Let’s discuss the differences between the large-scale ammonia synthesis process using coal (300,000 tons or more) and smaller-scale ammonia synthesis

The company has two ammonia synthesis units; one of the older units has evolved from small-scale synthesis to medium-scale synthesis, and is now at a level close to large-scale synthesis (with an ammonia synthesis capacity of 260,000 tons per year). The synthesis tower is operated by several 1-meter tall towers working in parallel, while the compression is carried out by over 10 reciprocating compressors. A 30W ammonia synthesis plant consists of only one syngas compressor and one ammonia refrigeration machine. A synthesis tower. The cost per ton of ammonia currently differs by 400 yuan. All are coal tips.

Currently, in China, there are only 2 companies that possess both small and medium-sized facilities as well as large-scale facilities: Shandong Hualu and Guangxi Liuhua. I’m not sure which organization you are The differences between small and medium-sized units and large-scale units, as I know them, are as follows: (1) The pressure used in synthesis varies; small and medium-sized units typically operate at 30 MPa, with the lowest values around 22 MPA, while large-scale units generally operate at less than 15 MPa. Large-scale units have a significant advantage in terms of energy consumption. (2) There are also substantial differences in the process flow between large-scale and small-scale units (it’s difficult to compare them one by one here). (3) The ratio of gas components entering the synthesis tower is approximately 3:1 in large-scale towers, whereas it is only around 2.2:1 in small-scale towers, and so on

Thank you to friends 3# and 4#; it was rewarding

“The differences between small and medium-sized units and large-scale units, as I know them, are as follows: (1) The pressure used in synthesis – small and medium-sized units generally operate at 30 MPa, with the lowest values around 22 MPa; large-scale units, on the other hand, usually operate at less than 15 MPa, giving them a significant advantage in terms of energy consumption. (2) There are also major differences in terms of the process flow between large-scale and small-scale units (it’s difficult to make a detailed comparison here). (3) The ratio of gas components entering the synthesis tower – large-scale towers achieve a ratio close to the theoretical 3:1, while small-scale towers can only reach a ratio of around 2.2:1, and so on. Who can provide a comparison regarding the “process flow”? ? ? ? ? ? ?

Synthesis section: 1. For large-scale nitrogen fertilizer production, turbine-driven centrifugal compressors are typically used; the system pressure is low, and multi-stage ammonia cooling is employed. Some companies use molecular sieves to purify the feed gas and the ammonia separated from the tower. High-pressure steam is generally produced as a by-product, resulting in lower energy consumption. These facilities are equipped with efficient hydrogen recovery systems or advanced devices for the deep purification of feed gas. The catalyst has a very long lifespan ； 2. Small and medium-sized nitrogen fertilizer plants typically use reciprocating compressors; the system pressure is high, with primary ammonia cooling. Ammonia separation usually takes place before the tower, and low-to-medium pressure steam is generated as a by-product. These plants have high energy consumption and a short catalyst lifespan ； Purification section: 3. For large-scale nitrogen fertilizers, physical methods are generally used for desulfurization, the Benfield process for decarburization, and methanation for purification; in recent years, low-temperature methanol washing and liquid nitrogen washing have become quite popular ； 4. For small and medium-sized nitrogen fertilizers, oxidation is generally used for desulfurization, while the Benfield process, carbon propylene method, NHD method, or ammonia solution method is employed for decarburization; methanation, copper washing, alcohol hydrocarbonation/alcohol alkylation methods, etc., are used for purification ； Gasification section: 5. For large-scale nitrogen fertilizers, water-coal slurry gasification is used extensively ； 6. Medium and small nitrogen fertilizer plants use atmospheric-pressure fixed-bed reactors; some companies have made improvements in this regard ； Please point out any shortcomings. The differences in manufacturing processes are not the biggest; the differences in management are!

Let’s keep it going and continue the discussion! ! !

The main difference may lie in the conversion and compression sections. Continuous conversion and batch conversion ； Differences between reciprocating compressors and centrifugal compressors. Of course, there are also some differences in the process. Generally speaking, large factories have lower energy consumption than small ones. Currently, small factories take advantage of lower costs: the electricity used for compressors comes at a favorable rate, which is much cheaper compared to steam. Hehe, the discounts won’t last forever.