Failure Diagnosis Of Primary Reformer Of Branu Technology Ammonia Synthesis Plant And Countermeasures

Branu ammonium synthesis is widely adopted in chemical fertilizer industry because of its relatively lower energy consumption. It is characterized by mild primary reforming, application of gas turbine and cryogenic purification, and adoption of a unique braun circuit design as an energy saving method. The primary reformer is the key equipment in ammonia production, whose main function is to produce H₂ and to drive high pressure steam of gas turbine in subsequent section. Thus, a stable operation of the primary reformer is of paramount importance to the whole ammonia production.The energy consumption has being high in the production of Urumqi Petrochemical Company 2nd Fertilizer Plant by Branu ammonium synthesis. After the application of refining gas mixture combustion, failure appears in many aspects: overheating of exteriors of burner box, burnt out of natural gas burner and serious deformation of superheated steam coil.In this study, we conducted systematic research to find out the real causes of high energy consumption of primary reformer in order to put forward solutions of the faults mentioned above, and to optimize the actual running conditions of primary reformer so as to enhance the energy efficiency of primary reformer. The study is divided into the following parts.Part one is to find out the relationship among imported products, exported products and import reactants in primary reformer through calculating material balance and energy balance on design condition, checking whether they have arrived material balance under the design conditions of primary reformer. Besides, to find out calculation methods in accordance with the design condition and set up unified benchmarks for energy balance and material balance calculation in the following practical working condition. In part one, we also check if there are design defects in the designed working conditions by contrasting to the value of equipment design,.Part two is to do calculations in actual operation conditions, to contrast design conditions and changes by comparing operating data with design index, and to analyse the cause of higher energy consumption of primary reformer and propose solutions. Besides, to provide theoretical basis and concrete scheme for major repair of primary reformer.Part three is to provide guidance suggestion to modification scheme of major repair of primary reformer, according to the results of failure diagnosis.Part four is to do the check for the actual working conditions after major repair of primary reformer, and check the effects of major repair by analyzing the primary reformer's energy consumption after major repair.Calculated results of this research finally reveal that: burner overloading, irrational distribution of gas turbine exhaustion, lower combustible components in fuel and emission and excessive high-pressure steam production are major causes of faults of primary reformer.We put forward an improving plan for major repair of primary reformer according to failure causes. After major repair, consumption of natural gas decreased significantly and there is a substantial increase in the efficiency of gas combustion. Overheating exterior problem of a burner has also been solved effectively. Burners' flame length of the furnace is normal, and the exhaust temperature of primary reformer has dropped to 175℃. Replaced superheated steam coils have run smoothly for three years.