INTRODUCTION TO AMMONIA PLANT COLD BOX

Presented By:

ABDUL JABBAR GTE TSD

4/18/2012

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CONTENTS
1. Application of Cold box 2. Brief description of Ammonia Plant Cold Box

Process Flow Schematic Construction of cold box

Fouling of Exchangers Bad Mode Operation Gas Mal-Distribution in Exchangers High P across the Expander

3. Operational issues relating to Cold box

4. Important Practices at Kemira

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COLD BOX
What is a Cold Box? Cold Box is a group of multi-fluid exchanger cores assembled in a single structure and Purifier column for separation of gases. Net refrigeration is provided by
Expander and Joule Thomson Valve.

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Purpose of Cold Box

Cold Box provides Cryogenic Purification. Word Cryogenic means Generation of cold. Temperature below -150C is considered to be cryogenic temperature. Principle of cryogenic purification is liquefaction i.e. separation of gases by decreasing the temperature. Cryogenic Purification is achieved in Cold box.

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FFCL COLD BOX

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FFCL Cold Box (KBR Purifier):

Function of FFCL cold box is to purify Feed Gas (FG) by separating argon (brought in with the air), excess nitrogen and methane (contained in the synthesis gas) by cooling and distillation. Basically cold box fixes ratio of H2/N2 at synthesis machine suction by condensing excess nitrogen and almost all inert. Extent to which inerts are removed Methane Removal Efficiency Argon Removal Efficiency Carbon Dioxide

99.9% 60% 50%

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1. Process Flow Schematic

Waste Gas
H2 = 4.26 N2 = 74.59 CH4 = 19.14 Ar = 1.99 H2 = 74.17 N2 = 24.95 CH4 = 0.001 Ar = 0.244 T= 3C P = 23.6Kg/cm2

Feed Gas
H2 =64.173 N2 = 32.433 CH4 = 2.88 Ar = 0.508 T= 4 C P = 27.3Kg/cm2

Syn Gas

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Construction of Cold Box

Main Components of
FFCL Cold Box Plate and Fine Exchanger (Compact Heat Exchanger) Joule Thomason (JT) Valve Purifier Rectifier Column Purifier Expander
Perlite

Insulation
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Plate and Fine Exchanger (Compact Heat Exchanger)

Plate-fin heat exchangers are a matrix of flat plates and corrugated fins in a sandwich construction.

Primary Heat Transfer Surface

Secondary Heat Transfer Surface

Provide Sealing b/w Plates

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Corrugated fins and Plates in a sandwich construction.

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Core of Plate-Fin Heat Exchanger

Flow Through Single Element

Feed Gas

Waste Gas

Syn Gas

Many Elements Combine to form a complete Core

Complete Core of Plate- Fin Heat Exchanger: These elements are built into a complete core and then vacuum brazed to form an integral unit Core of plate-fin heat exchanger
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Cores Assembled in Parallel

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Exchanger Arrangement in Series and Parallel

Cores of E-125A1

Cores of E-125A2

Cores of E-126

Cores of E-126 = 8 Cores of E-125 = 16

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Operational issues of COLD BOX

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(A). Fouling in Cold box

Fouling:
Accumulation of unwanted material on heat transfer surfaces of exchangers is called fouling. Fouling results in retardation of heat transfer across the surfaces.

Generally three kinds of fouling persists in cold box exchangers: 1. 2. 3. Rime of H2O, CO2 and NH3 Non-uniform solids fouling Fouling by oil

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1. Rime of H2O, CO2 and NH3 Rime of H2O, CO2 and NH3 solid water
carbon dioxide

and ammonia can continuously accumulate in the feed gas passages (FG) of the upper
part of exchangers (i.e. E-125A1 and E-125B1).

Minimizing Rime Fouling:

Rime fouling can be suppressed and minimized by correct regeneration and operation of driers.

Removal of Such Kind of Fouling:

Such kind of fouling can be removed by De-riming.

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2. Non-uniform solids fouling

Non-Uniform solid fouling

Desiccant and filter material from the drier Sand and debris from other sources can cause partial plugging and mal-distribution of flow from the cores.

Minimizing Non-Uniform solid fouling:

Non-uniform fouling can be minimized by monitoring Filter Delta P Drier Delta P Alternatively replacement of filters preferably after each 2 months. (Reference Kemira Study Report)

Removal of Such Kind of Fouling:

Such kind of fouling can be removed by Rupture Disc Blowing and back blowing.

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3. Oil Fouling Fouling by Oil:

Slight slip of oil along feed gas passage to E-126 always persists and results in oil film fouling after a period of six months to year in E-126 exchanger.

Major sources of oil slippage are:

Lube oil may enter the process side during normal operation During uncontrolled shut down and major upsets

Removal of Such Kind of Fouling:

1.
2.

De-riming Cold Box exchangers up to 80C

Solvent Wash By Methylene Chloride By Naphtha

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Identification of COLD BOX fouling Two methods proved to be very effective for identification of fouling in Cold box are: Temperature Pattern across the exchangers (This method was recently used to locate fouling across the exchanger during plant shut down on 13th August). Pressure Pattern across various section of cold box

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(B). Bad mode Operation of COLD BOX

Liquid carried to the cores of E-126 When waste Gas exit T of E-126 becomes much cooler Waste Gas instead of cooling FG in E-126 , itself being Cooled by FG from Expander. So Expander has to do more Refrigeration

E-125 A2/B2 apparently seems to be performing over-efficient

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Bad mode Operation of COLD BOX

Reasons for cold box Bad Mode operation

Conditions which accelerates cold box shift to bad mode.

Fouled exchangers are greater chances to stuck in Bad Mode. Cold Box going to Bad Mode during start-up. But it is very difficult to come with a set of procedure that always will force the operation back to good mode if plant deteriorates into bad mode. 1. 2. Decrease waste gas P as far as Possible. Venting Waste gas between E-126 and E-125.

(sometimes prove to be helpful to force operation back to good mode specially during start-up)

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Modification at Kemira to avoid Bad Mode

WG Flow reversal of E-127 (Partial condenser) to avoid liquid carry to E-126 WG Passages

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Bad mode of COLD BOX WG Flow through E-127 before May, 1979
Syn Gas tube side out

waste Gas in Shell Side

waste Gas out Shell Side

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Syn Gas in Tube Side

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Bad mode of COLD BOX WG Flow reversal of E-127 Partial condenser

Waste Gas Flow in E-127

Impingement Plate

Longitudinal Baffles

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(C) Mal-distribution in cold box exchangers

Situation at Dispersed Flow:

Waste Gas in E-126

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Mal-distribution in cold box exchangers

Situation at Segregated Flow:

Waste Gas in E-126

Difference between Mal-Distribution and Bad mode ?

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(D) High P across Expander 1-C-103 Following Parameters contributes to high P across the Expander: Mal-distribution in WG Passage of Exchangers
Bad Mode Operation of Cold Box Fouling In Cold Box Exchangers Leakages in Cold Box Level loss in Purifier rectifier column

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Important Practices at Kemira

Liquid Nitrogen Injection system Frequent back blowing and Rupture Disc blowing of Feed Gas passages of E-125 (upper exchangers) Deriming of cold box Solvent wash under supervision of Linde Experts Kemira Research Technical Services Department (RTS)

Simulation study on Cold Box Performance

Addressing issues relating to cold box in collaboration with Process, Operation and Linde Experts)

New cold box study (Oil Free expander)

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THANKS

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