SUMMER INTERNSHIP REPORT ON

“OVERVIEW OF AMMONIA PROCESS PLANT”

KANPUR FERTILIZERS AND CEMENT LIMITED,
(JAYPEE GROUP)

Submitted to: Submitted by:

H.C.L. DAS SIR UTKARSH VAJPAI
(CGM, AMMONIA PROCESS)

Guided By: College:

SONU DHAKAD SIR H.B.T.U. KANPUR

Roll Number:
1504551044

Department of Chemical engineering, [Link]. KANPUR

 CERTIFICATE
DEPARTMENT OF CHEMICAL ENGINEERING

HARCOURT BUTLER TECHNICAL UNIVERSITY

KANPUR- 208002

BONAFIDE CERTIFICATE

Certificate that this project is “INDUSTRIAL TRAINING AT KANPUR FERTILIZERS AND

CEMENT LIMITED” is the bonafide work of UTKARSH VAJPAI who carried out the project under my
supervision. This is to further to the best of my knowledge, that this project has not been carried out earlier
in this vocational training at KANPUR FERTILIZERS AND CEMENT LIMITED.

SIGNATURE AND SEAL

NAME OF SUPERVISOR

It is to be certified that above mentioned project has been duly carried out as per the norms of the college
and training.

SIGNATURE AND SEAL

HEAD OF DEPARTMENT

Department of Chemical engineering, [Link]. KANPUR

 ACKNOWLEDGEMENT

The internship opportunity I had with KFCL, KANPUR was a great chance for learning and gaining
practical knowledge. Therefore, I consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people and
professionals who led me through this internship period.

I would like to acknowledge my profound and sincere gratitude to Mr.V.K. Mehta Sir (Vice president,
Production), Mr. H.C.L. Das Sir (CGM, Ammonia Process) and Mr. V.K. Shahni Sir (GM, Ammonia
Process) who guided and helped me to finish this task successfully.

I express my sincere thanks to Mr. Sonu Dhakad Sir, my mentor for his outstanding guidance and moral
support at times whenever necessary during this period of Internship.

I also wish to express my sincere regards and deep sense of gratitude to Dr. S.K. Gupta Sir, H.O.D.
(Department. of Chemical Engineering, HBTU) and the rest of the faculty members for their constant
support and allowance for a productive and worthy industrial exposure.

I offer thanks and gratitude to all the respondents who extended their co-operation by answering all the
queries on time and helping me in the internship period.

Department of Chemical engineering, [Link]. KANPUR

 CONTENTS
Title Page No.

1. Plant Overview 1

2. Ammonia Introduction 2

3. NG/PA Heater 5

4. Desulphurization 6

5. Reforming (Natural Gas) 7

6. MGG (Make Gas Generator) 15

6. Shift conversion (CO) 15

7. CO2 Removal 16

8. Methanator 16

9. Compressor 17

10. Ammonia Convertor 19

11. Deaerators 23

12. Types of Reboilers 24

13. Types of Pumps 25

14. Pump Priming 26

15. PROJECT 28

16. Discussion 49

Department of Chemical engineering, [Link]. KANPUR

1) PLANT OVERVIEW
Jaypee group is an industrial conglomerate which is involved in well diversified infrastructure conglomerate
with business interests in Engineering & Construction, fertilizer Power, Cement, Real Estate, Hospitality,
Expressways, IT, Sports & Education (not-for-profit). The group has made investment in fertilizer business
through its subsidiary, Jaypee Fertilizers & Industries Limited (JFIL) JFIL has participated as a strategic
investor in the revival scheme of the Kanpur Fertilizer Plant of Duncan Industries Ltd.
KFCL is now owned by Jaypee Uttar Bharat Vikas Private Limited (JUBVPL), which is a joint venture
promoted by Jaypee Fertilizers & Industries Limited and Duncans (DIL) promoters' group company, ISG
Traders Limited.
The three ammonia production plants are Natural Gas based plant based on ICI technology each plant
capacity is 430 TPD. The fertilizer plant of KFCL is based on TOYO technology and three unit each of plant
and capacity 730 TPD.

KFCL is a leading Manufacturer & Supplier ol Fertilizers, ammonium sulphate, urea from Kanpur, Uttar
Pradesh From safety point of view, the industry is listed under “MAJOR ACCIDENTAL HAZARD
INDUSTRY”
Production of Chand Chaap Urea- India's one of the largest ammonia urea complex was an amazing
experience for the author. With an industrial training report over Ammonia Production Plant chemistry and
performance improvement parameters, the author has compiled the information on plant design of ammonia
production, chemistry and operation which could serve as a comprehensive study aid on the subject. The
recommendations generated are but most effective to date, which should be considered with economic
feasibility.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 1

There are 4 sections in the plant-
1. Ammonia Production Plant (3 units)
2. Urea Production Plant (3 units )
3. CPP (Captive power plants)
4. OFF SITES
4.1 Water Treatment Plant
4.2 Effluent Treatment Plant
4.3 Inert Gas Plant
4.4 Cooling Tower
4.5 Refrigeration System
4.6 Ammonia Storage
4.7 Air Station

2) AMMONIA INTRODUCTION

Ammonia is one of the most important basic chemical of the world, ranking with materials such as sulfuric
acid and sodium carbonate In the fertilizer field, anhydrous ammonia itself has become the major supplier of
the fertilizer nitrogen in India and it is also important inter mediate production of more complex chemicals.
The major use of ammonia, both directly and indirectly, is as an intermediate in the fertilizer area There are
many other uses, although relatively minor, in both organic and inorganic chemical production for e.g.
manufacturing of explosives and acrylonitrile. The main function of ammonia, both as an end product and as
an intermediate, is to supply nitrogen in a relative form Ammonia is unique in that, unlike the other basic
chemicals, the main constituents, nitrogen is readily available without need for transport and in unlimited
quantity.
Unfortunately, element nitrogen is a very uncreative and inert material, of little use unless converted to a
chemically reactive form. To accomplish such conversion, it has been necessary to adopt extremes of
temperature and pressure that are not required for the other basic materials. Conversion of atmospheric
nitrogen to usable form is often referred to as “Nitrogen Fixation” That is converting to solid or liquid form
i.e. reactive enough to be useful. Some plants have roots nodules in which fixation of nitrogen by
microbiological means takes place during the growing process Unfortunately, only a few plant types can do
this moreover, the process is so slow that it is not adequate in modern farming practice The production of
ammonia has been found to be more economical than either fixation by plants or production other nitrogen
compounds.
Since nitrogen is so readily available, the main problem is getting hydrogen that will react with it to form
ammonia, water, also readily available is an obvious raw material for making hydrogen. Therefore, the
starting material of main importance is the hydrocarbon or coal use to tie up oxygen in the water molecule,
thereby reading hydrogen. The major materials used the order of importance are natural, liquid hydrocarbon.
Department of Chemical Engineering, H.B.T.U. Kanpur Page 2
All are widely available, but bringing them to surface, purifying and transporting them involve costs. Each
differs in delivered cost and in processing difficulty in hydrogen production.
A direct application of ammonia as a fertilizer involved injection of ammonia under the sot face of the soil
where’ high pressure ammonia after release of pressure is held by adsorption on soil practical until
converted by soil or plant mechanisms to other forms. This unusual application procedure of ammonia (82%
nitrogen) has associated with some hazards because the liquid is handled under pressure and it is toxic
chemical Ammonia contributes significantly to the nutritional needs of terrestrial organisms by serving as a
precursor to foodstuffs and fertilizers. It is either directly or indirectly building block for synthesis of many
pharmaceuticals. In spite of its wide usage, ammonia is both caustic as well as hazardous.

Properties of Ammonia (End Product of Ammonia Plants)

 Molecular Wt- 17gm/mol

 Boiling Point - (-)33.34°C

 Freezing Point- (-) 77.7°C

 Solubility - Soluble in Chloroform, Ether,Ethanol

 Density - 0.769 Kg/m3 atSTP

 pH indicator shows a value of 11.6

 Formula : NH3 , Compound of Nitrogen andHydrogen

 Colorless Gas

 Pungent Smell

 Natural occurrence

 Soluble In Water

 Explosive Nature

4NH3 +3O2 2N2 + 6H2O (g) (ΔH°r= −1267.20kJ/mol)

Department of Chemical Engineering, H.B.T.U. Kanpur Page 3

Overview of different stages for Ammonia Formation

NATURAL GAS INTRODUCED TO PLANT

 The Natural Gas (NG) received at GAIL Metering Station, situated at KFCL PLANT
premises, is received at 70- 80 Kg/Cm2 and400C.

 It is then stepped down to 41.50 Kg/Cm2and sent to the battery limit of KFCL,Panki.

FUNCTION OF NATURAL GAS SEPARATOR

 Heavy hydrocarbon separates out.

 Operating Condition:

39.2 kg/cm2 at 24°C

 The natural gas pressure is controlled to maintain a constant flow to the reformer.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 4

 Natural Gas Pre heater

 U tube heat exchanger with 92 tubes

 From shell side natural gas enters while IP steam from tube side.

NATURAL GAS/PROCESS AIR HEATER (NG/PA Heater)

It is a Natural draught Furnace. Excess Air: 10% of excess air is given to process the fuel in
the heater. There are 2 process air coils are located in radiation section.
There coils are installed in the furnace for natural gas feed preheating: two of them located in
the convection section of furnace and the third located in the radiant section of the furnace.
NOx emission allowable on dry basis: 140mg/Nm3
 Burners: There are 4 Main Burners and each main burner has one pilot burner each totaling 4
Pilot Burners.
 Fuel: Natural Gas is used as a fuel.
 Negative Pressure: The furnace draft pressure is maintained at (-) 2.5 to (-) 4mmwc.
 The mixture of natural gas and hydrogen flows downward through the desulphurization
converter.

Figure 1 : NGPA HEATER

Department of Chemical Engineering, H.B.T.U. Kanpur Page 5

 HDS (Desulphurization Converter) or (Hydrogen Desulphurizer)

Inlet composition of Desulphurization Converter feed:

CH4: 98.64%, C2H4: 1.15%,N2: 0.10, S : <10 ppm (Approx.)

Necessity of HDS Converter

 The Primary Reforming catalyst is poisoned by sulphur and for this reason all sulphur
compounds need to be removed from the incoming natural gas.

Reactions Involved:
The natural gas is desulphurized in two stages:
 First Stage: Preliminary Hydrogenation of “Non-Reactive” sulphurcompounds.
In the presence of hydrogen to about 3800C and passing over Catalyst bed, the “Non-Reactive” sulphur
compounds are transformed to H2S.
The chemical reactions involved are:-
RSH + H2 RH + H2S

R2S + 2H2 2RH + H2S

R2S2 + 3H2  2RH + 2H2S

 Second Stage: Absorption ofH2S.
Following the hydrogenation of sulphurcompounds, H2S
formed is absorbed by the Zinc Oxide according to the
following reaction:
ZnO+H2S  ZnS + H2O
16 m3 of catalyst is loaded in the desulphurization Converter. Figure – Desulphuriser
Outlet Composition Of Desulphurised Gas:
CH4: 98.64%, C2H4:1.15%, N2: 0.10%, S: < 0.5ppm (approx)

CATALYST USED AT KFCL:

Name of Catalyst – Actisorb-G1.

The composition of the catalyst includes ZnO(85-90%),CuO (1.8-2.1%) and MoO3(3.5-3.9%)

Department of Chemical Engineering, H.B.T.U. Kanpur Page 6

 NATURAL GAS PRIMARY STEAM REFORMING
Reforming Section – To produce synthesis gas of the desired composition and quality such that
ammonia synthesis section can produce ammonia
PRIMARY REFORMER
Why require Primary Reformer?
 It is required to convert hydrocarbon into a mixture of CO2, CO and H2.
 The first reaction of the ammonia plant occurs over here.
 It reduces the methane slip from 98% to around 12%.

Figure – Primary Reformer

Department of Chemical Engineering, H.B.T.U. Kanpur Page 7

Primary Reformer Feed Pattern

Fuel System In Primary Reformer

 It is basically a Heat Exchanger (Heat comes from Reformer Furnace)
 Its function is to heat up Process Gas.
 It contains catalyst and carries out reactions inside the tube.
 Has combustion on the shell side.
 Multiple fuel supply points and heat transfer is basically by radiation.
 Rectangular insulated structure.
 Mechanical draft furnace.
 Mild steel refractory lined furnace.

REFORMER FURNACE
 3 Major types of reformer: Terrace wall, Side Fired and Top Fired.
 Each tackles the duty in different ways.

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 Figure: Reformer furnace types

REFORMER FURNACE HEAT TRANSFER – TOP FIRED

 Nearly all heat transfer is by radiation.
 Radiation from the flue gases to the tubes.
 Little direct radiation from refractory to the tube.
 Refractory acts as reflector.
 Radiation from flame to tube top.

A) BASIC REACTIONCHEMISTRY
The desulphurized natural gas is reacted with steam over the reforming catalyst to produce a gas
containing H2, CO2, CO and CH4.
Composition of inlet feed:-
CH4:98.64%, C2H4:1.15%, N2: 0.10%, S: 0.5 ppm(approx)

There are two reactions: Reforming and shift

1. Steam Reforming Reaction (Very Endothermic)
CH4+ H2O  CO+ 3H2 (endothermic)
2. Gas Shift Reaction (Slightly Exothermic)
CO+ H2O  CO2 +H2 (exothermic)

Overall endothermic catalytic reaction

B) CARBON FORMATION
There can be carbon layout on the catalyst resulting into high pressure drop across the tubes,
further more the flow may siege through the tubes. The tubes may over heat and loose
mechanical/thermal strength. The possible causes of carbon formation are:-
 The gasification rate is lower than the carbon formation
 Steam/Carbon molar ratio is too low.
 Catalyst is not active enough.
Department of Chemical Engineering, H.B.T.U. Kanpur Page 9
  Presence of significantly amount Higher Hydrocarbon in gas.
 Tube walls are too hot (High Temperature Flux)
 Catalyst has Poor Heat transfer characteristics.

The formation of carbon on the Primary Reformer catalyst may occur in two ways:
 By thermal decomposition of hydrocarbons (CRACKING OF HYDROCARBONS)
This carbon forming reaction is comparatively slow and leads to the decomposition of sooty carbon.

CH4  C + 2H2 (Thermal Cracking)

C2H6  2C + 3H2 etc. (Thermal Cracking)

Usually this carbon can be removed by prolonged heating of catalyst with a mixture of Steam and
Air at about750OC.
 By thermal equilibrium in the system, for example by the simultaneous
equations:

BOUDARD REACTION
2CO  CO2 + C
CO REDUCTION
CO+H2  C + H2O
GASIFICATION REACTION
C+ H2O  CO + H2

 EFFECT OF CARBON FORMATION

1. Physical Poisoning
- Carbon covers the catalyst Surface and also penetrates in the pores.
2. Pressure Drop increase
- Carbon fills catalyst bed voids
- Carbon formed will weaken or break the catalyst
3. Hot Tubes
- Carbon lay down on the inside of the Tube wall
- Lower catalyst activity.
- Resistance to flow, catalyst disintegration or carbon
formation The following helps to arrest carbon layout on
catalyst:
 Use better and active catalyst
 Reduce levels of higher hydrocarbon

Department of Chemical Engineering, H.B.T.U. Kanpur Page 10

  Maintain the required steam/carbon ratio
 Use of potash doped Catalyst reduces the probability of carbon formation
 The Exit temperature is the operating variable that has the most pronounced effect
on the reaction equilibrium. This variable is controlled by regulating the amount of
fuel fired in the furnace.

PRIMARY REFORMER TUBES

 5” ID alloy steel catalyst tubes
 4 rows having 33 tubes in each (132tubes)
 Tube Wall Temperature / Tube Skin Temperature is measured by optical pyrometer.

 CATALYST REQUIREMENTS

 High and stable activity – Low

CH4 slip, Lower tube wall
temperature , reduced fuel usage

 Low pressure drop

 Good heat Transfer – reduced wall Temperature, small sized
catalyst, Shape must be optimized for high heat transfer with
lowed
 High resistance to carbon formation
 Also area of concern:
- Geometrical surface area
- Packing in the tube
- Breakage characteristics

CATALYST USED:
Generally two kinds of catalyst used in primary reformer for gas reforming:
1. Refromax250 (Top)
2. Refromax 330 LDP(Bottom)

Composition of the catalyst :

REFROMAX 250 [NiO(18%), K2O(1.8%) SiO2 (0.15%)]
REFROMAX 330[NiO(16%) SO2 (.15%) SiO2 (.05%) Support Bed(Balance) Al2O3/ CaO]

Outlet Composition:H2: 68%, N2: 0.33, CH4:10% ,CO: 8% , CO2: 11.6%

Department of Chemical Engineering, H.B.T.U. Kanpur Page 11

  Pigtails in bottom of tubes connect the tubes to collective header known as Hot Collector.
The figure shows the arrangement of pigtails being connected to hot collector. These pigtails are
helpful to bear expansion and contraction.
 Counter weights – to balance the header

Figure : Primary reformer bottom

PRIMARY REFORMER BURNERS

 Downward firing arch burners

 9 burners in each of 5 rows (45 burners) between the reforming tube sharps.

 There are 18 Side burners and 27 Center Burners. Heat released per burner is as follows:

 Side Burners: 1.040 Gal/h

 Center Burners: 1.73Gcal/h

Steam/Carbon Ratio Calculation

Carbon Number = Carbon Atoms in feed NG.
Steam/Carbon Ratio = moles of Steam per mole of
carbon

Here the Steam to Carbon ratio is kept close to 3.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 12

 SECONDARY REFORMERMING
 Function of Secondary Reformer?
 Air is injected to Secondary reformer to perform the following duties:-
- To provide N2 for ammonia production
- To reduce methane slip to a very low-level
- Heat Generated is used for HP Steam Generation
 INLET FEEDCOMPOSITION
H2: 67.89%, N2: 0.44, CH4:12.44%, CO: 9.74%, CO2: 9.48%
 The primary reformer effluent, partially reformed gas, flows through the two transfer lines
to the Secondary Reformer D-202. The air is compressed in a motor driven centrifugal air
compressor J-201 and discharged at 32.5 Kg/cm2g & 180°C. The temperature of process
air is raised in PA/NG Heater. The air flows through the air coils B-1203 located in the
radiant section of furnace.
 Process air is fed to secondary reformer at a pressure of 31.5Kg/cm2and a temperature of
485OC. The air flow rate to the reformer is controlled by FIC-40. Process air flow may be
closed off to the Secondary Reformer by the operation of trip valves Trip-29VA and Trip-
29VB, which is part of the reformer, fail safe shutdown circuit.
 The process air enters the plenum chamber of the air mixer. The effluent from the reformer
is at a temperature level significantly greater than the auto ignition temperature of any of
the combustibles contained therein.
Reactions Involved:
Non catalytic reaction
CH4+ 2O2 --> CO2 +2H2
Catalytic reaction
CH4+ H2O --> CO +3H2
CO2+ H2 --> CO +H2O
CH4+CO2 --> 2CO +2H2
 Catalytic exothermic reaction
 Conversion of CH4 is continued in auto thermal condition.
 Partially burning of primary reformed gas
 Mild steel refractory lined
 Catalyst: 14.2 m3NiO based (single bed)
 Support : layer of brown fused alumina chips

Department of Chemical Engineering, H.B.T.U. Kanpur Page 13

  Pressure drop across the bed : 0.6kg/cm2

Three Key Components for Secondary Reformer

 Burner Design (Air gun)
 Mixing Volume
 Catalyst Bed
CATALYST USED:
There are two kinds of catalyst used in Secondary reformer:

1. REFROMAX 400GG (Top) - 10% [Ni(9%) Al2O3(FOR BALANCE)]

2. REROMAX 330 LDP (BOTTOM)- 90%[NiO(9-10%)AND CaO(10-14%)]

 General Problems:
-Poisoning
-Carbon formation
-Air leaks

 OUTLETCOMPOSITION

CO2:7.09%, CO:13.7 %, N2:22.75%, H2: 56.25% CH4 0.44%

Department of Chemical Engineering, H.B.T.U. Kanpur Page 14

 MAKE GAS GENERATOR
 Two pass in line tube in shell exchanger.
 TIC 47, temperature controlled internal bypass valve on the second pass
 Down comers to take water from water/mud drum
 Risers to give steam to steamdrum

Figure: Make gas generator

HIGH TEMPERATURE SHIFT CONVERTOR

 HTS Role: Conversion of CO to water gas.
 REACTION INVOLVED:
CO + H2O --> CO2 +H2 (+) 890.3KJ
The above reaction is called SHIFT REACTION.
 Operating Condition:
 Inlet pressure: 26.5kg/cm2
 Outlet pressure: 26.2kg/cm2
 Inlet temperature: 340oC
 Outlet temperature: 416.4oC
 Type of reaction: Exothermic
 CATALYST USED: SHIFTMAX-120

CONTITUENTS PERCENTAGE
COMPOSITION
Chromium Oxide 8

Copper Oxide 1.8

Ferric Oxide Balance

INLET COMPOSITION OF REFOMERED GAS:

CH4: 0.44% CO2:7.09% CO:13.7% N2:22.75% H2:56.25% Ar:0.29%
OUTLET COMPOSITION SHIFT GAS:
CH4:0.4 %, CO 2: 15.52%, CO:2.89%, N2:20.7%, H2:60.23%, Ar:0.26%
Department of Chemical Engineering, H.B.T.U. Kanpur Page 15
 LOW TEMPERATURE SHIFT CONVERTER
 CO is converted to CO2 at Low temperature from 2.89% to0.21%.
 Another shift converter for CO conversion of residual CO after HTS.
 REACTION INVOLVED:

An Exothermic reaction which occurs in this section is:

CO + H2O  CO2 +H2 (+) 890.3KJ

Why CO2 is required to remove?

 It is poisonous for synthesis converter catalyst.
 It’s a by-product to be used for Urea Production.
 Used as a product of its own
- Carbonated drinks
- Refrigeration Units
 Used for Methanol Production
METHODS FOR REMOVAL OF CO2
- Monoethanolamine(MEA)
- Benfield Solution (Hot Potassiumcarbonate)
- GiamarkoVetrocoke
- MDEA
METHANATOR
 Methanation is a process in which the residual CO & CO2 slipped from LT Shift Converter
and CO2 Absorber respectively are converted into METHANE ( CH4). CO & CO2oxidise
Ammonia Synthesis catalyst deactivate thus the gases are known as poison to referred
catalyst. Methanation reaction is highly Exothermic Reaction.
 The gas from CO2 removal section is fed to Ammonia Synthesis loop i.e. Decarbonated gas
must have the value of CO and CO2 less than 5 ppm. Methanation is required to bring down
the tolerable level of CO and CO2 less than 5 ppm to avoid ammonia synthesis catalyst
poisoning.
REACTION INVOLVED :
CO+ 3H2  CH4+ H2O

CO2+ 4H2  CH4+ 2H2O

The above reactions are called Methanation Reaction that occurs at 280 0C and 23.1 kg/cm2g.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 16

 SYNGAS COMPRESSOR
 There are two Reciprocating compressors for each plant.
 3 stage compressor and 1 recirculator stage.
 1st, 2nd and circulator stages are double acting.
 3rd stage is single acting (with balance line to minimize vibrations).
 Water cooled jackets are provided to each stage.

 Syn gas is compressed from21.9kg/cm2to270kg/cm2in three stages.

 Circulator stage compresses 258 kg/cm2 to 270kg/cm2.
 1st stage provided with three pockets to turn down from 100 % to 70%.
 Pocket position :-
 3 pocket open = 70 %load.
 2 side pockets x 7.5% each =15%
 Central pocket =15%
 Make up gas flow rate = 49,910Nm3.
 Lubricating Oil:-
 Menzel pump delivers oil to stuffing box, tail rod @ 300 kg/cm2max.
 Lube oil circulation @ 5kg/cm2.
 Barring motor :-
 Used during startup to provide low rpm to pistons.
 Checks proper lubrication and proper functioning before engaging main motor (300
rpm).
Alarms/Trips
 1st stage suction pressure Low (10 kg/cm2g)
 Pressure difference across 2nd stage High (120 kg/cm2g)
 Motor cooling air temp High (70°C)
 Lube oil pressure of filter exit Low (1.7 kg/cm2g)
 High vibration.
 Primary catch pot level High.
 Syn-gas cooler catch pot level High.
 Motor bearing temp High.
 Circulation delivery high temp High

Department of Chemical Engineering, H.B.T.U. Kanpur Page 17

 Process Air Compressor

A centrifugal compressor achieves a pressure rise by adding velocity to fluid through the
impeller. This kinetic energy is then converted to increase in potential energy through a
diffuser. Centrifugal compressor is used for high flow rate and low discharge pressure
applications.

 There are two casing LP and HP.

- LP casing has 6 stages and 8impellers.
- HP casing has 6 stages and 6impellers.

 Specifications of PA Compressor:
- 4725 KW, 1500rpm induction motor.
- Compressor speed 9926rpm.
- Rate 18,223 Nm3/hr.
- Discharge
Pressure 32.5
2
kg/cm
- Casing with
adjustable inlet guide
vanes
 Intercooler
- Each stage in LP
casing has integral
CW cooler
- 1st stage after cooler
- 2nd stage Inter-stage cooler
 Lube oil circulation Pressure = 3.5kg/cm2.

Surging

 'Surging' is defined as 'A momentary back-flow' through the compressor from discharge to
suction.

- This can occur when the mass flow of gas to the compressor falls below a critical level with
a high pressure difference across the machine.
- 'Surging' in the machine is very damaging to the compressor, associated piping and
equipment due to heavy vibrations and high temperature set up in the system.

- Surging can cause the machine to 'Over speed' before the control system can react. This can
also cause damage and is prevented by an 'Over speed and high vibration Trip Mechanism'
which will again shut down the machine.
- Generally, if the suction flow drops too low, a 'Low-flow Trip' will shut down the machine.
Department of Chemical Engineering, H.B.T.U. Kanpur Page 18
 Ammonia Convertor:
Haber–Bosch process: an artificial nitrogen fixation
process The Reaction is as follows:
N2 + 3 H2 --> 2 NH3 (ΔH = − 92.4 kJ·mol−1)
This involves the direct combination of Nitrogen and Hydrogen.
The Reaction is reversible, means that some ammonia will be formed, but not all will react.
From the above Reaction it is clear that forward reaction is exothermic and proceeds with decrease
in the number of gaseous moles .Therefore, according to Le-Chartlier’s Principle, the condition is
favorable for the forward process are:
 Low Temperature
 High Pressure
 However, at low Temperature the Rate of the reaction will be slow therefore in practice the
Optimum temperature is opted and father rate is increased by usage of catalyst
 The Catalyst mainly consists of finely divided iron containing molybedenum as promoter
and a few other metals to increase its thermal and mechanical properties.
Brief Process Description of Ammonia Synthesis and Recovery Section:
• Compression: Syn gas reciprocating compressor comprises of 3 Stages and a recirculation
stage. The makeup gas from 3rd stage discharge joins circulator discharge and enters the
loop at a pressure of 269Kg/cm2.
• Chilling system: Exchangers are provided for chilling the gas after compressor delivery for
water removal that is poison for Converter [Link] effect is provided with the help
of Liquid Ammonia for making the gas free of moisture. Ammonia present in the incoming gas
liquefies arresting water vapors and dehumidifies the circulating gas.
• NH3 Convertor: Ammonia Casale’s exclusive Axial Radial 3-bed convertor is installed for
ammonia conversion from Syn gas. The converter inlet/exit gas contains 4.31/20.56 % of
ammonia.
• Waste Heat Recovery Boiler: Converter exit gas is sent to Waste heat Boiler for heat
recovery by reducing its temperature from 320 – 220°C. The heat is utilized to generate IP
steam. Steam is generated at a pressure of 16Kg/cm2g.
• BFW heater: The heat of Converted gas is further utilized to heat Boiler feed water to
reduce gas temperature to 128°C.
• Hot Gas/Gas Exchanger: The low grade heat in the converter gas is used to heat incoming
gas going to converter. The converted gas temperature is brought down to 70°C.
• Water Cooler: The unrecoverable heat is sunk into cooling water and temperature is
brought down to 37 °C to liquefy ammonia.
• Primary catch pot: Liquid ammonia condensed in effluent cooler flows to catch pot along
with the un-reacted gas is separated here. Liquid ammonia is sent to LDV and vapors are
sent to re- circulator section of compressor and an optimum purge from the loop is
maintained to keep the inert level with in the permissible limits to avoid reduction in

Department of Chemical Engineering, H.B.T.U. Kanpur Page 19

 Ammonia yield and wastage of useful gas.
• Purge gas chiller: The ammonia collected in the bottom of purge gas chiller is sent back to
primary Catch Pot. The purge gas from Purge gas chiller is sent to HP absorber for
ammonia recovery and further to primary reformer fuel system.
• Oil Filter: Removes oil from the gas carried over from the compressor, if oil is carried
further into the convertor then oil will vaporize releasing the sulphur compounds causing
catalyst damage. Furthermore oil also acts as poison to the catalyst.
• Recycle interchanger: Cools down the gas going to chiller by exchanging cold from the
out coming gas of the chiller. This exchanger mainly known as cold gas/gas exchanger also.
• Recycle chiller: Heat Exchanger used for chilling the stream to the convertor by using
liquid ammonia for knocking the water by means of condensing ammonia in the system.
• Secondary Catch pot : Used for removing the ammonia and moisture from the system.
• LPA & HPA: Absorbs NH3 by spraying water from the purge gas going to primary
reformer section to be burnt as fuel gas.
• Ammonia Still: Removal of ammonia from ammonical solution coming from HPA and LPA.

NH3 Converter:

 Ammonia Casale’s Patented Axial Radial Flow Converter with 3 catalyst Beds with 1
cold Shot , 1 quench and 1 Bottom Exchanger By-Pass valves . Major flow of Gas is
Radial so that the Pressure Drop can be reduced.
 1st Bed inlet/outlet Temperature: 379 / 516°C
 2nd Bed inlet/outlet Temperature : 421 / 495°C
 3rd Bed inlet/outlet Temperature : 412 / 460°C
 Oxidized iron is used as Catalyst. Oxygen is removed during reduction without shrinkage.
This process of reduction with hydrogen (The reducing gas) produces metallic iron which is
extremely porous and suitable to convert synthesis gas mixture under high pressure and
temperature to Ammonia.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 20

 Figure: Ammonia Convertor

Department of Chemical Engineering, H.B.T.U. Kanpur Page 21

 Behavior of NH3 Convertor without Heat Exchanger
When Only Quench is introduced in the converter NH3 conversion is around 17%. Temperature
continuously decreases with quench which is a favorable condition but concentration of N 2 and
H2 is increasing continuously, decreasing the overall concentration

Behavior of NH3 Convertor with Heat Exchanger

After introducing heat Exchangers: Temperature decrease is achieved but with Increasing
concentration. Therefore, NH3 conversion approaches to maximum with introduction of Internal
Exchangers since gas ammonia dilution does not take place by adding quench gas directly.
1. Gas Enters Through nozzle ‘A’ Heat is exchanged from the Shell by the Cold Gas Keeping
the temp in the annulus and outer shell optimum. Enters the bottom Exchanger through the
Shell Side.
2. At the exit of bottom exchanger the gas coming from shell side of the exchanger is mixed
with by-Pass gas coming from ‘D’ valve. Further it enters the Tube side of the second Heat
Exchanger.
3. After getting through the Electrical Heater Gas enters the 1st Bed where 1st quench through
‘C’ Nozzle. Reaction is picked up in this region .Temp is around 380 - 500 deg.C with 4 %
- 14 % conversion.
4. Flow pattern is outwards. Maximum conversion takes place in this region because the
concentration of reactants is enough for NH3 production and conditions along with catalyst
activity is perfect for conversion.
5. Gas coming from 1st bed is cooled by the quench gas coming from nozzle ‘F’, the flow is
inward, and Heat is exchanged from the tubes of the second Heat exchanger before entering
the 3rdbed. Conversion is around 17%.
6. Again the flow pattern is inward while entering The third bed , heat is exchanged from the
bottom exchanger shell side As the final unconverted gas and 20-22 % NH3 Is passed
through tubes to the WHRB.
Role of Catalyst in NH3 converter:
 Nitrogen is initially inert, for its dissociation, high temperatures are required but the
reaction will proceed in backward direction, therefore optimum temperatures are required
that is why catalyst is used.
 Catalyst as Energy saver, Increases Reaction rate because of which less energy is consumed.
 Alumina and potash are used as promoters; they help structurally and provide thermal stability.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 22

 Deaerators

Deaerators are normally used in any Chemical Process Industry or in Power Plants where boiler is employed
for steam production from boiler feed water. Deaerator solves the purpose of removal of unwanted dissolved
gases and dissolved oxygen from the boiler feed water before entering into boilers. Most of the deaerators
are designed in such a way that the dissolved oxygen content in the outlet water is about 7 ppm by wt%

a) From Henry’s Law- According to William Henry in 1803 it state, that gas solubility in a solution
decreases as the gas partial pressure above the solution decreases. In simple we can say that the solubility of
any gas dissolved in a liquid is directly proportional to the partial pressure of the gas.
b) The second principle state that, deaeration is the relationship between gas solubility and temperature.
Easily explained, gas solubility in a solution decreases as the temperature of the solution rises and
approaches saturation temperature.
A deaerator utilizes both of these natural processes to remove dissolved oxygen, carbon dioxide and other
non-condensible gases from boiler feedwater. The feedwater is sprayed in thin films into a steam atmosphere
allowing it to become quickly heated to saturation. Spraying feedwater in thin films increases the surface
area of the liquid in contact with the steam, which results in more rapid oxygen removal and lower gas
concentrations. This process reduces the solubility of all dissolved gases and removes them from the
feedwater. The liberated gases are then vented from the deaerator.

Necessity of deaerator
The presence of oxygen, and other non-condensable gases, in the feed water is a major cause of corrosion in
the feed water piping, boiler, and condensate piping line. The dissolved oxygen content of the feed water is a
major factor of corrosion in boiler. Low pH levels in feed water cause severe acid attack throughout the
boiler [Link] remove of desolved gasses and oxygen process is known as deaeration. There are two
types of deaeration is generally happen as chemical deaeration and mechanical deaeration. The main
function of deaerator is -
1)Removing the dissolved gases to prevent corrosion feed water heated.
2) Work as a feed water storage tank.
3) Increase thermal efficiency.
4) Provide required Net positive suction head to feed water pump.

Types of deaerator
a) Tray-type deaerator- It consists of over several rows of trays. Makeup water and pumped returns are
sprayed into the deaerator tray section through a stainless steel spray nozzle. The spray nozzle provides a
thin conical sheet of water that condenses the vapors while permitting oxygen to exit through the vent. The
partially deaerated water then begins to cascade through the trays. The combined makeup and pumped
returns are heated with steam that flows upward through the stainless steel trays. The steam vigorously
scrubs the dissolved oxygen from the makeup and pumped returns. The trapped returns enter the deaerator
storage section. Steam from the returns also flows upward through the deaerator trays, while the water drops
to the water level in the deaerator storage section. The fully deaerated water remains in the deaerator storage
section for use by the boiler, while the excess steam flows into the deaerator tray section. Non-condensable
gases enter the vent and pass to the atmosphere.

Figure 1- Tray type deaerator

Department of Chemical Engineering, H.B.T.U. Kanpur Page 23

TYPES OF REBOILERS

Thermosyphon natural circulation reboiler: The boiling occurs inside the tubes in vertical thermosyphon
reboiler and inside shell in horizontal thermosyphon reboiler. In vertical thermosyphon reboiler, the liquid
circulation occurs due to density difference between vapor-liquid mixture (two phase) in the exchanger from
the reboiler and the liquid through the downcomer to the reboiler.
Advantages: most economical because no pump is required.
Limitations: not suitable for heavily viscous fluid; high construction cost for the installation of the column
base at suitable elevation to get thermosyphon effect; not suitable for low temperature difference processes
due to boiling point elevation imposed by static head.

Figure – Thermosyphon reboiler

Kettle reboiler :The tube bundle is immerged in a pool of liquid at the base of the column in an oversize
shell. Kettle reboiler is also called a “submerged bundle reboiler”. The height of the tube bundle is usually
40-60% of the shell ID. The submergence of the tube bundle is assured by an overflow weir at height of
typically 5-15 cm from the upper surface of topmost tubes.

Advantage: suitable for vacuum operation and high vaporization rate up to about 80% of the feed.

Limitations: low heat transfer rate than other types as there is no liquid circulation (low velocity); not
appropriate for fouling fluids; kettle reboiler is not suitable for heat sensitive materials as it has higher
residence time.

Figure –Kettle type reboiler

Department of Chemical Engineering, H.B.T.U. Kanpur Page 24

PUMPS USED IN INDUSTRY

Centrifugal pumps: Centrifugal pumps are a sub-class of dynamic axisymmetric work-absorbing turbo
machinery. Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic energy to
the hydrodynamic energy of the fluid flow. The rotational energy typically comes from an engine or electric
motor. The fluid enters the pump impeller along or near to the rotating axis and is accelerated by the
impeller, flowing radially outward into a diffuser or volute chamber (casing), from where it exits.

Common uses include water, sewage, petroleum and petrochemical pumping; a centrifugal fan is commonly
used to implement a vacuum cleaner. The reverse function of the centrifugal pump is a water turbine
converting potential energy of water pressure into mechanical rotational energy.

Figure – Centrifugal pump

Reciprocating pump: A reciprocating pump is a class of positive-displacement pumps which includes the
piston pump, plunger pump and diaphragm pump. When well maintained, reciprocating pumps will last for
years or even decades; however, left untouched, they can undergo rigorous wear and tear.[1] It is often used
where a relatively small quantity of liquid is to be handled and where delivery pressure is quite large. In
reciprocating pumps, the chamber in which the liquid is trapped, is a stationary cylinder that contains the
piston or plunger.

Figure – Centrifugal Pump

Department of Chemical Engineering, H.B.T.U. Kanpur Page 25

PUMP PRIMING

Most centrifugal pumps are not self-priming. In other words, the pump casing must be filled with liquid

before the pump is started, or the pump will not be able to function. If the pump casing becomes filled with

vapors or gases, the pump impeller becomes gas-bound and incapable of pumping. To ensure that a

centrifugal pump remains primed and does not become gas-bound, most centrifugal pumps are located

below the level of the source from which the pump is to take its suction. The same effect can be gained by

supplying liquid to the pump suction under pressure supplied by another pump placed in the suction line.

HOW TO PRIME A PUMP

When the suction supply is above the pump

Figure – Pump priming

1. Discharge isolation valve

2. Check valve
3. Suction isolation valve

Following are the steps to priming the pump:

 Slowly open the suction isolation valve.

 Open the air vents on the suction and discharge piping until the pumped fluid flows out.
 Close the air vents.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 26

When the suction supply below the pump

Figure – Pump priming

1. Discharge isolation valve

2. Shutoff valve
3. From outside supply.
4. Foot valve
5. Check valve

Consider using a foot valve and an outside source of liquid in order to prime the pump.

 Close the discharge isolation valve.

 Open the air vent valves in the casing.
 Open the valve in the outside supply line until only liquid escapes from the vent valves.
 Close the vent valves.
 Close the outside supply line.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 27

 PROJECT

OBJECTIVE : To calculate heat duty and fouling factor of Recycle Chiller.

THEORY :
Recycle chiller is a heat exchanger used for chilling the streams to the convertor by using liquid ammonia
for knocking the water by means of condensing ammonia in the system.
Heat duty:
Heat duty is the amount of heat needed to cool or heat the process fluid to desired temperatures over the
unit.
Heat duty = energy required to cool or heat the process stream+ energy required to condense the process
stream

Q = m Cp ∆T + mλ

Fouling:
Fouling is the accumulation and formation of unwanted materials on the surface of process equipment,
which deteriorate the capacity of surface to transfer heat under temperature difference condition for which
they are designed . It is a complex phenomenon and occurs in most chemical and process industries.
Fouling is one of the major unresolved problem in heat transfer. Firstly, the fouling layer has low thermal
conductivity. This increases the resistance to heat transfer and reduce effectiveness of heat exchanger.
Secondly, as the deposition occurs, the cross section area is reduced, which causes an increase in pressure
drop across the apparatus.

ACTION PLAN :
Step 1: Obtain the required data :
 Inlet flow rate of fresh feed compressor.
 Composition of inlet fresh feed compressor.
 Inlet flow rate of circulating compressor.
 Inlet composition of circulating compressor.
 Inlet and outlet temperatures of cold gas-gas exchanger and recycle chiller.
 Specific heat values of mixture.

Step 2:
 By component balance find the composition of cold gas-gas exchanger.
 Calculate amount of ammonia condensed in cold gas-gas exchanger.
 Find inlet composition and mass flow rate of recycle chiller.
 Calculate the amount of ammonia condensed in recycle chiller.
 Finally, find the outlet composition and mass flow rates of recycle chiller.
Step 3: Find heat duty:
Total heat transfer = Sensible heat + Latent heat

Q = mCp ∆T + mλ

Department of Chemical Engineering, H.B.T.U. Kanpur Page 28

 Step 4: Calculate LMTD ( Log mean temperature difference)

For counter current Tlm= (T1-t2) – (T2-t1)/ [ln T1-t2/T2-t1]

For co current Tlm= (T1-t1) – (T2-t2)/ [ln T1-t1/T2-t2]

Now, Q = UATlm
Where U is overall heat transfer coefficient.
Step 5: To calculate fouling factor

Fouling resistance Rf = 1/Ud - 1/Uo

GIVEN DATA :
Circulation gas analysis

DESCRIPTION DESIGN CASALE Ammonia 1 Ammonia 2 Ammonia 3

H2 53.85 62.88 51.31 56.47

N2 18.48 16.09 20.09 18.65
CH4 10.90 7.95 10.36 9.20
Ar 5.23 3.18 4.14 3.68
NH3 11.53 9.90 14.10 12
Circulation 177007 226900 232300 232000
flow
(Nm3/ hr)

Fresh make up gas analysis

DESCRIPTION DESIGN Ammonia Ammonia Ammonia

CASALE 1 2 3
H2 74.04 73.94 73.63 73.83
N2 24.78 16.09 20.09 25.11
CH4 0.84 7.95 10.36 0.76
Ar 0.31 0.30 0.30 0.30
CO <1 <1 <1 <1
CO2 <5 <5 <5 <5
Fresh make up gas 54700 50600 55100
(Nm3/ hr)

Cold gas gas exchanger

Plant Inlet temperature (℃) Outlet temperature (℃)

A1 45 25
A2 49 32
A3 45 25.1
Design 51.0 17.0

Department of Chemical Engineering, H.B.T.U. Kanpur Page 29

 Recycle Chiller

Plant Inlet temperature (℃) Outlet temperature (℃)

A1 25 16.8
A2 32 17.8
A3 25 5.3
Design 17 4

DESIGN CALCULATIONS :
Given : Cpmix = 0.7540 KJ/Kg K

Composition at cold gas gas exchanger inlet

CH4 8.16

H2 59.93

N2 20.2

NH3 8.38
Ar 3.89

Molar flow rate = 7897 Kmol/hr

Mass flow rate = 88049 Kg/hr

Vapour pressure of NH3 at 17 ℃ = 7.883 Kg/ cm2

At 4℃ = 4.994 Kg/ cm2

Total pressure = Pt =267.5 Kg/ cm2

yi = 0.0838

yf = PAsat/ Pt = 7.883 / 267.5 = 0.02946

yi – yf = 0.05434

NH3 condensed = 0.05434 × 7897

=429.05
No. of moles in gas phase in cold gas gas exchanger =7897-429.05 Kmol/hr = 7467.877 Kmol/hr
No. of moles in liquid phase = 429.05 Kmol/hr

For Chiller

Outlet composition from cold gas gas exchanger Inlet composition in gas phase
for chiller
H2 59.53 62.95
N2 20.2 21.36
CH4 8.16 8.63
Ar 3.89 4.11

Department of Chemical Engineering, H.B.T.U. Kanpur Page 30

 NH3 2.946 3.115
Flow 7897 7467.877
rate

Component Balance

For H2
0.5953*7897 = xH2 (7467.877)

xH2= 0.6295

For N2
0.202*7897 = xN2 (7467.877)

xN2= 0.2136

For CH4

0.0816*7897 = xCH4 (7467.877)

xCH4= 0.0863

For Ar
0.0389*7897 = xAr (7467.877)

XAr = 0.0411

For NH3
0.02946*7897 = xNH3 (7467.877)

xNH3= 0.03115

yi = 0.02946

yf= PA sat/ PT = 4.994/ 266 = 0.0188

yi - yf = 0.01066

NH3 condensed = 0.01066 × 7467.87

=92.419
No. of moles in gas phase in cold gas gas exchanger =7467-92.419 Kmol/hr = 7375.451 Kmol/hr

Inlet composition in chiller Outlet composition in gas phase for chiller

H2 62.95 63.74
N2 21.36 21.63
CH4 8.63 8.74
Ar 4.11 4.16
NH3 3.115 1.904

Department of Chemical Engineering, H.B.T.U. Kanpur Page 31

 Flow rate 7467.877 7375.451

Component Balance

For H2
0.6295*7467.877 = xH2 (7375.451)

xH2= 0.6374

For N2
0.2136*7467.877 = xN2 (7375.451)

xN2= 0.2163

For CH4

0.0863*7467.877 = xCH4 (7375.451)

xCH4 = 0.0874

For Ar
0.0411*7467.877 = xAr (7375.451)

xAr = 0.0416

For NH3
0.03115*7467.877 = xNH3 (7375.451)

xNH3= 0.01904

Calculation of CPmix :
CPmix= [m 1 CP1+ m2CP2 + m3CP3 + m4CP4] / [m1 + m2 + m3 + m4]

For H2
CP1=14.25 KJ/ Kg hr

m1 = 0.6295*7467.877*2
= 9402.057 kg

For N2
CP2= 1.04 KJ/ Kg hr

m2 = 0.2136*7467.877*28
= 44663.88 kg

Department of Chemical Engineering, H.B.T.U. Kanpur Page 32

 For CH4

CP3= 2.2 KJ/ Kg hr

m3 = 0.0863*7467.877*16
= 10311.64 kg

For Ar
CP4= 0.52 KJ/ Kg hr

m4 = 0.52*7467.877*40
= 12277.19 kg

CPmix=2.733KJ/KgK = 0.6538 Kcal / Kg K

(MAvrg) = 10.3936 kg

Flow rate of gas not involving NH3

= 7375.451 – (0.01904)(7375.451)
=7235.022 Kmol / hr
=75197.93 Kg/hr

Qgas = m CP∆T
= (75197.93) (0.6538) (17-4)
= 639137.286 Kcal/hr

Finding temperature at which NH3 would condense in chiller :

yi = 0.01904

yi*PT = Partial pressure of ammonia

= (0.01904)(267.5)
=5.1 Kg/cm2

Temperature corresponding to this temperature = 4℃

(QNH3)liq = 429.05 17 1.12 ×(17-4)

=106293.276 Kcal/ hr

(QNH3)gas = 140.4286 17 0.498 ×(17-4)

=15454.344 Kcal/ hr

Department of Chemical Engineering, H.B.T.U. Kanpur Page 33

 (QNH3) = 92.419 17 0.498 ×(17-4)
+ 92.419 298
=478366.104 Kcal/ hr

(Qtotal) = 1717617.114 Kcal /hr

= 1.7176 Gcal/ hr
Diameter D = 19 mm
Length of tube, l = 13.39 m
No. of tubes ,n = 277

A=πDln
= (3.14) ( .019) ( 13.39) (277)
=221.393 = 2454 ft2

∆TLMTD = [ 17- (3.5)] – [ 4 – (3.5)] / ln [ 20.5 / 7.5]

= 13 / 1.0055 = 12.93

(Qtotal) = U A ∆TLMTD
1.7176 Gcal / hr = U

Department of Chemical Engineering, H.B.T.U. Kanpur Page 34

 Ammonia 1

Object: To estimate the heat duty and fouling factor of recycle chiller.

Figure: Ammonia 1 plant

Data given:

Point 1 Composition:- H2: 73.94%(by moles), N2: 25.09%(by moles), CH4: 0.67%(by moles), Ar:
0.30%(by moles).
Point 1 volumetric flow rate:- 54700Nm3/hr.

Point 2 composition:- H2: 62.88%, N2: 16.08%, CH4: 7.95%, Ar: 3.18%, NH3: 9.90%.

Point 3 volumetric flow rate :- 226900Nm3/hr.

Temperature of cold gas-gas exchanger:- Inlet: 450C, Outlet: 250C.
Temperature of recycle chiller:- Inlet: 250C, Outlet: 16.80C.
Calculation:
Molar flow rate at point 1
= (57720Nm3/hr)/(22.4m3/kmoles).
=2576.7kmoles/hr.
Molar flow rate at point 2
=169180/22.4
=7552.67kmoles/hr.
Molar flow rate at point 3
=226900/22.4
=10129.46kmoles/hr.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 35

 Component balance:
H2:
(xH2)1F1+(xH2)2F2=(xH2)3F3.
0.7394*2576.7+0.6288*7552.6=(xH2)3*10129.46
(xH2) =0.6569
N2:
0.2509*2576.7+0.1608*7552.6=(xN2)*10129.46
(xN2)=0.1837

CH4:

0.0067*2576.7+0.0795*7552.6=(x CH4)*10129.46

(x CH4)=0.0609

Ar:
0.003*2576.7+0.0318*7552.6=(xAr)*10129.46
(xAr)=0.0244
NH3:
0.099*7552.6=(xNH3)*10129.46
(xNH3)=0.0738

Cold gas-gas exchanger:

Inlet composition of cold gas exchanger:

H2: 65.69%, N2: 18.37%, CH4: 6.09%, Ar: 2.44%, NH3: 7.38%.
Molar flow rate: 10129.46.
Inlet temp. 450C, Outlet temp. 250C.
Vopour pressure of NH3 at 250C is 10.19Kg/cm2.
Yi(initial composition of NH3)=0.0738.
Yf(final composition of NH3 at end of cold gas exchanger)=PNH3/PT.
=1019/267.5 .
Yf=0.03809
Moles condense of NH3 in cold gas exchanger
(Yi-Yf)*10129.46=(0.0738-0.03809)*10129.46=361.72Kmoles/hr.
Outlet flow of cold gas exchanger:
Flow rate of gases =9767.74

Department of Chemical Engineering, H.B.T.U. Kanpur Page 36

 Flow rate of liquid NH3 =361.72
Outlet composition of cold gas exchanger :
(a) Gas phase :

H2: 68.12%, N2: 19.05%, CH4: 6.31%, Ar: 2.53%, NH3: 3.95% .
(b) liquid phase:
NH3=361.74Kmoles/hr.
Recycle chiller:
Inlet temp. =250C, Outlet temp. =16.80C.
Vapour pressure of NH3 at 16.80C is =7.88Kg/cm2.
Yi=0.0395.
Yf=7.886/266 =0.0296.
Moles condense of NH3 in recycle chiller:
(Yi-Yf)*9767.74=(0.0395-0.0296)*9767.74=96.7Kmoles/hr
Outlet of recycle chiller :
(a) Gas phase :
Molar flow rate =9671.04Kmole/hr
Composition:

H2: 68.8%, N2: 19.24%, CH4: 6.37%, Ar:2.54%, NH3 : 2.98%.

(b) liquid phase :

NH3: 458.42 Kmole/hr.
Heat capacity(avg.) of gases:

CH4=2.2 KJ/KgK.

H2=14.25 KJ/KgK.
N2=1.04 KJ/KgK.
Ar=0.52KJ/KgK.
NH3(gas)=0.498 Kcal/KgK.
NH3(liquid)=1.121 Kcal/KgK.
Cpmix=(m1Cp1+m2Cp2+m3Cp3+m4Cp4)/(m1+m2+m3+m4).
M1(H2): 13307.56 Kg/hr.
M2(N2): 52101.125 Kg/hr.

M3( CH4): 9861.5 Kg/hr.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 37

 M4(Ar): 9884.95 Kg/hr.
Cpmix = 0.7603 Kcal/KgK.
Mav.= 8.7712Kg/Kmole

Amount of gas only(H2,N2, CH4,Ar):

M =82290.52 Kg/hr.
Amount of NH3 in gas :
M = 4915.2 Kg/hr.
Amount of NH3 in liquid:
M =7788.04 kg/hr.
Q=MCp(T1-T2).
Qgas=82290.52*0.7603*(25-16.8).
Qgas=5513028.23 Kcal/hr.
Q=MCp(T1-T2)+ML.
QNH3=4915.2*0.498*8.2+6149.24*1.121*8.2+1643.9*0.498*8.2+1643.9*287.56.
QNH3=556029.643 Kcal/hr.
Qtot.=1069057.873 Kcal/hr.
Q=1.069 Gcal/hr.
Area of tubes : 2454sq ft.
TLMTD=[(Th1-Tc1)-(Th2-TC2)]/ln[(Th1-Tc1)/(Th2-Tc2)].
TLMTD=12.982C.
Q=UdATLMTD.
Ud=33.27 Kcal/hr ft2K.
Fouling factor :
Rd=(1/Ud)-(1/Uo).
Rd=0.0115 (ft2Khr/Kcal).
Results:
Heat duty ammonia 1 = 1.069 Gcal/hr.
Fouling factor ammonia 1 = 0.0115 (ft2Khr/Kcal).

Department of Chemical Engineering, H.B.T.U. Kanpur Page 38

 AMMONIA- 2
OBJECTIVE : To calculate heat duty and fouling factor of Recycle Chiller.

DESCRIPTION At point 1 At point 2

Fresh feed
H2 73.63 51.31
N2 24.92 20.09
CH4 1.15 10.36
Ar 0.3 4.14
NH3 14.10
Circulation 52500 179800
flow
(Nm3/ hr)

Equipment Inlet temperature (℃) Outlet temperature (℃)

Cold gas gas 49 32

exchanger
Recycle Chiller 32 17.8

Calculation:

Department of Chemical Engineering, H.B.T.U. Kanpur Page 39

 Molar flow rate
 At point 1:

= (52500 Nm3/hr) / (22.4 m3/kmoles).

=2343.75 kmoles / hr.
 At point 2:

= (179800 Nm3/hr) / (22.4 m3/kmoles).

=8026.786 kmoles / hr.
 At point 3:

= (232300 Nm3/hr) / (22.4 m3/kmoles).

=10370.536 kmoles / hr.
Component Balance

For H2
(0.7363*2343.75) + (0.5131*8026.786) = xH2*10370.536

xH2= 0.5635

For N2
(0.2492*2343.75) + (0.2009*8026.786) = xN2*10370.536

xN2= 0.2118

For CH4

(0.0115*2343.75) + (0.1036*8026.786) = x CH410370.536

x CH4= 0.0828

For Ar
(0.0032343.75) + (0.0414*8026.786) = xAr10370.536

xAr= 0.0327

For NH3
(0) + (0.141*8026.786) = xNH3*10370.536

xNH3= 0.1091

yi = 0.1091

Vapour pressure of ammonia at 32℃ = 12.64 Kg/cm2

yf= PAsat/ PT = 12.64/ 267.5 = 0.04725

Department of Chemical Engineering, H.B.T.U. Kanpur Page 40

 yi - yf = 0.06185

NH3 condensed = 0.06185*10370.536

=641.73 Kmol/hr
No. of moles in gas phase in cold gas gas exchanger =10370.536 - 641.73 Kmol/hr
= 9728.806 Kmol/hr

Inlet composition in chiller Outlet composition in gas phase for chiller

H2 56.35 60.07
N2 21.18 22.58
CH4 8.28 8.82
Ar 3.3 3.52
NH3 4.725 5.04
Flow 10370.536 9728.806
rate

Component Balance

For H2
0.5635*10376 = xH2*9728.806

xH2= 0.6007

For N2
0.2118*10376 = xN2*9728.806

xN2= 0.2258

For CH4

0.0828*10370.536 = x CH49728.806

x CH4= 0.0882

For Ar
0.033*10370.536 = xAr*9728.806

xAr= 0.0352

For NH3
0.04725*10370.536 = xNH3*9728.806

xNH3= 0.0504

yi = 0.0504

Vapour pressure of ammonia at 17.8℃ = 8.10425 Kg/cm2

yf= PAsat/ PT = 8.10425/ 266 = 0.03047

Department of Chemical Engineering, H.B.T.U. Kanpur Page 41
 yi - yf = 0.0199

NH3 condensed = 0.01099 × 9728.806

=193.895 Kmol/hr
No. of moles in gas phase in cold gas gas exchanger =9728.806 - 193.895 Kmol/hr = 9534.911 Kmol/hr
Component Balance

For H2
0.6007*9728.806 = xH2*9534.915

xH2= 0.6129

For N2
0.2258*9728.806 = xN2*9534.915

xN2= 0.2304

For CH4

0.0882*9728.806 = x CH4 *9534.915

x CH4= 0.09

For Ar
0.0352*9728.806 = xAr *9534.915

xAr= 0.0359

For NH3
0.0504*9728.806 = xNH3 *9534.915
xNH3= 0.0514
Mass flow rates ( in Kg/hr )of :

 H2= 11678.46
 N2 = 61509.42
 CH4 =13729.297
 Ar = 13698.16
 NH3 = 8335.644

Calculation of CPmix :

CPmix= [m1CP1+ m2CP2 + m3CP3 + m4CP4] / [m1 + m2 + m3 + m4]

Heat capacity(avg.) of gases:

CH4=2.2 KJ/KgK.

H2=14.25 KJ/KgK.
N2=1.04 KJ/KgK.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 42

 Ar=0.52KJ/KgK.
NH3(gas)=0.498 Kcal/KgK.
NH3(liquid)=1.121 Kcal/KgK.

Therefore, CPmix=2.45KJKgK = 0.586 Kcal/hr

(MAvrg) = 10.553 Kg /Kmol

Amount of ammonia in gas phase in chiller = 8335.644 Kg/ hr = mNH3

Other gases in gas phase = (9534.915 – 490.33)10.553 = 95447.48 Kg/hr = mgas

Amount of ammonia in gas phase = 296.15 * 17 = 5034.55 Kg/hr
Amount of ammonia in liuid phase = 641.73* 17 = 10909.41Kg/hr
Amount of ammonia condensed = 193.895 * 17 = 3296.215 Kg/hr

Q=MCp(T1-T2).
Qgas=95447.48*0.586*(32-17.8).
Qgas= 794237.5706 Kcal/hr.
Q=MCp(T1-T2)+ML.
QNH3=5034.55*0.586*14.2+1.121*10909.41*14.2+3296.215*0.498+3296.215*287.2.
QNH3=1157574.957 Kcal/hr.
Qtot.=1951812.528 Kcal/hr.
Q= 1.95 Gcal/hr.
Area of tubes : 2454 ft2.
TLMTD=[(Th1-Tc1)-(Th2-TC2)]/ln[(Th1-Tc1)/(Th2-Tc2)].
TLMTD=27.80C.
Q=UdATLMTD.
Ud=28.58 Kcal/hr ft2K.
Fouling factor :
Rd=(1/Ud)-(1/Uo).
Rd=0.0164 (ft2 Khr/Kcal).

Results:
Heat duty ammonia 2 = 1.95 Gcal/hr & Fouling factor for ammonia 2= 0.0164 (ft2Khr/Kcal).

Department of Chemical Engineering, H.B.T.U. Kanpur Page 43

 AMMONIA- 3
OBJECTIVE : To calculate heat duty and fouling factor of Recycle Chiller.

DESCRIPTION At point 1 At point 2

Fresh feed
H2 73.83 56.47
N2 25.11 18.65
CH4 0.76 9.20
Ar 0.3 3.68
NH3 12
Circulation 55000 177000
flow
(Nm3/ hr)

Equipment Inlet temperature (℃) Outlet temperature (℃)

Cold gas gas 45 25.1

exchanger
Recycle 25.1 5.3
Chiller

Department of Chemical Engineering, H.B.T.U. Kanpur Page 44

 Calculation:
Molar flow rate
 At point 1:

= (55000 Nm3/hr) / (22.4 m3/kmoles).

=2455.357 kmoles / hr.
 At point 2:

= (177000 Nm3/hr) / (22.4 m3/kmoles).

= 7901.786 kmoles / hr.
 At point 3:

= (232000 Nm3/hr) / (22.4 m3/kmoles).

=10357.143 kmoles / hr.
Component Balance

For H2
(0.7383*2455.357) + (0.5647*7901.786) = xH2×10357.143

xH2= 0.6058

For N2
(0.2511*2455.357) + (0.1865*7901.786) = xN2×10357.143

xN2= 0.2018

For CH4

(0.0076*2455.357) + (0.092*7901.786) = x CH4×10357.143

x CH4= 0.072

For Ar
(0.003*2455.357) + (0.0368*7901.786) = xAr×10357.143

xAr= 0.0323

For NH3
(0) + (0.12*7901.786) = xNH3×10357.143

xNH3= 0.09155

yi = 0.09155

Vapour pressure of ammonia at 25.1℃ = 10.19 Kg/cm2

yf= PAsat/ PT = 10.19/ 267.5 = 0.038

Department of Chemical Engineering, H.B.T.U. Kanpur Page 45
 yi - yf = 0.05355

NH3 condensed = 0.05355 10357.143

=553.657 Kmol/hr
No. of moles in gas phase in cold gas gas exchanger =10357.143 – 553.657 Kmol/hr = 9803.4Kmol/hr

Inlet composition in chiller Outlet composition in gas phase for chiller

H2 60.58 64.11
N2 20.18 21.36
CH4 7.2 7.62
Ar 3.23 3.42
NH3 9.155 4.01
Flow 10357.143 9803.453
rate

Component Balance

For H2
0.6058*10357.143 = xH2*9803.453

xH2= 0.6411

For N2
0.2018*10357.143 = xN2*9803.453

xN2= 0.2136

For CH4

0.072*10357.143 = x CH4*9803.453

x CH4= 0.0762

For Ar
0.033*10357.143 = xAr *9803.453

xAr= 0.0342

For NH3
0.03809*10357.143 = xNH3*9803.453

xNH3= 0.0401

yi = 0.0401

Vapour pressure of ammonia at 5.3℃ = 5.33 Kg/cm2

yf= PAsat/ PT = 5.33/ 266 = 0.02003

yi - yf = 0.0201
Department of Chemical Engineering, H.B.T.U. Kanpur Page 46
 NH3 condensed = 0.0201 × 9803.4
=198.618 Kmol/hr
No. of moles in gas phase in cold gas gas exchanger =
9803.453 – 198.618 Kmol/hr = 9604.835 Kmol/hr
Component Balance

For H2
0.6411*9803.453 = xH2*9604.835

xH2= 0.654

For N2
0.2136*9803.453 = xN2*9604.835

xN2= 0.218

For CH4

0.0762*9803.453 = x CH4*9604.835

x CH4= 0.0777

For Ar
0.0342*9803.453 = xAr*9604.835

xAr= .0349

For NH3
0.0403*9803.453 = xNH3*9604.835

xNH3= 0.04112
Mass flow rates ( in Kg/hr )of :

 H2= 12565.903
 N2 = 50640.876
 CH4 =11943.376
 Ar = 13411.32
 NH3 = 6716.343

Calculation of CPmix :

CPmix= [m1CP1+ m2CP2 + m3CP3 + m4CP4] / [m1 + m2 + m3 + m4]

Heat capacity(avg.) of gases:

CH4=2.2 KJ/KgK.

H2=14.25 KJ/KgK.
N2=1.04 KJ/KgK.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 47

 Ar=0.52KJ/KgK.
NH3(gas)=0.498 Kcal/KgK.
NH3(liquid)=1.121 Kcal/KgK.

Therefore, CPmix=2.992KJKgK = 0.7158 Kcal/hr

(MAvrg) = 10.0512 Kg /Kmol

Amount of ammonia in gas phase in chiller = 6714.25 Kg/ hr = mNH3

Other gases in gas phase = (9604.783 -394.955)10.05 = 9408.8 Kg/hr = mgas

Amount of ammonia in gas phase = 195.92 * 17 = 3330.64 Kg/hr
Amount of ammonia in liuid phase = 553.65* 17 = 9412.05Kg/hr
Amount of ammonia condensed = 198.62 * 17 = 3296.215 Kg/hr

Q=MCp(T1-T2).
Qgas=94558.95*0.716*(25.1-5.3).
Qgas=1340543.322 Kcal/hr.
Q=MCp(T1-T2)+ML.
QNH3=3330.64*0.498*19.8+1.121*9412.05*19.8+3376.54*0.498+3376.54*287.2.
QNH3=243417.47136 Kcal/hr.
Qtot.=1583960.7936 Kcal/hr.
Q= 1.584 Gcal/hr.
Area of tubes : 2454sq ft.
TLMTD=[(Th1-Tc1)-(Th2-TC2)]/ln[(Th1-Tc1)/(Th2-Tc2)].
TLMTD=16.80C.
Q=UdATLMTD.
Ud=38.42 Kcal/hr ft2K.
Fouling factor :
Rd=(1/Ud)-(1/Uo).
Rd=0.0075 (ft2Khr/Kcal).

Results:
Heat duty ammonia 3 = 1.584 Gcal/hr & Fouling factor ammonia 3 = 0.0075 (ft2 Khr/Kcal).

Department of Chemical Engineering, H.B.T.U. Kanpur Page 48

 SUMMARY:

PLANT A1 A2 A3 DESIGN
Cold gas gas inlet temperature
(℃) 45 49 45 51
Cold gas gas outlet
temperature (℃) 25 32 25.1 17
Chiller inlet temperature (℃) 25 32 25 17
Chiller outlet temperature (℃)
16.8 17.8 5.3 4
Heat Duty
(Gcal / hr ) 1.069 1.95 1.584 1.717

Overall heat transfer

coefficient (U) 33.27 28.58 38.42 53.89
(Kcal/hr ft2K.)
Fouling factor
(ft2 Khr/Kcal). 0.0115 0.0164 0.0075

DISCUSSSION
I visited the KFCL plant with an intention to get a basic feel of plant operations and the deviations of
these processes from the theoretical concepts.
I tried to trace the line and follow each and every operation stepwise. There are three plants with a
production of 430 tons of ammonia per day. The reformer section and the compressor house were of
major interest. The different types of reboilers and condensers were distinguished on the basis of their
appearance and working.
Apart from that I also noticed the instrument air plant and different types of valves in the workshop
section which are considerably vital from the fluid dynamics point of view.
As a part of the project, I along with my other group members were asked to find out the heat duty and
fouling factor of the recycle chiller which is basically a heat exchanger present in the back-end of the
plant.

Department of Chemical Engineering, H.B.T.U. Kanpur Page 49