INTERNSHIP REPORT

AMMONIA-2
Submitted by:
ANFAL ZAFAR
Intern session 2022
UET Lahore

Submitted to:
Training Section
Engro fertilizers ltd.
Daharki

ACKNOWLEDGEMENT
First, I would like to express my gratitude to ALLAH almighty for enabling me to complete this
report. Also big thanks to Engro Fertilizers Ltd for granting me this opportunity.

The internship has been a very good experience for me in the way that it has given me the chance
to understand the real world outside the classroom. I learned about the industrial environment
and plant operations. I saw my four years of degree knowledge implemented in the plant field.

A deep sense of appreciation is owed to Meer Salman (GL), Mr. Waqas Iqbal (Mentor and
SIC) and Mr. Usama Majeed (Mentor and SS) for their kind attitude and generous support
during my internship.
A special Thanks to Rashid Ahmad (SIC) and Syed Saeed Ahmad (GTE) who helped me in
completing the Internship project.

Mentor’s Signature Dated:

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 AMMONIA-2
INTRODUCTION

PLANT LOCATION Daharki, Sindh

PLANT DESIGNED BY Bechtel Corporation, USA

PRODUCTION CAPACITY 1650 MPTD

COMMENCEMENT OF 1992
COMMERCIAL PRODUCTION

RAW MATERIALS NATURAL GAS, PROCESS

STEAM AND AIR
OFF-SITE FACILITIES NATURAL GAS FROM MARRI
GAS FIELDS

Plant Division
Ammonia plant 2 is divided into two main portions:
 Front End:

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It consists of desulfurization section, reforming (Pre, primary and secondary) sections, shift
conversion (high temperature shift converter and low temperature shift converter) sections, CO2
removal section (absorber and stripper) and methanation section.
 Back End:
It consists of mole sieves, compression section, Ammonia reactor, and refrigeration section and
storage unit.

BLOCK DIAGRAM
Compressed air

Desulfurization Primary Secondary

Pre-Reforming HTS
of Feed Reforming Reforming

Steam

NH3 Synthesis gas LTS

Synthesis Methanation CO2 Removal
Compression

Product
Ammonia

The process involved takes place in the following sequence

 Feed gas compression
 Feed
 Feed gas desulfurization

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  Pre-Reforming
 Compressed Air
 Secondary Reforming
 Carbon mono oxide Shift Conversion
 Carbon dioxide removal
 Methanator
 Removal of residual CO2 and water
 Synthesis gas compression
 Catalytic conversion of synthesis gas to ammonia
 Conversion of ammonia
 Product

Feed
Feed to the Ammonia Plant is natural gas, steam, and air.

Feed gas desulfurization

Feed gas is desulfurized before steam reforming because reforming catalyst activity is hindered
by the presence of sulfur. Catalysts used in desulfurizer are NiMo, ZnO and CuO. NiMo converts
organic sulfur (mercaptan) into inorganic sulfur by hydrogenation reaction and hydrogen for this
reaction comes from Recycle syngas Thru FRC-160.ZnO removes converted inorganic sulfur
compounds. Both NiMo and ZnO removes maximum sulfur and if there remains any residual
sulfur it is removed in the bed of copper oxide. Feed gas before coming to desulfurizer is pre-
heated by convection coils of F-2501.
 Temperature conditions are Inlet-520F-Outlet-500F
 Pressure should be Inlet-550-Outlet540 PSIG
Following reactions take place in the desulfurizer:

C4H4S + 4H2 C4H+H2S

ZnO + H2 ZnS + H2O

CuO + H2S CuS + H2S

Reforming:
Partial conversion of hydrocarbons to hydrogen is called Reforming. The gas coming from
desulfurizer is reformed by
 Pre-Reformer

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  Primary Reformer
 Secondary Reformer

In the reforming section the components that are compulsory to produce ammonia synthesis
gas are produced.

1. Pre-Reformer:
This plant was designed on 100% load and after modification it is running on 154% load
therefore to divide the load of primary reformer, gas is passed through pre reformer. Not only it
shares the load but also converts the higher hydrocarbons to lower hydrocarbons. Catalyst used
in pre reformer is 30% Nickel.
Temperature and pressure conditions are:

Temperature Inlet 940F - outlet 850F

Pressure Inlet 535PSIG – Outlet 538PSIG

The gas leaving from pre reformer (R-2501) contain following contents:
Components Composition (mole %)
Hydrogen 18.08
Nitrogen 14.16
CO 0.16
CO2 12.12
CH4 55.49

Following reactions take place in pre reformer:

C2H6 + 2H2O 2CO+ 5H20
CH4 + H20 CO + 3H2
CO + H20 CO2 + H2
CH4 + 2H20 CO2 + 4H2

2. Primary Reformer:

Here the superheated steam is mixed with desulfurized gas. This mixed gas is passed through
vertical nickel catalyst tubes in the primary reformer heater, F-2501.Under operating
conditions Methane is converted into hydrogen, carbon monoxide and dioxide.
Reaction is endothermic, so to provide heat of reaction burners are installed. The primary
reformer has 240 burners are installed.it has total 392 reforming tubes installed.
Catalyst used in primary reformer is 20% Nickel.
Following reactions take place in the primary Reformer:
CH4 + H2O CO + 3H2
CO + H2O CO2 + H2

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First reaction is highly endothermic, but second reaction is slightly exothermic. The overall
reaction:
CH4 + 2H20 CO2 + 4H2
Temperature and pressure conditions are:

Temperature Inlet 970F- Outlet 1405F

Pressure Inlet 532PSIG – Outlet 500PSIG

The gas leaving from primary reformer (F-2501) contain following contents:
Components Composition (mole %)
Hydrogen 62.82
Nitrogen 6.42
CO 10.11
CO 2 11.64
CH 4 9.03

3. Secondary Reformer:

Pre-heated compressed air up to 500PSIG enters the process at the secondary reformer and
mixes with reformed gas to get nitrogen. Oxygen is consumed by reacting with combustible
components i.e., CH4 and CO in the synthesis gas stream. The first reaction is Exothermic in
nature
CH4 + 2O2 CO2 + 2H2O

These reactions are endothermic in nature

CH4 + H20 CO + 3H2

CO + H20 CO2 + H2
Temperature and pressure conditions are:

Temperature Inlet 1405F – Outlet 1680F

Pressure Inlet 465PSIG – Outlet 458PSIG

The gas leaving from Secondary reformer (F-2501) contain following contents:

Components Composition (mole %)

Hydrogen 54.93
Nitrogen 22.42
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CO 12.62
CO2 9.19
CH4 0.80
CO conversion:
Carbon monoxide at the reformer outlet is converted to carbon dioxide and hydrogen in two shift
reactors

 High temperature shift converter

 Low temperature shift converter

In both reactors the reaction is same, and it is exothermic

CO + H2O CO2 + H2
This reaction is called water gas shift reaction. It also takes place in reforming but due to high
temperature in the reforming the reaction retards and leaves high CO concentration in the
reformer effluent.
 High Temperature Shift Converter (HTSC)

Effluent from secondary reformer is cooled by three exchangers from 1680 F to 680F before it
enters the HTSC, D-2510 because shift reaction equilibrium is favorable at lower temperature.
HTSC is charged with iron oxide (volume of catalyst is 1600 ft 3) which operates at the outlet
temperature of 790F.The concentration of CO in the gas stream leaving the HTSC is about 2.1%.
The Composition of gas leaving from the H.T.S.C:

Components Composition (mole %)

Hydrogen 58
Nitrogen 20.41
CO 2.53
CO 2 17.33
CH 4 0.73

 Low Temperature Shift Converter (LTSC)

LTSC, D-2513 almost completes the conversion of CO to carbon dioxide. It operates at outlet
temperature of about 435-450 F and charged with the copper oxide catalyst (Volume of catalyst
is 1600 ft3). Concentration of CO leaving the LTSC is less than 0.17vol %.

The Composition of gas leaving from the H.T.S.C:

Components Composition (mole %)
Hydrogen 59
Nitrogen 19.96 7|Page
CO 0.27
CO 2 19.16
CH 4 0.71
CO2 Removal

Synthesis gas leaving the LTSC contains 18% CO 2, and it is necessary to remove all carbon
dioxide from the synthesis gas before it enters the ammonia synthesis loop. CO 2 removal section
has two processes:
 Absorption

Absorption is done by an absorber C-2519.Process gas comes at 318 F, and it is cooled to 210 F
by exchangers before entering in the absorption column. From the top solution of hot potassium
carbonates is poured. Pressure is kept at 380 PSIG. The gas leaving the absorber contains Carbon
dioxide 0.17% on dry basis.
Following reaction takes place in absorber:
K2CO3 + CO2 + H2O 2 KHCO3 (Absorber)
The composition of the gas leaving absorber:
Components Composition (mole %)
Hydrogen 73.67
Nitrogen 24.63
CO 0.35
CO 2 0.17
CH 4 0.92

Favorable conditions for absorption are:

High Pressure
Low Temperature

 Stripper
The CO2 absorbed in the solution is stripped out in the CO stripper C-2515.Rich solution
containing CO2 comes out from the bottom and goes to hydraulic turbines 2503 A/B(these
turbines run semi lean solution pumps) and then enters in stripper from the top. Three heat inputs

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come from 40pound steam, ejectors and reboilers 2508 A-D. The Regenerated CO 2 gas is
stripped out from the top and sends to urea plant.

2KHCO3 K2CO3 + CO2 +H2O

Favorable conditions for stripping are:

Low Pressure
High Temperature

Methanator:

It is the final purification step in the synthesis manufacturing process. The process gas after
leaving the CO2 absorber passes through a fixed Nickel catalyst bed in the Methanator, D-
2520.This gives exothermic reaction:

CO + 3H2 CH4 + H2O

CO2 + 4H2 CH4 + 2H2O

The gas leaving from the Methanator has following composition:

Components Composition (mole %)

Hydrogen 70.79
Nitrogen 24.48
CO …..
CO2 …..
CH4 1.45

Ammonia synthesis gas compression:

Purified synthesis gas is compressed to 3000PSIG with the help of multistage compressor K-
2502.Syngas coming from Methanator is cooled down by chiller E-2515A and condensate is
removed by knockout drum D-2521.Then syngas goes to first stage of compression where it is
compressed to 1000 PSIG and then again cooled down because to compress high T gas, requires
more horsepower by the compressor. Next are the mole sieves which adsorbed even the rare
amounts of CO2 and moisture as both are poison for converter catalyst. In the second stage gas is
compressed to 2000 PSIG and after cooled down it is further compressed to 3000 and sends to
ammonia converter at the top.

Ammonia Converter:

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Ammonia converter D-2525 consists of three inter heat exchanging beds. Gas coming to
converter is mixture of reactive (nitrogen and hydrogen) and inert gases (methane and argon).
Nitrogen and hydrogen react to form about 17% ammonia.

3H2 + N2 2NH3 + Heat

While rest of the mixture remains unconverted. Inert gases retard reactions and build up pressure
in the converter so a purge gas is bled from the separator. This purge gas is used as fuel for
boilers.

Favorable Conditions in Ammonia Converter are:

High Pressure
low Temperature

Ammonia Condensation:

The synthesis gas leaving the converter contains 17 % ammonia. It is cooled to 33F (where it
becomes liquid) from 745 F at 3000 Psig by various heat exchangers and chillers. Synthesis gas
is cooled from 745F to 505 F by waste heat boiler E-2524 A/B and further cooled to 505 F by
BFW E-2525 A/B. It is further cooled down (using Pinch technology) to 175 F by two converter
feed effluent exchangers E-2523 A/B. Finally, gas is cooled to 33F by two converter effluent
chillers E-2528 A/B and the liquid ammonia is trapped out in ammonia separator and transfers to
D-2528 ammonia product drum at about 30 to 35 F.
Ammonia is pumped from the plant and sends to two urea plants, Urea 1 and 2.

Internship Project
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 Catacarb Stripping index calculations and ways of improvement
Catacarb system consists of two operations
1) Absorption
2) Stripping

Catacarb System

Stripping Index

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Amount of energy to remove 1 lb mole of CO2 from stripper.

Heat Inputs to Amm-2 Stripper

Major heat input sources to Stripper are as followings:

 Heat input from reboilers E-2508

 Heat input from ejectors of 60# steam
 Heat of 40# steam

Heat Input to Stripper C-2515

Heat of 40#
steam
32.9
MMBtu/hr E-2508-Re-
boilers
76.67
MMBtu/hr

Heat from ejectors

65.03 MMBtu/hr

E-2508-Reboilers Heat from ejectors Heat of 40# steam

Stripping Index Calculation

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Comparison of Stripping Index @ FEL 154 % Vs 125%

Heat Input Sources At FEL 154% At FEL 125%

Heat from E-2508 55.79 MMBtu/hr 76.67 MMBtu/hr

(Reboilers)
Heat from ejectors 66.95 MMBtu/hr 65.03 MMBtu/hr

Heat from FR-413 51.7 MMBtu/hr 32.9 MMBtu/hr

Total Heat Input 174.33 MMBtu/hr 173.61MMBtu/hr

CO2 flow 202.9 KPPH / 4611 168 KPPH / 3818 lbmol/hr

lbmol/hr
Stripping Index 37.83 MMBtu/hr 45.47 MMBtu/hr

Recommendations:
 Stripping index requirement w.r.t load chart should be configured at DCS.

 From following table, it is evident that at 125% FEL compartment pressure is lower
@PT-706/707 so these two ejectors should be cleaned in FAO.

Feedback

Six weeks which I have spent here have passed like a clock does tick tick for 6 times and it’s
ended. But it does not mean I did not get anything here. These six weeks have given me a lot of
new learning experiences from visiting plant to working in shifts. This period has also added
some new connections in my life and expanded my social circle. The most beautiful thing I

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found in Engro is that everyone is friendly and welcoming from an employee to management. I
have had a wonderful time here.

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