The ammonia manufacturing processes are grouped into 4 processing units with the following sequences:
(1) Feed Treating Unit
Natural gas which still containing impurities especially sulfuric compound must be at first purified in this unit before taken into the Reforming Unit to avoid catalyst toxication in the Reforming Unit. For desulfurization, the natural gas must be passed in a vessel called Desulfirizer. The sulfur-free natural gas is then delivered to the Reforming Unit.
(2) Reforming Unit
The purified natural gas at the Reforming Unit is mixed with water vapor, heated, then reacted at Primary Reformer, the reaction outcome in the form of hydrogen gases and carbon dioxide are taken into the Secondary Reformer and reacted with air to produce the following gas:
Gas produced from this reaction is transferred into the Purification Unit and Methanation to which the carbon dioxide gas is separated.
(3) Purification & Methanation
Carbon dioxide contained in gases produced from the reaction at Reforming Unit is separated first in Purification Unit, and then delivered as raw material in Urea Plant. The residual carbon dioxide contained in the process gas will produce poison in ammonia converter catalyst, hence, before this process gas being sent off to the Synloop & Refrigeration Unit must be firstly entered into the Methanator.
(4) Compression Synloop & Refrigeration Unit
Process Gas produced from Methanator with hydrogen:nitrogen ratio = 3:1, is pressuried or compacted to reach an expected pressure by Ammonia Converter for formation reaction, this gas is then entered into the Refrigeration Unit to produce ammonia in liquid phase, which is then used as urea manufacturing raw material.
The product of this process is liquid ammonia which with carbon dioxide are used as urea manufacturing raw material.
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