1. GROUP 11 MUHAMMAD FAIZ MOHD FUDZAILI 10821 MUHAMMAD FAUZI KHAMIS 10826 MUHAMMAD NUR AZIZI ABDUL AZIZ 10853 NUR IZZATI BOHER @ BUJANG AMRI 10935 SOFIA KEETASOPON 10564 SUPERVISOR: DR MOHANAD EL-HERBAWI

2. GENERAL OVERVIEW

4. INTRODUCTION

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

7.  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 15 th International Forum  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 15 th International Forum

9.  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 NH 3 over 2009.  Global ammonia capacity is projected to be 224.1 Mt NH 3 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 NH 3 over 2009.  Global ammonia capacity is projected to be 224.1 Mt NH 3 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 2009 and 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 2009 and 2014.

10. 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 396, 000 tonnes ammonia per year.

12. ALTERNATIVE PROCESSES

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

14. Alternative Processes  Steam Reforming Process  Partial Oxidation Process  Electrolysis Process

15. Steam Reforming Process Reaction : CH 4 + H 2 O → CO + 3 H 2 CO + H 2 O → CO 2 + H 2 CH 4 + 2 H 2 O → CO 2 + 4 H 2 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. Reaction : CH 4 + H 2 O → CO + 3 H 2 CO + H 2 O → CO 2 + H 2 CH 4 + 2 H 2 O → CO 2 + 4 H 2 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: 1.Produced more hydrogen if compare to other processes. 2.Less energy requirement. 3.Economically competitive due to the low price of the feedstock. 4.Less carbon monoxide produced. Advantages: 1.Produced more hydrogen if compare to other processes. 2.Less energy requirement. 3.Economically competitive due to the low price of the feedstock. 4.Less carbon monoxide produced.

16. Partial Oxidation Process Reaction : C n H(2n + 2) + ½ nO 2 → nCO + (n + 1)H 2 Process Description :  Oxygen is used instead of air for the reaction  The carbonaceous materials are burned with a limited quantity of oxygen in the presence of steam at a temperature of about 1300-1500  C Reaction : C n H(2n + 2) + ½ nO 2 → nCO + (n + 1)H 2 Process Description :  Oxygen is used instead of air for the reaction  The carbonaceous materials are burned with a limited quantity of oxygen in the presence of steam at a temperature of about 1300-1500  C Disadvantages: 1.Demands careful control of the feed rates to the combustion chamber. 2.Heat resisting materials are needed for the construction of the reaction vessels bricks. 3.Not economically competitive due to the high price of the oxygen. 4.More carbon monoxide produced. 5. Less hydrogen produced. Disadvantages: 1.Demands careful control of the feed rates to the combustion chamber. 2.Heat resisting materials are needed for the construction of the reaction vessels bricks. 3.Not economically competitive due to the high price of the oxygen. 4.More carbon monoxide produced. 5. Less hydrogen produced.

17. Electrolysis Process Reaction : H 2 O ↔ H 2 + O 2 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.  Water decomposed at a voltage different of from 2.0 to 2.3 V between the electrodes, giving rise to hydrogen at the cathode and oxygen at the anode. Reaction : H 2 O ↔ H 2 + O 2 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.  Water decomposed at a voltage different of from 2.0 to 2.3 V between the electrodes, giving rise to hydrogen at the cathode and oxygen at the anode. 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. 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. Steam Reforming Process Partial Oxidation Process Electrolysis Process CHOOSEN! Produced more hydrogen if compare to other process. Less energy requirement. Less carbon monoxide produced. Economically competitive due to the low price of the feedstock Economically competitive due to the low price of the feedstock

19. CHOOSEN!

20. *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. CHOOSEN!

21. PLANT DESIGN

22. Feed (NG, Air, Steam) Product(NH 3 ) By-Product (H 2 O,CO 2 ) Process Purge Recycle Purification of feed stream is not required Purge stream is required Recycle is required (Product & By-Product)

23. Flow Pattern Models of Reactor CHOOSEN!

24. Reactor Configurations

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

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

27. Heterogeneous mixture (liquid and gas) Heterogeneous mixture (liquid and gas) Two-phase separator To separate water and gas (N 2 and H 2 ) To separate fully converted ammonia product (liquid) and partially converted ammonia product (gas) To separate water and gas (N 2 and H 2 ) To separate fully converted ammonia product (liquid) and partially converted ammonia product (gas)

28. MATERIAL BALANCE

29. HEAT INTEGRATION

30. What is pinch technology? 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. Identification of hot, cold and utility streams in the process Thermal data extraction for process and utility streams Construction of problem table algorithm Selection of initial ∆Tmin value 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

34. ∆Tmin = 10˚C CP = ∆H/∆T, ∆H is obtained from iCON 1 2 NOTE THAT:: Ts*= Ts - ∆T/2 Tt*= TT + ∆T/2 Back

35. Interval Temperature (˚C) Stream Population ∆T interval (°C) ∑CP C -∑CP H (kW/°C) ∆H interval (kW) Surplus/Deficit 455.00 32.78-171.0079-5605.6382Surplus 422.22 67.22-316.1228-21249.7738Surplus 355.00 60.00-137.0871-8225.2272Surplus 295.00 80.00-50.8882-4071.0528Surplus 215.00 15.56-380.1290-5914.8075Surplus 199.44 4.83-235.0141-1135.1181Surplus 194.61 49.61-378.4663-18775.7150Surplus 145.00 90.0030.49322744.3841Surplus 55.00 20.00-148.5425-2970.8502Surplus 35.00 102 103 109 110 104 105 106 Back

36. Interval temperature (˚C) ∆H interval (kW)Heat flow (kW) Adjusted heat cascade (kW) 455.000.0000 -5605.6382 422.225605.6382 -21249.7738 355.0026855.4120 -8225.2272 295.0035080.6392 -4071.0528 215.0039151.6920 -5914.8075 199.4445066.4995 -1135.1181 194.6146201.6176 -18775.7150 145.0064977.3326 2744.3841 55.0062232.9485 -2970.8502 35.0065203.7987 Q H,min Q C,min T pinch (˚C): 455 + 10/2 = 460˚C

37. Combine Composite Curve Grand Composite Curve Back

39. Cp rules: Above pinch region: C pc > C ph Below pinch region: C p h > C pc No temperature crossover of hot and cold stream through the heat exchanger 1 2

40. 1) 28715 kW/2 = 171.0079 kW/˚C x (460˚C - T) 2) T = 376.04˚C Back

41. Name (Refer to iCON) ∆H (kW) Remaining Heat For Cooling Requirement (kW) C10232328.699817971.1135 C10359263.353830421.7298 C10927361.260313003.6740 C11025379.67225126.3367 H10420253.33550.0000 H10528841.62400.0000 H10628715.17260.0000 Total 222143.118266522.8540 Total Utility Consumption Before HI Total Utility Consumption After HI

42. Total Utility Consumption Base Case Design Before HI (kW) 222143.1182 After HI (kW) 66522.8540 Energy Saved (kW) 155620.2642 % Reduction 70.05% = (222,143.1182 kW – 65,522.8540 kW) / 155620.2642 kW = 70.05%

43. PLANT LAYOUT

44. Plant Site Selection Location Gebeng Industrial Area 25km from Kuantan town and 250km from Kuala Lumpur city Type of industry Chemical and petrochemical Price & Land Area RM10.00 per ft 2 168 million ft 2 (3800 acres) area available Raw Material Sources Natural Gas – CUF Gebeng Steam – CUF Gebeng Transportation 5km from Kuantan Port 9km Gebeng-Kuantan pipe-rack network Kerteh-Gebeng-Kuantan railway Utilities Power Supply- Tenaga Nasional Berhad, Tanjung Gelang Water supply- Loji air Semambu Waste treatment Kualiti Alam Sdn Bhd

45. Sources of Raw Materials and Transportation Ammonia plant has been identified to be located at Gebeng, Kuantan. Raw material LocationCondition (At ambient) Unit Price (RM/kg) TransportationStorage Natural Gas CUF Gebeng Gas0.00939 Piperack network Central Storage Facility (CTF) Steam CUF Gebeng Gas63.42 Piperack network Central Storage Facility (CTF)

46. ● Other sources such as: UtilitiesSourcePrice Raw WaterLoji Air SemambuRM 0.99/m 3 Electricity Tenaga Nasional Berhad, Tanjung Gelang RM 0.27/kWh (peak) ; RM 0.16/kWh (off peak)

49. PROCESS FLOWSHEETING

50. INSTRUMENTATION & CONTROL

51. SAFETY & LOSS PREVENTION

52. Objective of HAZOP To indentify potential hazards and potential operability problems that may arise from the deviations of design intent. To indentify potential hazards and potential operability problems that may arise from the deviations of design intent.

53. None of design intent is achieved. NO Quantitative increase MORE Quantitative decrease LESS The logical opposite of the intention REVERSE An additional activity occur AS WELL AS Only some of design intent is achieved PART OF Complete substitution OTHER THAN

54. 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) HAZOP Study Nodes

55. Node 1

56. Parameter : Flow

59. Parameter : Temperature

60. Parameter : Pressure

61. WASTE TREATMENT

62.  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.

67. PROCESS ECONOMICS & COST ESTIMATION

68.  Total Capital Investment: = Fixed Capital Investment + Working capital + Land Cost = RM 379,071,028.14 + RM 18,953,551.41 + 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 71,415,500.21 + RM 180,306,114.35 + RM 7,581,420.56 ≈ RM 259,303,035.12

69. 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 UNDISCOUNTED CASH FLOW ANALYSIS

70. 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%

71.  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.

72. CONCLUSION