What is the minimum operating load for 150,000 tons of synthetic ammonia?
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A 15-ton synthetic ammonia production unit in our company is about to go into operation. The process involves 1.2 million tons of coal coking, chemical processing, precise desulfurization, conversion, shift reaction, PSA carbon removal, methanation, and synthesis. I am concerned that any problems with the coking unit could affect the gas supply to the synthetic ammonia unit. I would like to know what the minimum stable operating load for the synthetic ammonia unit is. Please feel free to provide your guidance; thank you very much!
It depends on the configuration of your system: how many reciprocating compressors or one centrifugal compressor there are, as well as how many ammonia synthesis units are in use. A case-by-case analysis is necessary. Generally, if the gas flow rate is less than 30%, there’s no need to keep it running; otherwise, the compressors may experience problems. It’s better to maintain the temperature and pressure and wait for the system to return to normal
In ammonia synthesis plants, the minimum operating load rate is generally 60% of the plant’s production capacity; below this level, thermal balance cannot be maintained, and electric heaters are required to supply heat. It is possible to maintain operation without shutting down the plant for short periods, but operating at such low loads for extended times is not economically viable.
The poster should clarify whether it is operating safely or economically. Operating at a load below 60% may not be economical; the decision to keep it running or shut it down should be based on your financial capabilities and settlement methods. However, co-production in coking is likely to offer better economic benefits. When it falls below 40%, unsafe operation may occur; this is neither economical nor safe, so it is recommended to stop operating.
Generally, a level of not less than 60% is required for operation; reciprocating compressors can function at 50%, but centrifugal compressors cannot.
Additionally, it is necessary to consider whether the steam generated in the process is sufficient, and whether external supply is required. Lack of steam is also a factor.