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Single PR for up to 3,500 mtpd ammonia plantSingle PR for up to 3,500 mtpd ammonia plantwithout prewithout pre--reformer or reforming exchanger reformer or reforming exchanger or High flux Primary Reformeror High flux Primary Reformer
Single PR for up to 3,500 mtpd ammonia plantSingle PR for up to 3,500 mtpd ammonia plantwithout prewithout pre--reformer or reforming exchanger reformer or reforming exchanger or High flux Primary Reformeror High flux Primary Reformer
4
Secondary Reformer
Excess Air
Primary ReformerEffluent
To boiler880 oC
700 oC
-No burner
-Shell water jacket
-Bottom dome design
Steam Generation & Superheat
BFWMake-up
Syngas from
SecondaryReformer
Cooled Syngas to Shift
Steam to
superheat coil
370 C
125 bar328 C
KBR proprietary
natural circulation
floating head design
SSHWHB
Waste Heat Boiler - References
Client Location Start Up-Year Capacity
Methanex Chile 1988 NA
SCW China 1990 600
Pusri 1B Indonesia 1992 1350
Sherritt (1) Canada 1993 1350
Gresik Indonesia 1993 1350
Korashan Iran 1995 1000
PLNL Trinidad 1998 1850
PCS Nitrogen Trinidad 1998 1850
Norsk Hydro (1) Norway 1999 ~
Zepu China 2000 600
CNC Trinidad 2002 1850
CNOOC China 2003 1500
N2000 Trinidad 2004 1850
Waste Heat Boiler - References (continued)
Client Location Start Up-Year Capacity
PIM2 Indonesia 2004 1200
Kujiang 1B Indonesia 2005 1000
BFPL Australia 2006 2200
EBIC Egypt 2009 2000
MHTL Trinidad 2009 1850
Jianfeng China U/C 1500
Pequiven, Moron Venezuela U/C 1800
Pequiven, Jose Venezuela U/C 1800
Pequiven, Puerto Nutrias Venezuela U/C 1800
Matix India U/C 2200
Tierra Del Fuego Argentina U/C 1500
Petrobras Brazil U/C 2200
CFCL # 3 India U/C 2200
5
Syngas Production Comparison
Primary Reformer Purifier Conventional
No. of tubes 65% 100%
Tube Diameter, mm OD 125 110
Heat Flux, kcal/hr-m2 55,000 76,000
Radiant Duty 66% 100%
Tube Life, years 12-25 ~10
Catalyst Volume 85% 100%
Catalyst Life, years 10 <5
Outlet Temperature, C 700 800-840
Secondary Reformer Purifier Conventional
Outlet Temperature, C 880 1000
Methane Leakage, % dry1.7 <0.3
Gas Turbine / Air Compressor
Reduce start-up steam and size of off-plot boiler
Reduce cooling water requirement
Energy efficient cogeneration system
Syngas Production Comparison
aMDEA Carbon Dioxide Removal
RawSyngas
fromShift
CO2
CO2
Absorber
LP Flash
Condensateto Stripper
Separator160 C
70 C
Flash gas
to fuel
Syngas to
Methanation
Stripper
CO2 production CO2 production for total conversionfor total conversionNH3 to Urea. NoNH3 to Urea. Norecovery fromrecovery fromFlue gasFlue gas
CO2 production CO2 production for total conversionfor total conversionNH3 to Urea. NoNH3 to Urea. Norecovery fromrecovery fromFlue gasFlue gas
BASF aMDEA CO2 Removal Systems Usedby KBR in New Ammonia Plants
Client Location Year System Heat InputKcal/Kgmole of CO2
BASF Germany 1982 2-Stage 10,200
Yara # D Netherlands 1982 2-Stage 10,200
Yara # E Netherlands 1987 2-Stage 10,200
Sinopec China 1997 2-Stage 13,900
CNOOC China 2003 2-Stage 7,700
PIM2 Indonesia 2004 1-Stage 22,000
Kujang 1B Indonesia 2004 1-Stage 19,900
BFPL Australia 2006 2-Stage 8,700
MHTL Trinidad 2009 1-Stage 21,000
Jianfeng China 2010 2-Stage ~7,000
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BASF aMDEA CO2 Removal Systems Usedby KBR in New Ammonia Plants
Client Location Year System
Pequiven, Moron Venezuela U/C 1800
Pequiven, Jose Venezuela U/C 1800
Pequiven, PN Venezuela U/C 1800
Matix India U/C 2200
Tierra Del Fuego Argentina U/C 1500
Petrobras Brazil U/C 2200
CFCL # 3 India U/C 2200
Purifier Conventional
Purified Syngas
Percent Inert <0.3 >1
Moisture dry wet syngas
CO2 0 5-10 ppm
PG H2 Recovery Integral Separate Unit
H2/N2 Ratio Control Simple & Precise Complex
Catalyst Deactivation Full Prod Reduced Prod or Shutdown
Syngas Purification Comparison
Synthesis Loop
Syngas
fromPurifier
HP
Steam
BFW
CW
Synloop Purge
to Dryers
0 C
155 bar-a
1 C
31.6 bar-a Refrigeration
Compressor
Horizontal MagnetiteConverter
UnitizedChiller
Minimum # of equipment in loop 10 ~15% smaller loop equipmentMinimum # of equipment in loop 10 ~15% smaller loop equipment
3-Bed Horizontal IntercooledAmmonia Converter
OUTLET
BYPASS
INLET
BED 3A BED 2 BED 1
MAIN
INLET
BED 3A
KBR can provide single converter up to 3,500 KBR can provide single converter up to 3,500 mtpd ammonia plant Cold Wall Design. mtpd ammonia plant Cold Wall Design. NO HOT WALL CONVERTER. NO HOT WALL CONVERTER.
KBR can provide single converter up to 3,500 KBR can provide single converter up to 3,500 mtpd ammonia plant Cold Wall Design. mtpd ammonia plant Cold Wall Design. NO HOT WALL CONVERTER. NO HOT WALL CONVERTER.
• If your planning a 1,500 ~ 2,200 MTPD Ammonia Plant
• KBR is executing number of ammonia plants with capacity of 1,500 to 2,200 MTPD. See the reference list of KBR plants
• KBR can provide specification and technical requisition of long lead items within 6~8 weeks
• KBR can provide MTO quickly for long lead bulk items
• If your planning a 1,500 ~ 2,200 MTPD Ammonia Plant
• KBR is executing number of ammonia plants with capacity of 1,500 to 2,200 MTPD. See the reference list of KBR plants
• KBR can provide specification and technical requisition of long lead items within 6~8 weeks
• KBR can provide MTO quickly for long lead bulk items
15
Topics
• Project Execution Options
• TIC of Project
• KBR Solution
• Summary
• Project Execution Options
• TIC of Project
• KBR Solution
• Summary
Summary
• Option “A” is best in a competitive environment. However client should have capability to accept risk and strong project management team.
• In case client can’t accept risk then it should be better to explore option “B” or “C”
• LSTK option is the most expensive option and takes longest time to implement
• KBR has extensive basic/detail design available for long lead equipment for plant sizes 1500 ~2,200 MTPD ammonia plant. This will result in lowest TIC and shortest schedule to implement
• Option “A” is best in a competitive environment. However client should have capability to accept risk and strong project management team.
• In case client can’t accept risk then it should be better to explore option “B” or “C”
• LSTK option is the most expensive option and takes longest time to implement
• KBR has extensive basic/detail design available for long lead equipment for plant sizes 1500 ~2,200 MTPD ammonia plant. This will result in lowest TIC and shortest schedule to implement