Risk analysis tools such as hazard identification (HAZID), is often a first step in broader risk management and is especially valuable for green ammonia, where new technologies and processes introduce novel risks. This article explores various aspects of HAZID, from the basics of hazard identification to unique considerations specific to green ammonia facilities.
A review of papers presented at CRU’s Nitrogen+Syngas 2025 Expoconference, held in Barcelona from February 10th-12th 2025.
A European ammonia plant, has successfully restarted following a revamp of the process gas cooling section, executed by Casale. Casale replaced the outdated boilers located downstream of the secondary reformer with three new double-tube type boilers supplied by Arvos. The new boilers were installed in the same location as the previous ones, minimising investment costs and plant modifications. The more robust and reliable design of the Casale-Arvos boilers has resulted in enhanced overall performance and reliability of the ammonia plant.
Paralloy has developed Omega technology, an advanced reformer tube design that enhances heat transfer, gas turbulence, and process efficiency. Dr Dominique Flahaut of Paralloy explores the real-world implications of Omega reformer tubes.
Esben Sørensen and Glenn Rexwinkel of Plug Power review the safety aspects of integrating hydrogen production by electrolysis into existing ammonia processes. Novel safety risks associated with such changes are surmountable and the analysis presented shows that green ammonia production can be no more hazardous than traditional ammonia production.
The partners in the HyLion network are planning to produce low carbon hydrogen from renewable energy in Scotland and convert it into methanol for use as a low carbon fuel in the shipping, aviation, and motorsport sectors in the UK and Europe. The HyLion project partners include ARUP, McPhy Energy, Bosch, E.On, CO2 Recovery Ltd, Mareneco Ltd, Cadeler A/S, and P1 Fuels. Management and IT consultancy MHP is providing strategic and operational advice on the development and digitalisation of an efficient supply chain. Around 9,000 t/a of hydrogen and around 45,000 t/a of green methanol are planned in the initial pilot plant, which will use 63,000 t/a of biogenic CO2 from E.On’s biomass power plant at Lockerbie and from local whisky distilleries for the production of methanol. Hydrogen will come from an 80 MW electrolyser supplied by McPhy Energy, using local wind energy, with pure water being supplied using Bosch technology. P1 Fuels’ technology will convert e-methanol into an e-fuel that fits seamlessly into the existing fuel infrastructure and offers a decarbonisation solution for the automotive industry, international and national racing series, and light aircraft, for example. Another customer for the e-methanol will be the shipping company Cadeler A/S. The plant is expected to start production at the beginning of 2028.
In part 5 of this series on stripper efficiency issues we conclude the discussion with a focus on fouling inside stripper tubes.
The first installed combination of a regenerative SO2 scrubbing system with a sulphuric acid plant using Worley Chemetics’ CORE™ reactor technology started up in November 2022. The combination of these technologies allows production of high-grade sulphuric acid from gases with low and/or fluctuating SO2 concentrations. C. Trujillo Sanchez and R. Dijkstra of Worley Chemetics report on the design concepts of this integrated process, highlight where it is most effective and report on the start-up and first years of operation of the plant.
Apart from having a good plant design, good maintenance practices and good operational discipline are key to optimise the performance of an acid plant and to protect it from corrosion and achieve a long life. B. Mumba, T. Mwanza and P. Ng’ambi of Kansanshi Mining PLC explore the Kansanshi sulphuric acid plant operations and the key parameters monitored and practices adopted that have helped to extend the catalyst campaigns from two years to four years.
Preventing regenerator amine carryover to the sulphur recovery unit can have catastrophic consequences and must be avoided at all costs. B. Spooner and M. Sheilan of SGS Amine Experts detail how by correctly interpreting operating data, having proper instrumentation and good chemical analysis, amine carryover can be prevented.