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Ammonia@Max

Advanced Process Control for Ammonia Plants

Download the Ammonia@Max brochure (PDF)  from our download section

The pressure on production managers of ammonia plants is increased in order to maximize the profitability due to global competition, world-wide saturation of markets, tightening legislation on ecosphere load and fluctuating oil/gas prices. IPCOS provides optimization solutions for ammonia plants in order to relieve the pressure and increase the margins.

The benefits are obvious:

Benefits of base layer control optimization and maintenance services of IPCOS:

• Improved plant stability (optimal on-stream factor)
• Minimal alarms (operators can focus on essential operations)
• Minimal operator interventions
• Standardization of controls (ease of maintenance)
• Highly trained operators and maintenance engineers

Benefits of MES layer control optimization and maintenance services of IPCOS:

• Increased ammonia production (up to 2%)
• Minimize specific natural gas consumption (up to 1%)
• Increased steam export or minimized steam consumption (depends on plant layout)
• On line key performance indices computations used for accurate performance monitoring 

Control targets of APC on ammonia units:

• Reforming:
  • Constant and optimal make-up gas composition, reduce fluctuations
  • Uniform optimal methane cracking
  • Tolerate heating value fluctuations of the fuel gas
  • Optimize energy usage (compressors, firing,….)
  • Avoid coking in the reformer tubesShift convertors:
  • Maximize CO-conversion
  • Keep temperature specifications
• CO2 removal:
  • Minimize aMDEA Solution Flow for given CO2 slip
  • Minimize Stripping Steam for given CO2 slip
  • Maximize total throughput taking care of the allowed CO2 slip to the methanizer
• Cold Box:
  • Constant H2/N2 ratio
• Synthesis:
  • Maximize Conversion Rate at minimum energy consumption (compressor)
  • Maximize steam production
• Steam Generation:
  • Maximize production of high pressure steam
    

All solutions are completly integrated with the DCS as shown on the right:

References

• Yara
• Kemira Grow-How
• Tringen
  
• BASF
• PIC (Kuwait)
• PCS Nitrogen
• Qafco
• SAFCO
• Abu Qir
• PLNL