Ammonia Manufacturing, Storage and Loading System

Introduction

• Ammonia is one of the most important inorganic basic chemicals, not only for the manufacture of fertilizers (85%) but also for the production of plastics, fibers, explosives, and intermediates for dyes and pharmaceuticals.
• It is an essential reaction component for the synthesis of numerous organic chemicals used as solvents and intermediates.
• This course provides an up-to-date overview of the product properties, synthesis and reaction mechanisms, including catalysis and commercial catalysts, modern production technology for different feedstocks, quality specifications and environmental health and safety aspects, uses and economic data of this important commodity chemical.
• The course also presents the perspectives of future developments of commercial ammonia production.
• Chemical engineers, process engineers and chemists in industry, engineering companies, catalyst manufacturers, equipment makers and chemical engineering university departments will certainly profit from this course.
• This course is designed to provide participants with the different types of storage tanks; operation, shutdown and troubleshooting.
• Participants will be aware of concepts related to ammonia, loading and unloading and all precautions to be taken care of during the loading and after loading completed.
• Participants will be aware of the different types of ammonia containers.
• Participants will be aware of loading arms operations.

Objectives

After the program, the participants will be able to learn:

• Recognize the ammonia manufacturing process.
• Recognize the different catalysts used in the ammonia manufacturing process.
• Recognize the different types of storage tanks; codes and standards.
• Review the operating parameters of ammonia storage.
• Learn how to deal with all different types of ammonia and loading.
• Recognize the loading arm details ( Assembly, Parts. Etc.)
• Recognize the loading arm hydraulic system operation and alarm system.
• Know the operation of the loading arm ( Connection, Draining sequence, and Disconnection).
• Recognize the anticipated emergencies and their handling.
• Learn how to use loading arms in normal operation and put in maintenance positions and made ready for a maintenance job.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

• People who are making day to day decisions regarding operation and maintenance of ammonia storage and loading system.
• This course is intended for process operations staff and maintenance staff.
• Shift foremen, plant supervisors, and other technical staff will gain excellent knowledge from the practical aspects of this course.

Course Outline

Day 1: Introduction to Ammonia Synthesis

• Definitions & Terminology.

• Ammonia Synthesis - Theory and Operation.

• Ammonia Production; Ammonia and Anhydrous Ammonia MSDS.

• Ammonia production plants;

• Steam reforming ammonia plants

• Ammonia plants based on partial oxidation

• Ammonia synthesis units;

• Primary Reforming (Hydrogen Production)

• Secondary Reforming (Nitrogen Adjusting)

Day 2:  Introduction to Ammonia Synthesis – Continued

• HTS High-Temperature Shift Convertor

• LTS High-Temperature Shift Convertor

• CO2 Removal

• Methanation

• Compression

• Ammonia Converter

Day 3:  Ammonia Storage Operation, Shutdown/Turnaround Preparation

• Types of storage tanks.

• Tanks Codes and Standards.

• API 653 - Tank Inspection, Repair, Alteration, and Reconstruction.

• Ammonia Storage Operations.

• Operational awareness at storage side

• Precautions/activities at storage end when ship loading is taking place

• General safety precautions

• Flare (Ammonia Vapour Return) handling

• Anticipated emergencies and its handling

Ammonia Handling and Loading

• Definitions & Terminology;

• ISGOTT (International Safety Guide for Oil Tankers & Terminals)

• ISPS (International Ship and Port Facility Security)

• The ship-shore interface.

• Preloading meeting and safety checklist.

• Cargo Documentation.

Day 4: Ammonia Handling and Loading

• The different types of ammonia loading;

• Cargo Tanks (Cargo Tank, Nurse Tank, and Bobtail)

• Rail

• Loading arm details ( Assembly, Parts. Etc.)

• Loading arm hydraulic system operation and alarm system.

• Loading arms ESD tests.

• The Operation of PERC.

• The operation of loading arm ( Connection, Draining sequence, and Disconnection).

• The anticipated emergencies and its handling.

• How to use loading arms in normal operation and put in maintenance positions and made ready for maintenance job

Day 5: Ammonia Handling and Loading

• Marine Terminal & Ship Loading.

• The ship equipment & instrument.

• Cargo handling operation.

Safety, Quality & Risk Management

• Preloading Checklist at Shore Side.

• Precautions and activities at Shore (Tank Area) during ship loading.

• Tank ventilation arrangements; Flare Handling.

• Flare Tip Types; design and operation.

• Approved intrinsically safe cargo monitoring equipment.

• Emergency procedures.