NitricAcid@Max

Advanced Process Control for Nitric Acid Plants

 

To help production managers increase the profitability of their Nitric Acid production facilities, IPCOS’ NitricAcid@Max solution is one of the members of IPCOS’ Fertilizer@Max solution family.  This Fertilizer@MAX solution family includes members like Ammonia@Max, Urea@Max, and other solutions.  These solutions help fertilizer producers to maximize their profits by maximizing production and minimizing energy consumption, while making use of their existing assets, thus without the necessity to make any changes to the plant equipment.

IPCOS’ NitricAcid@Max solution is the advanced control solution for Nitric Acid plants.  The solution is based on IPCOS’ State-of-the-Art INCA APC control software, which connects to the DCS and controls and optimizes the plant minute by minute, every hour of the day, every day of the year.  NitricAcid@Max was specifically developed for Nitric Acid plants.  It captures best-in-class APC technology and extensive process and operations knowledge that IPCOS’ project consultants have gained over many years working in the industry.  And since we know what we’re doing, we are not afraid of guaranteeing the benefits you will get from our solutions!

 

The benefits are obvious:

• Maximized ammonia conversion efficiency
• Maximized plant throughput (typical increase 1-2%)
• More consistent product quality
• Better absorption efficiency
• Improved stability and safety in operation
• Minimized precious metal losses

 

How does NitricAcid@Max  generates your benefits?

General Improved Stability
Each NitricAcid@Max solution will bring more stability to your plant operation.  Significant reduction in variation of all your plant parameters is achieved, typically with more than 50%.  Obviously, improved stability of the plant leads to more reliable operation, and hence higher uptime.

Optimal Control of the Combustion Temperature at the Platinum Gauge

By controlling the burner temperature more tightly to the desired optimal burner temperature, the specific consumption of ammonia is minimized, and the precious metal catalyst loss is minimized as well.  As an example, the impact of the day/night variations (as a result of the air temperature variations) is greatly reduced.

Optimal Control of the Absorption Unit

By improved control of the absorption unit, product quality giveaway is reduced, and NOx emissions are minimized.

Optimal Control of the Compressor(s)
Improved efficiency of the air system helps to minimize the specific energy related to air compression.  It also helps to minimize emissions and to stabilize the tailgas. 

Optimal Control of the Cooling Water and Steam System

By optimizing the operation of the unit, including the cooling water and steam system, energy optimization is performed on a minute-to-minute basis.  At times when the burner temperature is at its limit, the steam pressure is kept at (or above) the desired low limit.  If the burner temperature is unconstrained, the steam pressure is maximized (between limits).