1

CATPER PROFORMA FOR

AMMONIA PLANT
CATALYST EVALUATION
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Introduction to CATPER

The CATPER catalyst evaluation program simulates the main process units of a typical ammonia or
hydrogen plant and has been developed over the years to meet the needs of plant operators to
assess plant operation and characterise catalyst performance.

CATPER performs a "best fit" theoretical and consistent heat and mass balance utilising the plant
data. The program calculates the difference between each measured data item and the theoretical
"best fit" value from the consistent heat and mass balance. It then normalises these errors and
calculates standard errors using expected deviations in the particular measurement before calculating
an overall root mean square (RMS) error.

The programme varies the calculated data, consistent with fitting a heat and mass balance, until the
RMS error is minimised, hence calculating the overall best fit to the original data. It is this "best fit" we
use to comment upon the plant data because this process smoothes out any analytical or instrument
errors in the raw data.

It should be noted that catalyst properties are not used in the data fitting. Only the appropriate
measured plant operating data is used for the H&M balance data fitting exercise. It should also be
recognised that the output of the CATPER will be the “best fit” H & M balance to the measured data –
this does not necessarily mean it is the correct fit. Hence it is important that before data is collected,
time is spent to ensure key instruments on the plant and in the laboratory are calibrated. Also it is
important that the plant is at steady state conditions and preferably at as high a rate as possible. It is
also important that care is taken when taking samples to ensure they are as representative as
possible and that samples and plant data readings are taken as close to simultaneously as possible.
Please remember that our evaluation and recommendations can only be as good as the data
customers provide – garbage in often equals garbage out, even with our skills of manipulating the
data.

It is worthwhile providing a similar data set for the design conditions of the plant – this can then be
used to compare the performance with actual conditions and highlight any operation changes
recommended.

Use of CATPER has a number of benefits:

 The simulation provides a useful consistency check on plant data. This gives confidence that
the plant is really operating as the readings indicate and can help identify any process
measurements that are inconsistent and hence show where instrument re-calibration may be
needed.

 By using the software with accurate laboratory gas analyses it is possible that errors in plant
instrumentation (e.g. the steam flowmeter to the reformer) can be identified.

 Regular checks with CATPER allows catalyst performance to be evaluated; any changes in
catalyst performance to be identified and investigated; recommendations to be given on
optimisation of the catalyst; recommendations to be given on estimated remnant life of the
catalyst.

 Normally catalyst deactivation is slow, and so we would normally recommend that CATPER
evaluations are performed at 6 monthly or at most 3 monthly intervals. It is more important to
get good data less frequently from a proper test run of the plant and after key instruments
have been calibrated than to get poor data every week, which is often simply dumped from
the DCS system. We recommend plant data is supplied at SOR and then at intervals as
above to monitor catalyst performance. If however there as been a sudden step change in
apparent catalyst performance, then it would be appropriate to do a CATPER evaluation in
order to investigate the situation.
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Plant: CFCL Date: 06/06/2012

Location Gadepan Plant Rate 1719 MTPD
Feedstock Flow 43511 NM3/Hr Steam Flow to Primary 129420 Kg/Hr
Recycle Flow To Primary 1502 NM3/Hr Steam Flow to 4960 Kg/hr
Secondary
Steam To Pre-Reformer Air Flow To Secondary 65773 NM3/Hr

Desulphurisation Pre-Ref Primary Secondary

Catalyst Type(s) TK-550; CoMOx,12980L KATALCO25-4Q (50.09%) C14-4 GG;NiO
ICI 46-6 (22.5%)
HTG-1;Cl Guard, 2130L Top 4000L
KATALCO57-4GQ;
HTZ-3; ZnO, 28000L C14-2LDP;NiO
NiO (27.4%) Bottom31600L
Volume 43110 Litres 36700 Litres 35600 Litres
Start up date JULY’1999 Apr’2007 May’2011
Days on line Till now Till now Till now
Exit Exit Exit
Composition % (dry) Feedstock Recycle
CO <1 8.11 11.48
CO2 3.11 2.99 ppm 10.11 7.33
H2 74.62 69.35 59.23
N2 + Ar 0.16 24.51 0.55 21.53
O2
CH4 89.5 0.87 11.88 0.43
C2 5.64 * *
C3 1.28
C4 0.31
Others (please define)
Pre-Reformer Bed Temps
Naphtha (Kg/Hr) Catalyst % Depth Temp (°C)
Naphtha (C/H w/w) Ratio) Depth
Naphtha Mol. Wt.
(Or provide detailed PONA)

Poisons S
Cl
Others
Pre-Ref Primary Secondary
Pressure Inlet 43.06 39.16 35.92
(Kg/Cm2) Outlet 42.37 35.92 35.37
Bed Diameter 2100mm 4050mm
Bed Depth 12450mm 2764mm
Inlet (0C) 371.83 476.64 781.26
0
Exit ( C) 363.07 781.26 884.41*
Steam - 129420 Kg/Hr 4960 Kg/Hr
Air 65773 NM3/Hr
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Converter HTS LTG LTS Methanator

Catalyst type(s) ICI 71-5/C12-4;FeO C-18-7;CuO C-18-7;CuO C-13-4;NiO
Volume 73000 Litres 25000 Litres 75000 Litres 30000 Litres
Start up date July’1999, May’2011 Aug’1999 Aug’1999
23m3 replaced-
Apr09
Days on line Till now Till now Till now Till now
Pressure Inlet Exit Inlet Exit Inlet Exit Inlet Exit
35.16 34.4 34.15 33.93 34.15 33.96 32.32 32.04
Composition % Exit Exit Exit Inlet Exit
CO 2.84 0.24 0.29 0.33 <1
CO2 14.59 16.27 16.37 640ppm 2.99 ppm
H2 62.03 63.2 63.15 74.53 74.62
N2 + Ar 20.15 19.92 19.82 24.41 24.51
O2
CH4 0.39 0.37 0.37 0.46 0.87

Inlet Inlet Inlet

Quench Rate
Temperature
Depth Temp Depth Temp Depth Temp Depth Temp
Inlet 373.41 Inlet 213.54 Inlet 213.54 Inlet 284.28
1170mm 375.25 mm 211.75 1260mm 212.35 445mm 283.05
1890mm 423.2 mm 216.55 1750mm 212.5 890mm 301.82
2610mm 431.21 mm 227.99 2240mm 232.66 1335mm 313.2
3310mm 435.34 mm 231.84 2730mm 233.76 1780mm 302.86
Bed Temperatures 3220mm 230.28 2225mm 303.45
(0C)

Exit 435.74 Exit 233.6 Exit 232.93 Exit 303.42

Bed Depth (mm) 3590 2020 3690 3120
Bed Diameter 5100 4000 5100 3500
(mm)
MUG flowrate

MeOH By-product Calc. Data T (C1) P (C1) T (C2) P (C2) T (C3) P (C3)
Catchpot Temperatures &
Pressures (up to 3)
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Ammonia Synthesis Converter (Old)

Type of Converter..... Kellogg’s Horizontal, Axial-Radial Flow

Bed Catalyst Type Size Grade* Volume* Start up Time

(mm) (m3) date on- line
1 KMIR 1.5~3/3~6 25.7/2.9 Oct’1999 Till now
2 KMI 1.5~3/3~6 51.4/5.8 Oct’1999 Till now
3
4

Flow Rates

Flows Units Stream Position

*
Total flow to converter 614.15 KNM3/Hr -
Make up gas Flow 202.1 KNM3/Hr Before / After Catchpot1
Purge gas Flow* 16100** NM3/Hr After Catchpot1

1
Delete As Appropriate

Ammonia production* 1719 MTPD

Bed Cooling

Inter-Bed Cooling By Quench Gas Addition? Yes

Valve % Open Flow Units

Cold shot to bed 1 0
Cold shot to bed 2
Cold shot to bed 3

Pressures /Temperatures

Temperature (0C) Pressure (Kg/Cm2g)

*
Converter inlet 204.04 155.76
Converter exit* 435.36 154.27

Separator*

Temperatures (0C)
Bed 1 Inlet 276.6,288.91,299.15,309.16
Bed 1 Exit 497.19,497.4,493.05,495.51
Bed 2 Inlet 330.65,358.54,360.93,360.97
Bed 2 Exit 406.41,411.07,420.01,419.49
Bed 3 Inlet 406.41,411.07,420.01,419.49
Bed 3 Exit 449.27,445.91,447.16,445.03
Bed 4 Inlet
Bed 4 Exit
(If more than one thermocouple is available for the same measurement, record all readings)

Gas Analysis and Poisons

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Poisons In Make Up Gas Volume

(After Molecular sieve ppm
dryer)

CO <1ppm
CO2 <1ppm
O2

Compressor type: …..………………………………….. centrifugal

Any sign of oil contamination in the converter …NO

Do you use sulphur free seal oil ? ……………… NA (Dry Seal for Compressor)

H2 N2 CH4 Ar He NH3

% % % % % %
Make Up Gas
74.62 24.51 0.87
Purge Gas 60.4 23.36 11.15 3.67 1.42
*
Converter Inlet 66.55 22.95 6.81 2.36 1.33
Converter Exit* 53.3 19.74 7.86 2.68 16.42

H2 Recovery Unit

H2 N2
Gas recovery from purge stream %

Ammonia Synthesis Converter (NEW)

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Type of Converter …… Kellogg’s Vertical, Radial Flow

Bed Catalyst Type Size Grade* Volume* Start up Time

(mm) (m3) date on- line
1 KM1 73.49 MAY,2009 Till now
2
3
4

Flow Rates

Flows Units Stream Position

Flow meter is at 1st KNM3/Hr -
Total flow to converter*
Converter inlet
Flow meter is at 1st Before / After
Make up gas Flow KNM3/Hr
Converter inlet Catchpot1
Purge gas Flow* 16100** NM3/Hr After Catchpot1

1
Delete As Appropriate

Ammonia production* 1719 MTPD

Bed Cooling

Inter-Bed Cooling By Quench Gas Addition? NO

Valve % Open Flow Units

Cold shot to bed 1
Cold shot to bed 2
Cold shot to bed 3

Pressures /Temperatures

Temperature (0C) Pressure (Kg/Cm2g)

*
Converter inlet 353.04 153.92
Converter exit* 407.31 153.57
*
Separator

From top to bottom Temperatures (0C)

1st Location 405.87,406.54,408.44

2nd Location 408.4,407.6,406.59
3rd Location 399.34,404.22,397.09
4th Location 405.41,406.43,408.24
th
5 Location 404.44,409.96,406.59
6th Location 415.75,415.08,415.66

(If more than one thermocouple is available for the same measurement, record all readings)
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Gas Analysis

Poisons In Make Up Gas ppm v

(After mole. sieve dryer)
CO <1ppm
CO2 <1ppm
O2

H2 N2 CH4 Ar He NH3
Make Up Gas 74.62 24.51 0.87
Purge Gas 60.4 23.36 11.15 3.67 1.42

Converter Inlet* 53.30 19.74 7.86 2.68 16.42

Converter Exit*
50.44 18.86 8.42 2.87 19.41

H2 N2
Gas Recovery From Purge Stream

* These data should be provided as a minimum

PLEASE STATE PRECISE UNITS
* Temperature is showing less due to nitrogen cooling.
** Purge flow is from Circulator suction.