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PETROVIETNAM FERTILIZER AND CHEMICALS CORPORATION (PVFCCo)
AMMONIA PLANT REVAMP PROJECT
Project N Unit Document Code Serial N Rev. Page

2539 10 CN 0009 01 A 1/10
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior
written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
PROCESS DESCRIPTION
A 23/10/2015 ISSUED FOR BASIC DESIGN NDTS MG MG / LP
REV. DATE STATUS WRITTEN BY CHECKED BY APPROV./AUTHOR. BY

(name & visa) (name & visa) (name & visa)
DOCUMENT REVISIONS
TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68


2539 10 CN 0009 01 A 2/10
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other
INDEX
Page
1. GENERAL INFORMATION.................................................................................................3
1.1. Introduction......................................................................................................................... 3
1.2. Ammonia Plant...................................................................................................................4
1.3. Process Flow Diagrams......................................................................................................4
2. DESULPHURIZATION SECTION.......................................................................................5
3. REFORMING SECTION.....................................................................................................5
3.1. Reforming Summary........................................................................................................... 5
3.2. Primary Reformer, 10-H2001..............................................................................................5
than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
3.3. Secondary Reformer, 10-R2003.........................................................................................5

3.4. Heat Exchange Reformer, 10-HE2001...............................................................................5
4. CO CONVERSION AND CO2 REMOVAL SECTION..........................................................8
5. COMPRESSORS AND DRIVERS SECTION.....................................................................8
6. AMMONIA SYNTHESIS SECTION....................................................................................8
6.1. Synthesis Summary............................................................................................................9
6.2. Ammonia Converter, 10-R5001..........................................................................................9
6.3. Loop Waste Heat Boiler, 10-E5000.....................................................................................9
6.4. Ammonia Converter No.2, 10-R5002..................................................................................9


2539 10 CN 0009 01 A 3/10
1. GENERAL INFORMATION
2. Introduction
This document describes the process changes for the revamp for Phu My ammonia plant
revamping project, Petrovietnam Fertilizer and Chemical Corporation (PVFCCo), Vietnam.
The revamp is based on the basic engineering design package process conducted by
Haldor Topse A/S (HTAS) with the purpose of increasing the ammonia production for Phu
My ammonia plant by 20%. The increased ammonia production will be exported and
therefore it is not required to increase carbon dioxide production.
The plant was originally designed for a capacity of 1350 MTPD ammonia. The presented
revamp enables the plant to produce 1620 MTPD ammonia.
The revamp has resulted in addition of new pieces of equipment and modification of some
of the process parameters. The major changes are the following:
addition of a heat exchange reformer (10-HE2001) downstream the existing secondary

reformer (10-R2003)
addition of a HTAS S-50 series ammonia converter (10-R5002) downstream the
existing ammonia converter (10-R5001)
addition of a vertical waste heat boiler with integrated steam drum (10-E5000) into the
ammonia synthesis loop
addition of a CO2 cooler (10-E3007) working in parallel with the current CO 2 product
cooler (10-E3006)
decrease of inlet temperature to hydrogenator (10-R2001) to 344C
decrease of inlet temperature to primary reformer (10-H2001) to 514C
increase of outlet temperature from secondary reformer (10-R2003) to 1011C
increase of MDEA solution concentration to 50 %wt
modification of internal parts in synthesis gas compressor steam turbine (10-STK4031)
The following changes are foreseen in the compressor / steam turbines section
(changes to be confirmed by client)
replacement synthesis gas compressor inter-stage coolers (10-E4031/ 4032/ 4033) )
replacement of demisters in synthesis gas compressor separators (10-V4031/ 4032/
4033)
modification of internal parts in process air compressor steam turbine (10-STK4021)
replacement of process air compressor inter-stage coolers (10-E4021/ 4022/ 4023)
replacement of demisters in process air compressor separators (10-V4021/ 4022/
4023)
This document contains an overview of the process in the reforming section and ammonia
synthesis, with focus on the changes undergone during the revamp. The remainder of the
plant layout is unchanged, and therefore this document should be seen as an addendum to
the current process description.


2539 10 CN 0009 01 A 4/10
3. Ammonia Plant
In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen,
with a H2/N2 ration of 3.0.
The source of H2 is steam and the hydrocarbons in the natural gas. The source of N 2 is
atmospheric air. Besides ammonia, the plant produces a side stream of carbon dioxide. The
source of CO2 are the hydrocarbons in the natural gas feed.
The plant main function can be illustrated as follows:

4. Process Flow Diagrams
The process description refers to the process flow diagrams:
Desulphurization and Reforming 12-PFD-0010-01

Secondary Reformer 12-PFD-0010-02
CO Conversion 12-PFD-0010-03
Steam Generation 12-PFD-0010-04
MDEA CO2 Removal 13-PFD-0010-01
Methanation 13-PFD-0010-02
Steam Balance 14-PFD-0010-01
Ammonia Synthesis Loop Part 1 15-PFD-0010-01
Ammonia Synthesis Loop Part 2 15-PFD-0010-02
Ammonia Refrigeration 15-PFD-0010-03
Ammonia Recovery 15-PFD-0010-04
Cooling Water Balance 10-PFD-0010-01


2539 10 CN 0009 01 A 5/10
5. DESULPHURIZATION SECTION
6. REFORMING SECTION
7. Reforming Summary
In the reforming section, the desulphurized gas is converted into synthesis gas by catalytic
reforming of the hydrocarbon mixture with steam and addition of air.
The steam reforming process can be described by the following reactions:
(1) CnH2n+2 + 2H2O Cn-1H2n + CO2 + 3H2 - Heat

(2) CH4 + 2H2O CO2 + 4H2 - Heat

(3) CO2 + H2 CO + H2O - Heat
Reaction (1) describes the mechanism of reforming the higher hydrocarbons, which are
reformed in stages to lower and lower hydrocarbons, finally resulting in methane, which is
reformed as shown in reaction (2). The heat input required for the reverse shift reaction (3)
is very small compared to the heat input required for reactions (1) and (2).
The reforming of the hydrocarbon feed mainly takes place in two stages, a direct fired
primary reformer and a catalytic secondary reformer.
The main process changes to the reforming section are the new Haldor Topse Exchange
Reformer (HTER-P). The HTER-P ties in upstream the tubular reformer and operates in
parallel with the existing reformer. Heat exchanged from the reformed gas from the
secondary reformer is used to reform natural gas in HTER-P.
8. Primary Reformer, 10-H2001
Operational changes are as follows:
decrease of inlet temperature to primary reformer (10-H2001) to 514C
9. Secondary Reformer, 10-R2003
Operational changes are as follows:
increase of outlet temperature from secondary reformer (10-R2003) to 1011C
10. Heat Exchange Reformer, 10-HE2001
The HTER-P consists of a tube bundle of bayonet tubes each with an outer tube. This
means one bayonet tube with an outer tube consists of three concentric tubes. Catalyst is


2539 10 CN 0009 01 A 6/10
placed in the tube in the middle, meaning inside the annulus of the bayonet tubes. In the
vertically mounted tube bundle, the catalyst loading will be of the type R-87R HEAT-X TM,
RK-201, and R-87 HEAT-XTM. The reforming and shift reaction are according to Reaction
(1), (2) and (3) in Section 3.1.
Through a refractory lined transfer line, the gas from the secondary reformer is passed to
the HTER-P, where it passes through the annuli between the bayonet tubes and the outer
tubes.
The gas to be reformed flows downwards through the catalyst in the middle tube and out
upwards through the inner tube inside the bayonet tube and is mixed with the secondary
reformer gas flowing upwards through the outer tube in the top of the HTER-P. This means
flow is counter current between the gas to be reformed and the gases to be cooled by
transferring heat to the reforming process. Heat transfer is very efficient as it occurs from
both an inner side and an outer side of the catalyst.
The temperature of the reformed gas in the HTER-P reaches approximately 965C before
leaving through the inner tubes.
The high temperatures in the primary and especially in the secondary reformer necessitate
chemical resistivity of the catalysts and of the secondary reformer lining. We particularly
emphasize the use of catalysts free from silica, and lining with a very low content of silica,
as volatile compounds otherwise will be carried out of the unit and deposited on the waste
heat boiler surfaces.
Approximately 20% of the process gas coming from the desulphurization section is
branched off and sent to the HTER-P. The inlet temperature to the HTER-P will depend on
the addition of superheated steam. In the revamp cases, the steam to carbon ratio into the
HTER-P is adjusted to 3.4 by adding of superheated steam.
The process gas leaves the reforming section at about 795C. It is cooled to about 522C in
the waste heat boiler (10-E2008) where 118 barg saturated steam is produced, and further
to 360C in the steam superheater (10-E2009). After cooling, the gas flows to the high
temperature CO converter (10-R2004).

2539
Project N
10
Unit
CN 0009
Document Code
01
Serial N

A
Rev.
Page
7/10

2539 10 CN 0009 01 A 8/10
11. CO CONVERSION AND CO2 REMOVAL SECTION
The operation of the CO conversion section is almost unchanged.
The only changes to the OASE CO2 removal section are:
installation of an additional CO2 cooler (10-E3007) parallel to the current CO2 product
cooler (10-E3006) downstream the LP flash drum (10-V3001) as well as
increase of MDEA solution concentration to 50 %wt
Installing the additional CO2 cooler (10-E3007) with the same size as the current CO 2
product cooler (10-E3006) allows handling the higher gas rates in the CO2 removal section
due to the revamp and reduces the CO 2 product temperature. In addition, it allows online
maintenance on each of the coolers.
12. COMPRESSORS AND DRIVERS SECTION
The following changes are foreseen for the synthesis gas compressor train and process air
compressor train. The ammonia compressor can run in the new revamp operating point.
Synthesis gas compressor K-4031 can run in the new revamp operating point.
Revamping the synthesis gas compressor steam turbine (10-STK4031) with a modified
rotor will increase the turbine efficiency, resulting in increase the operating margin and
maximize the HP steam extraction, with steam saving from the auxiliary boiler 10-B-8001.
The following changes to be confirmed by client.
In order to handle the higher make-up synthesis gas flowrate in the revamp conditions and
the required cooling temperature of 42C, synthesis gas compressor interstage coolers 10-
E4031/4032/4033 are foreseen to be replaced with increased exchange surface.
In addition, it is foreseen to replace the demisters in interstage K.O. drums 10-V-
4031/4032/4033 in order to ensure adequate droplet separation at increased gas flowrate.
The process air compressor K-4021 can run in the new revamp operating point.
The steam turbine STK-4021 is recommended to be revamped in order to increase the
operating margin.
In order to handle the required flowrate in the revamp conditions, compressor interstage
coolers 10-E4021/4022/4023 are foreseen to be replaced with increased exchange surface.
In addition, it is foreseen to replace the demisters in interstage K.O. drums 10-V-
4021/4022/4023 in order to ensure adequate droplet separation at increased gas flowrate.
13. AMMONIA SYNTHESIS SECTION


2539 10 CN 0009 01 A 9/10
14. Synthesis Summary
The ammonia synthesis takes place in the ammonia converters according to the following
reaction scheme:
(4) N2 + 3H2 2NH3
The reaction is an equilibrium reaction and therefore only part of the hydrogen and nitrogen
can be converted into ammonia by passing through the catalyst beds. The composition of
the synthesis gas at chemical equilibrium is influenced by pressure and temperature, the
equilibrium concentration of ammonia being increased by high pressure and low
temperature.
The reaction rate is, however, very much enhanced by high temperature operation.
Therefore, there is a compromise between the theoretical conversion and the reaction rate
in a single pass over the catalyst. This relationship leads to an optimum level of catalyst
temperatures at which the maximum production is obtained. At higher temperatures the
equilibrium percentage (which theoretically is the highest obtainable percentage of
ammonia) will be too low, while at lower temperatures the reaction rate will be too low.
15. Ammonia Converter, 10-R5001
No changes are required for the existing equipment.
16. Loop Waste Heat Boiler, 10-E5000
The loop waste heat boiler is new and preferable a vertical waste heat boiler with integrated
steam drum. It ties in downstream the current ammonia converter (10-R5001).
17. Ammonia Converter No.2, 10-R5002
The ammonia synthesis converter No.2, is a new series 50 Haldor Topse Radial Flow
Converter. It consists of a pressure shell with one radial flow catalyst bed.
The synthesis gas is introduced into the converter through the inlet at the bottom of the
converter and flows upwards through the transfer pipe to the top. The gas flows through the
space below the basket cover to the annuli of the panels around the catalyst bed. From the
panels it passes the catalyst bed in inward direction and then flows to the annulus between
the catalyst beds. Even gas distribution in the catalyst bed is ensured by means of
appropriate perforation in the panels. The inlet temperature to the converter is controlled at
370C by a hot bypass around the upstream boiler (10-E5000).
The resulting converter outlet temperature is around 410C and the outlet gas will be
utilized for steam production in the existing waste heat boiler (10-E5001).
The installation of the ammonia converter No.2 (10-R5002) increases ammonia conversion
per pass and energy efficiency.

2539
Project N
10
Unit
CN 0009
Document Code
01
Serial N

A
Rev.
Page
10/10

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PETROVIETNAM FERTILIZER AND CHEMICALS CORPORATION (PVFCCo)

AMMONIA PLANT REVAMP PROJECT

Project N Unit Document Code Serial N Rev. Page

A 23/10/2015 ISSUED FOR BASIC DESIGN NDTS MG MG / LP

REV. DATE STATUS WRITTEN BY CHECKED BY APPROV./AUTHOR. BY

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

Project N Unit Document Code Serial N Rev. Page

3.3. Secondary Reformer, 10-R2003.........................................................................................5

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

Project N Unit Document Code Serial N Rev. Page

of the process parameters. The major changes are the following:

addition of a heat exchange reformer (10-HE2001) downstream the existing secondary

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

Project N Unit Document Code Serial N Rev. Page

The plant main function can be illustrated as follows:

4. Process Flow Diagrams

The process description refers to the process flow diagrams:

Desulphurization and Reforming 12-PFD-0010-01

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

Project N Unit Document Code Serial N Rev. Page

The steam reforming process can be described by the following reactions:

(1) CnH2n+2 + 2H2O Cn-1H2n + CO2 + 3H2 - Heat

(2) CH4 + 2H2O CO2 + 4H2 - Heat

8. Primary Reformer, 10-H2001

Operational changes are as follows:

decrease of inlet temperature to primary reformer (10-H2001) to 514C

9. Secondary Reformer, 10-R2003

Operational changes are as follows:

increase of outlet temperature from secondary reformer (10-R2003) to 1011C

10. Heat Exchange Reformer, 10-HE2001

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

Project N Unit Document Code Serial N Rev. Page

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

Project N Unit Document Code Serial N Rev. Page

11. CO CONVERSION AND CO2 REMOVAL SECTION

The operation of the CO conversion section is almost unchanged.

The only changes to the OASE CO2 removal section are:

12. COMPRESSORS AND DRIVERS SECTION

The following changes to be confirmed by client.

13. AMMONIA SYNTHESIS SECTION

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

Project N Unit Document Code Serial N Rev. Page

14. Synthesis Summary

(4) N2 + 3H2 2NH3

15. Ammonia Converter, 10-R5001

No changes are required for the existing equipment.

16. Loop Waste Heat Boiler, 10-E5000

17. Ammonia Converter No.2, 10-R5002

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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