Tianji Synthetic Ammonia Transforms Energy Saving and Production Increase
Tianji Group has recently upgraded its ammonia production facility, increasing annual output from 300,000 tons to 450,000 tons. At the same time, the company significantly reduced its energy consumption per ton of ammonia, bringing it down from 2.29 tons of standard coal to 1.89 tons. This major improvement has positioned Tianji Group as a leading player in energy efficiency within the coal chemical industry.
The project involved the adoption of advanced technologies, including pressure swing adsorption (PSA) for decarbonization and hydrogen extraction in ammonia synthesis. The company also introduced new equipment such as air separation units, PSA systems, and hydrogen sulfide removal devices, while upgrading key components like gas conversion units, liquid nitrogen cleaning systems, and synthetic compressors.
Compared to traditional methods like low-temperature methanol washing or liquid nitrogen washing, the PSA process is dry and does not require additional cooling. By implementing pure oxygen two-stage conversion technology, the system shares the load between stages, converting heat transfer into adiabatic processes. This reduces steam and fuel use in the first stage, improves thermal efficiency, and saves energy. Additionally, the methane content in the gas stream was significantly lowered, minimizing energy use and methane circulation.
The new setup also enhances compressor and turbine efficiency, lowers steam consumption, increases ammonia yield, reduces system resistance, and cuts overall energy usage. Moreover, the installation of heat pipe technology allows for more efficient recovery of waste heat from the furnace exhaust. The heat from the ammonia synthesis reaction is used to preheat boiler feed water, further reducing fuel needs. The upgrade also included the use of efficient tray technology in the methanol washing tower, increasing system capacity by 50% without adding new equipment.
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