DESIGN IMPROVEMENT ON THE AMMONIA PLANT WITH AN EMPHASIS ON ENERGY EFFICIENCY

Abstract

Ammonia is a highly valued compound utilized in a wide array of applications, particularly in the fertilizer industry for the production of various organic and inorganic compounds. Ammonia is traditionally produced using the Haber-Bosch process, which yields approximately 180 million tons annually worldwide. An ammonia plant typically requires several key inputs: natural gas, derived from fossil fuels, to obtain hydrogen as a raw material; raw water from off-site or demineralized water from steam drums; electric power generated from heat released within the plant; and compressed atmospheric air. These components are integrated within the plant, resulting in the production of steam, ammonia, and carbon dioxide, which are subsequently used for the production of urea or nitrogenous fertilizers. In the Haber-Bosch process, ammonia is synthesized through a catalytic reaction between hydrogen and nitrogen gas, accompanied by the release of heat. This reaction occurs under extreme operating conditions of 350-500 ℃ and 150-300 bar pressure, facilitated by an iron-based catalyst to accelerate ammonia synthesis. Oxygenated compounds such as water, carbon monoxide, and carbon dioxide are removed prior to the ammonia converter to protect the catalyst from poisoning and to maximize production efficiency. Ammonia production operates under highly demanding conditions of temperature and pressure, making it energy-intensive. The primary reformer, in particular, consumes about eighty percent of the fuel to convert higher-order hydrocarbons and natural gas into hydrogen, the main reactant. To enhance energy efficiency, the objective is to incorporate a pre-reformer in the existing ammonia plant of FatimaFert Limited. This addition will reduce fuel consumption in the radiant section of the primary reformer, improving overall energy efficiency and lessening the load on the primary reformer’s radiant section.