DesulphurizationThe sulphur contained in the natural gas is reduced to a very low level, less than 0.1ppm sulphur by weight.
ReformingsThe hydrocarbon feed coming from the desulphurization unit is mixed with steam. The reaction mixture is preheated and taken to the primary and secondary reformer where it is decomposed into hydrogen, carbon monoxide, and carbon dioxide over a catalyst by heat supply.
CO conversionThe CO conversion takes place in two adiabatic stages, in High temperature CO converter and in Low temperature CO converter. After reforming more then 10 vol % of CO is present in the gas (dry basis). In the CO converters CO is reduced to low level, less then 0.5 vol %.
CO2 removalFor removal of the carbon dioxide BASF’s process is used. Main equipment is the CO2 absorber and CO2 stripper and solution pumps. Nearly complete removal of CO2 is in absorber.
MethanationAfter the CO2 removal the gas contains less then 0,5 % vol CO2 and CO (dry basis). These compounds are poisons to the ammonia catalyst and must be removed before the gas is taken to the synthesis section. This is done in the Methanator where CO and CO2 react with H2 to form CH4 which is harmless to the ammonia catalyst.
Ammonia synthesisCompressionThe synthesis gas is compressed from aprox. 3 to 240 bar g in Synthesis gas turbo compressor.
Synthesis loopThe make-up gas from the compressor after cooler is introduced into the synthesis loop where ammonia in the converter is created. The mixture of synthesis gas and liquid ammonia passes from ammonia coolers and chillers to the ammonia separator in which the liquid ammonia is separated and transported to the storage tank.
Total number of equipment (reactors, vessels, tanks, exchangers, pumps, turbines, compressors, …. ) is more than 160 pieces.
Main pieces of equipment:
- Natural Gas supply on continuous basis as feed and Gas fuel. - Electricity - Potable water - Service water - Instrument and Service air - Demineralized water - Cooling water - Fire water - Steam- Laboratory Facilities
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