Vinod Arora

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Supervisors: Independent Consultants for Ammonia/Methanol and Petchem Plants
Phone: (1)-2817731629 Houston USA
Address: Kinetics Process Improvements, Inc.
16000 Park Ten Pl,
Suite#903, Houston- Txeas (USA) 77084
www.kpieng.net

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Papers by Vinod Arora

Challenges in Conversion to Clean Ammonia-p

Chemical Engineering, 2025

Ammonia producers face mounting pressure to decarbonize, yet most existing assets were built arou... more Ammonia producers face mounting pressure to decarbonize, yet most existing assets were built around steam methane reforming (SMR) with little flexibility for low-carbon alternatives. Forward-looking operators are now adopting strategic integration, targeted retrofits, and robust process adaptations to enable a smooth transition. Key systems—including synthesis loops, compression trains, and heat recovery units—can be upgraded to run on blue or green hydrogen with minimal disruption. This article shares lessons from one full-conversion project in Europe and three U.S. cases pursuing partial decarbonization through hydrogen blending and oxygen enrichment. Together, they illustrate a pragmatic, phased approach that aligns with policy trends and maximizes return on existing infrastructure.

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Benfield CO2 Revamp- Success & Lessons learnt

N2 + Syngas, 2025

This paper describes the systematic revamp of a Benfield CO₂ removal unit at a high-throughput a... more This paper describes the systematic revamp of a Benfield CO₂ removal unit at a high-throughput ammonia plant, emphasizing simulation-driven diagnostics and customized engineering solutions. The initiative was prompted by persistent operational challenges, including excessive steam consumption, elevated CO₂ slippage, and ongoing mechanical degradation—all of which had undermined energy efficiency, plant reliability, and overall performance. These issues were further compounded by hydraulic constraints in both the absorber and stripper, leading to unstable operation, solvent carryover, and increased cooling water demand.

A systematic upgrade strategy was applied, combining validated process simulation with detailed hydraulic and mechanical assessments to diagnose performance bottlenecks. Improvement options were ranked using a cost-benefit framework to ensure impactful and economically viable implementation.

The revamp yielded significant benefits: restored hydraulic stability, reduced CO₂ slippage, lower steam usage, and improved energy efficiency—all of which contributed to maximizing ammonia and urea production and enhancing long-term reliability.

Although implemented in an ammonia facility, the systematic methodology and solutions are broadly applicable to aging Benfield units in refineries and petrochemical complexes facing similar operational constraints.

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Challenges in Conversion to Clean Ammonia-p

N2+Syngas, 2025

Decarbonizing legacy ammonia plants poses significant technical and economic challenges. However,... more Decarbonizing legacy ammonia plants poses significant technical and economic challenges. However, with robust conceptual and process design, coupled with strategic integration planning, the extent of required modifications—and associated capital costs—can be significantly reduced. While these facilities were originally designed for hydrogen sourced via unabated steam methane reforming (SMR), many core systems—such as synthesis loops, compression trains, and heat recovery units—can be adapted to accommodate low-carbon feedstocks, including green and blue hydrogen. This enables a phased decarbonization pathway, where blue ammonia serves as a transitional step toward fully renewable production. By leveraging existing infrastructure and implementing targeted retrofits, operators can pursue a cost-effective, minimally disruptive transition that aligns with evolving regulatory expectations and long-term emissions-reduction goals.

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CO2 Removal using aMDEA & Benfield Systems in Ammonia Plants

Nitrogen & Syngas, 2017

Three actual Cost-effective revamps successfully implemented to substantially reduce CO2 slippage... more

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Ammonia Plant Upgrading-Multistage Integrated Chilling of Process Air Compressor with Ammonia Compressor Followed by Air Flow Split and Multistage Air Preheating to Secondary Ammonia Reformer

Use multistage integrated chilling to increase ammonia production Ammonia plant operators strive ... more Use multistage integrated chilling to increase ammonia production Ammonia plant operators strive to maximize energy efficiency and ammonia production while minimizing capital cost and downtime, without adding risk or sacrificing operating reliability. However, any significant improvement in energy efficiency without a reasonable increase in ammonia production rarely meets the payout criteria to justify such revamps, which typically require expensive upgrades and downtime to debottleneck compressors and other equipment.

format_quoteMIC leads to up to 15% energy efficiency and avoids costly compressor upgrades for ammonia production.format_quote

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Upgrading CO 2 removal systems

Real world experience of upgrading CO2 removal systems in three large ammonia plants with a payba... more

format_quoteRevamping ammonia plant capacity from 600 t/d to 1140-1170 t/d enhanced CO2 removal effectiveness using MDEA system.format_quote

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Use Holistic approach to Extend the Life & Reliability of Molecular Sieve beds

Use Holistic approach to Extend the Life & Reliability of Molecular Sieve beds Abstract This p... more Use Holistic approach to Extend the Life & Reliability of Molecular Sieve beds

Abstract

This paper presents and share the key lessons learnt to significantly improve the short life of Molecular sieve beds (<24 months) experienced in two large Ammonia plants for nearly four years. These beds were designed & configured in the up-flow mode and this very configuration was considered to be the main reason of this problem.

After the premature replacement of four charges of Molecular sieves & loss of Ammonia production, a detailed study was commissioned to review and analyze for all possible & relevant causes of premature high pressure drop build up resulting in the significant reduction in the life span of Molecular sieve beds.

The changes in the bed configuration- as suggested by suppliers were considered more cumbersome & were not guaranteed to solve the problem- therefore, not carried out. A holistic approach of the complete system identified various other relevant solutions. The recommended solutions were engineered & implemented without any changes in the original flow configuration. All the four Molecular beds have since been performing well without any issues of pressure drop build up. Based on the performance & low pressure drop trend after >36 months of operation, the beds are expected to last for many more years before their replacement.

The holistic approach to the lingering problem was the key in improving the life & reliability resulting from the shortcomings in the Molecular sieve system.

Authors

VK Arora, PE
Director- Process & Operations
Kinetics Process Improvements, Inc (KPI)
16000, Park Ten Place. Suite#903
Houston (Texas)- 77084 (USA)
Phone: 281 773 1629
Fax: 832 565 9360
E-Mail: [email protected]

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Economics of Ammonia production from offgases

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Vinod Arora

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