Improve Energy Efficiency & Capacity by Integrating Synloop & Process Compressors in Ammonia Plants

Abstract A revamp study of a stretched Ammonia plant is presented (already revamped twice from 1100 stpd to 1500 stpd to 1750 stpd) for an additional 11% capacity along with 8% reduction in Energy consumption. The current operation at 1750 stpd maxed out the operation of Primary Reformer as well all the major compressors- to the limits of their design rating- including Process Air Compressor, Make Up Gas compressor & Refrigeration Compressor. A new integrated scheme between Synloop & Compressors allowed offloading both the Primary Reformer & all major compressors without any increase in compression power or any hardware upgrades. Only a few proven upgrades in the Primary Reformer were required. As a result, the production could be further increased by additional 11% along with energy improvement of ~8% for a stretched Ammonia plant- with an attractive payback. The key operating parameters of the Base & Revamp case along with the major hardware changes will be presented along with overall economics.