Modernization of in-service ammonia plants.

Modernization concept:

• 10-20 % increase in productivity of the plant.
• 10-15 % decrease in specific energy consumption.
• Improving of plant operating stability and reliability.
• Decrease of the overall amount of harmful exhausts while increasing productivity.
• Optimization of revamp strategies.

The basic technical solutions:

• Upgrading of desulphurization reactor, secondary reformer, high and low temperature (HT and LT) shift converters, ammonia synthesis reactor by means of implementing of radial design types.
• Replacement of primary reformer tubes by those of bigger diameter and improved heat resistance.
• Using MDEA solution at the stage of syngas purification from CO2.

Construction of integrated plants and diversification.

ALVIGO has developed the technology for partial or full re-design of capital-intensive industrial plants with the object of producing more marketable products. The joint production of methanol and ammonia cuts energy expenses and offers useful ways of maneuvering by rates of individual product output depending on market demands. Adding to this system an extra installation for the further processing of above mentioned products, a new more marketable product can be produced as for example ethylene from methanol.

New conceptions of ammonia plant.

The construction of new ammonia plants with specific consumption of energy and natural gas less than 7 Gcal/t and 850 m3/t respectively is a vital problem for all ammonia and nitrogen fertilizers producers.

The latest techniques in the fields of technology, equipment engineering and catalysts design lie in the base of AM-98 plant conception.

Economical efficiency of new plant is ensured by the fact that the decrease of energy consumptions does not entail investments increase compared with the plants of earlier generations. This effect is provided by implementation of less expensive compressors and equipment for ammonia synthesis at 8 MPa, as well as using radial type catalytic reactors, primary reformer with heat exchange surface decreased by half, and simplified, less capital-intensive steam production and consumption system. We believe that new plant conception is at least in the line with expected technological level of ammonia production plants of the running decade, hence it will be of interest for a number of fertilizers producers in Russia and abroad. The construction of ammonia plants with energy consumption shown in the table below will ensure long-term competitiveness of any nitrogen industry facility. ALVIGO experts are well experienced and qualified in all aspects of ammonia, hydrogen, syngas, and methanol production, including start-up procedures of these plants. They took part in development of technology and equipment for many large-scale plants of those types.

New technology of ammonia synthesis catalyst passivation is created for radial type reactors.
This technology as applied to the case of plant shutdown with subsequent start-up has been carried into effect very successfully at a number of plants (Salavat, Kemerovo, Dniprodzerzhynsk).
All the projects listed above are developed and implemented in a close cooperation with JSC GIAP.

Basic indices of raw materials and energy specific consumption for ammonia plants of new generation (per 1 ton of NH3 produced).