GIAP has successfully upgraded the ammonia synthesis column at Ammonia-3 unit at JSC Grodno Azot
For the first time in modern history GIAP specialists implemented a fully Russian solution for upgrading the ammonia synthesis column packing.
GIAP has carried out modelling, calculation and equipment design of ammonia synthesis column packing, and arranged its production at the Russian producers. The project was implemented together with NovomoskovskGazDetal LLC, JSC ZAVKOM and Vitzeman LLC. In partnership with RESOL company, GIAP selected and supplied the optimal catalyst for this production, manufactured by LINQU DAXIANG FINE CHEMICAL CO., LTD.
The service package also included supervision and commissioning supervision at all work stages - from dismantling the old packing and unloading the 15-year-old catalyst to commissioning and performance testing.
Work on the project started in December 2023. The specialists carried out process calculations, developed sets of equipment design documentation, placed orders and monitored the quality of equipment fabrication, including internal heat exchangers, permeable elements of catalyst baskets, and cold bypass pipelines.
As part of the Import Substitution Program, the production of multi-zone thermocouples was arranged and certified in Russia. GIAP achieved complete independence from foreign suppliers in the production of the key element of ammonia synthesis - synthesis column packing, which had been supplied by foreign companies only over many years.
Already in 10 months from signing the contract, at the production site of JSC Grodno Azot the column was disassembled, internals dismantled, catalyst unloaded, new internals installed, fresh catalyst loaded, synthesis column reassembled, catalyst restored and internal pipelines completely replaced under the supervision of GIAP.
The whole scope of work within the framework of turnaround maintenance was completed ahead of the schedule. The start-up of Ammonia-3 unit, including catalyst recovery, was carried out in a planned manner. All guarantee performance was confirmed at the first try.
When designing the packing, an important task was to reduce hydraulic resistance of the column after catalyst replacement. As a result, when the unit reached 100% load, the column resistance was only 0.41 MPa (more than 5% lower) and, what is important, had no negative impact on the uniformity of syngas distribution over the volume of catalyst trays.
GIAP especially highlights the work done by the company's equipment design department. The ammonia synthesis column packing is a set of internal elements of three catalyst trays, two integrated heat exchangers, cold bypass pipelines and structural units that combine all the elements into a single structure. It was a challenging and painstaking task to tie together the elements inside the existing high pressure vessel which was fabricated more than 40 years ago, and GIAP employees managed to do it with high quality and in a short period of time.
Today, the ammonia unit is operating steadily at the Belarusian enterprise, and the column is not only put into the design mode, but also has a capacity margin.
GIAP is grateful to JSC Grodno Azot for its trust and the opportunity to implement interesting projects.