National Fertilizers Ltd.

Bathinda
AJAY NAGAR 10112001

Sections

Ammonia Plant Urea Plant Steam Generation Plant Bagging Plant

Ammonia Plant

Desulphurization Section Reforming Section Shift Section Carbon Dioxide Removal Section Methanation Section Ammonia Synthesis Section

Desulphurization Section
Natural Gas Feed Natural Gas With Recycle Hydrogen 400oC 38 Kg/cm2 395oC

HYDROGENATOR:
Reactions involved in Hydrogenator are: R1SSR2 + 3H2 R1H + R2H + 2H2S R1SR2 + 2H2 R1H + R2H + H2S COS + H2 CO + H2S If some content of CO2 is also exist in Natural Gas feed then: CO + H CO + HO CO + HS COS + HO
Hydrogenator CoMo or NiMo based catalyst is used in Hydrogenator. Feed Gas Preheater Recycle Hydrogen RSH + H2 RH + H2S

Sulphur Absorber No. 1

Sulphur Absorber No. 2

oC 395 351o

Desulphurization Section
HS ABSORBER:

The Hydrogenated Natural Gas is fed to the Sulphur Absorbers. Zinc oxide catalyst is in the form of 4 mm cylindrical extrudates. Operating temperature is approx. 395C.

ZnO + HS ZnS + HO
ZnO + COS ZnS + CO

Sulphur content in the natural gas is less than 0.1 ppm by weight.

Reforming Section

Desulphurized gas is converted into synthesis gas by catalytic reforming of the hydrocarbon mixture with steam and the addition of air. Reactions involve in Reformer Section:
CnH2n+2 + 2HO Cn-1H2n + CO + 3H - heat

CH + 2HO CO + 4H - heat
CO + H
1. 2.

CO + HO heat

Reactions take place in two steps Primary reforming Secondary reforming

Primary Reformer
Process Air Desulphurized Gas : (Mole As we have seen that we areComposition getting around Steam Carbon Mole Ratio=3/1 %) 12.86 mole % of methane and we dont want (At Inlet of Catalyst Process Steam Tubes) it to be exist in stream just because it will be Ar 0.02 CH4 79.68 acting as inert in whole further COprocesses. 2 ppm CO2 0.24 So we have to remove it. Composition H2 4.09 of catalyst (% w/w) N2 Nickel 2.54 Monoxide, NiO (17) 1. `For removing this access of methane we C2H6 6.48Oxide, CaO (7) 2. Calcium Primary C3H8 2.63 oxide, K2O (4) 3. Potassium use Secondary Reformer. Reformer C4H10 1.88 Oxide, Al2O3 (Balance) 4. Aluminum C6H12 - 0.24 Preheater

520oC
Composition: (Mole %) (At Outlet of Catalyst Tubes) Ar 47 ppm Secondary CH4 12.86 Reformer CO 9.5 CO2 10.70 H2 66.20 N2 0.74 Higher HC Neglegible 785-795oC Process Gas

Product Stream of Primary Reformer

34 - 31 kg/cm2 g

Secondary Reformer
The process gas is mixed with air with keeping the ratio of H2/N2 Ratio: 3.0. Partial combustion takes place in the top of reactor. Methane concentration is 0.60 mole%. Outlet gas contains about 13.05mole% CO and 7.24mole% CO that are removed further because catalyst may get poisioned. Gas inlet composition (mole%) 791oC Ar 47 ppm CH4 12.86 CO 9.5 CO2 10.70 30 kg/cm2 g H2 66.20 N2 0.74 Catalyst composition(%mole): NiO = 8 10% Al2O3 = 87 90 % Cao = < 0.05 %
550oC

1100-1200oC

Gas outlet composition (mole%) Ar 0.27 CH4 0.60 CO 13.37 CO2 7.65 H2 55.61 N2 22.47
958oC

CO Shift Section

Exothermic reaction which occurs in this section is: CO + H2O H2 + CO2 + heat

1. 2.

Shift reaction takes place in the two CO converters: HT CO-Converter. LT CO- converter with process gas cooling after each converter.

HT/LT CO Convertors
Composition (mole%) Process gas from Reformer Section of inlet stream of HT CO Converter is: Ar 0.27, CH4 0.60, composition CO Catalysts 13.37, CO2 (mole%) which is 7.65, H2 55.61, N2 HT form. CO available in pellet 22.47 Fe2O3 - 85- Convertor 95 % Cr2O3 7-9 % CuO 1-2% Al2O3 1.0%
432oC 360oC 29.6kg/cm2 205oC 28.6kg/cm2 (mole%)

Composition of outlet stream of HT CO Converter is: Ar 0.24, CH4 0.55 CO 3.22, CO2 Methanator 15.94 trim heater H2 59.59, N2 20.48

Catalyst consist the oxides of Cu, Cr and Composition (mole%) LT Al,CO Which is most Convertor of outlet stream of LT active in between 170250oC. CO Converter is: Ar 0.24, CH4 0.53 CO 0.30, CO2 18.32 H2 60.73, N2 19.88
227oC 160oC BFW Preheater 2

340oC Waste heat boiler

205oC BFW Preheater 1

CO2 Removal Section

Outlet gas from CO converter contain 18.32 mole% CO2 Based on two stage activated MDEA process The solvent used for CO2 absorption is aMDEA(40%) Consists of a two stage CO2 absorber, a CO2 stripper and two flesh vessels.

These are the reactions occurs in CO2 removal section. R3N + CO2 + H2O R3NH+ + HCO32R2NH + CO2 R2NH2+ + R2N-COO-

CO2 to Urea Chiller

72C 0.59 Kg/cm2 50C 5.1 Kg/cm2

LP Flash

Condensate

Cooler

Flash gas/ Inerts

160C 27.8 Kg/cm2

Stripper

95C

Output after CO2 Absorption 60C 26.8 Kg/cm2

Stripper Reboiler HE

Pump

HP CO2 Absorber Lean Solution

L S Pump 65C 27.8 Kg/cm2 Semilean Soln 65C Process gas saparator 65C

131C

BFW Preheater

Methanation Section

Methanation, a process in which the residual Carbon Oxides (CO, CO2) are converted into METHANE because it acts as inert in Ammonia Synthesis Section.
Reactions involve in Methanator are: CO + 3H2 CH4 + H2O + heat CO2 + 4H2 CH4 + 2H2O + heat

As we can see these reactions are exothermic so Low temperature, high pressure and a low water vapour content favours the methanation equilibrium. After converting all Carbon Oxides into METHANE, product stream is pressurised from 25Kg/cm2 to 187Kg/cm2 by using compressors and gas boosters and for maintaining temperature, chillers are being used.

300C

Process gas for LT CO Converter Process gas from HT CO Converter Trim heater

Nickel based catalyst Methanator is used here in methanator which consist around 27% wt Nickel. (280-420C)

322C Composition(%mole) at inlet is: Ar- 0.29, CH4- 1.08, H2- 73.95, N2- 24.88 Synthesis gas to loop 285C

60C 26.8 Kg/cm2

Gas/Gas HE

Composition(%mole) at inlet is: Synthesis Gas From Ar0.29, CH40.65, CO2 Removal Section CO2-0.05,CO-0.36, H2- 74.29,N2- 24.36

90C 25 Kg/cm2

Ammonia Synthesis Section

3H2 + N2 = 2NH3 + heat (H = 92.4 kJ/mol)
Feed gas inlet 130C 187 Kg/cm2

Fe Oxied (Fe3O4) % wt 93 2 High pressure and low temperature favourable equilibrium conditions of ammonia CaO, Al2O4, K2O, SiO2, % wt 7 2 reaction. With the irregular shape beads About 20% of N2 and H2 is converted into ammonia at given operating conditions. with the size of 1.5-3mm Unconverted remainder is recycled back. Bulk density 2.8kg/l There are three beds we use in Ammonia Convertor: First bed : 370-510 C Second bed: 425-480 C Third bed: 420-460 C
Feed gas inlet Outlet 354C Feed gas inlet 183.6 Kg/cm2

Composition(mole%) at Startup Inlet of Ammonia Heater Converter Ar- 1.82, CH4- 6.18, 130C H2- 65.95, N2- 21.99, 2 187Kg/cm NH3- 4.06 Ammonia Converter

Composition(mole%) of 10C Purge Gas of Ammonia 2 178.9Kg/cm Converter Purge Gas Ar- 2.49, CH4- 8.38 H2- 82.48, N2- 20.82 NH3- 5.82

Synthesis Hot Composition(mole%) at Heat Steam Outlet HE Exchanger Boilerof Ammonia Converter 2.11, CH47.14 354CAr180C 270C Cooler H2- 52.84, N2- 17.61 NH3- 20.30 Makeup Synthesis Gas

10C Chiller

Composition(mole%) of Let Ammonia Down Gas of Ammonia Separator Converter Ar- 3.16, CH4- 16.12 11C H2- 38.06, N2- 15.76 27Kg/cm2 Let Down NH3- 26.88 Gas

10C Product let Down tank Compressors Composition(mole%) of Product Ammonia Stream of Ammonia Converter (Product) Ar0.01, CH4- 0.16 12C 2 H20.06, N20.04 25Kg/cm NH3- 99.73

Ammonia Recovery
61C 20Kg/cm2 Composition(mole%) of Fuel Gas: Ar- 2.71, CH4- 9.46 Fuel Gas H2- 65.73, N2- 22.08 NH3- 0.01

Ammonia OH Drum Purge Gas Absorber Distillation Column Ammonia Reflux 45C 25Kg/cm2 Composition(mole%) of Product Gas: Ar- 64ppm, CH4- 0.03 Ammonia H2- 0.06, N2- 0.02 NH3- 99.88

Composition(mole%) of Purge Gas: Ar- 2.49, CH4- 8.38 H2- 82.48, N2- 20.82 10C NH3- 5.82 178.9Kg/cm2 Purge Gas Composition(mole%) of Let Down Gas Let Down Gas: 11C Ar- 3.16, CH4- 16.12 27Kg/cm2 H2- 38.06, N2- 15.76 NH3- 26.88 Steam 248C

Lean Soln Cooler Richlean Soln Exchanger Circulation Pump Reboiler

Conclusion

National Fertilizer Ltd. Bhatinda is producing 99.80% pure Ammonia by Using Natural Gas with the help of helder tropsch method for further production of Urea.

Thank You !!!