The Chemical Industry Is Primed for Change
As the demand for green alternatives grows, Emerson is at the forefront of driving the shift towards sustainable solutions in the chemical industry. Whether you're focused on ammonia production or downstream applications, our innovative valve solutions are designed to help you enhance efficiency, reduce emissions, and improve safety—key step toward sustainability.
With Emerson’s vast expertise and diverse product range, we are here to help you overcome operational challenges, achieve your safety goals, and minimize environmental footprint.
Rethinking Energy: The Rise of Ammonia in the Transition to Renewable Energy
Ammonia holds immense potential as a clean energy source. Currently, its production consumes 1.8% of global energy and contributes significantly to emissions. However, by investing in advanced technologies, we can unlock its potential as a cleaner fuel, reducing our reliance on fossil fuels and paving the way for a more sustainable future.
of ammonia used for fertilizer production
of ammonia used for industrial products
Capacity growth required to 2050
of the chemical industry’s CO2 emissions
How Do Valves Impact Operational Performance?
Safety
- Reliable valves reduce maintenance events
- Prohibit harmful fugitive emissions
- Prohibit dangerous steam leaks
- Protect personnel in emergency events
Production
- Reduce process variability
- Improve synthesis loop performance
- Achieve the highest possible CO2 capture rates
- Produce high purity ammonia
Reliability
- Lessen process excursions
- Optimize reformer performance
- Reduce process upsets and production losses caused by equipment failure
- Lessen unplanned repair costs
Emissions
- Achieve fugitive emissions compliance
- Reduce valuable product loss
- Minimize reprocessing due to contamination or inefficiencies
- Decrease compressor and pump workload with optimized valves.
Valve Solutions for Ammonia Producers
Ammonia Control Process Map
Fisher™ easy-e™ ET Control Valve
The Fisher easy-e ET valve is your solution for all general applications with high process temperatures, featuring a balanced plug design and cage-guided trim. Available in globe or angle body, these valves can provide up to Class V or VI shutoff.
Fisher™ FIELDVUE™ DVC6200 Digital Valve Controller
The Fisher FIELDVUE DVC6200 instrument allows for your operation to run closer to setpoint, improving product quality with more accurate control. Using FIELDVUE Performance Diagnostics, valve operation is monitored online to evaluate performance and reliability.
Fisher™ HP Series Control Valves
Fisher HP series control valves are single-port, high-pressure, globe- or angle-style valves with metal seats, cage guides, and push-down-to-close valve plug action. These valves are designed for high-pressure applications in process control industries such as power generation, hydrocarbon production, chemical processing, and refining.
Ammonia Pressure Process Map
Enardo™ Series 951 High-Performance Top-Mount Pressure Relief Valve
The Enardo Series 951 is an advanced design for vent-to-atmosphere applications. This high-performance valve utilizes advanced technologies to provide protection against positive overpressure, prevent air intake and evaporative loss of product, and help contain odorous and potentially hazardous vapors. The Series 951 offers features that exceed the performance of standard valves on the market, particularly in very cold ambient conditions and applications involving sticky materials.
Crosby™ J-Series Direct Spring Pressure Relief Valves
J-Series valves provide high quality and dependable overpressure protection for air, gas, steam, vapor, liquid and two-phase applications in one simple design. Now available with two new to the world technologies, Balanced Diaphragm and Bellows Leak Detection.
Crosby H Series Direct Spring Safety Valves
Direct spring safety valves that provide comprehensive overpressure protection for ASME Boiler and Pressure Vessel Code Section I, and Section VIII steam safety applications
Ammonia Actuation Process Map
Bettis XTE3000 Electric Actuator
The XTE3000 is an intelligent multi-turn electric actuator from the Bettis family of actuators. Specifically designed to meet the most challenging valve automation demands of the Oil & Gas, Power, and Process industries, the XTE3000 is compliant with a wide range of international standards and is the ideal solution to your plant’s safety and reliability requirements.
Bettis RTS Fail-Safe Mechanical Spring Return Electric Actuators
The Bettis RTS fail-safe product line is designed to meet critical shut-down requirements. These intelligent, non-intrusive actuators are available in a range of sizes for both part-turn and linear emergency shutdown (ESD) applications.
Bettis SCE300 Electric Actuator
The SCE300 is an intelligent quarter-turn electric actuator from the Bettis family of actuators. Compact and lightweight, this all-in-one actuator fits all the features of larger, heavier actuators into a neat, innovative design. Deploy the SCE300 to maintain effective control of low-torque, quarter-turn valves and dampers in even the largest and most complex plants.
Ammonia Isolation Process Map
KTM Series EB1 OM-2 Split Body Floating Ball Valve
Versatile KTM Series EB1 is a high performance, next generation ball valve with bidirectional soft-seats, LOW-E fugitive emission certification, high pressure & temperature options and competitive design with cavity relieving seats.
Vanessa Series 30,000 Standard Triple Offset Valve
The Vanessa Series 30,000 is a robust triple offset valve featuring an integral-to-body valve seat and optimized seating angles, that enables the Series 30,000 to handle isolation and process control through multiple functionalities.
KTM Series EF1 Floating Ball Valve
The KTM Series EF1 split body flanged ball valve is a general purpose ball valve available in a variety of material configurations and features the patented SEALMASTER® shaft seal that provides exceptional fugitive emissions performance.
Featured Services
Featured Solutions for Ammonia Production
Enhancing Plant Production with Synthesis Loop Control
To elevate total plant production and operate at optimal capacity, it is essential to navigate various challenges effectively. These challenges encompass maintaining precise control for stable ammonia synthesis operations, enhancing conversion efficiency to reduce compression energy, and monitoring exchanger conditions to minimize refrigeration energy costs.
Implementing strategic solutions plays a pivotal role in the successful operation of synthesis loops. This involves the integration of advanced control valve systems, utilizing welded valve connections for emission control and operational efficiency optimization, and selecting valve trims capable of withstanding high pressures and temperatures in toxic environments.
By adopting these solutions, reactor pressure is optimized, leading to increased yields and ensuring the hydrogen-to-nitrogen (H/N) ratio remains at the ideal level for efficient ammonia synthesis. While catalyst deactivation is an inevitable occurrence over time, deploying these measures facilitates effective process management, extending catalyst lifespan, and sustaining operational efficiency at peak levels.
PRV Monitoring
Efficient monitoring of pilot-operated relief valves, such as the Anderson Greenwood low-pressure pilot-operated relief valves, can significantly enhance operational efficiency and emission reduction. By measuring the differential pressure between the main valve dome and the valve inlet, this technology offers real-time insights that enable proactive interventions, optimized maintenance planning, and superior asset management, all while minimizing emissions.
The prompt notification of relief events not only ensures the safety of personnel but also aids in compliance with stringent environmental regulations.
In the case of direct spring pressure relief valves, Emerson's solution offers precise monitoring capabilities, detecting valve stem movement down to 1/10th of an inch. This detailed data on lift, duration, and timing of the event facilitates accurate calculation of volumetric release, contributing to a more controlled and optimized operational environment.
Bellow Failure Protection
Detecting bellows failures in pressure relief valves (PRVs) presents a unique set of challenges, primarily due to the extended service cycles, ranging from 3 to 6 years. Traditional methods such as manual rounds and portable sniffers are often employed for reporting, but these approaches are prone to inaccuracies and can pose safety risks for operators. Instances of flare gas emissions resulting from ruptured PRV bellows, leading to fires due to operator unawareness, underscore the critical need for improved detection methods.
The introduction of PRV bellows monitoring serves as a crucial solution to address these challenges. Not only does this implementation enhance safety by ensuring balanced operation with a backup piston in case of failure, but it also significantly reduces emissions by mitigating the risk of failure and leakage through the bonnet vent, achieving up to a remarkable 94% reduction in emissions.
Furthermore, PRV bellows monitoring enhances operational reliability by providing real-time notifications of bellows ruptures, along with continuous monitoring of volumetric emissions. These substantial benefits collectively contribute to creating a safer, more efficient, and environmentally friendly operational environment.
Tank Protection and Operation
Access to real-time operational status information empowers swift decision-making, allowing for timely actions to rectify any discrepancies, such as identifying instances when a unit is open when it should be closed, or vice versa. This capability extends to receiving notifications when devices operate beyond expected parameters, including scenarios such as a blanketing regulator being fully open or the activation of emergency vents.
Leveraging the data collected from this monitoring not only enables the establishment of precise maintenance schedules, eliminating the need for guesswork regarding servicing needs but also aids in troubleshooting malfunctioning devices. For instance, it facilitates the prompt identification of issues, such as a PVRV vacuum pallet being open while the blanketing regulator remains closed.
This proactive approach to monitoring plays a pivotal role in flagging potential problems before dispatching a work crew, thereby streamlining operational efficiency and minimizing downtime.
Highly Efficient Steam System
In ammonia production, steam plays a critical role, driving chemical reactions and distillation processes. Efficient steam management is essential for optimizing the process. Key components include boiler blowdown valves that remove impurities from the boiler, steam traps that remove condensate and other contaminants, and pressure reducing valves that adjust steam pressure for optimal performance. These components work together to increase efficiency, reduce fuel consumption, and lower emissions. Efficient steam management also improves equipment integrity, reduces maintenance needs, and enhances overall safety in the ammonia production process.
Featured Media & Articles
Get your ammonia production questions answered. Explore our FAQs.
This question aims to understand the different valves vital to the ammonia production process, such as control valves, safety relief valves, and shut-off valves. The roles of these valves include controlling the flow and pressure of gases and liquids, providing safety measures in case of process upsets, and isolating sections of the plant for maintenance. Learn more about Emerson's Final Control solutions here: https://www.emerson.com/en/final-control/catalog/products-and-software/valves
Valves in ammonia production must withstand highly corrosive environments and high pressures. Therefore, this question seeks to explore how selecting materials like stainless steel or other corrosion-resistant alloys can impact the durability, safety, and efficiency of valve performance in ammonia production facilities.
1.Given that control valves are crucial for maintaining the precise pressure and temperature conditions necessary for ammonia synthesis, this question targets the best practices for regular maintenance, common issues that can arise, and troubleshooting steps to ensure uninterrupted and efficient operation of the ammonia synthesis process. Learn more about the Ammonia Synthesis Process here: https://www.emerson.com/en/final-control/services
Emerson's valve technologies minimize fugitive emissions of ammonia by comprehensively addressing all potential leak paths within their low emission portfolio. This includes the utilization of proven, patented stem sealing systems designed to create a tight barrier and prevent ammonia from escaping through the valve stem. Furthermore, Emerson emphasizes high integrity connections in their valve designs, employing robust materials and designs to ensure leak-free joints and minimize ammonia emissions at connection points. Learn more about Fugitive Emissions here: https://www.emerson.com/en/final-control/catalog/solutions/fugitive-emissions
