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SYNGAS COMPRESSOR PERFORMANCE IMPROVEMENT BY MAKEUP GAS SUCTION CHILLER INSTALLATION Karthik Kamatchi Perumal, Process Engineer, Al-Bayroni Ahmad M. Al-Mulhim, Process Engineer, Al-Bayroni
SYNGAS COMPRESSOR PERFORMANCE IMPROVEMENT BY MAKEUP GAS SUCTION CHILLER INSTALLATION
Karthik Kamatchi Perumal, Process Engineer, Al-BayroniAhmad M. Al-Mulhim, Process Engineer, Al-Bayroni
AgendaAl -Bayroni Company ProfileBackground
Energy Optimization Project –Major ModificationsSyngas Compressor without
Suction Chiller Modification Syngas Compressor with
Suction Chiller ModificationBenefits Summary
| Steering the Fertilizer Industry through Challenging Times
Al-Jubail Fertilizer Company (Albayroni) is one of the Agri-Nutrient
manufacturing affiliate of SABIC, established in 1979.
Albayroni is producer of :
Ammonia : 430,000 MTPA
Urea : 600,000 MTPA
Technical Grade Urea (TGU) : 80,000 MTPA
2-Ethyl Hexanol (2-EH) : 150,000 MTPA
Di-Octyl Phthalate (DOP) : 50,000 MTPA
Albayroni Company Profile
Al -Bayroni Company ProfileBackground
Energy Optimization Project –Major ModificationsSyngas Compressor without
Suction Chiller Modification Syngas Compressor with
Suction Chiller ModificationBenefits Summary
| Steering the Fertilizer Industry through Challenging Times
Background
Al-Bayroni Ammonia plant,
Originally designed for 1000 MTPD in the year of 1983
Revamped in the year of 2002 to increase the capacity to 1300 MTPD
In year 2013, major revamp was carried out to reduce the energy consumption of ammonia plant by 18%
Al -Bayroni Company ProfileBackground
Energy Optimization Project
– Major ModificationsSyngas Compressor without
Suction Chiller Modification Syngas Compressor with
Suction Chiller ModificationBenefits Summary
| Steering the Fertilizer Industry through Challenging Times
Primary Reformer Furnace Waste Heat Recovery
Major Steam turbines Replacement with efficient designs
CO 2 removal system - Hydraulic turbine, LP Flash Column and increased heat recovery
Modified Synthesis loop
Syngas Compressor Suction Chiller
Hydrogen Recovery Unit & Ammonia Purge Gas Scrubber
Energy Optimization Project – Major Modifications
Al -Bayroni Company ProfileBackground
Energy Optimization Project –Major ModificationsSyngas Compressor without
Suction Chiller Modification Syngas Compressor with
Suction Chiller ModificationBenefits Summary
| Steering the Fertilizer Industry through Challenging Times
Syngas Compressor without suction Chiller
Knockout DrumSynthesis Gas
Syngas Compressor 1st
Stage
Syngas Methanator
Feed Exchanger
InterstageCooler
InterstageChiller
Knockout DrumStage 1
Syngas Compressor 2nd Stage
Syngas Compressor
3rd Stage
Pr: 23.60 BargT: 42.90 ̊C
Pr: 63.30 BargT: 184.20 ̊C
Power : 7827 kW
Pr: 62.19 BargT: 6.4 ̊C
Recycle CirculationGas
Pr: 133 BargT: 41.10 ̊C
To Synloop for Ammonia Conversion
Pr: 140 BargT: 66.10 ̊C
Ammonia Flash Drums
Refrigeration Compressor
LP & HP Stage
Power : 8599 kW
Syngas Compressor Block Diagram without Suction Chiller Modification:
Al -Bayroni Company ProfileBackground
Energy Optimization Project –Major ModificationsSyngas Compressor without
Suction Chiller Modification Syngas Compressor with
Suction Chiller ModificationBenefits Summary
| Steering the Fertilizer Industry through Challenging Times
Syngas Compressor with suction chiller
Knockout DrumSynthesis Gas
Syngas Compressor 1st
Stage
Syngas Methanator
Feed Exchanger
Interstage Cooler
Interstage Chiller
Knockout DrumStage 1
Pr: 23.60 BargT: 42.90 ̊C
Pr: 63.30 BargT: 126.2 ̊C
Power : - 1006 kW
Pr: 62.19 BargT: 6.4 ̊C
Recycle CirculationGas
Pr: 133 BargT: 41.10 ̊C
To Synloop for Ammonia Conversion
Pr: 140 BargT: 66.10 ̊C
Syngas Comp. Suction Chiller
Ammonia Flash Drums
Amm
onia
Liq
uid
Syngas Compressor 2nd Stage
Syngas Compressor
3rd Stage
Refrigeration Compressor
LP & HP Stage
Power : +700 kW
Amm
onia
Vap
or
Pr: 23.50 BargT: 4 ̊C
Syngas Compressor Block Diagram with Suction Chiller Modification:
Al -Bayroni Company ProfileBackground
Energy Optimization Project –Major ModificationsSyngas Compressor without
Suction Chiller Modification Syngas Compressor with
Suction Chiller ModificationBenefits Summary
| Steering the Fertilizer Industry through Challenging Times
Benefits Summary
Net Savings of 306 KW in compressor power
Reduced operating speed of syngas compressor from maximum continuous speed of 11000 RPM to 10637 RPM
Refrigeration Compressor was not overloaded by suction chiller duty as duties in other chillers were reduced due to syn loop modifications
Thank You!www.gpca.org.ae
