Reduction in copper consumption in ammonia synthesis

Total ammonia is 8.90 mol/L, and total acidity is 2.45 mol/L

Is the regeneration temperature too high? Some companies now use waste heat from synthesis to heat copper melt.

An increased circulation rate of the copper pump also leads to higher copper consumption, acid consumption, and steam consumption. Are the harmful gases entering the tower too high?

1. The H2S content in the production section affects copper consumption； 2. Using hot soft water from the synthesis or transformation units as a heat source can reduce steam consumption ； 3. Control the regeneration temperature and regeneration time to avoid heating losses of ammonia and acid.

Effectively reduce the content of imported hydrogen sulfide; control the level of imported CO/CO2. By modifying the hot water circulation, the hot water available at the synthesis unit or in the shift unit is sufficient to meet the production requirements, eliminating the need for steam

The composition of the copper melt in the original post is all normal. Reducing ammonia and acid consumption relies on controlling the regeneration temperature; 75–78 degrees is appropriate. The reduction temperature should be between 50–60 degrees. The regeneration pressure should be 200–700 mmH2O, and the residence time of the copper melt should be 30–45 minutes. Excessive steam consumption may also be due to overly high temperatures; the hot water at over 100 degrees coming out of the shift condenser is sufficient to heat the copper melt, and it can also be reused in the shift process

Perhaps it is possible to try increasing the total ammonia level slightly and reducing the copper ratio; the high copper consumption may be due to leaks or precipitation, so it would be worth investigating that. . . . . . For heating the regenerator and preheater, it is possible to use heated water plus steam – with the heated water providing the initial heating and steam serving for further heating; this might help reduce steam consumption

The consumption of refining is determined by the following factors: 1. Regeneration temperature； 2 Amount of recovered regenerated water ； 3. Consumption resulting from the composition of the gases. 1. By lowering the regeneration temperature while ensuring effective absorption by the copper melt, it is possible to reduce the consumption of acid and ammonia; the temperature can be reduced to 72–73 degrees, but it is necessary to maintain a steady flow rate of the solution to ensure stability at low levels. 2. The recovery of ammonia from the regeneration gas needs to be improved, and the recovered ammonia water should be utilized effectively. The carbonization level should be low and the concentration high, but it is important to take into account the possibility of copper ions being present in it. 3. Reducing the hydrogen sulfide content in the feed stream can help lower copper consumption. By controlling the level of CO/CO2 in the feed stream, it is possible to appropriately reduce the concentrations of acid and ammonia, provided that stability at low levels is maintained. Excessively high ammonia concentrations can increase copper consumption. 4. It is necessary to maintain stable levels of acid and ammonia addition, in order to avoid the formation of copper deposits due to high local concentrations of these substances, which would lead to increased consumption. 5. The waste heat from the shift, synthesis, and urea production units can be utilized to reduce steam consumption

1. Reducing the regeneration temperature and the CO2 content in the feed gas can lower the consumption of ammonia and acid in the copper melt (since a deficiency of acetic acid in the copper-ammonia solution leads to the formation of copper ammonium carbonate, which reduces the absorption capacity of the solution). 2. Reducing H2S in the feed gas can lower the copper consumption in the copper melt. 3. Replace the regenerative gas water tank with circulating hot water (synthetic high-pressure water can be used), control the copper ratio properly, and reduce steam consumption. 4. Eliminate leaks to prevent internal leakage in the regenerator and copper melt heaters, as well as the entry of hot water (or steam) into the copper-ammonia solution, which would dilute it and increase copper consumption.

Copper washing is still a relatively old technique; if that doesn’t work, switch to dual methanes.