1. PLANT DESIGN II (CAB 4023) PRODUCTION OF 396, 000 TONNE OF AMMONIA PER YEAR
GROUP 11
MUHAMMAD FAIZ MOHD FUDZAILI
MUHAMMAD FAUZI KHAMIS
MUHAMMAD NUR AZIZI ABDUL AZIZ
NUR IZZATI BUJANG AMRI
SOFIA KEETASOPON
SUPERVISOR: DR MOHANAD EL-HERBAWI

2. GENERAL OVERVIEW

4. INTRODUCTION

5. BACKGROUND STUDY Commercially known as anhydrous ammonia
Ammonia is a colourless gas with a sharp, penetrating odour.
The heart of ammonia manufacture is the Haber process
One of the most essential material of the world nitrogen industry

6. USAGE OF AMMONIA Household cleansing agent Fertilizer products
Manufacture synthetic fibers : nylon and rayon
Neutralize acidic by-products of petroleum refining

7. MARKET STUDY 78% used for fertilizer production.
3% used in direct application
19% consumed for industrial end uses.
Continuous growth in the ammonia import correspond to demand for fertilizer production.
The additional ammonia availability in the market from low cost capacity will displace local production in other regions where gas costs are higher e.g. Europe and US
Source : AFA 15th International Forum

9. Global ammonia capacity is projected to be 224.1 Mt NH3 in 2014.
Global ammonia capacity is projected to increase between 2010 and 2015 at an annual growth rate of 3.5%, equating to a net expansion of 37.4 Mt NH3 over 2009.
Global ammonia capacity is projected to be Mt NH3 in 2014.
Much of the growth in ammonia capacity is associated with new urea capacity.
Global urea capacity will expand by a net 30% between 2009 and 2014 corresponds to a compound annual growth rate of 5.4%.
International trade of urea and merchant ammonia is projected to expand by 15 and 20%, between and 2014.

10. PROBLEM STATEMENT Students are required to:
Select the most convenience way to produce ammonia.
Calculate the mass balance.
Perform heat integration for selected process.
Perform study on control and instrumentation.
Conduct the economics evaluation.
Identify the environmental and safety issues related to the plant.

11. To design a process plant that produce
OBJECTIVE
To design a process plant that produce
396, 000 tonnes ammonia per year.

12. ALTERNATIVE PROCESSES

13. Synthesis gas production
Three process steps of industrial ammonia production:
Synthesis gas production
Gas purification
Synthesis of ammonia

14. SYNTHESIS GAS PRODUCTION
Alternative Processes
Steam Reforming Process
Partial Oxidation Process
Electrolysis Process

15. Steam Reforming Process
Reaction : CH4 + H2O → CO + 3 H2
CO + H2O → CO2 + H2
CH4 + 2 H2O → CO2 + 4 H2
Process Description :
Natural gas consists mainly of methane and refinery gas is a mixture of hydrocarbon gases.
The resulting gas mixture contains by volume about 57% hydrogen, 21% nitrogen, 10% carbon dioxide 11% carbon monoxide and some impurities.
Advantages:
Produced more hydrogen if compare to other processes.
Less energy requirement.
Economically competitive due to the low price of the feedstock.
Less carbon monoxide produced.

16. Partial Oxidation Process
Reaction :
CnH(2n + 2) + ½ nO2 → nCO + (n + 1)H2
Process Description :
Oxygen is used instead of air for the reaction
This process is adapted to the partial oxidation of coal and fuel oil
The carbonaceous materials are burned with a limited quantity of oxygen in the presence of steam at a temperature of about C
Disdvantages:
Demands careful control of the feed rates to the combustion chamber.
Heat resisting materials are needed for the construction of the reaction vessels bricks.
Not economically competitive due to the high price of the oxygen.
More carbon monoxide produced. 5. Less hydrogen produced.

17. Electrolysis Process Reaction : H2O ↔ H2 + O2 Process Description :
Two electrodes are placed in a vessel full of water. The cathode is an iron plate and the anode is a nickel iron plate.
A diaphragm of asbestos is placed between the electrodes.
Advantages:
Yields very pure hydrogen
Disadvantage :
Has been utilized commercially where low-cost electricity is available, such as Canada but high cost of electricity in Malaysia.

18. SYNTHESIS GAS PRODUCTION
CHOOSEN!
Steam Reforming Process
Partial Oxidation Process
Electrolysis Process
Produced more hydrogen if compare to other process.
Less energy requirement.
Economically competitive due to the low price of the
feedstock
Less carbon monoxide produced.

19. CO2 REMOVAL Process Advantages Disadvantages Water scrubbing
Simple plant
No heat load
Solvent availability at minimal cost
Excessive loss of hydrogen
Very high pumping load
Poor CO2 removal efficiency
CHOOSEN!
Amine
Rapid absorption
Excellent stability
Easy regeneration
High heat consumption on reactivation
Less economical at high concentration of CO2
Hot carbonate
Inexpensive absorbent
Rapid absorption
Reactivation up to 100%
Less economical at low CO2 concentrations
Usually followed by a second absorber to reach low CO2 concentrations in gas

20. SYNTHESIS OF AMMONIA CHOOSEN! Designation Pressure, atm
Tempera-ture, °C
Catalyst
Recircu-lation
Conversion, %
Bleed to remove inert
CHOOSEN!
Haber-Bosch
550
Doubly promoted iron
Yes
10-30
Claude
Promoted iron No
40-85
Casale
600
500
Promoted iron
Yes
15-18 No
Fauser
200
500
Promoted iron
Yes
12-23
*40 % conversion of the gas upon passage through a single converter and 85 % conversion
after passage through a series of converters. Gas is vented after one passes through the
converters.

21. PLANT DESIGN

22. INPUT-OUTPUT STRUCTURE
Recycle
Purge
Product(NH3)
Feed
(NG, Air, Steam)
Process
By-Product
(H2O,CO2)
Purification of feed stream is not required
Purge stream is required
Recycle is required (Product & By-Product)

23. REACTOR DESIGN Flow Pattern Models of Reactor Reactor Type
Principal Application
Advantages
Disadvantages
Continuous Stirred Tank Reactor (CSTR)
Gas-liquid reaction
Consistent product quality due to reproducible process control
Low operating costs
Wide range of throughput
Final conversion lower than in other basic reactor types
Unfavorable if the reaction must take place in high pressure
Tubular Reactor
Homogeneous gas phase reactions
Favorable conditions for temperature control by heat supply or heat removal
No moving mechanical parts
High throughput
Very high degree of specialization
Relative large pressure drop
CHOOSEN!

24. Reactor Configurations Fluidized-bed Catalytic
REACTOR DESIGN
Reactor Configurations
Fixed-bed Catalytic
Reactor
Fluidized-bed Catalytic
The fixed-bed (packed-bed) reactor is a tubular reactor that is packed with solid catalyst particles.
Most designs approximate to plug-flow behavior.
In fluidized-bed reactors, solid material in the form of fine particles is held in suspension by the upward flow of the reacting fluid.
CHOOSEN!

25. Fixed-bed Catalytic Reactor
REACTOR SELECTION
Packed with solid catalyst particles.
Highest conversion per weight of catalyst.
Behaves as plug flow allows efficient contacting between reactants and catalyst.
Flexible
Fixed-bed Catalytic Reactor

26. SEPARATION SYSTEM
In general, a series of separations are required after the reaction has taken place. The purposes are follows:
- To achieve desired product purity.
- To recover unconverted reactants.
- To remove the hazardous or undesired components before discharging them to environment.

27. Heterogeneous mixture To separate water and gas (N2 and H2)
SEPARATION SYSTEM
Heterogeneous mixture
(liquid and gas)
Two-phase separator
To separate water and gas (N2 and H2)
To separate fully converted ammonia product (liquid) and partially converted ammonia product (gas)

28. MATERIAL BALANCE

29. HEAT INTEGRATION

30. What is pinch technology? Objective of pinch analysis
Methodology for minimizing energy consumption by optimizing heat recovery systems
Objective of pinch analysis
To achieve financial saving by constructing the best process heat integration
To optimize the process heat recovery and reducing external utility loads

31. METHODOLOGY
Identification of hot, cold and utility streams in the process
Thermal data extraction for process and utility streams
Selection of initial ∆Tmin value
Construction of problem table algorithm
Identification Tpinch, QH,min and QC,min via heat cascade table
Construction of heat exchanger network
Calculation of energy saving

32. Cold Stream
Hot Stream
Back

33. Supply temperature TS(°C) Target temperature TT(°C)
Stream
Supply temperature TS(°C)
Target temperature TT(°C)
Utility
∆H (kW)
No.
Name (Refer to iCON)
Name
Type 1
E105 H1
Hot
427.22
204.44 2
E103 H2
220.00
40.00 3
E115 H8
460.00
300.00 4
E116 H9
150.00 5
E107 C1
Cold
50.00
290.00 6
E113 C2
30.00
189.61 7
E114 C3
350.00
Back

34. Ts*= Ts - ∆T/2 Tt*= TT + ∆T/2 NOTE THAT::
Stream
Supply temperature TS(°C)
Target temperature TT(°C)
CP(kW/°C)
Shifted temperature (°C)
Utility
∆H (kW)
∆Tmin/2
No.
Name (Refer to iCON)
Name
Type
TS*
TT* 1
E105 H1
Hot
427.22
204.44
422.22
199.44 5 2
E103 H2
220.00
40.00
215.00
35.00 3
E115 H8
460.00
300.00
455.00
295.00 4
E116 H9
150.00
145.00
E107 C1
Cold
50.00
290.00
55.00 6
E113 C2
30.00
189.61
194.61 7
E114 C3
350.00
355.00
Ts*= Ts - ∆T/2
Tt*= TT + ∆T/2
NOTE THAT:: 1
CP = ∆H/∆T, ∆H is obtained from iCON 2
∆Tmin = 10˚C
Back

35. Interval Temperature (˚C)
PROBLEM TABLE ALGORITHM
Interval Temperature (˚C)
Stream Population
∆Tinterval (°C)
∑CPC -∑CPH (kW/°C)
∆Hinterval(kW)
Surplus/Deficit
455.00
32.78
Surplus
422.22
67.22
355.00
60.00
295.00
80.00
215.00
15.56
199.44
4.83
194.61
49.61
145.00
90.00
55.00
20.00
35.00
109
102
110
103
106
104
105
Back

36. Interval temperature (˚C) Adjusted heat cascade (kW)
HEAT CASCADE TABLE
Interval temperature (˚C)
∆Hinterval (kW)
Heat flow (kW)
Adjusted heat cascade (kW)
455.00
0.0000
422.22
355.00
295.00
215.00
199.44
194.61
145.00
55.00
35.00
QH,min
Tpinch (˚C): /2
= 460˚C
QC,min

37. Combine Composite Curve
Grand Composite Curve
Back

38. GRID DIAGRAM

39. Above pinch region: Cpc > Cph Below pinch region: Cph > Cpc1
Cp rules:
Below pinch region: Cph > Cpc
No temperature crossover of hot and cold stream through the heat exchanger 2

40. GRID DIAGRAM WITH HEAT EXCHANGER DESIGN
1) kW/2 = kW/˚C x (460˚C - T)
2) T = ˚C
Back

41. COMPARISON ON TOTAL UTILITY CONSUMPTION
Total Utility Consumption Before HI
Name (Refer to iCON)
∆H (kW)
Remaining Heat For Cooling Requirement (kW)
C102
C103
C109
C110
H104
0.0000
H105
H106
Total
Total Utility Consumption After HI

42. Total Utility Consumption
ENERGY SAVING AFTER HEAT INTEGRATION
Total Utility Consumption
Base Case Design
Before HI
(kW)
After HI
Energy Saved
% Reduction
70.05%
= (222, kW – 65, kW) / kW
= 70.05%

43. PLANT LAYOUT

44. PLANT LAYOUT

45. PROCESS FLOWSHEETING

46. INSTRUMENTATION & CONTROL

47. SAFETY & LOSS PREVENTION

48. HAZARD AND OPERABILITY STUDY (HAZOP)
Objective of HAZOP
To indentify potential hazards and potential operability problems that may arise from the deviations of design intent.

49. LIST OF HAZOP GUIDE WORDSNO
None of design intent is achieved.
MORE
Quantitative increase
LESS
Quantitative decrease
REVERSE
The logical opposite of the intention
AS WELL AS
An additional activity occur
PART OF
Only some of design intent is achieved
OTHER THAN
Complete substitution

50. HAZOP ANALYSIS HAZOP Study Nodes Node 1
Methanator (R105) including incoming line discharge from heat exchanger (E117)
Node 2
Ammonia Converter (R106) including incoming line discharge from heat exchanger (E105)
Node 3
Ammonia Separator (V106) including incoming line discharge from cooler (E120)

51. Node 1

52. HAZOP ANALYSIS: NODE 1 Parameter : Flow Guide Word Deviation
Possible Causes
Consequences
Safeguards
Recommendations NO
No Flow
1. Line (S22) leakage.
2. Loss of feed supply.
3. Blockage inside pipeline (S22).
1. No process gas into the reactor
2. Release of toxic material.
1. Flow indicator is provided.
2. Perform regular schedule inspection on process line.
1. Install gas detection system is provided.
2. Install No Flow alarm

53. Parameter : Flow Guide Word Deviation Possible Causes Consequences
Safeguards
Recommendations
LESS
Less Flow
1. Partially plug line.
2. Control valve failure.
3. Line (S22) leakage.
1. Pressure drop inside the reactor (R105)
2. Less process gas into reactor.
1. Flow indicator is provided.
2. Perform regular schedule inspection on process line.
1. Install gas detection system is provided.

54. Parameter : Flow Guide Word Deviation Possible Causes Consequences
Safeguards
Recommendations
MORE
More Flow
1. Control valve failure.
1. Over pressure inside the reactor.
2. May lead to reactor explosion
3. Undesired product quality
1. Flow indicator is provided.
2. Perform regular schedule inspection on process line.
1. Install gas detection system is provided.
2. Install high flow alarm.
REVERSE
Reverse Flow
1. Back pressure.
2. Failure of pressure controller.
3. Compressor trips.
1. Reverse flow from reactor (R105)
2. Less of product yield.
1. Flow indicator is provided.
2. regular schedule inspection on process line.
1. Install Non-return/check valve

55. Parameter : Temperature
Guide Word
Deviation
Possible Causes
Consequences
Safeguards
Recommendations
LOW
Low Temperature
1. Malfunction of heat exchanger (E117)
1. Rate of reaction is reduced.
1. Temperature indicator is provided.
1. Install low temperature alarm.
HIGH
High Temperature
1. Failure of cooler.
2. Poor heat transfer in the cooler.
3. HE (E117) failure.
1. Less of product goes to the storage.
1. Temperature indicator is provided.
2. High temperature alarm is provided.
1. Install high temperature alarm.

56. Parameter : Pressure Guide Word Deviation Possible Causes Consequences
Safeguards
Recommendations
LOW
Low Pressure
1. Compressor failure.
2. Pipe leakage.
1. Impact to reactor.
2. May lead to reverse flow.
1. Pressure indicator is provided to notify operator.
1. Install high temperature alarm.
2. Install Low pressure alarm.
HIGH
High Pressure
1. Failure of pressure relief valve.
2. More process gas into the reactor.
3. Pipe blockage.
1. Pipe vibration.
2. May lead to explosion.
1. Pressure indicator is provided to notify operator.
1. Install high pressure alarm.
2. Install emergency shutdown system.

57. WASTE TREATMENT

58. Generally, the effluent discharge from Ammonia Plant needs to comply with Environmental Quality (Sewage and Industrial Effluents) Regulations, (Regulation 8(1) Third Schedule, Standard A, EQA 1979).
The main consideration in wastewater treatment system is the COD and BOD value.
Parameter
Unit
Standard A B
Temperature °C 40
pH Value -
6.0 – 9.0
5.5 – 9.0
BOD at 20°C
mg/L 20 50
COD
100
Oil and Grease
Not detectable
10.0

59. WASTE STREAM Stream No. Component Composition Flow rate (kg/hour)
Phase W6
Hydrogen %
0.04
Liquid
Nitrogen %
2.89
Carbon dioxide %
173.78
Water % 54 %
Gas %
Methane %
294.57
Ammonia %
176.38

60. WASTEWATER STREAM

61. WASTEWATER STREAM

62. WASTEWATER TREATMENT SYSTEM

63. PROCESS ECONOMICS & COST ESTIMATION

64. PLANT SITE SELECTION 1 (selected) 2 Selected Site
Gebeng Industrial Estate
Phase IV
Pasir Gudang Industrial Estate
Kerteh Petrochemical Integrated Complex
Types of Industrial 5
Price and Land Areas 4 3
Raw Material Sources
Transportation
Utilities
TOTAL MARKS
23/25
21/25
22/25
PERCENTAGES (%) 88 76 80
RANKING
1 (selected) 2
CHOOSEN!

65. COMPARISON ON PLANT SITE LOCATION

66. GEBENG INDUSTRIAL ESTATE

67. ECONOMICS EVALUATION Total Capital Investment:
= Fixed Capital Investment + Working capital + Land Cost
= RM 379,071, RM 18,953, RM 6,151,254.01
= RM 404,175,833.56
≈ RM 404 million
Total Cost of Production/Total Operating Cost:
= Fixed Cost + Variable Charges + General Expenses
= RM 71,415, RM 180,306, RM 7,581,420.56
≈ RM 259,303,035.12

68. PROFITABILITY ANALYSIS
UNDISCOUNTED CASH FLOW ANALYSIS
From Cumulative cash flow diagram for undiscounted rate above:
The rate of return is 26.51%
Payback time is 3.3 years after plant start-up

69. DISCOUNTED CASH FLOW DIAGRAM
From the discounted cash flow diagram above:
At minimum discount rate of 15%, the net present value is RM550 million with payback time of 3.5 years
The discounted cash flow rate of return is 74.95%

70. From the economic analysis done, the plant is estimated to have a capital investment of RM 215 million.
At discount rate of 15%, the net present value of 550 million is attainable for a project life of 20 years and payback time of 3.5 years.
With DCFRR of 74.95% and rate of return of 41.33% which is larger than the minimum attractive rate of return of 15%, the project is economically attractive and feasible.

71. CONCLUSION