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 Case 2:
Ammonia Synthesis Plant

Abstract
Over 140 million tons of ammonia is produced worldwide each
year. The rewards for reducing costs, increasing efficiency and
improving the profitability of ammonia plants are enormous.
Computer simulation of the plant is the first step towards
identifying which parameters control the conversion rate, product
purity, energy usage, and the production rate of an existing facility.
This casebook demonstrates the use of PRO/II in the simulation of
an ammonia synthesis process. The entire plant is modeled, from
the reforming of the hydrocarbon feedstream to synthesis gas
through its purification to its conversion to ammonia in a synthesis
reactor. This casebook also outlines the use of the simulation for
parametric studies in the evolution of a control strategy.
The ammonia synthesis loop involves a large recycle compared to
the feed and product rates. In addition there are several thermal
recycles and two control loops. Special thermodynamics are used to
ensure the accurate prediction of the separation of ammonia from
the other materials.

Introduction
Chemically combined nitrogen is essential for the growth of all
living organisms. Animals and plants (with one or two exceptions)
are unable to assimilate free nitrogen from the air, so they depend
upon nitrates, ammonium salts or other nitrogen compounds found
in the soil.
The natural supplies of fixed nitrogen were adequate for many
centuries to satisfy the normal processes of nature. However, by the

PRO/II Case Book Ammonia Synthesis Plant 2-1

 beginning of the 19th century, the increase in world population
along with the growth of big cities created a demand from the more
industrialized countries for supplemental sources of fixed nitrogen.
This supplement was first found in imported guano and sodium
nitrate and later in ammoniacal solutions and ammonium sulphate
by-products from the carbonization of coal in gas-works and coke
ovens.
By the start of the 20th century the demand for fertilizer nitrogen
again outstripped supply. Three different processes for the fixation
of nitrogen were designed and put in commercial operation to
ensure adequate supplies of fertilizer nitrogen.
One of those three was the direct synthesis of ammonia from
nitrogen and hydrogen by the Haber-Bosch process. This was
developed in Germany between 1905 and 1913 and virtually all
fixed nitrogen is now produced by this process.
The total world production in 2005 was over 140 million tons of
fixed nitrogen. Global demand for ammonia is expected to increase
about 2% per year for the foreseeable future. More than 90% of this
is produced as ammonia and about 85% of the total fixed nitrogen
production is used in fertilizers.

Alternative Routes to Ammonia

There are several licensors of ammonia synthesis processes. All
produce ammonia from hydrocarbon feedstocks and air. The
hydrocarbon feedstock is usually a natural gas although others, such
as naphtha, are used where natural gas is not locally available. The
processes are all fundamentally similar: the feed hydrocarbon gas is
desulfurized then converted to synthesis gas in a reforming process
followed by a CO shift and methanation reactors. The resulting
syngas, after purification, is a mixture of hydrogen and nitrogen in
stoichiometric quantities (3:1). This is converted to ammonia in a
synthesis reactor which is located in a recycle loop, because of a
low conversion per pass.
Kellogg Brown & Root (KBR) is the largest licensor of Ammonia
Synthesis Technology with over 170 Kellogg plants and over 25
Braun (now owned by KBR) plants. These plants have accounted
for more ammonia capacity worldwide than any other licensor.1

1.1 "Ammonia", by Kellogg Brown & Root, 2000

2-2 Ammonia Synthesis Plant March 5, 2014

 The Kellogg Process
At over 170 units worldwide, the Kellogg process has been installed
in more ammonia plants than any other process. The simulation
considered in this Casebook is a generic Kellogg process.
Schematic diagrams of the full flowsheet may be found in
Appendix 2-A:.
Although the Kellogg process is a licensed process, operational
benefits can be gained from changing a number of the variable
parameters: temperatures, recycle rates, air and steam quantities and
so on. Recently there has been some work on lowering the steam to
carbon ratio to the primary reformer and modifying the catalysts
used in the shift converters.The emphasis in ammonia plants today
is for lower energy usage. New Kellogg plants claim 6.85Gcal/short
ton for all energy requirements over one year.

Process Overview
The Kellogg Ammonia process is a single train process, divisible
into four stages, which operate sequentially. In stage 1 the natural
gas undergoes catalytic reforming to produce hydrogen from
methane and steam. The nitrogen required for the ammonia is
introduced at this stage. In stage 2, the resulting syngas is purified
by the removal of carbon monoxide and carbon dioxide in a MEA
plant or similar process. Stage 3 consists of compression of the
syngas up to the pressure required in stage 4, the ammonia loop.

Feedstocks and Products

Main Feeds
The main feedstock for this ammonia process is 6 million SCFD of
natural gas at a temperature of 60oF and a pressure of 340 psig. Its
composition is shown in
Table 2-1: Main Feed Composition
Component Mole%
Carbon Dioxide 2.95
Nitrogen 3.05
Methane 80.75
Ethane 7.45
Propane 3.25
Butane 2.31
Pentane 0.24

PRO/II Case Book Ammonia Synthesis Plant 2-3

 Before entering the primary reformer, the natural gas is mixed with
superheated steam at 334 psig and 950 F. Nitrogen is supplied from
the air which is fed to the secondary reformer at 289 psig and 330 F.
The composition of air is displayed in Table 2-2:Air Composition.
Table 2-2: Air Composition
Component Mole %
Oxygen 21.00
Nitrogen 78.05
Argon 0.95
There is also a water feed which is used to saturate the syngas in the
MEA plant.

Products
The main product of an ammonia plant is, of course, ammonia. The
ammonia product stream must have a purity greater than 99.5%.
The major impurities are hydrogen, nitrogen, argon and methane.
The other product streams are:
letdown gas from the final separator consisting of
approximately 45% ammonia, 30% hydrogen with the rest
being nitrogen, argon and methane
purge gas from the ammonia loop consisting of approximately
8% ammonia, 57% hydrogen plus nitrogen, argon and methane
Ammonia is recovered from the letdown and purge gases in an
absorber.
Detailed descriptions of the product streams may be found at the
end of the Simulation section in Table 2-5.

2-4 Ammonia Synthesis Plant March 5, 2014

 Stage 1: Catalytic Reforming
Figure 2-1: Schematic of Catalytic Reforming Section

Following sulfur removal, the primary steam reformer converts

about 70% of the hydrocarbon feed into raw synthesis gas in the
presence of steam using a nickel catalyst.
The main reforming reactions are:
CH4 + H2O <> CO + H2 (2-1)
CO + H2O <>CO2 + H2 (2-2)
In the secondary reformer, air is introduced to supply the nitrogen.
The heat of combustion of the partially reformed gas raises the
temperature and supplies the energy to reform most of the
remaining hydrocarbon feed.
The reformer product stream is used to generate steam and to
preheat the natural gas feed.

PRO/II Case Book Ammonia Synthesis Plant 2-5

 Stage 2: Shift and Methanation
The shift conversion is carried out in two stages. The first uses a
high temperature catalyst and the second uses a low temperature
one. The shift converters remove the carbon monoxide produced in
the reforming stage by converting it to carbon dioxide by the
reaction:
CO + H2O <> CO2 + H2 (2-3)
This reaction also creates additional hydrogen for the ammonia
synthesis.

Figure 2-2: Schematic of Shift and Methanation Section

Shift reactor effluent is cooled and the condensed water is

separated. The gas is then passed to the purification section where
carbon dioxide is removed from the synthesis gas in any one of a
number of systems such as hot carbonate, MEA, Selexol etc.
After the purification stage, the last traces of carbon monoxide and
carbon dioxide are removed in the methanation reactions:

2-6 Ammonia Synthesis Plant March 5, 2014

 CO + 3H2O <> CH4 + H2 (2-4)
CO2 + 4H2 <> CH4 + 2H2O (2-5)
The methanation reaction is necessary not only to remove the
carbon monoxide and carbon dioxide, but also to create water
which can then be removed in the compression stage. This will add
efficiency to the process in that any water that is removed will not
have to be circulated in the large recycle loop in the ammonia
synthesis stage.

Stage 3: Compression
Figure 2-3: Schematic of Compression Section

The purified synthesis gas is cooled and the condensed water is

removed. The gas is then compressed in a three stage unit. The
centrifugal compressors are driven by steam turbines using steam
generated in the plant itself, reducing overall power consumption.

PRO/II Case Book Ammonia Synthesis Plant 2-7

 Stage 4: Conversion
Figure 2-4: Hydrogen Gas Conversion Section

The compressed synthesis gas is dried, mixed with a recycle stream

and introduced into the synthesis loop after the recycle compressor.
The gas mixture is chilled and liquid ammonia is removed from the
secondary separator. The vapor is heated and passed to the
ammonia converter. The feed is preheated inside the converter
before entering the catalyst bed.
The ammonia synthesis reaction is:
N2 + 3H2 <> 2NH3 (2-6)
Very high pressures (typically in excess of 300 atmospheres) are
required in order to obtain a reasonable conversion. The conversion
of hydrogen per pass is still less than 30% and so a large recycle of
unreacted gases is necessary.
The converter vapor product is cooled by ammonia refrigeration in
the primary separator to condense the ammonia product.
A purge is removed from the remaining gases to prevent the build
up of inerts in the loop. The molar concentration of inerts (argon
and methane) in the converter feed is maintained at 12%.

2-8 Ammonia Synthesis Plant March 5, 2014

 Energy Integration
The process features a high level of energy integration. Nearly all
the power and heating requirements of the process are met by the
heat available elsewhere in the process.

In the Reformer
The primary reformer passes the natural gas and steam mixture
through catalyst-packed tubes in a furnace. The furnace exhaust
gases are used to generate steam in a series of boilers. This steam is
then used to drive the compressors.
The effluent from the secondary reformer is used in a waste heat
boiler and then to preheat the feed to the desulfurizer.

In the Shift and Methanators

The methanator feed is preheated by exchanging with the
methanator product and then further heated by exchange with the
high temperature shift reactor effluent. Energy from this effluent is
further recovered in a waste heat boiler.
The effluent from the low temperature shift reaction is used in
another reboiler.

In the Conversion
The products from the ammonia converter are mixed with the
synthesis gas from the compressors and cooled for ammonia
separation by exchange with the converter feed. The converter feed
is preheated by the products inside the converter vessel.

Material Recycle
The final stage, the Synthesis Loop, is a recycle operation. The
conversion of nitrogen and hydrogen to ammonia in the converter is
very low - less than 30% of the hydrogen is converted per pass.
Therefore there has to be a large recycle in order to convert all the
feed and ensure that the final ammonia product reaches the required
purity.
The ratio of recycle to ammonia product is of the order of 3:1

PRO/II Case Book Ammonia Synthesis Plant 2-9

Process Simulation
The PRO/II input for the simulation may be found in PRO/II
Keyword Input File. This section explains the details of the
simulation used in this case study. The screen shots are meant to
illustrate specific data entry for points of interest.

General Data
Because stage 4 of this process involves a loop which has a large
recycle rate in comparison to the product rates, it is essential that
the flowsheet is in mass balance. The normal stream component
recycle convergence tolerance must therefore be tightened - in this
case to 0.05%. The stream Temperature and Pressure recycle
tolerances were also tightened to 0.1 and 0.001 respectively. The
Wegstein acceleration option is used to help speed up convergence.
The graphic below shows the data entry window for the recycle
convergence and acceleration options. .

2-10 Ammonia Synthesis Plant March 5, 2014

 The threshold mole fraction limit for trace components in the
recycle is also reduced to 0.0001 in order to ensure that all
components are checked for the loop convergence. The maximum
allowed number of recycle trials is increased to 150 to ensure that
the number of recycle trials is sufficient to converge the flowsheet.
PRO/II is also asked to report the overall flowsheet mass balance in
the Miscelleous Report Options menu.
.

PRO/II Case Book Ammonia Synthesis Plant 2-11

 Component Data
All the components in the simulation are available in the PRO/II
data bank.

Thermodynamic Data
For most of the units in the flowsheet the Soave-Redlich-Kwong
(SRK) equation of state is an excellent predictor of phase
equilibrium and thermal properties. However, in stage 4 where the
ammonia is being separated from the recycle gas in flash units, a
more accurate prediction is needed to represent the interaction
between ammonia and the other components in the streams. For
this, a second method is used with user-defined SRK binary
interaction parameters. Figure 2-5 illustrates the Data Entry
Window.
Figure 2-5: Entering Binary Interaction Data

The data used in this case study is defined in Table 2-3 below.

2-12 Ammonia Synthesis Plant March 5, 2014

 Table 2-3: SRK Binary Interaction Parameters
Comp i H2 H2 H2 N2 H2 N2 Argon C1
Comp j N2 Argon C1 C1 NH3 NH3 NH3 NH3
kija 0.085 0.0004 -0.2079 0.0204 0.276 0.31 0.3383 0.18
kijb 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
kijc 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
UOM R R R R R R R R

Invoking the second thermodynamic set for the ammonia separators

is as simple as selecting the second thermodynamic set from the
Thermodynamic System drop-down window in the Flash drum data
entry window. Figure 2-6 depicts this drop down list with the
available thermodynamic methods.

Figure 2-6: Selecting A Thermodynamic METHOD Set

PRO/II Case Book Ammonia Synthesis Plant 2-13

 Stream Data
Feed Streams
The main feed streams - natural gas, steam, and air - are defined in
the normal way by rate, composition, temperature, and pressure. In
addition there is a water feed to the MEA plant which ensures that
the syngas leaves the plant saturated.

Recycle Streams
There is a recycle stream in stage 4. The large flowrate of this
recycle stream relative to the flowsheet feeds and products along
with the fact that the ammonia species is created in the recycle,
necessitates an initial estimate of the rate and composition of the
recycle stream. The stream initial estimates are entered into stream
31R below:

2-14 Ammonia Synthesis Plant March 5, 2014

 Other Streams
There are several thermal recycles in this flowsheet. These may be
simulated in one of several different ways:
They can be input as they are and allowed to converge naturally
They can be replaced by simpler units and solved rigorously
after the flowsheet has solved
Or
They may be circumvented by using the REFERENCE
STREAM facility
The reference stream option was chosen in this simulation to
circumvent the thermal recycles. Thermal recycles can be broken
using reference streams because the composition of the stream
remains the same through the thermal recycle loop. The only thing
that changes within the thermal recycle loop is temperature and
pressure. If the temperature an pressure is know elsewhere in the
loop, a reference stream can be used to break the thermal recycle
loop. This will speed up the convergence time of the simulation
without sacrificing accuracy in the results.
In stage 2, the feed to the low temperature shift reactor (stream 13)
is referenced to the high temperature shift product (stream 11). This
defines all the properties of stream 13 as the same as stream 11.
Temperature and pressure are over-written and defined as 400 oF
and 274 psig. Similarly, stream 21 is referenced to stream 19 with a
temperature of 675 oF and a pressure of 254 psig. These reference
streams allow the heat exchangers to be solved separately after
converging the air flowrate controller loop.
Stream 13 is not defined as a product from a unit operation.
However, in stage 4, stream 38B is a unit operation product.
Nevertheless, in order to eliminate a thermal recycle around the
Ammonia Converter, it is referenced to stream 38.

PRO/II Case Book Ammonia Synthesis Plant 2-15

 Figure 2-7: Configuring Referencing Streams

This means that stream 38B takes its composition and rate at all
times from stream 38 but its temperature and pressure are calculated
by the heat exchanger from which it is a product.

2-16 Ammonia Synthesis Plant March 5, 2014

Unit Operations for Stage 1 - Catalytic Reforming
Input
Since there is no sulfur in the input, the Desulfurizer RX1 is
modeled as an isothermal flash to set the temperature and pressure
of the reformer feed.
Both the reformers, RX2 and RX3, are modeled as Gibbs Free
Energy reactors with typical temperature approaches specified.
The rate of air feed to the secondary reformer must be such that the
syngas product from stage 2 has the correct nitrogen:hydrogen
ratio. This is achieved by putting a controller on the stage 2
Methanator product and varying the air feed rate to the secondary
reformer. This means that stages 1 and 2 are in a controller loop.

Figure 2-8: Stage 1 Unit Operations - Catalytic Reformng

To satisfy the primary reformer, the molar ratio of steam (stream 5)

to natural gas (stream 1) should be 6:1. The flow rate of the steam
could be set to the correct value in the Stream Data Section.
However, that would involve calculating the molar rate of natural
gas (the stream is known only in volume units) before the
simulation begins. It is much easier to let PRO/II perform that

PRO/II Case Book Ammonia Synthesis Plant 2-17

 calculation. Furthermore, allowing PRO/II to perform this
calculation allows the natural gas stream to be changed at any time
(for a turndown case or a different design case) and the steam rate to
be automatically recalculated.

The secondary reformer product (stream 8) is used to preheat the

desulfurizer feed (stream 2). This thermal recycle is not a simple
one in that the process demands a fixed temperature for both the
products from exchanger X-1. This is achieved by dividing the
exchanger into two halves: the cold side is X-1A and is solved
before the desulfurizer; the secondary reformed product is cooled in
H-1, a combination of waste heat boiler WHB1 and the hot side of
X-1.
After stages 1 and 2 have solved, H-1 is divided into WHB1 and the
hot side of X-1 (X-1B). This can be achieved because PRO/II
allows the use of reference streams to link two streams. The define
feature is similar to reference stream feature except that it links unit
operation parameters. The define feature was used to link the duties
from one exchanger to another. In this case stream 8_R1 was

2-18 Ammonia Synthesis Plant March 5, 2014

 referenced to stream 8 and the duties for X1-B and WHB1 were
defined as the duties for X-1A and H-1 respectively.
The graphics below illustrate the use of the define feature to line the
duties together.

WHB1's duty is calculated as the difference between the duties of

H-1 and X-1A. X1-B's duty is simply the same as that for X1-A
except with the opposite sign.

PRO/II Case Book Ammonia Synthesis Plant 2-19

 Results
The stream calculator determines the steam flowrate as 3952.7 lb
mole/hr which is six times the natural gas flowrate.
Virtually all of the C2 and higher hydrocarbons are broken down in
the primary reformer and converted to hydrogen, carbon monoxide
and carbon dioxide. 58% of the methane in the feed is also
converted. 95% of the residual methane is converted in the
secondary reformer along with the remaining traces of ethane and
propane. All of the oxygen is consumed in the secondary reformer.
The duties of WHB1 and X-1 are 53.62 and 4.17 MM Btu/hr
respectively.

Unit Operations for Stage 2 - Catalytic Shift and

Methanation
Figure 2-9: Stage 2 Unit Operations: Catalytic Shift & Methanation

2-20 Ammonia Synthesis Plant March 5, 2014

 Input
Both the High Temperature Shift Reactor (RX4) and the Low
Temperature Shift Reactor (RX5) are modeled by an equillibrium
reactor unit operation using the built-in shift reaction equilibrium
data. They operate adiabatically and the products are assumed to be
at equilibrium.
The MEA plant removes the bulk (99.92%) of the carbon dioxide
from the shift reactor product and is modeled as a stream calculator
(T-1). The treated gas is saturated with water in flash unit SAT and
excess water discharged.
The final part of stage 2 is the Methanator (RX6), modeled by an
equillibrium reactor unit operation using the built-in methanator
and shift reaction equilibrium data. The reactor operates
adiabatically and equilibrium is assumed to be achieved.
The syngas must have a hydrogen:nitrogen molar ratio of 3:1 to
satisfy the stoichiometry of the ammonia reaction. This is
accomplished by inserting a controller to measure that ratio in the
Methanator product and vary the air feed to the Secondary
Reformer until the required ratio is achieved. Thus there is a
significant loop involving most of the units of stages 1 and 2. This
makes it more important for any thermal recycles within that loop to
be eliminated if at all possible.
The thermal recycle in stage 2 of the plant is a complex one,
involving preheating the Methanator feed first with its own product
and then with the RX4 product. This recycle is eliminated by
referencing streams 13 and 21 to bypass these exchangers
completely.
Stream 13 is the same as stream 11 except for its temperature and
pressure, both of which are known. Therefore stream 13 is set in the
Stream Data Section and referenced to stream 11. It gets its rate and
composition from stream 11 and its conditions from the Stream
Data Section.
In the same way, stream 21 is referenced to stream 19.
After the control loop has solved, exchangers X-2, WHB2 and X-3
are solved in the normal way.

PRO/II Case Book Ammonia Synthesis Plant 2-21

 Results
The controller solves after 3 trials with an air flowrate of 1008 lb
mole/hr. This produces the required hydrogen:nitrogen ratio in the
product from the methanator.
85% of the carbon monoxide is converted in RX-4 and 93% of the
remainder is converted in RX-5. This gives a concentration of
0.055% carbon monoxide and 11.1% carbon dioxide in the exit gas
from RX-5. The concentration of carbon dioxide is reduced to
0.02% in the MEA Plant.
The final removal of all the carbon monoxide and carbon dioxide is
carried out in the methanator reactor.

2-22 Ammonia Synthesis Plant March 5, 2014

Unit Operations for Stage 3- Compression
Input
The Condensate Separator (D-2) is modeled as a flash unit,
decanting water in a declared water stream and using the PRO/II
built-in water solubility data.

Figure 2-10: Stage 3: Compression Unit Operations

The compressors are modeled as single stage isentropic

compressions with a specified adiabatic efficiency of 95%. Each
one has an aftercooler reducing the product temperature to 95 F.
The first and second compressors also have water decantation
streams to knock out any liquid water that may have condensed in
the aftercoolers. Finally, all the remaining water is removed in a
drying unit (SEP1), modeled as a stream calculator.

Results
The compressor work for the three stages is 1752, 1831 and 1776
HP respectively. The corresponding aftercooler duties are 4.73, 4.70
and 4.35 MM Btu/hr.
Most of the water is removed after the first compressor with a small
amount removed after the second compressor. The final separator
removes all remaining water from the synthesis loop feed.

PRO/II Case Book Ammonia Synthesis Plant 2-23

Unit Operations for Stage 4 Conversion
Figure 2-11: : Unit Operations for Stage 4 Conversion

Input
The fourth compressor (CP-4) is in the ammonia recycle loop. The
loop starts at that unit, stream 31R being the main recycle stream.
An initial estimate for this stream is needed, as discussed in the
Stream Data Section above.
The Ammonia Converter feed is preheated by exchanging inside the
converter with its product stream. This exchanger is modeled
separately in the flowsheet as FDEF. The exchangers before the
separators do not appear on the simulation flowsheet as they are
combined with the separators.
There are two thermal recycles in the loop. The loop involving the
convertor and feed preheater is split by referencing the convertor
feed (stream 38B) to the product from exchanger X-4 (stream 38) in
the Stream Data Section. FDEF is then solved after the convertor
when both feed streams have been calculated.
The loop involving exchanger X-4 is solved explicitly as it appears
in the flowsheet. This involves introducing an inner loop within the
ammonia recycle loop. This loop could also be eliminated by using
the devices mentioned above.

2-24 Ammonia Synthesis Plant March 5, 2014

 The Ammonia Converter (RX-7) is modeled using an equilibrium
reactor model with supplied equilibrium data. The Data Entry
Windows (DEWs) that follow were reformatted slightly to fit the
page size of this manual.

Figure 2-12: Ammonia Converter (Reactor) Main Input DEW

PRO/II Case Book Ammonia Synthesis Plant 2-25

 Figure 2-13: Ammonia Synthesis Reaction Definitions

Figure 2-14: Reaction Equilibrium Input Data

2-26 Ammonia Synthesis Plant March 5, 2014

 The reference condition for heat of reaction data is given as vapor at
800 F and the stoichiometry represents the well-known ammonia
synthesis reaction. The heat of reaction is given as -45.18 thousand
energy units per mole of base component reacted, in this case
nitrogen. The equilibrium constant is a function of temperature
according to the Arrhenius equation:

Ln (Keq) = A + B/T (2-7)

The equilibrium constant is computed at the reaction temperature
minus the approach temperature difference given.
The reactor feed has to contain 12 mole % inerts (argon and
methane). This is achieved by varying the rate of the recycle stream
31R using a controller (CTL1). This action of the controller could
conflict with the recycle convergence because this stream is also the
recycle stream for the main loop. This is avoided by solving the
recycle before the controller is invoked.
To maintain the inerts material balance, a purge is taken off the
recycle stream. Calculator BD-1 computes the purge draw rate.

Figure 2-15: Computing the Recycle Purge Rate

PRO/II Case Book Ammonia Synthesis Plant 2-27

 This acts similar to a valve on the purge stream regulating the flow.
The calculator builds a dummy stream 31X consisting of stream 28,
the dry syngas feed to the loop, minus the products from the loop,
streams 32 and 37. The splitter SP1 operates such that the argon rate
in the purge stream 31P is equal to the argon rate in the dummy
stream 31X - in other words equal to the net argon coming in to the
loop. Thus there is an exact argon balance in the loop and there will
be no build up of inerts as the flowsheet recycle solves.

Figure 2-16: Splitter SP1 Material Balance Specification

2-28 Ammonia Synthesis Plant March 5, 2014

 Results
The synthesis loop solves with a production of 1539.72 lb mole/hr
of 99.7% purity ammonia. The product compositions are shown in
Table 2-4:Product Stream Compositions. The overall conversion to
ammonia is 98% with a reactor conversion per pass of 27.4% based
on Nitrogen. The recycle stream rate is 10654 lb mole/hr giving a
recycle:feed ratio of 3.3:1. The purge stream is 74.1 lbmol/hr which
is 0.7% of the total recycle flowrate.
Table 2-4: Product Stream Compositions
Component NH3 Product Let Down Gas Purge
Hydrogen 1.69 21.45 42.39

Nitrogen 0.43 6.15 14.38

Argon 0.56 4.05 4.97

Methane 1.92 7.68 6.11

Ammonia 1535.03 33.3 6.27

Rate (lb_mole/hr) 1539.72 72.65 74.12

Temperature (F) 79.4 79.4 85

Pressure (psig) 350 350 4660

PRO/II Case Book Ammonia Synthesis Plant 2-29

Use of the Model in Process Control
Very clear benefits of using a computer model of a Kellogg
Ammonia plant were demonstrated in a paper published in
Hydrocarbon Processing, November 1980. The paper focuses on
the design of control strategies and uses a simulation model to
derive the responses of the plant to different settings of various
parameters.
The parameters that were examined were:
The ratio of synthesis loop recycle rate to fresh syngas
In many plants the fresh syngas feed to the synthesis loop is limited
by front-end restrictions such as insufficient synthesis compressor
power or absorber capacity.
The ratio of nitrogen to hydrogen in the syngas
At constant syngas make-up rates, ammonia production increased
as H/N decreased, but synthesis compressor loadings increased.
Synthesis loop pressure
Production of ammonia increases with increased loop pressure. The
design pressure, constrained by mechanical considerations, is the
limiting factor and the purge system should be operated the keep the
operating pressure just below the design pressure.
The temperature of the synthesizer feed
Production is extremely sensitive to this parameter and an optimum
temperature can be found. The control of this parameter is critical to
the profitability of the plant.
Methane content in syngas
Ammonia production decreases with increasing methane. Improved
primary reformer temperature control can alleviate this problem.
The results of these simulations have been put into practice in a
number of installations and these have consistently led to improved
productivity and higher conversion efficiency.

2-30 Ammonia Synthesis Plant March 5, 2014

 Appendix 2-A: Complete Ammonia
Plant Flowsheets

Graphical Representation: Complete Ammonia Plant Flowsheets

PRO/II Case Book Ammonia Synthesis Plant 2-31

 Figure 2-17: PRO/II Flowsheet: Processng Sections

Figure 2-18: : Catalytic Reforming

2-32 Ammonia Synthesis Plant March 5, 2014

 Figure 2-19: Catalytic Shift and Methanation

Figure 2-20: : Compression Stages

PRO/II Case Book Ammonia Synthesis Plant 2-33

 Figure 2-21: Schematic of Conversion Section

2-34 Ammonia Synthesis Plant March 5, 2014

Appendix 2-B: PRO/II Selected Output

The chart below was taken from the PRO/II output file. This depicts
the overall plant mass balance as calculated by PRO/II:
Table 2-5: Product Stream Summary t
Overall Plant Mass
Balance lb/hr lb/hr
Component Feed +Reaction -Product =Deviation % dev

1 h2o 200171.24 -19308.08 180863.16 0.00 0.00

2 o2 6773.16 -6773.16 0.00 0.00 0.00
3 co 11110.16 0.00 11110.16 0.00 0.00
4 co2 51686.75 32899.52 84586.27 0.00 0.00
5 h2 23765.16 124.05 23896.18 0.00 0.00
6 n2 135607.21 -22050.76 113588.40 -6.96 -0.03
7 a 2295.14 0.00 2295.14 -31.95 -0.30
8 c1 9501.45 -8284.17 1219.00 0.00 0.00
9 c2 1475.82 -1475.81 0.01 -1.71 -0.14
10 c3 944.14 -944.14 0.00 0.00 0.00
11 nc4 884.53 -884.53 0.00 0.00 0.00
12 nc5 114.08 -114.08 0.00 0.00 0.00
13 nh3 0.00 26811.15 26817.75 -6.60 0.02

total 444328.83 0.00 444376.06 -47.23 -0.01

The chart below was taken from the PRO/II output file. This depicts
the summary of RX-7,7, the ammonia converter.

Overall Operating Conditions

Reactor Type Adiabatic
Duty, MM Btu/hr 7.08086E-
Total Heat of Reaction at 800.00 F, MM Btu/ 05
hr -35.5038
Inlet Outlet
feed 38b
Vapor Product 29A
Temperature, F 571.29 926.82
Pressure, psig 4760.00 4730.00

PRO/II Case Book Ammonia Synthesis Plant 2-35

 Reaction Data
Rates, lb_mole/hr
Fraction
Component Feed Change Product Converted
2 o2 6.14596E-09 0.0000 6.14596E-09
3 co 1.04160E-05 0.0000 1.04160E-05
4 co2 9.67314E-08 0.0000 9.67314E-08
5 h2 8516.0375 -2361.2530 6154.7844 0.2773
6 n2 2875.2775 -787.0843 2088.1931 0.2737
7 a 723.2566 0.0000 723.2566
8 c1 892.0648 0.0000 892.0648
9 c2 1.23713E-03 0.0000 1.23713E-03
10 c3 1.21410E-08 0.0000 1.21410E-08
11 nc4 4.63078E-09 0.0000 4.63078E-09
12 nc5 3.02841E-09 0.0000 3.02841E-09
13 nh3 525.0477 1574.1687 2099.2164

Total 13531.6852 -1574.1687 11957.5165

Base lb_mole/hr Converted
Component reaction converted Fraction(1)

6 n2 1 787.0843 0.2737
Reactor Mass Balance Fraction
Converted
Rates, lb_mole/hr
2 o2 1.96663E-07 0.0000 1.96663E-07
3 co 2.91756E-04 0.0000 2.91756E-04
4 co2 4.25713E-06 0.0000 4.25713E-06
5 h2 17167.3105 -4760.0030 12407.3075 0.2773
6 n2 80546.5254 -22048.9708 58497.5546 0.2737
7 a 28892.6554 0.0000 28892.6554
8 c1 14311.1818 0.0000 14311.1818
9 c2 0.0372 0.0000 0.0372
10 c3 5.35374E-07 0.0000 5.35374E-07
11 nc4 2.69157E-07 0.0000 2.69157E-07
12 nc5 2.18500E-07 0.0000 2.18500E-07
13 nh3 8941.8560 26808.9734 35750.8294

Total 149859.5666 0.0000 149859.5662

2-36 Ammonia Synthesis Plant March 5, 2014

 The following pages show selected parts of the stream information
exported to Excel.

Component Rates
Stream ID nat gas 5 7 3IP 39 40
Description nat gas steam air purge LetDwn NH3Prod
Phase vapor vapor vapor vapor vapor liquid
Temperature, F 60.00 950.00 330.00 85.00 79.42 79.42
Pressure, psig 340.00 334.00 289.00 4660.00 350.00 350.00
Molecular Wt. 20.30 18.02 28.96 12.03 14.70 17.00

Component Molar Rates, lb_mole/hr

H2O 3952.7
O2 211.67 0.00 0.00 0.00
CO 0.00 0.00 0.00
CO2 19.43 0.00 0.00 0.00
H2 42.39 21.45 1.69
N2 20.09 786.70 14.39 6.15 0.44
A 9.58 4.97 4.05 0.56
c1 531.97 6.11 7.68 1.92
c2 49.08 0.00 0.00 0.00
c3 21.41 0.00 0.00 0.00
nc4 15.22 0.00 0.00 0.00
nc5 1.58 0.00 0.00 0.00
NH3 6.27 33.28 1535.03

Total, lb-mor/hr 658.79 3952.74 1007.95 74.12 72.61 1539.64

component mole fractions
H2O 1.00
O2 0.21 0.00 0.00 0.00
CO 0.00 0.00 0.00
CO2 0.03 0.00 0.00 0.00
H2 0.57 0.30 0.00
N2 0.03 0.78 0.19 0.08 0.00
A 0.01 0.01 0.06 0.00
c1 0.81 0.11 0.00
c2 0.07 0.00 0.00
c3 0.03 0.00 0.00
nc4 0.02 0.00 0.00
nc5 0.00 0.00 0.00
NH3 0.46 1.00

PRO/II Case Book Ammonia Synthesis Plant 2-37

 Stream ID nat gas 5 7
Description nat gas steam air
Phase vapor vapor vapor
Total Stream Properties
Mole Rate LB-MOL/HR 658.79 3952.74 1007.95
Weight Rate lb/hr 13371.05 71209.75 29194.01
Std Liq Rate FT3/HR 607.71 1141.79 536.33
Temperature f 60.00 950.00 330.00
Pressure psig 340.00 334.00 289.00
Molec. weight 20.30 18.02 28.96
Enthalpy MM BTU/HR 1.34 106.60 1.83
btu/lb 100.14 1497.06 62.55
Mole Frac.Liq. n/a n/a n/a
Reduced Temp 1.36 1.21 3.31
Reduced Pres 0.53 0.11 0.56
Acentric Factor 0.03 0.34 0.03
Watson K (UOPK) 17.48 8.76 6.00
Std Liq Density lb/ft3 22.00 62.37 54.43
Spec. Grav. 0.35 1.00 0.87
API gravity 269.59 10.00 30.62
Vapor Phase Properties
rate, mole LB-MOL/HR 658.79 3952.74 1007.95
Rate, Wt. LB/HR 13371.05 71209.75 29194.01
Std. Liq. Rate FT3/HR 9627.93 168399.02 28355.77
Std. vap.Rate FT3/HR 250000.00 1500000.13 382500.00
Spec Gravity
(Air=1.0) 0.70 0.62 1.00
Molec. wt. 20.30 18.02 28.96
Enthalpy BTU/LB 100.14 1497.06 62.55
cp BTU/LB-F 0.51 0.53 0.25
Density LB/FT3 1.39 0.42 1.03
thermal
conductivity BTU/HR-FT-F n/a 0.04 n/a
viscosity cp n/a 0.03 n/a
Liquid Phase Properties n/a n/a n/a

2-38 Ammonia Synthesis Plant March 5, 2014

 Stream ID 3IP 39 40
Name purge LetDwn Gas NH3 Prod
phase vapor vapor liquid
Total Stream Properties
Mole Rate LB-MOL/HR 74.12 72.61 1539.64
Weight Rate lb/hr 891.78 1067.09 26211.19
Std. Liq. Rate FT3/HR 37.68 36.41 682.83
temperature f 85.00 79.42 79.42
pressure psig 4660.00 350.00 350.00
Molec. weight 12.03 14.70 17.02
Enthalpy MM BTU/HR 0.07 0.34 1.54
btu/lb 76.90 319.43 58.89
Mole Frac.Liq. n/a n/a 1.00
Reduced Temp 2.92 1.27 0.74
Reduced Pres 10.49 0.38 0.22
Acentric Factor -0.09 0.06 0.25
Watson K 11.88 12.29 12.26
(UOPK)
Std Liq Density lb/ft3 23.67 29.31 38.39
Specific Grav. 0.38 0.47 0.62
API gravity 241.36 169.61 98.40
Vapor Phase Properties
Rate lb_mole/hr 74.12 72.61 n/a
lb/hr 891.78 1067.09 n/a
ft3/hr 105.55 1087.83 n/a
Std. vapor Rate ft3/hr 28127.78 27552.61 n/a
Sp. Gravity n/a
(Air=1.0) 0.42 0.51 n/a
Molec. wt 12.03 14.70 n/a
Enthalpy Btu/lb 76.90 319.43 n/a
cp Btu/lb-F 0.68 0.57 n/a
Density lb/ft3 .45 0.98 n/a
therm conduct. Btu/hr_ft_F n/a n/a n/a
viscosity cp n/a n/a n/a
Liquid Phase Properties n/a n/a n/a

PRO/II Case Book Ammonia Synthesis Plant 2-39

 Appendix 2-C:
PRO/II Keyword Input File

TITLE DATE=NH3 SYN

DESC This is the PRO/II simulation file corresponding to the
DESC PRO/II Casebook on Ammonia Synthesis.
DESC For more information on this model
DESC please contact Technical Support DESC
PRINT INPUT=ALL, STREAM=COMPONENT, RATE=M, MBALANCE, ION=NONE
TOLERANCE STREAM=0.0005,-0.1,0.0001,0.001
DIMENSION ENGLISH, PRES=PSIG
SEQUENCE DEFINED=GASHEATER,

X-1A,RX-1,S1,RX-2,RX-3,H-1,RX-4,RX-5, & REB1,CW-1,D-1,T-
1,SAT,RX-6,CT1,X-3,X-2,WHB2,WHB1,X1-B,CW2, & D-2,CP-1,CP-2,CP-
3,SEP1,REFC,CP-4,X-4,M1,D-7,DM2,DM1,RX-7, & FDEF,D-
6,DM3,DM4,BD1,SP1,DUM1,CAL1,DUM2,CTL1,D-8

CALCULATION TRIALS=150, RECYCLE=ALL, COMPCHECK=CALC, DVARI-
ABLE=ON, &

FLASH=DEFAULT, MAXOPS=1000000, CDATA=FIX
COMPONENT DATA
LIBID1,H2O/2,O2/3,CO/4,CO2/5,H2/6,N2/7,A/8,C1/9,C2/10,C3/
11,NC4/ & 12,NC5/13,NH3, BANK=SIMSCI,PROCESS
THERMODYNAMIC DATA
METHOD SYSTEM=SRK, TRANSPORT=NONE, DENSITY(L)=RCK1, &
SET=1, DEFAULT
METHOD SYSTEM=SRK, DENSITY(L)=RCK1, SET=2
KVAL(VLE)
SRK(R) 5,6,0.085,0,0
SRK(R) 5,7,0.0004,0,0
SRK(R) 5,8,-0.2079,0,0
SRK(R) 7,8,0.0204,0,0
SRK(R) 5,13,0.276,0,0
SRK(R) 6,13,0.31,0,0
SRK(R) 7,13,0.3383,0,0
SRK(R) 8,13,0.18,0,0
STREAM DATA
PROPERTY STREAM=1, TEMPERATURE=60, PRESSURE=340, &
PHASE=M, RATE(GV)=250000, &
COMPOSITION(M)=4,2.95/6,3.05/8,80.75/ & 9,7.45/10,3.25/ &
11,2.31/12,0.24
PROPERTY STREAM=5, TEMPERATURE=950, PRESSURE=334, PHASE=M, &

2-40 Ammonia Synthesis Plant March 5, 2014

 COMPOSITION(M,LBM/H)=1,1000
PROPERTY STREAM=7, TEMPERATURE=330, PRESSURE=289, PHASE=M, &
RATE(GV)=375000, COMPOSITION(M)=2,21/6,78.05/7,0.95
PROPERTY STREAM=WAT, TEMPERATURE=100, PRESSURE=271, PHASE=M, &
COMPOSITION(M,LBM/H)=1,1000
PROPERTY STREAM=31R, TEMPERATURE=85, PRESSURE=4660, PHASE=M, &
COMPOSITION(M,LBM/H)=5,6000/6,2000/7,300/8,1000/13,700
PROPERTY STREAM=31X, TEMPERATURE=85, PRESSURE=4660, PHASE=M, &
COMPOSITION(M,LBM/H)=7,7
PROPERTY STREAM=36A, TEMPERATURE=40, PRESSURE=4840, PHASE=M, &
COMPOSITION(M,LBM/H)=5,8514.13/7,724.309/2,6.16216E-9/ &
3,1.04288E-5/4,9.6746E-8/6,2874.7/8,893.043/9,0.00123812/&
10,1.21531E-8/11,4.64927E-9/12,3.04016E-9/13,525.107
PROPERTY STREAM=S1, TEMPERATURE=93.719, PRESSURE=4950, &
PHASE=M, &
COMPOSITION(M,LBM/H)=5,8517.75/7,724.917/2,6.18542E-9/ &
3,1.04418E-5/4,1.01574E-7/6,2875.69/8,894.384/9,0.00124165/&
10,1.21867E-8/11,4.65563E-9/12,3.04603E-9/13,902.201
PROPERTY STREAM=13, TEMPERATURE=400, PRESS=274, REFSTREAM=11
PROPERTY STREAM=21, TEMPERATURE=675, PRESS=254, REFSTREAM=19
PROPERTY STREAM=38B, TEMP=571.14, PRESSURE=4760, REFSTREAM=38
PROPERTY STREAM=8_R1, REFSTREAM=8
NAME 1,NAT GAS/5,STEAM/7,AIR/31R,RECYCLE/11,HTS OUT/ &
19,TRTD GAS/ 38,RX FEED/8,SEC REF OUT/6,PR REF OUT/ &
14,LTS OUT
NAME 17,MEA FEED/22,METH PROD/25,SYN GAS/31P,PURGE/ &
31,PRI SEP/ & 36,SEC SEP/39,LETDWN GAS/40,NH3 PROD
RXDATA
RXSET ID=1
REACTION ID=1
STOICHIOMETRY 5,-3/6,-1/13,2
HORX HEAT=-45.108, REFCOMP=6, REFTEMP=800
EQUILIBRIUM A=-32.975, B=22930.4
UNIT OPERATIONS
HX UID=GASHEATER
COLD FEED=1, M=2
OPER DUTY=1.6
HX UID=X-1A
COLD FEED=2, V=3, DP=2
OPER CTEMP=750
FLASH UID=RX-1, NAME=DESULFURIZER
FEED 3
PRODUCT V=4 ISO
TEMPERATURE=740, DP=2
CALCULATOR UID=S1, NAME=STM-GAS FLOW
SEQUENCE STREAM=1,5
PROCEDURE
R(1) = 6.0 * SMR(1) $ CALCULATE STEAM RATE

PRO/II Case Book Ammonia Synthesis Plant 2-41

 CALL SRXSTR(SMR,R(1),5) $ SET STEAM TO CALCULATED RATE
RETURN
GIBBS UID=RX-2, NAME=PRI REFORMER
FEED 4,5
PRODUCT V=6
OPERATION DP=45,
TEMPERATURE=1360, ISOTHERMAL
ELEMENTS REACTANTS= 1/3/4/5/8/9/10/11/12
CONVERSION APPROACH=-35
GIBBS UID=RX-3, NAME=SEC REFORMER
FEED 6,7 PRODUCT V=8
OPERATION DP=5, ADIABATIC
ELEMENTS REACTANTS= 1/2/3/4/5/8/9/10/11/12
CONVERSION APPROACH=-35
HX UID=H-1, NAME=COOL REFGAS
HOT FEED=8, M=10, DP=4
OPER HTEMP=675
EQUREACTOR UID=RX-4, NAME=H T SHIFT
FEED 10
PRODUCT V=11
OPERATION ADIABATIC, DP=2 RXCALCULATION MODEL=SHIFT
REACTION SHIFT
EQUREACTOR UID=RX-5, NAME=L T SHIFT
FEED 13
PRODUCT V=14
OPERATION ADIABATIC, DP=2
RXCALCULATION MODEL=SHIFT
REACTION SHIFT
FLASH UID=REB1, NAME=REBOILER
FEED 14
PRODUCT V=15
ADIABATIC DP=4, DUTY=-45
HX UID=CW-1
HOT FEED=15, V=16, DP=2
OPER HTEMP=100
FLASH UID=D-1, NAME=COND SEP
FEED 16
PRODUCT V=17, W=18
ADIABATIC
STCALCULATOR UID=T-1, NAME=MEA COLUMN
FEED 17,1
OVHD V=CO2, DTAD=0
BTMS L=19A, DP=12, TEMPERATURE=100
FOVHD(M) 1,3,0
FOVHD(M) 4,4,0.9992
FOVHD(M) 5,13,0
OPERATION STOP=ZERO
FLASH UID=SAT, NAME=H2O SAT

2-42 Ammonia Synthesis Plant March 5, 2014

 FEED 19A,WAT
PRODUCT V=19, W=XS
ISO TEMPERATURE=100
EQUREACTOR UID=RX-6, NAME=METHANATOR
FEED 21
PRODUCT V=22
OPERATION ADIABATIC, DP=2
RXCALCULATION MODEL=METHANATION
REACTION METHANATION
REACTION SHIFT
CONTROLLER UID=CT1
SPEC STREAM=22, RATE(LBM/H), COMP=5,WET, DIVIDE, 7
STREAM=22, RATE(LBM/H), COMP=6,WET, VALUE=3
VARY STREAM=7, RATE(LBM/H)
CPARAMETER IPRINT, NOSTOP
HX UID=X-3
HOT FEED=22, M=23, DP=2
COLD FEED=19, V=20, DP=2
CONFIGURE COUNTER, U=90, AREA=1025
HX UID=X-2
HOT FEED=11, V=12, DP=2
COLD FEED=20, V=21X, DP=2
CONFIGURE COUNTER
OPER CTEMP=675
HX UID=WHB2
HOT FEED=12, V=13X, DP=2
OPER HTEMP=400
HX UID=WHB1
HOT FEED=8_R1, V=9, DP=2
DEFINE DUTY(BTU/HR) AS HX=H-1, DUTY(BTU/HR), MINUS, &
HX=X-1A, DUTY(BTU/HR)
HX UID=X1-B
HOT FEED=9, V=10X, DP=1
DEFINE DUTY(BTU/HR) AS HX=X-1A, DUTY(BTU/HR), TIMES,-1
FLASH UID=CW2
FEED 23
PRODUCT M=24
ISO TEMPERATURE=100
FLASH UID=D-2, NAME=COND SEP
FEED 24
PRODUCT V=25, W=24W
ADIABATIC
COMPRESSOR UID=CP-1, NAME=1ST STAGE
FEED 25
PRODUCT V=26, W=WA1
OPERATION CALCULATION=GPSA, PRES=700, EFF=95
COOLER ACDP=5, ACTEMP=95
COMPRESSOR UID=CP-2, NAME=2ND STAGE

PRO/II Case Book Ammonia Synthesis Plant 2-43

 FEED 26
PRODUCT V=27, W=WA2
OPERATION CALCULATION=GPSA, PRES=1950, EFF=95
COOLER ACDP=5, ACTEMP=95
COMPRESSOR UID=CP-3, NAME=3RD STAGE
FEED 27 PRODUCT V=28A
OPERATION CALCULATION=GPSA, PRES=4960, EFF=95
COOLER ACDP=5, ACTEMP=95
STCALCULATOR UID=SEP1, NAME=WATER REMOVL
FEED 28A,1
OVHD L=WA3, TEMPERATURE=95
BTMS V=28, TEMPERATURE=95
FOVHD(M) 1,1,1
FOVHD(M) 2,13,0
OPERATION STOP=ZERO
CALCULATOR UID=REFC, NAME=REF_RATE
SEQUENCE STREAM=31R
DEFINE P(1) AS STREAM=31R, RATE(LBM/H),TOTAL,WET
PROCEDURE
IF (R(1) .GT. 0) GOTO 100
R(1) = P(1)
100 CALL SRXSTR(SMR,R(1),31R)
RETURN
COMPRESSOR UID=CP-4, NAME=RECYCLE COMP
FEED 31R
PRODUCT V=33
OPERATION CALCULAT=GPSA, PRES=4950, EFF=95, WTOL=1E-5
HX UID=X-4
HOT FEED=S1, M=34, DP=50
COLD FEED=36A, V=38, DP=50
CONFIGURE COUNTER
OPER CTEMP=84.999
MIXER UID=M1
FEED 33,28
PRODUCT M=S1
FLASH UID=D-7, NAME=SEC SEP
FEED 34
PRODUCT V=36, L=37
ISO TEMPERATURE=39.999, PRESSURE=4840
METHOD SET=2
FLASH UID=DM2
FEED 36
PRODUCT V=36A
ISO TEMPERATURE=39.999
FLASH UID=DM1
FEED 37
PRODUCT L=37A
ISO TEMPERATURE=39.999

2-44 Ammonia Synthesis Plant March 5, 2014

 EQUREACTOR UID=RX-7, NAME=CONVERTER
FEED 38B
PRODUCT V=29A
OPERATION ADIABATIC, PHASE=V, DP=30, TEMP=900
RXCALCULATION MODEL=STOIC
RXSTOIC RXSET=1
REACTION 1
BASE COMPONENT=6
APPROACH DT=20
HX UID=FDEF, NAME=RX EFFL EXCH
HOT FEED=29A, V=29, DP=30
COLD FEED=38, V=38B, DP=30
CONFIGURE COUNTER
OPER HTEMP=430
FLASH UID=D-6, NAME=PRI SEP
FEED 29
PRODUCT V=31, L=32
ISO TEMPERATURE=84.999, PRESSURE=4660 METHOD SET=2
FLASH UID=DM3
FEED 31
PRODUCT V=31A
ISO TEMPERATURE=84.999
FLASH UID=DM4
FEED 32
PRODUCT L=32A
ISO TEMPERATURE=84.999
CALCULATOR UID=BD1, NAME=PURGE RATE
SEQUENCE STREAM=31X
DEFINE P(1) AS STREAM=28, RATE(LBM/H), COMP=7,WET
DEFINE P(2) AS STREAM=32A, RATE(LBM/H), COMP=7,WET
DEFINE P(3) AS STREAM=37A, RATE(LBM/H), COMP=7,WET
PROCEDURE
V(1) = P(1) - P(2) - P(3)
IF (V(1) .LE. 0.001) V(1) = 0.001
CALL SRXSTR(SMR, V(1), 31X)
RETURN
SPLITTER UID=SP1, NAME=PURGE
FEED 31A
PRODUCT M=31P, M=31RA
OPERATION OPTION=FILL
SPEC STREAM=31P, RATE(LBM/H), COMP=7,WET, DIVIDE, &
STREAM=31X, RATE(LBM/H), COMP=7,WET, &
VALUE=1, RTOLER=1E-5
FLASH UID=DUM1
FEED 31RA
RODUCT M=31RB
ADIABATIC
CALCULATOR UID=CAL1, NAME=SET_RATE

PRO/II Case Book Ammonia Synthesis Plant 2-45

 SEQUENCE STREAM=31RB
DEFINE P(1) AS CALCULATOR=REFC, R(1)
PROCEDURE
CALL SRXSTR(SMR,P(1),31RB)
RETURN
FLASH UID=DUM2
FEED 31RB
PRODUCT M=31R
ADIABATIC
CONTROLLER UID=CTL1
SPEC STREAM=38,FRACTION, COMP=7,8,WET, VALUE=0.12, &
ATOLER=0.001
VARY CALCULATOR=REFC, R(1), STEPSIZE=10, EST2=10500
CPARAMETER NOPRINT, NOSTOP, ITER=39
FLASH UID=D-8, NAME=LETDOWN
FEED 32A,37A
PRODUCT V=39, L=40
ADIABATIC PRESSURE=350
RECYCLE DATA
ACCELERATION TYPE=WEGSTEIN, STREAM=36A,31R
LOOP NUMBER=1, START=X-4, END=DM2,WEGSTEIN, TOLE=2E-6
LOOP NUMBER=2, START=CP-4, END=DUM2,WEGSTEIN, TOLE=0.0015
END

2-46 Ammonia Synthesis Plant March 5, 2014

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