01 a Malhotra - KBR PurifierTM Technology and Project Execution Options for Ammonia Plants

Topics KBR PurifierTM Technology and Project Execution Options for Ammonia Plants

• Introduction to PurifierTM Process • Technology Features & Benefits of PurifierTM Process • Purifier Experience, Energy Consumption & Reliability

Avinash Malhotra Jim Gosnell KBR

• Project Execution Options • Summary

FAI December 1, 2010

Typical Purifier™ Process

Conventional Process

Mild Reformer Conditions 40% smaller radiant section Synloop 10~15% smaller

Severe Reformer Conditions Air Flow Fixed

Feed

Feed Primary Reformer

Secondary Reformer

Shift & CO2 Rem

Methanation & Dryers

Compression

Magnetite Synthesis

Steam Purge Gas Recovery To Fuel

T=810C CH4 11%~

T=1000C CH4 ~0.3%

Methanation & Dryers

Excess Air

Stoichiometric Air

NH3 Product

Primary Reformer

Secondary Reformer

Shift & CO2 Rem

Recycle Purge

Methanation & Dryers

Purifier

Compression

NH3 Product

Steam To Fuel (includes excess N2 & CH4)

Loop Purge

H/N = 3 Inerts > 1~1.5%

T= ~ 700C CH4 = 25%

Synthesis

H2/N2=3 Inerts 200 Reformer built

Feed Air Reformer Outlet

BFW

Steam

700 oC

ID Fan Mixed Feed

Superheated Steam

3

Secondary Reformer

Excess Air Primary Reformer Effluent

700 oC

Steam Generation & Superheat -No burner -Shell water jacket -Bottom dome design

BFW Make-up KBR proprietary natural circulation floating head design Syngas from Secondary Reformer

880 oC

125 bar 328 C

370 C

Cooled Syngas to Shift

SSH

WHB

Steam to superheat coil

To boiler

Waste Heat Boiler - References

Waste Heat Boiler - References (continued)

Client

Location

Start Up-Year

Client

Location

Methanex

Chile

1988

NA

PIM2

Indonesia

2004

1200

SCW

China

1990

600

Kujiang 1B

Indonesia

2005

1000

Pusri 1B

Indonesia

1992

1350

BFPL

Australia

2006

2200

Sherritt (1)

Canada

1993

1350

EBIC

Egypt

2009

2000

Capacity

Start Up-Year Capacity

Gresik

Indonesia

1993

1350

MHTL

Trinidad

2009

1850

Korashan

Iran

1995

1000

Jianfeng

China

U/C

1500

PLNL

Trinidad

1998

1850

Pequiven, Moron

Venezuela

U/C

1800

PCS Nitrogen

Trinidad

1998

1850

Pequiven, Jose

Venezuela

U/C

1800

Norsk Hydro (1)

Norway

1999

~

Pequiven, Puerto Nutrias Venezuela

U/C

1800

Zepu

China

2000

600

Matix

India

U/C

2200

CNC

Trinidad

2002

1850

Tierra Del Fuego

Argentina

U/C

1500

CNOOC

China

2003

1500

Petrobras

Brazil

U/C

2200

N2000

Trinidad

2004

1850

CFCL # 3

India

U/C

2200

4

Syngas Production Comparison

Syngas Production Comparison Primary Reformer No. of tubes Tube Diameter, mm OD Heat Flux, kcal/hr-m2 Radiant Duty Tube Life, years Catalyst Volume Catalyst Life, years

Purifier 65% 125 55,000 66% 12-25 85% 10

Conventional 100% 110 76,000 100% ~10 100%