PRODUCTION OF AMMONIA FROM SYNTHESIS GAS

PROJECT ADVISOR: Mr. MAZHAR HUSSAIN CO ADVISIR: Mr. UMAIR ASLAM

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11/16/2012 Production of Ammonia from Synthesis Gas

GROUP MEMBERS
NADEEM AKHTAR NAVEED YOUSAF WAQAS NIAZ 2006-CHEM-22 2006-CHEM-96 2006-CHEM-30

SOHAIB AHMED ZAIDI

2006-CHEM-08

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Production of Ammonia from Synthesis Gas

Contents
Literature Survey

Capacity Selection
Process Description and Process Flow Diagram Material Balance

Energy Balance

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Production of Ammonia from Synthesis Gas

Ammonia/Urea Plant, Pak-American Fertilizers, Mianwali

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Literature Survey
Synthesis Gas.
Properties of Ammonia. Hazards of Ammonia.

Manufacturing Processes for Ammonia.

Uses of Ammonia. Production of Ammonia in Pakistan.

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Production of Ammonia from Synthesis Gas

Inventors of Commercial Process for Ammonia

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Production of Ammonia from Synthesis Gas

Molecular structure of Ammonia

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Production of Ammonia from Synthesis Gas

Synthesis Gas
Pure Synthesis Gas used for Ammonia Manufacturing

has following composition.

Componet Hydrogen (H2) Amount 73.65%

Nitrogen (N2) Methane (CH4)

Argon (Ar) Oxides of Carbon (COx) Water Vapours (H2O)
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24.55% 0.8%
100ppm 2-10ppm 0.1ppm
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Production of Ammonia from Synthesis Gas

Properties of Ammonia
Property Chemical Formula CAS Registry Number Odor Molecular Weight Refractive Index Specific Gravity at 0oC Value NH3 7664-41-7 Pungent odor 17.03g/gmol 1.325 0.639 (w.r.t Air)

Melting Point Boiling Point Specific Heat at 0oC

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-77.7oC -33.3oC 2097J/kgK

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Production of Ammonia from Synthesis Gas

Hazards of Ammonia
Ammonia is irritant and corrosive to eyes, skin and

respiratory tract. May cause sever burns to eyes, lungs and skin. Over exposure can cause death. Exposure Limits: 50ppm for 8hours. OSHA Standard

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Manufacturing Processes for Ammonia

Process
Haber Bosch Process

Source of Synthesis Gas

Coal gasification by Steam and Air

Company Introduced
BASAF

Haldor Topsoe Process

Pre Reforming of Higher Hydrocarbons and then Reforming of CH4 with Steam and Air
Reforming of Naphtha

Haldor Topsoe

ICI Process Kellogg Process

ICI Chemicals Limited

Primary reforming of M.W Kellogg (Pullman Natural Gas by Steam Kellogg) and Secondary Reforming by Air
Production of Ammonia from Synthesis Gas 11

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Uses of Ammonia
Use Direct Application Ammonium Nitrate Urea Ammonium Sulfate Ammonium Phosphate Percentage of Global Market 27.1% 18.9% 16% 5.5% 8.8%

Commercial Explosives Fibers-Plastics

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4.0% 12.7%
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Production of Ammonia from Synthesis Gas

Ammonia Production in Pakistan

Company Capacity to Produce Process Ammonia (Tons/Day)
2250 1550 950 850 600 Haldor Topsoe Process Haldor Topsoe Process Kellogg Process Kellogg Process Kellogg Process

Fauji Fertilizer Company Limited Engro Chemicals Pakistan Limited Pak Arab Fertilizers Limited DH Chemicals Limited Pak American Fertilizers Limited
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Production of Ammonia from Synthesis Gas

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Capacity Selection

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Capacity Selection
According to Prospects of Chemical Industry in

Pakistan, Ministry of Industries and Production In the next 10 years there will be a shortage of around 1.2 million MTPY of urea Therefore two plants of urea with average capacity of 600,000 MTPY each would be required to meet the future requirement of Fertilizer
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Capacity Selection
To produce 600,000 MTPY of Urea we will have to

produce around 400,000 MTPY of Ammonia. single plant will have around 1500 MTPD Capacity for Ammonia

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Production of Ammonia from Synthesis Gas

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Process Description & Process Flow Diagram

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Process Description
Three major steps are involved in production of Ammonia

Preparation of Synthesis Gas

Purification of Synthesis Gas

Ammonia Synthesis

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J30001

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Production of Ammonia from Synthesis Gas

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Material Balance

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Production of Ammonia from Synthesis Gas

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Basis & Assumptions

BASIS: One Hour Operation

62.5tons/hr production of ammonia

Percent conversion in the reactor is 26%

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Production of Ammonia from Synthesis Gas

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Absorber
T=620K

K2CO3 + H2O + CO2

2 KHCO3
Hr =-3.2MJJ/KgMol

Stream Number 1

H2 (kg/hr) 13424

N2 (kg/hr) 61407

CO2 (kg/hr) 89760

Ar (kg/hr) 1095.2

CO (kg/hr) 938.8

CH4 (kg/hr) 391.6

H2O (kg/hr)
2646

Total (kg/hr)
169794

13433

61243

385

1100

923

391.8

1680

79263

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Absorber

Stream Number
6 5

K2CO3 (kg/hr)
26463 91803

KHCO3 (kg/hr)
0 20485

H2O (kg/hr)
61748 570567

Total (kg/hr)
88212 682856

3
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15318

619269

227012

861599
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Production of Ammonia from Synthesis Gas

Stripper

Stream Number
3 4 8
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K2CO3 (kg/hr)
15318 91803 26463

KHCO3 (kg/hr)
619269 20485 0

H2O (kg/hr)
227012 570567 61748

Total (kg/hr)
861599 682856 88212
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Production of Ammonia from Synthesis Gas

Stripper
8

Stream Number 9

H2 (kg/hr) 30.72

N2 (kg/hr) 140.91

CO2 (kg/hr.) 89564

CO (kg/hr) 3.51

Ar (kg/hr) 5.04

CH4 (kg/hr) 2.016

H2O (kg/hr) 732.6

Total (kg/hr) 90296

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Methanator
CO2 + 4H2 T=620K Nickel T=620K Hr =-6.3E+6KJ/hr CH4 + 2H2O Hr =-1.6E+6KJ/hr

CO + 3H2

Nickel

CH4 + H2O

Stream Number
12 14
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H2 (kg/hr)
13122 13433

N2 (kg/hr)
61255 61255

CO2 (kg/hr)
0 385

Ar (kg/hr)
1090.3 1090.3

CO (kg/hr)
0 923

CH4 (kg/hr)
1061.2 391.8

H2O (kg/hr)
2598 1683

Total (kg/hr)
79264 79263
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Production of Ammonia from Synthesis Gas

Molecular sieve

Stream Number 20 21

H2 (kg/hr) 13037 13004

N2 (kg/hr) 60850 60695

CO2 (kg/hr) 0 o

Ar (kg/hr) 1088 1088

H2O (kg/hr)

CO (kg/hr) 0 0

CH4 (kg/hr) 1054 1051

Total (kg/hr) 76029 76026

27

26.39 0

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Production of Ammonia from Synthesis Gas

Reactor
P=20265Kpa, T=727K 3H2 +N2 Ruthenium Hr=-1.7E+8KJ/hr
Stream Number H2 (kg/hr) N2 (kg/hr) CO2 (kg/hr) Ar (kg/hr) CO (kg/hr)

31

2NH3

21 24 25

30

CH4 (kg/hr)

NH3 (kg/hr)

Total (kg/hr) 74760 299718

21 24

13013 41652

60696 193497

0 0

1086 32967

0 0

1051 30506

0 1096

25 30
31
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29670 3.0
29514

137607 237
136875

0 0
0

31912 103
31810

0 0
0

26298 71
24753

71557 62314
8079

297044 62728
231031
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Production of Ammonia from Synthesis Gas

Overall material balance

Carbon Dioxide 90296.8kg/hr

Synthesis Gas

169794kg/hr

Ammonia 62727kg/hr

Ammonia Plant

Water Condensate 16566kg/hr

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Energy Balance

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Reference State
250C Temperature & 1 atm (101325 Pa) Pressure

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Absorber

Streams Number 1 2 3 5 6
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Temperature (K) 348 343 392 387 343

Production of Ammonia from Synthesis Gas

Enthalpy (J/sec) 5702767.2 5800532.4 779455.2787 162226333 9487994.672

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Stripper
E2

Streams Number 3 4 8 9 10 11
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Temperature (K) 392 343 401 311 390 390

Enthalpy (J/sec) 779455.2787 162226333 21716965.58 292964.88 136500 136762

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Production of Ammonia from Synthesis Gas

Methanator
E3 2 12

Streams Number

Temperature (K) 343 620 373 589 314

Production of Ammonia from Synthesis Gas

Enthalpy (J/sec) 5800532.4 23407739.91 5382014.733 21560688.97 1131547.179

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2
12

13
14 15
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Molecular Sieve

Streams Number 20

Temperature (K)

Enthalpy (J/sec)

277.4
21 277.4

-1432205.588
-1420392.633

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Reactor
E7

Streams Number 23 24 25 26
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Temperature (K) 327 524

Enthalpy (J/sec) 7170535.979 58723498.29

727
551
Production of Ammonia from Synthesis Gas

106654776
53180340.93
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THANK YOU

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