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Chapter 22.4.4 Revamp: increase capacity and energy efficiencyDescriptionThe revamp of a 20 year old reduced primary reforming ammonia plant (1100 tonnes/day) isaimed to improve the efficiency of the primary reformer furnace/gas turbine combination byextensive preheating of the mixed feed going to the furnace and by the installation of a highlyefficient gas turbine of which the operating conditions can be adapted to suit the oxygenrequirements of the furnace. Table 2.11 gives an overview of the implemented measures.MeasureExtended preheating of thehydrocarbon/steam feedNew gas turbineModifications of the burnersRearrangement of theconvection coils and addadditional surfaceDescriptionTo reduce the fuel gas consumption, the duty of the radiant sectionwas decreased by extended preheating of the hydrocarbon/steammixture before it reaches the catalyst tubes. This was done byinstalling a new highly alloyed mixed feed preheat coil in theconvection section of the furnace. In this way, radiant heat issubstituted by heat available in the convection section at asufficiently high temperature level.A second key factor in achieving the fuel gas savings was theinstallation of a second generation gas turbine. The amount ofoxygen available in the exhaust gases from this machine matchesclosely the oxygen requirements of the primary reformer furnace. Inthis way, the flow through the radiant box of the furnace isminimised and allows the high temperatures required in the fire boxwith less fuel gas consumption.Due to the low oxygen surplus, the furnace burners have requiredmodifications to assure an adequate distribution of gas turbineexhaust over the burners. This is important to obtain completecombustion of the furnace fuel and to assure a uniform heat releasein the fire box. This last issue is critical for the lifetime of thecatalyst tubes, as local overheating of the tubes might causepremature tube failure. After revamp, the power of the new gasturbine is sufficient to drive the process air compressor, so thehelper steam turbine was eliminated. The gas turbine exhaust gasesshow temperatures of about 520 °C and all exhaust is sent throughthe radiant section to provide sufficient oxygen for combustion inthe furnace.Because of the reduced fired duty and because a larger share of thetotal heat is absorbed in the reforming process (mixed feed preheatcoil + radiant tubes), a lower heat load is available for the rest ofthe convection section.For this reason, all convection coils in the heat recovery sectionwere rechecked for the revamped process requirements and, wherenecessary, additional surface was added.The rearrangement of the convection coils which is an integral partof the proposed furnace revamp, also serves another objective: theheat conservation is further optimised by reducing the stack losses.MaintenanceAbout 50 % of the efficiency increase is achieved by re-establishingthe original state of the plant, e.g. closing leaks.Table 2.11: Some implemented measures to revamp the 20 year old plant64 Large Volume Inorganic Chemicals – Ammonia, Acids and Fertilisers
Chapter 2Achieved environmental benefits• reduced NO x emissions
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EUROPEAN COMMISSIONIntegrated Pollu
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Executive SummaryEXECUTIVE SUMMARYT
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Executive SummaryII.Production and
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Executive Summarybed, using a cesiu
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Executive SummaryConversion process
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Executive SummaryBAT is to treat al
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PrefacePREFACE1. Status of this doc
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Preface5. How to understand and use
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2.2.4.2 Gasification of heavy hydro
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5.4.2 Hemihydrate process (HH) ....
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10.4.3 Fluoride recovery and abatem
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Figure 8.1: Overview of the product
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Table 4.20: Energy balance of a dou
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ScopeSCOPEThis document on Large Vo
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Chapter 197 % of nitrogen fertilise
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Chapter 11.1.2.3 High exhaust gas v
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Chapter 1the SSD of NPK does not le
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Chapter 11,8Relative production cap
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Chapter 11.2.3 Supply of steam and
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Chapter 11.3 Overview of emissions
Page 42 and 43: Chapter 1ApplicabilityGenerally app
Page 44 and 45: Chapter 11.4.3 Handling excess stea
Page 46 and 47: Chapter 11.4.5 Optimisation/mainten
Page 48 and 49: Chapter 1Operational dataNo informa
Page 50 and 51: Chapter 1ApplicabilityEspecially ap
Page 52 and 53: Chapter 11.4.9 Environmental manage
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Page 56 and 57: Chapter 1iv. allow for comparison w
Page 58 and 59: Chapter 1A number of studies show t
Page 60 and 61: Chapter 11.5 Common BATIn understan
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Page 64 and 65: Chapter 2Location CompanyCapacity F
Page 66 and 67: Chapter 22.2.2 Output from ammonia
Page 68 and 69: Chapter 22.2.3.2 Primary reformingT
Page 70 and 71: Chapter 2Process name Solvent/reage
Page 72 and 73: Chapter 22.2.4 Partial oxidationThe
Page 74 and 75: Chapter 2In the moving bed process,
Page 76 and 77: Chapter 22.2.6 Storage and transfer
Page 78 and 79: Chapter 2Production process Feedsto
Page 80 and 81: Chapter 22.3.2 NO x emissionsTable
Page 82 and 83: Chapter 22.3.3 Other consumption le
Page 84 and 85: Chapter 2ParameterProcessEmission l
Page 86 and 87: Chapter 22.4 Techniques to consider
Page 88 and 89: Chapter 22.4.2 Processes with reduc
Page 90 and 91: Chapter 22.4.3 Heat exchange autoth
Page 94 and 95: Chapter 22.4.5 Pre-reformingDescrip
Page 96 and 97: Chapter 2ApplicabilityGenerally app
Page 98 and 99: Chapter 22.4.7 Advanced process con
Page 100 and 101: Chapter 22.4.9 Combined Claus unit
Page 102 and 103: Chapter 2Operational dataSee Descri
Page 104 and 105: Chapter 22.4.12 Preheating of combu
Page 106 and 107: Chapter 22.4.14 Isothermal shift co
Page 108 and 109: Chapter 22.4.16 Stripping and recyc
Page 110 and 111: Chapter 22.4.18 Use of sulphur resi
Page 112 and 113: Chapter 22.4.20 Indirect cooling of
Page 114 and 115: Chapter 22.4.22 Ammonia removal fro
Page 116 and 117: Chapter 22.4.24 Metal recovery and
Page 118 and 119: Chapter 2Driving force for implemen
Page 120 and 121: Chapter 22.5 BAT for ammoniaBAT is
Page 123 and 124: Chapter 33 NITRIC ACID3.1 General i
Page 125 and 126: Chapter 3Pressure in bar Temperatur
Page 127 and 128: Chapter 33.2.5 Tail gas properties
Page 129 and 130: Chapter 33.3 Current emission and c
Page 131 and 132: Chapter 3N 2 O emission levelProces
Page 133 and 134: Chapter 3N 2 O emission levelProces
Page 135 and 136: Chapter 3Process typeNO x emission
Page 137 and 138: Chapter 3Process typeNO x emission
Page 139 and 140: Chapter 3140120Generation factor %1
Page 141 and 142: Chapter 33.4.2 Optimisation of the
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Chapter 33.4.3 Alternative oxidatio
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Chapter 33.4.4 Optimisation of the
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Chapter 3Achieved environmental ben
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Chapter 33.4.5 N 2 O decomposition
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Chapter 33.4.6 Catalytic N 2 O deco
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Chapter 3According to [89, Kuiper,
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Chapter 33.4.7 Combined NO x and N
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Chapter 3EconomicsInvestment costs.
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Chapter 3Operational dataSee descri
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Chapter 3NOx removal efficiency in
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Chapter 33.4.10 Addition of H 2 O 2
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Chapter 33.4.11 NO X reduction duri
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Chapter 3Installing a low temperatu
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Chapter 3NO x emission level as NO
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Chapter 3Operational dataNo specifi
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Chapter 4Country Company Location C
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Chapter 4Country Company Location C
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Chapter 4Figure 4.2 gives an overvi
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Chapter 4Two general converter type
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Chapter 4Figure 4.6 gives an impres
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Chapter 44.2.3 Sulphur sources and
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Chapter 44.2.3.5 Non-ferrous metal
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Chapter 4Sulphur source/SO 2 produc
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Chapter 44.3 Current emission and c
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Chapter 410Tail gas specific SO2 lo
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Chapter 4Capacity in tonnesof 100 %
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Chapter 4Capacity in tonnesof 100 %
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Chapter 4SO 2 sourceSpent acid and
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Chapter 4Cross-media effectsWithout
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Chapter 44.4.3 Addition of a 5 th b
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Chapter 44.4.4 Application of a Cs-
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Chapter 4EUR/yearWaste gas volume (
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Chapter 44.4.6 Replacement of brick
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Chapter 4EUR/yearWaste gas volume (
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Chapter 4PlantSO 2 sourceInlet SO 2
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Chapter 44.4.10 Combination of SCR
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Chapter 4Driving force for implemen
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Chapter 44.4.14 Monitoring of SO 2
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Chapter 4EconomicsCost benefits can
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Chapter 4Energy inputRecovery and l
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Chapter 44.4.16 Minimisation and ab
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Chapter 44.4.17 Minimisation of NO
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Chapter 44.4.19 Tail gas scrubbing
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Chapter 44.4.21 Tail gas treatment:
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Chapter 4Economics[58, TAK-S, 2003]
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Chapter 4EconomicsNo specific infor
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Chapter 4BAT is to minimise and red
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Chapter 55.2 Applied processes and
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Chapter 55.2.2.1 Raw materials5.2.2
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Chapter 5OriginChinaMine/regionRare
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Chapter 55.2.2.2 GrindingDepending
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Chapter 5Emission of mg/l g/tonne P
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Chapter 55.4 Techniques to consider
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Chapter 55.4.2 Hemihydrate process
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Chapter 55.4.3 Hemi-dihydrate recry
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Chapter 55.4.4 Hemi-dihydrate recry
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Chapter 55.4.5 Di-hemihydrate recry
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Chapter 55.4.6 RepulpingDescription
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Chapter 55.4.7 Fluoride recovery an
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Chapter 55.4.8 Recovery and abateme
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Chapter 5Operational dataNo informa
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Chapter 55.4.11 Decadmation of H 3
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Chapter 55.4.12 Use of entrainment
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Chapter 5Cross-media effects• dis
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Chapter 5Cross-media effectsTable 5
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Chapter 5ApplicabilityAt present, o
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Chapter 66 HYDROFLUORIC ACID6.1 Gen
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Chapter 6Component Portion (mass co
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Chapter 66.2.4 Process gas treatmen
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Chapter 6Emission of kg/tonne HF Re
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6.4 Techniques to consider in the d
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Chapter 66.4.2 Energy recovery from
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Chapter 66.4.4 Valorisation of fluo
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Chapter 66.4.6 Scrubbing of tail ga
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6.4.7 Scrubbing of tail gases: fluo
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Chapter 66.4.8 Abatement of dust em
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Chapter 66.4.9 Waste water treatmen
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Chapter 6Cross-media effects• 5 -
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Chapter 77 NPK AND CN7.1 General in
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Chapter 77.2.3 Direct neutralisatio
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Chapter 7Fluorine compounds origina
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Chapter7Per tonne productkWh Nm 3 k
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Chapter7Emission levelmg/Nm 3 ppm k
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Chapter7Emission levelmg/Nm 3 ppm k
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7.4 Techniques to consider in the d
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Chapter7Driving force for implement
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Chapter7Achieved environmental bene
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Chapter77.4.6 Recycling warm airDes
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Chapter77.4.7 Optimising the recycl
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Chapter7Operational dataThe volume
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Chapter77.4.11 Recycling of scrubbi
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Chapter77.4.12 Waste water treatmen
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Chapter7ParameterLevelmg/Nm 3Phosph
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Chapter 88.2.1.1 Particle formation
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Chapter 8Consumption of Per tonne u
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Chapter 8Per tonne urea Unit Remark
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Chapter 8Waste water per tonne urea
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Chapter 8Pollutant Source g/tonne u
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Chapter 8Plant Emission Amount (ton
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Chapter 8Operational dataSee Table
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Chapter 8Operational dataSee Table
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Chapter 88.4.6 Redirecting fines to
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Chapter 8Existing plantCase 2Revamp
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Chapter 88.4.8 Heat integration in
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Chapter 88.4.9 Combined condensatio
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Chapter 88.4.10 Minimisation of NH
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Chapter 8Other approaches to proces
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Chapter 88.5 BAT for Urea and UANBA
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Chapter 9Country Company LocationBe
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Chapter 99.2.2 NeutralisationThe ex
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Chapter 9Scrubbing devices• packe
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Chapter 9Pollutant mg/Nm 3 g/tonne
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Chapter 99.4 Techniques to consider
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Chapter 99.4.2 Recovery of residual
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Chapter 99.4.3 Energy consideration
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Chapter 99.4.4 Steam purification a
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Chapter 99.4.5 Autothermal granulat
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Chapter 9ApplicabilityIrrigated can
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Chapter 1010 SUPERPHOSPHATES10.1 Ge
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Chapter 10Emissionto airEmissionto
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Chapter 10Input Indirect granulatio
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Chapter 10Volume5 - 10 m 3 /hourTem
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Chapter 1010.4.2 Recovery and abate
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Chapter 1010.4.4 Recycling of scrub
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Chapter 1111 CONCLUDING REMARKS11.1
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Chapter 11Production of HNO 3 : De-
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References26 Dipankar Das (1998).
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References89 Kuiper (2001). "High t
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References147 Uhde (2006). "The Uhd
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GlossaryCalculation of steam proper
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GlossaryIPCCIPPCISO 14001Intergover
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GlossaryChemical formulasAl 2 O 3Ca
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Annexes14 ANNEXES14.1 Cost calculat
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