CONTROL OF AN AMMONIA SYNTHESIS LOOP AT PARTIAL LOAD

Abstract

A process for synthesis of ammonia including generation of makeup gas in a frontend and conversion of said makeup gas in an ammonia synthesis loop including a circulator, a converter, a condensation section and a liquid ammonia separation section, including: when the loop operates at a partial load and a flow rate of makeup gas transferred from the front end to the synthesis loop is reduced, the loop is controlled by separating a gas stream from a converter feed line at a point upstream of the converter thus forming a bypass stream; reintroducing said bypass stream at the suction side of the circulator or at a point of the loop downstream of said separation section.

Claims

1-16. (canceled)

17. A process for synthesis of ammonia, the process comprising: producing an ammonia make-up synthesis gas in a front-end; raising a pressure of said ammonia make-up gas in a first compressor; feeding high-pressure make-up synthesis gas delivered by said first compressor to an ammonia synthesis loop; wherein said ammonia synthesis loop includes at least: a converter where ammonia is synthesized catalytically; a circulator, which is a compressor configured to maintain circulation in the loop and to deliver a feed gas, which includes the make-up synthesis gas, to said converter; a converter feed line from the circulator to the converter; a condensation section arranged downstream the synthesis section to receive an ammonia-containing gaseous product; a separation section wherein a condensate produced in said condensation section is separated into an ammonia liquid product and a gaseous recycle stream; a recycle line from the separation section to the suction of the circulator; wherein the ammonia synthesis loop has a full load condition corresponding to the processing of a nominal flow rate of ammonia make-up gas transferred from the front end to the synthesis loop, controlling the loop at a partial load condition, wherein the flow rate of ammonia make-up gas transferred from the front end to the loop is smaller than said nominal flow rate, by: separating a gas stream from said converter feed line, at a point upstream of the converter, to form a bypass stream; reintroducing said bypass stream at the suction side of the circulator or into the ammonia synthesis loop at a point downstream of said separation section.

18. The process according to claim 17, further comprising: detecting the synthesis pressure in the converter or at another location of the ammonia synthesis loop; and determining the amount of gas in the bypass stream so that the difference between the detected synthesis pressure at partial load and the synthesis pressure at full load is maintained within a target range.

19. The process according to claim 17, further comprising: detecting the difference of temperature across the converter, by detecting the difference between the temperature of the gas feed entering the converter and the temperature of an ammonia-containing product withdrawn from the converter; determining the amount of gas in the bypass stream so that said difference of temperature across the converter is maintained within a target range.

20. The process according to claim 17, further comprising: determining the amount of gas in the bypass stream as a function of the instant amount and/or of the variation over time of the flow rate of makeup gas transferred from the front end to the ammonia synthesis loop.

21. The process according to claim 17, wherein at partial loads the amount of gas in the bypass stream is controlled so that the pressure in the converter is not less than 90% of the nominal synthesis pressure.

22. The process according to claim 21, wherein at partial loads the amount of gas in the bypass stream is controlled so that the pressure in the converter is not greater than 110% of the nominal synthesis pressure.

23. The process according to claim 17, wherein said condition of partial load include loads until the ammonia make-up gas transferred from the frontend to the synthesis loop is 15% of the nominal flow rate.

24. The process according to claim 17, further comprising: detecting a drop or surge of the flow rate of flow rate of makeup gas transferred from the front end to the synthesis loop, and reacting to said drop or surge of flow by: a) increasing the amount of gas in the bypass stream in the event of a drop of flow or decreasing said amount in the event of a surge of flow; b) after the above step a), controlling the amount of gas in the bypass stream to keep the pressure in the converter, or the difference of temperature across the converter, at a constant value or within a target narrow range.

25. The process according to claim 17, including the step of cooling the bypass stream before its reintroduction at the suction of the circulator or in the loop.

26. The process according to claim 17, wherein the production of makeup gas in the front end includes the production of hydrogen from a renewable energy source.

27. A method for controlling an ammonia synthesis loop running at a partial load, wherein: said ammonia synthesis loop includes: a converter where ammonia is synthesized catalytically; a circulator, which is a compressor configured to maintain circulation in the loop and to deliver a feed gas, which includes the make-up synthesis gas, to said converter; a converter feed line from the circulator to the converter; a condensation section arranged downstream the synthesis section to receive an ammonia-containing gaseous product; a separation section wherein a condensate produced in said condensation section is separated into an ammonia liquid product and a gaseous recycle stream; a recycle line from the separation section to the suction of the circulator; wherein the ammonia synthesis loop has a full load condition corresponding to the processing of a nominal flow rate of make-up gas transferred from the front end to the synthesis loop, and said partial load corresponds to a condition wherein an amount less than said nominal flow rate is transferred from the front end to the loop, the method comprising: separating a gas stream from said converter feed line, at a point upstream of the converter, to form a bypass stream and reintroducing said bypass stream at the suction side of the circulator or into the ammonia synthesis loop at a point downstream of said separation section.

28. The method according to claim 27, wherein the amount of gas in the bypass stream, at said condition of partial load, is determined as a function of one or more of the following: the instant amount and/or of the variation over time of the flow rate of makeup gas transferred from the front end to the ammonia synthesis loop; the pressure in the synthesis loop or in the converter; the difference of temperature across the converter, detected as the difference between the temperature of the gas feed entering the converter and the temperature of the ammonia-containing product withdrawn from the converter.

29. The method according to claim 27, wherein the amount of gas in the bypass stream is determined in such a way that the pressure in the converter is: not less than 90% of the nominal synthesis pressure, preferably not less than 95% and more preferably not less than 98%, and not greater than 110% of the nominal synthesis pressure, preferably not greater than 105% and more preferably not greater than 102%.

30. The method according to claim 27, wherein the amount of gas in the bypass stream is determined to keep the difference of temperature across the converter, detected as the difference between the temperature of the gas feed entering the converter and the temperature of an ammonia-containing product withdrawn from the converter, within a target range.

31. The method according to claim 27, further comprising: detecting a drop or surge of the flow rate of flow rate of makeup gas transferred from the front end to the synthesis loop, increasing the amount of gas in the bypass stream in the event of a drop of flow or decreasing said amount in the event of a surge of flow; after the above increasing the amount of gas, controlling the amount of gas in the bypass stream to keep the pressure in the converter, or the difference of temperature across the converter, at a constant value or within a target narrow range.

32. A synthesis loop for the synthesis of ammonia from ammonia make-up synthesis gas, the synthesis loop comprising: a converter where ammonia is synthesized catalytically; a circulator, which is a compressor configured to maintain circulation in the loop and to deliver a feed gas, which includes the make-up synthesis gas, to said converter; a converter feed line from the circulator to the converter; a condensation section arranged downstream the synthesis section to receive an ammonia-containing gaseous product; a separation section wherein a condensate produced in said condensation section is separated into an ammonia liquid product and a gaseous recycle stream; a recycle line from the separation section to the suction of the circulator; a bypass line arranged to take a gas stream from said converter feed line, at a point upstream of the converter, and to reintroduce said bypass stream at the suction side of the circulator or into the ammonia synthesis loop at a point downstream of said separation section; a flow control valve installed on said bypass line; and a control system of the converter configured to control the opening of said valve and therefore an amount of gas bypassing the converter via the bypass line; wherein the control system is configured to operate with the method according to claim 27.

Description

[0064] The invention is now further elucidated with reference to the figures, wherein:

[0065] FIG. 1 illustrates a scheme of an ammonia synthesis loop according to an embodiment of the invention.

[0066] In FIG. 1, the block 1 denotes a front-end which produces a make-up ammonia synthesis gas (syngas) 2. The make-up gas 2 is fed to a main compressor 3 which delivers a compressed gas 4 to a synthesis loop 5.

[0067] The loop 5 comprises basically a circulator 6, a converter 7, a condenser 8 and a separator 9. The condenser 8 forms a condensation section and the separator 9 forms a separation section.

[0068] A gas feed is provided to the converter 7 via a converter feed line 10. A hot ammonia-containing gaseous product at line 11 is withdrawn from the converter 7 and is condensed in the condenser 8; the condensate in line 12 is separated in the separator 9 into a liquid ammonia product exported via line 13 and a gaseous phase in line 14 containing some unreacted hydrogen and nitrogen and residual vapors of ammonia, which is recycled to the suction of the circulator 6.

[0069] The feed line 10 from the circulator 6 to the converter 7 is connected to a bypass line 15 which bypasses the converter 7, the condenser 8 and the separator 9, thus connecting the delivery side of the circulator 7 back to its suction. The bypass line 15 optionally comprises a by-pass cooler 16.

[0070] The lines 10, 11 and 14 may include heat exchangers (not shown).

[0071] A valve 17 is provided on the bypass line 15 to control the flow rate through said line 15. In the example, the valve 17 has a controller 18 connected to a control unit 19.

[0072] The control unit 19 is connected to a flow gauge 20 which is arranged to detect the incoming flow rate of makeup gas from the front-end 1. For example the flow gauge 20 senses the flow rate of makeup gas 2 at the suction of the main compressor 3.

[0073] The control unit 19 is also connected to a loop pressure sensor 21 which detects the pressure at the converter inlet, for example on the line 10.

[0074] Based on the input signals from the flow gauge 20 and the loop pressure sensor 21, the control unit 19 calculates the appropriate opening of the valve 17 and, consequently, the amount of gas flowing in the bypass line 15.

[0075] An anti-surge line 22 of the main compressor 3 is also illustrated. Said line 22 includes a gas cooler 23. With the anti-surge line 22, some gas taken from the line 4 can be sent back to the suction of the main compressor 3.

[0076] In operation, the circulator 6 receives at its suction inlet 24 the compressed make-up gas 4 delivered by the main compressor 3, mixed with the gaseous phase via line 14 from top of the loop separator 9 and possibly mixed with bypass gas in the line 15.

[0077] The flow rate at the delivery side 25 of the circulator 6 can be partially deviated to the bypass line 15 according to the position of the valve 17; the remaining portion is fed to the converter 7 via the delivery line 10.

[0078] The converter 7 has a nominal ammonia synthesis pressure (also termed loop pressure) at 100% capacity, for example about 140 bar. At partial loads, the control unit 19 operates the valve 17 to vary the amount of make-up gas actually admitted to the converter 7, to keep the pressure in the loop and the converter, for example the pressure detected by the sensor 21, within a target range. Preferably this target range is a narrow range around the nominal pressure, i.e. the valve 17 is operated to keep the loop pressure substantially constant regardless of the amount of gas actually provided by the frontend 1.

[0079] In another embodiment, the circulation in the loop and the bypass flow rate in the line 15 can be controlled on the basis of the converter delta-T, e.g. by taking a converter inlet temperature T.sub.10 at converter input line 10 and a converter output temperature T.sub.11 at line 11. In this embodiment, the control unit 19 may be configured to keep the converter delta-T (T.sub.11-T.sub.10) within a target range.

[0080] Particularly, the system may be configured to avoid overheating of the converter and to avoid that the temperature falls below a minimum, which may cause the converter to lose the self-sustaining condition.

[0081] Additionally, the control unit 19 may be configured to react to a rapid change in the flow rate measured by the gauge 20. For example, the control unit 19 may command a pre-opening of the valve 17 in case of a sudden drop of the flow rate of makeup gas 2. In this step the unit 19 may operate with a feed-forward control technique. Then, the unit 19 switches to normal control to keep the loop pressure stable. Similarly, the control unit 19 may react to a surge of the flow by closing the valve.

Example 1

[0082] The following example 1 relates to a small-scale ammonia production plant with a capacity of 3 metric tons per day (MTD) of ammonia. The relevant parameters are reported for operation at 100% load and operation at 30% load wherein the plant is controlled according to the invention. At 30% load, 70% of the circulation flow is bypassed. The symbol m.sup.3/hEFF denotes the cubic meters per hour at the conditions of temperature and pressure of the synthesis loop. The symbol N m.sup.3/h denotes cubic meters per hour at normal conditions of atmospheric pressure and 0° C.

TABLE-US-00001 EXAMPLE 1 100% load 30% load Pressure (bar g) 226 226 MUG flow (Nm.sup.3/h) 338 101 Circulation m.sup.3/h.sub.EFF 12.04 3.61 Converter ΔT (Tout-Tin) 122.4 122.9 Ammonia @ converter inlet (mol %) 11.3 11.3 Ammonia @ converter outlet (mol %) 20.99 21.03 Delta Ammonia (CUT-IN)-mol % 9.69 9.73

Example 2

[0083] The following example 2 relates to a large ammonia production plant with a capacity of 1000 metric tons per day (MTD) of ammonia. The relevant parameters are reported for a 100% load and a 30% load wherein the plant is controlled according to the invention. At 30% load, 70% of the circulation flow is bypassed.

TABLE-US-00002 EXAMPLE 2 100% load 30% load Pressure (bar g) 138.5 138.5 MUG flow (Nm.sup.3/h) 109737 32921 Circulation m3/h.sub.EFF 4713 1435 Converter ΔT (Tout-Tin) 265.7 265 Ammonia @ converter inlet (mol %) 2.58 2.58 Ammonia @ converter outlet (mol %) 20.64 20.57 Delta Ammonia (OUT-IN)-mol % 18.06 17.99

[0084] The examples show that the converter is maintained in a stable operation at constant pressure. The parameters determining the kinetic of the conversion remain stable.