Process Description of Ammonia Plant

Gujarat Narmada Vally fertilizer Co. Ltd.
1 of 12
Process Description Of Ammonia Plant
SECTION -100 “Air Separation Unit”
We have M/s.Linde A/G process which is a modified low pressure process, employing a
medium pressure Nitrogen recycle and internal compression For production of pressurised
oxygen gas.
About 230000 Nm3/hr of air is filtered and compressed by means of an axial centrifugal
compressor up to 6.4 bar pressure. After cooled in a direct water spray cooler, air enters the
main reversing heat exchangers at approx. +20ºC.
In these exchangers air is cooled to near liquification temperature against separate cold
product streams. Water and carbon dioxide contains in the air are deposited on the plate
surfaces where they are scavenged after flow reversal in the reversing exchangers controlled
by an electrical switching device. Switching is done in 25%. portion of four exchangers within a
very short time interval thereby reducing the pressure fluctuations in the system.
Air separation is carried out in two columns operating at different pressures. The air
which is near its liquifaction temperature flows to the lower columns which is operated at 6.2
bar pressure. 40% oxygen enriched liquid in the bottom of this column is flashed to the upper
column after having passed through crude liquid adsorbed wherein hydrocarbon impurities
(mainly acetylene) are removed. The upper column is operate at 1.4 bar pressure.
Pure nitrogen is withdrawn from the top of the lower column. Approx. 12% of this
stream is taken from the plant as low pressure nitrogen product at 5.7 bar pressure and the
other portion is fed to the nitrogen recycle stream.
Waste Nitrogen containing 8% oxygen withdrawn from the top of upper column is
vented to atmosphere after recovering its coldness.
Oxygen product is withdrawn from the bottom of the Upper column in liquid form and
pressurised in cryogenic liquid oxygen plunger pump at 97 bar pressure. The pressurized liquid
oxygen is vaporized in nitrogen recycle exchanger and leaves the plant in gaseous form at 96
bar pressure and 70ºC temperature.
The additional pure nitrogen is compressor in recycle centrifugal compressor unto 75.6
bar. pressure. It is then split into two streams. One stream leaves the plant as HP nitrogen
product at 75.5 bar pressure while the other stream is used as recycle nitrogen.
A nitrogen recycle system is used to economically generate some refrigeration as well
as the heat required to vaporise the end warm-up the liquid oxygen to ambient temperature.
A part of the refrigeration requirement of the plant is obtained by the expansion air
which is withdrawn from the lower column. Air is expanded with the work of expansion taken
off by an electric generator and returned to the Upper column. A second expansion turbine is
installed to increase the cryogenic refrigeration capacity during shut down of the unit. The
second turbine is available as standby during normal operation.
The following are the major products from the Unit :-
1. Gaseous Oxygen at 7ºC and 96 bar
Purity : Oxygen : 98 . 5 % by vol.
Quantity : : 35100 Nm3/hr which is equivalent to 1200 M tones/day.
2. Gaseous HP Nitrogen at 15ºC and 75 bar
Purity : Oxygen : 10 ppm
Quantity : : 39000 Nm3/hr
Gujarat Narmada Vally fertilizer Co. Ltd. 2 of 12
SECTION-200 “Gas generation unit”
There are two world renowned partial oxidation processes for Ammonia production.
The Texaco and the Shell. GNFC selected Texaco process which has certain inherent
advantages like lower operating cost lesser capital costs lesser pollution problems etc. It
avoids waste heat boiler, a critical equipment and instead adopts water quenching system.
further GNFC has adopted Texaco's total carbon recycle process whereby all the soot
formation is recycled back to gasification. This process which eliminates pollution also reduces
consumption of fuel oil thus reducing the operational cost.
We have two gasifiers of 8 ft/285 ft3 size in the plant. Each gasifier is having a capacity
to produce maximum 91.9 x 103 Nm3/hr of (H2+C0) raw synthesis gas which is equivalent to
1080 MT /day of ammonia (80% of ammonia plant capacity 1350 MT /day). Thus in our case,
one gasifier running on full load is sufficient to keep the urea production at 1800 MT /day.
During partial oxidation hydrogen, carbon monoxide, carbon dioxide, methane, soot
and some impurities in traces are generated. For economical reasons carbon equivalent to
approx. 2% of the fuel oil feed stock usually remains as solid carbon (soot) in the gas and is
removed downstream the reactor. We have two gasification trains, each is having a separate
fuel oil change system (with separate pumps and HP steam oil heaters), separate quench and
soot agglomeration.
The reciprocating fuel oil charge pumps take suction from low pressure oil circulation
loop and deliver the feed at max. 120 bar to the process oil pre heaters. The oil is mixed with
saturated high pressure steam of 105 bar pressure before entering gasifier. High pressure
oxygen at 96 bar pressure is preheated and than fed to the burner. There is a steam addition
to the oxygen stream of about 5% of the HP steam feed to the gasifier.
The fuel oil/steam and oxygen/steam mixture are injected into the reaction chamber
through a water cooled burner, which is simple, yet highly efficient in mixing. The combustion
chamber of the generator is lined with a high temperature resistant NORTON refractory.
The generator is designed to operation at 85 bar combustion temperature up to 1540ºC
with a shell temperature of 200 - 315ºC. The generator is constructed of low chrome steel (13
Cr.Mo.44), as required by the Nelson curves for hydrogen service. The temperature in the
generator reaction zone is maintained in the range of 1200ºC to 1540ºC. The soot yield and
temperature are controlled by adjusting the oxygen to hydrocarbon ratio. Besides this, the
reaction temperature is moderated by the charge rate of process HP steam. The methane
content in the synthesis gas is controlled primarily by the generator temperature.
BASF' process burners are selected for Texaco generators. The Texaco generators
usually can be turned down to 50% load and can be overloaded up to 110% without changing
the burner. However, for a long duration of turn down it is recommended to change the burner
tip.
The hot gases leaving the combustion chamber pass downwards through a quench
tube. Here they are quenched to saturation temperature of about 255ºC with water delivered
by soot water pumps from the bottom of the carbon scrubber. The gas easily picks up the
enormous quantity of water required for subsequent shift conversion, thus no special
saturation device is needed after gas cooling.
By quenching roost of the enriched carbon is eliminated from the gas in the form of
carbon water slurry which is blown down from the generator bottom via heat exchangers to
the section-300 carbon extraction unit.
The gas leaving the generator passes through the scrubbing nozzles. Grey water (soot
free water) and process condensate are injected into this device. The gas having been
accelerated to a high velocity in order to achieve a turbulent mixing. The carbon particles
enriched in water droplets are separated from the gas in the bottom carbon scrubber by dip
and draft tube device. The trays in the scrubber completely eliminate carbon particles from the
gas.
The composition (on dry basis) of the raw. gas exit gasification section:
GAS COMPOSITION: H2 : 43.0 % by Volume
N2 : 00.11 % by Volume
CO : 47.69 % by Volume
Ar : 00.41 % by Volume
CH4 : 00.75 % by Volume
CO2 : 6.93 % by Volume
H2S : 1.05 % by Volume
COS : 0.06 % by Volume
H2O : 159.42 % by Volume
SECTION - 300 “Carbon extraction unit”

The Texaco soot remover system is a well proven operation to recycle all the soot
extracted from quench water to the combustion chamber.
The superiority of this process is characterised by a total soot recovery and thereby
avoiding pollution.
The higher affinity of soot to hydrocarbons than to water has been used to separate
soot from water by mixing soot water with extraction naphtha.
The soot water leaving the generator bottom is cooled to 150ºC and later on mixed with 100ºC
naphtha at 24.5 bar pressure. To achieve an intensive contact between water and naphtha a
two stage mixing has been provided, which influences the grade of mixing and hence the
transfer of soot to naphtha. The naphtha and water (grey water) phase from the bottom of the
decanter is flashed into the water flash tank to remove traces hydrocarbons. To avoid
enrichment of solids and dissolved salts in the water cycle ( originating from the feed oil) a
small part of the grey water from water flash tank is continuously discarded as an effluent.
The naphtha-soot mixture from the top of decanter is mixed with fresh feed oil. After
additional heating, the mixture is fed to the naphtha stripper for separation of naphtha and
feed oil soot mixture (soot oil) .The naphtha stripper operates at 20.5 bar pressure and
saturated at 26 bar pressure. Steam is feed directly to bottom of the stripper. The overhead
naphtha water vapors from naphtha stripper is condensed and collected in the naphtha buffer
tank. The naphtha cycle starts here. Make-up naphtha is fed directly to the soot-naphtha-oil
line before naphtha stripper.
The soot oil is sent back to Section-200 as a recycle stream to gasifier for combustion.
SECTION-400 "CO-Shift conversion unit”
The process is a high temperature three stage shift conversion employing the
BASF-KS-11 catalyst which contains cobalt and molybdenum oxides on a special carrier.
Catalyst K8-11 can be used only with gases produced from heavy feed-stock containing
sulphur content above 0.6% and is fully active in the sulfide state. During first startup,
sulfurisation of the catalyst KS-11 is to be carried out.
The advantages of BASF K8-11 catalyst are as follows :

1) High activity in the presence of sulfur compound in the process gas.
2) High mechanical strength.
3) Lack of sensitivity towards high H2O partial pressure and water in liquid form.
4) Sulphur active catalyst saves energy-being consumed for 2 stage H2S/CO2 removal system.
During the 3 stages of shift conversion, CO content is reduced to less than 1.5% by
volume in the process gas. The shift reaction also reduces the content of COS, HCN and
organic acids present in the process to, below 1 PPM.
In the 1st catalyst bed up to 85% CO is converted which results in a temperature
increase from 340°C to 485°C This heat is used for heating feed gas to first bed and raising HP
steam in BORSIG Waste Heat Boilers.
Inlet gas temperatures to 2nd and 3rd catalyst beds are 363°C and 322ºC respectively.
The inlet temperature of the 3rd catalyst bed is controlled by direct injection of hot process
condensate.
Downstream the 3rd catalyst bed process heat is recovered from the gas in a series of heat
exchangers and boilers. Thereby, steam at different pressures levels is generated and high
pressure; process condense is collected in the knockout drums and sent to carbon scrubber of
gasification.
After the heat recovery section, the gas is further cooled down indirectly by bailor feed
water to approx. 45ºC before entering the Rectisol Wash Unit.
The composition of the process gas leaving this section is :
GAS COMPOSITION: H2 : 60.78 % by Volume
N2 : 00.10 % by Volume
CO : 1.50 % by Volume
Ar : 00.27 % by Volume
CH4 : 00.52 % by Volume
CO2 : 35.91 % by Volume
H2S : 0.75 % by Volume
COS : 0.00 % by Volume
H2O : 0.17 % by Volume

SECTION -500 “Recticol wash unit”
M/s.Linde's Rectisol Process is a physical absorption process operating at about -63°C
temperature and 74 bar pressure, removing CO2, H2S other impurities like COS from gas in one
step only.
The feed gas from shift conversion is cooled down by refrigerant (ammonia) to
separate condense from the gas. After injection of methanol into the gas to prevent ice
formation, the gas is further cooled down to separate condensed methanol-water mixture. The
water from gas is fed to the methanol scrubber. In the lower section H2S and COS absorbed by
methanol.
In order to minimise the heat of solution in the lower section, CO2 loaded methanol from the
CO2 wash section of the tower is used for sulfur removal. In the upper part of the tower, CO2 is
removed down to 20 PPM using cold lean methanol from the methanol regeneration tower.
The heat of solution for CO2 absorption is recovered partly by temperatures rise of the
lean methanol, fed to the top of the methanol scrubber partly by cooling the methanol by
refrigerant and cold methanol. As the solubility of CO2 in methanol is less than the solubility of
H2S the methanol to be cycled in this section is greater than the H2S section. The methanol
surplus from the CO2 section of the tower is branched off from the middle of the column. In
the methanol leaving the scrubber, some H2 and CO are dissolved.
In order to reduce the hydrogen loss and to reduce the H2 content in CO2 product, both
methanol streams are flashed. The flash gas is recycled by a reciprocating compressor to the
feed gas.
The CO2 loaded methanol is further expanded to release CO2 which is used for CO2
production. The CO2 free methanol is than split into two streams. One stream is sent into the
top of the CO2 desorption tower to wash out H2S and CO2 from the CO2 stream leaving this
column. The other part is fed into top of the H2S concentration tower to wash out H2S and COS
from the gas leaving this column.
The H2S loaded methanol after flashing is further expanded into the middle section of
the H2S concentration tower. From the middle of this column, the CO2 and H2S containing
methanol is pumped through exchangers for heating and fed to CO2 desorption tower to flash
out CO2. Now the H2S concentrated methanol from the bottom of CO2 desorption tower is sent
to the lower section of H2S concentration tower, where the CO2 is stripped by nitrogen. This is
necessary to achieve a H2S concentration in the H2S fraction which enables the Use of this gas
in the Claus Unit.
The methanol from the bottom of the H2S concentration tower with enriched H2S in
solution is pumped via exchangers into the methanol regeneration tower Here the complete
desorption of H2S takes place by stripping with methanol vapour which is generated in reboiler
The H2S rich gas stream leaves the top of the methanol regeneration towel to Claus Unit after
recovering cold. The regenerated methanol from the bottom of this tower is fed into the
methanol holdup tank after cooling from where it is again pumped back to methanol scrubber
tower.
The methanol water mixture separated from the feed gas is sent to Methanol/ H2S
separation tower. The methanol vapour leaving the top of this tower is condensed and sent to
methanol holdup tank. Water separated in the bottom of this tower is discharged to effluent
treatment section.
Four different gas streams from methanol scrubber tower are takes to make methanol
synthesis gas which will be sent to methanol plant for the production of 60 MT /day of
methanol.
Following are the product the streams from the Unit:-
1. Purity
H2 : 96.30 %
N2 : 00.16 %
CO : 2.34 %
Ar : 00.41 %
CH4 : 00.76 %
Temperature / Pressure : -63ºC/73 bar
Quantity : 116405 Nm3/Hr.
2. CO2 Production Purity

CO2 : 98.80 %
H2 : 0.91 %
Temperature / Pressure : -15ºC /2.55 bar
3. Methanol Synthesis Gas Purity

CO : 1.0 %
CO2 : 22.0 %
H2 : 75.0 %
Temperature / Pressure : 10ºC /71.6 bar
4. H2S Fraction Composition

N2 : 2.0 %
CO2 : 54.6 %
H2S : 43.375.0 %
SECTION-600 “Liquid Nitrogen Wash unit”
The feed gas leaving the Rectisol Wash Unit, flows through one of the interchangeable
adsorber where traces of methanol and CO2 are removed. The feed gas then enters the cold
box. In heat exchangers, the gas is cooled down against product streams to 85ºC -192ºC in
the scrubbing column at -192°C and 72 bar the, impurities Ar, CO and CH4 are washed out by
liquid nitrogen an dissolved with a small part of hydrogen in the bottom stream of the column.
The purified hydrogen containing about 10% volume N2, leaves the top of the column.
The nitrogen required for the wash process and for the right proportion and ammonia
synthesis gas, enters the wash unit at about +15°C and is cooled down in heat exchangers
against product streams. One nitrogen stream adjusted proportional to the feed gas flow
enters the scrubbing column. The part of the nitrogen is mixed with the purified hydrogen.
This nitrogen stream is controlled as a constant part of the feed gas flow rate in order to
provide for the correct ratio H2:N2 in the synthesis gas. Part of the synthesis gas is warmed
up in Rectisol Wash Unit and the other part warmed up within the unit area joined to gather
and sent to the suction of synthesis gas compressor. fine turning of H2:N2 ratio is done by an
analyser controlled Valve outside of the cold box.
The tail gas leaving the bottom of wash column is expanded to the medium pressure
Flash drum where hydrogen rich gas is separated from the liquid. The gas is recycled to
section-400 and liquid is then expanded to low pressure and finally evaporated warmed up and
sent outside as fuel gas.
The cryogenic refrigeration required to compensate the refrigeration losses is
generated by the expansion and vapor is at ion of column's bottom stream. further
refrigeration is generated by a sort of Joule Thomson Effect caused by injection of nitrogen
into the hydrogen.
following are the composition and flow rate of synthesis gas :-
N2 : 2.0 %
CO2 : 54.6 %
H2S : 43.375.0 %
Flow Rate : 148460 Nm3/Hr.
Compression : H2 : 75 % by Vol.
N2 : 25 % by Vol.
Ar : 40 PPM
CH4 : 1 PPM
SECTION-700 "Ammonia synthesis unit”
The synthesis gas is compressed from 72 kg/cm2 9 to 231 kg/cm2 9 in the BHEL
supplied centrifugal synthesis gas compressor. Before compression the make-up gas is mixed
with off-gas from the ammonia let down drum. After compression to about 218 kg/cm2 g, the
total make-up gas is mixed with the recalculation gas coming from the ammonia separator and
mixture is finally compressed to 231 kg/cm2 g in the last stage of the compressor. The
gas leaving the compressor enters the hot heat exchangers where it is heated to the converter
inlet temperature of 240ºC by heat exchanger with the hot effluent gas from the BFW pre
heater.
At the outlot of the synthesis converter the gas contains about. 16.24% by volume of
NH3 and temperature is about 429ºC. The gas is further cooled to 338ºC raising HP steam in
BOR5IG Waste Heat boiler. The gas enters BFW pre heater where it is cooled to 85°C Then
cooling continues in heat exchanger and in the water cooler where substantial part of ammonia
product is condensed.
The gas then passes the cold exchanger and ammonia chillier where it is cooled to +10ºC.
The mixture of synthesis gas and liquid ammonia is separated in the ammonia
separator. The gas still containing about 4.9% by volume NH3 is heated in cold exchanger and
enters the last stage of synthesis gas compressor.
The liquid ammonia separator the Ammonia separator is depressurised to 75 kg/cm2 g
in the let down drum. The most of the dissolved gases in the liquid ammonia are Flashed off.
The liquid ammonia is delivered at battery limits at a pressure of 74 kg/cm2 g.
The process described above is Haldor Topsoe synthesis process which utilises radial
flow converter. It is a single radial flow quench converter which requires minimum volume and
has minimum pressure drop. The radial flow converter containing two catalyst beds with
quench between the beds, The total catalyst volume; installed is 34.3 M3. The upper bed
contains 10.4 M3 of Haldor Topsoe pre-reduced KMIR catalyst and the lower bed contains 23.9
M3 of Haldor Topsoe unreduced KMI catalyst.
The synthesis loop' is designed with one startup electric heater which is placed outside
the Pressure shell of the converter.
SECTION-900 "The sulfur recovery unit”

The sulfur recovery unit is designed to produce elemental sulfur from the H2S present
in the acid feed gas according to the Claus Process. An overall recovery of sulfur is 94% on the
unit which consists of a split flow thermal stage followed by the catalytic stages.
Feeds to this unit are H2S fraction acid gas from Rectisol Wash Unit and additional feed
gas from carbon recovery unit which also contains some hydrocarbons. 70% of the total acid
gas and additional food gas are fed to thermal stage where they are burnt with arractic
controlled flow of air. 30% of the total acid gas by passes the thermal stage. The amount of
air fed to the thermal stage is sufficient to burn all the hydrocarbons of the unit. The following
are two main reactions:
3
1. H2S + 2 02 = H2O + 502 + Heat
3
2. 2H2S + S02 = 2H20 + 8 S8 + Heat
The hot process gas from the thermal stage are cooled to 165°C in a Waste Heat boiler
where approx. 35% of the total sulphur is recovered as liquid sulphur and flows to the sulfur
pit. In the catalytic stags, more sulfur is produced by promoting following Cause reaction which
is favored at low temperature .
3
2H2S + S02 = 2H20 + 2 S2 + heat Catalyst used is synthetic alumina.
The process gas from thermal stage and bypass stream are mixed and heated up to
240°C by mixing the process gases in the line burner. Mixing chamber with hot flue gases
obtained by burning fuel gas stochiometrically. The heated process gas passes to the first
catalytic reactor. The effluent from the reactor is cooled from 335ºC to 165ºC in the first sulfur
condenser where a further 46% of the sulfur is condensed.
The second catalytic reactor is operated at reactor inlet temperature of 200ºC the
effluent from second catalytic reactor is cooled down to 130°C in second sulfur condenser
where further 13% of the sulfur is recovered.
Entrained sulfur in the process gas leaving the 2nd sulfur condenser is recovered by
passing the gas through the sulfur coalescer. This vessel is equipped with a bed of porcelain
rasching rings and SS demister mat.
The gas leaving the sulfur coalescer still contains approx. 0.5% volume H2S, a small
amount of sulfur vapour and mist. These compounds are converted to S02 with excess of air in
the catalytic incinerator at 350°C. Due to conversion the process gas heats up to 400ºC. The
final effluent gas stream is discharged to the stack.
The sulfur product drained from the various points in the unit is collected in the sulfur
pit provided with steam coils to keep the sulfur in a liquid state.
The sulfur pit is stripped with air to reduce H2S content in liquid sulfur product. The
minute quantity of H2S removed from the sulfur together with the stripping air is reused to the
catalytic incinerator.
The sulfur recovery unit is designed to take up feed gas containing as low as 14.6% by
volume of H2S. The unit is having a capacity of produce max.
47 tons/day of liquid sulphur.
SECTION-1000 "Storage tanks section”
The storage tank section consists of :-
Charge oil tank :98 M3 capacity

Soot Water tank :100 M3 capacity
Liquid Ammonia tank :15000 M3 capacity
1) Charge oil tank:

This tank recovers heavy oil feed stock after heating from fuel oil storage tank and soot
oil from carbon extraction unit. The oil + soot from this tank is supplied by centrifugal pumps
to feed oil charge pumps and then to gasifiers. The tank is provided with steam heating coils
and purged with nitrogen all the time.
2) Soot Water tank:
Its purpose is to collect soot water from gasification and carbon recovery section in
case of shutdown. Further more it can take soot water for several hours from the process in
case of disturbances in carbon extraction unit. Later on this soot water can be fed back for
soot recovery. One no. re-circulation pump has bean provided to keep soot in suspension in
water.
3) Liquid Ammonia tank:
The liquid ammonia product is stored most economically at atmospheric pressure. As

the operating temperature 23.9ºC thickness of insulation is so designed that the boil off rate is
below 0.05% of the full storage capacity per day. The tank is located on piles with free air
conversion under the base plate. The tank pressure control is designed to keep the
absolute gas pressure in the tank constant. The small wound coils in exchanger generate
vapour ammonia to balance the tank pressure in case of startup or if pressure decreases at full
unloading capacity. Vertical submersible centrifugal pumps are installed to transfer liquid
ammonia to loading station and Urea plant.
NH3 - Boil off compressor:
The purpose of this unit is to recover NH3 from boil off gas emerging from the liquid
ammonia storage.
The unit consists of a two stage reciprocating compressor (plus 100% spare) with
inter-stage coolers, condensers and ammonia knockout drums and an inert gas condenser.
When urea plant is under shutdown and total ammonia production comes to storage
tank the gas quantity to be treated is approx. Four times larger & hence service of the
standby compressor foreseen.
SECTION-1100 “NH3 refrigeration unit”
The refrigeration required in sections 100,500,700 & 1000 is generated by NH3

refrigeration Unit. It consists of one turbo compressor, eight ammonia condensers, five
ammonia collecting drums, on blow-down vessel, one sub cooler one vaporizer and one cold
trap For ammonia removal from inert gas.
The turbo compressor is) double casing machine with four Stage. The unit works at
four refrigeration levels e.g. -40ºC -21ºC, +3ºC and +10ºC. The total refrigeration process is
20.8 x 106 Kcal/hr which is equivalent to about 700 tons of refrigeration.
After compression of ammonia vapour approx. to 17.9 bar ab. in turbo compressor, the
ammonia gas is cooled down and condensed in ammonia condensers by cooling water. The
condenser is further sub cooled in order to save power. From the sub cooler a part of the liquid
ammonia flows to the consumers, while remaining is lst down to next drum. For each of the
refrigeration level the liquid is split alike into one stream serving refrigeration consumer & the
other one feeding into the next drum.
This refrigeration system is equipped with a control system which protects the
compressor from surging when little or during startup no refrigeration is consumed.
The ammonia contained inert (if any) is condensed in refrigerant condenser and thus
recovered. The above service removes air penetrated through seals packing etc., of the
vacuum suction side of first stage. In this way the hazard of missing combustible inert with air
is avoided.
SECTION-1200 “Flare and fuel gas system”
1) Flare system:
The ammonia plant is equipped with two flare systems, one for all gases containing
ammonia and one for all other gases including the H2S fraction in case of claus Unit failure.
The flare system can handle all combustible or toxic gases, which will be relived from safety
valves or control systems during startup, upsets and, any fault or emergency conditions or
man operation in the plant.
The cold gas from Section 500 and 600 are led to a flow header fabricates in high alloy
steal. To minimise the use 0f high alloy steal the cold gases will be heated up to at least OºC
by means of steam injection. Cold liquids (i.e. Methanol) are not led to the flare system.
The drainage of the cold liquids of the nitrogen wash unit is done via liquid fool gas storage.
These cold liquids are vaporised and superheated These cold liquids are heaving
heat values. They are fed to fuel gas system or the flare systems.
The two flare stacks are built together in a common steel structures. The height of flare
stack is 75 meter The flare stack bottoms are designed for accumulation of liquids. For the
ignition of the pilot burner, a flame front ignition panel is installed near the flare base. The
pilot burners are provided with flame supervisory equipment to prevent a flash back of flame.
To prevent a flash back of flue, both flare stacks are provided with molecular sieves. The seal
is purged with nitrogen to prevent air being drawn in.V.H.Jain 2689
2) FUEL GAS SYSTEM:
Fuel gas used in the ammonia plant is mainly produced in nitrogen wash unit and from
there it is routed to the fuel gas system through two different ways.
Carbon monoxide rich excess liquid which is not required in section-600 for balancing
cold losses is fed to the liquid fuel gas storage. The liquid from this storage is vaporised and
warmed up to about 40ºC and mixed with tail gas from the nitrogen wash unit. The mixture is
distributed to the different consumers.
To make up fuel gas in case of low heating values or for startup LPG can be fed to the
system as fuel gas. Whenever LPG is required to be used it is admixed with nitrogen in order
to lower the heating value of the fuel to its required value.
Excess fuel gas which can not be consumed by system super heater of Claus Unit may
be routed to Boiler Section or process flare.
SECTION-1300 “Steam and condensate system”
Steam is used to several section for process requirements and for driving of steam
turbines. There are five steam pressure levels:-
1) HP Super heated steam : at 90 bar / 500ºC
2) HP Saturated steam : at 105 bar / 315ºC
3) MP-I Super heated steam : at 26 bar / 340ºC
4) MP-II Super heated steam : at 15 bar / 200ºC
5) LP steam : at 4 bar / 150ºC
HP steam is produced by coal fired steam bailors (278 t/hr) and process waste heat
boilers (83 t/hr). An amount of 278 t/h HP steam is superheated in the steam boilers and 47
t/h in the gas fired steam super heater. About 325 t/h HP superheated steam is consumed by
four turbines driving air nitrogen; synthesis gas and carbon dioxide compressors.
MP-I steam level is determined by the requirement of the urea plant. The biggest
quantity is produced by exhaust steam from turbine driving synthesis gas compressor. This
MP-I steam is used to drive turbine of ammonia compressor and turbine of BFW pump. The
rest is consumed by Urea Plant for process reasons 3nd off sites.
MP-II steam level is selected in order to get an optimum process heat recovery in the
CO shift conversion. This steam is generated in Waste heat boiler in section- 400.
LP steam is generated by heat recovery in the Urea Plant, Sulfur Recovery Unit, CO
shift conversion unit and exhaust of steam turbine of BFW pump. It is used for process heating
requirements and the rest is let to turbine of ammonia compressor.
1) Condensate system:
Most of the condensate is generated by the four total Condensing turbine. The process
condensate is passed through activated carbon bed filter to remove contaminated oil and
mixed with turbine condensate. The mixed condensate is treated in a Cat ion exchanger and a
mixed bed filter
To cover up the condensate and steam losses, demineralised water make-up is mixed
with treated condensate and fed to the deaerator. The treated urea plant condensate is also
added in the deaerator.
2) Boiler feed water pumps:

The BFW is pumped from the deaerator to the several consumers.
HP BFW pumps supply BFW at 143 bar to waste heat boilers, steam super heater,
reducing stations and BHEL boilers. The pumps are provided with a minimum flow by passes
in order to protect the pumps.
MP BFW pumps are provided to pump BFW at 32 bar to waste heat boiler and for
process use.
Hydrazine end ammonia solutions are injected at the suction side of BFW pumps to
eliminate oxygen and to increase pH respectively. V.H.Jain 2689
***

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Gujarat Narmada Vally fertilizer Co. Ltd.

H2O : 159.42 % by Volume

SECTION - 300 “Carbon extraction unit”

The advantages of BASF K8-11 catalyst are as follows :

H2O : 0.17 % by Volume

2. CO2 Production Purity

3. Methanol Synthesis Gas Purity

4. H2S Fraction Composition

SECTION-900 "The sulfur recovery unit”

Charge oil tank :98 M3 capacity

1) Charge oil tank:

The liquid ammonia product is stored most economically at atmospheric pressure. As

The refrigeration required in sections 100,500,700 & 1000 is generated by NH3

2) Boiler feed water pumps:

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