Topsøe’s Ammonia Technology Today
G h 2007
Topsøe’s Ammonia Technology Today 2/22
Outline
Today’s ammonia technology
– Current design
– Developments
Highlights of specific process features
– Reforming section
– Ammonia synthesis converter
Reference situation
Future trends
– Capacity
– Process lay-out
– Potential for large plants
Conclusion
Outline
The current design will be described, and developments in reforming an ammonia synthesis will be
described in detail. The actual reference situation will be considered as well.
Finally, the trends for future ammonia plants will be discussed, and alternative schemes for very large
ammonia plants will be described.
Topsøe’s Ammonia Technology Today 3/22
Current scheme
Desulphurisation Reforming Shift
Process steam
Natural gas
Process air
Stack
Purge gas
CO2-
removal
Process
Ammonia
product cond.
Ammonia synthesis Methanation
Current Scheme
The Topsøe Low Energy Ammonia Process features a well-proven concept – desulphurization,
primary and secondary reforming, two-step shift conversion, carbon dioxide removal, methanation,
compression, ammonia synthesis, and product recovery.
The process lay-out is identical to the scheme proposed many years ago, but the performance has
significantly improved due to improvements in catalysts and new developments in equipment designs.
Topsøe’s Ammonia Technology Today 4/22
Developments
High flux primary reformer with prereformer
HTER (Haldor Topsøe Exchange Reformer)
S-300 converter
Improved catalysts
Developments
Two main areas have significant impact on the performance and cost of an ammonia plant – the
reforming section and the ammonia synthesis section.
In particular the design and performance of the side-fired primary reformer has been significantly
improved. This has been possible due to the availability of better tube materials with higher strength.
Better tube materials permit a reduction in tube wall thickness, thus reducing the level of thermal
stress in the tube wall, which again will give potentials for increased lifetime of the tubes. Very high
heat flux can be accepted in a modern type reformer, and with a prereformer in front of the reformer
the acceptable heat flux can be increased further.
A new Haldor Topsøe Exchange Reformer (HTER) has been developed and commercialised. This
new equipment allows reduction of the size of the primary reformer, and of the plant steam production.
In the ammonia synthesis section, the 3-bed radial flow converter – the S-300 – has been developed
and commercialised as an improved version of the work horse - the S-200. A highly efficient
combination of the S-300 converter and the one-bed S-50 converter – the S-350 synthesis loop – has
been developed.
In general introduction of improved catalysts have made the designs of the reactors more compact
and efficient.
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Prereforming
S-removal Prereformer High flux reformer
Hydrocarbon feed
Steam Fuel gas channel
Fuel
To heat recovery
Prereforming
Adiabatic prereforming can be used for steam reforming of feedstocks ranging from natural gas to
heavy naphtha. In the prereformer all higher hydrocarbon are converted into a mixture of carbon
oxides, hydrogen and methane. When a prereformer is installed as shown in the figure, the primary
reformer has to reform methane only, and at the same time at sulphur free conditions, because the
prereforming catalyst will pick up sulphur components quantitatively. This is one of the reasons for
allowing a much higher heat flux in the high flux reformer.
The prereformed feed can be reheated to 650°C before entering the primary reformer. This will result
in reduced firing in the primary reformer, and thereby a reduced fuel consumption. When the hot flue
gas is used to reheat the reformer feed, the amount of heat available for HP steam production is
reduced. This will result in a reduced HP steam production in the ammonia plant.
In general, the reformer size can be reduced by about 25% in a natural gas based plant by
incorporating a prereformer.
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HTER-p flowsheet
Tubular reformer Secondary reformer HTER-p
Process
steam
Desulp.
natural gas
Process air
HTER Flowsheet
Another feature that can be used to reduce the size of the primary reformer, and at the same time
reduce the HP steam production, is the HTER (Haldor Topsoe Exchange Reformer). This is a new
feature, initially developed for use in synthesis gas plants. In ammonia plants this unit is operated in
parallel with the primary reformer.
The HTER is heated by the exit gas from the secondary reformer, and thereby the waste heat
normally used for HP steam production can be used for the reforming process down to typically 750–
850°C, depending upon actual requirements. Operating conditions in the HTER are adjusted
independently of the primary reformer in order to get the optimum performance of the overall reforming
unit. Typically up to around 20% of the natural gas feed can in this way by-pass the primary reformer.
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The HTER-p
Feed gas Compact
Optimised utilisation of pressure
vessel volume
Allows for removal of internals
No restriction of thermal
Product gas
movement
Sec. ref.
effluent
The HTER-p
The HTER is a very compact, combined heat exchanger and catalytic reactor. Heat transfer surfaces
match the catalytic reactions taken place in the catalyst in such as way that the pressure vessel
volume is minimised.
The steam to carbon ratio can be adjusted individually to the HTER-p and the tubular reformer to
assure optimal conversion of methane.
The HTER-p is like a normal heat exchanger where the tube bundle can be removed, if desired.
Thermal movement due to changing operating conditions is unrestricted since mechanical design
allowing the bundle to expand freely downwards.
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S-300 ammonia synthesis converter
S-300 Ammonia Synthesis Converter
In the ammonia synthesis loop, an updated version of the radial flow converter has been developed –
the S-300.
The S-300 converter features three radial flow catalyst beds and two interbed heat exchangers.
With the S-300 converter, the catalyst volume can be reduced by approx. 20% compared with the S-
200 converter for the same ammonia conversion. Alternatively, when the feedstock is expensive, the
ammonia conversion can be increased for the same catalyst volume to reduce to specific energy
consumption.
Topsøe’s Ammonia Technology Today 9/22
S-350 ammonia synthesis loop
S-300 S-50
Converter Converter
Purge gas
NH3(l)
BFW
CW
Boiler Boiler NH3(l)
Product
ammonia
Make-up gas
S-350 Ammonia Synthesis Loop
The figure above describes a typical Topsøe ammonia synthesis loop.
As can be seen, the loop comprises two ammonia converters, i.e. a S-300 followed by a S-50
converter. The S-50 converter is a single bed radial flow converter, which is added downstream of the
main converter to increase the ammonia conversion, and at the same time to improve the steam
generation. By having two converters, the heat of reaction after the last bed in the first converter can
be utilised for boiling or superheating of HP steam, and the two converter configurations can be used
as a mean to close the overall plant steam balance, if the waste heat available for boiler feed water
preheat and boiling of steam is not in balance.
Topsøe’s Ammonia Technology Today 10/22
References – current scheme
Profertil, Argentina started up 2000
– With a capacity of 2,050 MTPD of ammonia in one single line,
this is one of the world’s largest grassroots plants. The plant
produces ammonia for urea
PT Kaltim Pasifik Amoniak, Indonesia started up 2000
– This ammonia plant has a capacity of 2,000 MTPD in one single
line. The ammonia plant is a stand-alone plant
Sohar, Oman, start up ultimo 2007
– This ammonia plant has a capacity of 2,000 MTPD in one single
line. The ammonia plant produces ammonia for urea
Engro, Pakistan, start up 2010
– This ammonia plant has a capacity of 2,200 MTPD in one single
line. The ammonia plant produces ammonia for urea
References – Current Scheme
Profertil in Argentina with a nominal capacity of 2,050 MTPD is the largest operating grassroots
ammonia plant designed by Topsøe. It is part of an ammonia-urea complex constructed by
Snamprogetti, Italy, and has been in successful operation since year 2000.
P.T. Kaltim Pasifik Ammoniak plant in Indonesia is a stand-alone ammonia plant with a nominal
capacity of 2,000 MTPD constructed by MHI (Mitsubishi Heavy Industries), Japan and successfully
started up in year 2000.
The Sohar plant in Oman is under construction by MHI. This will be a 2,000 MTPD ammonia plant
producing ammonia for urea. Start-up is scheduled for the end of year 2007.
Finally, the Engro Plant in Pakistan is in the engineering and procurement phase with Snamprogetti as
the Contractor. This will be a 2,200 MTPD ammonia plant producing ammonia for urea. Start-up is
scheduled for year 2010.
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General reference information
Energy consumption
– Lowest specific energy consumption achieved in PT Kaltim
Pasifik Amoniak, Indonesia: 6.6 Gcal/MT NH3
– Generally: Figures between 6.5 – 7 Gcal/MT NH3 can be
achieved in a new plant depending on site conditions
Maximum production
– Highest ammonia production achieved in Profertil, Argentina:
2,295 MTPD
General Reference Information
The ammonia plant with P.T. Kaltim Pasifik Amoniak was designed for low specific energy
consumption. The plant features aMDEA CO2-removal, ammonia synthesis loop with a S-200 and a S-
50 converter and a cryogenic purge gas recovery unit.
The highest recorded capacity in a Topsøe designed ammonia plant was achieved in the Profertil
plant in Argentina. This plant has produced as much as 2,295 MTPD of ammonia on a continuous
basis.
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Trend in capacity
Capacity year 1980 - 1995
– 1,000 – 1,750 MTPD
Capacity year 1995 – 2006
– 2,000 – 3,300 MTPD
Capacity year 2007 - ?
– 2,000 - ?
What are the possibilities?
Trend in Capacity
What is the future trend of the ammonia technology?
The market is focusing on larger and larger plants in areas where the gas cost is low, like The Middle
East, Australia, and Trinidad. Capacities have already gone up for the last 25 years, and the
experience with scaling up is therefore quite significant.
Will a further scale up of the plant capacities known today still be possible with the technology known
today. The available possibilities will be described in the following.
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Conventional scheme – 4,000 MTPD
Desulphurisation Reforming Shift
Process steam
Natural gas
Process air
Stack
Purge gas
CO2-
removal
Ammonia Process
product Ammonia synthesis Methanation cond.
Conventional Scheme – 4,000 MTPD
The ‘conventional’ scheme can be scaled further up compared to the capacities being considered
today. This is a simple scale-up where optimised operating conditions for the reforming section and
the ammonia synthesis loop in particular are defined in order to keep the equipment size at a
minimum.
Looking at the investment cost, the reformer cost goes up more or less proportionally with the number
of tubes, and since the reformer cost is a significant part of the overall plant cost, fully effect of
economy of scale is not applicable in this scheme when the reformer becomes larger and larger.
From an energy point of view there is, however, no doubt that this scheme is very energy efficient and
gives the lowest specific energy consumption figures of all schemes considered for large-scale plants.
Our investigations show that up to a capacity of approx. 4,000 MPD this is the preferred scheme.
Topsøe’s Ammonia Technology Today 14/22
Autothermal reformer Oxygen
lay-out (ATR) Natural gas
+ steam
CTS burner
Combustion zone
CH4 + 1½O2 CO + 2H2O
Thermal and catalytic zones
CH4 + H2O CO + 3H2
CO + H2O CO2 + H2
Synthesis gas
Autothermal Reformer Lay-out (ATR)
In the ATR, partial combustion of the hydrocarbon feed with oxygen is followed by conversion by the
steam reforming reactions in the catalyst bed. The exit temperature is typically above 1000°C, and this
ensures low CH4 leakage even at high pressure.
Contrary to the primary reformer (where the cost increases almost proportionally with the number of
tubes), the ATR is scaled up by increasing the size of the adiabatic reactor. In such a case there is a
benefit of the economy of scale, and the cost will not increase proportionally to the capacity increase.
Also for the air separation unit (ASU), supplying oxygen for the ATR and nitrogen for the NWU, there
is a benefit of economy af scale. Especially for capacities above 4000 MTPD the ATR along with an
ASU becomes attractive from investment point of view compared to the ”conventional” scheme
previously described.
Energy consumption is however, slightly higher for the ATR scheme compared to the ”conventional”
scheme. Mainly due to the energy consumption of the ASU. However, in cases where the gas is
cheap, this is normally considered of minor importance.
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The autothermal reformer (ATR)
Refractory-lined pressure vessel
Combustion and thermal and catalytic reactions
Special designed burner
The Autothermal Reformer (ATR)
The ATR is a refractory-lined pressure vessel, in principle similar to the secondary reformer.
Combustion of the hydrocarbon feed takes place with oxygen, and this requires a different burner
design than the nozzle type burner normally used in the air- fired secondary reformer.
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Computational fluid dynamics
Computational Fluid Dynamics
The design and further development of the ATR reactor is carried out by advanced models which have
been developed and optimised over many years. Transient simulations in 3 dimensions by
computational fluid dynamics (CFD) are used to calculate the flow distribution in the combustion
chamber and for design of the CTS burner. The graph shows the calculated temperature distribution
and the velocity profiles in the combustion chamber.
Topsøe’s Ammonia Technology Today 17/22
CTS burner
CTS Burner
The photo shows a burner for the ATR under final preparation in the workshop. The burner supplied
by Topsøe is a proprietary piece of equipment.
Topsøe’s Ammonia Technology Today 18/22
ATR features
ATR is used in many differerent industries
– Gas-to-liquids (GTL)
– Methanol
– Ammonia
– Synthesis gas generation
Simple unit operation
Well-proven technology in Topsøe ammonia plants since
1958
Easy to scale up to very large capacities
ATR Features
The ATR is not a new development. Topsøe has designed ATR’s for many years. The first ATR was
installed in an ammonia plant in 1958.
Since then the ATR has been found useful in many different types of process plants such as gas-to-
liquids (GTL) plants, methanol plants and for various synthesis gas applications. This means that the
knowledge and experience from these technologies can advantageously be transferred and used also
for designing very large ammonia plants.
Topsøe’s Ammonia Technology Today 19/22
References – ATR scheme
Statoil, Norway, start up 1997
– Capacity corresponds to 2,700 MTPD NH3
Sasolburg, South Africa, start up 2004
– Capacity corresponds to 2 x 2,600 MTPD NH3
Oryx, Qatar, expected start up 2nd Q 2006
– Capacity corresponds to 2 x 6,150 MTPD NH3
Escravos, Nigeria, expected start up end 2008
– Capacity corresponds to 2 x 6,150 MTPD NH3
Ar-Razi, Saudi Arabia, expected start up 2008
– Capacity corresponds to 5,700 MTPD NH3
References – ATR Scheme
The capacities of selected reference plants are given above. The production of H2 and CO in the ATR
has been converted into equivalent ammonia production.
As can be seen, the equivalent ammonia capacities are impressive, and the reforming unit as such is
not the bottleneck for the plant capacity. Actually, the ATR can be made even bigger than shown
above.
For the rest of the plant equipment, we have studied a capacity of 5,000 MTPD, and found it possible
to design a single stream plant for this capacity. For even higher capacities some of the equipment
might be duplicated, however depending upon a case to case decision.
Topsøe’s Ammonia Technology Today 20/22
Comparison of process schemes for very
large ammonia plants
Process concept Steam reforming ATR
Capacity, MTPD 4,000 5,000
Steam reforming Yes No
Secondary reforming Yes No
ATR No Yes
Final purification Methanation N2 wash
Synthesis loop configuration S-350 S-350
with inert Inert-free
Net energy consumption,
Gcal/MT NH3 Base + 6%
Rel. specific investment
(per MT NH3 capacity) Base -14%
Comparison of Process Schemes for Very Large Ammonia Plants
At very high capacities, the ATR scheme has an advantage with respect to investment cost due to the
economy of scale considerations mentioned earlier.
The energy consumption is approx. 6% higher, mainly due to the consumption of the ASU.
Topsøe’s Ammonia Technology Today 21/22
Potential for large plants
Economy of scale
– Conventional scheme beneficial up to about 4,000 MTPD NH3
– Benefit for the ATR scheme above 4,000 MTPD NH3 (ASU and
ATR size scale up)
Front-end size
– Very large synthesis gas production units based on ATR can be
constructed, e.g. for several synthesis units like ammonia and
methanol
Potential for Large Plants
For ammonia plants, a change in technology around 4000 MTPD of ammonia is beneficial. The ATR
scheme is preferred at higher capacities. This is due to the scale up advantages of the ATR and the
ASU in particular.
An ATR based front end can be made to produce even very large amounts of synthesis gas. One ATR
can produce synthesis for several large downstream synthesis unit, like for example ammonia and
methanol.
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Conclusion
Ammonia technology is continuously developed by
introduction of new equipment designs and improved
catalysts
Two viable schemes based on Topsøe technology
– Conventional
– ATR
The most attractive scheme will depend on:
– Plant capacity
– Operating cost (cost of natural gas)
– Investment (cost of capital)
Conclusion
Today we see two viable schemes for ammonia production. The choice between the two schemes
depends on plant capacity, cost of plant feedstock and cost of capital.
The optimum design will be tailor-made by Topsøe based on the actual conditions for the specific site.
