December 2010

Process Control/Information Systems

Implementing advanced process control on ammonia plants

Benefits exceeding the guarantee were realized through APC by simultaneously stabilizing and optimizing the plant in the presence of significant feed density variations that impact the entire plant operation

Banerjee, P., Aspen Tech Middle East (ATME); Siva Rama Brahmam, K. V., ATME Group; Al-Azmi, S., Nayfeh, L., Al-Azmi, K., Petrochemical Industries Company

Advanced process controllers (APCs) were implemented on the ammonia and steam-generation facilities comprising two ammonia production lines of different capacities interacting with a common downstream purge-gas recovery unit (PGRU) and ammonia absorption units. The steam facility has several boilers and super heaters contributing to the steam grid. Plant operation was significantly affected by large variations in the natural gas (NG) density that sometimes led to trips if prompt actions were not taken. Density variation affects the plant operation since NG serves as the feed and also fuel for the reformer and boilers. The operational stability problem was compounded due to manual compresso

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