KBR - Ammonia Specific Examples

Ammonia Technology for Tomorrow

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The best people and technologies delivering the right solutions.

Technology Options to Meet Your Needs Kellogg Brown & Root (KBR) has over sixty years of experience licensing and designing ammonia plants. During these years KBR has pioneered many process innovations that have resulted in more competitive plants for its Clients. As a result, KBR is unique among ammonia contractors. We offer a portfolio of technology options to meet our Clients’ needs. These options are as follows.

For syngas preparation, we offer: Conventional Reforming KBR steam-methane primary reformer operating at high pressure coupled with secondary reforming using the stoichiometric amount of process air. KRES KBR Reforming Exchanger System, which replaces the primary reformer with a patented reforming heat exchanger. KBR Purifier Mild primary reforming at approximately 700˚C, secondary reforming with excess process air, and removal of methane, argon, and excess nitrogen in a proprietary cryogenic Purifier, resulting in an almost inert-free synthesis gas.

For ammonia synthesis, we offer: Conventional Loop Synthesis over promoted iron catalyst at a pressure in the range of 140 – 170 bar. KAAP Loop KBR’s Advanced Ammonia Process (KAAP) features ammonia synthesis over a proprietary catalyst that uses ruthenium on a graphite base. This catalyst is up to 20 times more active than iron catalyst, which allows the loop pressure to be reduced to about 90 bar.

KBR combines these technologies to provide five options for your process flow sheet: Conventional Process This flow sheet combines conventional reforming with a conventional synthesis loop. KBR has licensed about 200 plants using this process. KAAP Process This flow sheet combines conventional reforming with a KAAP synthesis loop. KBR has licensed four KAAP plants. Purifier Process This flow sheet combines the KBR Purifier with a conventional synthesis loop. KBR has licensed 17 Purifier Plants. KRES + Purifier Process With the successful start up of an 1100 t/d KRES unit in China in 2003, KRES is now proven at large capacities. The plant in China is the second KRES unit. The first KRES unit has been on-stream in Canada at a capacity of 350 t/d since 1994. KBR offers KRES for new plants in combination with its Purifier technology, which eliminates the need for an air separation plant. The KRES + Purifier combination has a lower capital cost than the Purifier Process. KAAPplus Process This process combines KRES, Purifier, and KAAP in one flowsheet. It offers our clients the lowest capital cost and the lowest energy consumption. The KAAPplus flow sheet is illustrated on the next page.

H

N

H

H

KAAPplus Process KBR offers several process schemes for manufacturing ammonia. Our preferred offering is our KAAPplus Process, as it provides both the lowest capital cost and lowest operating cost. KAAPplus features three proprietary process technologies, all pioneered by KBR: KRES, Purifier and KAAP. These technologies and their benefits to the ammonia producer are summarized in the following paragraphs.

AIR KRES HT SHIFT

AIR COMPRESSOR FEED

UREA PROCESS CONDENSATE

CONDENSATE STRIPPER

SULFUR REMOVAL

LT SHIFT MP STEAM

PROCESS HEATER

AUTOTHERMAL REFORMING REFORMER EXCHANGER

CLEAN CONDENSATE TO BFW SYSTEM STEAM

RAW SYNTHESIS GAS SYNLOOP PURGE SYNLOOP RECYCLE METHANATOR

REFRIGERATION COMPRESSOR

MAKEUP SYNTHESIS GAS WARM AMMONIA PRODUCT

DRYERS

CARBON DIOXIDE

SYNTHESIS GAS COMPRESSOR

REJECT GAS TO FUEL

UNITIZED CHILLER CO2 STRIPPER PURGE AMMONIA SEPARATOR CO2 ABSORBER

KAAP AMMONIA CONVERTER PURIFIER

RECYCLE

COLD AMMONIA PRODUCT

KAAPplus - Delivering technology benefits to our Clients... KRES

KAAP Synthesis

KBR Reforming Exchanger System (KRES) eliminates the primary reformer resulting in the reduction of plant capital cost. The radiant tubes of a traditional fired reformer are replaced with a unique and robust shell and tube reforming exchanger. The open-ended tubes are packed with conventional reforming catalyst. Heat to drive the reforming reaction in the tubes is externally supplied by the effluent gas from an autothermal reformer (ATR) which operates in parallel with the reforming exchanger. In order to have enough heat to drive the reaction, the ATR is fed excess process air, usually about fifty percent more than required for nitrogen balance.

In 1992 the first commercially produced ammonia using KBR Advanced Ammonia Process (KAAP) technology was synthesized at the Methanex (formerly Pacific Ammonia) plant in Kitimat, British Columbia, Canada. This revolution in ammonia technology was the result of a retrofit of an existing plant with a new ammonia converter filled with KAAP catalyst. KAAP catalyst, which uses ruthenium on a stable graphite carbon support, has an activity that is up to twenty times higher than traditional iron-magnetite catalyst. As a result, synthesis loop pressure is lowered to about 90 bar. In 1998 two grassroots KAAP plants producing 1850 t/d ammonia began operating in Trinidad. A third KAAP plant in Trinidad started up in 2002 and a fourth began operating in 2004.

Purifier KBR’s cryogenic Purifier technology simultaneously removes impurities from the synthesis gas and adjusts the hydrogen to nitrogen ratio to 3:1. It also serves as a purge gas recovery unit as purge gas rejected from the synthesis loop is passed through the Purifier. The Purifier removes all the methane and most of the argon by washing them out with the excess nitrogen. Benefits of the Purifier technology include: • Allowing the reforming section to be operated with excess air and higher methane slip resulting in lower reforming temperatures, which provide energy savings. • Providing a very clean makeup gas to the synthesis loop allowing lower synthesis pressure, reduced catalyst volume and lower purge rate. • Providing operating flexibility, because the reforming section does not need to be operated to produce an exact hydrogen-to-nitrogen ratio. • Stabilizing the operation of the synthesis loop, because minor variations in methane, carbon monoxide and carbon dioxide slips will not reach the synthesis loop.

Benefits of KAAP technology include: • A single-case synthesis gas compressor, which reduces capital, operating and maintenance costs. • Reduced synloop capital cost due to lower design pressure. • Higher ammonia conversions with reduced catalyst volumes. As a result of the combination of these three process technologies, capital cost is reduced by five to ten percent and energy consumption is reduced by 0.1 to 0.2 Gcal/ton, when compared with designs offered by other licensors. KAAPplus, which combines commercially proven KRES, Purifier, and KAAP technologies, is the ammonia technology for tomorrow.

KBR’s Ammonia Equipment Technology The driving forces for advancing ammonia technology are improved safety, lower capital cost, lower energy consumption, higher reliability, improved operability and environmental compliance. KBR’s ammonia equipment technology is developed based on all these factors to better serve our Clients and provide them a competitive advantage.

Fired Reformer

KRES Reforming

KBR has been an active leader in reformer furnace design for many years. Our fired steam-methane reformers have been installed in more than 200 ammonia, methanol and hydrogen plants worldwide. Primary reforming presents complex mechanical design problems.

KBR Reforming Exchanger System (KRES) is a reliable proprietary technology consisting of a fired preheater, an autothermal reformer (ATR) and a reforming exchanger. KRES uses the ATR effluent to supply heat for the reforming reaction.

The preheated feed is distributed to catalyst tubes suspended in the radiant section. The burners are located between the rows of tubes allowing the tubes to be heated from both sides. The firing is downwards from the top of the firebox providing a relatively even load along the tubes. The convection section provides heat recovery from the flue gas for optimum furnace efficiency. KBR’s fired reformer may be coupled with a gas turbine that drives the air compressor. In this arrangement the gas turbine exhaust is used as preheated combustion air for the reformer radiant section.

Design features include: • Open-ended tubes that hang from a single tube sheet at the cold end to minimize expansion problems. • No direct firing, therefore no hot spots will occur on the tubes. • Removable top head for easy access for catalyst loading. • Removable tube bundle for easy maintenance. Advantages of KRES compared to a traditional fired reformer are: • Decreased capital cost. • Decreased operator attention required due to fewer burners in the fired heater. • Lower process temperatures in fired heater vs. fired reformer.

• Decreased size and cost of plant steam system due to reduced steam generation. • Decreased operation and maintenance costs. • Smaller plot space required. • Lower emissions.

Feed Gas & Steam

Tubesheet

Combined Reformed Gas

Catalyst Filled Reformer Tubes

Open Ended Tubes

Autothermal Reformer Effluent

Refractory Lining

Distributor

KBR Reforming Exchanger

Waste Heat Boiler Heat is recovered from the secondary reformer (or KRES) effluent in a waste heat boiler, often in combination with a steam superheater. KBR developed a proprietary design for this challenging heat exchange service. We offer a vertical, natural-circulation, water-tube, floating-head design with refractory lining. KBR's waste heat boiler design has a low initial cost and is highly reliable and easy to maintain. The bundle is removable, unlike bundles in a fired-tube design.

magnetite catalyst. This allows operation at 90 bar synthesis loop pressure. At this low pressure, only a single-casing synthesis gas compressor is needed. This results in major savings in capital cost and maintenance.

Purifier KBR’s Cryogenic Purifier technology is a simple system consisting of three pieces of equipment: the feed/effluent exchanger, the column with its built-in condenser, and the expander. These items and the connecting piping are enclosed in a cold box, which is filled with perlite insulation. The exchanger is a plate fin type made of aluminum. The column operates in the range of minus 170˚C to minus 200˚C and the integral condenser is a shell and tube design. The expander is a compact, low-speed unit that typically is coupled to a generator to recover power. A 2000 ton/day ammonia plant requires an expander with a capacity of about 200 kW.

Horizontal Synthesis Converter For conventional (non-KAAP) synthesis loops, KBR offers its horizontal synthesis converter. The horizontal ammonia synthesis converter contains two or three reaction stages, each with vertical downward flow in the magnetite catalyst beds. Intercoolers are provided between the catalyst beds for maximum conversion and heat recovery. The catalyst basket can be removed from the converter shell for catalyst loading and unloading. A heavy crane is not needed to lift the catalyst basket out of the converter as it can be rolled out on tracks.

KAAP Synthesis Converter KBR's Advanced Ammonia Process (KAAP) ammonia synthesis converter uses one stage of traditional magnetite catalyst, followed by three stages of KAAP catalyst. All of the catalyst beds are radialflow for low pressure drop. Intercoolers are located between the catalyst beds for maximum conversion and heat recovery. The proprietary KAAP catalyst consists of ruthenium on a stable graphite carbon base. It is the first major advance in catalyst technology since the original BASF ammonia plant started up in 1913. The KAAP catalyst has an activity up to twenty times higher than

Unitized Chiller The Unitized Chiller is a specially designed, multi-stream heat exchanger that cools the effluent from the ammonia synthesis converter with recycled gas and boiling ammonia refrigerant at several temperature levels. In doing so, the Unitized Chiller combines several heat exchangers, compressor knockout drums and interconnecting piping into one piece of equipment. This design saves pressure drop in the synthesis loop and reduces capital cost.

Plant Safety and Reliability KBR ammonia plants set the industry standard for safety and reliability. Safety and reliability considerations are thoroughly addressed in our process and mechanical design and operating procedures, and integrated into all stages of project execution, including materials procurement, construction and commissioning. We also carefully evaluate feedback from startups and operating plants, as well as information published by the ammonia industry. Our “lessons learned” are included in future plant designs. Independent third-party surveys have shown that ammonia plants using KBR technology have longer runs and require less downtime than plants by other licensors. We have collected additional information through our own research to support these third-party findings: • A U.S. ammonia plant using KBR technology achieved 1,395 consecutive days of ammonia production. • Two ammonia plants in Europe using KBR technology each reported an average on-stream factor of 97.6 percent for a recent seven-year period, which included downtime for turnarounds. Uninterrupted runs of 960 and 920 days were obtained. • A Netherlands ammonia plant using KBR technology produced more than 15,000,000 tons of ammonia, which is a world production record for a single ammonia plant. • A plant that started up in China in 2003 produced ammonia only eighteen days after introducing the natural gas feed. Many older KBR-designed ammonia plants are still in full operation. A number of them have been upgraded to achieve higher capacity and lower energy consumption.

Environmental Protection KBR offers cost-effective solutions to today's environmental challenges, particularly in the ammonia industry. Our ammonia plants meet all applicable regulations regarding emissions, effluent quality, and noise generation. The main emissions from a plant using KBR technology are reformer flue gas and excess carbon dioxide, if applicable. Main effluent is boiler feed water blow-down. The regulations on reformer flue gas are mainly met by use of low-NOx burners. If the plant uses the KRES reforming system, then a much smaller amount of flue gas will be generated, and NOx emissions are further reduced. Carbon dioxide is often used in an adjacent urea plant. However, if there is no urea plant, the carbon dioxide can be discharged to the atmosphere. Boiler blow-down is often disposed of in the plant cooling water system. Noise control includes use of acoustic insulation, enclosures, and plot plan considerations.

Process Condensate KBR's ammonia plants use a high-pressure process condensate stripper resulting in a major reduction in the quantity of effluents which prevents wastewater and atmospheric pollution. The stripper overhead vapor is used as process steam in the reforming section, and the stripped condensate is re-used as boiler feed water.

KICS KBR’s Integrated Condensate Stripper (KICS) technology is offered to ammonia producers if the ammonia plant is adjacent to a urea plant. KICS combines the ammonia plant condensate stripper with the urea plant condensate hydrolyzer/stripper and eliminates several pieces of equipment, avoids plant effluents, and saves capital and maintenance cost.

Advanced Process Automation Advanced Process Control KBR offers Advanced Process Control (APC) systems as part of our ammonia technology and has successfully implemented them on a number of projects. APC systems have demonstrated significant and measurable economic benefits for ammonia plants by providing process performance improvements through constantly operating the unit close to the design process limits and constraints. APC systems have low maintenance requirements and are easy to operate. Our proprietary knowledge of ammonia process technology and plant operation is used to provide a better APC system. KBR’s APC system uses Multivariable Predictive Control (MPC) technology to implement a control layer above the standard regulatory control strategies to improve plant profitability and productivity. In addition to the higher level control applications, KBR’s APC system provides a number of plant performance indicators to the operator on a real-time basis. These indicators provide the operator valuable information regarding the health of the plant, which allows the proper corrective actions to be taken at the appropriate time.

Operator Training Simulators KBR also offers Operator Training Simulators (OTS) as part of our ammonia technology to both new and existing plants. Our OTS systems not only improve the operator’s knowledge of plant operations prior to plant startup, but can also be used to maintain competency level after startup. Our OTS system for ammonia plants is based on a detailed first principle model that fully incorporates our proprietary knowledge of the technology and plant operation. The model is customized to the flowsheet process conditions of each plant and provides the operator with realistic training experience for plant start-up, normal operation, and shutdown. The system also trains operators in managing emergency conditions and/or equipment malfunctions. This valuable experience can be obtained prior to plant startup without risk to the actual plant. Depending on Clients’ needs, functionality can range from a system designed exclusively to meet training needs to a system suitable for use in engineering studies.

Other Automation Tools: In addition to the above described APC and OTS systems, KBR offers other automation solutions to our clients. Examples are: • Alarm rationalization & management systems • Operator advisory systems • Real time operation (RTO) for performance monitoring

Scope of Services KBR is a leading international, technology-based engineering, construction and maintenance contractor. Our approach to project execution is based on a company-wide commitment to quality management. We maintain close communications with our Clients to assure that we meet project objectives including scope of work, quality, schedule and budget. KBR has a corporate commitment to achieve an accident-free workplace. KBR offers a complete portfolio of engineering services to the nitrogen fertilizer industry:

Pre-Project Services • • • • •

Technology development and licensing Technical / economic studies Project development Front end loading Front end engineering design (FEED)

Project Services • • • • • • •

Project management and construction management Engineering, procurement and construction Advanced process control Training simulators Operator training Commissioning and start-up Operations and maintenance

After-Project Services • Continuing technical advice • Contract operation and maintenance • Revamp studies for debottlenecking and energy savings • Revamp projects

KBR - A World Leader in Ammonia Technology KBR was formed in 1998 by a merger of The M. W. Kellogg Company and Brown & Root Inc. Brown & Root had previously acquired the former C F Braun & Co. Therefore, KBR today offers the combined ammonia technology, engineering, and construction experience of M.W. Kellogg, Brown & Root, and Braun. For more than 60 years, KBR has been on the leading edge of advancing ammonia plant technology. Ammonia plants that we have designed and constructed are recognized worldwide for superior performance and serve as a cornerstone of the nitrogen fertilizer industry, which is increasingly vital for feeding the growing global population. Our continuing commitment to technology is backed by KBR’s Technology Center, pictured above, situated twenty miles west of downtown Houston. At this site we continue to test improvements to our process technologies and proprietary equipment designs. KBR’s first ammonia plant was designed in 1943. Since then, we have licensed/designed over 200 ammonia plants that produce more ammonia than plants designed by all other companies in the industry. An important contributor to plant economics is economy of scale. Today’s largest ammonia plants produce more than 2000 metric tons per day (mtpd) of ammonia. We offer designs for single-train ammonia plants ranging in capacity from 600 to 5000 mtpd. Our continued success in ammonia plant design is driven by strong commitments to sustainable growth, health, safety and environment, technological improvement, plant reliability, and most importantly, Client service. These commitments provide our Clients with competitive capital and operating costs, safe operation, and superior on-stream time. In a competitive commodities business, we believe these characteristics are crucial to our Clients' profitability. KBR’s ammonia technology is supplemented by a full range of services, from project development and technical/economic studies through project execution, project commissioning and start-up, contract operation and maintenance, and advance process automation. Our portfolio of services are delivered individually or as part of a seamlessly integrated service package. KBR’s goal remains to position our Clients as the low-cost ammonia producers by offering a portfolio of proven, energy-efficient, low-cost proprietary ammonia technologies.

Recent KBR Ammonia Experience CLIENT

LOCATION

CAPACITY MT/DAY

KBR PROCESS

YEAR ON LINE

P. T. Pupuk Kujang

Indonesia

1000

Conventional

2005

Burrup Fertilizers

Australia

2200

Purifier

2005

Nitrogen 2000

Trinidad

1850

KAAP

2004

P. T. Pupuk Iskandar Muda

Indonesia

1200

Conventional

2004

CNOOC Chemical Ltd.

China

1500

Purifier

2003

Shenzhen Liaohe Tongda

China

1100

KRES

2003

Caribbean Nitrogen Co.

Trinidad

1850

KAAP

2002

Zepu Petrochemical

China

600

Conventional

2001

SAFCO

Saudi Arabia

1500

Purifier

2000

Chambal Fertilisers

India

1350

Conventional

1999

Point Lisas Nitrogen Ltd.

Trinidad

1850

KAAP

1998

PCS Nitrogen

Trinidad

1850

KAAP

1998

Ammonia Headquarters 601 Jefferson Houston, Texas 77002 Tel: 713.753.2000 Fax: 713.753.2541 www.halliburton.com/ammonia

Worldwide Headquarters 4100 Clinton Drive Houston, Texas 77020 P.O. Box 3 Houston, TX 77001-0003 Phone: 713.753.3011

www.halliburton.com K0670_1 08/04 Printed in the U.S.A. © 2004 Kellogg Brown & Root, Inc. a Halliburton company Printed by KBR Communications