Ammonia Converter Operation

Makoto Shimagaki and Kenjiro Miyashita

Toyo Engineering Corporation, Funabashi, Chiba, Japan
and

Alita llyas and Aslam Kalyubi

P.T. Asean Aceh Fertilizer, Aceh, Sumatra, Indonesia

Optimization for the operating conditions of Kellogg 's four-stage adiabatic quench converter was achieved in a 1000 MTPD plant of Asean Aceh Fertilizer in Indonesia by adjusting the temperature profile through the catalyst beds with adjustments of quench flows.

INTRODUCTION

P.T. Asean Aceh Fertilizer (P.T. AAF) operates a 1,000 MTPD Ammonia Plant in its complex at Aceh, Sumatra, Indonesia. The Ammonia Plant is a large single train unit based on an M.W. Kellogg steam reforming process, and which had been designed in detail and constructed by Toyo Engineering Corp. (TEC). The plant acceptance had been completed in December, 1983 and since then, the plant has continued the commercial operation satisfactorily with 102-108% production capacity. P.T. AAF and T E C found that the operating temperature profile of catalyst beds in Kellogg's four stage adiabatic quench type ammonia converter was far different from an optimized temperature profile by the computer simulation and carried out the optimization of ammonia converter operation jointly in November, 1985. Under the conditions of constant ammonia production rate, the adjustment of the temperature profile through the catalyst beds had been done by controlling the quench rate to each bed, which results in the synthesis pressure drop by approximately 5 Kg/cm2and accordingly the speed decrease of the Syn. Gas Compressor Turbine by 80 r.p.m. This is equivalent to 0.02-0.03 MMKcaU Ton-NH, saving energy of natural gas. Furthermore, longer catalyst life will be expected due to relatively lower operating temperature of catalyst beds. In this article, an example of the optimization procedure of the quench type Ammonia Converter and the results are introduced. Also included are several points for the optimization of the ammonia converter operation which has contributed to the good performance of the ammonia plant.
PLANT OUTLINE Process Flow

The Mock flow diagram of overall process flow is shown in Figure 1. The process flow for ammonia synthesis loop and the configuration of Ammonia Synthesis Converter is shown in Figure 2 and Figure 3 respectively.

T h e synthesis gas is compressed in a centrifiig, 1 com<I pressor. Recycle gas from the synthesis section is admitted to an interstage wheel in the high pressure casing and goes through the final stages of compression nirxed with the synthesis loop fresh feed. The total compressor discharge is first water cooled and then split into two parallel streams. One stream passes through two ammonia refrigerated chillers operating at successively lower temperatures while the other stream is heat exchanged against the ammonia separator vapor to recover refrigeration. The two streams are then reconbined and further cooled in a third ammonia refrigerated chiller. The chilled vapor-liquid stream then flows to the ammonia separator where condensed ammonia product is disengaged from the converter feed gas. This separation at -23C removes any traces of water of saturation and the remaining carbon oxides entering the synthesis toop with fresh feed. It, in effect, serves to purify the feed gas to the converter which in turn provides for long catalyst life, since all oxygen compounds, including w'<It er capor, are deleterious to the synthesis catalyst. The gas from the separator is heated against a portion of the compressor discharge and then against converter effluent. Converter feed then enters the ammonia synthesis converter. The ammonia synthesis converter consists of a high pressure shell containing a catalyst section and ii heat exchanger. The catalyst section is a cylindrical shell which fits inside the pressure shell of the vessel, leaving an annulus between the two. The catalyst basket conlains four catalyst beds. In order to maintain all the catalyst at an optimum temperature for maximum yield, provision is made to inject feed gas as quench in the space between the beds. The catalyst beds are arranged so that the top bed contains the smallest quantity of catalyst to limit the teinperature rise before the first quench point. Since the temperature gradient is smaller in succeeding beds, the bed sizes are graduated with the largest bed at the bottom. Located above the catalyst section is a heat exchanger which preheats part of the fresh inlet gas against hot reacted gas

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hr
QUENCH

OUTLET INTER CHANGER

SYNTHESIS GAS COMPRESSOR

AMMONIA SEPARAIOR

A*l*ONiA PRODJCT

Figure 2. Process flow for ammonia synthesis loop.

from the last catalyst bed. A by-pass line is provided to permit introduction of feed gas without preheating and provides temperature control to the top catalyst bed. The normal point of entry for the feed is at the bottom of the converter. The gas flows upward between the pressure shell and the wall of the catalyst section. It serves as a cooling medium for the shell and thus receives preheat prior to entering the exchanger. It enters the exchanger at the top of the converter and is preheated against hot effluent by circulating downward around exchanger tubes. For temperature control to the top bed, a portion of the feed gas will be introduced directly to the converter where it by-passes the exchanger and meets the preheated feed. This gas passes downward through the catalyst with a rapid temperature rise as the ammonia reaction proceeds. It passes through a grid supporting the catalyst into a space between the bottom of the first and second beds. At this point, the temperature is reduced and the ammonia content diluted by the injection o f a portion of cold feed gas. In like manner, the gas flows downward through the four beds. In the presence of the iron catalyst, a portion of the total hydrogen and nitrogen combines at a temperature of approximately 400C to 480C and a pressure of 140-147 Kg/cm2Gto yield ammonia in a concentration of about 12% in the effluent from the last catalyst bed. The hot effluent from the bottom bed passes up through a center return pipe into the tubes of the exchanger giving up heat to the incoming fresh feed on the shell side. From the exchanger inside of the converter shell, the converter effluent flows to the boiler feed water heater where the gas is cooled. Then the converter effluent undergoes heat exchange with the feed to the converter, lowering the converter effluent temperature. This cooled gas passes to the interstage of the second casing of the centriftigal compressor for recycle back to the converter, thus completing the synthesis loop. A portion of recycle gas is vented to the fuel system through ammonia recovery unit as continuous purge to control the concentration of methane and argon inerts in the synthesis loop. PIant/Operations Progress (Vol. 6, NO. 2)

U
MAIN INLET
Figure 3. Configuration of ammonia synthesis converter.

Ammonia Synthesis Converter Operating Conditions

Table 1 shows the ammonia converter operating conditions before optimization tests. The ammonia converter was operated steadily in about 103% production rate with 139 Kg/cm2G synthesis pressure at the inlet of the converter. The converter feed gas was preheated to about 432C by the hot effluent from the last catalyst bed at the interchanger provided at the top of the converter and then red to the first catalyst bed directly without mixing with by-pass flow of interchanger. Accordingly all exit temperature of four catalyst beds lay around 480C to 495C which seemed to be relatively high and close to the equilibrium line except the first catalyst bed.
PROCEDURE FOR OPTIMIZATION OF AMMONIA CONVERTER OPERATION Approach for Optimization and Analysis o Ammonia Synthesis by f Computer Simulotion

For the temperature profile optimization of the ammonia converter and the resulting analysis, the computer April, 1987

1 19

TABLE OPERATINC 1. CONDITION BEFORETEST Production Hate (%) Pressure (KG/cm2G) ACV Inlet ACV AP 103

139 5.8
0

Quench Flow Rate (%) of Total Feed Flow (Estiniatrtl) # 1 Bed #2 Bed #3 Bed #4 Bed

10.7
11.6

8.5

simulation program owned by TEC was utilized. The kinetic system of TEC simulation program is based on the kinetic equation advanced by Temkin and Pyzhev. Though there are many factors involved in the ammonia synthesis reaction, the simplified equation (1)for the reaction rate per unit catalyst volume is derived from the basic Tenikin and Pyzhev kinetic equation.

V
Where

A F U ) (F(Zecl) - F(z)) F(P, Z, 10, Y)

(1)

v
A F P
T

=
= = =
=

ze,
I" Y

=
=

reaction rate per unit catiilyst volriine constant fiunction total pressure temperature mole fraction NH,, in gas equilibrium mole fi-action NII, mole fraction inerts coefficient measuring deviation from stoichiometric composition (3yH, and IN,)

first catalyst bed inlet temperature which is indicated in Figure 4. In this manner, the optimized ttbmperature profile prepared b y the computer simulatiori aided the smooth approach of the optimization test. The optimization test was cariied out r d e r the following conditions: (1) Make-up gas flow rate to the synthesis gas compressor and purge gas flow rate were kept unchanged and the ammonia production rate was kept constant accordingly. (2) Quench valve opening ratio for second, third arid fourth catalyst beds was remained unchanged, because each quench valve in the existing operating condition had been already opcmed to the degree of the opening ratio giving the. optimized quench flow. The following shows the procedure for the tcmperatrire profile adjustment: (1) By-pass valve of the interchanger \\.as opened stepwise to get 400C inlet temperatiire of the first catalyst bed. The temperature decrease at the inlet of the first catalyst Iled with one action was aimed at about 5C. (2) Once action was taken, the conditionr were kept at.least 30 minutes confirming the steady ammonia synthesis reaction in order to ;disolutely prevent reaction failure which results i ti synthesis loop shut-down.
O P T I M I Z A T I O N RESULTS Tendency of Temperature Profile Movement on Optimization Test

F(T) and (F(Zeq) - F(z)) in Eq. (1)are function ofteinperature and have general tendency against temperature at some NI-I,?concentration as lielow.

In the course of the test to decrease thc teniperature of the first catalyst bed, the operating conditions ofthe mimonia converter indicated the phenomena such a s : (1) When the inlet temperature of the first catalyst bed was decreased up to 420C, aboirt 5 Kg/cin, reduction of the synthesis pressni-e was observed. On the way to decrease the inlet tcmperatiire (2) from 430C to 415"C, the outlet temperature of the first catalyst bed decreased to a same degree,

LOW

I
LOW

TEMP

HIGH

Accordingly the reaction rate per unit catalyst volume, V, has an optimum point at a temperature point.
Test Procedure

The existing operation conditions of the ainrnoiiia converter were simulated and aiialyzed b y the computer prior to the optimization test. The best way to get an optimized temperature profile through the catalyst beds was discussed and a decision was made to decrease the inlet temperature of the first catalyst bed to aroiiiid 400C from existing 432C by feeding onIy first bed quench flow. Then, the predicted quench flow for each catalyst bed was determined to achieve an optimized temperature profile by the computer simulation on a basis of 400C

0 -----

BEFORE

EST

8 1 1 1 1 1 1 1 ,

SIMULATED AFTER TEST

1 1 1

400

450
TEMP.
("C)

500

Figure 4. Temperature profile through catalyst beds.

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SUMMARY

Before Test
~ _

After

-rest

Production Rate (%) 103 103 Pressure (KGicm'C) Synthesis gas compressor dis145 138 charge 139 134 ACV Inlet 15.2 14.7 Loop AP 5.9 5.5 ACV Al' of Quench Flow Hate (70) Total Feed Flow (Estiniated) 10.7 8.2 #2 Bed 11.6 10.0 #3 Bed 8.5 8.2 #4 Bed 9.74 9.85 Pcr Pass Conversion (%) Calciilated Power (KW) Of. synthesis gas compressor 15,020 14,530 490 Difference Turbine Speed (RPM) 10,160 10,080 Difference 80 0.02-0.03 MM KcdlT-NII, Expected Energy Saving

whereas the outlet temperature of the succeeding catalyst beds remained as they were. ( 3 ) On the way from 415C to 400"C, the synthesis pressure was kept as low as 134 Kg/cm2Gand the outlet temperature for each catalyst bed was decreased according to inlet temperature decrease of the first catalyst bed. The comparison of operating condition after the test with that before test is shown in Table 2 . Figure 4 shows the temperature profile through the catalyst beds with each inlet temperature estimated b y the computer using the measured data.
Optimization Test Results

The optimization test of the ammonia converter operation was carried out during the normal operation, i n ac_ cordance with the temperature profile through the catalyst bed optimized by computer. T h e results, the effects and the expectation in future obtained by this test can be summarized as below. Results: (1) Temperature decrease of catalyst beds by 10-40C (2) Synthesis pressure decrease b y al)out 5 Kg/cmz (3) Synthesis loop pressure drop b y ahoiit 0.5 Kg/cm2 (4) Conversion per pass improvement from 9.74% to 9.85% Effects : (1) 0.02-0.03 MMKcaliTon-NH, energy saving Expectation in future: (1) Longer catalyst life due to relatively lower operating temperature (2) Production rate increase with same energy consumption In short, significant power savings and an expected longer catalyst life.

Makoto Shimagaki holds a B . E . in cheniical engineering from Kyoto University in Japan. H e has over fifteen years experience in animonia, inethano1 and fertilizer process design. H r is currently senior engineer of process engineering department of Toyo Engineering Corp.

The optimization test results under the condition of constant production rate are ta1)ulated in Talile 2 . The remarkable improvement of the ammonia converter operation are: (1) Temperature of the catalyst beds went down to 440-470C by 10-40C t l e c ~ ~ a s e . (2) Synthesis pressure decreased b y about 5 Kg/cm2. (3) Pressure drop through the synthesis loop decreased by about 0.5 Kgicm'. (4) Per pass conversion in the Ammonia converter was improved from 9.74% to 9.85%.
Consideration

Kenjiro Miyashita holds a h1.E. in chemical engineei-ing from Kyushn University in Japan. H e has ten years experience in aniinonia and metharrol procevs design. He is currently lead engineer of process engineering department 1 1 f Toyo Engineering Corp.

The optimized temperature profile could be established during the normal operation by the adjustment of the quench valve. This results in the improvement of per pass conversion. The effect is equivalent to the power reduction of '11,out 490 KW o f t h e synthesis gas compressor which corresponds to 0.02-0.03 MMKcal/Ton-NH, energy saving of natural gas. And further the Ammonia Plant in P.T. AAF will be able to expect the fo!lowing from the plant operation point of view: (1) Longer catalyst life due to relatively lower operating temperature (2) Production rate increase with same natural gas consumption by reducing the purge gas rate This test may make a suggestion to the ammonia manufacturers: (1) It is significant to grope for an optimized temperature profile of the ammonia converter depending on plant by plant operating conditions. (2) Temperature control of the first catalyst I)ed is most important for the optimized operation. Plant/Operations Progress (Vol. 6,

Alita Ilyas joined in P.T. .4sean Aceh Fertilizer (P.T. AAF) in 1980. H e is cnrrently the opcratioir manager of P.T. AAF.

Aslam Kalyubi holds R.E. in chenricd engineering from Institotc, o f T e c h n ( ~ l ( ~Baiidnng in Ingy doncsia. H e is currently developnrent engineer of P T Ascan Aceh Fei-tiIizt>r.

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