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    SynCOR Ammonia™ - New process for grassroots plants

    SynCOR Ammonia™ - New process for grassroots plants

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    Steam-to-carbon ratio of just 0.6

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    Relative energy consumption of 97

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    Reduced steam throughput of 80%

    By rewriting the book on ammonia plant capacities, SynCOR Ammonia™ enables greater economies of scale and paves the way for new benchmarks, new financials and new opportunities – all using proven technologies.

    SynCOR Ammonia™ is a technology break-through in the ammonia industry. Where all ammonia plants today rely on conventional two-step reforming based on tubular steam methane reforming and an air-fired secondary reformer, SynCOR Ammonia™ utilizes the unique Topsoe SynCOR™ solution, a process based on oxygen-fired autothermal reforming.

    SynCOR Ammonia™ introduces a previously unseen scaling factor for single-train ammonia plants, thanks to a steam-to-carbon ratio of just 0.6 – reducing steam throughput by 80%. The result can be double-digit reductions in the cost per ton of producing ammonia – with greater savings achieved the further you scale up.

    By introducing new economies of scale into ammonia production, SynCOR Ammonia™ gives plant owners breakthrough options for profitable expansion and provides new investors with an opportunity to enter the market with a sharp competitive edge.

     

    Simplified process layout

    syncor-ammonia-process-diagram
     

    Most significant differences between conventional plant concepts and SynCOR Ammonia™

    Technology

    Conventional NH3 plant

    SynCOR Ammonia™

    Desulfurization section Standard Standard
    S/C ratio 3.0 0.6
    Reforming section Tubular steam reformer and air blown secondary reformer  Pre-reformer and oxygen blown SynCOR™
    Shift section High-temperature shift followed by low temperature shift Two high-temperature shifts in series
    CO2 removal section Standard Standard
    Synthesis gas cleaning Methanation Nitrogen wash with purge and nitrogen addition
    Ammonia synthesis Ammonia synthesis loop with purge Inert free synthesis loop with no purge
    Purge gas treatment Ammonia wash followed by hydrogen recovery No treatment required
    Relative energy consumption 100 97
    Relative make-up water consumption 100 40-50
    MAX referenced capacity, single train NH3/other industries 3,500 MTPD / - 4,000 MTPD*)/>6,000 MTPD

    * An equivalent production of 4,000 MTPD

    Definition

    Catalysts

    Catalysts can accelerate chemical reactions, control selectivity, and reduce energy requirements. Their ability to optimize process efficiency and product quality make them indispensable in industrial processes.

    Definition

    Outputs

    The output is the result or end product you're looking to get out of your refinery or chemical process. The output helps determine which technologies and catalysts you need.

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