KBR Ammonia Technologies Improve

Production Cost, Reliability, and

Efficiency
Akhil Nahar, Vikram Singh – GPCA, Bahrain 2017

© 2017 KBR, Inc. All Rights Reserved

Agenda

– Introduction
– KBR Technologies Overview
 KRESTM TECHNOLOGY
 KBR’s TRUE COLD WALL ADD-ON AMMONIA CONVERTER

– Case Studies
 CASE STUDY FOR KRESTM TECHNOLOGY
 CASE STUDY FOR ADD-ON AMMONIA CONVERTER

– Conclusion

© 2017 KBR, Inc. All Rights Reserved

Present market context - need for
reduction in NG consumption

 High price & reduced supply of natural gas

 New ammonia plants in countries with low

cost natural gas and lower energy
consumption

 Existing plants have to stay competitive by:

– Expanding capacity – revamping of existing
assets
– Improving energy efficiency
– Reducing dependence on natural gas

© 2017 KBR, Inc. All Rights Reserved

Revamp Strategy - Owner’s
Dilemma
 Use of proven technology, update flow sheet
 Conventional methods sometimes don’t provide value for money
 Piece meal approach NOT providing full lifecycle cost benefit
 Revamp project goals (?)
– Capacity increase: 20-25%
– Steep energy saving > 0.5 G Cal/T
 What about customized solution for any type of flow-sheet?
– Available for all existing technology plants
– Proven and viable with documented commercial examples
– Guaranteed ISBL plant performance

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Do You Wish to..?

– Increase plant capacity

– Reduce plant energy consumption
– Reduce NG consumption of plant
– Reduce steam export from ammonia ISBL
– Reduce load on primary reformer furnace, RG WHB
– Move to alternative energy source e.g. coal available?
– Improve plant reliability
– Reduce Operating cost by using low cost energy alternative

KBR HAS A SOLUTION !!!

© 2017 KBR, Inc. All Rights Reserved

Agenda

– Introduction
– KBR Technologies Overview
 KRESTM TECHNOLOGY
 KBR’s TRUE COLD WALL ADD-ON AMMONIA CONVERTER

– Case Studies
 CASE STUDY FOR KRESTM TECHNOLOGY
 CASE STUDY FOR ADD-ON AMMONIA CONVERTER

– Conclusion

© 2017 KBR, Inc. All Rights Reserved

K KBR
R Reforming
E Exchanger
S System

© 2017 KBR, Inc. All Rights Reserved

 Case History : Reforming capacity
increase by KRESTM
Reforming Exchanger upstream WHB: 30%+ more Syngas

To Heat
Recovery

Air + Mixed
Steam Feed
~

To Heat
Recovery
Primary Secondary
Reformer Reformer

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KBR Reforming Exchanger

• Simple, compact, robust design

• Tubes packed with reforming catalyst
• Single tube sheet at the top
• Each tube free to expand
• Removable tube bundle
• Dual-layer refractory lined shell
• External water jacket
• Very reliable

© 2017 KBR, Inc. All Rights Reserved

KRESTM Heat Curve

Sec. Reformer
Outlet Heat used for
1000
reforming
Temperature, oC

Process
Heat used for
Gas
steam generation

HTS Inlet
370
325
HP Steam

Heat Duty

© 2017 KBR, Inc. All Rights Reserved

KRESTM Technology salient
features
 Operating experience only with KBR
 KBR’s propriety and patented technology
 Debottleneck front end reforming capacity by 30%
 Improvement in Furnace efficiency
 Milder operating conditions for RG WHB
 No modification in steam system for revamped capacity
 Robust design
 KBR’s responsibility from design to commissioning

© 2017 KBR, Inc. All Rights Reserved

Benefits of KRES-based Revamps

 KRES increases reforming capacity by 25-30% or alternatively for

same capacity, reduces the usage of expensive natural gas
 Expensive furnace modifications avoided
 Better use of high grade heat
 Reduces overall furnace emissions
 Parallel installation reduces pressure drop
 KRES can be installed while plant is in operation and tie-ins
completed in short turnaround
 Reduces severity/constraints in waste heat boiler
 Lost steam production can be replaced using cheaper, alternative
energy sources or by other efficiency improvements

© 2017 KBR, Inc. All Rights Reserved

KRESTM Technology Reference List

CLIENT LOCATION YEAR Remark

Methanex Canada 1994 revamp

Liaohe China 2003 revamp

Chambal #1 India 2009 revamp

PCS Nitrogen Lima USA 2015 revamp

Grass-
PAU Indonesia 2018 root/Fabrication in
progress
Grass-root/KRES
PCPL India 2019
fabricated
Confidential Russia 2019 revamp

© 2017 KBR, Inc. All Rights Reserved

Agenda

– Introduction
– KBR Technologies Overview
 KRESTM TECHNOLOGY
 KBR’s TRUE COLD WALL ADD-ON AMMONIA CONVERTER

– Case Studies
 CASE STUDY FOR KRESTM TECHNOLOGY
 CASE STUDY FOR ADD-ON AMMONIA CONVERTER

– Conclusion

© 2017 KBR, Inc. All Rights Reserved

TRUE Cold Wall Add-on Converter
Feed

• Added in series to boost conversion

• Proven vintage MWK design, cold Product Cooling Gas
Cold Bypass
sweep gas, like “Slim-Jim” of 1960s
• Cold wall 150+ still in use, 30-50 yrs
• Patented annulus flow feature
• Revamp for capacity gain, energy
saving or reliability
• Replace hot wall converters
• Low cost/multiple vendors
• Cold wall (vs hot wall) provides
higher reliability
• Catalyst use/conversion: Overall life
cycle better due to ability to run the
bed hotter Cooling Gas
© 2017 KBR, Inc. All Rights Reserved
COLD WALL ADD-ON CONVERTER
BENEFITS

• Higher optimum bed inlet T for

add-on converter due to NH3%,
cold wall technology better fit,
reliable, cost effective

• Bed inlet temperature control,

startup connection- existing
heater

• Cooler shell allows multiwall

shell, more vendor options,
faster delivery, no startup
restrictions

© 2017 KBR, Inc. All Rights Reserved

Typical Flowsheet with Add-On
Converter

LOW TEMP GAS SUITABLE

AS SWEEP GAS

© 2017 KBR, Inc. All Rights Reserved

Add-on Converter Reference List

Customer Capacity NH3 Commissioned

CFCL Ammonia I 1800 MTPD 2016
CFCL Ammonia II 1750 MTPD 2017
Confidential In progress
* Allied Chemicals
(PCS Nitrogen) 1000 STPD 1967
* Agrico Chemicals
1000 STPD 1967
(Mosaic)
* Comm/Solvents 970 STPD 1967
* Allied Chemicals 1000 STPD 1968
* Union Explosives 992 STPD 1969

© 2017 KBR, Inc. All Rights Reserved

Agenda

– Introduction
– KBR Technologies Overview
 KRESTM TECHNOLOGY
 KBR’s TRUE COLD WALL ADD-ON AMMONIA CONVERTER

– Case Studies
 CASE STUDY FOR KRESTM TECHNOLOGY
 CASE STUDY FOR ADD-ON AMMONIA CONVERTER

– Conclusion

© 2017 KBR, Inc. All Rights Reserved

Case study : KRESTM Technology

Facility Description
 Plant location - Lima, Ohio, USA
 Constructed in 1971
 Ammonia technology/EPC - Bechtel
 Reformer design - Foster Wheeler
 Original capacity - 1360 MTPD (1500 STPD)
 Capacity prior to revamp - 1678 MTPD (1850 STPD)
 Target capacity of revamp - 1955 MTPD (2150 STPD)

© 2017 KBR, Inc. All Rights Reserved

Case study for KRESTM Technology

Why KRES (KBR Reforming Exchanger System) for Revamps?

 Minimal modification for primary reformer
 Minimal impact on reformed gas waste heat boiler
 Previous successful installations:
– Methanex, Canada, 1994
– Liaohe, China, 2003
– Chambal Fertilizer and Chemicals, India, 2009
– Lima, Ohio, USA, 2015
 KRES Island supported by KBR throughout all phases, from
conceptual study to startup

© 2017 KBR, Inc. All Rights Reserved

Case study for KRESTM Technology

Study Phase
 PCS evaluated options & selected KRES for study phase
 Study began in May 2012
 Confirmed the benefit of KRES technology in this revamp
 Preliminary constructability study & review
 Preliminary equipment arrangement including new secondary reformer

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Case study for KRESTM Technology

Engineering Phase
 Began in August 2012
 Process simulations finalized
 Confirmed equipment and piping
arrangement
 P&IDs completed
 HAZOP performed
 Equipment requisition produced for
secondary reformer and transfer
lines
 Structural design completed
 Constructability review completed
 Model review completed
 Coordination of three engineering
contractors

© 2017 KBR, Inc. All Rights Reserved

Case study for KRESTM Technology
Construction
 2014
– Installed foundations for new Secondary Reformer and KRES Exchanger -
August
– Erected new Secondary Reformer and KRES Exchanger in the operating plant
- December
 2015
– Install castable refractory and dome brick in the new Secondary Reformer –
July/August
– Loaded KRES catalyst - July
– Demolished old Secondary Reformer, transfer piping, and process air line -
August*
– Install new transfer line, process air line, mixed feed line, and primary steam
coil piping - August*
– Loaded Secondary Reformer catalyst – August*
– Installed KRES bundle - August*
(*) 6 week plant outage

© 2017 KBR, Inc. All Rights Reserved

Case study for KRESTM Technology

Construction Benefits
 KBR Construction and Installation Plan
 KBR Construction Quality Checklist
 KBR onsite personnel to support construction contractors
 Significant efforts to plan all crane lifts resulted in zero incidents or injuries
for extremely complex lifts
 Constructability and 3D model reviews aided construction by designing in
lift-points

© 2017 KBR, Inc. All Rights Reserved

Case study for KRESTM Technology

© 2017 KBR, Inc. All Rights Reserved

Case study for KRESTM Technology

Commissioning, Start-up, Performance Test

 Commissioning and start-up began in October 2015
 Daily operations meetings
 Punch lists used
 KRES start-up was smooth and trouble-free
 Performance test was performed in March 2016
 No performance issues - all guarantees were met
 Performance test run – 2090 MTPD (2300 STPD) ammonia capacity not limited by
KRES
 Quality of reformed syngas on spec, CH4 slip and steam import within limits

© 2017 KBR, Inc. All Rights Reserved

 Case Study : Add-on Converter
revamp at CFCL

Before After
revamp revamp
Ammonia MTPD 1604 1781
Production
Synthesis Pressure Kg/cm2g 208 174
NH3 exit converter mol% 19.6 23.2

 Non-KBR Technology plant

 High per pass conversion despite ~ 30 Kg/cm2g lower loop pressure
 No change in catalyst for existing converter
 Power for Syn and Refrigeration compressor reduced
 Steam requirements for turbines reduced
© 2017 KBR, Inc. All Rights Reserved
 Recent revamp projects

Client Location Type Description Online

Togliatti Azot Russia KRES + PGRL Capacity & Energy Ongoing
Qafco Qatar KRES Capacity & Energy Ongoing
Fertial Algeria Conventional Capacity & Energy Ongoing
Fatima Pakistan Purifier Capacity & Energy 2015
Yara - YPFL Australia Purifier Converter Basket Ongoing
Petrokemija Croatia HPCS Environmental Ongoing
PCS Geismar USA KRES Capacity & Energy Ongoing
SAFCO-III KSA Purifier Capacity & Energy Ongoing
PEMEX Mexico Conventional Capacity & Energy Ongoing
Nitrogenmuvek Hungary KRES + PGRL Capacity & Energy Ongoing
SAFCO-IBB KSA Conventional Converter Basket 2015
PCS N2, Lima Ohio, USA KRES Capacity 2015
Agrium, Borger USA Conventional Capacity & Energy Ongoing
Zuari, Goa India Conventional Capacity & Energy Ongoing

© 2017 KBR, Inc. All Rights Reserved

 Recent revamp projects

Client Location Type Description Online

First Global Iraq Conventional Capacity Delayed
SABIC KSA Conventional Energy Ongoing
CNC Trinidad Conventional Capacity Ongoing
Huajin China Conventional Cap. & Energy 2014
NFL India HP Reformer + Feedstock 2014
Purifier
Neochim Bulgaria Conventional Capacity 2012
Kribhco #1,#2 India Purifier Cap. & Energy 2012
Al Bayroni KSA Conventional Energy 2010
Zuari India Conventional Cap. & Feed 2011
Chambal #1 India KRES + Add-on Cap. & Energy 2009/2016
Chambal #2 India KRES + Add-on Cap. & Energy 2009/2017
Daqing China Conventional Capacity 2006
Lutianhua China Conventional Cap. & Energy 2005

© 2017 KBR, Inc. All Rights Reserved

Agenda

– Introduction
– KBR Technologies Overview
 KRESTM TECHNOLOGY
 KBR’s PURIFIERTM TECHNOLOGY
 KBR’s HIGH PRESSURE REFORMING
 KBR’s TRUE COLD WALL ADD-ON AMMONIA CONVERTER

– Case Studies
 CASE STUDY FOR KRESTM TECHNOLOGY
 CASE STUDY FOR ADD-ON AMMONIA CONVERTER

– Conclusion

© 2017 KBR, Inc. All Rights Reserved

Conclusion

 There’s often a strong business case for revamp

• Lack of economy of scale
• High operating costs
• Aging equipment / older technology / unreliable equipment due to increased
load

 KBR is a pioneer in revamping existing ammonia plants for over 50 years

 KBR technology revamps improve reliability and operability

 Results in higher returns to plant owners

 KBR has solution for any client requirement

© 2017 KBR, Inc. All Rights Reserved

THANK YOU

© 2017 KBR, Inc. All Rights Reserved