Implementation of a Feed Gas

Saturation System to a 1970s Foster

Wheeler Steam Methane Reformer
For ammonia plants wanting to improve the efficiency of their steam methane reformers, the
installation of a feed gas saturator system provides a cost effective alternative to combustion air
preheat and other upgrade options. By utilization of cold process condensate, additional heat is
absorbed from cooler flue gas, steam demand is reduced, and condensate treatment is reduced.
Completed in 2014, such a system was successfully implemented on a 1970s Foster Wheeler reformer
at the Yara Trinidad Tringen 1 plant.

Treveno Stenn Mowassie

Yara Trinidad Ltd.

Daniel Znidersic
BD Energy Systems, LLC

Introduction proved to be an effective method for reducing

I
n an environment that requires continuous flue gas temperature and improving thermal
improvements to ensure sustainability and efficiency, without modification to the existing
productivity, safe innovative methods for combustion system.
energy reduction is a key success factor
towards competiveness. Innovative methods Description of process
utilizing waste heat to improve energy
efficiency show great potential for energy Background
reduction and improved productivity. The Tringen 1 plant original design production
capacity was 1160 MT/day. The first revamp in
Commissioned in 1977, the Tringen 1 Ammonia 1996 focused on increasing production capacity
Plant is located in Point Lisas Trinidad and is and as such, the production rate was increased
operated by Yara Trinidad Limited. The plant is to 1365MT/day. The plant uses natural gas
a 1970’s Flour Daniel design that was revamped in feedstock in a methane steam reforming side
1996. In 2014, another revamp followed with fired Foster Wheeler furnace with auxiliary
the intent of reducing plant specific energy convection burners. Furnace draft is created by
consumption by 12% while increasing the three (3) induced draft fans. Prior to the 2014
maximum achievable production rate by 5.5%. revamp, process steam for reforming was
Though numerous modifications were made to suppled from the medium pressure (MP)
the plant, the focus of this paper will be the 600psig (4140 kPag) header directly.
benefits achieved from a Feed Gas Saturator
System Unique features in this plant include the
following:
Through reduction of process steam demand
1. The plant has an aqueous ammonia
through cold process condensate utilization,
refrigeration system which is
implementation of a feed gas saturation system

2017 229 AMMONIA TECHNICAL MANUAL

 supplemented by motor driven 1. Primary Reformer Convection Coil Changes
refrigeration screw compressors. to improve thermal efficiency of the furnace.
2. There are two syngas compressors. The o The convection coils were redesigned to
first (LP Syngas Compressor) is located maximize use of reformer convection
on the inlet to the CO2 system and duty. The chosen approach to improve
compresses to approximately 1800psig. reformer thermal efficiency was the full
The second (HP Syngas Compressor) replacement of the convection section
compresses to the synloop operating coils. This included hip coils, while
pressure of 3300psig (22800 kPag). using the existing structure, and a
3. The CO2 removal is done by physical simplified coil configuration with the
absorption using Propylene Carbonate, addition of a feed gas saturation system.
which requires a high pressure, thus the 2. Installation of a once through Make Up Gas
location of the LP Syngas Compressor. (MUG) converter with an associated high
pressure steam boiler and boiler feed water
2014 Energy Revamp preheat.
In 2011 a revamp concept was launched with an 3. Conversion of the main synthesis loop from
energy reduction focus. The resulting revamp a wet gas loop to a dry gas loop using an
concept indicated the possibility of a reduction Ammonia Wash countercurrent column for
in specific energy consumption from 43.5 Syngas drying.
MMBtu/MT (HHV) to 38.3MMBtu/MT (HHV) 4. Modification of selected turbines to dual
while also increasing maximum production driver (motor/ turbine capability):
capability from 1440 MT/dy to 1520 MT/dy. o Two out of four Boiler Circulating
Water Pump Drivers
The principal strategy for energy reduction was o Two out of three Induced Draft Fans on
a change in the medium pressure steam balance the Primary Reformer
on the plant. It was identified that the plant was 5. Upgrade of the process condensate stripper
operating in a mode where the medium pressure from LP steam (to vent) to MP steam being
steam demand exceeded the HP steam recovered.
generation capability. As a result, additional MP 6. Installation of a booster process air
steam was imported from natural gas fired compressor for production increase.
auxiliary boilers. The revamp focused on areas 7. Installation of a supplemental ammonia
where MP steam demand could be reduced. bypass refrigeration compressor.
Several opportunities were identified. These 8. Modification of selected turbines to motor
included: drivers.

• Steam generation via waste heat After implementation of the above changes, the
recovery (Feed Gas Saturation) plant has been capable of achieving production
• Reducing synloop pressure by the volumes up to 1524 MT/dy at an energy
installation of a once through Make Up consumption of 39.1 MMBtu/MT (HHV). The
gas (MUG) converter leading to reduced modifications implemented have been
power consumption of the synthesis gas operationally stable and has not reduced plant
compressor turbine. reliability.
• Change from selected turbine drivers to
motor drivers or dual drivers. The main contributor in the overall energy
reduction was the use of the reformer flue gas
In 2014, the revamp was executed and the main waste heat for feed gas saturation. In the case of
changes to process included: the Tringen 1 furnace, this waste heat generated

AMMONIA TECHNICAL MANUAL 230 2017

 33% of the required process steam from In a typical ammonia plant, unreacted process
condensate. This steam would have otherwise steam is condensed for reuse. As this process
been produced via auxiliary boilers. The use of condensate can contain impurities (e.g.
feed gas saturation solely contributed to a dissolved gases and trace amounts of methanol
reduction in plant specific energy by 2.0 and ammonia), from upstream in the reforming
MMBtu/MT (HHV). process and shift converters, reuse of this
condensate as BFW normally requires
treatment. A feed gas saturator coil system
What is a Feed Gas Saturator Coil? allows utilization of this condensate – without
A saturator coil is a reformer convection coil pretreatment – by injection into the natural gas
bank that uses available flue gas heat that would feed. This process reduces the amount of “live”
otherwise be vented, to vaporize a water stream steam needed for mixing with the hydrocarbon
directly injected into the feed gas stream. This feed upstream of the radiant catalyst tubes.
water stream is usually process condensate or There is also the benefit of extracting additional
Boiler Feed Water (BFW). heat from cooler reformer flue gas.

Figure 1. Flow diagram of a saturator coil / feed gas saturation system.

2017 231 AMMONIA TECHNICAL MANUAL

 Inclusion of a feed gas saturator coil alters the Saturator Coil Control and Operation
feed gas flow path from a typical steam methane
reformer. As shown in Figure 1, the Natural Feed gas saturation is achieved on the Tringen 1
Gas feed is first preheated in an interchanger plant by direct injection of water into the inlet
before being further heated in a convection manifold of the saturator convection coil. The
section preheat coil to elevate the temperature water source can be process condensate, boiler
for the purpose of desulfurization. feed water (BFW) or a combination of both.
Process condensate is the primary source of
Following desulfurization, the feed is then water to the saturator coil with BFW as a back-
cooled by the interchanger before a water up supply.
stream is injected (typically process condensate
and/or BFW). Lowering the feed temperature
after desulfurization is necessary to achieve a
lower saturator coil inlet temperature thereby
potentially increasing efficiency. The
hydrocarbon feed and condensate mix passes
through the feed gas saturator coil. The stream
then passes through a separator (knockout) drum
to remove any remaining liquid condensate.
Generally, the saturator coil fully vaporizes the
injected water with some superheating;
however, where solid impurities are a concern,
the coil may be designed for less than 100%
vaporization. Following the separator drum,
additional process steam is added to achieve the
desired steam to hydrocarbon ratio before being
further preheated for the reforming reaction.

Due to the replacement of a portion of “live”

process steam by condensate, the combined
mixed feed temperature is lower than if “live”
steam only was used. To accommodate this,
additional design changes are made, such as
increased surface area to the mixed feed preheat Figure 2. Front view of Tringen 1 Plant
coil, rearrangement of coils, increased arch or Primary Reformer (Foster Wheeler Terrace
auxiliary firing, etc. Wall Design)
The colder saturator coil inlet temperature
allows for cooler flue gas stack temperatures
and higher reformer efficiency. Energy savings
are seen in the form of reduced steam
generation, reduced steam superheat, reduced
condensate treatment, and more efficient
induced draft (ID) fan operation due to
decreased flue gas volume.

AMMONIA TECHNICAL MANUAL 232 2017

 that the required total water flow to the coil is
maintained as well as the required steam to
carbon ratio.

In the event that the temperature of the gas

leaving the saturator coil reaches the dew point
and liquid exits the coil, there is a separator on
the outlet of the coil to prevent liquid from
reaching the mixed feed coil. This vessel is
equipped with a high level 2oo3 trip.

The control strategy has been tested in normal

operation, startup –up, shutdown and plant upset
conditions and has proven to be reliable.
Figure 3. Side View of Tringen 1 Plant Primary
Reformer (Foster Wheeler Terrace Wall
Design) Primary Reformer Configuration

Process condensate from the primary process Original Design

condensate knockout drum is pumped from the Built in 1977, the primary reformer is a Foster
drum to the saturator coil and is controlled Wheeler design, with twin radiant cells. The
through a flow control loop. The flow control convection section was design with six (6)
loop works in conjunction with the primary streams – natural gas fuel, demineralized water,
reformer steam to gas ratio controls and sets a process air, natural gas feed, mixed feed
remote set point for the total water flow required (hydrocarbon and steam), and high pressure
to the saturator coil. The exit temperature of superheated steam – heated in a total of 15 coil
mixed gas from the saturator coil is monitored banks – 7 in the vertical section and 4 in each
via the DCS. A temperature differential hip section.
indication is set up between the actual outlet
temperature and the process stream dew point. If Prior to the revamp, the furnace was also
the actual temperature out of the saturator coil experiencing multiple operational issues. Coils
approaches 50F of the dew point temperature, a were operating above their design metal
deviation alarm activates to alert the operator temperatures. Substantial air leaks were also
that the saturation temperature is being discovered.
approached.

In the event that process condensate (primary

water source) cannot supply the saturator coil
water requirements, the controls will
automatically begin injection of BFW to ensure

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 Figure 4. Pre 2014 Revamp Primary Reformer Configuration

Figure 5. Post 2014 Revamp Primary Reformer Configuration

AMMONIA TECHNICAL MANUAL 234 2017

 Primary Reformer Configuration

Revamp Design
To address the issues of air leakage, coils
operating outside of their design and mechanical
integrity, it was decided to redesign the entire
the convection section. In spite of the
redesigning of the convection section, the
existing convection height and structure was
maintained. Whereas the original convection
section was design to avoid pinch points by
dividing the process into numerous coil
sections, the addition of the feed gas saturator
was modular.

The revamped design introduced the saturator Figure 6. Coil module frame for improved
coil while reducing the number of streams to installation time
five – feed preheat, high pressure superheated
steam, feed with condensate, mixed feed, and
process air – across a total of only nine coil
banks – five in the vertical section and two in
each hip section, although the total surface area
has increased. As the number of coil banks has
decreased, so too has the number of jumpovers.
Modifications also included conversion of the
ID fan to dual drive operation (motor or turbine)
instead of strictly turbine driven in order to
further reduce plant steam demand.

Existing convection structural steel was reused.

To improve installation time, coil modules were
designed with straight walls for sliding into the
existing structure (see Figure 6).

To provide room for the saturator coil in the

existing structure, the fuel preheat and
demineralized water coils were removed. As
the saturator coil provides all the necessary cold
flue gas heat sink, efficiency is not lost by
removal of the fuel preheat; rather, a small
reduction in adiabatic flame temperature, and Figure 7. Process condensate injection
thus thermal NOx formation, may be a
tangential benefit to this design choice. To ensure proper mixing of the process
condensate and desulfurized feed, process
condensate is injected into the feed stream
directly following the manifold as in Figure 7.

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 Performance (63.9°C). At an average flue gas temperature of
285°F (140°C), the actual revamp efficiency
Performance prior to 2014 Revamp was 93.2% based on an O2% of 2 vol%, dry.
Before the revamp, the reformer stack
temperature was in the range of 690°F-710°F Due to the desire for operational stability should
(366°C-377°C), with thermal efficiencies of additional steam be needed, the HP boiler was
approximately 80% (3 vol% O2, dry basis) and not shut down but remains at minimum firing
81% (2 vol% O2, dry basis). The maximum when the plant is at full load.
demonstrated capacity was 1440 MTPD. The
maximum reformer firing rate was 684 Pre- Design Actual
Revamp
MMBtu/hr (722 GJ/hr), and the “live” process Capacity (MTPD) 1390 1520 1500
steam added to the feed stream was 227,000 Firing (MMBtu/h) 684 722.7 696.2
lb/hr (102,900 kg/hr). Duty (MMBtu/h) 615.4 657.8 648.9
Plant MMBtu/MT 43.5 38.3 39.1
Predicted Performance Crossover (°F) 964 930 975
Due to the full revamp design scope, the Condensate (lb/h) - 73,400 66,000
production capacity was increased to 1520 Condensate (°F) - 168 147
Steam Superheat 676,700 569,300 569,300
MTPD. The reformer was predicted to operate (lb/hr)
with a firing rate of 722.7 MMBtu/hr (762.4 Stack T (°F) 690 330 285
GJ/hr) and a stack temperature of only 330°F Table 1. Performance comparison
(166°C), having a fired efficiency of 91% based
on 10% excess air (~2vol% O2 dry in the flue
gas).
Conclusion
With the new design, predicted use of process
condensate for normal operation was 73,400 Utilization of waste heat from the primary
lb/hr (33,300 kg/hr) at 168°F (76°C). Due to reformer flue gas can provide significant
this, MP process steam could be reduced to opportunity for energy reduction especially in
157,000 lb/hr (71,200 kg/hr), with condensate older vintage plant designs. Though many
providing the remaining 31.8% of the total potential opportunities exist for both energy and
steam requirement. production improvements, a feed gas saturation
system, by itself, can be an attractive option for
Under pre-revamp conditions, the HP Boiler energy reduction. The design, control strategy
produced 176,000 lb/hr of HP steam. The and operation have been proven to be reliable
change of the ID fan from turbine to motor and stable with the potential to improve thermal
driven operation saves an additional 30,000 efficiency by 12% while reducing the need for
lb/hr of Steam. Together with the steam savings MP steam generation. In addition to the benefits
from the saturator coil, it was predicted the HP of improved efficiency, the modification also
Boiler could have been shutdown. results in the offloading of the ID fans and re-
use of process condensate without pre-
Actual Performance treatment.
From actual operating data taken on August 24,
2015 following the revamp, the plant was Overall, though the benefits should be assessed
running at 1500 MTPD, at 109% plant load. on a case by case basis, the potential of this
The average condensate to feed ratio was 0.947 method for energy reduction should not be
lbmol/lbmol, resulting in a 66,000 lb/hr (30,000 under-estimated.
kg/hr) process condensate utilization at 147°F

AMMONIA TECHNICAL MANUAL 236 2017