Professional Documents
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Ammonia Production
Ammonia Production
Ammonia Production
PRODUCTION PROCESSES OF
AMMONIA AND UREA AT NFCL
Presented by:
AMMONIA PRODUCTION
Production steps:
The various steps involved in the production of synthesis gas and ammonia are:
1. Natural Gas Supply
2. Desulphurisation section
3. Reforming section
4. Primary Reformer
5. Secondary Reformer
6. CO conversion section
7. CO2 removal section
8. Methanation
9. Process condensate stripping section
10.Ammonia synthesis section
11.Refrigeration section
12.Ammonia absorption section
AMMONIA PLANT:
TECHNICAL FEATURES:
Installed Capacity : 2 x 1500 MT Urea / Day
2 x 900 MT Ammonia / Day
Revamped Capacity :2 x 2325 MT Urea / Day
2 x 1325 MT Ammonia / Day
BAGGING PLANT:
1 BAG of urea contains = 50 Kg
Each empty bag weighs= 130gms
1 stream contains 250 tonnes of urea in 8hrs.
In NFCL they use 6 streams total which packs 1500 tonnes of
urea in 8hrs.
That is about 30000 bags of urea are packed in 8hrs and in
total 90000 bags in 1 day.
Fig: Catalyst
used
PRE-DESULPHURIZATION:
Natural gas contains sulfur compounds of types R-SH, R1-S-R, R-S-S-R1 etc
These compounds are removed by hydrogenation process where H2 is added.
The
reactionstothat
So, for liquid natural gas to react with hydrogen it is to be
converted
gaseous
state and thus it is sent to fired heater and then into HYDROGENATOR.
take place in
H2
PRE-HEATING FURNACE
(F-203)
hydrogenator are:
R-SH + H2 R-H +
H2S
R-S-RI + 2H2 R-H +
R1-H + H2S
R-S-S-RI + 4H2 R-H
+ R1-H + 2H2S
CATALYSTNIMOX(Nic
kel-Molybdenum)
HYDROGENATOR
(R-201) OPERATING
CONDITIONS:380OC &
24KSC
FINAL DESULPHURIZATION:
So, S is removed to a large extent as H 2S, to strip off the H2S
present in the product, the stream is sent into the stripper where
product stream falls from the top and the steam from the bottom.
0.5 ppm of sulfur is present and thus is to be further removed
because S acts as a poison to the catalyst in the reforming section .
So, the product obtained is sent into the final desulphurization unit
for further removal of S.
So the H2S formed now is sent into the reactors where ZNO beds are
present. The sulfur removal inside the beds takes as follows:
ZNO + H2S -> ZNS + H2O
Zno
Zno
R202
A
R202
B
REFORMING SECTION:
The process gas thus obtained is sent to the ADIABIATIC PRE-REFORMER
where high carbon chains of naphtha are broken into low carbon chains by
cracking and this gas is sent into REFORMING SECTION.
Reforming means conversion of hydrocarbons to CO 2 with the help of
steam. This takes place at high temperatures since it is a endothermic
reaction.
The reactions that take place are called as shift reactions.
CH4 + H2O -> CO + 3H2
CH4 + 2H20 -> CO2 + 4H2
CATALYST Ni based catalyst.
TEMPERATURE - The temperature required is nearly 950 oC & 30.5KSC.
Reaching this temperature at once is very difficult and thus it is done in 2 stages:
1.Primary Reforming
2.Secondary Reforming
PRIMARY REFORMER:
This reformer contains 190 tubes in 2 parallel sections.
Each section contains95tubes, divided into 5zones, i.e, each zone
contains 19tubes.
The furnace operates with side firing of fuel gas on both sides of
each row of tubes.
These tubes are filled with Ni catalyst.
Super heated steam along with natural gas is sent into small tubes.
Each
19
Nearly 86% conversion
takes place. Thus the product stream
tubes+CH +H 0.
contains C0+C0
2
4
2
z2
z3
z4
5z
z1
SECONDARY REFORMER:
Product stream along with air is sent inside the reformer where it is
heated to 945oC for the rest 14% conversion of CH4.
The off gases that are evolved during the stripping of H 2S gas are
used as a fuel to secondary reformer for maintaining high
temperatures.
The product stream now contains only CO, CO 2, H2 and AIR. In order
to convert CO to CO2 it is sent into the CONVERTER via WASTE HEAT
BOILER.
This waste heat boiler recovers the heat from the product stream
and is used for rising temperature.
secondary reformer
From waste heat boiler the process gas enters High Temperature CO
converter. This is maintained at 360 oC.
Although CO conversion to CO 2 takes place at low temperatures this
converter is used in order to increase the speed of reaction.
CO + H2O
CO2 + H2 + Heat
SOLn
GV+ CO2
CO2 REMOVAL
SECTION
CO + 4H -> CH + 2H 0
KM1R
Ammonia synthesis catalyst
It is a prereduced iron-based ammonia synthesis catalyst containing a number of
AMMONIA SEPERATION
Purpose: Toseparatetheammoniafromtheunconvertedprocessgas. It
included2sections.
1) AmmoniaRefrigeration2)Ammoniaabsorption
Ammonia Refrigeration:
TherefrigerationsectionisusedtoliquefygaseousAmmoniaandconsistsofacompressorunit,
acondenser,anaccumulatorandnumberofchillers.LiquidNH3flowsfromtheNH3
accumulator,totheNH3heater,whichservestoheatAmmoniasenttotheUreaPlant.
Ammonia Absorption:
AmmoniaproducedintheAmmoniaSynthesisConverterseparatedfromunreactedgas
mixtureinAmmoniaSeparator.
Fig: purge
gas recovery
unit
Production of UREA
Properties of urea
Urea is a white, odorless, hygroscopic solid. It
is non-corrosive.
CO2 and NH3 obtained in ammonia plant are sent into UREA PLANT. Since
the reaction requires high pressures both the reactants are compressed.
The molar ratio of ammonia to carbondioxide is in the range of 3.33.6 to 1. The molar ratio of water to carbondioxide is in the range
of 0.50-0.70 to 1.
PRILLING SECTION:
The height of the urea prilling tower is 100 meters and 22 meters in diameter.
The molten urea leaving the second vacuum separator holder, is sent to the prilling bucket, by means of
centrifugal pump.
The Urea coming out of the bucket in the form of drops fall along the prilling tower, and encounters a
cold air flow which causes its solidification. The heated air along with a few ppm of urea dust comes
out of the prilling tower top to atmosphere.
The solid prills falling to the bottom of the prilling tower are sent by the rotary scraper, to the belt
conveyor, and then to the belt conveyor, from where Urea can be taken either for bagging or to the
Silo.
The
The
Low
Snamprogetti process
USES OF UREA
About
About
Urea-formaldehyde
plywood adhesive.
Melamine-formaldehyde
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