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CHALLENGES & INNOVATIONSCHALLENGES & INNOVATIONS

IN TECHNOLOGY OFIN TECHNOLOGY OF

AMMONIA UREA PLANTSAMMONIA UREA PLANTS

First Foundation DayFirst Foundation Day

Indian Institute of Chemical EngineersIndian Institute of Chemical Engineers

Dr. U. S. Awasthi

Managing Director

Indian Farmers Fertiliser Cooperative Ltd.


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IntroductionIntroduction

Chemical Fertilisers played the key role to meet theChemical Fertilisers played the key role to meet the

on going demand of food grain production for theon going demand of food grain production for thefaster growing human population.faster growing human population.

Chemical fertilisers provide three primary nutrients:Chemical fertilisers provide three primary nutrients:

Nitrogen (N)Nitrogen (N)

Phosphorous (P2O5)Phosphorous (P2O5)

Potash (K2O)Potash (K2O)


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Nitrogenous FertilisersNitrogenous Fertilisers

Urea is one of the major nitrogenous fertilisers. OthersUrea is one of the major nitrogenous fertilisers. Others

are Ammonium Sulphate, Ammonium Chloride,are Ammonium Sulphate, Ammonium Chloride,

Ammonium Nitrate etc.Ammonium Nitrate etc.

With time, technologies have undergone tremendousWith time, technologies have undergone tremendous

developments resulting in reduction in capital cost anddevelopments resulting in reduction in capital cost and

energy consumption thereby leading to lower cost ofenergy consumption thereby leading to lower cost ofproduction.production.

Ammonia is the intermediate product in Urea production.Ammonia is the intermediate product in Urea production.

Efficient production of Ammonia has greatest impact onEfficient production of Ammonia has greatest impact on

Specific Energy consumption as 80% energy for UreaSpecific Energy consumption as 80% energy for Urea

production is consumed for Ammonia production.production is consumed for Ammonia production.


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Development in Ammonia TechnologyDevelopment in Ammonia Technology

First commercial production : 1913 in Germany.

plant size was 25 to 30 tpd

cost of production was very high.

Successive improvements inammonia production lowered the

cost of production resulting in

liberal use of fertiliser in crop

production.

In 1960s, use of centrifugalcompressors made possible

large single train ammonia

plants of 1000 or even 1500 tpd

capacity.

Development of special alloys reducedthe size and weight of equipment and

enhanced the capacity of plant

Ammonia technology

Present level is around

7.0 Gcal/tonne of Ammonia and capacity

increased to 2000 TPD.

Innovation in Technology

for further improvement


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Development in Ammonia TechnologyDevelopment in Ammonia Technology

By incorporating the latest technology energy requirement for AmBy incorporating the latest technology energy requirement for Ammoniamoniaplants has reduced to 7plants has reduced to 7 GCalGCal// tonnetonne from earlier 10 GCal/tonne.from earlier 10 GCal/tonne.

Further improvement is possible as the theoretical energy requirFurther improvement is possible as the theoretical energy requirement isement is4.5 GCal/tonne of Ammonia.4.5 GCal/tonne of Ammonia.

Reduction in specific energy consumption in Ammonia Plants

6

7

8

9

10

11

1960 1970 1980 1990 2000

GCalperTonneofAmmonia


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TechnologyTechnology

Various available Technologies for Ammonia are asVarious available Technologies for Ammonia are as

below:below:

Haldor Topsoe (HTAS)Haldor Topsoe (HTAS)

Kellogg Brown Root (KBR)Kellogg Brown Root (KBR)

ICIICI

CF BraunCF Braun

UhdeUhde


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TechnologyTechnology

The thrust area for future process technologies are:The thrust area for future process technologies are:

Low specific energy consumptionLow specific energy consumption

Innovative, yet proven technologyInnovative, yet proven technology

Superior economic performanceSuperior economic performance Reducing the emission of Green House GasesReducing the emission of Green House Gases

(GHG)(GHG)

Looking for various cost effective feed stocksLooking for various cost effective feed stocks


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Challenges being faced by Fertiliser industryChallenges being faced by Fertiliser industry

Major challenges are:Major challenges are:

Availability of Feed StockAvailability of Feed Stock

Reduction in Specific Energy ConsumptionReduction in Specific Energy Consumption

Innovations in TechnologyInnovations in Technology


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Availability of Feed StockAvailability of Feed Stock

For efficient production of Fertiliser, availability ofFor efficient production of Fertiliser, availability of

feed stock and its prices are most important.feed stock and its prices are most important. Natural Gas is preferred feed stock as it is clean andNatural Gas is preferred feed stock as it is clean and

efficient as compared to liquid fuels.efficient as compared to liquid fuels.

More than 70% of World production of Urea is basedMore than 70% of World production of Urea is based

on Natural Gas.on Natural Gas.

In India about 67% Urea capacity is based on NaturalIn India about 67% Urea capacity is based on Natural

Gas and balance 33% on Naphtha & Fuel Oil.Gas and balance 33% on Naphtha & Fuel Oil.


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Feed StockFeed Stock World ReserveWorld Reserve

World Oil reserves at present estimated to be 3World Oil reserves at present estimated to be 3

trillion barrels and expected to last for 40 yearstrillion barrels and expected to last for 40 years

with the reserve to current production rate.with the reserve to current production rate.

No major discoveries of oil in last few years.No major discoveries of oil in last few years.

Total reserves of Natural Gas in the world areTotal reserves of Natural Gas in the world areabout 6040 TCF. With the reserve to presentabout 6040 TCF. With the reserve to present

production rate the reserves will last up to 70production rate the reserves will last up to 70

years.years.


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Feed Stock : IndiaFeed Stock : India

In India, the total proven Natural Gas reserves areIn India, the total proven Natural Gas reserves are

26 TCF and with present production rate Gas26 TCF and with present production rate Gas

reserves will last up to 27 years.reserves will last up to 27 years.

New explorations by M/s GSPCL, M/s Reliance &New explorations by M/s GSPCL, M/s Reliance &

ONGC in KG basin are adding to its reserves.ONGC in KG basin are adding to its reserves. At present, the supply of Natural Gas is around 75At present, the supply of Natural Gas is around 75

MMSCMD to various industries.MMSCMD to various industries.

Present allocation of Natural Gas to FertiliserPresent allocation of Natural Gas to Fertiliser

Industry is around 29 MMSCMD against demandIndustry is around 29 MMSCMD against demand

of 33 MMSCMD.of 33 MMSCMD.


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Feed Stock : India .Feed Stock : India .

Sector wise split of Natural Gas Demand in India

Power, 43%

Fertiliser, 33%

Domestic Fuel, 3%

Industrial Fuel,

11%

Others, 10%


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Fertiliser industry needs around 35 MMSCMDFertiliser industry needs around 35 MMSCMD

additional Natural Gas for following purposes:additional Natural Gas for following purposes:

To meet the shortfall of Natural Gas in Gas basedTo meet the shortfall of Natural Gas in Gas basedplantsplants

To convert the Naphtha/FO/LSHS based plants toTo convert the Naphtha/FO/LSHS based plants to

Gas basedGas based

Additional requirement for proposed expansionsAdditional requirement for proposed expansions

Additional requirement may be met either byAdditional requirement may be met either byimporting LNG or sourcing gas from recent Gasimporting LNG or sourcing gas from recent Gas

discoveries.discoveries.


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Major discovery in Krishna Godavari (KG) basin inMajor discovery in Krishna Godavari (KG) basin in

Bay of Bengal is expected to produce around 80Bay of Bengal is expected to produce around 80

MMSCMD Gas from 2008 onwards.MMSCMD Gas from 2008 onwards. Demand supply gap of Natural Gas induces the searchDemand supply gap of Natural Gas induces the search

for different alternative feedstock for production offor different alternative feedstock for production of

Urea.Urea.

Some of the alternative feedstock are :Some of the alternative feedstock are :

Coal bed MethaneCoal bed Methane

Coal Gasification : Above ground & UndergroundCoal Gasification : Above ground & Underground

Gas HydratesGas Hydrates


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AlternativeAlternative FeedstocksFeedstocks

Coal Bed Methane (CBM):Coal Bed Methane (CBM):

A gas similar to natural gas with 90% methane whichA gas similar to natural gas with 90% methane whichis trapped inside Coal Bed and is an ecois trapped inside Coal Bed and is an eco--friendlyfriendly

source of energy.source of energy.

In India approximately 850 BCM of CBM GasIn India approximately 850 BCM of CBM Gas

reserves are estimated.reserves are estimated.

In the coming years, around 21 MMSCMD gas isIn the coming years, around 21 MMSCMD gas isexpected to be produced through CBM with anexpected to be produced through CBM with an

approximate cost of 5.5 US$ / MMBTU.approximate cost of 5.5 US$ / MMBTU.



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Coal Gasification : Above ground / UndergroundCoal Gasification : Above ground / Underground

Coal gasification is a viable option for Urea production withCoal gasification is a viable option for Urea production withdelivered coal price of 2.5 US$/MMBTU.delivered coal price of 2.5 US$/MMBTU.

Underground Coal gasification (UCG) is inUnderground Coal gasification (UCG) is in--situ gasification ofsitu gasification of

coal in the seam.coal in the seam. It is achieved by injecting oxidants, gasifying the coal andIt is achieved by injecting oxidants, gasifying the coal and

bringing the product gas to the surface through boreholes drillebringing the product gas to the surface through boreholes drilledd

from surface.from surface. India has large reserve of coal and lignite at unIndia has large reserve of coal and lignite at un--mineable depthmineable depth

which can be tapped through UCG.which can be tapped through UCG.

The lignite reserve atThe lignite reserve at MehsanaMehsana--AhmedabadAhmedabad block in Gujaratblock in Gujaratalone contain recoverable gas reserve of 15,000 Billion cubicalone contain recoverable gas reserve of 15,000 Billion cubicmeter equivalent of natural gas utilizing UCG.meter equivalent of natural gas utilizing UCG.

ONGC and GAIL are exploring the possibility of exploiting coalONGC and GAIL are exploring the possibility of exploiting coal

gas by UCG technology.gas by UCG technology.


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Reduction in Specific Energy ConsumptionReduction in Specific Energy Consumption

In India, huge quantity of Oil and Gas need to be importedIn India, huge quantity of Oil and Gas need to be importedto meet its energy requirement.to meet its energy requirement.

Limited availability of feed/fuel make the prices muchLimited availability of feed/fuel make the prices muchhigher.higher.

For Indian Fertiliser Industry, it is imperative to reduceFor Indian Fertiliser Industry, it is imperative to reducespecific energy consumption to remain competitive.specific energy consumption to remain competitive.

New technologies are incorporated from time to time toNew technologies are incorporated from time to time tomodify the existing plants to improve energy efficiency.modify the existing plants to improve energy efficiency.

For example, IFFCO Kalol was commissioned in 1975 withFor example, IFFCO Kalol was commissioned in 1975 witha design energy consumption of 10.2a design energy consumption of 10.2 GCalGCal, still operating, still operatingcontinuously after 31 years of commissioning at more thancontinuously after 31 years of commissioning at more than100% capacity100% capacity utilisationutilisation with a reduced energy level of 8.2with a reduced energy level of 8.2

GCalGCalperpertonnetonne..


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Specific EnergySpecific Energy

IFFCO always endeavored to implement latest energyIFFCO always endeavored to implement latest energysaving schemes in its plants.saving schemes in its plants.

IFFCO plants are among the most efficient plants in IndiaIFFCO plants are among the most efficient plants in India

and even in the worldand even in the world Major Energy Saving Schemes implemented by IFFCO areMajor Energy Saving Schemes implemented by IFFCO are

as below:as below:

Revamping of existing CO2 removal system with two stageRevamping of existing CO2 removal system with two stageaMDEA process which resulted in reduction of CO2 slip toaMDEA process which resulted in reduction of CO2 slip to10~50ppm from earlier level of 60010~50ppm from earlier level of 600700 ppm and energy saving700 ppm and energy savingto the tune of 0.21to the tune of 0.21 GCalGCal/MT./MT.

Process Condensate Stripper using MP process steam whichProcess Condensate Stripper using MP process steam whicheliminate emission to the atmosphere complementary with addedeliminate emission to the atmosphere complementary with addedbenefit of process water, CO2 and Ammonia recovery.benefit of process water, CO2 and Ammonia recovery.

Installation of Process Steam Super heater.Installation of Process Steam Super heater.


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Specific EnergySpecific Energy

Introduction of PreIntroduction of Pre--reformerreformer

High efficiency turbines for all critical drivesHigh efficiency turbines for all critical drives High efficiency catalystHigh efficiency catalyst

Accelerated start up techniquesAccelerated start up techniques

Introduction of Distributed Control SystemIntroduction of Distributed Control System

Addition of SAddition of S--50 Converter which has resulted in50 Converter which has resulted in

energy saving to the tune of 0.13energy saving to the tune of 0.13 GCalGCal/MT of/MT ofAmmoniaAmmonia


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Energy Consumption Trend in Ammonia Plants of IFFCOEnergy Consumption Trend in Ammonia Plants of IFFCO

8

8.2

8.4

8.6

8.8

9

2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07

(Targetted)

GCal/M

TAmmonia


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Innovations in Existing Ammonia PlantsInnovations in Existing Ammonia Plants

With the advancement of technology, presentWith the advancement of technology, present

Specific Energy Consumption in modern AmmoniaSpecific Energy Consumption in modern Ammoniaplant came down to 7.0plant came down to 7.0 GCalGCal perper tonnetonne ofof

Ammonia.Ammonia.

Further research being carried out to reduce energyFurther research being carried out to reduce energy

and with the implementation of new improvements,and with the implementation of new improvements,

the energy is expected to reduce up to 6.5the energy is expected to reduce up to 6.5 GCalGCalperpertonnetonne of Ammonia.of Ammonia.

I i i i i l


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Innovations in existing plantsInnovations in existing plants

Some of the improvement on which work is in advanced stage areSome of the improvement on which work is in advanced stage areas below:as below:

Advanced Instrumentation, Computation and ControlAdvanced Instrumentation, Computation and Control

ModernisationModernisation of Primary Reformer either as a auto thermalof Primary Reformer either as a auto thermalreactor or as heat exchanger by using heat of secondaryreactor or as heat exchanger by using heat of secondaryreformer which will eliminate CO2 emission caused by fuelreformer which will eliminate CO2 emission caused by fuelfiring..firing..

New and advanced catalyst in low pressure converterNew and advanced catalyst in low pressure converter

Flame less oxidation (FLOX) type burners with lower NOxFlame less oxidation (FLOX) type burners with lower NOxemission.emission.

Special Oxide Dispersion Stabilized (ODS) alloys withSpecial Oxide Dispersion Stabilized (ODS) alloys withhigher creep resistance as Primary Reformer Tube material.higher creep resistance as Primary Reformer Tube material.

Fuel cells as a source of electrical energy replacing theFuel cells as a source of electrical energy replacing the

captive power plant of Ammonia/Urea complex.captive power plant of Ammonia/Urea complex.


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Innovations in Conventional Technologies of AmmoniaInnovations in Conventional Technologies of Ammonia

At present, reducing the cost of plant by increasingAt present, reducing the cost of plant by increasing

the plant capacity is the major thrust in Conventionalthe plant capacity is the major thrust in ConventionalAmmonia process.Ammonia process.

To overcome the constraints in increasing the plantTo overcome the constraints in increasing the plant

capacity beyond 2000 metric tons per day followingcapacity beyond 2000 metric tons per day followingdevelopment in Technology made.development in Technology made.

Uhdes Dual Pressure Ammonia TechnologyUhdes Dual Pressure Ammonia Technology MEGAMMONIAMEGAMMONIA


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Uhdes Dual Pressure Ammonia TechnologyUhdes Dual Pressure Ammonia Technology

Main featureMain feature::

Introduction of once through synthesis reactor at an intermediatIntroduction of once through synthesis reactor at an intermediatee

pressure level in synthesis gas loop makes synthesis andpressure level in synthesis gas loop makes synthesis and

separation of Ammonia possible in between compressor casing.separation of Ammonia possible in between compressor casing.

Brief Process DetailBrief Process Detail::

The frontThe front--end process not to be modified.end process not to be modified.

Make up gas from front end is compressed in the low pressureMake up gas from front end is compressed in the low pressure

(LP) casing of the syngas compressor at a discharge pressure of(LP) casing of the syngas compressor at a discharge pressure of

110 bar and then passes through the newly developed three bed,110 bar and then passes through the newly developed three bed,interinter--cooled, oncecooled, once--through converter which will produce onethrough converter which will produce one

third of total ammonia. Effluent from this converter is cooledthird of total ammonia. Effluent from this converter is cooled

and 85% of ammonia produced is separated from gas.and 85% of ammonia produced is separated from gas.


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Brief Process DetailBrief Process Detail

Highly active well proven KATALCO 74Highly active well proven KATALCO 74--1 (Iron based)1 (Iron based)

catalyst is used in once through converter which iscatalyst is used in once through converter which isspecifically developed for lowspecifically developed for low--pressure synthesis.pressure synthesis.

In the next step, the remaining syngas is compressed to theIn the next step, the remaining syngas is compressed to the

operating pressure of the synthesis loop (up to 210 bar) in theoperating pressure of the synthesis loop (up to 210 bar) in thesyngas compressors highsyngas compressors high--pressure (HP) casing andpressure (HP) casing andammonia is then produced following conventional processammonia is then produced following conventional processsteps.steps.

There are no major deviations from established processThere are no major deviations from established processconditions.conditions.


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BenefitsBenefits::

Significant reduction of synthesis gas volume flow in highSignificant reduction of synthesis gas volume flow in high

pressure loop.pressure loop. Hydrogen yield is superiorHydrogen yield is superior

Significant increase in plant capacity (+65%)Significant increase in plant capacity (+65%)

Energy consumption decreased by 4%Energy consumption decreased by 4% A 3300 mtpd plant can be built with no critical equipmentA 3300 mtpd plant can be built with no critical equipment

exceeding the sizes of a current 2000 mtpd plantexceeding the sizes of a current 2000 mtpd plant

Uhdes 3300 MTPD Ammonia Plant based on Dual PressureUhdes 3300 MTPD Ammonia Plant based on Dual PressureTechnology has been commissioned for SAFCO in SaudiTechnology has been commissioned for SAFCO in SaudiArabia.Arabia.

Considerable reduction in cost of production of AmmoniaConsiderable reduction in cost of production of Ammonia

MEGAMMONIAMEGAMMONIA


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Designed jointly by M/s Lurgi and M/s Ammonia Casale for largeDesigned jointly by M/s Lurgi and M/s Ammonia Casale for largescale production capacity of 4000 MTPD Ammoniascale production capacity of 4000 MTPD Ammonia

Brief Process Detail:Brief Process Detail:

Ammonia is produced by using natural gas, steam and air asAmmonia is produced by using natural gas, steam and air asfeedstock following five principal steps as below:feedstock following five principal steps as below:

i.i. Air separation: 95% oxygen and 99.99% pure nitrogen isAir separation: 95% oxygen and 99.99% pure nitrogen isproduced from air.produced from air.

ii.ii. Catalytic Partial Oxidation :Catalytic Partial Oxidation : DesulphurisedDesulphurised natural gas, afternatural gas, afteraddition of steam is first preheated in a fired heater and thenaddition of steam is first preheated in a fired heater and thenreformed over a Nickel oxide catalyst to CO, H2 and CO2reformed over a Nickel oxide catalyst to CO, H2 and CO2following partial oxidation.following partial oxidation.

iii.iii. COCO--Shift: Reformed gas is passed through two beds ofShift: Reformed gas is passed through two beds ofconventional HT shift catalyst (Copper promoted Iron /conventional HT shift catalyst (Copper promoted Iron / chromiachromiabased) in series to convert remaining CO to H2 and CO2.based) in series to convert remaining CO to H2 and CO2.



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Process detailsProcess detailsiv.iv. Gas Purification: CO2 is removed by absorption in coldGas Purification: CO2 is removed by absorption in cold

methanol and other impurities like CO, CH4 and Ar aremethanol and other impurities like CO, CH4 and Ar are

removed by washing the gas with liquid nitrogen.removed by washing the gas with liquid nitrogen.v.v. Ammonia Synthesis: The extremely high purity of ammoniaAmmonia Synthesis: The extremely high purity of ammonia

synthesis gas results in higher conversion of gas per pass,synthesis gas results in higher conversion of gas per pass,lower circulator duty and lower refrigeration duty.lower circulator duty and lower refrigeration duty.

BenefitsBenefits::

Reduce the capital cost by approx. 18Reduce the capital cost by approx. 18--20%20%

Operating cost is expected to be lower around 12Operating cost is expected to be lower around 12--15% over15% overthe most advanced conventional technology.the most advanced conventional technology.

CO2 emission is expected to reduce by around 30% asCO2 emission is expected to reduce by around 30% as

compared to other conventional technologies.compared to other conventional technologies.

I i i U i l T h l iI i i U i l T h l i


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Innovations in Unconventional TechnologiesInnovations in Unconventional Technologies

in Ammonia productionin Ammonia production A lot of research is being carried out to develop newA lot of research is being carried out to develop new

unconventional technologies for the production ofunconventional technologies for the production of

Ammonia with the main focus as below:Ammonia with the main focus as below:

Development of environment friendly, efficient andDevelopment of environment friendly, efficient and

economical production of Ammonia.economical production of Ammonia.

Development of technologies for using renewableDevelopment of technologies for using renewable

sources of energy like biosources of energy like bio--mass, solar energy etc.mass, solar energy etc.

Innovations in Unconventional Technologies inInnovations in Unconventional Technologies in


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Innovations in Unconventional Technologies inovat o s U co ve t o a ec o og es

Ammonia productionAmmonia production

HydroMax TechnologyHydroMax Technology

AlchemixAlchemix Corporation, USA has developed the HydroMaxCorporation, USA has developed the HydroMaxTechnology for hydrogen production.Technology for hydrogen production.

Hydrogen is produced at very low cost utilizing Steam andHydrogen is produced at very low cost utilizing Steam andcarbon from cheaper/inexpensive sources like coal, municipalcarbon from cheaper/inexpensive sources like coal, municipalwaste, biomass and petroleum coke etc. in presence of metalwaste, biomass and petroleum coke etc. in presence of metal

like Iron.like Iron. In the first step, steam reacts with molten iron to form ironIn the first step, steam reacts with molten iron to form iron

oxide and hydrogen and in second step, iron oxide is reducedoxide and hydrogen and in second step, iron oxide is reducedback to pure metal by adding carbon. Iron simply act as aback to pure metal by adding carbon. Iron simply act as acarrier for oxygen.carrier for oxygen.

Both process steps, hydrogen production and reduction of ironBoth process steps, hydrogen production and reduction of ironoxide back into iron, occur in the same reactor at the sameoxide back into iron, occur in the same reactor at the same

temperature of 1250temperature of 1250C.C.

Innovations in UnconventionalInnovations in Unconventional


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ovat o s U co ve t o a

Technologies in Ammonia productionTechnologies in Ammonia production

HydroMax TechnologyHydroMax Technology

CarbonCarbon--didi--oxide and Hydrogen are produced in separateoxide and Hydrogen are produced in separatecompartments and do not require CO2 removal systemcompartments and do not require CO2 removal system

Cost of production is almost four times less than SteamCost of production is almost four times less than SteamMethane Reforming (SMR) production cost.Methane Reforming (SMR) production cost.

Emission of green house gases is 34% less than SMREmission of green house gases is 34% less than SMRprocess.process.

Clean and economic way to become energy independentClean and economic way to become energy independentfor coal rich, oil poor nations like India.for coal rich, oil poor nations like India.

Demonstration of the novel aspect of HydroMaxDemonstration of the novel aspect of HydroMaxtechnology has been successfully conducted by M/stechnology has been successfully conducted by M/sAlchemixAlchemix, USA. They are in the process of building the 1, USA. They are in the process of building the 1stst

commercial HydroMax facility.commercial HydroMax facility.

I i i T h l iI ti i T h l i


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Innovations in Technologies Innovations in Technologies

Biomass Pyrolysis / GasificationBiomass Pyrolysis / Gasification

Biomass like agricultural products including hardwood,Biomass like agricultural products including hardwood,

softwood and other plant specifies may be used to producesoftwood and other plant specifies may be used to producehydrogen either by direct gasification or by pyrolysis tohydrogen either by direct gasification or by pyrolysis toproduce liquid bioproduce liquid bio--oil for reformingoil for reforming

Direct biomass gasification takes place in three steps i.e.Direct biomass gasification takes place in three steps i.e.gasification, shift reaction and purification similar to coalgasification, shift reaction and purification similar to coalgasification.gasification.

In the gasification step, biomass is treated with steam inIn the gasification step, biomass is treated with steam inoxygenoxygen--blown or air blown gasifier to produce hydrocarbonblown or air blown gasifier to produce hydrocarbongases, hydrogen, CO, CO2, tar and water vapor followed bygases, hydrogen, CO, CO2, tar and water vapor followed byshift reaction and purification to produce CO2 & H2.shift reaction and purification to produce CO2 & H2.

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Biomass Pyrolysis / GasificationBiomass Pyrolysis / Gasification

In case of Biomass Pyrolysis, biomass first thermallyIn case of Biomass Pyrolysis, biomass first thermallydecomposed to liquid biodecomposed to liquid bio--oil at a temperature 450oil at a temperature 450--550550CC

called pyrolysis which is then steam reformed using a nickelcalled pyrolysis which is then steam reformed using a nickel--based catalyst at a temperature 750based catalyst at a temperature 750--850850C followed by shiftC followed by shiftreaction to convert CO to CO2.reaction to convert CO to CO2.

Biomass + energyBiomass + energy BioBio--oil + Char + Gas Impurities (Pyrolysis)oil + Char + Gas Impurities (Pyrolysis)

BioBio--oil+ Hoil+ H22OO CO + HCO + H22 (Reforming)(Reforming)

CO + HCO + H22OO COCO22 + H+ H22 (Shift reaction)(Shift reaction)

Needs improvement in bioNeeds improvement in bio--mass feed preparation, reactormass feed preparation, reactordesign. Work is under progress to design efficient fluidizeddesign. Work is under progress to design efficient fluidizedand poison tolerant catalyst.and poison tolerant catalyst.

Several pilot plant projects has proven the technology and itsSeveral pilot plant projects has proven the technology and its

commercial viability is being studied.commercial viability is being studied.

Innovations in TechnologiesInnovations in Technologies


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Aqueous Phase Reforming (APR)Aqueous Phase Reforming (APR)

Produce hydrogen from renewable bioProduce hydrogen from renewable bio--mass derived feedmass derived feed

stock like glycerol, sugars and sugar alcohols in place of fossistock like glycerol, sugars and sugar alcohols in place of fossill

fuels for ammonia production.fuels for ammonia production.

Reforming is done in liquid phase which generates hydrogenReforming is done in liquid phase which generates hydrogen

without volatilizing water.without volatilizing water.

Aqueous solutions containing 10wt% glucose is converted toAqueous solutions containing 10wt% glucose is converted to

H2 and CO2 in a reforming reactor in presence of Pt & PdH2 and CO2 in a reforming reactor in presence of Pt & Pd

bimetallic catalyst at around 220bimetallic catalyst at around 220CC..

Occurs at pressure typically 15 to 60 bar where the hydrogenOccurs at pressure typically 15 to 60 bar where the hydrogen--

rich effluent can be effectively purified using either pressurerich effluent can be effectively purified using either pressure

swingswing absoptionabsoption or membrane technologies.or membrane technologies.

Innovations in TechnologiesInnovations in Technologies


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Advantages of APR over conventional reformingAdvantages of APR over conventional reforming APR is compatible with wet or water soluble feedstockAPR is compatible with wet or water soluble feedstock

Improved capability to reform withoutImproved capability to reform without concominantconcominant reactantreactant

decomposition and carbon formation.decomposition and carbon formation.

Significant lower operating temperatures (220Significant lower operating temperatures (220CC vsvs 800800C)C)

enabling easier assimilation into heat sensitive.enabling easier assimilation into heat sensitive.

Generate 10 times more hydrogen per gram of catalyst thanGenerate 10 times more hydrogen per gram of catalyst than

steam reforming processsteam reforming process

Low CO byproduct due to facilitated water gas shift.Low CO byproduct due to facilitated water gas shift.

VirentVirent Energy Systems, USA has got exclusive right to the APREnergy Systems, USA has got exclusive right to the APR

process.process.

US Department of Energy has taken up laboratory scale project.US Department of Energy has taken up laboratory scale project.

A i i


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Alternative technologies to source hydrogenAlternative technologies to source hydrogen

Hydrogen is the major constituent in theHydrogen is the major constituent in the

production of Ammonia.production of Ammonia.

Present source of hydrogen is reforming of fossilPresent source of hydrogen is reforming of fossil

fuels.fuels.

Research is being carried out for production ofResearch is being carried out for production ofhydrogen from alternative sources which are inhydrogen from alternative sources which are in

different stages of development.different stages of development.

This will reduce dependence on non renewableThis will reduce dependence on non renewableenergy sources and will provide cleanerenergy sources and will provide cleaner

environment.environment.



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Alternative technologies to source hydrogen...Alternative technologies to source hydrogen...

Use of Hydrogen

60%

24%

16%

0% 40% 80%

Ammonia

production

Refining anddesulphurization

of oil

Methanol

production andhydrogenation of

fats



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Some of the alternative technologies under research to sourceSome of the alternative technologies under research to sourcehydrogen are as below:hydrogen are as below:

High Temperature ElectrolysisHigh Temperature Electrolysis

Electrolysis takes place at high temperature to break theElectrolysis takes place at high temperature to break thewater molecule using electricity for hydrogen productionwater molecule using electricity for hydrogen production

Economical and energy efficient than normal electrolysis atEconomical and energy efficient than normal electrolysis at

room temperatureroom temperature

Cost of production reduces considerably as the energyCost of production reduces considerably as the energy

required to break the water molecules decreases with rise inrequired to break the water molecules decreases with rise in

temperature.temperature.

For large unit with centralized facility cost of production mayFor large unit with centralized facility cost of production may

be comparable with conventional technologiesbe comparable with conventional technologies

This process is highly dependant on electricity cost.This process is highly dependant on electricity cost.



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Through SulphurThrough Sulphur Iodine CycleIodine Cycle Based on ThermoBased on Thermo--Chemical reactions and require onlyChemical reactions and require only

external heat source to operate.external heat source to operate.

In the first step, Iodine and sulphur diIn the first step, Iodine and sulphur di--oxide react in wateroxide react in waterto form hydrogen iodine and sulphuric acid which areto form hydrogen iodine and sulphuric acid which areimmiscible under the process condition and readilyimmiscible under the process condition and readilyseparated.separated.

Sulphuric acid is decomposed at about 850Sulphuric acid is decomposed at about 850C releasingC releasingoxygen and recycling sulphuroxygen and recycling sulphur--didi--oxide whereas hydrogenoxide whereas hydrogeniodide is decomposed at about 350iodide is decomposed at about 350C releasing hydrogenC releasing hydrogenand recycling iodine.and recycling iodine.

Literally no effluent process as all reagents are recyclingLiterally no effluent process as all reagents are recycling

Approximate cost of hydrogen will be around 1.8 to 2.0Approximate cost of hydrogen will be around 1.8 to 2.0US$ per Kg of hydrogen which is almost comparable withUS$ per Kg of hydrogen which is almost comparable with

cost of hydrogen produced by steam reforming of NG.cost of hydrogen produced by steam reforming of NG.



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Hydrogen from Solar EnergyHydrogen from Solar Energy

Special titanium oxide ceramics can harvest sunlightSpecial titanium oxide ceramics can harvest sunlightand split water to produce hydrogen fuel. This is inand split water to produce hydrogen fuel. This is in

early stage of research and efforts are needed to makeearly stage of research and efforts are needed to makethe process economically viable.the process economically viable.

Photosynthesis mechanism of plant based onPhotosynthesis mechanism of plant based on

Manganese atom to break water into hydrogen andManganese atom to break water into hydrogen andoxygen using sunlight is recently discovered byoxygen using sunlight is recently discovered byBritish Scientists.British Scientists.

Hydrogen may be produced with the help of certainHydrogen may be produced with the help of certaintype of green Algae using solar energy. Refinements totype of green Algae using solar energy. Refinements tothe bio reactor design and genetically altering Algaethe bio reactor design and genetically altering Algaecould make this technology viable.could make this technology viable.



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Hydrogen from Nuclear EnergyHydrogen from Nuclear Energy

Nuclear energy has the potential to efficientlyNuclear energy has the potential to efficiently

produce large quantities of hydrogen withoutproduce large quantities of hydrogen without

producing greenhouse gases.producing greenhouse gases.

Initiative to demonstrate the economic, commercialInitiative to demonstrate the economic, commercial--

scale production is being taken.scale production is being taken.

Nuclear energy can be utilized for the production ofNuclear energy can be utilized for the production of

hydrogen through Sulphurhydrogen through Sulphur--Iodine, High TemperatureIodine, High TemperatureElectrolysis of water, Thermo Chemical waterElectrolysis of water, Thermo Chemical water

splitting etc.splitting etc.

Various Innovation in Urea TechnologyVarious Innovation in Urea Technology


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Various Innovation in Urea TechnologyVarious Innovation in Urea Technology

Snamprogetti Urea TechnologySnamprogetti Urea Technology

Fertiliser plants based on Snamprogetti Urea TechnologyFertiliser plants based on Snamprogetti Urea Technology

came into operation in India in early eighties and carriedcame into operation in India in early eighties and carriedout various innovations with time to reduce energy forout various innovations with time to reduce energy forUrea production.Urea production.

The various innovations in Snamprogetti Urea TechnologyThe various innovations in Snamprogetti Urea Technologyimplemented in various fertiliser industries in Indian subimplemented in various fertiliser industries in Indian sub--continent are as under:continent are as under:

Installation of PreInstallation of Pre--concentratorconcentrator

Installation of PreInstallation of Pre--decomposerdecomposer

Energy saving expected with above modifications is 0.09Energy saving expected with above modifications is 0.09GCalGCalper MT of Urea.per MT of Urea.

Innovation in Urea TechnologyInnovation in Urea Technology


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ACES 21 Urea TechnologyACES 21 Urea Technology

Toyo Engineering Corporation (TEC) has developed theirToyo Engineering Corporation (TEC) has developed their

latest Urea synthesis technology, ACES 21, jointly with PTlatest Urea synthesis technology, ACES 21, jointly with PT

PupukPupukSriwidjajaSriwidjaja, Indonesia., Indonesia.

ACES 21 adopts two stage synthesis concept comprised byACES 21 adopts two stage synthesis concept comprised by

A Vertical Submerged Carbamate Condenser (VSCC)A Vertical Submerged Carbamate Condenser (VSCC)functioning as carbamate condenser, HP scrubber andfunctioning as carbamate condenser, HP scrubber and

primary urea reactorprimary urea reactor

A Vertical reactor, installed at ground level, to completeA Vertical reactor, installed at ground level, to completereaction from carbamate to Urea as secondary reactorreaction from carbamate to Urea as secondary reactor

A vertical falling film type stripper to decompose andA vertical falling film type stripper to decompose andseparate unreacted carbamate and excess ammonia by CO2separate unreacted carbamate and excess ammonia by CO2strippingstripping

A HP ejector to supply driving force for HP loop circulation.A HP ejector to supply driving force for HP loop circulation.



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ACES 21 Urea TechnologyACES 21 Urea Technology

AdvantagesAdvantages

Less HP piping and construction materials owing to lowerLess HP piping and construction materials owing to lowerelevation layout, fewer and smaller HP vessels.elevation layout, fewer and smaller HP vessels.

Easier operation and maintenanceEasier operation and maintenance

Reduction of heat transfer area due to Vertical submergedReduction of heat transfer area due to Vertical submergedconfiguration of Carbamate Condenser.configuration of Carbamate Condenser.

Higher CO2 conversion of 63%Higher CO2 conversion of 63% Optimizing N/C ratios at different levels for the VSCC (N/C 2.9)Optimizing N/C ratios at different levels for the VSCC (N/C 2.9)

and Reactor (N/C 3.7) at lower synthesis pressure i.e.and Reactor (N/C 3.7) at lower synthesis pressure i.e. 155155

Kg/cm2g resulting in lKg/cm2g resulting in less energy consumption (10% or more).ess energy consumption (10% or more). Based on ACES 21 Technology P.T. PupukBased on ACES 21 Technology P.T. Pupuk KujangKujang Plant inPlant in

Indonesia and Sichuan Chemical Works Ltd., China gotIndonesia and Sichuan Chemical Works Ltd., China gotcommissioned successfully in 2005.commissioned successfully in 2005.



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Stamicarbon MEGA Urea PlantStamicarbon MEGA Urea Plant Stamicarbon, the leading Urea process licensor, now ready toStamicarbon, the leading Urea process licensor, now ready to

offer their latest developed Mammoth single train Urea plantoffer their latest developed Mammoth single train Urea plant

up to a plant capacity 4500 TPD.up to a plant capacity 4500 TPD. The technology is based on Pool reactor/Condenser.The technology is based on Pool reactor/Condenser.

Plant is equipped with medium pressure recycle stage withoutPlant is equipped with medium pressure recycle stage without

a separate Ammonia loop with the advantage of low watera separate Ammonia loop with the advantage of low waterconcentration in recycle carbamate resulting in highconcentration in recycle carbamate resulting in highconversion and lower steam consumption.conversion and lower steam consumption.

Investment cost involved for MEGA capacity concept is 70Investment cost involved for MEGA capacity concept is 70--75% as compared with standard 2000 TPD Urea Plant.75% as compared with standard 2000 TPD Urea Plant.

High pressure steam consumption is considerably less inHigh pressure steam consumption is considerably less inMEGA Urea plants.MEGA Urea plants.

ConclusionConclusion


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ConclusionConclusion

With the improvement in technology, the specific energyWith the improvement in technology, the specific energy

consumption visconsumption vis----vis cost of production has reducedvis cost of production has reduced

considerably over last two decade.considerably over last two decade. Although, the conventional technologies are beingAlthough, the conventional technologies are being

improved continuously, but thrust should be given forimproved continuously, but thrust should be given for

improvement of unconventional technologies whichimprovement of unconventional technologies whichpromises use of renewable sources of energy and arepromises use of renewable sources of energy and are

environment friendly.environment friendly.

To improve these technologies, industry and educationalTo improve these technologies, industry and educational

institutions should join hands for the brighter future.institutions should join hands for the brighter future.


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