By installing a new single bed converter basket along with a waste heat boiler, at the downstream of existing ammonia converter, ammonia conversion increases. This results in lower gas circulation through the synthesis loop and allows for operating the synthesis loop at reduced pressure. This way, power consumption in synthesis gas compressor and thus overall steam consumption can be reduced (FAI, 2013).
In one plant, additional ammonia synthesis converter along with medium pressure (MP) waste heat boiler was installed during 2005. Ammonia conversion increased from 16.1 to 19.9 % and 30 tph additional MP steam can be produced. Similar systems have been installed in about 10 ammonia plants in India based on Haldor Topsoe technology(FAI, 2013).