Kellogg process

1-Converter 2-Heat recovery boiler 3-Gas-gas heat exchanger 4-Compressor 5-Water cooler 6,7,9-Ammonia cooler 8-Cold exchanger 10-separator 

Process type Small and medium plant Kellogg Tops0e Braun ICl AMV 

A major feature of this process is using the horizontal converter and small-particle catalyst, so that the gas flows the path shortly, its linear speed is small, the pressure drop decreases in the catalyst bed, and consequently the recycle-compress power can be saved the catalytic activity can be improved by 12%-25%. Thus the catalyst volume and the equipment size decreases, the net value of the ammonia increases, the amount of the recycle gas declines there is homogeneous distribution of the gas-flow so that gets the higher synthetic ratio, and the energy consumption is significantly reduced. 

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In addn to the above mentioned processes for the production of acetylene, several others were developed, of which the Tennessee Eastman process (Ref 22) and the Societe Beige de 1 Azote (SB A)-Kellogg process (Ref 27) are the most recent... 

Figure 6.1 Conceptual flowsheet for manufacturing cumene by Dow-Kellogg process [3] (R-l) alkykation, (R-2) transalkylation, (C-l) propane column, (C-2) benzene recycle column,...

Both the ARGE and Kellogg processes were commercialized in 1955 at the Sasol plant in South Africa with a capacity of 240000 t/a hydrocarbons. While the fixed-bed process proved reliable from the beginning, numerous modifications had to be made to the Kellogg process. The major difficulties encountered were concerned with the fluidization of the catalyst. This led to the development of the Sasol Synthol process which is now a highly reliable large-scale industrial operation [15]. 

Handles feeds ranging from gases to liquid hydrocarbons. Process is characterized by a highly selective pyrolysis coil. Steam pyrolysis temperature not as high as the Kellogg process reducing... 

Requires an oil quench (with liquid feed stocks) and also a water quench. Ethylene yields slightly less than that obtained with the Kellogg process. 

The major component of manufacturing cost is, quite obviously, raw materials. Hence, costs are quite sensitive to feed utilization and feed prices. The high selectivity of the Kellogg process is important in this respect. The eflFect of feed price on DCE cost is illustrated below, where costs for all HCl feed operation, with fresh HCl at 1.5 cents/lb. are compared on the basis of 3.0 as well as 4.0 cents/lb. ethylene ... 

The Fischer-Tropsch synthesis produces hydrocarbons from Hj and CO. Fluid beds were applied to it in the Hydrocol process using ordinary turbulent beds and in the Kellogg process using fast beds (Fig. 1). Development of the Hydrocol process has been reported by Grekel et al. (G15) and Hall and Taylor (HI). The main difficulties in scale-up of these fluidized beds were incomplete fluidization and low conversion. 

Kellogg Chlorine Process. The Kellogg process uses 1% nitrosylsulfuric acid [7782-78-7] catalyst and a dissimilar material containing a day desiccant having a reversible water content of 0.5 wt% and a crystalline structure stable to at least 760°C (72,73). Montmorillonite [1318-93-0] is the desired clay desiccant. It absorbs water as it forms, shifting the equilibrium of equation 28 to the right. The basic reaction is carried out on a fluidized bed in which the solids run countercurrent to the gaseous reactants at a temperature of 400—500°C and pressures of 300—1200 kPa (3—12 atm). Nitrosylsulfuric acid catalyst is fed into the top of the stripper column where it reacts with HQ to form nitrosyl chloride which then reacts with 02 in the oxidizer to produce Clg. 

Other examples of methanol production processes using adiabatic multiple-bed reactor concepts are the Haldor Topsoe process and the Kellogg process. 

It is well known that the conversion of hydrogen and nitrogen per pass is only 20%-30% for the present catalytic ammonia synthesis technology (Table 1.4). Most synthesis gases need to be returned to the reaction system, which increases power consumption. In order to increase conversion per pass, it must increase the outlet ammonia concentration of reactor. Accordingly, it can be seen from Table 1.4 that it is necessary to increase reaction pressure for small and medimn scale aimnonia plants and Topspe process, or to reduce the content of inert gas in sjmthesis gas for Topspe and Braun processes, or to reduce ammonia concentration in the inlet of converter for small and medium scale ammonia plants and Kellogg process. But all of these operations will add the power consumption or unit gas consumption. 

A major feature of the Kellogg process is the integrated heat recovery system to utilize the otherwise waste heat from various process streams and from the reformer flue gas, which is used to raise 100-bar superheated steam. The steam is let down in a turbine, which drives the synthesis gas compressor. Passout steam at 40 bar is used for process steam and for other machine drives. Passout steam from some of the smaller turbines at 4.5 bar is used for minor process heating duties. This total energy concept is largely responsible for the efficiency improvement over earlier processes. 

Many of the features of the Kellogg process, for example, centrifugal compressors, high-pressure steam systems, and high-pressure reforming, have subsequently been widely adopted by the ammonia industry. 

In recent years, the Kellogg process has been developed to improve its efficiency still further/ The process improvements fall into five areas ... 

In line with other modem processes, the Kellogg process can utilize one of the latest low-energy consumption carbon dioxide removal processes, such as Selexol or Lo-heat Benffeld. 

Fig. 63. Theoretical horsepower versus synthesis pressure for base case design (early M. W. Kellogg process) for plant capacity of 1500 short tons of ammonia per day (from [405])...

Uhde has recently commercialized a new low energy process scheme [41, 585, 775, 930]. A simplified process flow is shown in Fig. 6.31 (from [41]). The process scheme is, like the Topsoe and Kellogg process schemes, a further development of classical process schemes. Key features of the process are ... 

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