Large Volume Inorganic Chemicals - Ammonia ... - ammk-rks.net

Best Available Techniques Reference Document onthe manufacture of Large Volume Inorganic Chemicals(Ammonia, Acids and Fertilisers)EXECUTIVE SUMMARY ........................................................................................................................IPREFACE ................................................................................................................................................ XISCOPE..................................................................................................................................................XXV1 OVERVIEW TO THE PRODUCTION OF LVIC-AAF ................................................................11.1 General information....................................................................................................................11.1.1 Overview ..........................................................................................................................11.1.2 Environmental issues........................................................................................................31.1.2.1 Energy consumption and emission of greenhouse gases ..........................................31.1.2.2 Energy export ...........................................................................................................31.1.2.3 High exhaust gas volume flows ................................................................................41.1.2.4 Large volume by-products........................................................................................41.1.2.5 Issues arising from impurities in raw materials ........................................................51.1.2.6 Safety issues .............................................................................................................51.2 Integrated production sites..........................................................................................................71.2.1 Overview ..........................................................................................................................71.2.2 Some examples.................................................................................................................71.2.3 Supply of steam and electricity.......................................................................................101.2.3.1 Steam turbines and steam grid................................................................................101.2.3.2 Exporters and consumers on an integrated production site.....................................111.3 Overview of emissions and consumption levels .......................................................................121.4 Common techniques to consider in the determination of BAT.................................................121.4.1 Increase process integration (1)......................................................................................131.4.2 Increase process integration (2)......................................................................................151.4.3 Handling excess steam....................................................................................................161.4.4 Replacing old PRDS valves............................................................................................171.4.5 Optimisation/maintenance of vacuum pumps.................................................................181.4.6 Mass balances.................................................................................................................191.4.7 Recovery of NO x from exhaust gases.............................................................................211.4.8 Techniques described elsewhere in this document .........................................................231.4.9 Environmental management tools ..................................................................................241.5 Common BAT ..........................................................................................................................321.5.1 Common BAT for the LVIC-AAF industries.................................................................331.5.2 BAT for environmental management .............................................................................342 AMMONIA.......................................................................................................................................352.1 General information..................................................................................................................352.2 Applied processes and techniques ............................................................................................372.2.1 Overview ........................................................................................................................372.2.2 Output from ammonia production ..................................................................................382.2.2.1 Ammonia ................................................................................................................382.2.2.2 Carbon dioxide .......................................................................................................382.2.2.3 Sulphur ...................................................................................................................382.2.2.4 Steam ......................................................................................................................382.2.3 Conventional steam reforming .......................................................................................392.2.3.1 Desulphurisation.....................................................................................................392.2.3.2 Primary reforming ..................................................................................................402.2.3.3 Secondary reforming ..............................................................................................412.2.3.4 Shift conversion......................................................................................................412.2.3.5 CO 2 removal ...........................................................................................................412.2.3.6 Methanation............................................................................................................422.2.3.7 Compression ...........................................................................................................422.2.3.8 NH 3 synthesis .........................................................................................................432.2.3.9 Steam and energy system........................................................................................432.2.4 Partial oxidation..............................................................................................................442.2.4.1 Air separation plant.................................................................................................44xivLarge Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers