Table of Contant

CONTENT

CHAPTER

TITLE

PAGE

LETTER OF TRANSMITTER

i

ACKNOWLEDGEMENT

iii

CONTENT

iv

LIST OF TABLES

xii

LIST OF FIGURES

xv

TABLE OF NOMENCLATURE

xvii

LIST OF APPENDIX

xxiii

EXECUTIVE SUMMARY

xxivCHAPTER I

ROJECT CONCEPTION LITERATURE SURVEY11.1

Process Background

1

1.1.1Introduction to Ammonia

1

1.1.2History of Ammonia

2

1.1.3Synthesis of Ammonia

3

1.1.3.1Modified Haber-Bosch Process

3

1.1.3.2The Claude Process

4

1.1.3.3The Casale Process

5

1.1.3.4The Fauser Process

5

1.1.3.5The Mont Cenis Synthesis

5

1.1.4Uses

6

1.1.4.1Acids and Alkalies

6

1.1.4.2Cleaning Agents

6

1.1.4.3Explosives

6

1.1.4.4Fertilizers

7

1.1.4.5Food and Beverages

7

1.1.4.6Leather

7

1.1.4.7Pharmaceuticals

8

1.1.4.8Refrigeration

81.2

Market Survey

8

1.2.1Demand

8

1.2.2Ammonia Specification

9

1.2.3Market Price

10

1.2.4Uses

10

1.2.5Strength

10

1.2.6Weakness

11

1.2.7Prospect

11

1.2.8Production of Ammonia In United State

11

1.2.9Worldwide Producers of Ammonia

12

1.2.10Performance of The Manufacturing Sector In

Malaysia

14

1.2.11Ammonia Industry In Malaysia

16

1.2.12Future Outlook

17

1.2.13Raw Material

17

1.2.14Economic Potential

181.3

Project Feasibility Study and Site Study

191.3.1General

191.3.2Factors That Have To Be Consider In Selecting A

Site

19

1.3.2.1Reasonable Land Price

20

1.3.2.2Availability of Raw Material

20

1.3.2.3Electricity and Water Sources

20

1.3.2.4Man Power Availability

21

1.3.2.5Transport Facilities

22

1.3.2.6Government Incentives

23

1.3.2.7Waste and Effluent Disposal Facilities23

1.3.3Overview of Location

24

1.3.3.1Teluk Kalong, Terengganu

24

1.3.3.2Gebeng (Phase IV), Pahang

25

1.3.3.3Tanjung Langsat, Johor

27

1.3.4Site Selection

28

1.3.5Proposed Site and Plant Layout

291.4

Review And Screening of Alternative Processes

31

1.4.1Preparation of Hydrogen

31

1.4.2Purification of Hydrogen In Synthesis Gas

32

1.4.2.1Shift Conversion of CO to CO2

32

1.4.2.2Removal of Carbon Dioxide

32

1.4.2.3Methanation

34

1.4.3Ammonia Synthesis

34

1.4.4Process Selection

351.5

Physical And Chemical Properties

36

1.5.1Physical Properties of Ammonia

36

1.5.2Physical Properties of Hydrogen

37

1.5.3Physical Properties of Nitrogen

37

1.5.4Physical Properties of Methane

37

1.5.5Chemical Properties of Ammonia

37CHAPTER II

PROCESS MODELING AND FLOWSHEETING422.1

Process Description

42

2.1.1Ammonia Synthesis

43

2.1.2Ammonia Purification

44

2.1.3Recirculation

45

2.1.4Process Flow Diagram

462.2

Basic Equipment Selection

47

2.2.1Compressor

47

2.2.2Heat exchanger

48

2.2.3Reactor

48

2.2.4Expander

49

2.2.5Flash

492.3

Manual Material Balance

49

2.3.1Pre-calculation

50

2.3.2Summary of Mass Balance Calculation

512.4

Manual Energy Balance

51

2.4.1Summary of Energy Balance Calculation

53

2.4.2Summary of Equipment Energy Balance

542.5

Computer Simulation

54

2.5.1Comparison Result of Manual Calculation and

Result of Simulation

552.6 Optimization

552.6.1Introduction

552.6.2Parameter Optimization for Individual Equipment562.6.3General Procedure

572.6.4Economic Tradeoffs

572.6.5Brief Description

58

2.6.5.1Optimization of Reactor System

58

2.6.5.2Optimization of Flash Column

62CHAPTER IIIPROCESS ENERGY INTERGRATION

673.1

Introduction to Heat Exchanger Network Design

673.2

Stream Identification

683.3

The Pinch Technology

69

3.3.1Energy Targeting Procedure

703.4

Maximum Energy Recovery (MER) Heat Exchanger Network Design

73

3.4.1Above Pinch Design

73

3.4.2Below Pinch Design

74

3.4.3Stream Pairing Below the Pinch

743.5

Process Flow Diagram After Heat Integration

763.6

Conclusion

77CHAPTER IVWASTE TREATMENT AND WASTEMINIMIZATION

784.1

Introduction

784.2

Air and Water Quality Standards

79

4.2.1Ambient Air Quality Standards

80

4.2.1.1National Ambient Air Quality Standards80

4.2.2Water Quality

814.3

Government Specifications

834.4

Type of Pollutants

83

4.4.1Gaseous Pollutants

83

4.4.2Particulate Pollutants

844.5

Ammonia Activated Sludge System

85

4.5.1Material Balance Calculations for WasteTreatment Plant

87

4.5.2Kinetics of Bacterial Growth

90

4.5.3Nitrification-Denitrification Process in AerationTank

90

4.5.4Material Balance

92

4.5.5Energy Balance

934.6

Summary for Sizing and Costing of Waste TreatmentEquipment

94CHAPTER V

EQUIPMENT SIZING AND COSTING

965.1

Introduction

965.2

Reactor R-4

97

5.2.1Introduction

99

5.2.2Summary for Reactor Chemical Design

99

5.2.3Costing Summary

99

5.2.3.1Material of Construction

100

5.2.3.2Costing Summary

1005.3

Compressor and Expander

100

5.3.1Compressor C-2

100

5.3.1.1Work for Compressor

101

5.3.2Expander E-5 and E-9

1015.4

Flash Drum

1025.5

Mixer

1035.6

Storage Tank

1045.7

Heat Exchanger

104CHAPTER VIPROCESS CONTROL

1206.1

Introduction

1206.2

Typical Control System

121

6.2.1Level Control

122

6.2.2Pressure Control

122

6.2.3Flow Control

123

6.2.4Cascade Control

123

6.2.5Ratio Control

1246.3

Control System Design

1246.4

Control System Design for Individual Units

125

6.4.1Reactor

125

6.4.2Flash

128

6.4.3Heat Exchanger

129

6.4.4Compressor and Expander

133

6.4.5Mixer and Divider

1366.5

Piping and Instrumentation Diagram (P&ID)

138CHAPTER VIIPROCESS SAFETY STUDIES

1427.1

Introduction

142

7.1.1Hazards

143

7.1.2Risk

144

7.1.3The Chemical Hazards

145

7.1.3.1Identification

146

7.1.3.2Health and Safety Information

147

7.1.3.3Recommendations for Respiratory Selection: Niosh

147

7.1.3.4Chemical Reactivity

148

7.1.3.5Fire Information

149

7.1.3.6First Aid

149

7.1.3.7Environmental Information

1507.2

General Process Safety Procedures

150

7.2.1General Safety

151

7.2.2Plant Safety

152

7.2.3Worker Safety

154

7.2.4Detection of Possible Hazards

155

7.2.5Personal Protective Clothing and Equipment

157

7.2.6First Aid (Poison Information)

1597.3

Process Safety Study (Hazop Study)

160

7.3.1General

160

7.3.2Objective of HAZOP

161

7.3.3HAZOP Technique

162

7.3.4HAZOP Study In The Plant

164

7.3.4.1HAZOP on Heat Exchanger

164

7.3.4.2HAZOP on Compressor

168

7.3.4.3HAZOP on Reactor

169

7.3.4.4HAZOP for Flash

172

7.3.5Plant Start-Up and Shut Down

173

7.3.5.1Introduction

173

7.3.5.2Plant Start-Up

174

7.3.5.3Summary of Plant Start-up Procedure175

7.3.5.4Plant Shut-Down

175

7.3.5.5Summary of Plant Shut-down Procedure176

7.3.5.6Plant Emergency Shutdown

176

7.3.5.7Emergency Control and Operator Response176CHAPTER VIIIMECHANICAL DESIGN OF MAJOR EQUIPMENT1798.1

Introduction

1798.2

Equipment Specification Sheets

180

8.2.1Reactor, R-4

180

8.2.2Flash, F-7

182

8.2.3Flash, F-10

183

8.2.4Flash, F-17

184

8.2.5Summary For Flash Drum Mechanical Design185

8.2.6Heat Exchanger, X-15

186

8.2.7Heat Exchanger, X-16

191

8.2.8Heat Exchanger, X-3

194

8.2.9Heat Exchanger, X-6

197

8.2.10Heat Exchanger, X-8

200

8.2.11Storage Tank Nitrogen

203

8.2.12Storage Tank Hydrogen

204

8.2.13Storage Tank Ammonia

205CHAPTER IXPROFITABILITY ANALYSIS

2069.1

Introduction

2069.2

Gross Root Capital (GRC)

2069.3

Fixed Capital Investment (FCI) and Total CapitalInvestment (TCI)

2089.4

Manufacturing Cost and Total Production Cost

2099.5

Cash Flow Analysis

2129.6

Conclusion

218CHAPTER X

CONCLUSION AND RECOMMENDATION

21910.1

Conclusion

219

10.2

Recommendations

220BIBLIOGRAPHY

222APPENDIXESPAGE xi