AMMONIA PLANT

Ammonia plant based on Pullmann Kellogg catalytic steam reforming

process was commissioned in September 1978. The plant has a name
plate ammonia production capacity of 910 MTPD. A petrocarbon
designed cryogenic purge gas recovery unit was installed and
commissioned in February 1986 which enhanced the plant capacity to
960 MTPD. Replacement of primary reformer tubes harps and Haldor
Topsoe designed radial flow (S-200) type converter catalyst baskets
(instead of Kellogg designed axial flow quench type old baskets) were
made in special shut-down 1993. Current plant status and operational
problems are discussed below;
1.1

Hydrotreater

Hydrotreater catalyst was replaced in December 1997, its performance

is satisfactory. Pressure drop across catalyst bed is about 0.2 kg/cm 2,
yet sulfur slippage is on higher side (0.65 ppm).
1.2

Primary Reformer

Tube harps of primary reformer were replaced in December 1993 and

since then their performance is satisfactory. Welding of riser no. 1
failed in 1995 during start-up and same was replaced.
Primary reformer catalyst (ICI 57-4) was replaced in January 1997 and
its performance is satisfactory. Primary reformer pressure drop is 2.6
kg/cm2 and thermodynamic approach to equilibrium is about 3 C,

which is satisfactory. Catalyst replacement is scheduled in the year

2002.
Cleaning of the conversion section coils of the furnace was carried out
in the annual turn-around and it has resulted in energy conservation
from improved heat transfer and reduced thermal pollution, leading to
additional steam generation of comparatively lower cost and reduced
flue gas temperature (presently 263 C which was previously 296 C
with dampeners in closed position).
1.3

Secondary reformer

Present charge of secondary reformer catalyst (ICI 54-4) is in service

since December 1993 and its performance is satisfactory. Methane
slippage currently ranges 0.28 ~ 0.38 %, while pressure drop is about
0.3 kg/cm2. Catalyst is scheduled to be replaced in the year 2003.
1.4

High temperature shift converter

High temperature shift converter catalyst (ICI 73-3) was replaced in

May 1997 and since then it had performed well. Carbon monoxide in
HTS effluent is about 1.6 % and pressure drop is 0.3 kg/cm 2. Catalyst
replacement is scheduled in the year 2001/2002.
1.5

Low temperature shift converter

Low temperature shift converter catalyst was replaced in May 1997

and since then its performance is good. The catalyst is expected to
give three years life. Present carbon monoxide slippage is 0.24 % with

thermodynamic equilibrium approach at 5 C and catalyst will be

replaced in the year 2000/2001.
1.6

Carbon dioxide removal

Performance of carbon dioxide removal system (Catacarb system) is

satisfactory,

however

during

inspection

in

April

1998,

severe

pitting/corrosion was observed at bottom and first bed of the absorber

(101-E). This was rectified by sandblasting the effected portion and
application of an epoxy cement preparation. Corroded distributor/riser
and beam were also replaced. Performance of Catacarb reboilers (105C & 113-C) is not up to the mark due to fouling of these exchangers.
1.7

Methanator

Methanator catalyst (ICI 11-3) was replaced in December 1993 and is

performing well. Catalyst replacement is envisaged in the year 2003.
1.8

Ammonia converters

Ammonia converter shell (105-DA) inspection in January, 1998 by M/s

Condition Assessment & Testing Service, South Africa revealed defects
indications to be the original fabrication welding defects and not due to
hydrogen attacks, however as per recommendations, re-inspection of
circumferential welds were arranged in the recent annual turn-around
(January, 1999). Actual remaining life has been estimated as beyond
10 years.

Synthesis catalyst carry-over to synthesis loop circuit (boiler feed

water/converter effluent heat exchanger (123-C), converter feed/
effluent heat exchanger (121-C) and ammonia separators 106-F, 107-F
and 108-F)) was observed during annual turnaround 1999 (January,
1999). Total 12 drums (approx 5000 kg) catalyst was removed from
these vessels. M/s Haldor Topsoe (HTAS) were contacted about the
problem of the catalyst carryover, who after considering the relevant
plant data, informed that the problem had occurred due to failure of
second

bed

incorporation

centre
of

two

screen

of

additional

converter
separators

B.

HTAS

with

suggested

some

circuit

modification for accumulation of carried over catalyst, as an interim

measure for disruption free plant continued operation. However
replacement of second bed center screen and synthesis catalyst had
been informed to be the ultimate solution of the problem. Procurement
of requisite materials and services for necessary replacements has also
been taken in hand.
Plant is operating at consistent load of 970-980 MTPD since February
24th, 1999 after completion of annual turnaround, except for a 70
hours plant downtime in May, 1999 for rectification of leakage from
main flange of HTS Effluent/Methanator Feed Heat Exchanger.
HTAS is being informed of plant operational conditions for their
evaluation and further advice.

1.9

Synthesis loop exchangers

These heat exchangers converter influent/effluent (121-C) and

converter effluent/boiler feed water exchanger (123-C) have been
replaced in the recent annual turnaround (January, 1999).
1.10
1.11
1.12