Professional Documents
Culture Documents
Introduction
some cases.
Ammonia gas is used directly as fertilizer in heat treatment, paper pulping, nitric
acid and nitrate manufacturing, nitric acid esters and nitrocompound manufacture,
explosive of various types and as a refrigerant.
The most important field is of fertilizer. Importance of ammonia in this field is due
to the fact that it is by far the most simple form of actual nitrogen which can be
administrated and the most economical source of other nitrogen chemicals. Hence
ammonia is the backbone of Nitrogen fertilizer processes. Its production is the first
consideration in the initiation of a fertilizer industry. Great strides have been made in the
last few year in the economy and efficiency of ammonia processes.
The synthesis of ammonia from Nitrogen and hydrogen was first
scale. This synthesis reaction has probably been studied more extensively
The name of Haber, Corl Bosch, Claude, Casale, Fauser, Mont Cenis
stand out from those of early engineers and scientists, worked for the
In India, till 1948, the only factory which was producing synthetic
Barauni (1976).
examination of the process step by step and the severe economic pressure
and the most recent development on which researches have been made and
synthesis gases are obtained which have many advantages over low
MANUFACTURING PROCEDURES-
The principal manufacturing process that are used for synthetic ammonia
production are steam water gas process, the steam hydrocarbon process, the coke oven
gas process & electrolysis of water.
Much research work is still diverted to find cheaper manufacturing
raw material used. Raw material selection depends upon the availability
and cost of raw material. If the plant is near some refinery then raw
material can be naphtha, natural gas or LPG, but in case it is near a coal
mine, one should depend on coal as raw material for hydrogen. There may
electrolysis of water
Comparsion of processes
Many variation of the original Haber process for the synthesis of ammonia are now used
in commercial practice, some varying to such an extent that they are identified by a name,
often that of group of men developing them. Important among these are modified Haber
Bosch, Claude, Casale, Fauser, and Mont Cenis processes. All of them are fundamentally
the same in that nitrogen is fixed with hydrogen as ammonia in the presence of a
catalyst , but have variation in arrangement and construction of equipment , composition
of catalyst, temperature and pressure used. Table C gives a condensed comparison of
different processes 40% conversion of the gas upon passes through a single converter and
85% conversion after passes through a series of converter . gas is vented after one pass
through the converter.
Table C : Synthesis Ammonia Systems
Designation Pressure Temp. Catalyst Recir- Conver.
0C culation %
Haber-Bosch 200-350 550 Doubly Yes 8
Promoted
iron
Modified 200-300 500-550 -Do- Yes 20-22
Haber-Bosch
Claude 900-1000 500-650 Promoted No 40-85
iron
Casale 600 500 Promoted Yes 15-18
iron
Fauser 200 500 Promoted Yes 12-23
iron
atmosphere or utilized for its heat content. The large amount of heat
called for a special converter design. In his original process, Claude used
Among advantages claimed for the Claude process are the following:
Cited against these advantages are the shorter life of converters, high
7
Mixed hydrogen and nitrogen, after being compressed to 100 atm and heated to about
3000C in interchangers, passes through a carbon monoxide purifier. In the purifier, while
in contact with a nickel catalyst, carbon monoxide and oxygen contained in small
quantities in the gas react with hydrogen to form methane and water.
Material Balance
Ammonia Production = 1200 TPD=2941.18 kmol/hr
N2 + 3H2 2 NH3
Let % conversion=20%
Assuming losses=8%
Amoonia production=2941.18/0.92=3196.93kmol/hr
Hence, N2 required=3196.93/0.4=7992.34kmol/hr
Siimilarly, H2 required=3x7992.34=23977kmol/hr
At high temperature,
C = 84.98%
H = 12.07%
S = 1%
N = 0.4%
O = 1.5%
CO = 42%
H2 = 51.23%
H2S = 0.23%
CO2 = 5.7%
N2 = 0.18%
Ar = 0.02%
CH4 = 0.5%
CO = 42 kmole
1
0
H2 = 51.23 kmole
N2 = 0.18 kmole
Ar = 0.09 kmole
Now, maximum concentration of H2S in H2S free raw gas in limited to 0.3 ppm.
Total no of moles in the product stream = ( 46.4 + 92.14 + 1,26 + 0.501 + 0.09 + 0.18 )
= 140.77 kmole
= 30.45 kmole
CO2 in the product stream = 2.65 kmole
= 69.54 kmole
The main function of absorber is to adsorb H2S, CO & CO2. They are reduced to an
CH4 = 0.54
Ar = 0.095
N2 = 0.19/95 = 0.2
N2 is added in such a way that
H2 : N2 becomes 3 : 1
99 = ( 0.18 + x ) x 3
x = 32.80
= 132.43 kmole
= 24.76 %
= 74.76%
% of Ar = 0.072%
Now in NH3 Separator 3 streams are there out of which 2 are going out and one is making
in the stream that moves in F13 & stream that gives main product is F14 & F 15.
N2 = a
H2 = 3a
NH3 = b
Ar = c
CH4 = d
For F 14 stream
H2 = 0.0998/22414 x 17 x 3a x 22 x 298/273
= 5.45 x 10-3 a
N2 = 0.1195/22414 x 17 x a x 22 x 298/273
= 2.18 x 10-3 a
Ar = 0.154/22414 x 17 x c x 22 x 298/273
= 2.8 x 10-3 c
= 5.54 x 10-3 d
= 1200 x 1000/(17x24)
= 2941.18 kmole/hr
H2 = ¾ x 89.1 = 66.83%
N2 = ¼ x 89.1 = 22.28 %
NH3 = 5.9%
Ar + CH4 = 5%
Ar = 1.43%
CH4 = 3.57%
F 13 = F 14 + F 15
From (5)
d = 0.0359 F15
0.9972 c = 0.0143 F 15
c = 0.01434 F 15 (8)
Therfore
2941 = 0.985
F 15 = 2302kmol/hr
0.0019113
From (7)
a = 5133.7 kmol/hr
From (8)
c = 330.12 kmol/hr
From (6)
d = 826.45 kmol/hr
b = 4299.24 kmol/hr
N2 = 5133.7 kmol/hr
Ar = 330.12kmol/hr
H = 15401.1 = 59.26%
25990.61
N2 = 19.75%
NH3 = 16.52%
Ar = 1.28%
CH4 = 3.18%
H2 = 5.45 x 10-3 a
N2 = 2.18 x 10-3 x a
= 11.19 kmol/hr
= 4.58 kmol/hr
Ar = 2.8 x 10-3c
= 0.924 kmol/hr
= 2985.67 kmol/hr
2985.67
H2 = 27.98 = 0.94%
2905.67
N2 = 11.19 = 0.38%
2985.67
2985.67
Ar = 0.924 = 0.03%
2985.67
N2 = x kmole
H2 = y kmole
NH3 = z kmole
For N2 balance
X [1 – 0.2] = 5133.7
X = N2 = 6417.125 kmol/hr
= 2566.85kmol/hr
= 1732.4 kmol/hr
Ar in F12 = 330.12kmol/hr
28557.5
H2 = 19251.4 X 1000 = 67.42%
28557.5
28557.5
28557.5
28577.5
F11 + F 16 = F 12
F11 + F 16 = 28557.5
Applying H2 balance
F11 = 28557.5-26432.79
= 2124.79 kmol/hr
= 526.1kmol/hr
21
H balance,
0.6545
F7 = 2914.49 kmol/hr
F5 = 2920.75 kmol/hr
= 6.63 kmol/hr
Tr = 257 = 0.67
373.5
22
Pr = 49 = 0.55
39.63
( 0.67)1.6
( 0.67)4.2
0.67
PV = Z n RT
V = 1.297 m3
m3 of methanol
60 = 31.1 kg
kmol of methanol required = 31.1 = 0.97 kmol/hr
32
3% by weight of carbon is converted into coke, therefore only 97% of carbon is present
in raw gas.
23
= 523.5 kmol/hr
F3*=2920.75x14.6-523.5x12=36361 kg/hr
F1*=F3*-F2*=36361-462.42x32=21564 kg/hr
Energy Balance
Data for Specific heats
24
A 103 B 106 C
NH3 (l) 22.626 - 100.75 192.77
Methanol 41.653 - 210.32 427.20
Water 8.712 1.25 - 0.18
26
Solving this equation by heat & trail we get
T = 622.50 K
i.e.t = 349.50C
622.5)}
27
( ∆ H)F12 = 12585.8x 8.314 [4.12(298-923) + 0.8319/2 x
= 2095.60
Reactor Design
CATALYST
A triply promoted ( K2O-CaO-Al2O3) iron oxide catalyst will be used. The iron oxide
(Fe2O3-FeO) is in the form of nonstoichiometric magnetite. It is made by fusing the
magnetite with the promoters. The catalyst is reduced in situ, and the removal of oxygen
yields a highly porous structure of iron with promoters present as interphases between
iron crystals and as porous clusters along the pore walls. The pores range from 500A to
1000A and intraparticle diffusion is diffusion to occur by the bulk mechanism.
Alumina prevents sintering and corresponding loss of surface area and also bonds
the K2O, preventing its loss during use. The K2O and CaO neutralize the acid character of
Al2O3. Both K2O and CaO decrease the electron work function of iron and increase its
ability to chemisorb nitrogen by charge transfer to the nitrogen.
PROPERTIES
Particle size: Granules, in size range 6-10 mm
Bulk density: 1200kg/m3
Particle density: 305 lb/cu ft (4.9 g/cm3)
Activity loss in service, 30-35% in 3yr depending on severity of operating conditions and
presence of poisons. Catalyst is slowly deactivated at operating temperatures above
9850F.
CATALYSTS POISIONS
In addition these poisons, hydrocarbons such as lubricating oils and olefins can crack
and plug pores. Sulphur, phosphorous and arsenic compounds should not exceed 15ppm.
Though temporary poisons, they cause crystals growth and attendant area decline.
Chlorine compounds form volatile alkali chlorides with promoters.
The only reaction that needs to be considered is the formation of ammonia from H2 and
N2,
A common rate equation for ammonia synthesis is the Temkin-Pyzhev equation given
where R is the rate of nitrogen consumption per unit volume of catalyst, f is a catalyst
activity factor, and Pi is the partial pressure of component i in the gas. Values for K1 and
K2:
K1 = ko1exp(-E1/RT)
K2=ko2exp(-E2/RT)
One limitation of this rate equation is that the rate will be infinite if the amount of
ammonia in the gas is zero, and this may occur in a reactor being fed with fresh make-up
gas. To avoid this numerical problem, the rate equation may be multiplied by a factor
K3PNH3/(1+K3PNH3) ; this will avoid the approach to infinity at low PNH3 while having little
effect at high ammonia pressures. This modification re-casts the rate equation into the
Langmuir-Hinshelwood-Haougen-Watson (LHHW) form, which is one of the options for
the RPLUG reactor block in Aspen:
Assume that the bulk density of the catalyst is 1200 kg/m3 and that the catalyst costs
$12/kg.
39
K2=106.3 kmol-atm0.5/m3-hr
Using pAO=0.2247*200=44.94atm,pBO=0.6742*200=134.84atm,pCO=0.06*200=12atm
Finally, we get
pA=44.94(1-XA)/(1-0.5XA)
pB=134.84(1-3XA)/(1-1.5XA)
pC=12(1-2XA)/(1-XA)
1228.6(1-XA)(1-3XA)1.5 9.78(1-2XA)2(1-1.5XA)1.5
(1-0.5XA)(1-1.5XA)1.5 (1-XA)2(1-3XA)1.5
(-rA) =
24(1-2XA)
1 +
(1-XA)
4
0
Now plug flow reactor design equation
dxA = V
(-rA) FAO
1/(-rA) vs XA
0.045
0.04
0.035
0.03
1/(-rA)
0.025
Series1
0.02
0.015
0.01
0.005
0
0 0.05 0.1 0.15 0.2 0.25
XA
= 18 m3
Assume L/D = 4
Volume = Π /4 x D2 x L
18 = Π /4 x D2 x (4D)
D3 = 5.729
D = 1.212 m
Hence length (L) = 4 x 1.212
= 4.848 m
Now catalyst is divided in 2 beds in ratios 1:2.5
(as upper bed : lower bed)
Volume of catalyst in 1st bed = 18/3.5
= 5.14 m3
Volume of catalyst in 2nd bed = (18 – 5.14)
= 12.86 m3
Bulk density of catalyst = 1200 kg/ m3
Weight of catalyst in 2nd bed = 12.86 x 1200
= 15.432 tonne
Weight of catalyst in 1st bed = 5.14 x 1200
= 6.168 tonne
Now giving allowance for space for gas movement upward and downward and insulation
be 0.5 m
Hence diameter of reactor becomes = 1.212 + 0.5
= 1.712 m
Pressure at which reactor works = 200 kg/m2
4
2
Let factor of safety = 20%
Design pressure = 1.2 x 200
= 240 kg/m2
We use carbon steel with internal lining of titanium
Allowable stress = 66,000 psi {hesse & ruston}
= 4494 kgf/cm2
No. of pass=1
Fluids in shell are hydrogen ,nitrogen ,ammonia & inerts like argon
& methane
Design pressure=51 kgf/sq. cm=51atm
Shell diameter=1067mm
Where;
P=design pressure
D=shell ID
F=allowable stress
J=joint efficiciency
C=corrosion allowance
TUBE SIDE
therefore, OD of Reactor=ID+2 x t
=1.212+2x .039
=1.29m
h= depth of head=L-(L2-D2/4)1/2
=190 mm
e ffective length = 4.848+2x 0.190
47
= 5.228 m
Cost Analysis
Cost estimation is a specialized subject and profession in its own right. Chemical plants
are built to make a profit. An estimate of the investment required and the cost of
production needed before the profitability of project can be assessed.
Cost in plant can be classified as-
1. Fixed capital
2. Working capital
(1) Fixed capital:-
Fixed capital is the cost of the plant ready to start up. It includes
1. Design
2. Equipment and interaction
3. Piping instrumentation and control system
4. Building and structure
5. Auxiliary facilities such as utilities
(2) Working capital
Working capital is additional investment needed over and above fixed capital to start up
the plant. It includes
1. Start up
2. Catalyst cost
3. Raw material
4. Finished product inventories
These costs are required to be corrected to the specific
capacity and index price of the given year.
4
8
Correction of index price
Taking that our plant runs for 335 days /yr. deducting the
time for normal shut down period.
Capacity = 1200 x 335 tons/yr. = 402000 tons/yr.
C2 = 24 x 106 x (402000) 0.55
100000
= 51.59 x 106$
Cost index = 1200
From “chemical engineering” journal
CI =585.9(based on 1979)
Cost in yr. 2008 = cost in yr. 1979 x C.I. 2008
C.I.1979
Thus,
Cost in yr. 2008 = (51.59 x 106) x 1200
585.9
=105.663 x 106 $
DIRECT COST
Component Given range Assumed range(%FCI) Cost (Rs.crores)
Purchased equip. 15-40 25 116.25
Installation 06-14 09 41.85
Instrumentation 02-18 07 32.55
Piping 03-20 08 37.20
Electrical 02-10 05 23.25
B
uilding 03-18 05 23.25
Yarest 02-05 02 9.3
Service facilities 08-20 15 69.75
Land 01-02 01 4.65
Total direct cost = Rs. 358.05 crore
Indirect cost
Engineer and supervision 04-25 10 46.5
Construction expenses 04-16 12 55.8
Contractor fee 02-06 02 9.3
Contingency 05-15 08 37.20
Total Indirect cost = Rs. 148.8 crore
Direct + Indirect cost = Rs 506.85 crore
COST OF REACTOR
Volume of cylinder=3.14*l*(OD2-ID2)/4
OD=1.290m
ID= 1.212m
Length,l=4.848m
CATALYST
Volume of catalyst = 18 m3
OD = 1.115m
ID = 1.067m
Length=16 ft=16 x 12 x .0254m
Volume of shell material = 0.4012 m3
beneath rubber clothing should be cotton. Eye gogg1es or full face masks should be
provided. Easily accessible safety showers and bubble fountains for washing the eye
is .recommended.
Apart from the above, fire alarms, smoke detectors and fire hydrants are also provided in
plant.
CORROSION
Since ammonia is corrosive to alloys of copper and zinc, these materials must not be used
in ammonia service- iron or steel should usually be the only metal used for ammonia
storage tank, piping and fittings.
54
Cleaning and Repairs of Equipments
Wherever possible, ammonia tanks and other equipment should be cleaned and repaired
from the outside. When it is necessary to enter an ammonia vessel all lines leading to the
vessel should be disconnected and provided with blind flanges. Danger signs should be
placed at appropriate points to wary other work men and all electric apparatus should be
turned off. One person keeps close watch outside the tanks and has dosed at hand the
proper emergency equipment, respirator, and fire outing wishes. The tank should 'be
filled with water and drained before being entered and should purge with air and tested
for explosive atmospheres.
FIRST AID
A person who has been overcome of burned by ammonia should be placed under the case
of physician at once. The patient should be removed from contact with ammonia as soon
as possible and kept warm and quiet.
ppm
55
HAZARDS OF AMMONIA
1. Toxic hazards
In general ammonia gas under high concentration causes irritation to eyes.
2. Explosive Hazards
Ammonia is explosive with air in the range of 16 to 25% by volume. Its auto ignition
temperature is 651°C since such temperature are not encountered in practice; the
chance of fire and explosive hazards due to ammonia is relatively remote.
The presence of oil in mixture of ammonia with other combustible materials will increase
the /fire hazard. The explosive range of ammonia is;
Pollution Control
1) Ash Slurry treatment Scheme
The ash slurry from steam generation plant is pumped by the existing sat of pumps to the
proposed ash ponds. The ash is settled in the ponds by gravity settling. The clear
overflow from the ponds is discharged into sump from where the clear water is pumped
to steam generation plant for de-ashing purpose or can be drained to the river sump
directly.
2) Oily Effluent Treatment Scheme
5
6
Two nos. of oil separators are provided to receive oil effluent. Each separator has about
75 m3 capacity and both put together can receive 150m3 of effluent per day. Oil
separators are to be operated alternately. They are building with stilling, inlet chamber,
and deoiler pipe, baffle for retaining the floating oil and overflow weir. Oil separates and
floats to the surface by gravity separation.
In ammonia plant, the main source of liquid effluents is process condensate. It is well
known that steam is used in excess of stoichioimetric requirements for reforming and
shift conversion in ammonia plant. This excess steam is subsequently removed as process
condensate which contains impurities like carbon dioxide, ammonia, methanol etc. This
condensate cannot be directly used anywhere due to the presence of impurities.
Cooling water treatment is of vital importance for all the chemical process industry.
When the original plant was commissioned in 1974, chromate based cooling water
treatment was adopted. About 15-20 ppm chromate was maintained in the circulating
cooling water. The chromate is toxic and harmful to the environment. This hexavalent
chromate was converted into trivalent chromate and separated out as sludge.
To overcome chromate sludge storage problem and to adopt environmental friendly
system, non-chromate based cooling water treatment was adopted in Apirl,1998.
Non-chromate treatment programme are mainly based on o-phosphate and zinc with
different combinations. o- phosphate concentration of 6 ppm minimum and
Zincconcentration of 1 ppm maximum is maintained as corrosion inhibitor. Polymer
based bio-dispersant and boicides are also added.
Three different biocides are shock dosed alternatively in addition to chlorination for
micro biological growth control as per requirement. Dispersants are added to keep the
salts of circulating water in dispersion condition. All the chemicals used for non chromate
treatment are biodegradable chemicals.
5
7
Overhead vapours about 6000 kg/hr from condensate stripper were vented to atmosphere.
the overhead vapours contain ammonia, methanol, amines and CO2. Ammonia present in
the overhead vapours is about 5000 ppm. The limit specified by Gujarat Pollution Control
Board (GPCB) for ammonia is 100 ppm. To avoid the venting of ammonia to
atmosphere,
the overhead vapours from the top of the condensate stripper are diverted to the vent
condenser (172-C). All the vapours are condensed and non-condensables mainly CO2 is
vented to atmosphere. The condensate from the vent condenser can either be sent to
Ammonia recovery and stripping system in ammonia plant or to hydrolyser stripper
system in urea plant by condensate transfer pump. The system is shown as annexure - VI.
The system has reduced the 720 kg/d ammonia to atmosphere and pollution norms has
been also met.
DENTRIFICATION:
Heterotrophic bacteria in anaerobic condition reduce nitrite (N02) and Nitrate (N03) to
gaseous N2. An organic carbon, as methanol, acetic acid, acetone, ethanol or sugar is
reduced to act as a hydrogen donor to supply carbon for biological synthesis. The
required BOD is supplied by waste methanol (6000 ppm) which serves as an energy
source for survival and growth of bacteria.
First methanol reduces:
3O2 + 2 CH3OH - 2 CO2 + H2O
Then bacterial reduction of N02 & N03 takes place.
6 NO3- + 5 CH3OH - 3 N2 + 5CO2 + 7 H2O + 6OH-
2 NO2- + CH3OH – N2 + CO + H 2O + 2 OH-
Aeration is helpful for the removal of gaseous product and increase dissolved oxygen in
the effluent. In the step of hydrolysis urea (500 ppm) degrades to 50 ppm level.
Instrumentation
The even operation of a process is dependant upon the control of process variables. These
are defined as the conditions in the process material and equipments which are
subjected to change. There may be several materials and several pertinent operating
factors which may change in the simplest of process; the maintenance of control over an
5
9
entire process is an important aspect of process design. In Ammonia manufacture
temperature and pressure are two process variables on which operation of whole plant
depends upon. Instrumentation of each equipment is done separately.
1. REACTOR
Feed to the converter is at 750C which is made to pass through the internal heat
exchangers so that it may gain heat from outgoing gases to attain reaction initiation temp.
This temperature of gas at the inlet of catalyst bed is taken into account by TIC (temp.
indicator controller) put in line with the start up heater.
In case temperature goes below the reaction initiation temperature.
Then automatically start up heater works and temperature of product gas is increased
which in turn heats the incoming gases to the required reaction initiation temperature.
But if the temperature goes high then a portion of by pass feed controls the temperature.
Temperature control is necessary because in first case, reaction would not start till the
required temperature is attained. And in the later case, temperature goes too high then
catalyst may get spoiled. Pressure inside the reactor is 300 atm. and any change in
pressure will effect the conversion therefore pressure control is also necessary so we will
have to employ pressure gauges and pressure controller valves.
Temperature indicator devices are put on both inlet and outlet streams and if temperature
of outgoing gases goes below 162°C the water flow in the heat exchanger (waste heat
boiler) is reduced with the help of a hand controller valve.
3. AMMONIA SEPARATOR
Here also a level indicator controller is required to maintain a particular level of liquid
ammonia in it so no gas but only liquid product is obtained.
6
0
4. AMMONIA STORAGE
Ammonia is stored at a pressure of 40 psig and temperature 25.80 F. However, efficient
may be the insulation. Some of heat enters the tank from ambient and vapors of ammonia
are formed. Pressure inside the tank increases so there must be some arrangement to
reduce this pressure. A safety valve may be provided at the top of 'Horton Sphere'.
Whenever pressure inside the vessel rises some of the vapors are vented. These vented
gases either released at. 6 ft. high stack or can be compressed and condensed in a close
loop to reduce atmospheric pollution. In a closed loop system vent are stored in a small
vessel from where those gases are compressed, condensed and then fed to the storage
tank.
TEMPERATURE MEASUREMENT
Temperature measurement is done by using thermocouples. Since ammonia corrodes
metals like Cu and Zn. The thermocouple selected is chromel (Ni 90%, Cr 10%)
Alumd (Ni 94%, Mn 3%, Al 2%). It can be used in temperature ranging from 600 to 2100
of vertically in the converter. Slight variations of temperature inside the converter are
transmitted through the transmitter to the error is passed on to a diaphragm motor valve
which controls the flow of gases to the converter.
INSTRUMENT AND FITTINGS
Gasket material most suitable for anhydrous ammonia service is hard finished. Such as
flange facings where the gasket material is retained in a groove. And on gasket material is
retained in a groove. And on gasket bodies, lead may be used. Aluminum has been
applied satisfactorily as a gasket material for flat faced and grooved flanged joints but. is
not. Generally recommended Rubber rings cannot. be used. All ammonia piping should
be extra heavy (sch. 80). Steel piping may be used where joints are welded. Galvanized
pipe should never be used. Welded pipes should be used wherever possible. Welded pipe
flanges may be used on all pipe joints of 1.25" or larger. Under no circumstances brazed
joint be used, as they will deteriorate rapidly.
6
1
Industrial Applications of Ammmonia
Explosive Industry
The explosive industry is one of the largest consumers of ammonia.
It is used principally in the form of Nitric acid for the manufacture of compounds such as
TNT, Nitroglycerine, nitrocellulose, nitro starch, Pentaerythrital t1tranitrate, tetraethyl
and ammonium nitrate.
Textile Industry
In textile industries, ammonia is used in the production ff synthetic fibres such as
cupraammonium rayon and nylon. In the production of rayon, the ammonia is used in the
preparation of ammonical copper hydroxide solution (Schweiter's reagent) for dissolving
the cotton linters.
In the rayon process ammonia is used in the production of hexamethylene diamine, which
is considered with-adipic acid to form the monomer, which in turn is polymerized and
speen into polyamide fibres.
Fertilizer Industry
The fertilizer industry is a heavy consumer of ammonia and its compounds. The main
nitrogenous fertilizers are
- Anhydrous ammonia
- Ammonia liquor
- Ammonium Nitrate
- Urea
- Ammonium Sulphate
- Calcium Cynamide
- Sodium Ammonium Nitrate.
62
Pharmaceutical Industry
Ammonia is an important ingredient in the manufacture of sulfa drugs such as
sulfanilamide sulphath1azole and sulfapyridine. It. is also used in the manufacture of
vitamins and antimalarials.
Petroleum Industry
In the refining of crude oils, ammonia is used as neutralizing agent to prevent corrosion
in acid condensers, heat exchangers etc. of the distillation equipment.
Ammonia is also used to neutralize final traces of acid in acid-treated lubricating oil
stocks and pressure distillates,
Rubber Industry
Ammonia is used to raw latex to prevent coagulation during transportation from the
rubber plantation to Ammonia is also used in the nuconization the factory process for the
manufacture of fabrics, boots, shoes etc.
Refrigeration
Ammonia is most commonly used refrigerant, especially for large industrial installations.
It can be used in both compression and absorption system for
1) Production of ice
2) Refrigeration cold-storage plants
3) Quick – freezing units
4) Food-lockers
5) Air conditioning large industrial plants
Certain characteristics of ammonia such as high latent heat of vaporization low vapour
density. Chemical stability and low corrosion to compressor parts, make operating costs
per ton lower for ammonia than for any other refrigerants used in industrial systems.
Inorganic Chemicals Industry
A large number of ammonium salts having numerous industrial applications are produced
by direct neutralization of their respective acid with ammonia.
Important industrial compounds produced are ammonium nitrate, ammonium sulphate
6
3
mono and diammonium phosphate and ammonium acetate.
Acid Manufacture
In the lead chamber process for sulfuric acid manufacture, Ammonia is oxidized to give
Nitrogen oxide to provide required oxygen required for conversion of SO2 to sulphuric
acid.
Pulp and Paper Industry A recent development is the substitution of ammonia for
calcium in the bisulphate process for pulping wood. The ammonia base is said to improve
the yield and Quality of pulp.
Leather Industry
Ammonia is used as slime and mold preventive in tanning liquors.and as a. curing agent
in making leather.
64
Bibliography
1. Perry, R.H., "Perry's Chemical Engineers Handbook", 6th
Ed., McGraw Hill Company, 1984.
2. McCabe Warren L., Smith Julian C., Harriot Peter, "Unit
Operations of Chemical Engineering", 4th Ed., McGraw Hill,
Inc., 1981.
3. Levenspiel Octave, "Chemical Reaction Engineering 2nd
Ed., Wiley Eastern Ltd., 1991.
4. Peters M.S., Timmerhaus K.D., "Plant Design and
Economics for Chemical Engineers", 4th Ed., McGraw Hill,
1991.
5. Treybal R.E., "Mass Transfer Operations", 3rd Ed., McGraw
Hill Company, 1981.
6. Hesse, Herman C. and Rushton, J. Henry "Process
Equipment Design" Affiliated East-West Press Pvt. Ltd.,
New Delhi.
7. Richardson & coulson Vol 6
8. Operating Manual, "Ammonia Plant" of National Fertilizers ltd. Bathinda
9. Elementary Principles of Chemical Processes by Felder