What have everyone done to save energy and reduce consumption in the synthetic ammonia industry?

Our company achieves zero wastewater discharge! Hebei Zhengyuan

Jiangsu Linggu – Decarbonization rich-liquid energy recovery pump!

How can zero wastewater discharge be achieved, so that no wastewater is released at all? This post was last edited by *aoye613 on 2009-4-10 14:38.]

We also achieve zero discharge of wastewater here; in fact, it’s zero discharge of process wastewater

From a process perspective alone regarding the synthesis system: 1. Optimize the process flow of the synthesis system by locating the compressor makeup air supply at the lowest pressure point in the synthesis loop, thereby reducing the compressor backpressure and decreasing its energy consumption. 2. The copper washing tower uses structured packing to improve mass transfer efficiency, thereby reducing the volume of copper solution that needs to be circulated and lowering the power consumption of the copper pumps. 3. The synthesis system employs appropriate reactor internals and catalysts, as well as controlled operating conditions, to increase the one-pass conversion rate of the synthesis reaction, reduce system pressure, and lower energy consumption. 4. The ammonia separation internals utilize high-efficiency separation components to fully recover the separated liquid ammonia, reduce the system’s circulation volume, and alleviate the load on the circulator. 5. Reduce oil contamination of ammonia coming from the chiller, and improve the efficiency of the ammonia cooler. Reduce the freezing load.

1. Reduce the steam-to-gas ratio to the minimum, provided that the transformation process permits it. 2. By reducing the circulation rate to the minimum while ensuring that the process gas with low methane content does not exceed the specified limits, the load on the chiller can be reduced, as well as the amount of regeneration steam required. 3. The separation of synthetic ammonia was changed from before the tower to after the tower, increasing production capacity by 20%. 4. Replacing methanation with liquid nitrogen washing can reduce the emissions of vent gas. 5. For condensing turbines, it is necessary to maintain a proper vacuum level, and the inlet temperature of the compressor must be reduced to below the designated value. 6. The hydrogen-to-nitrogen ratio should be adjusted to the optimal value.

Energy conservation in the ammonia synthesis industry centers on the ammonia synthesis process itself. The quality of its operation and performance not only plays a crucial role in the utilization of the raw materials used for synthesis, that is, in the consumption of raw materials and energy during the synthesis gas production process, but the level of energy consumption associated with this process, as well as the efficiency of heat recovery from the ammonia synthesis reaction, also have a significant impact on the overall energy consumption in ammonia production.

1. Improve gas purification. 2. Where variable frequency control is available, use it whenever possible. 3. High-power equipment should preferably be powered by 6 KV or 10,000 V, with proper startup procedures.

Our company 1. Recycle and reuse wastewater； 2. Hydrogen separation by venting the air film.

The energy consumption per ton of ammonia in more advanced processes is around 29 GJ. Through years of improvements, our company has managed to reduce this figure to between 30 and 32 GJ. The specific measures taken include: 1) Reusing the waste heat from the flue gas from the first stage of the process, thereby reducing the flue gas temperature to 124°C (Yuntianhua has achieved even lower temperatures, around 100 degrees)； 2: Reform of the synthesis tower to increase the one-pass conversion rate. 3: The high-pressure liquid ammonia separation tank is equipped with efficient separation internals to reduce the circulation volume. There is also a relatively conventional approach, which involves changing the ammonia separation point from before the tower to after the tower.

1. The useful gases in the recycled synthetic purge gas are recovered using membrane separation; the non-useful gases are sent to the blowdown gas recovery system where they are used as fuel to generate steam. 2. Add an ammonia washing tower to perform water washing on the exhaust gases from the ammonia compressor, screw chillers, ammonia storage tanks, etc.; the ammonia solution is used to adjust the pH value in the circulating water, while the gas is sent to the blowout air system for recovery as fuel. 3. Avoid exhaust gas when draining the separator. 4. Operate with care, strictly control process parameters, and ensure stable production. 5. Conduct strict routine inspections; address any leaks or issues promptly to prevent the accident from escalating. 6. Optimize processes. 7. Use an appropriate catalyst. 8. Installing oil recovery equipment to recover waste oil reduces operating costs. 9. Reduce the emission of waste gases, waste water, and solid waste.

1. The circulating cooling water fans in our company, which were previously driven by motors, have now been replaced with hydraulic turbines driven by return water. 2. PSA is used to recover the CO2 emitted during low-temperature methanol washing, which helps increase urea production while reducing energy consumption per unit of product. 3. The Texaco process in the gas generation section has been optimized; the flow rate of the carbon black water cycle has been reduced, and the Venturi scrubber has been eliminated, thereby decreasing the system’s pressure drop.

Our approach to addressing the financial crisis also involves energy conservation and reduced consumption, through the following measures: 1. Enhancing the recycling of ammonia to simultaneously reduce environmental pollution; 2. Recycling the waste gases generated in gas production using blowair boilers; 3. Using briquetted coal for gas production whenever possible; 4. Using mixed coal for boiler operation