New and Used Industrial Plants

This 321 stainless steel, high-pressure ammonia recovery system was designed by ICI and built by Robert Jenkins, LTD.  The column is rated for 275 psig at 220°C.  The system used a high-pressure steam-driven reboiler to strip ammonia from crude amine products.

The 321 stainless steel (10.5% Ni) column is 2.5' diameter by 54' straight side.  It has a design pressure of 275 psig/FV @ 220°C.  The column has 22 single-pass valve trays also constructed of 321 stainless steel.  The column has an internal overhead condenser mounted in the top head.  It also has an internally mounted reboiler in the bottom section of the column.  The system includes a feed interchanger, and a column overheads cooler.

maximum proven capacity = 1.16 kt ammonia per day

feedstock: natural gas 50bar,

specific consumption 0.62-0.64 Tm³/t

energy/utilities: natural gas 5bar 0.35-0.37 Tm³/t;

• power 0.06-0.08 MWh/t;
• steam consumption needed only during startup
• 4bar steam generation (export) 1 – 1.27 t/t;
• 16bar steam generation 0.1-0.2 t/t

CO2 emission 2.0-2.1 t/t

last major TARs: 2021 (reformer tubes exchange, syngas line renovation, catalyst change, turbines & compression overhaul, incl. 2.5-yearly DLRG (pressure equipment directive) inspections), 2019 (DCS migration user interface, SLPC, CUI measures, incl. 10-yearly DLRG inspections), 2017, 2014, 2011

MAJOR UNITS

The plant consists of:

• Natural gas desulphurization
• Primary reformer (operates at 790°C and 30bar with the secondary reformer at 950°C)
• Secondary reformer with air compressors
• Natural gas desulphurization
• Primary reformer
• Secondary reformer with air compressors
• High and low temperature shift.
• CO2 removal
• Mechanization
• Syn gas compressor and air compressor
• Ammonia synthesis (reaction is 270 bar)
• Ammonia evaporation

Ammonia Converter

• 212801- Struthers Wells

• Capacity: 19,135 Gallons

• 7’ d x 75’l (overall)

• 2,600 PSI (Haldor Topsoe: S-200)

• Shell thickness 4.125"/ Head thickness 3.125"

  Download the Ammonia Converter Drawing

1,250 TPD Ammonia Plant Equipment Available

Compressors

212808 - Clark-Model #4M9-7-P, rotary air compressor

• Capacity: 24,979 ACFM
• Direct driven by steam turbine through gear reducer
• HP=8920/RPM 538
• 7 stages, 2670 critical speed
• 14.07 PSIA / PD-86.0 PSIA (1st Stage: Air)

212809 - Clark Model #2M8-6, CS rotary air compressor

• Capacity: 4,079 ACFM
• Driven by a steam turbine through a gear reducer
• 8920 hp / 10211 rpm
• 6stages 6500 rpm critical 10211 rpm
• PS-8.5 PSIA / PD-490 PSIA (2nd Stage: Air)

212812 - Clark Model #2BF-7(5), CS Centrifugal

• Capacity:611  ACFM, rated for 16930 hp/10585 rpm
• Driven by Turbine/Gear
• PS-1,796 PSIA / PD-2,530 PSIA (1st Stage: SynGas)

212813 - Clark Model #2BF-7, CS Centrifugal

• Capacity: 1,326ACFM, rated for 16930 hp
• Driven by Turbine/Gear
• PS-904 PSIA / PD-1,816 PSIA (2nd Stage: SynGas)

212814 - Clark Model #2BC-8, CS Centrifugal

• Capacity: 3,528 ACFM , rated for 16930 hp
• Driven by turbine/gear
• PS-358 PSIA / PD-914 PSIA (3rd Stage: SynGas)

212815 - Clark Model #2M8-5, CS Centrifugal

• Capacity: 4,284 ACFM, rated for 9185 hp
• Driven by turbine/gear
• 5 stages - 10,438 rpm speed/1,000 rpm max/6650 critical
• PS-140 PSIA / PD-230 PSIA (1st Stage: Refrigeration)

212816-Clark Model #4M8-7, CS Centrifugal

• Capacity 11,763 ACFM  rated for 918 5hp
• Driven by turbine/gear
• 7 stages, 5875 rpm speed/6220 rpm max/3000 critical
• PS-29 PSIA / PD-143 PSIA (2nd Stage: Refrigeration)

Ammonia Converter

212801- Struthers Wells

• Capacity: 19,135 Gallons
• 7’ d x 75’l (overall)
• 2,600 PSI (Haldor Topsoe: S-200)
• Shell thickness 4.125"/ Head thickness 3.125"

Gears

212811 - General Electric Model #S-234-BG

• Input RPM-5,380 / Output RPM-10,211
• HP-4,862

212818 - General Electric Model #S-234-BH

• Input RPM-5,875 / Output RPM-10,413
• rated for 1.78 ratio
• HP-3,267
• Clockwise rotation
• Gear and pinion

212819 - Lufkin Model #D290C

• Input RPM 1,749/ Output RPM-74
• Rated for 23.33:1 ration
• HP 155

95078 - General Electric Model #SI-458-A

• Input RPM-4,860 / Output RPM-10,585
• HP-20,000

Turbines

212810 - Model #3TDFOV2

• CS, horizontal multi stage condensing turbine
• Manufactured by Worthington
• RPM-5,650
• HP-9,800
• Inlet-540 PSIG
• Rotation clock wise
• 5 stage rateau (double 4th & 5th stage)

212817 - Model #3TDFOV2

• CS, horizontal condensing turbine
• Manufactured by Worthington
• 5 stage rateau (double flow 4th & 5th stage)
• RPM-6,175
• HP-10,100
• Inlet PSI-150 @ 450° max
• Exhaust-4” of Hg  ABS. at 128°F
• Rotation clockwise

212820 - Unused spare turbine rotor for Terry Turbine model GAF6

Heat Exchangers

282825

• 5,290 sq. ft Horizontal
• Manufactured by Struthers Wells
• CS Shell / CS Tubes / CS Heads
• 100 PSI Shell / 2,600 PSI Tubes (@600°F)
• Single pass Shell and Tube

212823

• 5,955 sq. ft Horizontal
• Manufactured by Heatran
• CS Shell / CS Tubes / CS Heads
• 2,600 PSI Shell / 2,600 PSI Tubes  (@600°F)
• Single Pass shell and tube

212821/212822

• 11,300 sq. ft., Horizontal
• Manufactured by Heatran
• CS Shell / CS Tubes / CS Heads
• 2,600 PSI Shell / 2,600 PSI Tubes (@ 600°F)
• single pass shell and tube

Tanks

212802

• 6,200 Gallon, CS, vertical storage tank, mounted on a skirt.
• Manufactured by National Tank Co.
• Rated for 644 psi at 460 degrees F, 6'6" diameter x 23' long, Welded dish heads.
• Wall thickness= 1.625"  Skirt height 5'.

212803

• 6,200 Gallon, CS, vertical storage tank, mounted on a skirt.
• Manufactured by Nooter.
• Rated for 644 psi at 460 degrees F, 6'6" diameter x 23' long, Welded dish heads.
• Wall thickness= 1.625"  Skirt height 5'.

212804

• 9,000 Gallon, CS,  vertical pressure tank.
• Manufactured by Delta Southwestern.
• Rated for 405 psi at 875 degrees F.13' diameter x 5' straight side with welded hemi heads.
• Wall thickness =2.9".  Eight lug supports.

212805

• 5,700 Gallon, CS, vertical pressure tank
• Manufactured by National Tank.
• Rated for 430 psi at 800 degrees F. 10'6" diameter x 7' straight side with welded hemi heads.
• Wall thickness is 1.6".  Support by lugs.

212806

• 6,200 Gallon, CS, vertical storage tank, mounted on a skirt.
• Manufactured by National Tank.
• Rated for 644 psi at 460 degrees F, 6'6" diameter x 23' long, Welded dish heads.
• Wall thickness= 1.625"  Skirt height 5'.

212807

• 6,200 Gallon, CS, vertical storage tank, mounted on a skirt.
• Manufactured by National Tank.
• Rated for 644 psi at 460 degrees F, 6'6" diameter x 23' long, Welded dish heads.
• Wall thickness= 1.625"  Skirt height 5'.

Furnace

212800

• 15.00 mm/btu, vertical furnace(SU heater) manufactured by Econo-Therm.
• Rated for 2750 psi at 950 degrees F.
• 6 burners, with stack.
• Overall height 111', stack section is 33'3" high, furnace section is 10'6" high.  Length is 111' long. 10'6" width with refractory lining.

Plant is designed to purify, condense, liquefy, and store raw carbon dioxide gas (CO₂) at the site. Production capacity is 15 tons/hour design, possible up to 16,5-17 tons/hour. Purity is 99.995%

Main process steps:

1. Washing of raw CO₂ gas
2. Compression of CO₂ gas(centrifugal compressor and screw compressor – 2 stages)
3. Purification and dehydration of CO₂ gas
4. Liquefaction of CO₂ gas (using a condenser operating with ammonia)
5. Distillation of liquid CO₂
6. Storage and loading stations

In melamine synthesis, urea is converted to melamine at approx. 400 °c and approx. 2 bar at a Si02 I Al203 catalyst in a synthesis line. As a by-product, ammonia and carbon dioxide are produced in stoichiometric quantities in the process gas.

Hydrogen cyanide as well as multinuclear condensation products of melamine and (partially) hydrolyzed melamine derivatives are also produced in small quantities as secondary components. After separating the melamine from the process gas, it is fed via catalytic decomposers to minimize the minor components. The process gas is then fed to the process gas separation plant in U 024. In addition, a partial flow in the process gas processing can be processed into ammonium nitrate solution and delivered to external factories such as the field fertilizer factory or the nitric acid factory. These plants are not part of the melamine factory, but the exhaust gas flow is generated and must be supplied.

Liquid ammonia (approx. 11 bar) from the gas separation plant is supplied to the external urea factory, fed into the plant network or fed back into the melamine synthesis. The C02-containing residual gases from the process gas processing plant U 028 and the process gas separation plant U 024 are emitted via the outlets

Capacity:

• 600 tons/day (25 tons/hr)

Raw Materials:

• CO2 supplied from a Long Residue Gasification Plant
• Liquid NH3 supplied from an Ammonia Production Plant

Product:

• Pelletized urea (carbonic acid diamide)
• The product is surface-modified - using URESOFT® 150 agent  to avoid  agglomeration. The typical content of this agent is 0.4% by weight.

• This is the largest unit in a highly integrated facility that sits on 57 acres of land, two-thirds of which are undeveloped.  The facility produces Methyl Amines for use in Higher Amines and Amine Derivatives.

• The Methyl Amines plant has a capacity of 46,000 metric tons per year mixed amines production.

The following products are produced from the reaction of methanol and ammonia:

• Monomethylamine (MMA)

• Dimethylamine (DMA)

• Trimethylamine (TMA)

The paraformaldehyde plant is a continuous process plant with a total capacity of 30,000 tons per year. Paraformaldeyhde product is 92% concentration and is a dry product. The plant also produces a distillate.

The hexamine (hexamethylenetetramine) plant was built in 1994 with a capacity of 5,000 tons per year. Hexamine production used a by-product from paraformaldehyde . Hexamine production is a continuous process that uses formaldehyde distillate and ammonia as raw materials

• The plant produces food grade CO2 at a capacity of 250Te/day. The CO2 final product spec is 99.998% purity.

• The plant mainly consists of

  • 3 off Sulzer 3 stage compressors 560psig discharge
  • Water scrubber to remove soluble impurities
  • Charcoal bed to remove traces of sulphur and oil
  • Activated alumina bed dryer (2 off for regeneration)
  • Condenser to produce liquid CO2 using ammonia as refrigerant
  • Stripping column to remove entrained inert gases using recycled CO2

Product specification:

Water 10.0 ppm w/w max

Sulphur 0.1 ppm w/w max

Gaseous inerts 100 ppm v/v

Methanne10 ppm v/v max

Argon 1.0 ppm w/w max

Boron 0.1 ppm w/w max

Halogens 1.0 ppm w/w max

Carbonyls 1.0 ppm w/w max

Oil 2.0 ppm w/w max

Arsenic 0.0 ppm w/w max