DYNAMIC MODE CONTROLLER DESIGN OF AMMONIA PRODUCTION UNIT

Abstract

This thesis designs dynamic mode controllers for ammonia unit to increase production, reduce troubleshooting time and automate the plant. The study begins by reviewing literature and selecting the best approach for dynamic calculation. A comprehensive literature review covers process basics, methods for dynamic simulation, comparison of different approaches and choosing the best approach. This literature evaluation lays the groundwork for the planned study and future research. Thesis then presents a process flow diagram and details about process and dynamic procedures. The specifications and design criteria for different equipment such feed tanks, centrifugal pumps, pre-heaters, packed bed reactors, and columns are carefully studied. Equipment undergoes material and energy balances. Thesis also covers critical equipment component design and specifications. The design, function, and design considerations of shell-and-tube heat exchangers are examined. Discussions include packed-bed reactor design and reactions. Aspen Hysys was used for process simulation and for process dynamics and behaviour, providing a complete picture. Component lists, fluid packages, parameters, and reactor and reactor requirements are simulated. Simulations reveal process performance and enable optimization. Operation and process monitoring require instrumentation and control. Ratio and cascade control solutions are described for process stability and production optimization. This thesis assesses primary equipment costs, total investment, direct production expenses, income generation, and payback period for any industrial operation. These financial studies reveal the parallel ammonia plant's economic viability. Hazard and Operability (HAZOP) research identifies process hazards and recommends risk assessment and reduction. Explaining HAZOP and identifying process hazards ensures safety and regulatory compliance. This final-year thesis suggests designing dynamic mode controllers at various points of ammonia plant gives boost production capacity and eliminate bottlenecks. Process overview, material and energy balance calculations, equipment design, simulation, instrumentation and control strategies, cost estimation, and HAZOP studies are examined in detail to inform future research