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AMM

ON

IA PLANT

NITRIC

ACID

PLANT

LIMESTO

NE AM

MO

NIU

M N

ITRATE PLANT

hydrocarbongas

steam

steam

amm

onia

amm

onianitric acid

limestone

LAN 29%

N

water

air

air

secondaryair

air

CO

MPRESSO

Rpressuriseshydrocarbongas to 35 atmto reduce itsbulk.

PROD

UC

ERG

AS from coal

as fuel inthe prim

aryreform

er.

PREHEATER

heats gasto 400ºC

—optim

umtem

peraturefor desulf-urization

DESU

LFERIZERSabsorb traces ofsulfur com

pounds(w

hich would poison

catalyst) fromthe gas usingzinc oxidepellets.

PRIMARY REFO

RMER

uses steam, catalyst

and heat from a

furnace to reformhydrocarbon gasinto a m

ixtureof hydrogen andcarbon m

onoxideat 800ºC

. C

H4 +

H2 O

C

O +

3H2

SECO

ND

ARYREFO

RMER

adds air to thegas m

ixture tointroduce nitro-gen and tocom

plete reform-

ing with oxygen.

Temperature

rises to 1000ºC.

2CH

4 + O

2 2C

O +

4H2

WASTE-

HEAT

BOILER

cools gasbyraisingsteam

forprim

aryreform

er.

SHIFT C

ON

-VERTERcatalyticallyconverts car-bon m

onoxidein the gasm

ixture to carbondioxideC

O +

H2 O

C

O2 +

H2

CARBO

ND

IOXID

EREM

OVAL

sectionabsorbscarbondioxideout of thegas m

ix-ture

METH

ANATO

Rcatalyticallyrem

oves residualtraces of carbonm

onoxide andcarbon dioxideby converting themto m

ethanew

hich is inertto synthesiscatalystC

O +

3H2

CH

4 + H

2 O

CO

MPRESSO

RSpressurise airto 35 atm

andprocess gas m

ix-ture to 350 atmgas m

ixture nowcom

prises onlyhydrogen,nitrogen andtraces ofm

ethane.

AMM

ON

IA SYNTH

ESISLO

OP catalytically reacts

hydrogen and nitrogen at 500ºC

and 350 atm to

form am

monia w

hichis condensed by cooling andseparated from

gas mixture

which is recycled until com

-pletely reactedN

2 + 3H

2 2NH

3

AMM

ON

IASTO

RAGE

SPHERE to

which the product

pure liquid amm

oniais sent for storageat -4ºC

.

TURBO

CO

MPRESSO

Rcom

presses large airvolum

e to 3 atm and

is driven by steamturbine and tail-gasturbine.

MIXER

introducesabout10%am

monia

vapourinto airstream

CO

NVERTERS in w

hicham

monia reacts w

ithair w

hile passing throughplatinum

catalyst gauzesto form

nirtrogen oxides.Tem

perature rises to 900ºCand hot gases are cooledby raising steam

4NH

3 + 5O

2 4N

O +

6H2 O

ABSORPTIO

N TO

WERS

absorb the nitrogen oxidesin w

ater to form 18%

strength nitric acid, which

is sent to storage tanks2N

O +

O2 2N

O2

3NO

2 + H

2 O 2H

NO

3 + N

O

NEU

TRALIZERS(first and secondstages) reactam

monia vapour

with nitric acid

to form am

mo-

nium nitrate

solution, 82%strength. N

H3 +

HN

O3

NH

4 NO

3

STORAG

E TAN

Kstores82%am

monium

nitratesolution

EVAPORATO

RSconcentrate theam

monium

nitrate solutionin tw

o stages:first to 96%then to 99%

PRILLING

TOW

ERin w

hich finelyground lim

estoneis added to theam

monium

nitratesolution and them

olten slurry issprayed dow

n thetow

er from a spinning

perforated bucket.

CO

OLIN

GD

RUM

where the

solidifiedbeads of LANare cooledfurther

SCREEN

ING

AND

CO

ATING

DRU

M w

here fines andoversize pills are rem

ovedand anti-cakingagent is added to the LANbefore it is sent to storageand dispatched via aw

eightbelt.