Efficient Opération of N Ha Plant at Reduced

Rates
This paper discusses the most efficient method to operate an existing plant. At low rates,
an efficiency gain of 0.77 million Btu/ton can be achieved.

R.E. Poore
Farmland Industries, Inc.
Enid, OK
U.C. Stover
Cooperative Farm Chemicals Assn.
Lawrence, KS

INTRODUCTION exchange area and catalyst volume per unit

of throughput which results in lower pressure
When ammonia was in short supply, the oper- drop in the plant. The lower pressure drop
ating philosophy tended to be to produce all in the plant reduces synthesis gas compressor
the ammonia possible. However, when market horsepower and improves the efficiency of
conditions dictate reduction in rates, the the steam cycle.
operating philosophy needs to change to one
of making a fixed amount of ammonia with the The intent of this paper is not to dis-
least possible amount of gas. Or, when gas cuss new designs or equipment that can be
availability dictates a reduction in rates, added to existing plants to reduce energy
the operating philosophy needs to become consumption, rather the intent is to show the
one of producing the most ammonia possible most efficient way to operate an existing
with a fixed quantity of gas. In either plant. That is, to do the most efficient
case, when rates are reduced, the operating job of operating with existing equipment.
philosophy should be to minimize gas consump-
tion per ton of ammonia. A plant capable of producing 400,000
tons (362,800 metric tons) per year of
Today, with gas costing about $2.50/MM ammonia may only be required to produce
BTU, it amounts to greater than 70% of the 300,000 tons (272,100 metric tons) per year.
total plant operating costs. The reduction By operating wisely, gas consumption can be
of gas use is one of the major ways to re- reduced by one million BTU/ton (1.16 kJ/MT).
duce operating costs when the operator is If gas costs $2.50/MM BTU, a savings of
caught in a price squeeze due to an over- $750,000/year can be realized.
supply of ammonia and the high cost of gas.
PLANT DESCRIPTION
Described in this paper is an operating
philosophy whereby efficiency actually im- The type of plant referred to in this paper
proves as rates are reduced. The improvement consists of 450 PSIG to 550 PSIG (3,201 kPa
in efficiency is due to an increase in heat to 3,792 kPa) steam reforming, followed by
secondary reforming, high temperature shift,
low temperature shift, CÛ2 removal, and
methanation. After the methanator, the
gas is compressed to about 2,200 PSI (15,158
kPa) for ammonia synthesis. Waste heat re-
0149-3701/81/4852 $02.00 ® 1981 AlChE covered from the process gas following the

83
secondary reformer, high shift, raethanator, rate. If the measured amount is.lower than
and ammonia converter is used to generate the calculated amount, it is time to look for
1,500 PSI (10,342 kPa) steam. a problem in the plant. This approach is
also useful in evaluating the effect of CH^
The steam generated from the process is leakage and S/C ratio on the overall energy
supplemented by an auxiliary boiler. All consumption per ton.
steam is superheated by heat exchange with
the primary reformer flue gas. All the It is very useful to record the fuel
steam generated is letdown through a topping gas rate in the control room in addition to
turbine coupled to the synthesis gas com- the feed gas rate. It makes the operator
pressor. A portion of the steam letdown aware of fuel gas consumption and as changes
goes into the process while the remainder are made, the effect on efficiency can be
is used to drive the centrifugal air com- evaluated.
pressor, refrigeration compressor, BFW pumps,
ID fan, additional power for the synthesis SYN GAS COMPRESSOR SURGE DETERMINATION
gas compressor, etc.
While running at low rates, one of the big-
EVALUATING EFFICIENCY gest gains in efficiency is obtained in the
power cycle, since there is less pressure
It is necessary to have a good method for drop through the front end of the plant. In
determining energy consumption per ton. order to take advantage of these gains in
Quite frequently, changes that improve feed efficiency, it is important that the syn gas
gas efficiency are more than offset by in- compressor be operated with the kickbacks
creases in fuel gas consumption. For this closed and, of course, always maintaining a
reason, when determining the energy use per safe distance from surge.
ton, it is necessary to have a breakdown
between feed gas and fuel gas used per ton With the use of compressor section
of ammonia produced. curves and calculation of suction volume
to each stage, the operating position rela-
For a given feed gas rate and composi- tive to surge can be determined." One method
tion, the ammonia production is set by the for determining the suction volume at each
CH4 and H2/Np ratio to the synthesis loop stage is to determine the mass flow rate to
and the inert level in the loop. With this the syn gas compressor based on a material
information and a measurement of fuel gas to balance knowing the feed gas rate to the
the unit, the BTU/ton (kJ/MT) can be calcu- plant. This particular method is recommended
lated. because feed gas is metered by one of the
most accurate flowmeters in the plant. For
The concept is illustrated with a black given compressor speeds, the mass flow rate
box approach shown below (Illustration 1). can be plotted versus suction pressure to
establish a safe operating line relative to
surge.
The first step is to look at the com-
pressor section curves and determine the
NH3 Plant suction volume required at various speeds to
*CH^ Makeup to Loop
keep the machine at a safe distance from
surge, say 20%. Looking at the curves shown
*Feed Gas Rate & LHV *% Inerts in Loop in Figure 1 for the low case, it can be seen
*Fue1 Gas Bate & LHV . *H2/NZ Ratio Exit **NH3 Production that at 90% speed a safe distance from surge
Methanator is 1,993 ACFM. At 95% speed a safe distance
from surge is about 2,100 ACFM. With the
Known
Calculated from known
use of a material balance, the maximum suc-
tion pressure at various feed gas rates can
be used to calculate the volumetric gas flow
rate to maintain a safe distance from surge.
For example:
@ 784 TPD - Makeup to loop
The calculated NHo production rate =8,181 MPH and 90% Speed
serves as a check on the measured production

84
 As one can see from this equation,
small changes in Pi or suction pressure
have a large effect on compressor horsepower,
x (10.73 x 545 x 1.01) while the same change in discharge pressure
P has a much smaller effect on compressor
horsepower. For this reason, it is impor-
P = 400 PSIA (2,756 kPa) tant to operate at the highest possible
suction pressure.
This means that at a rate of about 784 TPD
and 90% compressor speed with a suction Someone may argue that the syn gas
pressure of 400 PSIA (2,756 kPa), the oper- suction pressure does not matter too much
ating point is 20% from surge. For these since with a lower suction pressure the
conditions, if the suction pressure is less, intermediate steam header pressure can be
the distance from surge is greater. lowered accordingly and more work obtained
through the topping turbine. True, as the
Based on the compressor curves shown intermediate steam header pressure is lowered
in Figures 1, 2, and 3 graphs can then be the water rate decreases on the topping tur-
made showing the relation between feed gas bine; however, it increases on the condensing
rate and maximum suction pressure to main- turbine. In looking at the overall steam
tain a distance of 20% from surge. These cycle, the same amount of work is obtained
graphs are shown in Figures 4 and 5. from steam that goes through both the topping
and condensing turbines irregardless of the
It is important to note that these intermediate steam header pressure. This is
curves were based on the low pressure case. because thermodynamic work is independent
Knowing the flow condition to the low case, of path and depends only on the endpoints.
the volume flow to the second case can be This also holds true in the plant since the
checked. For this particular compressor, adiabatic efficiencies of the topping tur-
at low rates, high suction pressure, low bine and condensing turbines are nearly the
speed, and low discharge pressure* the same. This is not to say that the inter-
second case operates further from surge mediate steam header pressure should not be
than the low case. run as low as possible. By lowering the
intermediate steam header pressure, the
The final recycle stage is almost im- cycle efficiency does improve on the portion
possible to surge because the whole loop acts of steam that goes through the topping tur-
like a kickback valve. Only if flow is bine and then into the process; however,
greatly restricted in the loop, can the re- the intermediate steam header pressure should
cycle wheel be surged. not be lowered at the expense of lowering
the suction pressure to the syn gas com-
SYN 6AS SUCTION PRESSURE AND 550 IB. pressor. The reason for this is that an
INTERMEDIATE HEADER PRESSURE increase in suction pressure reduces the
power requirement on all the gas being com-
The basic equation for compressor horse- pressed while lowering the suction pressure
power (watts) is: only improves cycle efficiency on that por-
tion of the steam that goes through the
(Watts) or Horsepower topping turbine and into the process. This
portion of steam that goes through the
(K-D/K) -1 topping turbine and into the process pro-
vides only about 30% of the power for the
syn gas compressor*
rad
Table 1 presents data which show the
W = mass flow rate effect of plant rate» synthesis gas suction
K = specific heat ratio Cp /C pressure and intermediate steam header pres-
R = gas constant sure on energy requirements for synthesis
T = temperature gas compression. Cases 1 and 2 are a com-
P = absolute pressure parison of energy requirements for the syn
<»ad = adiabatic efficiency gas compressor at low rates (78% of design)
and high rates (113% of design). Case 3 is
Subscripts: 1 = suction also at low rates, but represents another
2 = discharge mode of operation.

85
 One will note that any differences in The improvement in converter perfor-
power requirements between cases will show mance is evidenced by the fact that as
up in the steam generated by the auxiliary rates are reduced it is possible to in-
boiler. crease the inert level—17% @ 784 TPD (71
MTD) versus 14% @ 1,136 TPD (1,030 MTD)
In comparing Cases 1 and 2, low rates eight year old catalyst. The effect of
versus high rates, notice that the 784 TPD inert level on efficiency is shown below.
(711 MT) case requires 0,74 MM BTU/ton
(.858 MM kJ/MT) less energy than the 1,136 Effect of Jnerts Level in Purge
TPD case (1,030 MT). The difference in en- on NHg Production Efficiency
ergy requirement is due to the following:
Percent Inerts in 18% 16% 14%
1. At high rates the pressure drop through Purge
the plant is about 180 PSI (1,240 kPa) Production Rate, 793 787.5 780
versus about 88 PSI (606 kPa) at low TPD
rates. This has two effects: Increase in MM 0.08 0.21
BTU/Ton
A. At high rates the syn gas suction (MM kO/Metric Ton) .0928 .24
pressure is limited to 380 PSIA
(2,618 kPa) due to the relief valve Note: CHA in Loop Makeup =0.7%
on the secondary reformer. At low
rates the suction pressure is 400 At low rates the pressure drop through
PSIA (2,756 kPa) and limited only the loop is about 130 PSI (895 kPa) at 78%
by approach to surge and by the rate compared to 270 PSI (1,800 kPa) at 113%
relief valve on the suction of the rate. The circulation in the loop has to
synthesis gas compressor. The high fall somewhere in the recycle wheel curve.
suction pressure is obtained by re» To avoid overcirculating the loop it helps
dueing compressor speed. This in to throttle on the recycle wheel suction.
turn reduces the overall compression This reduces loop circulation and recycle
ratio. As a result, as rates are wheel horsepower by pushing one back on the
reduced 31% from 1,136 TPD (1,030 operating curve.
MTD) to 784 TPD (711 MTD), syn gas
compressor horsepower is reduced The temperature rise across the con-
by 41%, from 20,847 (15,531 kW) to verter is an indication of loop circulation.
12,354 (9,204 kW). By throttling pn the recycle suction, the
AT at low rates is about the same as that
B. At lower rates the lower intermedi- at high rates. However, with the higher
ate steam header pressure results inerts possible due to low rates, there is
in about 12% more power from the less AT for each percent conversion. This
steam that goes through the topping is because Cfy has a higher molar specific
turbine and into the process. heat than H2, N2> or Ar.
Case 3 is the same as Case 1 but with AIR COMPRESSOR AND REFRIGERATION COMPRESSOR
the syn gas compressor running faster which
results in a lower suction pressure (330 The horsepower on the refrigeration com-
PSIA versus 400 PSIA) or (2,273 kPa versus pressor is nearly proportional to rate.
2,756 kPa) and a "lower steam header pressure. It is favored slightly at lower rates
Case 1 is favored by 0.24 MM BTU/ton (.2784 due to better conversion in the syn loop.
MM kJ/MT).
The air compressor used in this study
SYNTHESIS LOOP OPERATION requires more power per ton at low rates
than at high rates. At low rates it is
Performance of the converter improves as necessary to vent air from the discharge
rates are reduced due to the increase in of the low case in order to keep the second
catalyst volume per unit of production. stage away from surge. The horsepower at
Although the pressure is about 250 PSI low rates is about 1,500 horsepower (1,117
(1,722 kPa) lower, the converter outlet kW) more than the proportional amount would
runs about 30°F (17°C) cooler. This cooler be.
temperature favors equilibrium conversion
and offsets the effect of lower pressure.

86
STEAM SYSTEM. GENERAL a given feed rate or, said another way, an
Table 2 shows the effect of steam superheat, increase in' feed gas rates is necessary to
intermediate steam header pressure, and hold the same production rate. However,
surface condenser vacuum on the energy per this decrease in feed gas efficiency is nor-
ton of ammonia produced. As the table mally more than offset by an increase in fuel
shows, it is important to run with as high gas efficiency.
a superheat as possible, low intermediate The methane leakage to the syn loop
header pressure, and low vacuum. needs to be optimized. The lowest leakage
As rates are reduced, overload valves is not necessarily the optimum. One of the
should be closed on turbines driving such simplest methods for finding the optimum is
equipment as BFW pumps, ID fan, etc. When to make a change in the plant and then evalu-
running with a low ring pressure, the pres- ate it. A good rule of thumb is that an
sure drop.is being taken across the governors increase or decrease of 0.1% methane leakage
instead of the turbine, and this makes the into the loop will increase or decrease am-
turbine inefficient. On some turbines such monia production by 1%. As an example,
as BFW and ID fan, steam savings as much assume the plant is operating at 750 TPD
as 2,000 lbs/hr to 5,000 lbs/hr (906 to (680 M/T) and the change is made that in-
2,270 kg/hr) are possible. creases methane to the loop by 0.1%. The
production rate will then drop by 7.5 TPD
REFORMER AND ID FAN (6.8 M/T). However, if the fuel gas de-
creases by 20,000 SCFH (566 SCMH), that 7.5
When running at high rates, it is nearly TPD is being produced at an energy consump-
impossible to pull too much air into the tion rate of 64 MM BTU/ton (74.24 MM kJ/MT).
furnace; however, at low rates, unless the It is worthwhile examining how S/C
ID fan is slowed down, the excess air in the ratios can be reduced as rates are reduced.
reformer will be high and will lower the
efficiency of the reformer. The data given below illustrates the effect
of S/C ratio on the primary reformer. All
At low rates with the ID fan slowed cases are based on 0.3% methane leakage.
down and the excess air under control, the (Data provided by United Catalyst, Inc.).
reformer is actually more efficient. This Case I (400 PSI6 Exit Secondary Reformer)
is evidenced by observing the flue gas ex-
haust temperature. At low rates (784 TPD) Primary CH4 Exit
this temperature is about 35°F cooler than T-Out. O
at high rates (1,136 TPD). This amounts to Primary
about 0.104 MM BTU/ton (0.120 MM kJ/MT). 3.11 45
Another reason to slow down the ID fan 3.37 1474 30
is that the horsepower varies with the cube 36 1460 1
of speed. At low rates the horsepower re- 89 1447 8.9
quired by the fan is about 32% of that at 15 1435 8.7
high rates. This amounts to about a 300 hp 4.41 1423 8.6
(223 kW) reduction in power. Case II (450 PSI6 Exit Secondary Reformer)
STEAM-TO-CARBON RATIO 3, 11 1510 9.3
Steam-to-carbon ratio is another area where 3. 37 1495 9.1
efficiency improves at low rates. At high 3. 63 1481 8.9
rates due to tube wall temperatures, S/C 3. 89 1468 8.75
ratios are often 4 or more. However, at 4. 15 1455 8.6
low rates S/C can be reduced resulting in 4.41 1444 8.4
an overall increase in efficiency. A paper Basis of Table
by Craig and Burklow (Jj concluded that "as
production rate is lowered relative to the 1. 0.3% CH* exit secondary reformer
design value, the optimum S/C ratio shifts
to lower values." In-plant it has been de- 2. 3/1 Hp/Np exit methanator
termined that efficiency favors lowering S/C
ratio as rates are reduced. As the S/C ratio 3. 20°F approach to equilibrium exit primary
is reduced, the production rate decreases for

87
Basis of Table (continued) net effect of putting only 105 BTU/lb (244
kO/kg) into the 1,500 PSI (10,350 kPa) steam
4. 5°F approach to equilibrium exit secon- system. That is, other than the heat put
dary into the steam by the primary reformer, a
pound of steam to the process generates only
As the data shows, tube outlet tempera- about 0.1 pound of steam at the 1,500 PSI
tures need to be increased as S/C ratio de- (10,350 kPa) level.
creases to hold methane leakage from the
secondary constant. The effect of these Most fixed steam users, such as lube
changes on tube wall temperatures can be oil pumps, exhaust into the 50 PSI (344 kPa)
approximated with the following equation. header; therefore, at low rates there is
This expression was developed by Lombard and proportionally more steam available in the
Culberson (2). 50 Ib. (344 kPa) header than at higher rates.
This extra steam is available to the CU£ re-
ATWT * (-25°) (2°) 075 moval system and helps compensate for the
lesser amount of heat available downstream
of the low temperature shift due to lower
S/C ratios in the primary reformer.
ATWT = change in tube wall temperature, °F CONCLUSIONS
C = increase in CH» leakage from base As shown in Table 3 (Overall Effect of Energy
case, mole percent CH* Consumption at Low Rates and High Rates),
there is an efficiency gain of 0.77 MMBTU/ton
R = increase in operating rate from base (0.89 MM kJ/MT) at low rates. The primary
case, percent of design gains in efficiency are:
S = increase in S/G ratio from base case 1. Less syn gas horsepower due to higher
suction pressure and a lower compression
T = increase in mixed-gas inlet tempera- ratio
ture from base case, °F
2. Lower intermediate steam header pressure
Note: If variables are decreased from base due to less pressure drop in the plant
case, they should be entered into
expression with appropriate minus sign. 3. Lower S/C ratio due to more reformer
tubes per unit of production
Assume that at 1,136 TPD and an S/C
ratio of 4 the tube wall temperatures are 4. Higher inerts in the synthesis loop due
about 1,650°F (885°C). Now rates are re- to more catalyst per unit of production
duced to 784 TPD and S/C ratio is reduced to
3. Holding the same methane leakage out of These gains in efficiency more than
the secondary the tube wall temperatures will offset the penalties of the fixed steam con-
drop by about 30°F (16.4°C). This expression sumers and the inefficiency of the air com-
is an approximation and each operator must pressor at low rates.
use his own discretion concerning tube wall
temperatures. Results may vary from plant LITERATURE CITED
to plant due to the condition of the catalyst,
1. Craig, Donald, and Burklow, Bruce,
The problem in running too much steam Effect of Primary Reformer,
to the reformer is that most of the energy Steam-to-Carbon Ratios on_
in the steam is condensed out of the system Ammoni à PI ant Effi ciency. Pre-
at a very low level, normally in the CU£ sented at the AIChE Ammonia Plants
removal system reboilers. Process steam is and Related Facilities Safety
not a good heat source for generating 1,500 Symposium, November 1979.
PS|A (10,350 kPa) steam. Most of the high
pressure steam generated from process steam 2. Lombard, John, and Culberson, Robert,
results from heat put into it in the primary Defining Reformer Performance.
reformer. The enthalpy of the steam enter- Presented to American Institute
ing the mixed feed coil is about 1,315 BTU/lb of Chemical Engineers' Ammonia
(3,058 kJ/kg) and the enthalpy leaving the Plants and Related Facilities Safety
low shift is 1,210 BTU/lb (2,814 kJ/kg) for a Symposium, August 1972.

88
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STOVER, J.C.
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90%

4 8 10 IZ
t/321 n' 22i.54 f!3 S03.ÏÏ f!3 35ÎSO f?1

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Figure 2. Synthesis gas compressor: section H
of III.

3.5 'M.

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Figure 1. Synthesis gas compressor: section I
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i l l l
1 3
2 3
3 4 3
5
28.32 n 5&<i3/7 1I32T/? /4/.5?/73

ÓVMITY AC/W* /O'3

Figure 3. Synthesis gas compressor: section
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89
 400

OPERATIV* AKS A

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657 70S 737 753 755
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Figure 4. Maximum synthesis gas suction pressure vs. production rate at 90% speed.

90
390

65 T 785

Figure 5. Maximum synthesis gas suction pres sure vs. production rate at 95% speed.

91
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95
 TABLE 3

OVERALL EFFECT OF ENERGY CONSUMPTION

AT LOW RATES AND HIGH RATES

Low Rates High Rates

Production Rate, TPD 784 1,136
Feed Gas, Ib. moles/hr 1,939 2,810
Total Horsepower 28,500 42,068
Fixed Steam Consumption, Ib/hr 45,000 45,000
S/C Ratio 3.0 4.0
Steam to Process, Ib/hr 100,331 194,834
LTS, S/G .346 .536
LTS Equilibrium CO <? 440°F .285 .18
Percent Methane to Loop ,78 .65
Inerts in Loop 17% 14%
Purge Gas, MPH 505 784
LHV Purge, BTU/SCF 284 266
Intermediate Steam Header Pressure, PSIA 480 565
Horsepower from Steam to Process 3,752 6,275
Topping Turbine Water Rate, Ib/hp hr. 26.87 31.046
Remaining Horsepower 24,748 35,793
Steam Generation for Remaining Horsepower, Ib/hr 172,246. 249,119
Total Steam Generation, Ib/hr 317,577 488,953
Total MM BTU/hr for Steam Generation 435.11 669.93
Credit for Purge to Fuel, MM BTU/hr (54.35) (79.04)
Credit for Higher Enthalpy of Steam to Process, MM BTU/hr (2.53)
Credit for Extra Steam Generated from Process, MM BTU/hr (5.11)
Credit for Furnace Efficiency, MM BTU/hr (3.4)
Net MM BTU/hr Input 377.3 583.24
MM BTU/Ton for Steam Generation 11.55 12.32
Difference in MM BTU/Ton .77
$/Ton @ $2.50/MM BTU $1.93

Notes:
Fixed steam consumption includes: topping turbine gland leakage; 50 PSIA backpressure turbines
such as lube oil pumps, CO» removal pumps, etc.
Horsepower on small turbine drivers was assumed to be proportional to plant rate.
Steam generation differences are made up in the auxiliary boiler and a furnace efficiency of 87%
was used as the basis, with 1,500 PSIA steam superheated to 875°F exhausting to 4" Hg. Turbine
efficiency at 70%.
Process gas MM BTU/ton is the same in each case @ 19.11 MM BTU/ton.
Compressor Horsepower: 784 TPD 1.136 TPD
Syn Gas 12,354 20,847
Refrigeration & Air 16.146 21.221
Total Horsepower 28,500 42.068

96
 TABLE 3A

OVERALL EFFECT OF ENERGY CONSUMPTION

AT LOW RATES AND HIGH RATES

Low Rates High Rates

Production Rate, MTD 711 1,030
Feed Gas, kg moles/hr 879 1,273
Total kW 21,232 31,341
Fixed Steam Consumption, kg/hr 20,385 20,385
S/C Ratio 3.0 4.0
Steam to Process, kg/hr 45,450 88,260
LTS, S/G .346 .536
LTS Equilibrium CO (? 227°C .285 .18
Percent Methane "to Loop .78 .65
Inerts in Loop 17% 14%
Purge Gas, kg moles/hr 229 355
LHV Purge, kJ/M3 10,587 9,895
Intermediate Steam Header Pressure, kPa 3,307.2 3,927
kW from Steam to Process 2,795 4,675
Topping Turbine Water Rate, kg/kW hr. 16.34 18.87
Remaining kW 18,437 26,666
Steam Generation for Remaining kW-kg/hr 78,027 112,851
Total Steam Generation, kg/hr 143,682 221,496
Total MM kJ/hr for Steam Generation 459 706.7
Credit for Purge to Fuel , MM kJ/hr (57.34) (83.38)
Credit for Higher Enthalpy of Steam to Process, MM kJ/hr -- (2.67)
Credit for Extra Steam Generated from Process, MM kJ/hr -- (5.39)
Credit for Furnace Efficiency, MM kJ/hr (3.587)
—
Net MM kJ/hr Input 398 615.3
MM kJ/MT for Steam Generation 13.4 14,29
Difference in MM kJ/MT .89
—
$/MT (B $2.37/MM kJ -- $2.11

Notes :
1. Fixed steam consumption includes: topping turbine gland leakage; 344 kPa backpressure turbines
such as lube oil pumps, COo removal pumps, etc.
2. Horsepower on small turbine drivers was assumed to be proportional to plant rate.
3. Steam generation differences are made up in the auxiliary boiler and a furnace efficiency of
87% was used as the basis, with 10,335 kPa steam superheated to 468°C exhausting to 101 CM Hg.
Turbine efficiency at 70%.
4. Process gas MM kJ/MT is the same in each case @ 22.16 MM kJ/MT.
5. Compressor kW:
711 MTD 1,030 MTD
Syn Gas 9,204 15,531
Refrigeration & Air 12.029 15.809
Total Horsepower 21.233 31,340

97
 DISCUSSION

MANOVRA, Indian Farmers Pert. Co.: We too operate same work is obtained from the steam that goes
same plant in India based on natural gas. But, we have through both the topping and condensing turbines
some problem when it comes to running on the lower regardless of the intermediate steam header pressure.
rate^ When it comes down lower than 80% we have This is because thermodynamic work is independent
proDiems maintaining the steam balance. We have to of path and depends only on the end points. However,
fire the auxiliary boiler harder to make more steam. you get more work out of the portion of steam that goes
Have you any ideas that can help me? through the topping turbine and into the process if the
J.C. STOVER: If I understand correctly, you have pressure is lower.
trouble generating enough steam at low rates. Our JOHN LIVINGSTON, ICI: We have been exchanging
auxiliary boiler has four burners. At high rates, about information with John about the turned-down experi-
115% of design, we need to use all four burners. At low ment. Although the Billingham plants are different
rates, about 75% of design, we operate with only two from this plant, we have been doing similar experiments
burners. Therefore, we have not had the problem of on turndown. We have been able to turn down (over
generating enough steam at low rates. 700 tons) further than you have indicated. I would like
MANOVRA: Yes. When we turned on to low rate, we to ask you what caused you to stop where you stopped.
find that our steam balance is tight. It is not enough to In the normal CO2 removal system with two pumps in
keep the plant going. So, we have to get the extra operation, each of those pumps takes about 12 an hour
amount from the auxiliary boiler. This necessitates a of ventilated pressure steam. We find that running with
little harder firing in this area. one pump at a time is more beneficial than reducing
STOVER: Do you slow down your synthesis gas the intermediate pressure to get the increased power
compressor, lower your intermediate steam header from the exhaust
pressure, and reduce your S/C ratio?
MANOVRA: We don't bring down the steam gas ratios. STOVER: We, too, have gone lower than 780 TPD;
We still maintain that steam gas ratio of 3.5. however, due to marketing conditions, we haven't had
to run at lower than 780 TPD for extended periods of
STOVER: Lowering the S/C ratio should reduce the time. The 780 TPD rate is probably an optimum for our
load on the auxiliary boiler. plant, since below 780 we intentionally have to reduce
MANOVRA: I don't understand. Why do we bring down the suction pressure on the synthesis gas compressor
the intermediate steam header pressure? to keep the low case away from surge. This, of course,
STOVER: By lowering the intermediate steam header increases synthesis gas compressor horsepower. At
pressure and letting it float on front end pressure, you high rates we also operate two lean COz removal
get more work out of the portion of steam that goes pumps that are steam-driven. We are also able to cut
through the topping turbine and into the process. That back to one pump at low rates.

98