrease in catalyst
activity will be , and accordingly the lifetime will be prolonged. It is therefore
recommended to maintain the lowest possible catalyst temperature during operation,
especially for the 2 nd bed which determines the conversion.

All compounds containing oxygen, such as water, CO and carbon dioxide, are poisonous
gas is clean again. But as some permanent deactivation will take place, high
concentrations of oxygen compounds at the convertor inlet, even of short duration,
should be avoided.

Sulphur and phosphorous compounds are severe poisons, as the catalyst deactivation
will be permanent. A probable source of introduction of such contaminants is the seal
oil.

Refrigeration
The purpose of refrigeration circuit is to carry out the various cooling tasks in the
ammonia synthesis loop. The primary task is to condense the ammonia, which is
produced in the convertor. Other cooling tasks are cooling of make-up gas, purge gas,
let-down gas, and inert gas.

6 chillers operating at three different pressure (3 “chillers levels”),

 A refrigeration compressor,
 An ammonia condenser,
 And an accumulator.
Besides the above-mentioned equipment the refrigeration circuit includes the following.
Three K.O drums (one for each compressor stage), to protect the refrigeration
compressor of droplets of ammonia.

A flash vessel, from where the makeup ammonia is fetched and the spent ammonia is
returned to from the refrigeration circuit.

The first ammonia chillier, E 3506and the make-up gas chillier, E 3514 operate at the
highest level which is a temperature of 18.8°C, corresponding to a pressure of 7.8
Kg/cm2g. The second ammonia chillier, E 3507, operates at the medium level, where the
ammonia boiling temperature is 6.9°C with a corresponding pressure of 4.6Kg/cm2g.

The three chillers: purge gas chillier, E 3511, let down gas chillier, E 3508, and the inert
gas chillier, E 3509, operate at the lowest chillier level, where the ammonia boiling
temperature range from -33 to -30°C and the corresponding pressure is approximately
0.05 kg/cm2g.

Ammonia Wash Section

General
The ammonia wash section removes and recovers the major part of the ammonia
contained in the off gas, let down gas, and the inert vent gas from the loop.
 The purge gas steam is taken out from the loop just after the 1 st ammonia chiller,
E 3506. Still under pressure the gas is cooled down to -25°C in the E 3511. Some
of the ammonia is separated as liquid. The gas fraction from the separation is
sent to the purge gas absorber, F 3522.
 In order to avoid accumulation of inerts in the refrigeration section, a purge flow
of the non-condensable gases is sent to the inert gas chiller. E3509, where they
are cooled further to about -25°C. At this temperature some of the ammonia is
removed as liquid. The gas fraction from the separator is sent to the off gas
absorber, F 3523.
 The letdown gas is produced in the letdown vessel. The liquid ammonia from B
3501 is sent to the letdown vessel B 3502. The main part of the dissolved gases
will be released due to the pressure reduction from the loop pressure of
209kg/cm2g to pressure in the letdown vessel of 26kg/cm 2g. At this pressure the
gas is cooled to -25°C in E 3308. Some of the ammonia is separated as liquid. The
gas fraction from the separation is sent to the off gas absorber, F 3523.
The let down and inert gas is mixed before entering the ammonia wash section.
Off Gas Absorber, F 3523
The off gas containing ammonia is introduced at the bottom part of the off gas absorber,
F 3523, where it is washed in counter-current with water introduced at the top of the
absorber. The purified off gas leaving the absorber at the top contains approx. 0.02mole
% ammonia, whereas the ammonia water solution leaving the absorber at the bottom
contains approximately 10 mole% ammonia. Operating pressure is 81 kg/cm 2g.
The absorber, F 3523 has been provided with two beds, each of 2500 mm height,
containing 1 “pall rings (2*0.22 m3)

Purge Gas Absorber, F 3522

The purge gas containing ammonia is introduced at the bottom part of the purge gas
absorber, F 3522, where it is washed in counter- current with water introduced at the
top of the absorber. The purified off-gas leaving the absorber at the top contains
approximately 0.01 mole ammonia, whereas the ammonia water solution leaving the
absorber at the bottom contains approximately 18 mole % ammonia. Operating
pressure is 15 kg/cm2g.

The absorber, F 3522 is provided with 20 trays, to ensure a good contact between the
liquid and vapour phase.

PURGE GAS RECOVER ADVANTAGES

1. Hydrogen in 15000 Nm³/hr of purge gas is around 9000 Nm³/hr. The equivalent
feed saving in primary reformer is around 2.175 T/hr of NG.
2. Or feed can be maintained same increase ammonia production and hence urea
production provided there are no bottlenecks.

3. Consequent to this primary reformer pressure is reduced increasing conversion

and less energy in GV or back pressure is increased saving energy in synthesis
compressor and better absorption in GV.

4. Reduction in firing in primary reforming corresponding to the reduction in feed

and increases in methane slip.

5. Moreover a saving of less than 7 T/h SM steam in reforming countered by loss in

production of HP steam in RG boiler.

PURGE GAS RECOVER DISADVANTAGES

1. Process air to be made up in secondary reformer equivalent to hydrogen
recovered (for feed 15000 Nm³/hr) is around 3.8 KNm³/hr.
2. However process air reduced due to reduction in feed is around 3.5 KNm³/hr
3. So net increase in process air in secondary reformer is around 0.3 KNm³/hr
4. Loss of CO2 around 2.66 KNm³/hr which means under full load, load on CDR
(Carbon Dioxide Recovery) is increased being a costly affair. However energy on
GV is also reduced.
 5. Although fuel is reduced in primary corresponding to the reduction in feed, fuel
is increased to compensate the energy of hydrogen from recovery fuel gas.
6. Overall however there is net energy saving in the PGR project and is considered
feasible.

CONCLUSION
In this paper the economic aspects of setting up a Purge gas recovery unit with
ammonia production process is analyzed and the benefits that can be obtained by using
this small unit is illustrated. The installation of a purge gas converter ensures a very
Efficient use with respect to hydrogen and nitrogen balancing. An increased ammonia
production, along with hydrogen recovery and environmental regulation, has been
 obtained. Furthermore, fixed capital investment for raw gas purification and
preparation sections reduces.A cryogenic purge gas recovery unit recovering hydrogen
at a pressure of 85 kg/cm2 g improved the efficiency of ammonia synthesis loop.
Ammonia recovery unit was provided prior to the hydrogen recovery unit to minimize
ammonia loss and finally leading to NOx reduction in the primary reformer. It has been
possible to select these operating conditions in view of the high conversion per pass in
the S-250 synthesis loop, and also due to the inclusion of a cryogenic purge gas recovery
unit. The reformer inlet pressure is 38 kg/cm2 g, a slightly higher operating pressure
than used in the past. PRISM Membrane Systems provide operating flexibility when
planned or unexpected process changes occur. Some turndown is absorbed by the
flexibility of the system and increased capacity requirements are met by the addition of
more separators. Additional turndown is accomplished by valving off separators which
maintains recovery and purity. Multiple takeoffs from the permeate manifold provide
streams of different purities and flow rates. Some applications require feed gas pre -
treatment.

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