Installing a Feed Gas Saturator

A feed gas composed of steam and natural gas with a volumetric ratio of steam to carbon of about 3.5 to 1 is reacted in the primary reformers of ammonia plants. The required steam is generated from heat sources within the plant and the balance is produced in auxiliary boilers. By installing a feed-gas saturator, the low-level heat from the flue gases that otherwise would be lost, can be utilized for saturating the natural gas feed with water. This will result in extra steam generation that can replace a part of the steam generated in the boiler. With this measure, more medium pressure steam is available for use in the plant. The water used for feed-gas saturation is process condensate that contains some methanol and ammonia. 

This measure is applicable as a retrofit in existing plants. 

Development Status Products

Installing a Feed Gas SaturatorCosts & Benefits

Parent Process: Steam Reforming
Energy Savings Potential
CO2 Emission Reduction Potential

Installing a Feed Gas Saturator Publications

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Installing a Feed Gas Saturator Tools

Assessment to Action (A2A) Toolkit

Developed by IIP, in collaboration with energy expertsat ICF Marbek, members of the IFA and experts in China, the A2A (Assessment to Action) Toolkit is a free suite of resources on energy management and technology best practices created for ammonia companies. The A2A Toolkit provides a first-order, high-level assessment to identify and prioritize energy efficiency opportunities. It does so by drawing on various assessment modules on technical best practices, management best practices (based on ISO 50001 standard) and productivity improvements.