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Ammonia Storage:
Selection & Safety Issues
G S Lele
This article describes the advantages and disadvantages of
various structures of ammonia storage tanks. It also provides
the various codes and standards applicable for flat bottomed,
vertical and cylindrical storage tanks. The author also lists rel-
evant safety aspects to be considered for storage of
liquid ammonia.
AUTHOR
G S Lele is a chemical engineer and an alumnus of Laxminarayan Institute of Technology, Nagpur.
He is presently Deputy General Manager - Process, with Uhde India Ltd, where he is actively
involved with the Cryogenic Storage Group. He has participated in the conceptualization, design
and commisisoning of Uhde India's cryogenic storage projects.
Chemical Industry Digest. May 2008
85
' " " ' " ~ "'" Ammonia Storage
Introduction
S
torage of liquid ammonia has been done in the
chemical industry for the past several decades,
right from the time ammonia began to be com-
mercially produced. Due to the inherent physical prop-
erty of ammonia, the earlier designs for handling liq-
uid ammonia used the pressurized storage concept as
ammonia liquid could be stored at ambient tempera-
tures. However the tanks were to be designed for el-
evated pressures. To enable liquid ammonia to be
stored at near atmospheric conditions meant that am-
monia had to be cooled and refrigerated to -33C.
Inspite of the best insulation methods utilized, a re-
frigeration system is required to keep the ammonia in
liquefied form.
ally have outer tanks or walls made
from pre-stressed concrete, reinforced
concrete with an earth embankment
or one of the metals specified for the
inner tank.
Types of the ammonia
storage tanks
Primarily, there are 3 prevalent methods for stor-
ing liquid ammonia.
Pressurized storage at ambient temperature for
small capacities (up to 100 MT) in horizontal pres-
sure vessels (pressure: 12-18 kg/ cm
2
g)
Until the 1970's it was normal practice to store re-
Semi-refrigerated storage in spheres for capacities
upto 2000 MT (pressure 4-6 kg/ cm
2
g)
Atmospheric pressure storage at -33C for large ca-
frigerated ammonia in single con-
tainment tanks. Since that time it
has increasingly become the prac-
tice for the inner tank for ammonia
to be surrounded by an outer tank
or wall. The outer tank or wall is in-
tended to prevent the release of the
liquefied products into the sur-
rounding area in case of leakage
from or damage to the inner tank.
This philosophy results in in-
creased safety for the surrounding
area. Such constructions are known
as double containment and full
containment tanks. The double
~ - - - - - - - - - - . . . _ _ pacities (2000 MT and higher) with
For large scale atmo-
spheric cryogenic storages
for liquefied gases like am-
monia, design can be se-
lected from three basic types
as defined in BS 7777 taking
into account local regula-
tions, location of the storage
tank with respect to adjacent
plants, inhabitants and type
of product stored.
containment tanks and full containment tanks gener-
86
siporex
blocks
Inner cup
liqammonia
1----=san""-d-------1 siporex
foam glass
blocks
FIG- 1 Typical double containment tank
Mineral wool insulation
PUF insulation with AI cladding
.---
!+---tank
~ - - Annular space
Chemical Industry Digest. May 2008
the following types:
o Single wall tank
o Double wall tank
o Double wall full containment
tank
Disadvantages of pre-
ssurised storages
There are certain limitations in
storage of ammonia in pressurized
tanks. Some of them are outlined
below:
Limitations in terms of storage ca-
pacity (1000- 2000 MT), as present day
large capacity plants need more stor-
age space.
A major factor is the safety aspect
wherein escape of ammonia under
pressure is potentially more danger-
ous than leakage of ammonia from an
atmospheric tank.
Construction of pressurized spheri-
cal tank is much more difficult and
costly per MT of ammonia stored in
comparison with an atmospheric tank.
Atmospheric ammonia stor-
age tanks
For large scale atmospheric cryo-
genic storages for liquefied gases like
ammonia, design can be selected from
three basic types as defined in BS 7777
Ammonia Storage
(single, double and full containment design) taking
into account local regulations, location of the storage
tank with respect to adjacent plants, inhabitants and
type of product stored. Toxicity, flammability, explo-
sive limits, auto ignition temperature & density of va-
por need special attention.
Single wall tank
In this type of design, primary container (Inner
tank) is provided to hold liquid at low temperature
and vapor product under normal I design operating
conditions. Insulation is provided on the external sur-
face to minimize heat leakage.
External secondary containment is provided in the
form of low height dyke wall to contain the liquid com-
ing out due to rupture of inner tank. Emission to at-
mosphere of vaporized gas is reduced by providing
suitable foaming system. This design has been
adopted for storages of gases because of its low toxic-
vapor ammonia
OIL PUMP
AMMONIA CONO NSER OIL COOLER

q j >
)/:"
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FIG - 2 Typical screw compressor refrigeration system
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ity hazards. For ammonia, these designs have been
used in some plants which have been located far away
from populated areas due to safety reasons.
Double wall tank
LIQUID AMMONIA
Vapors
Inner cup
Ammonia storage tank
A double contain-
ment tank is designed
and constructed so
that both the inner &
outer tanks are ca-
pable of containing
the refrigerated liquid
stored independently.
The inner tank con-
tains the refrigerated
liquid and vapor un-
der normal operating
conditions. The outer
tank (which is located
< 6m distance from in-
ner tank) is intended
to contain refrigerated
product leakage from
the inner tank but is
not intended to con-
tain any vapor result-
Chemical Industry Digest. May 2008 87
Ammonia Storage
ing from product leakage from the in-
ner tank which means, it will be re-
leased to atmosphere.
The outer container is normally
provided in the form of "Bund Wall"
of height corresponding to hold
equivalent amount of liquid in the
storage tank. This concept again has
been used for storage of non-toxic
gases like hydrocarbons world-wide,
but not for storage of toxic material
like ammonia.
The present day tanks
are constructed on elevated
concrete foundations to
avoid the problem of ice
formation and propagation
in the soil below. Addi-
tionally, double integrity
tanks provide an extra va-
por space of 15 - 20% de-
pending on dimensions.
tures down to -165 C.
API STANDARD 620 10th edition,
Feb. 2002 -Addendum 1, June 2004
- Design and construction of large,
welded, low pressure storage tanks.
Appendix R- Low pressure storage
tanks for refrigerated products.
- DIN 4119, sheet 1 & 2, Edition 1961
for roof structure design.
IS 4544: 2000
Double wall full containment tank
In this type both the inner and outer tanks are ca-
pable of containing the refrigerated liquid stored in-
dependently. The inner tank contains the refrigerated
liquid under normal operating conditions. T h ~ roof
is supported by the outer tank. The outer tank 1s ca-
pable of containing both the refrigerated liquid and the
vapor resulting from product leakage and is located
between 1-2 meters from the inner tank. In such tanks,
secondary containment in the form of dyke wall is not
required. The double containment tank design, also
known as the "cup-in-tank" (Double Integrity) design
is widely adopted for Ammonia Storage Tanks. The in-
ner cup of the tank is separated from the outside tank
by a suspended deck resting on the top of the inner
cup. A typical sketch of a full containment tank is
attached as Fig 1.
The present day tanks are constructed on elevated
concrete foundations to avoid the problem of ice for-
mation and propagation in the soil below (a problem
experienced with tanks resting on the surface with con-
sequences of likely damage to tank bottom plates due
to frost heaving). Additionally, double integrity tanks
provide an extra vapor space of 15 - 20% depending
on dimensions, which is very useful for maintaining
tank pressure within operating limits especially un-
der emergency conditions.
Applicable codes & standards
BS -7777- 1993
Applicable for flat bottomed, vertical and cylindri-
cal storage tanks for low temperature service.
Part 1- Guide to the general provisions for design,
construction, installation and operation.
Part 2- Specification for the design and construc-
tion of single, double and full containment metal
tanks for the storage of liquefied gas at tempera-
It is a standard for ammonia code of safety.
- Prescribes a code of safety concerning the hazards
related to ammonia.
- It also describes the properties and essential infor-
mation for safe handling and use of ammonia.
ANSI K61.1-1999
It prescribes safety requirement for the storage and
handling of anhydrous ammonia.
- This standard is intended to apply to the design,
construction, repair, alteration, location, installa-
tion, and operation of anhydrous ammonia sys-
tems including refrigerated ammonia storage sys-
tems.
- This standard does not apply to
o Ammonia manufacturing plants
. o Refrigeration systems where ammonia is used
solely as a refrigerant
o Ammonia transportation pipelines
o Ammonia barges and tankers
The above standard also prescribes guidelines for
installation of refrigerated storage tanks (above-
ground). Some of these are outlined below:
- Tanks shall be supported on suitable non combus-
tible foundations designed to accommodate the
type of tank being used.
- Adequate protection against flotation or other wa-
ter damage shall be provided wherever high flood
water might occur.
- Tanks shall be supported in such way that heat
shall be supplied to prevent the effects of freezing
and subsequent frost heaving of the soil.
Wherever dike is employed, the capacity of the dike
enclosure shall be 110% of the capacity of the larg-
est tank served.
- Each refrigerated tank container shall be equipped
with an approved liquid level gauging device and
high liquid level alarm.
- In addition to the above, this standard also gives
88 Chemical Industry Digest. May 2008
Ammonia Storage
the guidelines for,
Requirement of number of compressors
Provides guidelines for the pressure relief valves
capacity, location etc
Requirement of minimum safety equipment
Other general guidelines
Types of insulation used
As liquid ammonia is stored in refrigerated condi-
tion in the atmospheric tank, it is important to keep
heat ingress into the tank to the minimum possible.
Insulation plays a key role in this aspect. The insula-
tion type and thickness decides the overall boil off rate
from the storage tank, i.e. the kg of ammonia evapo-
rated per day per ton of tank capacity. The boil off rate
therefore is indicative of the atmospheric heat ingress
into a storage tank when other tank operations are not
taking place. The commonly used insulation for the
tanks is Polyurethane foam (PUP) which is cast in situ
on the outside tank shell and covered with aluminum
cladding. Insitu application of PUP is also used for
large bore piping and equipments. For small bore pip-
ing, pre-cast PUP split sections are available.
Other than the tank outer surface, insulation is re-
quired to be provided at various other places in and
around the tank. It can be summarized as below:
Shell bottom- foam glass (load bearing insulation)
along with sand
Below annular space between cup and shell
- Siporex block or perlite block or wooden block.
The presence of ammonia vapor in the annular
space between the cup and shell acts as an insu-
lating media and helps in reducing the heat in-
gress from outside. In some cases, the annular
space is filled with a naturally occurring insulat-
ing material like perlite.
Suspended deck top - mineral wool (resin bonded
glass wool). Between the suspended deck and the
top roof, the presence of ammonia vapor acts as an
insulating media. There is no insulation required
on the top of the roof as no liquid comes in contact
with the suspended deck.
Generally a sand layer is placed between cup bot-
tom and shell bottom plate
Safety aspects for ammonia storage
system
As ammonia storage terminal and its associated fa-
cilities are generally located away from plants, follow-
ing considerations in design are made to ensure safety
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of storage tank and connected operations:
Remote shut-off valves on liquid ammonia roam
inlet and outlet line to I from ammonia storage tank.
Dual measurement for tank level/pressure and in-
terlocking with refrigeration compressors, ammo-
nia receipt and pumping, emergency vent to flare.
Dual level measurement for the annulus portion of
the tank and annulus draining facility. This is im-
portant as there is a possibility of damage to the
cup bottom plates due to buoyancy effect (caused
when annulus level exceeds cup level).
Refrigeration system based on reliable screw com-
pressors. Optional auto loading/unloading facil-
ity for tank pressure control can be included.
Stand-by equipment for critical duties and utilities.
Closed vent and drain system for ammonia.
Redundancy in critical instrumentation & control.
Adequate fire water grid and water curtain around
ammonia pumps and road tanker loading stations.
Thermal relief valve are installed on the ammonia
lines where there is any possibility for blockage or
heat ingress.
Ammonia leak detection system for storage instal-
lation.
Chemical Industry Digest. May 2008
89
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en
Ammonia Storage

Lightening protection and earthing protection for
storage tank
Emergency power to one refrigeration holding com-
pressor to maintain tapk pressure during power
failure.
Flare for controlled venting under extreme emer-
gency situation.
Safety and vacuum relief valves on tank top (de-
signed as per API 520).
Wind direction indicator.
Emergency plant lighting.
0