Production of Ammonia

2500 MTPD OF AMMONIA FROM NAPHTHA
Contents
INTRODUCTION:..........................................................................................................................
1.1 Ammonia................................................................................................................................
1.1.1 History of Ammonia...........................................................................................................
1.1.3 Raw Material Used.............................................................................................................
1.1.4 Anhydrous Ammonia Properties:........................................................................................
1.1.5 Expansion in the industry...................................................................................................
1.1.5.1 Improvement in NH3 Production process:.....................................................................
1.1.6 Uses of Ammonia:............................................................................................................
1.1.6.1 Minor and Emerging Uses:............................................................................................
1.2 Naphtha................................................................................................................................
1.2.1 Properties:.........................................................................................................................
1.2.2 Production of Naphtha in Refineries and Uses:................................................................
1.2.3 Exported Naphtha specification of ARL:.........................................................................
1.3 Ammonia in Pakistan:..........................................................................................................
1.3.1 PakArab fertilizer ltd. (Pfl) Multan..................................................................................
1.3.2 Fauji fertilizer ltd. Goth Macchi.......................................................................................
1.3.2.1 Base Unit-Goth Machhi(Plant-1)...............................................................................
1.3.2.2 Expansion Unit-Goth Machhi(Plant-II).....................................................................
1.3.3 FFC Ltd. Mirpur Mathelo.:...............................................................................................
1.3.4 Agritech Ltd. Daudkhel:...................................................................................................
1.3.5 Engro Chemicals ltd. Dharki:...........................................................................................
1.3.6 Dawood Hercules Chemicals Limited:.............................................................................
1.4 Ammonia Production in Pakistan:.......................................................................................
1.5 Naphtha Exports at Loss:.....................................................................................................
1.6 Capacity:..............................................................................................................................
MANUFACTURING PROCESS..................................................................................................
2.1 Haldor Topsoe A/S Process..................................................................................................
2.2 Kellogg Brown and Roots Advanced Ammonia Process (KAAP)......................................
2.3 Krupp Uhde GmbH ammonia Process................................................................................
2.4 Haber process:.....................................................................................................................
2.5 Braun Purifier process:........................................................................................................
2.6 Foster Wheeler Process:.......................................................................................................
2.7 ICI process:..........................................................................................................................
2.8 Selection Criteria of Process:...................................................................................................
2.8.1 Advantages:.......................................................................................................................
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2.8.2 Disadvantages:..................................................................................................................
2.9 Process Description:................................................................................................................
2.9.1 Main Section.....................................................................................................................
2.9.2 Desulfurizer......................................................................................................................
2.9.3 Steam Reforming..............................................................................................................
2.9.4 Carbon monoxide Conversion..........................................................................................
2.9.4.1 HTSC.........................................................................................................................
2.9.4.2 LTSC..........................................................................................................................
2.9.5 CO2 Absorption.................................................................................................................
2.9.6 Methanation......................................................................................................................
2.9.7 Ammonia Synthesis..........................................................................................................
2.10 Process Flow Diagram:......................................................................................................
MATERIAL BALANCE...............................................................................................................
3.1 Primary Reformer:...............................................................................................................
3.2 Secondary Reformer:...........................................................................................................
3.3 High Temperature Shift Convertor (HTSC):.......................................................................
3.4 Low Temperature Shift Convertor (LTSC):.........................................................................
3.5 Absorber:..............................................................................................................................
3.6 Methanator:..........................................................................................................................
3.7 Concertor:............................................................................................................................
ENERGY BALANCE...................................................................................................................
4.1 Primary Reformer................................................................................................................
4.2 Secondary Reformer............................................................................................................
4.3 High Temperature Shift Convertor (HTSC)........................................................................
4.4 Low Temperature Shift Convertor (LTSC)..........................................................................
4.5 Methanator...........................................................................................................................
4.6 Convertor.............................................................................................................................
EQUIPMENT DESIGN.................................................................................................................
5.1 Reactor.................................................................................................................................
5.1.1 Introduction...................................................................................................................
5.1.2 Justification...................................................................................................................
5.1.4 Design calculations.......................................................................................................
5.1.5 Catalytic reactor............................................................................................................
5.1.6 Reactor thickness..........................................................................................................
5.2 Heat Exchanger....................................................................................................................
5.2.1 Shell and Tube Heat Exchanger........................................................................................
5.2.2 Heat Exchangers Selection Criteria.............................................................................
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5.2.3 Reasons of Maximum Utilization of this Exchanger..................................................

5.2.4 Design Standards for Shell and Tube Heat Exchangers..............................................
5.2.5 Fluid Allocation in Tube Side and Shell Side..............................................................
5.3 Compressor..........................................................................................................................
5.4 Absorber...............................................................................................................................
5.5 Separator..............................................................................................................................
5.6 Pressure Let Down Valve.....................................................................................................
COST ESTIMATION....................................................................................................................
6.1 Factors Affecting Investment and Production Costs:..........................................................
6.1.1 Types of Capital Cost Estimates:......................................................................................
6.1.2 Cost Indexes:....................................................................................................................
6.1.3 Methods for Estimating Capital:.......................................................................................
6.2 Cost of Equipments..............................................................................................................
6.3 Direct Cost...........................................................................................................................
6.4 Indirect Cost.........................................................................................................................
6.5 Fixed Capital Investment.....................................................................................................
6.6 Total Capital Investment......................................................................................................
6.7 Total Product Cost...............................................................................................................
6.8 Net Profit.............................................................................................................................
6.9 Payout Period.......................................................................................................................
6.10 Rate of Return....................................................................................................................
INSTRUMENTATION and CONTROL.......................................................................................
7.1 General Control system.......................................................................................................
7.1.1 Feed Forward Control:......................................................................................................
7.1.2 Feed Back Controller:.......................................................................................................
7.3 Process Variables:................................................................................................................
7.3.1 Temperature Measurements:.............................................................................................
7.3.2 Pressure Measurements:...................................................................................................
7.3.3 Flow measurement:.........................................................................................................101
7.3.4 Level Measurement:.......................................................................................................101
7.4 Automatic Control Mechanism:.........................................................................................104
7.4.1 Proportional controller (P)..............................................................................................105
7.4.2 Proportional integral controller (PI)...............................................................................106
7.4.3 Proportional derivative controller (PD)..........................................................................106
7.3.4 Proportional Integral Derivative Controller....................................................................106
SITE SELECTION FOR PROCESS...........................................................................................109
8.1 Site Selection:........................................................................................................................109
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8.1.1 Raw materials availability:.............................................................................................109

8.1.2 Energy availability:.........................................................................................................110
8.1.3 Meteorological data:.......................................................................................................110
8.1.4 Market Study...................................................................................................................110
8.1.5 Transport Availability......................................................................................................110
8.1.6 Water Supply...................................................................................................................110
8.1.7 Waste Disposal................................................................................................................111
8.1.8 Labor Supply...................................................................................................................111
8.1.9 Taxation and Legal Restrictions......................................................................................111
8.1.10 Site Characteristics........................................................................................................111
8.1.11 Safety and Environmental Measures.............................................................................112
8.1.12 Community Factors.......................................................................................................112
8.1.13 Others:...........................................................................................................................112
8.2 Selecting Site for Project:......................................................................................................113
HAZOP & SAFETY....................................................................................................................116
9.1 Safety.................................................................................................................................116
9.1.1 OSHA Hazard Communication Standard.......................................................................116
9.2 HAZOP Study....................................................................................................................117
9.2.1 When to Perform a HAZOP?..........................................................................................117
9.2.2 Characteristics...........................................................................................................118
9.2.3 Common Uses...........................................................................................................118
9.2.4 Limitation of HAZOP Study.....................................................................................118
9.2.5 Procedure for HAZOP Analysis................................................................................118
9.2.6 Definition of some Useful Items...............................................................................119
9.2.7 Main Process of the HAZOP Analysis:.....................................................................119
REFERENCES............................................................................................................................120
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CHAPTER 1
INTRODUCTION
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INTRODUCTION:
In this chapter we have discussed about Ammonia and Naphtha. The whole
chapter comprises of their history, physical and chemical properties, Raw materials used for
their manufacturing, Expansion in overall industries in Pakistan according to the production
point of view and about the market analysis and survey.
1.1 Ammonia
Ammonia is an intermediate product in the manufacture of nitrogenous fertilizers. It is also
used for direct application to the soil and in aqua condition with solutions of other
nitrogenous fertilizers like ammonium nitrate and/or urea. Besides these, ammonia finds
applications in the production of nitric acid, soda ash, cleaning agents, leather tanning,
petroleum refining, pulp & paper industry, textiles, refrigeration, rubber & synthetic resin
industries, explosives and food & beverages.
1.1.1 History of Ammonia

The history of ammonia cannot be detached from the large subject of nitrogen supply to the
fertilizer and chemical industry. In the early days of chemical industry dependence was
placed on natural and waste products of various kinds. Ammonia is the most stable form of
fixed nitrogen which is used as an essential part of almost all types of fertilizers.
Before 1800, the principle sources of nitrogen were by product, organic material of various
types which include manure, seed, meals, fish scraps, leather scraps and slaughter wastage.
First of allPriestly produced ammonia in 1754 by heating sub-ammonia (ammonium
chloride) with lime. The new compound was named for Egyptian god arm mow, because
ammonium chloride was first made fourth century (B.C) from camel dung near the temple of
arm mow.
In 1975, Hildebraud tried to synthesize ammonia from nitrogen and hydrogen at
atmospheric pressure. In 1923, Dobernier realized that a catalyst would be needed for
practical method. Between 1850 &1900, the general development of physical chemistry, the
new concept of mass action chemical equilibrium did much to pave the way for ammonia
synthesis.
First full plant scale was placed on stream in Badishe Aniline und soda Fabric A.G. (BASF)
by Fritz Haber and Carl Bosch at Oppau. Germany.
The process became commercial Haber-Bosch process. Although several processes have
developed since 1913.The main differences were the methods for the preparation of
synthesis gas, the purification of synthesis gas, the design of ammonia convertor and
method of receiving ammonia from converted flue gas.
Prior to 1945, coat and coke oven gas was the major raw material used for the production of
hydrogen required for ammonia synthesis. During the past 35 years, there has been a trend
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towards the use of petroleum products. Most of the plants built during the past 25 years,
throughout the world designed for the use of a natural gas, heavy oil as feed material. During
last 15 years, Naphtha has become the most popular feed material in the areas where natural
gas is not present. At present almost all of the ammonia plants in USA are based on natural
gas.
1.1.3 Raw Material Used
Ammonia is produced by the reaction between nitrogen (N2) and hydrogen (H2)
N2 + 3H2 2NH3
Source of Nitrogen is atmospheric air and following hydrocarbons are generally used as the
source of hydrogen.
Natural gas
Naphtha
Heavy Oil
Other sources of hydrogen which were used earlier for manufacture of Ammonia are:
1) Semi-water gas made by gasification of coke/ coal with steam.
2) Hydrogen produced by electrolysis of water.
3) By product Hydrogen from chlorine production.
1.1.4 Anhydrous Ammonia Properties:

Table 1.1 Physical Properties of Ammonia
Property Value or Detail
Molecular Mass 17.03 g/mol
Colour Colourless
Odour Sharp, Irritating
Physical State Gas (at room temperature)
Melting Point -77.7oC
Boiling point -33.35 oC
Flash Point 11 oC
Decomposition Point 500 oC
Density(Gas) 0.7710 g/L
Density(Liquid) 0.6818 g/L
Vapour Density 0.5697
Critical Temperature 132.4 oC
Critical Pressure 111.3atm
Heat Of Fusion 58.1 kJ/mol
Heat Of Vaporization 23.3 kJ/mol
Heat Of combustion -316 kJ/mol
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Chemical Properties:
Table 1.2 Chemical Properties of Ammonia

Property Value or Details
Chemical Formula NH3
Type Of Base Weak
Affinity(Water) High
Corrosiveness Corrosive to Some Metals
Oxidation Power Strong Reducing Agent
Reactivity Quite Reactive
Volatility Increases with increase in pH
1.1.5 Expansion in the industry
Major expansion of the ammonia industry began in 1963.The demand for nitrogen based
fertilizer throughout the world and the prospects for increased consumption in future years
stimulate fertilizer producers to build many new ammonia plants. During the last 8 years, a
trend has developed towards building large scale train plants with capacities of 600 to 1500
tons per day. During the last quarter century many improvements have been made in plant
equipment, catalysts and instrumentation. These developments have contributed to
substantiate reduction in the capital cost and operation costs of ammonia plants.
In 1960, the world production of ammonia was about 13 million ton. The use of ammonia can
be apprehended by the fact that in 1967, 12 million of ammonia was manufactured in United
States of America raised to 18 million tons the very next year.
Major development of ammonia began in 1963, so that ammonia requirement for the fertilizer
industry can be fulfilled. During the last quarter century many improvements have been made
in plant design technology. Significant improvements have been made in plant equipment
catalyst and instrumentation .These developments have caused a substantiate reduction in
capital cost and operation costs of ammonia plants. Research work is not so ancient .At the
time of Independence, there was no ammonia industry in Pakistan. The trend of ammonia
industry was developed with the use of fertilizer. The start of fertilizer/ammonia industry
was taken up in after 1960s during the rule of Field Marshal Ayyub Khan. Afterwards many
fertilizer industries were set up in Pakistan in private as well as public sector. Now National
Fertilizer Corporation of Pakistan is making its best efforts for the prosperity.
Since 1954the following sweeping changing in the technology of ammonia manufacture has
taken place.
1 Feed ranging from natural gas to naphtha have been processed by steam hydrocarbon
reforming at pressure up to 500lb/in2 gauge.
2 Electric power consumption has been reduced to practically zero due primarily to the
use of a highly efficient energy cycle which incorporates high pressure steam
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generation in conjunction with the maximum use of turbine drives to pumps and
centrifugal compressors.
3 Enormous improvements in the gas purification processes .several low utility
process are available for CO2 removal including promoted MEA, promoted hot
potassium carbonate process, sulfinol, the two stage Tri ethanol amine /Mon
ethanolamine system and others. Moreover, removal of residual CO has been
enormously simplified by the use of the methanation system. Space requirements for
the purification system have been minimized.
4 Improved heat recovery, particularly in the reformer effluent system and the various
catalyst reaction services.
5 Efficient use for steam
6 Use of higher activity catalyst for all the process services. The introduction of low
temperature shift conversion catalyst has simplified the design of the raw gas
generation system and permitted substantial reduction in the quantity of feed
processed in the reformer because of the associated reduction in purge in the
synthesis loop.
7 Plant capacities have been increased from 600 to 1700 tons/day as 100% single train
operations throughout the unit including the ammonia convertor. In addition, there
have been significant improvements in the fabrication of ammonia convertors. Full
closure convertors can be offered in a wide range of capacities and operating
pressures. Moreover, the internal layout of ammonia convertors have been modified
in the direction of low pressure drop which still retaining efficient distribution of gas
through the catalyst beds. The number of catalyst beds for the quench type
convertor has been optimized. Also, more use has been made of reduced size
synthesis catalyst which has reduced both the volume of catalyst and the convertor
size by 10-25% depending on the size of catalyst used and the available pressure
drop of the loop.
8 Improvement in compressor design for all process service. Centrifugal compressors
can be provided for the synthesis gas service for pressure up to 4700lb/in(g) for size
in excess of 1700 tons /day operating over a wide range of speeds and horsepower.
9 Development of improved method for feed desulfurization including hydro
desulphurization of naphtha feeds. Improvements in both cobalt molybdenum
catalyst and zinc oxide sulfur absorbent catalyst have enabled all feeds to be
desulfurized to levels of less than 0.25 ppm sulfur, thus ensuring protection of
reforming catalyst against sulfur poisons with a resultant long catalyst life.
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1.1.5.1 Improvement in NH3 Production process:
1940 to 1952
Main features:
Capacity : 150T/D
CO2 Removal system : Water wash, 20% MEA
No. of NH3 converter : 3
Process characteristics
1 .Low pressure catalyst reforming of natural gas i.e. (0.6-1.0)kg/cm2
2. Low pressure efficiency High power consumption.
1953
Main features:
Capacity : 160T/D
CO2 Removal system : 20% MEA
1.
First increase in reforming i.e. 4.2 kg/cm2
2. Substantial reduction in power consumption
3. Gas holder and associated operation eliminated
1955
Main features:
Capacity : 300T/D
CO2 Removal system : 20% MEA Hot k2co3
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1. Reduction in Fuel & power consumption
2. First use of centrifugal compression in raw synthesis gas service.
3. Additional feeds processed include refinery gas and naphtha.
4. Use of Hot K2CO3 for CO2 removal.
5.
Further increase in reformer pressure i.e. 8.8 kg/cm2
1960 to 1962
Main features:
Capacity : 360T/D
1. Further increase in reformer pressure i.e. (14.5-18.4)kg/cm2
2. Elimination of copper liquor system.
3. Elimination of compression in raw gas.
4. Use of high air pre-heat for secondary reformer.
5. Internal main folding of reformer catalyst lube to reduce heat losses.
6. Greater recovery of heat of reaction for all catalytic services.
1963
Main features:
Capacity : 320T/D
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Further increase in reformer pressure i.e. (21-28.3)kg/cm2

High thermal efficiency, reduced fuel consumption
Introduction of improved low temperature co shift catalyst.
Reduced purge rate in synthesis loop.
1964
Main features:
Capacity : 600T/D
1. First single train 600 ton ammonia plant.
2. First use of centrifugal compressor to compress synthesis gas to 150 atm.
3. Approximately 80% of all compression horsepower (including air + Refrigeration)
based on use of centrifugal machines.
1965 to 1972
Main features:
Capacity : 600 to 1700T/D

CO2 Removal system : 20% MEA Vertrocoke
Catacarb, Carsol, Sulfinol,
TEA/MEA
1. Further increase in reformer pressure in conjunction with low pressure synthesis
i.e. (31.7-33.5)kg/cm2.
2. Entire synthesis gas compression (including recycling service) handled by a two
stage centrifugal compressor for synthesis pressure up to 220 atm.
3. All compression services based on centrifugal compressors.
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4. Synthesis up to 320atm accommodated by centrifugal compressor (using three

stage machines).
5. High efficiency energy cycle in conjunction with more use of steam turbine for
pump and compressors for high pressure steam generation.
6. Low pressure consumption (especially zero to some design).
7. Low feed and utility cost.
8. High secondary reformer air pre-heat temperature, mild primary reformer
condition despite increase in reformer pressure.
9. First 1700 ton ammonia plant based on a single train operation.
10. Improved low pressure drop ammonia convertor design.
1.1.6 Uses of Ammonia:
Fertilizer
Approximately 83% (as of 2004) of ammonia is used as fertilizers either as its salts or as
solutions. Consuming more than 1% of all man-made power, the production of ammonia is a
significant component of the world energy budget.
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Precursor to nitrogenous compounds
Ammonia is directly or indirectly the precursor to most nitrogen-containing compounds.

Virtually all synthetic nitrogen compounds are derived from ammonia. An important
derivative is nitric acid. This key material is generated via the Ostwald
process by oxidation of ammonia with air over a platinum catalyst at 700850 C, ~9
atm. Nitric oxide is an intermediate in this conversion:
NH3 + 2 O2 HNO3 + H2O
Nitric acid is used for the production of fertilizers, explosives, and many organic nitrogen
compounds.
Cleaner
Household ammonia is a solution of NH3 in water (i.e., ammonium hydroxide) used as a

general purpose cleaner for many surfaces. Because ammonia results in a relatively streak-
free shine, one of its most common uses is to clean glass, porcelain and stainless steel. It is
also frequently used for cleaning ovens and soaking items to loosen baked-on grime.
Household ammonia ranges in concentration from 5 to 10 weight percent ammonia.
1.1.6.1 Minor and Emerging Uses:
Refrigeration R717
Because of its favorable vaporization properties, ammonia is an attractive refrigerant. It was

commonly used prior to the popularization of chlorofluorocarbons (Freons). Anhydrous
ammonia is widely used in industrial refrigeration applications and hockey rinks because of
its high energy and low cost. The Kalina cycle, which is of growing importance to geothermal
power plants, depends on the wide boiling range of the ammonia-water mixture. Ammonia is
used less frequently in commercial applications, such as in grocery store freezer cases and
refrigerated displays due to its toxicity.
For remediation of gaseous emissions
Ammonia is used to scrub SO 2 from the burning of fossil fuels, and the resulting product is
converted to ammonium sulfate for use as fertilizer. Ammonia neutralizes the nitrogen oxides
(NOx) pollutants emitted by diesel engines. This technology, called SCR (selective catalytic
reduction), relies on a vanadium-based catalyst.
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As a fuel
Ammonia was used during World War II to power buses in Belgium, and in engine and solar
energy applications prior to 1900. Liquid ammonia was used as the fuel of the rocket
airplane, the X-15. Although not as powerful as other fuels, it left no soot in the reusable
rocket engine and its density approximately matches the density of the oxidizer, liquid
oxygen, which simplified the aircraft's design.
Ammonia has been proposed as a practical alternative to fossil fuel for internal combustion
engines. The calorific value of ammonia is 22.5 MJ/kg (9690 BTU/lb) which is about half
that of diesel. In a normal engine, in which the water vapor is not condensed, the calorific
value of ammonia will be about 21% less than this figure. It can be used in existing engines
with only minor modifications to carburetors/injectors.
To meet these demands, significant capital would be required to increase present production
levels. Although the second most produced chemical, the scale of ammonia production is a
small fraction of world petroleum usage. It could be manufactured from renewable energy
sources, as well as coal or nuclear power. It is however significantly less efficient than
batteries. The 60 MW Rjukan dam in Telemark, Norway produced ammonia via electrolysis
of water for many years from 1913 producing fertilizer for much of Europe. If produced from
coal, the CO2 can be readily sequestrated (the combustion products are nitrogen and water).
In 1981 a Canadian company converted a 1981 Chevrolet Impala to operate using ammonia
as fuel.
Ammonia engines or ammonia motors, using ammonia as a working fluid, have been
proposed and occasionally used. The principle is similar to that used in a fireless locomotive,
but with ammonia as the working fluid, instead of steam or compressed air. Ammonia engines
were used experimentally in the 19th century by Goldsworthy Gurney in the UK and
in streetcars in New Orleans in the USA.
Antimicrobial agent for food products
As early as in 1895 it was known that ammonia was "strongly antiseptic. It requires 1.4
grams per liter to preserve beef tea. Anhydrous ammonia has been shown effective as
an antimicrobial agent for animal feed and is currently used commercially to reduce or
eliminate microbial contamination of beef. The New York Times reported in October, 2009
on an American company, Beef Products Inc., which turns fatty beef trimmings, averaging
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between 50 and 70 percent fat, into seven million pounds per week of lean finely textured
beef by removing the fat using heat and centrifugation, then disinfecting the lean product
with ammonia; the process was rated by the US Department of Agriculture as effective and
safe on the basis of a study (financed by Beef Products) which found that the treatment
reduces E. coli to undetectable levels. Further investigation by The New York
Times published in December, 2009 revealed safety concerns about the process as well as
consumer complaints about the taste and smell of beef treated at optimal levels of ammonia.
As a stimulant in sports
Ammonia has found significant use in various sports particularly the strength sports
of power lifting and Olympic weightlifting as a respiratory stimulant (psychoactive drugs).
Textile
Liquid ammonia is used for treatment of cotton materials, give properties

like Mercerization (It is a treatment for cotton fabric and thread that gives fabric or yarns a
lustrous appearance and strengthens them using alkalies). In particular, it is used for pre-
washing of wool.
Lifting gas
At standard temperature and pressure ammonia is lighter than air, and has approximately 60%
of the lifting power of hydrogen or helium. Ammonia has sometimes been used to fill weather
balloons as a lifting gas. Because of its relatively high boiling point (compared to helium and
hydrogen), ammonia could potentially be refrigerated and liquefied aboard an airship to
reduce lift and add ballast (and returned to a gas to add lift and reduce ballast).
Woodworking
Ammonia was historically used to darken quarter sawn white oak in Arts & Crafts and
Mission style furniture. Ammonia fumes react with the natural tannins in the wood and cause
it to change colors.
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1.2 Naphtha
It normally refers to a number of flammable liquid mixtures of hydrocarbons, i.e., a
component of natural gas condensate or a distillation product from petroleum, coal tar or peat
boiling in a certain range and containing certain hydrocarbons. It is a broad term covering
among the lightest and most volatile fractions of the liquid hydrocarbons in petroleum.
Naphtha is a colorless to reddish-brown volatile aromatic liquid, very similar to gasoline.
In petroleum engineering, full range naphtha is defined as the fraction of hydrocarbons in

petroleum boiling between 30 C and 200 C. It consists of a complex mixture of
hydrocarbon molecules generally having between 5 and 12 carbon atoms. It typically
constitutes 1530% of crude oil, by weight. Light naphtha is the fraction boiling between
30 C and 90 C and consists of molecules with 56 carbon atoms. Heavy naphtha boils
between 90 C and 200 C and consists of molecules with 612 carbons.
Naphtha is used primarily as feedstock for producing high octanegasoline (via the catalytic
reforming process). It is also used in the bitumen mining industry as a diluents, the
petrochemical industry for producing olefins in steam crackers, and the chemical industry for
solvent (cleaning) applications. Common products made with it include lighter fluid, fuel for
camp stoves, and some cleaning solvents.
1.2.1 Properties:
To obtain the product known as naphtha, a complex soup of chemicals is broken into another
range of chemicals, which are then graded and isolated mainly by their specific gravity and
volatility.
Naphtha is insoluble in water.
They are colorless (with a kerosene odor) or red-brown (with an aromatic odor).
They are incompatible with strong oxidizers. Less dense naphthas ("light naphthas")
have higher paraffin content. They are therefore also called paraffinic naphtha. The
denser naphthas ("heavy naphthas") are usually richer in naphthenes and aromatics.
Table 1.3 Properties of Naphtha

Property Value or Detail
Molecular weight 100-215

Specific gravity 0.75-0.85
Boiling point 70-430 F
vapor pressure 5 mm mercury
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1.2.2 Production of Naphtha in Refineries and Uses:

Naphtha is obtained in petroleum refineries as one of the intermediate products from the
distillation of crude oil. It is a liquid intermediate between the light gases in the crude oil and
the heavier liquid kerosene. Naphtha is volatile, flammable and has a specific gravity of about
0.7. The generic name naphtha describes a range of different refinery intermediate products
used in different applications. To further complicate the matter, similar naphtha types are
often referred to by different names.
The different naphthas are distinguished by:
density (g/ml or specific gravity)
PONA, PIONA or PIANO analysis, which measures (usually in volume percent but
can also be in weight percent):
Paraffin content (volume percent)
Iso paraffin content (only in a PIONA analysis)
Olefins content (volume percent)
Naphthenic content (volume percent)
Aromatics content (volume percent)
Paraffinic (or light) naphtha

The main application for paraffinic ("light") naphtha is as feedstock in the petrochemical
production of olefins. This is also the reason they are sometimes referred to as "light distillate
feedstock" or LDF. (These naphtha types may also be called "straight run gasoline" (SRG) or
"light virgin naphtha" (LVN).)
When used as feedstock in petrochemical steam crackers, the naphtha is heated in the
presence of water vapor and the absence of oxygen or air until the hydrocarbon molecules fall
apart. The primary products of the cracking process are olefins (ethylene / ethene, propylene /
propene and butadiene) and aromatics (benzene and toluene). These are used as feed stocks
for derivative units that produce plastics (polyethylene and polypropylene, for example),
synthetic fiber precursors (acrylonitrile), and industrial chemicals (glycols, for instance).
Heavynaphtha
The "heavy" naphtha can also be used in the petrochemical industry, but they are more often
used as feedstock for refinery catalytic reformers where they convert the lower octane
naphtha to a higher octane product called reformate. Alternative names for these types are
"straight run benzene" (SRB) or "heavy virgin naphtha" (HVN).
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Additional applications
Naphthas are also used in other applications, such as:
In the production of gasoline.
in industrial solvents and cleaning fluids
an oil painting medium
The sole ingredient in the home cleaning fluid Energize, which has been discontinued.
You can purchase this type of naphtha at any hardware store.
an ingredient in shoe polish
An ingredient in some lighter fluids for wick type lighters such as Zippo lighters.
an adulterant to petrol
A fuel for portable stoves and lanterns, sold in North America as white
gas or Coleman fuel.
historically, as a probable ingredient in Greek fire (together with grease, oil, sulfur,
and naturally occurring saltpeter from the desert)
A fuel for fire spinning, fire juggling, or other fire performance equipment which
creates a brighter and cleaner yet shorter burn.
To lightly wear the finish off guitars when preparing "relic" instruments.
To remove oil from the aperture blades of camera lenses, which if present can slow
the movement of the blades, leading to overexposure.
1.2.3 Exported Naphtha specification:
Table 1.4 Naphtha Specification
Test Description Units Test Model ARL Space Max/Min
Page 36
Specific Gravity 15.5/15.5C - D-1298 0.65-0.74 -

Colour Say bolt - D-156 +30 Min
Copper strip corrosion - D-130 1 Max
at 50C (122F)
Mercaptan Sulphur ppm D-3227 3 Min
Total Sulphur ppm D-1266 50 Max
Reid Vapor Pressure psi D-323 12 Max
@ 37.8 kpa
Lead ppb IP-224 25 Max
o
Distillation C ASTM-86
IBP 25 Min
End Point 180 Max

PONA Vol% ASTM 65 Min
Paraffins D-1319
Olefins 1 Max
Arsenic ppb UOP-296 20 Max
Organic Chloride ppm UOP-317 1 Max
Mercury ppb APHA-320A 1 Max
Oxygenates ppm - Nil Max
1.3 Ammonia in Pakistan:
Pakistan is an agricultural country where about 72% of the total population not only resides
in rural areas but also relies for its sustenance on Agri-activities. This sector is contributing a
lion's share in the national economy. Most of the national economic target is dependent on the
performance of our agricultural sector; It contributes 24% to the; total GDP. Cotton, Rice,
Sugarcane and Wheat are major crops having economics importance. The fertilizer is an
important input, which boosts the Agri-production. Unfortunately, it is used three times lower
in our country than that of the developed countries in the world. We are not still self-
sufficient in producing our staple food grain, soil deterioration, nutrient mining. And there is
insufficient and inadequate use of fertilizer. The industries that produce ammonia in Pakistan
are listed below:
1. PakArab fertilizer ltd. Multan
2. Fauji fertilizer ltd. Goth Macchi.
3. Paksaudi Fertilizers (Now FFC) Ltd. Mirpur Mathelo.
4. Pak American (Agritech) Ltd. Daudkhel
Page 36
5. Engro Chemicals ltd. Dharki.
6. Dawood Hercules Ltd. Lahore.
1.3.1 PakArab fertilizer ltd. (Pfl) Multan
Pak Arab was first established on 15th November,1972 by the federal government to further
strengthen and develop fraternal ties between Islamic Republic of Pakistan and state of Abu-
Dhabi. Pfl is largest fertilizer complex in Pakistan and only factory that is producing
CAN(Calcium Ammonium Nitrate) and NP(Nitro Phosphate).It uses Pullman Kelloggs
catalytic Steam hydrocarbon reforming process for the production of ammonia. It uses (56 to
62 million cubic feet/day) of natural gas as a raw material supplied by SNGPL. Ammonia
plant was first
established on 27 September 1978.its annual capacity of producing ammonia is 316,800

MTonns.
1.3.2 Fauji fertilizer ltd. Goth Macchi
Fauji Fertilizer Company Limited (FFCL), is a public listed company, incorporated in 1978.
It was a joint venture between Fauji Foundation Pakistan and M/S HaldorTopsoe A/S
Denmark. At Goth Machhi, in District Rahim Yar Khan, FFC operates the largest fertilizer
producing complex in Pakistan. The plant has an initial capacity of 330,000 Met/Year (june
1982) and was upgraded to 403,000 Met/Year (Revamped 1992) of Ammonia.
1.3.2.1 Base Unit-Goth Machhi(Plant-1)

The plant starts up in June 1982 having a designed capacity of 330,000 Met/Year of ammonia
and was upgraded to 403,000 Met/Year in July, 1992
Page 36
1.3.2.2 Expansion Unit-Goth Machhi(Plant-II)

It was initialized with a design capacity of 363,000 Met/Year of ammonia in 1993.
1.3.3 FFCLtd. Mirpur Mathelo.:
Fauji Fertilizer Company Limited (FFC) is the largest chemical fertilizer producer
of Pakistan with biggest market share in the country. It was established by the Fauji
Foundation which holds a controlling interest.FFC was established in 1978 as a joint venture
of Fauji Foundation and Haldor Topsoe. The first urea complex was commissioned in 1982.
Plant-1 was improved in 1992, and a second plant was built in 1993. In the year 2002, FFC
acquired ex Pak Saudi Fertilizers Limited (PSFL) Urea Plant situated at Mirpur
Mathelo, District Ghotki from National Fertilizer Corporation (NFC) through
a privatization process of the Government of Pakistan. It starts up in Oct, 1980 and then
merged with FFC on 1 July, 2002. It has a designed capacity of producing 330,000 Met/year
of ammonia and after that capacity was enhanced to 413,000 Met/year on Feb, 2009.
1.3.4 Agritech Ltd. Daudkhel:
Agritech Limited (formerly Pak American Fertilizers Limited) was incorporated in 1959 as
unquoted public limited company. Our company remained wholly owned subsidiary of
National
Fertilizer Corporation of Pakistan. Pak American Fertilizers is a urea manufacturing Plant

with annual Production capacity of 346,500 tons. Now its using DCS technique. Its designed
capacity of producing ammonia is 600 MTPD and now it is operatingbetween 650 to 750
MTPD of ammonia.
1.3.5 Engro Chemicals ltd. Dharki:
Engro fertilizer is the worlds largest single train ammonia-urea plant in Daharki, which has a
production capacity of 268,000 tons per annum.
Page 36
1.3.6 Dawood Hercules Chemicals Limited:
It is a large manufacturer of urea fertilizer in Pakistan under the Bubber Sher brand name.
The company was founded in 1971, and its plant is located near Sheikhupura, about 28 Km
from Lahore, in the province of Punjab. The manufacturing facility was established in 1968
as a joint venture with Hercules Chemicals Inc. of the USA. It was the first private sector
venture in Pakistan to receive a loan from the World Bank and was the largest ammonia/urea
plant in country at that time. Initially designed to produce625 MTPD of ammonia but now
upgraded to produce 850 MTPD of ammonia.
1.4 Ammonia Production in Pakistan:
Table 1.5 Ammonia production in Pakistan

INDUSTRIES AMMONIA CAPACITY
(MTPA)
PakArab fertilizer ltd.(Pfl) Multan 316,800
FFC (Goth Macchi). 403,000
FFC (Mirpur Mathelo) 413,000
Pak American (Agritech) Ltd. Daudkhel 237,250
Engro Chemicals ltd. Dharki 268,000
Dawood Hercules Ltd. Lahore. 310,250
Page 36
1.5 Naphtha Exports at Loss:
Exports of naphtha from Pakistan also dropped in recent months. The data shows that the
cumulative quantity of two different grades of the hydrocarbon mixture exported from the
country in the first eight months of the current fiscal stood at 895,588 tons, compared with
almost 920,000 tons exported in the corresponding period of last year. Overall production of
local refineries has been limited in the past few months.
Naphtha is a by-product of crude oil, obtained through refineries. The substance is used for
making paraxylene, which is in turn used to make polyester fibre utilized by the textile sector.
Our refineries cannot control the proportion of different petroleum products made in the
refining process, so even though there is no capacity to make paraxylene in the country, we
cannot reduce the production of naphtha for other variants.
The analyst explained that naphtha is exported at relatively cheaper rates, only to be imported
in the form of paraxylene which is a lot more costly.
While the quantity of naphtha exports has not registered a significant increase, rising prices
helped shore up the export value. During the July-February period of year 2011 $698.7
million worth of naphtha was exported, compared with exports of $609.8 million during the
same period last year. Asian naphtha prices climbed above $1000 per ton in March for the
first time in 30 months in 2011.different refineries that export naphtha on yearly bases are
listed under.
Page 36
Table 1.6 Naphtha export per Annum
REFINERYEXPORT (Tons/Annum)
NRL 300,000
PRL 178460
ARL 200,000
BOSICOR 37,000
Dhodak 83,000
PARCO---
Total Country Exports Potential 798460
Page 36
1.6Capacity:
Pakistan is likely to face shortage of up to 400,000 tons urea in December, 2011 due to
unavailability of natural gas used as a raw material for ammonia that further produces urea.
Even after imports by the Trading Corporation of Pakistan (TCP) of 440,000 tons. There
would be a urea shortage of at least 200,000 tons in December 2011, which is the peak urea
consumption time in Rabi because of wheat sowing. It can go up to 400,000 tons in case of
delay in import. Majority of urea shipments are coming from Russia and China, which might
arrive at Gwadar port in 20 to 25 days.
Table 1.7 Urea Export

Companies Urea Exports
(tons)
Dreymor (Russia and China) 100,000
Keytrade (Russia and China) 150,000
Middle East 75,000
Transammonia 100,000
Indian Potash Ltd. 90,000
Industry sources said production losses due to continued curtailment of gas from the Sui
Northern Gas Pipelines Limited (SNGPL) to urea manufacturers are also complicating this
situation. Rabi Season could still be shielded from acute shortage if all fertilizer plants were
operated in November and December to cover December demand of up to 800,000 tons to
850,000 tons of urea. In order to overcome the shortage of natural gas which is a raw material
for ammonia that is used in urea manufacturing. We have decided to build a plant that can
produce 2500 MTPD of ammonia using naphtha as a source instead of natural gas. It may
provide benefit in economics of country. And we may reduce the short fall.
Page 36
CHAPTER 2
PROCESS DESCRIPTION
Page 36
MANUFACTURING PROCESS
The synthesis gas for manufacture of Ammonia is produced by steam reformingor partial
oxidation of Hydrocarbon feed. In most industries steam reforming isused normally.The
various processes used commercially in industries for production of Ammonia are
1. Haldor Topsoe process

2. Kellogg Brown and Roots Advanced Ammonia Process (KAAP)
3. Krupp Uhde GmbH ammonia Process
4. The Linde Ammonia Concept (LAC) ammonia process
5. Haber process
6. Braun Purifier process
7. Foster Wheeler AM2 process
8. ICI process
2.1 Haldor Topsoe A/S Process
The companys low energy ammonia process uses the conventional sequence of process steps
which are optimized by the introduction of improved catalysts, new equipment design and
extensive process optimization studies. A pre-reformer containing nickel catalyst has been
also provided upstream of primary reformer for converting all the higher hydrocarbons, so
that only methane, carbon monoxide, carbon dioxide, hydrogen and steam are present in the
product gas. Firing in primary reformer is reduced by 15% due to pre-reformer. Highly active
shift catalyst ensures the lowest carbon monoxide (less incomplete combustion) at the exit of
converters and thus highest utilization of feedstock. New temperature resistant iron free
catalyst makes it possible to operate at low steam to carbon ratio at high temperature shift
converter. The company has also developed Heat Exchange Reforming Process. Low energy
CO2 removal processes, such as selexol, MDEA or low heat potassium carbonate, are used.
Topsoe has developed new converters especially for high conversion loops.
2.2 Kellogg Brown and Roots Advanced Ammonia Process (KAAP)
KAAP uses a high-pressure heat exchange based steam reforming process integrated with a
low-pressure advanced ammonia synthesis process. Raw synthesis gas is produced by steam
reforming of hydrocarbon in a heat exchange based system under pressure, based on Kellogg
Brown and Root Reforming Exchange System (KRES). KRES also reduces energy
consumption and capital cost besides reduced emission and enhanced reliability.
The main features of this technology are
Page 36
Single case compression

Four bed, intercooled, radial flow, hotwall design converter contained in one shell.
Combined drive synthesis and refrigeration compressor
Combined drive air compressor and electrical generator
Low pressure synthesis-loop
High activity synthesis catalyst
2.3 Krupp Uhde GmbH ammonia Process
The Krupp Uhde Gmbh process uses conventional steam reforming for synthesis gas
generation (front end) and a medium-pressure ammonia synthesis loop. The primary
reforming is carried out at pressure 40 bar and temperature range of 800-8500C. The steam
reformer is top fired and tubes are made of centrifugal high alloy steel which enhances
reliability. Process air is added in secondary reformer through nozzles installed in the wall of
vessel. This provides proper mixing of the air and reformer gas. Subsequent high pressure
steam generation & superheating, guarantee maximum heat usage to achieve energy
efficiency. Carbon monoxide is converted to carbon dioxide in HT and LT shift converters.
The MDEA or Benfield system is used for carbon dioxide removal. The ammonia synthesis
loop uses two ammonia converters with three catalyst beds with waste heat boiler located
downstream of each reactor. The converters have small grain iron catalyst. The radial flow
concept minimizes pressure drop and allows maximum ammonia conversion.
2.4 Haber process:
Ammonia production usually requires the formation of molecular hydrogen followed by

contacting the hydrogen with molecular nitrogen over a catalyst in the Haber Bosch process
for ammonia synthesis, more commonly known as simply the Haber process. This concept
for a small-scale liquid anhydrous ammonia reactor has the potential to allow for the
production of ammonia on a distributed and as-needed basis from water vapor and air
(nitrogen source). The ammonia reactor and process currently under development is also able
to produce ammonia at relatively low temperatures as well as atmospheric pressure. Once
formed, ammonia can be used in fertilizer production.
2.5 Braun Purifier process:
In the secondary reformer 1.5 times the stoichiometric quantity of air is used. This increases
the heat load and reduces the radiant duty of the primary reformer to less than two thirds its
usual duty. Excess nitrogen is removed by a cryogenic purification unit after methanation
occurs.
Page 36
Large air compressors used are driven by gas turbines. Owing to the high purity of synthesis
gases, lower recylce gas flow, lower refrigeration duty and lower purge duty will suffice.
2.6 Foster Wheeler Process:
In the secondary reformer excess air is used as in the previous case. Instead of treating the
whole feed in primary reformer, some bypass is fed to the secondary reformer. Partial
reaction in primary reformer will allow for a lower steam to carbon ratio. Excess air used is
much higher than in the case of Braun purifier process. A cryogenic unit removes nitrogen
form the exit gases leaving the methanator. CO2 is removed using physical solvents.
Absorption system provides refrigeration for ammonia recovery.
2.7 ICI process:
Hydrocarbon feed is subjected to steam reforming in two stages to form oxides of Carbon,
methane and hydrogen. In the secondary reformer air is mixed with the gases to get a N 2 : H2
ratio of 1:3. Carbon monoxide is removed by shift conversion. Carbon dioxide is removed by
absorption into MEA or Potassium Carbonate solution. Traces of CO and CO 2 are removed
by conversion into methane. Synthesis gas is used to produce ammonia.
Advantages of this process are
1. Intensive heat recovery
2. Generation of steam which can be imported.
3. Less dependancy on electricity
4. Capital cost is least.
2.8 Selection Criteria of Process:
For the production of ammonia we have decided to select the Haldor topsoe because of its
energy efficient nature. Ammonia production usually requires the formation of molecular
hydrogen followed by contacting the hydrogen with molecular nitrogen over a catalyst for
ammonia synthesis.Topsoe's low energy ammonia process scheme can be optimized for a
wide range of operating conditions by selecting proper process technology and by adjusting
the process parameters. Topsoe's ammonia plant designs are characterised by being highly
energy efficient.
In comparison, Haldor Topsoe process operates at the pressures lower than Claude process
and against the disadvantage of using heat exchanger for heat recovery and less compactness
in converter design. Recovery of 20% of unconverted gas and recycling it to increase the
Page 36
efficiency and conversion of complete process and the large and massive compressors which
are used in Claude process are required to maintaining 900 atm which cost millions
of Dollars are avoided in Haldor Topsoe and is thus more economic and good especially for
large capacity process. Also the life of the converter is very long and ammonia is removed by
water-cooling and by knockout drum.Through this method we can achieve 15.8 mol% of
ammonia per pass.
2.8.1 Advantages:
1. Greater compactness, simplicity in case of converter design since under high pressure
gases have smaller volume.
2. Elimination of expensive heat exchanger required in processes operated at low pressure.
3. Removal of ammonia with water cooling alone.
4. Energy Efficient Process.
5. Most economical Process.
2.8.2 Disadvantages:
1. Shorter life of converters
2. High apparatus upkeep in the high pressure operations
3. Efficiency loss in approximately 20% of making up gas, which is unconverted.
2.9 Process Description:

The process for converting hydrocarbon feed into ammonia consists of following
main sections. The hydrocarbon used is Naphtha.
2.9.1 Main Section
The main sections for Ammonia production are

Hydrofining or desulphurization
Steam Reforming,
Shift CO conversion,
CO2 removal
Final purification,
Ammonia synthesis
Recovery
Cracking,
Liquefaction & Storage.
Page 36
2.9.2 Desulfurizer
As the virgin naphtha had high sulphur content, the Hydrofining or Desulphurization process
is used to bring down the sulphur content to 2 ppm by a suitable process in which the
preheated mixture of vaporized naphtha and hydrogen rich washed purge gas is superheated
and routed to the reactor where it flows over Cobalt Molybdenum catalyst at a temperature of
about 673 K or 399 oC.
H2 + S H2S
H2S + ZnO H2 O +ZnS
The sulfur content is reduced to less than 5ppm. The mixture is sent to Final Desulphurizer
where the last traces of organic sulphur is converted to H 2S by reaction over COMoX catalyst
and H2S is removed by an Absorbing Column containing ZnO. Subsequently Naphtha vapors
are mixed with steam and sent to reforming section.
2.9.3 Steam Reforming

The Topsoes reformation process is carried out in following stages:
Pre-Reforming
Adiabatic prereforming can be used for steam reforming of feed stock ranging from natural
gas to heavy naphtha. In this all higher hydrocarbons are converted into a mixture of carbon
oxides, hydrogen and methane. When it is installed, the primary reformer has to reform
methane only, and at the same time at sulphur free conditions, because prereforming catalyst
will pick up sulphur components quantitatively. This is one of the reasons for allowing much
higher heat flux in the high flux reformer.
The prereformer feed can be reheated to 650 oC before
entering the primary reformer. This will result in reduced firing in the primary reformer, and
thereby reduced fuel consumption. When the hot flue gas is used to reheat the reformer feed,
the amount of heat available for HP steam production is reduced. This would result in a
reduced HP steam production in the ammonia plant.
Primary Reformer
In the first stage desulfurized naphtha is mixed with steam in a tubular reforming furnace.
The reformation reactions occur at a temperature of about 673K. Steam to carbon ration must
be maintained between 3.5 and 4.5 to ensure that Carbon deposition does not occur.
CnHm + nH2O nCO + (n+m/2) H2
CO + H2O CO2 + H2
CO + 3H2 CH4 + H2O
Page 36
The overall reaction is highly exothermic and the outlet temperature is about1093 K. The
primary reforming process is characterized by a low pressure.
Secondary Reformer
The gases from the primary reformer are mixed with air and steam at the outlet temperature
of the primary reformer. The remaining hydrocarbon like methane is further subjected to
reformation and the overall yield of hydrogen is increased. Air is mixed to form a mixture of
H2 and N2 for the synthesis process.
CH4 + H2O CO +3 H2
Other side reactions occurring are

H2 + O2 H2O
CO +H2O CO2 +H2
CO + O2 CO2
Initially the carbon monoxide burns in air to produce carbon dioxide and the temperature
increases to about 1200 oC. Then adiabatic reaction of methane with steam occurs and the
outlet temperature decreases to about 1000 oC at the outlet.
2.9.4 Carbon monoxide Conversion
Concentration of CO is reduced to about 0.1 0.3 % by volume in two stage converter.

CO + H2O CO2 + H2
.
2.9.4.1 HTSC
CO concentration is reduced to about 3% by volume by means of water gas shift reaction at a

temperature of about 593 to 693 K. The reaction being exothermic the exit gases are at a
higher temperature. They are cooled before being sent to the secondary reformer. The process
gas is passed over Iron Oxide catalyst in the HT converter where CO reacts with steam to
form CO2and Hydrogen. A layer of Alumina balls are placed over the top catalyst bed with
the aim of filtering any solid particles entering the gas to be treated and for the uniform
distribution of gas through the catalyst bed.
Page 36
2.9.4.2 LTSC
The reaction occurs at a temperature of about 523 K. Concentration of CO in the exit gas is
reduced to about 0.3 % by volume. The gas leaving the HT converter is then cooled and sent
to LT converter where the gas passes over Copper catalyst. The remaining CO is converted to
CO2 in shift convertor.
2.9.5 CO2 Absorption
Monoethanolamine solution is used as the absorbing medium. The absorption operates at

atmospheric pressure and a temperature of about 100 oC. The tower is usually a packed tower.
Counter current absorption is practiced. The spent MEA solution is regenerated in a
regenerating column by steam stripping.
Table 2.1 Absorption Solution with Specification

Absorbent Solution Constituent
Vetrocoke Potassium Carbonate (20-25%) and
arsenic trioxide (15%)
Benfield Potassium Carbonate (30%)
Diethanolamine (3%) and
Arsenic trioxide (0.3 to 0.9%)
Monoethanolamine (MEA) MEA (15-20%)
Rectisol Methnaol
Catacarb Potassium Carbonate, Diethanolamine and
VanadiumPentaoxide
Glycine Potassium Carbonate and Glycine
2.9.6 Methanation
Even trace quantities of Carbon monoxide and Carbon dioxide will act as catalyst poisons in
the synthesis loop. Hence they must be removed by conversion into methane. Methane
though not an inert gas is nevertheless inert in the ammonia synthesis process. The reaction in
the methanator occurs at a temperature of about 573 to 673 K. The exit gases contain steam
are condensed and cooled before being stored for the synthesis loop.
Page 36
CO + 3H2O CH4 + H2O

CO2 + 4H2 CH4 + H2O
2.9.7 Ammonia Synthesis
Synthesis gas is compressed to about 50 MPa and heated t about 673 K before passing
through the catalyst beds. The reaction being a reversible one high pressure favors the
forward phase. As the concentration of ammonia in the exit gas is low, recycling of gas is
necessary. The converter used is a vertical type of converter. Catalyst activity increases with
increase in temperature; hence ideal temperature profile is one in which rate of ammonia
production is a maximum at all parts of the bed. In the upper part of the converter the
concentration of ammonia being low the temperature is high ensuring high reaction rates. In
the lower parts temperature must be low due to increasing influence of equilibrium
concentration.
Process Block Diagram:
FIGURE 2: AMMONIA PRODUCTION BY STEAM REFORMATION PROCESS
Page 36
2.10 Process Flow Diagram:
Page 36
CHAPTER 3
MATERIAL BALANCE
Page 36
MATERIAL BALANCE
3.1 Primary Reformer:
Primary Reformer
Conversion =90%
C8H18 = 680,000 tons/yr C8H18 = 7762.56 kg/hr
C8H18 = 77625.57 kg/hr H2 = x
CO = y
CO2 = z
Steam = 110310 kg /hr
Reactions:
C8H18 + 8 H2 O 8 CO + 17 H2
CO + H2 O CO2 + H2
Basis:
Naphtha = 680,000 tons/yr

Naphtha = 77625.57 kg/hr
Degree Of Freedom:
Unknown Equations
X C
Y H
Z O
Page 36
Steam Balance:
1 mole of C8H18 requires steam = 9 moles

(1 mole) x (114 kg/mole) of C8H18 requires steam = (9 moles) x (162 kg/mole)
1 kg/hr of C8H18 requires steam = (9 x 162) / (114) kg/hr
96689.49 kg/hr of C8H18 requires steam = 110310 kg/hr
Carbon Balance:
77625.57 x (96/114) = Y x (12/28) + Z x (12/44)

65368.90 = 0.428 y + 0.273 z ----------- (1)
Hydrogen Balance:
77625.57 x (18/114) + 110310 x(2/18) = X x(2/2)

12256.67 + 12256.67 = x
X = 24513.34 kg/hr
Oxygen Balance:
110310 x(16/18) = Y x (16/28) + Z x (32/44)

98053.33 = 0.5714 Y + 0.7273 Z
Putting value of y in (1)
Y = 171601.91 1.273 Z --------- (2)

65368.90 = 0.4286 (171601.91 1.273 Z) + 0.273 Z
65368.90 = 73548.58 0.5456 Z + 0.273 Z
65368.90 = 73548.58 0.2729 Z
0.2729 Z = 73548.58 65368.90
Z = 29973.18 kg/hr
So, putting the value of Z in eq. (2)
Y = 133446 kg/hr
INPUT OUTPUT
C8H18 = 77625.57 kg/hr C8H18 = 7762.56 kg/hr
Steam = 110310 kg/hr H2 = 24513.34 kg/hr
CO = 133446 kg/hr
CO2 = 8179.68 kg/hr
Page 36
3.2 Secondary Reformer:
Secondary Reformer
Conversion = 99%
C8H18 = 7762.56 kg/hr C8H18 = 77.625

kg/hr
CO2 = x
H2 O (v) = y
O2 = z
N2 =
91216.7mkg/hr
Air = 27246.55 kg/hr
Basis:
Naphtha = 7762.56 kg/hr
Reaction:
C8H18 + 12.5 O2 + N2 8 CO2 + H2 O + N2
Degree of Freedom:
Unknown Equations
X C
Y H
Z O
Air Balance:
1 mole of C8H18 requires O2 = 12.5

(1 mole x 114 kg/hr) of C8H18 requires O2 = 12.5 x 32 kg/mol
1 kg/hr of C8H18 requires O2 = 3.51
7762.55 kg/hr of C8H18 requires O2 = 3.51 x 7762.55 = 27246.55 kg/hr
Page 36
Carbon Balance:
7762.55 x (96/114) = 77.62 x (96/114) + X x (12/44)

6536.88 = 65.36 + 0.273 X
X = 23792.4 kg/hr
Hydrogen Balance:
7762.55 x (18/114) = 77.62 x (18/114) + Y x (2/18)

1225.67 = 12.26 + 0.111 Y
Y = 10931.6 kg/hr
Oxygen Balance:
27246.55 x (32/32) = 23792.4 x (32/44) + Z x (32/32)

27246.55 = 17303.56 + Z
Z = 9942.98 kg/hr
N2 Balance:
0.23 kg of O2 requires N2 = 0.77 kg

1 kg of O2 requires N2 = 0.77/0.23
27246.55 kg/hr of O2 requires N2 = 27246.55 x (0.77/0.23) = 91216.7 kg/hr
INPUT OUTPUT
C8H18 = 7762.56 kg/hr C8H18 = 77.62 kg/hr
Air = 27246.55 kg/hr CO2 = 23792.4 kg/hr
H2O (v) = 10931.6 kg/hr
O2 = 9942.98 kg/hr
N2 = 91216.7 kg/hr
Page 36
3.3 High Temperature Shift Convertor (HTSC):
HTSC
Conversion = 70%
CO = 133446 kg/hr CO = 40034 kg/hr
CO2 = x
H2 = y
H2 O (v) = z
Steam = 85786.7 kg/hr
Basis:
Carbon Monoxide = 133446 kg/hr
Reaction:
CO + H2O (v) CO2 + H2
Degree of Freedom:
Unknown Equations
X C
Y H
Z O
Steam Balance:
1 mol of CO requires steam = 1 mole

(1 mol x 28 kg/mol) of CO requires steam = 1 x 18
28 kg/hr of CO requires steam = 18 kg/hr
1 kg/hr of CO requires steam = 18/28
133446 kg/hr of CO requires steam = (18/28) x 133446 = 85786.7 kg/hr
Carbon Balance:
133446 x (12/28) = 40034 x (12/28) + X x (12/44)

57191.14 = 17157.43 + 0.273 X
X = 147182.76 kg/hr
Page 36
Hydrogen Balance:
85786.7 x (2/18) = Y x (2/2) + Z x (2/18)

9531.85 = Y + 0.11 Z
9531.85 = Y + 0.11(25065.68)
Y = 6774.6 kg/hr
Oxygen Balance:
133446 x (16/28) + 85786.7 x (16/18) = 40034 x (16/28) + 147182.76 x (32/44) + Z x (16/18)

76254.86 + 75721.51 = 22876.57 + 107042 + Z (0.88)
151976.37 = 129918.57 + 0.88 Z
Z = 25065.68 kg/hr
INPUT OUTPUT
CO = 133446 kg/hr CO = 40034 kg/hr
Steam = 85786.7 kg/hr CO2 = 147182.76 kg/hr
H2 = 6774.6 kg/hr
Page 36
3.4 Low Temperature Shift Convertor (LTSC):
LTSC
Conversion = 99%
CO = 40034 kg/hr CO = 40034 kg/hr
CO2 = x
H2 = y
H2 O (v) = z
Steam = 25736.14 kg/hr
Basis:
Carbon monoxide = 40034 kg/hr
Reaction:
CO + H2 O (v) CO2 + H2
Degree of Freedom:
Unknown Equations
X C
Y H
Z O
Steam Balance:
18 mole of CO requires steam = 28 moles

1 mole of CO requires steam = 18/28 moles
40034 kg/hr of CO requires steam = 40034 x (18/28) = 25736.14 kg/hr
Page 36
Carbon Balance:
40034 x (12/28) = 40034 x (12/28) + X x (18/28)

17157.42 = 171.57 + 0.273 X
X = 62448 kg/hr
Hydrogen Balance:
25736.14 x (2/18) = Y x (2/2) + Z x (2/18)

2859.57 = Y + 0.11 Z
2859.57 = Y + 0.11 (122.4)
Y = 28 46.1 kg/hr
Oxygen Balance:
40034 x (16/28) + 25736.14 x (16/18) = 400.34 x (16/28) + 62448 x (32/44) + Z x (16/18)

22876.57 + 22897.57 = 228.77 + 45416.7 + 0.88 Z
Z = 122.35 kg/hr
INPUT OUTPUT
CO = 40034 kg/hr CO = 400.34 kg/hr
Steam = 25736.14 kg/hr CO2 = 62448 kg/hr
H2 = 2846.1 kg/hr
H2O(v) = 122.35 kg/hr
Total Components:
CO2 = (8179.68 + 23792.4 + 147182.76 + 62448) kg/hr
CO2 = 241602.84 kg/hr
CO =400.34 kg/hr
H2 = (24513.34 + 6774.6 + 2846.1) kg/hr
H2 = 34134.04 kg/hr
N2 = 91216.7 kg/hr
Page 36
3.5 Absorber:
The absorber is used to absorb Carbon Dioxide from mixture of gases. Here we
are using Benfield solution for the absorption of CO2.
CO2 = 241.60nkg/hr Benfield Solution (30% K2CO3)
Absorber
Absorption = 99.9%
CO2 = 241602.84 kg/hr
Reaction:
CO2 + K2CO3 + H2O 2 K2CO3
Benfield Solution Calculation:
1 mol of CO2 requires K2CO3 = 1 mol

(1mole x 44 kg/mol) of CO2 requires K2CO3 = 1 mole x 54 kg/mole
44 kg/hr of CO2 requires K2CO3 = 54 kg/hr
1 kg/hr of CO2 requires K2CO3 =54/44
241602.84 kg/hr of CO2 requires K2CO3 = 241602.84 x 54/44 = 296512.58 kg/hr
INPUT OUTPUT
CO2 = 241602 kg/hr CO2 = 241.60 kg/hr
K2CO3. H2O = 296512.58 kg/hr
Page 36
3.6 Methanator:
CO2 = 241.60 kg/hr

Methanator
Conversion = 99%
CO = 400.34 kg/hr CH4 = x

H2O (v) = y
H2 = z
CO = 4 kg/hr
CO2 = 2.42
kg/hr
H2 = 34134.04 kg/hr
Reactions:
CO + 3H2 CH4 + H2O (v)
CO2 + 4H2 CH4 + 2H2O (v)
Degree of Freedom:
Unknown Equations
X C
Y H
Z O
Carbon Balance:
241.60 x (12/44) + 400.34 x (12/28) = X x (12/16) + 4 x (12/28) + 2.42 x (12/44)

65.89 + 171.57 = 0.75 X + 1.714 + 0.66
X = 313.45 kg/hr
Page 36
Hydrogen Balance:
34134.04 x (2/2) = 313.45 x (4/16) + Y x (2/18) + Z x (2/2)

34134.04 = 78.36 + 0.11 Y + Z
34055.6 = 0.11(455.03) + Z
Z = 34005.54 kg/hr
Oxygen Balance:
241.60 x (32/44) + 400.34 x (16/28) = Y x (16/18) + 4 x (16/28) + 2.42 x (32/44)

175.71 + 228.76 = 0.88 Y + 2.28 + 1.76
Y = 455.03 kg/hr
INPUT OUTPUT
CO2 = 241.60 kg/hr CH4 = 313.45 kg/hr
CO = 400.34 kg/hr H2O (v) = 455.03 kg/hr
H2 = 34134.04 kg/hr H2 = 34005.54 kg/hr
CO = 4 kg/hr
CO2 = 2.42 kg/hr
Page 36
3.7 Concertor:
N2 = 91216.7kg/hr
Convertor
Conversion = 98%
NH3 = x
H2 = 19546.44kg/hr N2 = 1824.33 kg/hr

H2 = 390.93 kg/hr
Reaction:
N2 + 3 H2 2 NH3
Hydrogen Calculations:
1 mol of N2 requires H2 = 3 mole

(1 mol x 28 kg/mole) of N2 requires H2 = (3 mole x 2 kg/mole)
28 kg/hr of N2 requires H2 = 6 kg/hr
1 kg/hr of N2 requires H2 = (6/28) kg/hr
91216.7 Kg/hr of N2 requires H2 = 6 / 28 x 91216.7kg/hr
= 19546.44 kg/hr
As our required Hydrogen is 19546.44 kg/hr and till by convertor we are producing 34134.04
kg/hr.
So, the rest of Hydrogen which is 145876 kg/hr can be used for other processes.
Nitrogen Balance:
(91216.7 x 28/28) = (X x 14/17)

91216.7 = 0.823 X
X = 110834.4 kg/hr
INPUT OUTPUT
N2 = 91216.7kg/hr NH3 = 110834.4kg/hr
H2 = 19546.44kg/hr N2 = 1824.33kg/hr
H2 = 390.93kg/hr
Page 36
Total Ammonia:
Ammonia = 110834.4(kg/hr) x (24 hr /1day) x (1 MT /1000 kg)
Ammonia = 2660 MTPD
This is quite near to our decided capacity that is 2500 MTPD.
Page 36
CHAPTER 4
ENERGY BALANCE
Page 36
ENERGY BALANCE
Primary Reformer
4.1 Primary Reformer
TREF = 300 oC
T1 = 314 oC T3 = 828 oC
C8H18 = 68092.60 mole/hr

C8H18 = 680926.05 mole/hr H2 = 12256670 mole/hr
CO = 4765928.6 mole/hr
T2 = 300 oC CO2 = 185901.8 mole/hr
Steam = 6128333.3 mole/hr
Heat Balance equation
H + Ek + Ep = Q W
As, no moving parts and equipment is not at height and external work is not going to taking
place so kinetic and potential energy terms can also be neglected.
Q = H
Q = HOUT - HIN
Q = {68092.60 [Hf C8H18 + HC8H18]} - {680926.05 [Hf C8H18 + HC8H18]} + {6128333.3 [H f H2O +
HH2O]} {12256670 [H f H2 + HH2]} {4765928.6[H f CO + HCO]} {185901.8[ H f CO2 + HCO2]}
Heat of Formation:
Hf C8H18(g) = -208.4 KJ/mole
Hf H2O(g) = -241.83 KJ/mole
Hf H2 =0
Hf CO(g) = -110.52 KJ/mole
Hf CO2(g) = -393.5 KJ/mole
Q = {68092.60 [ -208.4 + HC8H18]} - {680926.05 [ -208.4 + H C8H18]} + {6128333.3 [ -241.83

+ HH2O]} {12256670 [ 0 + H H2]} {4765928.6[ -110.52 + H CO]} {185901.8[ -393.5 +
HCO2]} ----------(1)
Page 36
Molar Enthalpy
Using Table B.2 Felder Rousseau 3rd Edition in order to calculate molar enthalpy
H = a + bT + cT2 + dT3
H C8H18 = 202.98 KJ/mole
HH2O = 33.46x10-3 + 0.688x10-5(300) + 0.760x10-8(300)2 3.59x10-12 (300)3
HH2O = 0.0361 KJ/mole (AT TAVG = 300 oC)
HH2 = 28.84x10-3 + 0.0076x10-5(560) + 0.328x10-8(560)2 0.869x10-12 (560)3
HH2 = 0.02975 KJ/mole (AT TAVG = 560 oC)
HCO = 28.95x10-3 + 0.411x10-5(560) + 0.3548x10-8(560)2 2.22x10-12(560)3
HCO = 0.03197 KJ/mole
HCO2 = 36.11x10-3 + 4.23x10-5(560) 2.88x10-8(560)2 + 7.46x10-12(560)3
HCO2 = 0.0521 KJ/mole
As,
Q = {68092.60 [ -208.4 + 202.98]} - {680926.05 [ -208.4 + 202.98]} + {6128333.3 [

-241.83 + 0.0361]} {12256670 [ 0 + 0.02975]} {4765928.6[ -110.52 + 0.03197]}
{185901.8[ -393.5 + 0.0521]}
Q = - 612833.45 [5.42] [ - 1481793609 ] + [ 364635.93 ] [ 526578062.1 ]

[ 73142672.82 ]
Q = 7.218x108 KJ/ hr = 200536.88 KWatt
Page 36
4.2 Secondary Reformer Secondary Reformer
TREF = 468 oC
T1 = 848 oC T3 = 996 oC
C8H18 = 680.9 mole/hr

C8H18 = 680926.05 mole/hr O2 = 310718.1 mole/hr
H2O = 607311.1 mole/hr
T2 = 468 oC N2 = 3257739.2 mole/hr
CO2 = 540736.4 mole/hr
O2 = 851970.33 mole/hr
N2 = 3277739.2 mole/hr
Applying Heat balance,
Q = H
Q = {680.9 [Hf C8H18 + HC8H18]} - {680926.05 [Hf C8H18 + HC8H18]} + {607311.1 [H f H2O + HH2O]}
+ {3257739.2 [H f N2 + HN2]} + {310718.1[H f O2 + HO2]} - {3277739.2 [H f N2 + HN2]}
{851970.33[H f O2 + HO2]} + {540736.4 [H f CO2 + HCO2]}
Q = {-680245.15 [Hf C8H18 + HC8H18]} + {540736.4 [H f CO2 + HCO2]} + {607311.1 [H f H2O +

HH2O]} {541252.23[H f O2 + HO2]}
Heat of Formation:
Hf C8H18(g) = -208.4 KJ/mole
Hf H2O(g) = -241.83 KJ/mole
Hf O2= 0
Hf CO2(g) = -393.5 KJ/mole
Molar Enthalpy
Page 36
Using Table B.2Felder Rousseau 3rd Edition in order to calculate molar enthalpy
H = a + bT + cT2 + dT3
H C8H18 = 100.48 KJ/mole (At T = 393 oC)
HC2O = 36.11x10-3 + 4.23x10-5(732) - 2.88x10-8(732)2 + 7.46x10-12 (732)3
HC2O = 0.0545 KJ/mole (AT TAVG = 732 oC)
HH2O = 33.46x10-3 + 0.688x10-5(732) + 0.760x10-8(732)2 3.59x10-12 (732)3
HH2O = 0.04111 KJ/mole (AT TAVG = 732 oC)
H2O = 29.10x10-3 + 1.158x10-5(732) - 0.6076x10-8(732)2 + 1.31x10-12(732)3
H2O = 0.03197 KJ/mole
Q = {-680245.15 [-208.4 + 100.8]} + {540736.4 [-393.5 + 0.0545]} + {607311.1 [-241.83 +

0.04111]} {541252.23[0 + 0.03197]}
Q = 73194378.14 212750303.3 146841076.8 17303.83
Q = - 286.41x106 KJ/hr = - 79558.33 KWatt.
Page 36
Page 36
4.3 High Temperature Shift Convertor (HTSC)

HTSC
TREF = 300 oC
T1 = 314 oC T2 = 434 oC
CO = 1.429x106 mole/hr
CO = 4.765x106 mole/hr H2O = 1.392x106
mole/hr
H2 = 3.387x106 mole/hr
T2 = 300 oC CO2 = 3.345x106 mole/hr
Steam = 4.765x106 mole/hr
Q = H
Q = {3.345x106 [Hf CO2 + HCO2]} - {1.429x106 [H f CO + HCO]} + {3.387x106 [H f H2 + HH2]} +

{1.392x106 [H f H2O + HH2O]}
Putting all values from Table B.1 and B.2 Felder Rousseau 3rd Edition. We get,
Q = {3.345x106 [-8943.2 + 1.09]} - {1.429x106 [-3947.1 + 1.107]} + {6774.6 [14.65]} +

{25065.65 [-13435 + 2.04]}
Q = -1.10x109 KJ/hr = -305555.5 KWatt.
Page 36
LTSC
4.4 Low Temperature Shift Convertor (LTSC)
TREF = 230 oC
T3 = 240 oC T1 = 217 oC
CO = 1.429x104 kmole/hr
CO = 1.429x106 kmole/hr
CO2 = 1.42x106
kmole/hr
T2 = 230 oC H2 = 1.423x106 kmole/hr
H2O = 6797.22 kmole/hr
Steam = 1.429x106 kmole/hr
Q= H
Q = {62448 [Hf CO2 + HCO2]} - {39633.66 [H f CO + HCO]} + {2846.1 [H f H2 + HH2]} + {122.35

[H f H2O + HH2O]}
Putting all the values from table B.1 and B.2 Felder Rousseau 3rd Edition. We get,
Q = {62448 [-8943.2 + 1.01]} - {39633.66 [-3947.1 + 1.075]} + {2846.1 [14.5]} + {122.35 [-

13435 + 1.97]}
Q = -558421881.1 + 156395413.2 + 41268.45 1643531.22
Q = -4.03x108 KJ/hr = -1.12x105 KWatt.
4.5 Methanator
Page 36
T3 = 347 oC
METHANATOR
T1 = 316 oC
TREF = 316 oC
CO2 = 241.60 Kg/hr
CO = 400.34 Kg/hr
CH4= 313.45 Kg/hr
H2O= 455.03 Kg/hr
T2 = 318 oCH2= 34005.54 Kg/hr
CO= 4 Kg/hr
CO2= 2.42 Kg/hr
H2= 34134.04 Kg/hr
Q = {313.45 [Hf CH4 + HCH4]} - {239.18 [H f CO2 + HCO2]} - {396.34[H f CO + HCO]} - {128.5 [H f
H2 + HH2]}
- {455.03 [H f H2O + HH2O]}
Putting all values, using Table B.1 and B.2 Felder Rousseau 3rd Edition. We get,
Q = {313.45 [-4678.1 + 3.28]} - {239.18 [-8943.2 + 1.08]} - {396.34[-3947.1 + 1.09]} -

{128.5 [14.6]} - {455.03 [-13435 + 2.03]}
Q = -1465510.39 + 2138776.26 + 1563961.60 1876.1 + 6112404.33
Q = 2.846x106 KJ/hr = 790.72 KWatt.
4.6 Convertor
Page 36
N2 = 91216.7 Kg/hr T2 = 454 oC
CONVERTOR
T1 = 250 oC
TREF = 250 oC
H2 = 19546.44 Kg/hr
NH3= 110834.4 Kg/hr
N2= 1824.33Kg/hr
NH3= 110834.4 Kg/hr
H2= 390.93 Kg/hr
Q = {110834 [Hf NH3 + HNH3]} - {89392.37 [H f N2 + HN2]} - {19155.51[H f H2 + HH2]}
Putting all values, using Table B.1 and B.2 Felder Rousseau 3rd Edition. We get,
Q = {110834 [-2713.87 + 2.69]} - {89392.37 [1.08]} - {19155.51[14.62]}
Q = - 300490924.1 96543.76 280053.55
Q = - 300867521 KJ/hr
Q = -3.01x108 KJ/hr = - 83611.11 KWatt.
Page 36
CHAPTER 5
EQUIPMENT DESIGN
Page 36
EQUIPMENT DESIGN
This chapter consists of designing of equipment and their specification used in ammonia
process industry involving Reactor, Heat exchanger, Separators, let down valve, absorber and
Compressor.
5.1 Reactor
5.1.1 Introduction
Chemical reactors are classified into two ways, according to type of operation, according to
design feature
1) Batch reactor
2) Continuous reactor
3) Packed reactor
4) Fluidized and catalytic reactor
We selected the catalytic reactor for our process in which iron catalyst used and having beds.
5.1.2 Justification
1) Large scale application
2) Reduce operating cost
3) Control of product quality
4) Better temperature control
5.1.3 Function
The function of a reactor is to convert synthesis gas into ammonia in the presence of iron
catalyst. The synthesis gas involves nitrogen and hydrogen.
5.1.4 Design calculations

Inlet temperature = 250 o C
Outlet temperature = 454 o C
Pressure = 370 psi = 25.17 atm
Flow rates H2 = 19600 Kg / hr
N2 = 91216 Kg / hr
H2 = 0.0849 Kg / m3 = 5.5x10 -3
Page 36
N2 = PM / RT = 1025 lb / ft3 = 16421.49 kg / m3
H2 + N2 = (5.5x10 -3) + 1025
Density of feed = 1025.08 lb / ft3
Flow rate of H2 = 19600 Kg / hr
Flow rate of N2 = 91216 Kg / hr
Total flow rate of feed = G = (53777.6 + 2.5 x 105) lb / hr
Total flow rate of feed = 243491 lb / hr = 1084485 Kg / hr
Volumetric flow rate = Q = G / = (243491lb/hr) / (1025.08lb/ft3)
Volumetric flow rate = Q = 237.5 ft3/hr = 6.92 m3/ hr
Space velocity = S = 4 hr-1
Space time = t = 0.25 hr
Volume of reactor = Vr = t x Q = (0.25 hr x 237.5 ft3 / hr)
Volume of reactor = Vr = 59.38 ft3 = 1.6827 m3
The catalyst particles in the form of sphere of 5 / 16 dia.
Void fraction = 0.416
Volume of catalyst = Vc = Vr (Vr x ) = 59.38(1 0.416) = 34.68 ft3 = 0.9828 m3
% of catalyst = Vc / Vr = (34.68 / 59.38)x100 = 58%
5.1.5 Catalytic reactor
L/D = 3.5 ----------- (1)
Vr= ( / 4) x d2 L
Page 36
73.8 = ( / 4) x d2 (3.5d)
73.8 = ( / 4) x (3.5d3)
d = 2.994 ft = 0,912 m
Now putting the value of d in eq. (1)
L = 3.5x2.994 = 10.479 ft = 3.9 m
So our assumption for Four Reactors = (4x11) = 44 ft = 13.41 m
Height of catalyst bed = 103.2 ft = 31.45 m
Let the Height of distributing phase = 1.5 ft = 0.457 m
Height of bottom feed = 1.0 ft = 0.304 m
Total height of reactor = (103.2 + 1.5 + 1.0) ft = 105.7 ft = 32.21 m
5.1.6 Reactor thickness
W = (Pi D) / (2f Pi)
By taking 50% above operating pressure = 1.15 x 11 = 12.65 Kg / cm3
= (12.65/10) N / mm2
= (1.265) N / mm2
At the average temperature the design stress for low alloy steel
f = 190 N / mm2
W = (1.26x2133.6)/(2x(190-1.26))
W = 7.098 mm
Page 36
Corrosion allowance = 3%
W = (7.098 + 3) = 10.098 11 mm
Specifications of Reactor
Diameter of reactor 2.994 ft = 0.9125 m

Design pressure 370 psi = 25.17 atm
Volume of catalyst 43.09 ft3 = 1.3 m3
Volume of reactor 73.08 ft3 = 22.274 m3
Height of catalyst bed 103 ft = 31.39 m
Wall thickness 1.1 in = 0.0279 m
Material of construction SST with 8% Cr
Height of Reactor (4 beds) 106 ft = 32.30 m
Page 36
Fig. 5.1 REACTOR
Page 36
5.2 Heat Exchanger
Introduction
Heat exchanger are the device which is use to exchange the heat between two fluids from hot
to cold body called source and receiver respectively. There are many types of heat exchanger
for large area heat transfer we selected shell and tube heat exchanger. It may be one pass or
more depend on our requirement.
5.2.1 Shell and Tube Heat Exchanger
A Heat Exchanger is a heat transfer device that is used for transfer of internal thermal energy
between two or more fluids available at different temperatures. In most of the exchangers the
fluids are separated by a heat transfer surface and ideally dont mix with each other.
In process industries, shell and tube exchangers are used in great numbers, far more than any
other type of exchanger. More than 90-95% of heat exchangers used in industry are of the
shell and tube type. The shell and tube heat exchangers are the work horses of industrial
process heat transfer. They are the first choice because of well-established procedures for
design and manufacture from a wide variety of materials, many years of satisfactory service,
and availability of codes and standards for design and fabrication. They are produced in the
widest variety of sizes and styles. There is virtually no limit on the operating temperature and
pressure.
Fig. 5.2 Shell and Tube Heat Exchanger
Page 36
Function
It acts as the first pre-heater for the feed going to the reactor and simultaneously lowers the
temperature of the compressed gas from 115oF to 15oF
5.2.2 Heat Exchangers Selection Criteria
The selection process for an effective heat exchanger includes a number of factors, depending
upon heat transfer application and desired requirement.
Space Operating temperature
Efficiency Flow rates
Availability Flow arrangements
Ease of construction. Intended application
Operating pressure Fouling tendencies
Material Compatibility Types and phases of fluids
Material of construction Fabrication technique
Operational maintenance Overall economy
Thermal requirement and repair Maintenance, inspection,

possibilities cleaning, extension
5.2.3 Reasons of Maximum Utilization of this Exchanger
It occupies less space.

Its maintenance is easy.
Its compactness is more.
They can tolerate dirty fluids.
It is used for high heat transfer duties.
These are mostly employed in industry.
Means of directing fluid through the tubes.
Means of controlling fluid flow through the shell.
Used where large heat transfer surfaces are required
Page 36
Consideration for ease of maintenance and servicing.

Consideration for differential thermal expansion of tubes and shell.
It can be fabricated with any type of material depend up fluid properties.
They can be operated at higher temperature difference b/w coolant and gas.
Shell and Tube heat exchangers are used on applications where the demands on high
temperatures and pressures are significant.
5.2.4 Design Standards for Shell and Tube Heat Exchangers
There are two major standards for designing shell and tube heat exchangers:
TEMA standards
ASME Standards
The Standards of the Tubular Exchanger Manufacturers Association (TEMA) describe these
various components of shell and tube heat exchanger in detail. An STHE is divided into three
parts: the front head, the shell, and the rear head. For example; a BFL exchanger has a bonnet
cover, a two-pass shell with a longitudinal baffle, and a fixed tube sheet rear head.
5.2.5 Fluid Allocation in Tube Side and Shell Side
The criteria for fluid allocation in shell and tube heat exchangers are:
Specific pressure drop.
The most corrosive to be tube side
The higher pressure fluid to be tube side.
Shell side boiling or condensation is usually preferred.
Severe fouling fluids are allocated on the tube side.
Less viscous fluids on the shell side.
More flow rate is proffered in the tube side.
More viscous on the tube side.
Design Calculations
Hot Fluid (Tube Side):

(Compressed gas)
T1 = 115 oF = 319.26 K , T2 = 15 oF = 263.70 K
W = Feed rate = 243491 lbs/hr = 1084485 kg/hr
Heat Load: Q = 20x106 Btu/hr
Cold Fluid (Tube Side):
Page 36
(Chilled Gas)
t1 = 10 oF = 260.92 K , t2 = 75 oF = 297.03 K
W = 488030 lbs/hr = 221832 kg/hr
LMTD
Hot Cold
T1 = 115 oF
75oF = t2 15oF = T2
t1 = 10oF
m = 40 5 / ln(40/5)
= 16.83 oF = 264.72 K
As the log mean temperature is very low, therefore, we shall use average temperature.
Design Calculations
Assuming, UD = 160 Btu/ft2oF
As Q = UDAm
Q

A U Dm
20 x 106
= 160 x 16.83
A = 7427 ft2 = 689.92 m2
Assuming the length of the tube = 35 ft = 10.66 m
Page 36
Dia of Tube = in = 0.0625 ft = 0.0190 m
I.D = 0.0546 ft = 0.0166 m
BWG = 18
Surface/ft Length = 0.1963 ft2 = 2.136 x 10-4 m2
HeatTransferArea
No. of tubes = Surface/linfttube length
7427
= 0.1963 x 35
= 1080
The approaching No. of /tubes = 1074
Shell I.D = 3.08ft = 0.938 m
Pitch = 1-triangular
Passes = 1
Corrected Area = 1074 0.1963 35

= 7379 ft2 = 685.464 m2
Corrected UD = 20 106 / 7379 16.83

= 161 Btu/hr ft2oF
Let Rd = 0.003
Flow area/tube = 0.00232 ft2 = 2.155 x 10-4

= Flow Area / Tube No. of tube / No. of Passes
= 0.00232 1074
at = 2.49 ft2 = 0.2313 m2
Page 36
Mass Velocity
Gt = G / at
Gt = 488030.4 / 2.49
Gt = 195996 lb / hr ft2 = 956460.48 Kg / hr ft2
GeGt
Ret =
At Tavg = 43oF = 280 K , = 0.0256 lb / hr ft = 0.03739 kg / hr.

m
Ret = 0.0546 x 195996 / 0.0256
Ret = 418022 = 4.18x105
Pr. No. = ( Cp / K )1/3
At 43oF = 0.0256 lb / hr ft = 0.03739 kg / hr. m
Cp = 0.50 Btu / lb oF
K = 0.29 Btu / hr ft2 (oF/ft)
= (0.50 x 0.0256 / 0.29)1/3

Therefore Pr. No. = 0.354
jH = 980
Now,
hi = jH x k / D (Pr. No.)1/3
= 980 x 0.29 / 0.0546 x (0.354)1/3
Therefore hi = 3695 Btu / hr ft2oF
Page 36
hio = hi x I.D / O.D = 3695 x 0.0546 / 0.0625
hio = 3227.8 Btu / hr ft2oF
Pressure Drop Calculation for Tube Side:
As Re = 4.18x105
F = 0.001 ft2/in2
We know that,
fG 1 ln

Pt 5.22 x 10 10 D s s 1
0.001 x ( 221832 ) 2 x 35 x 1
Pt
5.22 x 1010 x 0.0546 x 0.93 x 0.50
Pt = 0.01156 atm
As,
V = G / 3600 = 0.576 m / sec
Now,
Pr = 4n (V2 / 2g) = 0.0149 atm
PT = Pt + Pr = 0.0272 atm
Shall Side:
I . Dx C ' B
Flow Area, as = 144 Pt = (37x0.345x29) / (0.902x144)
= 0.26474 m2
= Gs = 336993 / 2.85
= 118243 lb/hr ft2=577375 kg/hr.m2
Page 36
Equivalent Diameter:
De = 4(1/2Pt x 0.86Pt x /4 x do2) / do
d0 = 0.75
Pt = 0.902
De = 0.438
Now,
Res = De Gs /
At Tavg = 65oF, = 0.0284 lb / hr ft
Res = 0.438 x 118243 / 0.0284 x 12 = 151967
As,
Pr. No. = Cp / k
At Tavg = 65oF,
k = 0.29 Btu / hr ft2 (oF/ ft)
Pr. No. = 0.048
Now,
h0 = jH K / De (Cp / k)1/3s
At Res = 151967 (From Fig. 28 KERN) JH = 260

Then
h0 = 260 (0.29 / 0.438) (0.048)1/3
h0 = 62.56 Btu / ft2oF
Page 36
Pressure Drop Calculations:
As, Res = 151967
Ps = fGs2Ds (N + 1 ) / 5.22x1010 Dcs s

Here,
N+1 = No. of crosses = 12(L / B) = 14.48
Say = 15 per pass
Ds = 3.08 ft . s = 0.50
Ps = 0.36 psi
Page 36
Page 36
5.3 Compressor
Introduction
During compression large energy is generated in our plant we use centrifugal compressor and
compression is carried in stages of compressor thats why we use two centrifugal
compressors.
Function
The function of the compressor in our ammonia section is to compress the synthetic gas in
order to the reactor.
Design Calculations
Flow rate of air = 725 kg / hr
Suction pressure = P1 = 14.7 psi
P1 = 14.7 lbf / in2 X (12 in)2 / ft2
P1 = 2116.8 lbf / ft2 = 144 atm
Discharge Pressure = P2 = 74 psi
P2 = 74 lbf / in2 X (12 in)2 / ft2
P2 = 10656 lbf / ft2 = 724.89 atm
Density of gas at 40oC
G = (mol. Wt. / std. vol.) x (std. temp. / given temp.) x (given pressure / std. pressure)
G = (29 / 359) x (273 / 313) x (14.7 / 14.7)
G = 0.07 lbm / ft3 = 1.12 kg / m3
Volumetric flow rate = Qfm = (725 kg / hr) x (m3 / 1.12 kg)
Qfm = 647 m3 / hr = 10.75 m3 / min
Page 36
hp = 3.03x10-5 x (k / k-1) x P1 x Qfm (p2 / p1 )k-1/k 1)
hp = 3.03x10-5 x (1.4 / 1.4 - 1) x 2116.8 x 380 (10656/ 2116.8)1.4 1 / 1.4 1)
hp = 49.8
The efficiency of compressor is 60 %
hp = 83
A 83 hp motor should been satisfactory
Page 36
5.4 Absorber
Function
In our process function of absorber is to absorb Carbon Dioxide using Benfield solution. It
normally takes place at low temperature and high pressure.
Design Calculations
CO2 = 246102 kg / hr (From material balance)
CO = 400.34 kg /hr
H2 = 34134.04 kg / hr
N2 = 91216.7 kg / hr
Avg. Mol. Wt. = 36.097 kg / kmole
Lbmole of CO2 = 12094.6
Lbmole of CO = 31.49
Lbmole of H2 = 37592.5
Lbmole of N2 = 7175.64
Y1 = (12094.6 lbmole/hr) / (44799.63 lbmole/hr)
Y1 = 0.269
X2 = 0 (fresh solvent)
Page 36
Y2 = x X2 = 0
Absorber
Y1 = 0.269 X1 = z
% CO2 absorption in the absorber = (241602 241.6) / 241602
= 99.89%
Y2 = 0.269(1 0.9989)
Y2 = 0.00029
CO2 absorb in Benfield solution = X1 = Y1 Y2
X1 = 0.268
Gm of inert gas = 55884.349 lbmole/hr
Applying mass balance equation on absorber
Lm [X1 X2] = Gm [Y1 Y2]
Lm [0.268 0] = 44799.63[0.269 0.00029]
Page 36
Lm = 44918.32 lbmole / hr
Density of Benfield solution = 30% K2CO3 solution

= (0.30x138) + (0.70 x18)
= 54 kg/kmole
Lm = 44918.32 lbmole/hr = 1.18x106 kg/hr
Usually on practical scale semi-lean solution entering in absorber is 8 times more than the
lean
solution
Lm = (1.18x106) x 8 kg/hr
Lm = 9.4x106 kg/hr
Total liquid entering in absorber = (1.18x106) + (9.4x106)
= 1.06x107 kg/hr
Feed gas containing CO2 entering in absorber = Mg = 367490.89 kg/hr
Avg. specific gravity of Benfield = L = 80.3 lbm / ft3 = 1271 kg / m3
Viscosity of Benfield = L = 0.93 Cp = (0.93 x 2.42) lbm / hr.ft
= 2.3 lbm / hr.ft
Specific gravity of a feed gas = 15.19
Density of gas = G = (15.19 x 0.99) kg / m3
G = 15.03 kg / m3 = o,938 lbm / ft
Pressure drop co-relation for packed column
Page 36
[Gp2L0.1. Fp(w / L)0.1] / [32.17 G(L - G)] = 0.015
Gp = [(0.015(32.17 G(L - G)) / (L0.1. Fp(w / L)0.1)]0.5
Gp = [(0.015(32.17 x 0.938(80.3 0.938)) / (2.30.1. 27x0.96x(62.4 / 80.3)0.1)]0.5
Gp = 0.881 lb / ft2
Area of Absorber
Area = MG / Gp
Area of absorber = (367490.89 kg/hr) x (1 / 0.881 ft 2 sec / lbm) x (2.2046 lbm / kg)x (1 hr /
3600 sec)
Area of absorber = 255.45 ft2
A = / 4 D2
Diameter of the absorber = 18.04 ft
Height of Packing of absorber
Operating pressure = 274 kg / cm3
Operating Temperature = 76 oC
GM = Gp = (0.881 lb/ft2.sec) x (1 lbmole / 36.097 lb) x (3600 sec / hr)
Gm = Gp = 87.663 lbmole / ft3.hr
LM = LM / A = (1.1x107 kg/hr) x (1/317.85 ft2) x (1 kmole/54kg) x (2.204 lbm / kmole)
LM = 1501.89 lbmole/ft2.hr
m = 1.7 (slope)
Page 36
m GM / LM = 0.121
Substituting, (m GM / LM = A = 0.121)
NOG = [1 / (1 A)) ln [(1 A)(Y1 / Y2) + A] ----------------(1)
As,
Y1 = 0.269
Y2 = 0.00029
Putting all values in eqn (1)
NOG = 7.63
HOG = GM / KGA.P ------------------(2)
As we know that KGa = 6.42 kmole/hr.m3.atm
Putting all values in eqn.(2) we get HOG
HOG = 10.632 m
So,
Z = HOGx NOG
Z = 10.632 x 7.63
Z = 81.122 m
Page 36
5.5 Separator
Function
To separate the condensed ammonia from synthesis gases
Design Calculation
Total ammonia in mixture = 908.532 kmole / hr
(Assuming 100% separation of condensed ammonia)
Amount of gas in the mixture going to heat exchanger
= 725740 304051.597
= 100671.1 kmol / hr
Density of liquid NH3 at 10 oF = 660 kg / m3
Volume of liquid NH3 = 304051.597 / 41.2 = 208.94 m3 / hr
Let the vessel be drained after every five minutes.
Volume occupied by liquid ammonia = 7379.893 x 5 / 60
= 17.41 m3
Allowance 40 % space for gases
Total volume = 615 + 246 = 861 ft3
Let the volume of vessel = V
And liquid seal = 10% of total volume
V = 861 + 0.1 x 861
V = 741407.1 ft3
Page 36
Let the dia of the column be 5 ft
Cross section area = /4 d2
= 3.14 +25 / 4 x 19.9 ft2
Height of column = 741.401 / 19.9 = 4.22 m
Height of liquid seal = 0.4145 m
Thickness of Vessel
(From plant design chapter-14, Table-4)
Pri
+ Cc
Thickness of vessel = (t) = SEj0.6 P
220 0 x 2.5 x 12
+1/16
= 13700 x 0.850.6 x 2200
= 6.39 + 0.0265
= 6.45
Giving 10% allowance = 6.45 + 0.645
= 8.093
Page 36
5.6 Pressure Let Down Valve
Function
To reduce the pressure of liquid ammonia in order to facilitate the storage at atmospheric
pressure
Design Calculations
Temperature = 100F
Pressure = 250 psig
Total amount of ammonia in tank
= L + L
= 141.1 + 5263.3
= 5404.4 lbmole / hr
Density of liquid ammonia at 10oF = 41.75 lbs / ft3
Volume of liquid ammonia = 91875 / 41.75

= 62.28 m3
Volume of Vessel = volume of liquid ammonia + volume of liquid ammonia in

separator
Volume of Vessel = 179 + 29 = 5.8890 m3
Giving 40% empty space
Volume of vessel = 208 + 83.2 = 8.23m3
Let the dia of the vessel = 6m
Area of vessel = / 4d2 = 3.14 / 4 x (6)2

= 28.26 m2
Page 36
Height of vessel = 291 / 28.26 = 0.2839 m3
Thickness of vessel
Pri
+ Cc
Thickness of vessel = (t) = SEj0.6 P
1500 X 2 x 12
+1/16
= 13750 x 0.850.6 x 1500
= 3.752 + 0.0625
t = 3.8145
Page 36
CHAPTER 6
COST ESTIMATION
Page 36
COST ESTIMATION
An acceptable plant design must present a process that is capable of operating under
conditions which will yield a profit. Since net profit equals total income minus all expenses,
it is essential that the chemical engineer be aware of the many different types of costs
involved in the manufacturing processes.
A capital investment is required for any industrial process and determination of the necessary
investment is an important of a plant design project. The total capital investment for any
processes consist of fixed capital investment for physical equipment and facilities in the plant
plus working capital, which must be available to pay salaries, keep raw materials and
products on hand.
6.1 Factors Affecting Investment and Production Costs:

When a chemical engineer determines cost for any type of commercial process, these costs
should be of sufficient accuracy to provide reliable decisions. To accomplish this, the
engineer must have complete understanding of the factors that can affect costs. Some
important factors are;
Sources of equipment Price fluctuations
Company policies
Operating time and rate of production
Government policies
6.1.1 Types of Capital Cost Estimates:

An estimate of the capital investment for a process may vary from a redesigned estimate
based on little information except the proposed project to a detailed estimate prepared from
complete drawings and specifications:
1. Order of magnitude estimate (or Ratio estimate) based on similar previous cost data
probably accuracy estimate over 30 percent.
2. Study estimate (or factored estimate) based on knowledge of major items of
equipment; probable accuracy of estimate up to 30 percent.
3. Preliminary estimate (or budget authorization estimate, scope estimate)
based on sufficient data to permit the estimate to be budgeted probable accuracy
of estimate within 20 percent.
4. Definitive estimate (or project control estimate) based on complete data but
before completion of drawings and specifications, probable accuracy of estimate within
10 percent.
5. Detailed estimate (or contractor's estimate) based on complete engineering
drawings, specifications and site surveys, probable accuracy of estimate within 5 percent.
Page 36
Predesign cost estimates (1 3) requires less detail than firm estimates such as the definitive
or detailed estimate. However, the predesign estimates are extremely important for
determining if a proposed project should be given further consideration and to compare
alternative designs.
6.1.2 Cost Indexes:

Most cost data which are available for immediate use in a preliminary or prodesign
estimates are based on conditions at sometime in the past.
A cost index is merely an index value for a given point in time showing the cost at that time
relative to a certain base time. If the cost at sometime in the past is known the equivalent cost
at the present time can be determined by multiplying the original cost by the ratio of percent
index value to the index value applicable when the original cost was obtained.
Many different types of cost indexes are published regularly. The most common of these
indexes are;
Marshall & Swift Allindustry and process industry equipment
indexes.
Engineering News Record Construction index.
Chemical engineering plant cost index.
6.1.3 Methods for Estimating Capital:

Various methods can be employed for estimating capital investment. The choice of any one
method depends upon the amount of the detailed information available and the accuracy
desired. Seven methods with each requiring progressively less detailed information and less
preparation time are named below. The degree of accuracy decreases with each succeeding
method.
1. Detailed item estimate
2. Unit cost estimate
3. Percentage of delivered equipment cost
4. "LANG factors for approximation of capital investment.
5. Power factor applied to plant capacity ratio.
6. Investment cost per unit of capacity.
7. Turn over ratios.
Estimating by percentage of delivered equipment cost is commonly used for preliminary and
study estimates. It yields most accurate results when applied lo projects similar in
configuration to recently constructed plants. For comparable plants of different capacity this
method has been reported to yield definitive estimate accuracies.
Detailed lost estimate
Purchased lost of the equipment needed for the production of ammonia in ammonia.
Synthesis and refrigeration loop, taking lost index of 1975 as 452 from Marshall & swift
installed equipment indexes for process industry.
Page 36
Using a generate form of estimation the cost of each equipment as,

cos t index ofE
E0
cos t index E0
Cost of E= cost of
Here,
E = New cost of equipment
E0 = Old cost of equipment
Cost Index of E0 in 1991 = 914
Cost Index of E in 2013 = 1545
6.2 Cost of Equipments
Primary reformer
Cost of Primary Reformer = 9.09 x105 $

Cost of primary reformer in 2013 = original cost x(cost index in 2013/cost index in 1991)
Cost of Primary Reformer in 2013 = (9.09 x105)x(1545/914)
= 15.36 x 105 $
High Temperature Shift Convertor (HTSC)
Cost of High Temperature Shift Convertor = 4.3 x 105 $

Cost of HTSC in 2013 = original cost x(cost index in 2013/cost index in 1991)
Cost of HTSC in 2013 = (4.3 x 105) x (1545/914)
= 7.27 x 105 $
Low Temperature Shift Convertor (LTSC)
Cost of Low Temperature Shift Convertor = 3.6 x 105 $

Cost of LTSC in 2013 = original cost x(cost index in 2013/cost index in 1991)
Cost of LTSC in 2013 = (3.6 x 105) x (1545/914)
= 6.08 x 105 $
Stripper
Cost of Stripper = 5.6 x 106 $

Cost of Stripper in 2013 = original cost x(cost index in 2013/cost index in 1991)
Cost of Stripper in 2013 = (5.6 x 106) x (1545/914)
= 9.46 x 106 $
Page 36
Absorber
Cost of absorber = 1.7 x 106 $

Cost of absorber in 2013 = original cost x(cost index in 2013/cost index in 1991)
Cost of absorber in 2013 = (1.7 x 106)x(1545/914)
= 2.87 x 106 $
Heat Exchangers
No of Heat Exchanger = 6
Cost of one Heat Exchanger = 116082.96 $
Cost of 6 Heat Exchanger = 6(116082.96)
= 696497.76 $
Cost of absorber in 2013 = (696497.76)x(1545/914)
= 11.77x105 $
Compressors
No of Compressors = 2
Cost of one Compressor = 24466000 $
Cost of two Compressors = 4.89 x107 $
Now,
Cost of compressor in 2013 = (4.89 x107)x(1545/914)
= 8.26 x 107 $
Pumps
No of Pumps = 7
Cost of Pump = 199137 $
Cost of 7 pumps = 1393959 $
Cost of compressor in 2013 = (1393959)x(1545/914)
= 2.35 x 106 $
Total Equipment Cost
Total Cost = 1.0134 x 108 $
Page 36
6.3 Direct Cost
Table 6.1 Direct Cost

Items % of delivered equipment Cost Cost in Million 106 $
IPC 18 18.24
Piping 66 66.88
Electrical install 11 11.14
Building install 18 18.24
Yard improvement 10 10.134
Service Facility Install 70 70.94
Land Purchase 6 6.08
Total Direct plan cost 201.654 6.4
Indirect Cost
Engg. and Supervision 33% of Equip. cost 33.44 x 106 $

Construction 41% of Equip. cost 41.55 x 106 $
Contractor Fee 5% of direct cost 10.08 x 106 $
Contingency 10% direct cost 20.16 x 106 $
Total Direct and Indirect cost
Direct + Indirect cost = 306.88 x 106 $
6.5 Fixed Capital Investment
Direct + Indirect cost = 306.88 x 106 $
Working Capital
Working Capital 15% FCI 46.03 x 106 $
Page 36
6.6 Total Capital Investment
TCI FCI + WC 352.91 x 106 $
TOTAL CAPITAL INVESTMENT = 352.91 Million Dollars
6.7 Total Product Cost

Assume that FCI depreciate by straight line method for 20 years
assuming 5% of salvage value at the end of plant life.
(V Vs)
Depreciation=D= ----------- (1)
N
V = FCI = 304.154 x 106 $
VS = 0.05 x FCI = 15.20x 106 $
N = No. of years = 20
Put value of V, VS and in eqn. (1)

D=14447700$
Product Cost = TCI - D
Product Cost = (349.77 x 106)$ - 14447700$
Product Cost = 33.53 x 107 $
Product Cost = 335.3 Million $
Fixed Charge 12 % of PC 40.23 x 106 $

Direction Production cost 55 % of PC 184.4x 106 $
Plant overhead 10 % of PC 33.53x 106 $
Total manufacturing cost = Fixed Charges + direct Production Cost + Plant Overhead
Page 36
Total manufacturing cost = (40.23 x 106 $) + (184.4 x 106 $) + (33.53 x 106 $)

Total manufacturing cost = 258.16 Million $
Raw Materials Cost:

30% of Product Cost
= (0.30x335.3x106)
= 100.59x106$
Admin. Cost 5 % of PC1 6.76 x 106 $

Distribution and selling cost 18 % of PC 60.35 x 106 $
Research & Development Cost 5 % of PC1 6.76 x 106 $
Financing 6 % of TCI 21.17 x 106 $
General Expenses = Admin cost + Distribution and selling cost + Research & Development
Cost + Financing
General Expenses = 115.04 Million $
Total Product Cost = Manufacturing cost + General Expenses

Total Product Cost = 258.16 Million $ + 115.04 Million $
Total Product Cost = 373.2 Million $
6.8 Net Profit

Gross Earning/Income
Wholesale price of ammonia per ton = 3000 $

Total income = selling Price x quantity of product manufacture
Total income = 7500000 $
Total income per year = $2737.5x106
Gross income= total income total product Cost
Gross income= 2364.30x106 $
Let the tax rate is 45 %
Taxes = 45% of gross income
Page 36
Taxes = 0.45(2364.30x106) $
Taxes = 1063.93x106 $
Net Profit = gross income Taxes
Net Profit = 2364.30x106 $ - 1063.93x106 $
Net profit = 1300.37x106 $/yr

Net Profit = 3562657.53 $/day
6.9 Payout Period
Depreciable FCI
Payout Period =
Avg profit per yr .+ Avg . Depriciation per yr .
Payout Period = 5 years
6.10 Rate of Return
Rate of Return = (net profit x 100) / total investment

Putting all values in equation we get
Rate of Return = (1300.37x106 / 352.91x106) x 100
Rate of return = 3.69%
Page 36
CHAPTER 7
INSTRUMENTATION and PROCESS

CONTROL
Page 36
INSTRUMENTATION and CONTROL
Process may be controlled more precisely to give more uniform and higher quality products
by the application of automatic control, often leading to higher profits. Additionally, process
which respond too rapidly to be controlled by human operators can be controlled
automatically. Automatic control is also beneficial in certain remote, hazardous, or routine
operations. After a period of experimentation, computers are being used to operate and
automatically control processing systems. It may too large and too complex for effective
direct human controls.
Since process profit is the most important benefit to be obtained by applying automatic
control, the quality of control and its cost should be compared with the economic return and
the process technical objectives. The economic return includes reduced operating cost,
maintenance and off-specification product along with improved process operate ability and
increased throughout.
7.1 General Control system

The various aspects of an automatic control can best be described as,
(a) Feed Forward Control
(b) Feed Back Control
7.1.1 Feed Forward Control:

Feed forward control is becoming widely process disturbances are measured and
compensated without waiting for a change in controlled variable to indicate that a disturbance
has occurred. Feed forward control is also useful when the final controlled element cant be
measured. As shown in fig, the feedback controller has the computation at ability, using the
measured input liquid flow rate and temperature to compute the necessary steam flow rate to
maintain the desires output liquid temperature.
7.1.2 Feed Back Controller:

In the closed-loop control system, information about the controlled variable is feed back as
the basis for control of a process variable; hence the designation closed-loop feedback
control. This feedback can be accomplished by human operators and by use of automatic
control instruments.
For automatic control a temperature sensitive device is used to produce a signal (electrical,
pneumatic etc.) proportion at to the measured temperature. This signal is feed to the
controller which compares it with a present desired value or set point. If a difference exists,
the controller changes the opening of a steam control valve to correct the temperature as
shown in Fig
Page 36
Fig. Block Diagram of a feed forward Control System
Fig. Co-controlled Block Diagram of a feed forward Control System
7.3 Process Variables:

It is impossible to achieve absolute constancy in even the simplest of industrial operations.
The variables which are normally selected for measurement are temperature, pressure, flow
rate, liquid levels and composition. An automatic control is used to measure, correct and
modify changes of a four principles type of process variation.
1. Temperature Recorders & Indicators.
2. Pressure Indicator Controller.
3. Flow Indicator Controller.

4. Level Controllers.
Page 36
7.3.1 Temperature Measurements:

To provide, a consistent basis for precise and convenient temperature measurements the
International Practical Temperature scale has been established. This scale covers the range
from the triple point of hydrogen to incandescent bodies and flames. Various equipment has
been discovered so far which are efficiently used in the industry. They are;
Thermocouples, pressure spring thermometers, resistance thermometers, filled system
thermometers, bimetallic thermometers, liquid-in-glass thermometers, pyrometers.
The use of all these temperature measuring devices depends upon the process requirements
and cost factor. The normal method for controlling a heat exchanger is to measure the exit
temperature of the fluid being processed and to adjust the input of the cooling and heating
medium to hold the desired temperature. Therefore, the temperature recorder controllers are
installed to control the chillers and heat exchangers.
7.3.2 Pressure Measurements:

Pressure defined as force per unit area is usually expressed in terms of familiar units of
weight-force and area or height of a column of liquid which produces a like pressure at the
base. More common units are pound-force per square inch, kilogram per square centimeter,
inches or millimeters of mercury or inches or mercury of water. Process pressure-measuring
devices are divided in three groups:
Those which are based on the measurement of the height of a liquid column. Those which are
based on the measurement of the distortion of an elastic pressure chamber , and Electrical
sensing devices. Pressure indicator controller is used to control the pressure of compressed
synthesis stream from the compressor entering the refrigeration loop.
The pressure inside the separator and stream entering the reactor also the pressure in the let
down vessel are important to note.
The variation in the pressure causes marked effect on the conversion rate, therefore this
control is very precise.
There are different instruments used for pressure measuring. They are;
1. Liquid Column Methods
2. Elastic Element Methods.
Elastic element pressure measuring devices are those in which the measured pressure deforms
some elastic material within its elastic limits. Those devices may be classified into three
types;
1. Bourdon Tube Element.
2. Bellows Elements.
3. Diaphragm Elements.
Diaphragm is a flexible material generally rubber, leather, impregnated fabric or plastic.
Page 36
Electrical Methods:
1. Strain Gauges.
2. Piezoresistive transducer.
3. Piezoelectric Transducer.
Page 36
7.3.3 Flow measurement:

Flow indicators and controllers are used to control a flow of a reactor and a flow of the purge
from recycle stream. The principle of flow measuring instruments used in process industries
are variable head, variable area, positive displacement and turbine instruments, mass flow
meters, weirs and flow meters for flow measurement in open channels and more recently
vertex shedding and ultrasonic flow meters.
7.3.4 Level Measurement:

The level indicators and controllers are used to control the flow of a liquid ammonia. The
measurement of a level might be defined as the determination of the location of the interface
between two fluids. A commonly used basis for classification of level devices is as follows:
visual, float-actuated, displacer etc.
1- Visual Devices
The category includes such devices as dipsticks tape and plump bob, open manometer,
and gauge glass.
2- Float-Actuated Device
Float-actuated devices are characterized by a buoyant member which floats at the

interface between two fluids. Float-actuated devices are generally limited to liquid gas
interfaces. Float-actuated devices may be classified on the basis of method used to couple
the float motion to the indicating system.
3- Change or Tape Float gauge
In these types of gauges, the floating is connected to the indicating mechanism by means
of flexible change or tape. These gauges are commonly used in large atmospheric storage
tanks.
4- Lever and Shaft Mechanism
In pressurized vessels, float-actuated lever and shaft mechanisms are frequently used for
level measurement. This type of mechanism consists of hollow met at float and level
attached to a rotary shaft which transmits the float motion to the outside of the vessel
through a rotary seal.
Page 36
Page 36
5- Magnetically couple devices
A variety of float-actuated level devices which transmits the float motion by means of
magnetic coupling have been develop. This class of devices are magnetically operated
level switches and magnetic-bond float gauges.
6- Displacer devices
Displacer-actuated level measuring devices used the buoyant force-on partially

submerged displacer as a measure of the location of the interface along the axis of the
displacer. Some of the displacer devices are
Torque-tube displacer
Magnetically coupled displacer
7- Head devices
A variety of devices utilize hydrostatic head as a measure of level. As in a case of

displacer devices, accurate level measurements by hydrostatic head require an accurate
Page 36
knowledge of the densities of both heavier phase and lighten phase fluids. Some of them
are
Pressure gauge systems on open vessels
Rubble tube system
Head systems on pressurized vessels
7.4 Automatic Control Mechanism:

The controller is the device that resets the error signal and produces and output signal
proportional to some function of error. The output signal of the controller is the activating
force positioning the final control element.
The four basic modes of control are
1- Two position control (ON-OFF)
2- Integral or proportional speed floating or reset
3- Proportional control
4- Rate or derivate control
Actuate industrial controller may employ any of these action singly, or combined. In this
report the combination of the proportional and integral modes in which case the later is called
automatic reset is recommended. The selection of the controller mode depends upon the
sensitivity of the system.
Page 36
Fig. Automatic Controller
Types of Controllers
There are four types of controller given as
1- Proportional controller (P)
2- Proportional integral controller (PI)
3- Proportional derivative controller (PD)
4- Proportional integral derivative controller (PID)
7.4.1 Proportional controller (P)

A controller which takes input in to the form of the errors from the comparator and give
output in the form of proportional.
P = KcE + PS
P PS = KCE
P PS = P
P = KCE
Taking Laplace
P (s) / E(s) = Kc
Where,
Kc = Gain
P(s) = Constant
Page 36
7.4.2 Proportional integral controller (PI)

Types of controller in which the control signal is a linear combination of the error signal and
its integral.
Transfer equation of PI Controller:
P(s) / E(s) = Kc[1 + 1/i(s)]
Where
Kc = Gain
i = Integral time (min)
P(s) = constant
7.4.3 Proportional derivative controller (PD)

Proportional derivative or PD controller combines proportional control and derivative control
in parallel
Transfer function of PD controller
P(s) / E(s) = Kc[1 + 1/D(s)]
Where
Kc = Gain
D = Derivative time (min)
P(s) = constant
7.3.4 Proportional Integral Derivative Controller

This type of controller widely used in industrial control systems. A PID is the most
commonly used feedback controller. A PID controller calculates an error value as the
difference between a measured process variable and a desired set point. The controller
attempts to minimize the error by adjusting the process control inputs.
Transfer function of PID controller
P(s) / E(s) = Kc[1 + D(s) + 1 / i(s)]
Where
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Kc = Gain
D = Derivative time (min)
i = Integral time (min)
P(s) = constant
CHAPTER 8
SITE SELECTION
Page 36
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SITE SELECTION FOR PROCESS
8.1 Site Selection:

The geographical location of the plant contributes a lot to the success of any chemical
business venture .Utmost care and judgment is required for selecting the plant site, and many
different factors must be considered while selecting the plant site. The plant site should be
ideally located where the cost of production and distribution can be at a minimum level .Also
there has to be a good scope for plant expansion and a conductive environment, safe living
conditions for easy plant operation. But other factors, such as safe living conditions for plant
personnel as well as the surrounding community are also important. The choice of the final
site should be based on a detailed survey of various geographical areas, and ultimately, on the
advantages and disadvantages of available real estate. An initial outline regarding the plant
location should be obtained before a design project reaches the detailed estimate stage, and a
firm location should be established upon completion of the detailed estimate design The
factors that must be evaluated in a plant location study indicate the need for a vast amount of
information. The following factors should be considered in selecting a plant site:
Raw materials availability.

Energy availability.
Meteorological data.
Market study.
Transportation facilities.
Water supply.
Waste disposal.
Labor supply.
Taxation and legal restrictions.
Site characteristics.
Safety and Environmental measures.
Community factors.
Others.
8.1.1 Raw materials availability:
The source of raw materials is one of the most important factors influencing the selection of a
plant site .This is particularly true if large number of raw materials source permits
considerable reduction in transport and storage charges. Attention should be given to the
purchased price of the raw materials, distance from the source of the supply, freight or
transportation expenses, availability and reliability of supply ,purity of the raw materials, and
storage requirements.
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8.1.2 Energy availability:
Power and steam requirements are high in most of the chemical plants, and fuel is ordinarily
required to supply these utilities .Power and fuel can be combined as one major factor in the
choice of a plant site. If the plant requires large quantities of coal or oil, location near a
source of fuel supply may be essential for economic operation. The local cost of power can
help determine whether power should be purchased or self-generated.
8.1.3 Meteorological data:
If the plant is located in a cold climate, costs may be increased by the necessity for
construction of protective shelters around the process equipment, and special cooling towers
or air-conditioning equipment may be required if the prevailing temperatures are high.
Excessive humidity or extremes of hot or cold weather can have serious effect on the
economic operation of the plant, and these factors should be examined when selecting a site.
8.1.4 Market Study
The location of markets or distribution centers affects the cost of product distribution and the
time required for shipping .Proximity to the major markets is an important consideration in
the selection of a plant site, because the buyer usually finds it advantageous to purchase from
nearby sources. It should be noted that markets are needed for by products as well as for
major final products.
8.1.5 Transport Availability
Water, railroads, and highways are common means of transportation used by major industrial
concerns. The kind and quantity of products and raw materials determine the most suitable
type of transportation facilities. Careful attention should be given to local freight rates and
existing railroad lines. The proximity to railroad centers and the possibility of canal, river,
lake or ocean transport must be considered. Motor trucking facilities are widely used and can
serve as a useful supplement to rail and water facilities. If possible, the plant site should have
access to all three types of transportation and, certainly, at least two types should be available.
There is usually a need for convenient air and rail transportation facilities between the plant
and the company head quarters, and effective transportation facilities for the plant personnel
are necessary.
8.1.6 Water Supply
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The process industries use large quantities of water for cooling, washing, steam generation,
and as a raw material in process. Hence, the plant must be located where a dependable supply
of water is available. A large river or lake is preferable, although deep wells or artesian wells
may be satisfactory if the amount of water required is not too great. The level of the existing
water table can be checked by consulting the state geological survey ,and information on the
constancy of the water table and the year round capacity of local rivers or lakes should be
obtained .If the water supply shows seasonal fluctuations, it may be desirable to construct a
reservoir or to drill several standby wells. The temperature, mineral content, silt or sand
content, bacteriological content, and cost for supply and purification must also be considered
when choosing the water supply.
8.1.7 Waste Disposal
In recent years, many legal restrictions have been placed on the methods for disposing of
waste materials from the process industries. The site selected for a plant should have adequate
capacity and facilities for correct waste disposal. In choosing a plant site, the permissible
tolerance levels for various methods of waste disposal should be considered carefully, and
attention should be given to potential requirements for additional waste-treatment facilities.
8.1.8 Labor Supply
The type and supply of labor available in the vicinity of a proposed plant site must be
examined .Consideration should be given to prevailing pay scales ,restrictions on number of
hours worked per week, competing industries that can cause dissatisfaction or high turnover
rates among the workers, and variations in the skill and productivity of the workers.
8.1.9 Taxation and Legal Restrictions
State and local tax rates on property income, unemployment insurance and similar items vary
from one location to another. Similarly, local regulations on zoning, building codes, nuisance
aspects, and transportation facilities can have a major influence on the final choice of a plant
site. In fact, zoning difficulties and obtaining the many required permits can often be much
more important in terms of cost and time delays than many of the factors discussed in the
preceding sections.
8.1.10 Site Characteristics
The characteristics of the land at a proposed plant site should be examined carefully. The
topography of land and the soil structure must be considered, since either or both may have a
Page 36
pronounced effect on construction costs. The cost of the land is important, as well as local
building costs and living conditions. Future changes may make it desirable or necessary to
expand the plant facilities. Therefore, even though no immediate expansion is planned, a new
plant should be constructed at a location where additional space is available.
8.1.11 Safety and Environmental Measures
Many industrial plants are located along rivers or near large bodies of water, and there are
risks of flood or hurricane damage. Before selecting a plant site, the regional history of
natural events of this type should be examined and the consequences of such occurrences
considered. Protection from losses by fire is another important factor for selecting a plant
location. In case of a major fire, assistance from the fire departments should be available. Fire
hazards in the surrounding area of plant site must not be overlooked.
8.1.12 Community Factors
The nature and facilities of a community can have an effect on the location of the plant. If
minimum number of facilities for satisfactory living of plant personnel does not exist, it
becomes a burden for the plant to subsidize such facilities. Cultural facilities of the
community are important to sound growth. Facilities such as religious centers, libraries,
schools, civic theatres, concert associations, and other similar groups do much to make a
community progressive. The efficiency, character, and history of both state and local
governments should be evaluated. The existence of low taxes is not in itself a favorable
situation unless the community is already well developed and relatively free of debt.
8.1.13 Others:
Site Identification Grade Level
Location Gross Acres Estimated Value Safety.
Adjacent to or near roadways with a high volume of traffic.
Within 1,500 feet of railroad tracks
Within two miles of an airport runway
Close to high-voltage power lines
Close to high-pressure lines, for example natural gas, gasoline sewer or water lines
Close to high decibel noise sources
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In a dam inundation area or 100- year flood plain
Social hazards in the neighborhood, such as high incidence of crime and drug or
alcohol abuse.
Safe walking areas
Centrally located to avoid extensive transporting and to minimize student travel

distance.
Compatible with current and probable future zoning regulations.
Close to libraries, parks, museums, and other community services.
Favorable orientation to wind and natural light.
Environment .Free from sources of noise that may impede the instructional process.
Free from air, water and soil pollution. Free from smoke, dust, odors, and pesticide
spray.
Compatible with the educational program.
Stable subsurface and bearing capacity .Danger of slides or liquefaction.
Percolation for septic system and drainage.
Adequate water table level.
Existing land fill is reasonably well compacted.
Sufficient open play area and open space
Length-to-width ratio does not exceed 2:1
Surface and subsurface drainage
Level area for playfields
Potential for expansion for future needs
Area for adequate and separate bus loading and parking
Page 36
Check for Obstacles such as crossings on major streets and intersections, narrow or
winding streets, and heavy traffic patterns.
Freeway access for bus transportation.
Routing patterns for foot traffic.
Remote areas (with no sidewalks) where students walk to and from school
Easily reachable by emergency response vehicles
Fire and police protection, including firelines
Available public transportation
Trash and garbage disposal.
8.2 Selecting Site for Project:
For the installation of our plant we have decided Karachi as a place. Because the basic raw
material for our production is naphtha which is a product of oil refineries situated there like
NRL, PRL, Coastal, and New Bosicor. This site selection would become key way to success
and better economy for our homeland.
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CHAPTER 9
HAZOP & SAFETY
Page 36
HAZOP & SAFETY

9.1 Safety
The safety for this plant include the following sections, which should consider during the
performing the safety procedures.
1. OSHA hazard communication standard
2. Hydrogen sulphide poising
3. Precaution for entering any contaminated or inert atmosphere
4. Preparations for vessel entry
9.1.1 OSHA Hazard Communication Standard
The OSHA is the U.S. Federal regulation requiring chemicals manufacturers, importers and
distributers to evaluate the hazards of their chemical products and convey hazards
information through labels and material safety data sheets to its employees and customers.
OSHA provides the information to its employee about the hazardous chemicals to which they
could be exposed by mean of
a. Material and data sheets
b. Labels and other forms of warning
c. A written hazard communication program
d. Training and information program
Material Safety Data Sheets:
The MSDS requirements fall primarily on chemical manufacturer, importers and distributers.
The OSHA standard requires them to develop and provide a MSDS for each hazardous
chemical they produce or handle.
The MSDS should include the following things
Chemical and Common name
Ingredient information
Physical and chemical characteristics
Physical hazards Potential reactivity, fire and explosion
Health Hazards
Symptoms of exposure
Primary route of likely entry into the body on exposure
OSHA permissible exposure levels
Precaution for use
Waste disposal
Protective measures and equipment including maintenance
Emergency and first- aid procedures
Date of MSDS preparation and last revision
Emergency contact of manufacturer or distributor
Page 36
Labels and other Forms of Warning
The OSHA standard states that all portable containers of hazardous chemical must have a
large, readable tag on it, which has
a. The name and address of the manufacturer
b. The name of the chemical
c. A numerical hazard warning or other appropriate warnings supplied by the
manufacturer
d. Labels could also be color coded as
Orange: Carcinogen Hazards (i.e. Benzene)
Red: Chemical Burn Hazards (i.e. Acid, Bases)
Yellow : Toxic Vapor Hazard (i.e..H2S)
White : All other
A Written Hazard Communication Program:
The OSHA standard requires that employers make available to their employees the
companys written Hazard Communication Program. This document is intended to describe
how the company will implement the OSHA standard. The program explains the companys
labeling system, material safety data sheets and employ information and training.
Training and Information:

All employees should receive the training and know how about all the standards and MSDS
and should have knowledge about everything.
9.2 HAZOP Study
Hazard is the study of true picture or proper structured and systematic analysis of operational
plant or current process or running plant operation in order to locate and identify the potential
hazards and evaluate operability problem. It is made ensure competency of plant equipments
in order to design purpose. It is systematic process technique which is used to identify the
possible deviation of the plant from normal routine conditions. It is also made ensure that
suitable safeguards for operational plant. HAZOP analysis is also helpful to prevent disaster,
accident or horrible situation. Its adjective to combine with process condition through
systematic channel and detect all possible deviation from normal condition.
9.2.1 When to Perform a HAZOP?
HAZOP studies may also be used more extensively, including:

At the initial concept stage when design drawings are available
When the final piping and instrumentation diagrams (P&ID) are available
During construction and installation to ensure that recommendations are
implemented
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During commissioning
During operation to ensure that plant emergency and operating procedures are
regularly reviewed and updated as required
9.2.2 Characteristics
A systematic, more organized judgment relying on HAZOP guide words and team
hardworking to create a complex review and ensure that suitable safeguards against
accidents are in place
Applicable to any system or process
Mostly used as a system-level risk judgment technique
Generates primarily qualitative results
9.2.3 Common Uses
It is used primarily for locating safety hazards and operability problems of continuous
process systems, especially fluid and thermal systems.
It is also used to review procedures and sequential operations.
9.2.4 Limitation of HAZOP Study
Requires a well-defined system or activity

Time consuming
Focuses on one-event causes of deviations
9.2.5 Procedure for HAZOP Analysis
Definition of some useful items

Define the system or activity
Main process of the HAZOP Analysis
Conduct HAZOP reviews
Use the results in decision making
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9.2.6 Definition of some Useful Items
Node
Node is some particular sections of the system in which (the deviations of) the
design/process purpose are evaluated. A node can be a subsystem, a function group, a
function or a sub function.
Guideword:
It is a short word to create the imagination of a deviation of the design/process intent. The
most commonly used set of guide-words is: no, more, less, as well as, part of, other than,
and reverse. In addition, guidewords like too early, too late, instead of, are used; the latter
mainly for batch-like processes. The guidewords are applied, in turn, to all the
parameters, in order to identify unexpected and yet credible deviations from the
design/process intent.
Guide-word + Parameter = Deviation

Deviation
A deviation is a way in which the process situation may depart from their design/process
purpose. It is generated by combining guidewords with process parameters resulting in a
possible deviation from design purpose.
Design Intent
The design intent is a description of how the process is expected to behave at the node;
this is qualitatively described as an activity (e.g., feed, reaction, sedimentation) and/or
quantitatively in the process parameters, like temperature, flow rate, pressure,
composition, etc.
Process Parameters
The process parameters are the relevant parameter for the situations of the process. For
example, pressure, temperature, composition, voltage, data, direction, etc.
9.2.7 Main Process of the HAZOP Analysis:
Divide the system into sections and develop credible deviations and define node.
Determine the cause of the deviation and evaluate the consequences/problems.
Find the safeguard which help to reduce the occurrence frequency of the deviation or
to mitigate its consequences actions required compensating the consequences.
Actions allocated toward the department or person which performs the required
action.
Page 36
REFERENCES
1- Ammonia and Synthesis by Noyes R.N.D.C (1967)
2- Chemical Engineering Handbook by Perry J.H
3- Plant design and Economics for Chemical Engineers by Max S. Peters and
Klaus D. Timmerhaus
4- Chemical Process Principles by Octave Levenspiel
5- Basic Principles and Calculations in Chemical Engineering by David M.

Himmelblau
6- Chemical Engineeringby R.K Sinnot and J.F. Richardson
7- Introduction to Chemical Engineering Thermodynamics by J.M Smith and H.C

Vanness
8- Technology and manufacture of ammonia by Smuel Strelzoff
9- Operating Manual of Pak Arab Fertilizers Ltd. Multan
10- Operating Manual of Fauji Fertilizer Co. Ltd. Goth Machhi
11- Process Heat Transfer by Donald Q. Kern
12- Encyclopedia of Chemical Technology by Kirk Othmer
13- Elementary Principles of Chemical Processes by Felder and Rousseau
14- Shreves Chemical Process Industries by George T. Austin

Production of Ammonia

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2500 MTPD OF AMMONIA FROM NAPHTHA

5.2.3 Reasons of Maximum Utilization of this Exchanger..................................................

8.1.1 Raw materials availability:.............................................................................................109

1.1.1 History of Ammonia

1.1.3 Raw Material Used

1.1.4 Anhydrous Ammonia Properties:

Table 1.2 Chemical Properties of Ammonia

1.1.5 Expansion in the industry

1.1.5.1 Improvement in NH3 Production process:

Further increase in reformer pressure i.e. (21-28.3)kg/cm2

Capacity : 600 to 1700T/D

3. All compression services based on centrifugal compressors.

4. Synthesis up to 320atm accommodated by centrifugal compressor (using three

1.1.6 Uses of Ammonia:

Precursor to nitrogenous compounds

Ammonia is directly or indirectly the precursor to most nitrogen-containing compounds.

NH3 + 2 O2 HNO3 + H2O

Household ammonia is a solution of NH3 in water (i.e., ammonium hydroxide) used as a

1.1.6.1 Minor and Emerging Uses:

Because of its favorable vaporization properties, ammonia is an attractive refrigerant. It was

For remediation of gaseous emissions

Antimicrobial agent for food products

Liquid ammonia is used for treatment of cotton materials, give properties

In petroleum engineering, full range naphtha is defined as the fraction of hydrocarbons in

Table 1.3 Properties of Naphtha

Molecular weight 100-215

1.2.2 Production of Naphtha in Refineries and Uses:

density (g/ml or specific gravity)

Paraffin content (volume percent)

Iso paraffin content (only in a PIONA analysis)

Olefins content (volume percent)

Naphthenic content (volume percent)

Aromatics content (volume percent)

Paraffinic (or light) naphtha

In the production of gasoline.

in industrial solvents and cleaning fluids

an oil painting medium

an ingredient in shoe polish

1.2.3 Exported Naphtha specification:

Table 1.4 Naphtha Specification

Test Description Units Test Model ARL Space Max/Min

Specific Gravity 15.5/15.5C - D-1298 0.65-0.74 -

End Point 180 Max

1.3 Ammonia in Pakistan:

1. PakArab fertilizer ltd. Multan

2. Fauji fertilizer ltd. Goth Macchi.

3. Paksaudi Fertilizers (Now FFC) Ltd. Mirpur Mathelo.

4. Pak American (Agritech) Ltd. Daudkhel

5. Engro Chemicals ltd. Dharki.

6. Dawood Hercules Ltd. Lahore.

1.3.1 PakArab fertilizer ltd. (Pfl) Multan

established on 27 September 1978.its annual capacity of producing ammonia is 316,800

1.3.2 Fauji fertilizer ltd. Goth Macchi

1.3.2.1 Base Unit-Goth Machhi(Plant-1)

1.3.2.2 Expansion Unit-Goth Machhi(Plant-II)

1.3.3 FFCLtd. Mirpur Mathelo.:

1.3.4 Agritech Ltd. Daudkhel:

Fertilizer Corporation of Pakistan. Pak American Fertilizers is a urea manufacturing Plant

1.3.5 Engro Chemicals ltd. Dharki:

1.3.6 Dawood Hercules Chemicals Limited:

1.4 Ammonia Production in Pakistan:

Table 1.5 Ammonia production in Pakistan

1.5 Naphtha Exports at Loss: