Ammonia

ThyssenKrupp

A company
of ThyssenKrupp
Technologies
Uhde
2 Table of contents

Page

1. Company profile 3

2. Uhde’s ammonia experience 5

3. The Uhde ammonia process 7

3.1 Steam reforming 8
3.2 CO2 removal 10
3.3 Ammonia synthesis 11
3.4 Steam system 12
3.5 Concept variants 13
3.6 The Uhde Dual-Pressure Process 14

4. Uhde proprietary equipment designs 16

4.1 The primary reformer with a cold outlet manifold system 17
4.2 The secondary reformer 20
4.3 Process gas cooling train downstream of the secondary reformer 21
4.4 Ammonia converter and waste heat recovery 22
4.5 Production and Consumption Figures per Metric Ton of Ammonia 25
5. Services for our customers 26

6. Recent references 27

Ammonia technology has evolved

Evolution has brought perfect proportion for a new era in
ammonia technology. A new 4,000 plus mtpd plant design from
the world-leading ammonia partnership between Uhde and
Johnson Matthey Catalysts. The Uhde Dual-Pressure Process
minimises both compression requirements and equipment
dimensions. Based on fully-proven, dependable equipment, it
offers total reliability with no risks or surprises.
Are you looking for cost-effective investment and operation
through economies of scale?
Then see page 14.
 1. Company profile 3

Uhde’s head office

in Dortmund, Germany

With its highly specialised workforce of more than 4,900 employees and its
international network of subsidiaries and branch offices, Uhde, a Dortmund-based
engineering contractor, has, to date, successfully completed over 2,000 projects
throughout the world.

Uhde’s international reputation has been built on the successful application of

its motto Engineering with ideas to yield cost-effective high-tech solutions for its
customers. The ever-increasing demands placed upon process and application
technology in the fields of chemical processing, energy and environmental protection
are met through a combination of specialist know-how, comprehensive service
packages, topquality engineering and impeccable punctuality.
4

Process flow sheet of Uhde’s

first ammonia plant in Herne,
Germany, completed in 1928

Ammonia plant in fertiliser complex

in Tecen, Turkmenistan
Capacities: 600 mtpd of ammonia
1,050 mtpd of urea synthesis
1,050 mtpd granulation unit
2. Uhde’s ammonia experience 5

Ever since the company was established in In recent years, ammonia plant technology has
1921, Uhde has been involved in the design undergone radical developments in terms of
and construction of ammonia plants and has both design and equipment. In order to improve
played a leading role in the development of plant efficiency, efforts have had to be focused
ammonia technology. As far back as 1928, the on reducing power consumption, improving
first ammonia plant to use an Uhde proprietary process heat recovery, minimising stack losses
process went on-stream at the site of the Mont- and cutting energy consumption for CO2 removal.
Cenis coal mine at Herne-Sodingen. The plant
Uhde’s objective of making a substantial improve-
had an output of 100 mtpd of ammonia and
ment in energy efficiency has relied heavily on
comprised four reactors with a capacity of
experience and involved a broad spectrum of
25 mtpd each, the loop operating at a pressure
technical expertise including a technical review
of 100 bar.
of process design, engineering design, research
The fact that the first Uhde-engineered ammonia and development and the evaluation of operat-
reactors were equipped with an internal heat ing data. Equally important has been the
exchanger and a synthesis loop with an integrated enhancement of plant operability and reliability.
two-stage refrigeration unit deserves a special Hence, much attention has been paid to past
mention. Unfortunately, this efficient system was successful experience and proven energy-saving
soon considered outdated, and it was not until features.
the seventies that these design principles were
In 1998, Uhde joined forces with Synetix, now
taken up again.
Johnson Matthey Catalysts (JMCatalysts), to
Rising energy prices have posed an increasing further improve the Uhde ammonia process.
challenge for ammonia plant designers since this This partnership builds on the traditional strengths
period. As early as 1968, Uhde took up the of the two companies and takes advantage of
challenge and engineered a plant with an energy JM Catalysts know-how in catalysis, ammonia
consumption of only 7.8 Gcal per tonne of plant operation and support services together
ammonia. with Uhde’s experience in design, engineering
and project execution. The partnership allows
This natural gas-based plant with a capacity of
strong collaboration between JM Catalysts and
880 mtpd incorporated the following essential
Uhde engineers so that the Uhde ammonia
elements for reducing energy consumption:
process can be further optimised to take best
• Maximum heat recovery from the primary advantage of the latest high-performance cata-
reformer flue gas by cooling it to 135°C at lysts from JM Catalysts, thus improving efficiency
the stack inlet. and lowering cost.
• Preheating of the combustion air for the The most recent successful implementations of
primary reformer. the Uhde ammonia process include a plant in
Turkmenistan with a capacity of 600 mtpd, a
• Generation of 125 bar steam from process
2,000 mtpd plant for Qatar Fertiliser Co. (QAFCO)
waste heat downstream of the secondary
in Mesaieed, Qatar, and five 1,200 mtpd plants
reformer and in the ammonia synthesis unit.
in Egypt, where three more 1,200 mtpd plants
• High-pressure steam superheating with waste based on the Uhde ammonia process are also
process heat downstream of the secondary under construction.
reformer.
A new milestone in ammonia technology has
• Three-bed ammonia reactor with heat now been achieved with the plant built for Saudi
exchangers between catalyst beds. Arabian Fertilizer Company (SAFCO) in Al Jubail,
Saudi Arabia. It is the first plant to be based on
All subsequent ammonia plants designed by
the "Uhde Dual Pressure Process" and, with a
Uhde have incorporated most of these low-
single-train capacity of 3,300 mtpd, it is by far
energy features.
the world's largest ammonia plant. It has been
in operation since 2006. A second plant of this
type is now under construction in Ras As Zawr,
Saudi Arabia.
6
3. The Uhde ammonia process 7

The adjacent block diagram of an Uhde The following process areas have undergone
ammonia plant shows the conventional major modifications in order to achieve these
sequence of process steps that form the basis figures:
of most present-day ammonia processes.
• The steam reforming section including its
However, ammonia processes cannot be judged
waste heat recovery system.
solely on the basis of a block diagram. A more
detailed scrutiny of the facts and figures shows • The CO2 removal unit.
that what appears to be a conventional set-up is
• The ammonia synthesis unit.
in fact a most up-to-date ammonia plant concept.
Assuming the reader to be familiar with the
The total consumption figure (feed + fuel + elec-
fundamentals of ammonia technology, attention
tric power) per metric ton of ammonia produced
in the following sections has been restricted to
is in the range of 6.6 to 7.2 Gcal (27.6 - 30.1 GJ),
those aspects specific to the Uhde low-energy
depending on local conditions (e.g. cooling
concept.
water temperature) and project-specific require-
ments (such as the natural gas price, etc.).

Block diagram Natural gas feed

of an Uhde ammonia plant

Desulphurisation
Fuel Process steam

Combustion
Primary reformer
air

Process air
Secondary reformer

HP steam
superheated

BFW
CO shift

CO2
CO2 removal

Methanation
Syngas compressor

HP steam to
superheater

Product
Refrigeration NH3 synthesis
NH3

H2 to syngas compressor Fuel

H2 recovery

1,500 mtpd ammonia

plant and fertiliser complex,
Saskferco, Canada
8 3.1 Steam reforming

Primary and secondary reformer The following modifications to conventional • Increase in the feed/steam mixture preheat
of the AFC ammonia plant in Egypt.
plant designs have contributed to improvements temperature. This reduces the firing
in overall efficiency: requirements in the primary reformer by
shifting the heat transfer duty from the
• Shift of part of the reforming reaction from
radiant section to the convection section.
the primary to the secondary reformer as a
result of the following measure: • Decrease in the steam-to-carbon ratio to 3.0.
This includes an adequate safety margin
Installation of a purge gas recovery unit, by
against the formation of carbon deposits on
means of which hydrogen is recycled to the
the primary reformer catalyst. Reducing the
suction side of the syngas compressor,
admixture of steam to the feed results in less
thereby allowing operation of the secondary
heat being absorbed in the primary reformer
reformer with excess air while the hydrogen-
radiant section and therefore lower fuel
to-nitrogen ratio of the make-up gas is kept
consumption. Nevertheless, the steam-to-gas
close to 3:1.
ratio is high enough to minimise by-product
• Preheating of the process air for the secondary formation in the HT shift through the use of
reformer to a higher temperature (540°C). commercially proven catalysts.
Shifting part of the reaction to the secondary
The process data of the reforming section are
reformer leads to lower operating tempera-
summarised below:
tures in the primary reformer and therefore to
fuel savings. Steam/carbon ratio 3.0
Feed/steam, primary reformer inlet °C 530 - 580
• Optimum use of the reduced primary reformer Pressure, primary reformer exit bar 39 - 43
load is achieved by increasing the reformer Methane, primary reformer exit vol.% 10 - 13
pressure to about 40 bar whilst maintaining Methane, secondary reformer exit vol.% 0.3 - 0.6
the estimated lifetime of the reformer tubes at Process air temperature °C 520 - 600
100,000 hours. This step entails a reduction in Combustion air temperature °C 250 - 440
overall energy consumption as the aggregate 125 bar steam, superheated °C 530 - 540
power required for the compressors is reduced. Stack temperature °C 120 - 180
 9

Steam reforming
and CO shift

Fuel HP steam
Secondary
reformer

Steam drum
Reformer HP steam
Desulphurisation
➀➁ ➂ ➃ ➄ superheater

Process
gas cooler
HP steam
Feed
MP steam
LT shift HT shift
Process air
Combustion air

Convection bank coils BFW

➀ HP steam superheater Process gas
➁ Feed/steam preheater
➂ Process air preheater BFW
➃ Feed preheater
➄ Combustion air preheater
Special mention should be made of an essential superheater of choice in all of the ammonia
item of equipment in the steam reforming section: plants recently built by Uhde. On the one hand,
the steam superheater, located in the process this arrangement provides the necessary
train downstream of the secondary reformer. flexibility to adapt the plant to any given set of
process requirements, and on the other, it
In a low-energy plant, the objective is to recover
enables the steam system to operate safely
as much heat as possible from the convection
under any normal, or abnormal, operating
section for direct process use, thereby reducing
conditions. An internal bypass in the evaporation
the fuel requirement. This reduces the heat
section permits the shifting of heat transfer
available in the convection section for super-
duty between the evaporator and the steam
heating HP steam. The balance of the energy
superheater. In normal operation, the internal
required for this purpose is therefore recovered
bypass remains partially open. By closing it, the
in the superheater downstream of the secondary
gas temperature at the superheater inlet can be
reformer. The duty of this superheater is in the
reduced, thus increasing steam generation. This
range of 15 to 40% of the heat available
is important in overcoming partial plant failures,
between secondary reformer exit and HT shift
e.g. in the case of a loss of steam production in
inlet, depending on the process parameters
the ammonia synthesis section.
selected.
The lower the consumption figure, the more
process gas heat is utilised to superheat the HP
steam, whereas the total HP steam generated is
reduced. In other words: fuel savings also reduce
the net energy export.
A superheater of this type was installed by Uhde
for the first time in the Gewerkschaft Victor plant,
which went on stream in 1970. This same design
configuration was also used for the CIL plant in
Canada (on-stream since 1985) and is now the
10 3.2 CO2 removal

Various chemical and physical absorption without any need for stripping energy. Final
systems are available for the removal of CO2, purification to the ppm range then takes place in
e.g. aMDEA®, Benfield, Amine Guard and Selexol. the upper part of the absorber with a relatively
Uhde has used all these processes in the past small portion of the total circulating solvent. It is
and has the experience of many years of com- only this portion that has to be thermally regen-
mercial operation. The lowest energy consump- erated by a stripping process in a reboiling col-
tion is achieved using the activated aMDEA® umn. This process scheme permits a reduction
process licensed by BASF. The key to these energy in the specific energy consumption of the CO2
savings is that the solution is primarily regenerated recovery system to 1,340 kJ/Nm3 of CO2
by flashing rather than steam stripping. (13,000 BTU/lb mole of CO2).

aMDEA® CO2
removal system
CO2 (high purity)
Fuel Absorber

Flash
vessel

Stripper

C.W. C.W. Pure

gas
LP steam

Process gas

The activated aMDEA® process uses a solution In addition, the process offers the following
of N-methyldiethanolamine and water with a advantages:
special activator as the solvent. As the aMDEA®
• High CO2 recovery rate (> 96%) and
solution isotherms for CO2 are between those of
CO2 purity (> 99% by volume).
a typical chemical solvent and a physical
solvent, this process combines the benefits of • No need for corrosion inhibitors as the
both chemical and physical CO2 removal solution is not corrosive to carbon steel.
processes.
• Minimisation of solution losses because
The design selected incorporates a two-stage aMDEA® has a low vapour pressure and does
absorber. Most of the CO2 is removed in the not degrade during operation. No reclaiming
lower part using a semi-lean solution that has of the solution is required.
been regenerated in a two-stage flash loop
• No toxic solvents.
• No crystallisation problems.
 3.3 Ammonia synthesis 11

The most fundamental improvements to earlier For maximum reliability and cost-effectiveness
designs have been effected in the ammonia Uhde therefore uses only well-proven magnetite-
synthesis unit. based catalysts in all three beds. The first of the
three beds will typically be filled with prereduced
The main feature of this unit is its high
catalyst to accelerate the initial start-up.
conversion rate which is achieved by a large
catalyst volume. In order to minimise reactor Depending on the site-specific and project-specific
size and cost while keeping the pressure drop conditions, the three catalyst beds are arranged
low, the large catalyst volume requires: in either one or two ammonia reactors.
• The use of small grain-size catalyst. Designs with one ammonia reactor and one waste
heat boiler cannot optimally exploit the reaction
• Application of the radial-flow concept in the
heat for the generation of high-pressure steam.
Ammonia synthesis ammonia reactor.
However, optimum heat recovery can be
HP steam
achieved if an additional waste heat boiler is
introduced between the second and third bed.

Refrigeration
Purge
Ammonia
converter
C.W.

NH3
BFW (liquid)
Make-up gas Syngas compressor

Uhde has always advocated three-bed reactors This arrangement improves the gas-side
with high ammonia conversion rates per pass. temperature of the boilers and provides an
Therefore, the Uhde ammonia synthesis unit is additional advantage in that it permits a higher
based on a three-bed reactor system, each bed boiler feed water temperature at the boiler inlet,
with a radial flow. A high-conversion synthesis which means that the preheating of the boiler
loop offers considerable advantages since the feed water can be enhanced by using the low-
recycle gas quantity is considerably reduced and, level heat available in other plant sections, for
consequently, power requirements for the circu- example downstream of the LT shift.
lator are lower and heat exchanger surfaces
The effect of a two-boiler system on high-pressure
smaller. Refrigeration requirements also decrease
steam generation is significant:
overproportionately because most of the ammo-
it is increased from 1.1 to 1.5 t/t of ammonia.
nia produced is condensed upstream of the loop
The process parameters of the synthesis loop
chiller.
design are shown below:
Studies on innovative high-activity precious-met-
H2/N2 ratio, methanation exit 2.95
albased catalysts have revealed that no economic Synthesis loop pressure bar 140 - 210
advantage can be gained through their use in NH3 reactor inlet vol.% 3-5
view of the uncertainty of future prices for the NH3 reactor outlet vol.% 20 - 25
precious metals required. Furthermore, due to HP steam generation t/t NH3 1.1 - 1.5
the different physical properties operational Number of reactors 1 or 2
problems can be expected.
12 3.4 Steam system

The diagram shows the heat management system Medium-pressure steam at 49 bar, 415°C,
underlying Uhde’s low-energy ammonia plant is used as process steam or for the following
concept, the essence of which is the optimum equipment:
utilisation of process waste heat for the generation
• Condensing turbine driving the syngas
of superheated high-pressure steam.
compressor.
High-pressure boiler feed water is heated in a
• Condensing turbine driving the process air
first step downstream of the LT shift; the stream
compressor/alternator.
is then split into two, one part-stream going to
the ammonia synthesis unit and the other to the • Back-pressure turbine driving the boiler feed
HT shift for further preheating. water pump.

Steam system
Process gas Flue gas

HP steam header
112 bar, 530 °C
Turbine syngas compressor
Steam drum
125 bar
Process gas

NH3
Process gas synthesis Process gas

Process steam MP steam header

415 °C, 49 bar
Turbine process air
compressor and alternator

LP steam consumers BFW pump

LP steam header

C.W. Surface condenser

BFW
Condensate Condensate
treatment Condensate pump

High-pressure steam is only generated from Depending on the plant requirements, the process
process waste heat at two locations: air compressor turbine or the refrigeration com-
pressor turbine can be fed with HP-steam. All
• Downstream of the secondary reformer.
other machines are driven by electric motors.
• In the ammonia synthesis unit.
Superheating of high-pressure steam takes
place downstream of the secondary reformer
and in the primary reformer convection bank.
The superheated steam is expanded in the high-
pressure part of the syngas compressor turbine
and fed to the medium-pressure system.
3.5 Concept variants 13

The plant concept presented here constitutes

the basis of Uhde’s low-energy ammonia tech-
nology. The design can easily be adapted to suit
the specific conditions of any project. Variations
may range from minor process modifications
(e.g. in the steam system) to the replacement of
entire units (e.g. substitution of the aMDEA® CO2
removal system for an Amine Guard, Benfield or
Selexol unit).
Moreover, gas turbines can be incorporated as a
compressor driver (e.g. process air compressor)
or alternator driver. The exhaust gases can be
utilised as high preheat combustion air for the
primary reformer or to generate export steam in
a heat recovery steam generator (HRSG).
14 3.6 The Uhde Dual-Pressure Process

Chemical plant capacities have for a long time

been taking on ever greater dimensions. The
reason lies in the reduction of the specific
production costs through economies of scale. Second
ammonia
More than ever before, the plant construction converter
sector is facing the challenge of exploiting this
advantage while at the same time continuing to HP HP
employ proven technologies and equipment. steam steam
Uhde and Johnson Matthey Catalysts have risen First
to this challenge and developed a process ammonia
based on existing technology which now enables converter
ammonia plants to produce very large capacities. ~ 110 bar
This new process (see flowsheet) delivers a
capacity of 3,300 mtpd using well-tried and
LP
tested equipment. It also provides the basis for casing
even larger plants (e.g. 4,000 - 5,000 mtpd).
Note: Molecular
The first plant based on this process is the sieves (dryers) CW
SAFCO IV ammonia plant in Al-Jubail, Saudi not shown
NH3
Arabia. With a capacity of 3,300 mtpd it is chiller
by far the largest ammonia plant worldwide.
The plant has been in operation since 2006.
Engineering for the next plant using the dual- H 2O
pressure process is ongoing.
The key innovation in Uhde's new dual-pressure CW
ammonia process is an additional medium-
pressure once-through ammonia synthesis con- Make-up gas from front-end NH3 chiller
nected in series with the conventional high-
pressure ammonia synthesis loop as follows:
1. The once-through ammonia synthesis involves Low pressure section
the compression of the make-up gas in a High pressure section
two-stage inter-cooled compressor. This is
the low-pressure (LP) casing of the syngas
compressor. The pressure at the discharge
of the compressor is about 110 bar. At this
pressure the three-bed, inter-cooled, once-
through converter produces approximately
one third of the total ammonia output. The
syngas-ammonia mixture leaving this con-
verter is cooled and 85% of the ammonia
produced is separated from the gas as liquid.
2. The remaining syngas is then compressed in
the high-pressure (HP) casing of the syngas
compressor to the operating pressure of the
ammonia synthesis loop (up to 210 bar). Since
the syngas has been cooled down the HP
casing can operate at a much lower tem-
perature than in the conventional ammmonia
process. The high synthesis loop pressure is
achieved through a combination of the chilled
second casing of the syngas compressor and
a slightly elevated front-end pressure. In this
conventional ammonia synthesis loop the re-
maining two thirds of the total ammonia is
produced.
 15

Technology highlights
• Well-proven magnetite-based catalysts can
Off-gas be used in all stages of the new process.
• Energy efficiency is improved by 4% compared
PGR unit to the conventional Uhde process.
~ 210 bar Purge gas recovery
• A high conversion rate in the high-pressure
synthesis loop combined with the reduced
CW
production requirement results in reduced
piping sizes in the high-pressure loop.
NH3 chiller NH3 Standard piping can be used for capacities
of 4,000 mtpd and more.
• The syngas compressor of a 3,300 mtpd
HP Once-through Ammonia dual-pressure plant is the same size as that in
casing ammonia converters from current 2,000 mtpd ammonia plants; several
HP loop reference compressors are in operation.
• Only 2/3 of the hydrogen recovered from
NH3 chiller the purge gas has to be recompressed to
the loop; 1/3 is converted to ammonia in the
HP
steam once-through synthesis.
• The process design is extremely flexible
with a large number of process parameters
available to optimise the use of catalyst and
machinery.

Ammonia from once-through conversion NH3 • It is now possible to achieve a synthesis

capacity of about 3,300 mtpd of ammonia
using conventional equipment and catalysts
that have proved to be reliable and efficient
in existing plants.
• There are no major deviations from proven
process conditions.
• The front-end of the plant is very similar to
the current Uhde design except that it
operates at a pressure of about 3 bar higher,
a process condition which is well within
Uhde’s proven long-term design and
operating experience.
 16 4. Uhde proprietary equipment designs

A good process alone is not sufficient. • Process gas cooling train downstream of the
secondary reformer for
It is at least as important to have proven and
- generating high-pressure steam
reliable designs for critical items of equipment.
- superheating high-pressure steam.
Only the two combined will make a good plant.
• High-efficiency ammonia converter system
Uhde has pioneered the development of
with three beds, indirect heat exchange and
essential items of equipment for ammonia
radial flow.
plants and is one of the leading contractors in
this field. These developments include: • Ammonia synthesis waste heat boiler.
• Primary reformer with a cold outlet manifold Uhde holds, or has pending, a number of
system. patents for such equipment and has granted
numerous manufacturing and marketing
• Secondary reformer.
licences to equipment manufacturers and
chemical engineering contractors.

Primary reformer Cold outlet manifold system

Inlet manifold
Secondary reformer

Burners
Process air

Reformer Water jacket

tubes
Refractory

Catalyst bed

Gas outlet

Cold outlet
Reformer radiant section, outlet manifold
manifold system
system and secondary reformer
 4.1 The primary reformer with a cold 17
outlet manifold system

The primary reformer is a furnace in which a The following main features show Uhde’s
multiplicity of tubes filled with catalyst are approach to fulfilling the above requirements:
heated by burning fuel. The process gas tem-
• Top-firing for an optimum uniformity of the
perature required at the outlet of the catalyst-
tube skin temperature profile.
filled tubes is about 800°C at a pressure of
approximately 45 bar. Inevitably, the service life • Small number of burners (in comparison with
of components such as the reformer tubes is a side-fired reformer).
limited. Material deterioration occurs through the
• Internally-insulated cold outlet manifold
combined effects of creep, alternating thermal
system made from carbon steel and located
and mechanical stresses, external and internal
externally under the reformer bottom.
oxidation and carburisation.
• Internally-insulated reformer tube-to-manifold
Consequently, the furnace designer is faced
connection which operates at moderate
with two main tasks:
temperatures.
• Firstly, to minimise the number of com-
• Each tube row is connected to a separate
ponents subject to wear and tear due to the
outlet manifold.
combined effects of high temperatures and
pressures. Advantages of the Uhde reformer:
• Secondly, to allow as smooth and safe an • No high-alloy outlet pigtails and/or outlet
operation as possible. manifolds or risers which work at creep
conditions.
Reformer tube-to-manifold connection
with skin temperature profile • Minimum number of components exposed to
Furnace bottom
the severe process conditions.

Catalyst grid
• Uniform temperature profile over the entire
length of the reformer tube with the lowest
Bellow
possible peak temperature, resulting in
Skin temperature optimum utilisation of the reformer tube
profile
material.
• No thermal expansion problems with the
Gas conducting tube outlet manifold system. The slight remaining
thermal expansions do not have to be com-
Shop weld pensated by materials exposed to the severe
Field weld process conditions. The design of very large
Carbon steel single-box reformers is possible.
Refractory

• The process gas outlet temperature is

monitored for each tube row and is
300 600
Skin temperature [°C]
900 adjustable during operation for optimum
Outlet manifold
reformer performance and temperature
uniformity.
• Almost unlimited service life of the Uhde
outlet manifold system with no maintenance
required other than painting.
• Considerable operational allowance of the
outlet manifold system with regard to process
gas temperature and pressure.

More than 60 reformers of this type have so far

been designed and constructed since 1966.
All have given excellent performance.
The two largest units are equipped with 630 and
960 tubes, respectively.
18
Fertiliser complex of AFC
in Abu Qir (near Alexandria), Egypt.
Capacities: 1,200 mtpd of ammonia
1,925 mtpd of urea
2,000 mtpd granulation unit
19
20 4.2 The secondary reformer

The process gas leaving the primary reformer Particularly challenging areas in secondary
enters the secondary reformer at the bottom. reformer design include:
The gas is routed through the central internal • The transfer line from the primary reformer
riser pipe into the combustion chamber at the outlet to the secondary reformer.
top of the secondary reformer. Process air is
introduced into this combustion chamber via • The refractory lining including the ceramic
nozzles, arranged at equal intervals round the arch which bears the catalyst weight.
circumference of the combustion chamber in • The burners.
two rows. The partially oxidised gas passes
Uhde’s answer to a safe and reliable secondary
through the catalyst bed from top to bottom, the
reformer comprises the following features:
catalyst bed being supported by a ceramic arch.
Finally, the gas leaves the secondary reformer • A refractory-lined transfer line between the
through the outlet nozzle at the bottom. primary and secondary reformer which is
only short as it is connected to the lower
nozzle of the secondary reformer. Once in the
secondary reformer, the gas passes through
Secondary reformer CFD optimisation
an central internal riser into the combustion
chamber. This design eases ducting and
eliminates thermal stress between the
transfer line and the secondary reformer.
• A multi-layer refractory lining with high-
alumina bricks in the hot zones.
• A ring-shaped arch made of high-alumina
Process air
bricks that provides a highly stable support
for the catalyst. Due to the internal riser, the
arch spans only half of the vessel diameter,
resulting in improved stability compared to
other designs.
Combustion
zone • A multiple nozzle burner system comprised of
nozzles equally distributed round the circum-
ference of the combustion chamber at two
Water jacket levels.
• Discharge of the process gas from the cen-
tral internal riser into the dome by reversing
the flow direction. Air is added via a specific
Catalyst
number of nozzles installed in the vessel wall
Refractory at a defined angle, thus creating a vortex
flow in the combustion chamber. The vortex
flow ensures optimised mixing of air and
process gas. The flames do not come into
Arch contact with the vessel refractory or the cen-
tral riser pipe.
Process gas
• A proprietary burner design, first applied in
1992, which avoids any metallic parts com-
ing into contact with the hot reacting process
gas.
Since its introduction in 1968, the Uhde second-
ary reformer has proved to be a reliable item of
equipment with a long service life.
Process gas
 4.3 Process gas cooling train 21
downstream of the secondary reformer

The process gas from the secondary reformer Features of the Uhde process gas cooling train
has to be cooled from 1,000°C to a controlled
Horizontal fire-tube boiler with:
temperature suitable for the downstream CO
shift. The sensible heat can best be utilised in • Thin flexible tube-sheet design.
the generation and superheating of high- • Full penetration tube to tube-sheets welds.
pressure steam.
• Tube inlets protected by ferrules to limit the
The challenge in designing suitable cooling train head flux at the tube inlet.
equipment is to arrive at a concept which pro-
• Double layer refractory lining for the inlet and,
vides safe temperature limitation for all parts
if necessary for the outlet chamber with high
according to their particular load sensitivity and
duty bricks on the hot surface.
materials of construction. In addition, the equip-
ment should be available at competitive prices. • Internal gas bypass for temperature control
with steam cooled damper blades.
Since 1966, Uhde has both used and promoted
the use of the horizontal fire-tube boiler for this • Steam drum mounted on top of the boiler and
purpose. In 1969, the process gas cooling train supported by downcomers and risers.
was first modified to include a high-pressure High-pressure steam superheater with:
steam superheater.
• Process gas inlet and outlet at the bottom.
• Preferably vertical arrangement of the
superheating coil.
• Pressure shell in contact with the cooled
process gas only.
• Internal bypass for temperature control.
Advantages of the horizontal fire-tube boiler:
• Simple, fixed-tubesheet design.
• No crevice corrosion.
• Reliable natural water circulation.
• No heated dead ends on water side where
debris can settle.
• Low metal temperatures at and near
tubesheets due to efficient insulation and
ferrules.
• Simple and reliable process gas temperature
control.

Uhde secondary reformer • Easy access for inspection and maintenance.

and process gas cooling train
• Low erection costs due to shop assembly of
boiler and drum.
Advantages of the high-pressure steam
superheater:
• Coil designed for high mechanical flexibility.
• Thermal expansions compensated within the
coil.
• Safe metal temperatures maintained by
efficient bypass control.
• Temperature of the pressure-bearing shell
governed by cooled outlet gas.
• Simple steam and process gas temperature
control.
22 4.4 Ammonia converter and waste heat recovery

Fertiliser complex of EFC The demand for energy-efficient Features of

in Ain Shukna (near Suez), Egypt.
Capacities: 1,200 mtpd of ammonia
ammonia production dictates the the single-converter design:
1,925 mtpd of urea following criteria for the design • Heat exchanger between • Heat exchangers extractable
2,000 mtpd granulation unit of the ammonia synthesis unit: catalyst beds for indirect without removal of cartridge.
• High conversion rates cooling of synthesis gas; • An externally-arranged BFW
and therefore large catalyst consequently, highly-efficient preheater/HP steam boiler
volume. temperature control. downstream of the third bed.
• Maximum utilisation of • Radial flow from outside to
reaction heat for the gener- inside through all catalyst
ation of high-pressure steam. beds.
• Low pressure drop in the loop. • Design adaptable to full-bore
or drawn-in top closure
Such criteria, in turn, of converter, depending on
call for the : project constraints.
• Use of small grain-size
catalyst. Gas inlet

• Application of the radial-flow Start-up gas Bypass

principle. control

• High-pressure steam gener-

ation wherever feasible.
The Uhde ammonia synthesis
design therefore incorporates First bed
three radial-type catalyst beds
arranged in either one or two
ammonia converters.

Second bed

Third bed

Gas outlet

Three-bed ammonia converter,

radial flow
 23

Features of Features of
the two-converter design: the HP steam boilers:
• Location of the first two converter, depending on • Tubesheet cooling to prevent
catalyst beds in the first project constraints. nitriding.
converter vessel and of the • Easy withdrawal of internal • Channels in contact solely
third bed in the second heat exchanger without with the cooled synthesis gas
converter vessel. removing catalyst. leaving the boiler.
• Radial flow from outside to • Smaller dimensions and • Freely-movable U-tube
inside through all catalyst lower weight of vessels to design of the bundle.
beds. reduce transport and
• Internal bore welding, the
• Simple U-tube heat ex- handling problems.
heat exchanger tubes being
changer between first and • An external HP steam boiler joined to the tubesheet by
second catalyst beds for downstream of the second means of full-penetration Vane
indirect cooling of the catalyst bed.
Steam outlet
welds. separator
synthesis gas.
• An externally arranged BFW • Steam/boiler water separ-
• Design adaptable to full-bore preheater/HP steam boiler ation in the upper part of the
or drawn-in top closure of downstream of the third bed. waste heat boiler.
Start-up gas Gas inlet
The design of HP synthesis Cont.
loop boilers is a long-standing blow down
BFW
tradition at Uhde, dating back bypass
to 1969 when equipment of Temp.
this type was pioneered. blow down
First bed

Advantages of
HP steam boilers:
• All components fabricated
from hydrogen-resistant,
Third bed easy-to-handle, low-alloy
materials.
Second bed
• Elimination of stress
corrosion cracking and
crevice corrosion.
• Low thermal stress. BFW inlet

• Integrated boiler feed water

preheating.
• Tube-to-tubesheet welds Gas Gas outlet
inlet
all subjected to non-
Gas outlet
destructive tests.
Gas inlet Gas outlet

Ammonia converter I, Ammonia converter II , HP Steam boiler

radial flow, catalyst beds 1 and 2 radial flow, catalyst bed 3
24

SAFCO IV fertiliser complex.

Capacities: 3,300 mtpd of ammonia
3,250 mtpd of urea
3,600 mtpd granulation unit
4.5 Production and consumption figures 25
per metric ton of ammonia

Overall view of the QAFCO 4

ammonia/urea complex successfully
commissioned by Uhde as early as 2004.
Capacities: 2,000 mtpd of ammonia
3,200 mtpd of urea
3,500 mtpd granulation unit

Feed and Energy Consumption

Natural gas as feed and fuel Gcal(1) 6.8 to 7.4
Elctric power kWh 15 to 90
Overall feed and energy(2) Gcal(1) 6.7 to 7.4

Utilities
Cooling water ( T = 10 K) mt 120 to 260
Demineralised water (net cons.) mt 0.65 to 0.75

Effluents
Treated process condensate(3) mt 0.85 to 1.15

Product Quality
Ammonia content % by wt. 99.8 to 100.0
Water content % by wt. 0.0 to 0.2
Oil content ppm by wt. max. 5
(1) expressed as lower heating value of natural gas per ton of ammonia
(2) electricpower and steam export converted into fuel equivalents
(3) routed back to the demineralisation unit for re-use

All consumption figures are per metric ton of liquid ammonia and serve as general information only.
Local climatic conditions and gas composition may have a considerable influence on the performance figures.
26 5. Services for our customers

Uhde is dedicated to providing its customers The policy of the Uhde group and its
with a wide range of services and to supporting subsidiaries is to ensure utmost quality in the
them in their efforts to succeed in their line of implementation of our projects. Our head office
business. and subsidiaries worldwide work to the same
quality standard, certified according to:
With our worldwide network of subsidiaries,
DIN/ISO 9001/EN29001.
associated companies and experienced local
representatives, as well as first-class backing We remain in contact with our customers even
from our head office, Uhde has the ideal after project completion. Partnering is our
qualifications to achieve this goal. byword.
We at Uhde place particular importance By organising and supporting technical sympo-
on interacting with our customers at an early sia, we promote active communication between
stage to combine their ambition and expertise customers, licensors, partners, operators and
with our experience. our specialists. This enables our customers to
benefit from the development of new technolo-
Whenever we can, we give potential customers
gies and the exchange of experience as well as
the opportunity to visit operating plants and to
troubleshooting information.
personally evaluate such matters as process
operability, maintenance and on-stream time. We like to cultivate our business relationships
We aim to build our future business on the and learn more about the future goals of our
confidence our customers place in us. customers. Our after-sales services include
regular consultancy visits which keep the owner
Uhde provides the entire spectrum of services
informed about the latest developments or
associated with an EPC contractor, from the
revamping options.
initial feasibility study, through financing concepts
and project management right up to the com- Uhde stands for tailor-made concepts and
missioning of units and grass-roots plants. international competence. For more information
contact one of the Uhde offices near you or visit
Our impressive portfolio of services includes:
our website:
• Feasibility studies/technology selection
www.uhde.biz
• Project management
Further information on this subject can be found
• Arrangement of financing schemes in the following brochures:
• Financial guidance based on an intimate • Uhde Reformer Technology
knowledge of local laws, regulations and • Urea
tax procedures • UFT fluid bed granulation
• Nitric acid
• Environmental studies
• Nitrate fertilisers
• Basic/detail engineering
• Utilities/offsites/infrastructure
• Procurement/inspection/transportation services
• Civil works and erection
• Commissioning
• Training of operating personnel
• Plant operation/plant maintenance
 6. Recent references 27

E Engineering
P Procurement
C Construction

Completion Customer Plant Site Plant Capacity Contract Project Notes

2010 Orascom Construction Arzew, Ammonia 2 x 2,200 t/d E, P
Industries for Sonatrach Algeria
Orascom Fertiliser
Company (Sorfert)
2010 Saudi Arabian Mining Co. Ras Az Zawr, Ammonia 3,300 t/d E, P
via Samsung Engineering Saudi Arabia
Co., Ltd.,
2010 Egyptian Agrium Nitrogen Damietta, Ammonia 2 x 1,200 t/d Turnkey
Products Co. SAE Egypt
(EAgrium)
2008 Misr Oil Processing Co. Damietta, Ammonia 1,200 t/d Turnkey
Egypt
2008 Kuibyshev Azot Togliatti, Ammonia 1,800 t/d E Expansion
Russia
2007 Duslo a.s. Sala, Ammonia 1,300 t/d E Expansion
Slovakia Expansion by 300 t/d
2007 Helwan Helwan, Ammonia 1,200 t/d Turnkey
Fertilizer Co. Egypt
2006 Egyptian Fertilizer Ain Sukhna/Suez, Ammonia 1,200 t/d Turnkey
Co. (EFC II) Egypt
2006 Alexandria Fertilizers Co. Alexandria, Ammonia 1,200 t/d Turnkey
(AlexFert) Egypt
2006 Saudi Arabian Fertilizer Al Jubail, Ammonia 3,300 t/d Turnkey
Company (SAFCO IV) Saudi Arabia
2004 Turkmendokunhimiya Tecen, Ammonia 600 t/d E,P
via Gap Insaat Turkmenistan
2004 Qatar Fertiliser Mesaieed, Ammonia 2,000 t/d Turnkey
Company (QAFCO IV) Qatar
2003 ASEAN Bintulu Fertilizer Bintulu, Ammonia 1,350 t/d E 3. Expansion
Sdn Bhd (ABF) Malaysia Expansion by 30 t/d
2000 Egyptian Fertilizer Co. Ain Sukhna/Suez, Ammonia 1,200 t/d Turnkey
(EFC) Egypt
1999 Istanbul Gübre Körfez, Ammonia 1,200 t/d E, P Expansion
Sanayii A.S. (IGSAS) Turkey Expansion by 50 t/d
1998 Abu Qir Fertilizers and Abu Qir, Ammonia 1,200 t/d Turnkey
Chemical Ind. (AFC) Egypt
(Abu Qir III)
1997 ASEAN Bintulu Fertilizer Bintulu, Ammonia 1,320 t/d E, P 2. Expansion
Sdn Bhd (ABF) Malaysia Expansion by 120 t/d
1997 Saskferco Products Inc. Belle Plaine, Ammonia 1,800 t/d E Expansion
Canada Expansion by 300 t/d
1997 SASTECH (Pty) Ltd. Sasolburg, Ammonia 830 t/d E Expansion
South Africa Expansion by 100 t/d
1997 Qatar Fertiliser Mesaieed, Ammonia 1,500 t/d Turnkey
Company (QAFCO 3) Qatar
1993 SASTECH (Pty) Ltd. Sasolburg, Ammonia 730 t/d Turnkey
South Africa
1992 Saskferco Products Inc. Belle Plaine, Ammonia 1,500 t/d Turnkey
Canada
1991 BASF Antwerpen N.V. Antwerp, Belgium Ammonia 1,800 t/d Turnkey
FL 110e/2000 12/2007 DÖ/Hi/ Printed in Germany
PDF 22.1.2009