DESULPHURISATION

Cat vol = 7 M3
Ni-Oxides 24 %
Mo O3 =12 15 %
Al2O3 rest

R-102
AG/RLNG P: 39 Kg/cm2
Feed T: 380 0C Cat vol = 13 M3
P: 40Kg/cm2 ZnO = Min 90%
F-103
T: 20 0C R2O3( Fe2O3+ Al2O3)
= Rest

P: 38 Kg/cm2
AG FUEL T: 380 0C

On NiMox bed: On ZnO bed:

C4H4S + 4H2 <--> C4H10 + H2S ZnO + H2S <--> ZnS + H2O
RSH + H2 <--> RH + H2S
 PRIMARY REFORMER
Flue Gas
TUBES = 168
BURNERS= 504
Gas + Steam
Cat. Vol.=25m3
from E-201
NiO=1820%
reactor CaO=810 %
P: 36 Kg/cm2
Al2O3=Rest
T: 520 0C

CnH(2n+2)+(H2O Cn-1 H2n + CO2+H2 -Heat------(1)

CH4 +2H2O CO2 +4H2- Heat--- (2)

CO2+H2 CO+H2O- Heat ----(3)

Fuel

To Secondary
Reformer
P: 34.5 Kg/cm2
T: 780 0C
 SECONDARY REFORMER
P: 35 Kg/cm2
T: 500 0C

PROCESS AIR
from PAC

R203

Volume :24 m3
NiO = 10- 12 %
CaO = 1- 2 %
Al2O3 = Rest

BFW/Steam
From
P: 33 Kg/cm2
Primary T: 430 0C
Reformer E208

Above catalyst on bed..

0.075 O2 + 0.3 N2 + 0.15 CO 0.15 CO2 + 0.3 N2 (Exothermic)
On bed
0.2 CH4 + 0.2 H2O 0.2 CO + 6 H2 (Endothermic)
0.2 CO2 + 0.2 H2 0.2 CO + 0.2 H2O (Endothermic)
 CARBON MONOXIDE CONVERTER
REFORMED GAS
FROM E208 P: 31 Kg/cm2
T: 2200C P: 30 Kg/cm2
T: 2000C
HTS Convertor
LTG Convertor LTM Convertor

R202 R204

CO=0.3% R203
CO=3%
P: 31 Kg/cm2 LTG Vol=17 m3
T: 480 0C
HTS Vol= 51m3 LTM Vol=60 m3
Fe2O3 = 85 to 90% CuO = 30 to 32%
ZnO 30 to 32 %
Cr2O3 = 7 to 9 %
Al2O3 rest CO=0.17%
CuO = 1 to 2 %

In all CO converter:
CO + H2O CO2 + H2 + Heat.
 CARBON DIOXIDE REMOVAL
P: 160 Kg/cm2
CO2 to UREA P: 26 Kg/cm2
T: 1150C
To Methanator
P: 0.5 Kg/cm2
CO2 Compressor T: 780C

Pack
Packing ing

Benfield Packi
Solution ng

Packing
T: 1100C

Flash Vessel Packing

Packing
0.17 Kg/cm2

Benfield P: 36 Kg/cm2
Solution T: 1100C Packing
Packing Pump Process
Gas From
LT Main
1 Kg/cm2
P: 26 Kg/cm2
T: 1200C Absorber
Regenerator
In Regenerator: In Absorber:
2KHCO3 K2CO3 + CO2 + H2O K2CO3+CO2 + H2O 2KHCO3
 METHANATOR

Make-up gas Compressor

From Absorber

Synthesis gas
Compressor

P: 200 Kg/cm2
T: 350C

R301
Compressed
Gas to Ammonia
P: 26 Kg/cm2
Convertor
Cat. Vol= 19m 3 T: 150C

Ni.:25%

In Methanator
CO + 3H2 CH4 + H2O + heat
CO2 + 4 H2 CH4 + 2H2O + heat.
 AMMONIA CONVERTER

Recycle gas
compressor
Compressed
Gas
P: 207 Kg/cm2 P: 207 Kg/cm2
T: 3400C T: 350C Unconverted
Synthesis gas

Let Down
Ammonia
20% Gas P: 205 Kg/cm2
Converted to T: 00C P: 25 Kg/cm2
Ammonia T: -330C

Ammonia Ammonia
Coolers Chillers
Ammonia
Separator Ammonia
To Urea
R-501 R-502 plant

AMMONIA CONVERTERs
N2(g) + 3H2(g) 2NH3(g)
 PRODUCT SPECIFICATION

(a) Specifications:-

Anhydrous ammonia
Ammonia : 99.8 by wt% (min)
Moisture : 0.2 by wt% (max)
Oil Content : 5.0 ppm
Residue on Evaporation : 0.05 % by vol
 Uses
Fertilser production of:
Ammonium sulfate, (NH4)2SO4
ammonium phosphate, (NH4)3PO4
ammonium nitrate, NH4NO3
urea, (NH2)2CO
CO2+ 2NH3 ----
H2NCOONH4 --- Heat, Pressure -- (NH2)2CO
Amm. Carbonate Urea