Simulation of Ammonia Plant Using Hysys

SIMULATION OF AN INDUSTRIAL SCALE AMMONIA PLANT USING HYSYS™

Presented By

Mohammad Shamsus Saleheen
#0602001 Md. Abu Abdullah Al Hasanat #0602002

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Outline of the Presentation
 Objectives  Simulating an ammonia plant using Aspen HYSYS  A simplified block diagram of Haldor Topsoe ammonia production process  Steady-state Model  Comparison of steady-state simulation results with real plant data  Response of the Model to Changes in Process Variables  Scope of future work
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Objectives
 Building a steady-state model of an industrial scale ammonia plant  Comparison of simulation model performance with real plant  To study the variation of performance of the plant on some specific variables

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Simulating an Ammonia Plant Using Aspen HYSYS
Creating a component list

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2. Selection of an appropriate Fluid property model 3. Creating Reaction Set
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Modeling of the primary reformer Developing the model of ammonia synthesis loop

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A Simplified Block Diagram of Haldor Topsoe Process
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Steady-State Model

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Comparison of Steady-State Simulation Results with Real Plant Data
Variables Product flow rate, kg/hr NH3 % in Product PRF outlet temperature ⁰C H2/N2 after shift convertor PRF outlet composition of CH4 (%) Plant Data 1078 kg/hr 99.34 796 2.896 6.65 Simulation Data 1080 kg/hr 95.26 807.4 2.806 5.85 Deviation from Plant Data, % 0.18553 4.10710 1.43216 3.10773 12.0300

Source: Real plant data obtained from Jamuna Fertilizer Company Ltd, Jamalpur
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Comparison of Steady-State Simulation Results with Real Plant Data

Product ammonia flow rate(1000 NM3/hr) JFCL HYSYS Model 1078 1080

Product ammonia percentage 99.34 95.26

H2/N2 after shift converter 2.896 2.806

PRF outlet temperature (°C) 796 807.4

Source: Real plant data obtained from Jamuna Fertilizer Company Ltd, Jamalpur
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Response of the Simulation Model to Changes in Process Variables
Effect of 5% change in Converter Feed