Kellogg Brown + Root LLC

The M.w. Kellogg Company

Other

Sansyco Consulting, LLC

Stephen Allen Noe

Shashi Prakash Singh

Akhil Jain Nahar

Shiliang Zhan

Girish Chimanlal Joshi

Sachin Kalatrakkal

Deyuan Wu

An ammonia synthesis converter for small production units which provides full access for routine maintenance and catalyst replacement while providing adequate catalyst pressure drop to ensure kinetic performance and reduce heat leak from the catalyst beds. A shell has a removable top head and an annular basket is removably mounted in the shell. First and second catalyst beds are disposed in the annular zone of the basket for axial down-flow in series. A quench gas is introduced into effluent from the first catalyst bed and the resulting mixture into a top of the second catalyst bed. A feed-effluent interchanger in the inner basket zone is adapted to receive effluent from the second catalyst bed and indirectly heat a feed to the first catalyst bed. Also, methods of operating and servicing the converter.

Ammonia synthesis converter and method for small production units

A method of revamping vertical converters having a bolt-on flanged pressure shell extension for housing an internal heat exchanger is performed by replacing an existing pressure shell extension with a larger pressure shell extension for housing a plurality of internal heat exchangers.

Method for revamping vertical converters having a flanged pressure shell extension for housing an internal heat exchanger

Methods and systems for making ammonia are provided. The method can include heating a first compressed syngas to produce a heated first syngas. The heated first syngas and a second compressed syngas can be combined to produce a combined syngas. The combined syngas can be reacted within a first ammonia converter and a second ammonia converter to produce an ammonia product. Heat from the ammonia product can be transferred to a first heat transfer medium to produce a first cooled product and a second heat transfer medium. Heat from the first cooled product can be transferred to a third heat transfer medium to produce a second cooled product. Heat from the second cooled product can be transferred to the combined syngas to produce a third cooled product. The third cooled product can be separated to produce a purified ammonia product and a recycle gas.

Methods and systems for making ammonia in a double ammonia converter system

Methods and systems for making ammonia are provided. The method can include converting carbon monoxide in a first syngas to carbon dioxide to produce a shifted syngas. At least a portion of the carbon dioxide can be separated from the shifted syngas to produce a carbon dioxide-lean syngas. Carbon monoxide and/or carbon dioxide in the carbon dioxide-lean syngas can be converted to methane to produce a methanated first syngas. A second syngas can be separated to produce a purified second syngas and a waste gas. The methanated first syngas and the purified second syngas can be combined to produce an ammonia feedstock. The ammonia feedstock can have a hydrogen to nitrogen molar ratio of about 3.5:1 to about 2.5:1. At least a portion of the hydrogen and nitrogen in the ammonia feedstock can be reacted to produce an ammonia product.

Methods and systems for producing and processing syngas in a pressure swing adsorption unit and making ammonia therefrom

Disclosed is an in situ design for a runoff rain gaugecomprising an elevated storage panfor storing precipitation above grade, a splitter panfor partitioning the split of flow from storage to runoff and infiltration, a saturation cupfor measuring surface saturation of the infiltration resistance medium and a saturation capand splitter balance linefor communicating water levels in the saturation cupto the splitter pan

Runoff rain gauge elevated in situ design

Disclosed is a runoff rain gaugewhich includes a collector tube, soil infiltration resistance medium, a runoff resistance flow element, a standard rain gauge, and runoff collection tube. Precipitation enters the collector tubeand is divided to flow into the infiltration mediumand runoff collection tubevia flow element. Total precipitation is read in standard rain gauge, runoff in tube, and soil infiltration in mediumis calculated by the difference between total precipitation and the runoff. Also disclosed are a runoff rain gaugecomprising: a seal legdownstream from the runoff resistance flow element; a collector tubemounted directly to the ground so that the bottom of the soil infiltration resistance mediumcontacts the ground surface; and/or a horizontal capillary tube in the runoff resistance flow elementto insure self-sealing via capillary forces.

Runoff rain gauge

Disclosed is a runoff rain gaugewhich includes a collector tube, soil infiltration resistance medium, a runoff resistance flow element, a standard rain gauge, and runoff collection tube. Precipitation enters the collector tubeand is divided to flow into the infiltration mediumand runoff collection tubevia flow element. Total precipitation is read in standard rain gauge, runoff in tube, and soil infiltration in mediumis calculated by the difference between total precipitation and the runoff.

A method for modifying a standard two-bed horizontal ammonia converter to provide increased conversion and/or production capacity by placing the first secondary catalyst bed of the existing converter in parallel flow with the existing primary catalyst bed and replacing magnetite catalyst in the second secondary catalyst bed with high activity ruthenium-on-carbon catalyst.

Horizontal ammonia converter adapted for high activity catalyst

Methanol emissions in the CO.sub.2 vent from a synthesis gas unit in an ammonia or hydrogen plant are reduced by contacting raw synthesis gas from a low temperature shift converter with recycled stripped condensate to absorb methanol. The synthesis gas is treated in a purification unit to form the CO.sub.2 vent of reduced methanol content. The condensate from the contacting step is steam stripped to form a process steam stream suitable for feed to the reformer and a stripped process condensate stream suitable for offsites polishing, a portion of which is recycled for contacting the raw synthesis gas.

Reducing methanol emissions from a syngas unit

A fixed bed, dual-zone radial flow catalytic reactor is disclosed. In particular, the catalyst bed configuration includes a first freeboard outwardly radial flow catalyst zone in series with a second inwardly radial flow zone separated by an interconnecting substantially impermeable catalyst chute to accommodate catalyst settling while preventing hot spots and/or fluidization in the freeboard area. A gas distributor divides the freeboard zone into segments including a bypass segment and one or more catalyst segments. The radial flow of gas through each segment is essentially unaffected by the level of catalyst so that the flow pattern is not adversely affected by catalyst setting in the freeboard zone.

Catalytic reactor bed

A vertical, cold wall, three bed ammonia converter having upper and lower shell and tube heat exchangers wherein the lower heat exchanger is disposed axially within the upper, annular catalyst bed and preheated synthesis gas from the heat exchangers is initially converted in the middle catalyst bed which is penetrated by first, second, and third coaxial pipes. Partially converted gas from the middle catalyst bed flows upwardly through the annulus formed by the second and third axial pipes through the hot side of the lower exchanger and is then divided for parallel flow through the upper catalyst bed and, by way of the annulus formed by the first and second axial pipes, the lower catalyst bed. Converted gas from the upper and lower catalyst beds is then combined and introduced to the hot side of the upper feed/effluent exchanger.

Ammonia synthesis converter

A horizontal, cold wall, multi-bed ammonia converter having two, shell and tube interchangers for cooling reaction gas streams leaving respectively the first and second catalyst beds with incoming reactant gases wherein each of the interchangers is vertically oriented and physically located between catalyst beds. The catalyst beds are adiabatic, slab-shape beds defined in part by side portions of the inner wall of the converter and are arranged for downward, transverse flow of reacting gases. Longitudinal conduits and baffling in cooperation with the arrangement of catalyst beds and interchangers provide serial flow of gas through the cold side of each of the interchangers, a first catalyst bed, the hot side of one of the interchangers, a second catalyst bed, the hot side of the other interchanger, a third catalyst bed, and, optionally, a fourth catalyst bed.

Growing community of inventors

Tomball, TX, United States of America

Stephen Allen Noe