Ammonia Plant Revamps

KBR Ammonia Technology Workshop, Kuala Lumpur

Presented By: Shashi Singh, KBR Technology
Date: October 8th, 2012

Agenda

• Introduction
• Conventional Revamp Options
• KBR Technology based Revamp Options
• Recommended Execution Approach
• Case Studies
• Conclusions

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 Agenda

• Introduction
• Conventional Revamp Options
• KBR Technology based Revamp Options
• Recommended Execution Approach
• Case Studies
• Conclusions

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Historical Technology Progress

Kellogg
introduces Kellogg 1000 t/d Kellogg &
centrifugal standard design Braun KBR large
compressors technologies capacity
Kellogg merged = KBR designs
CF Braun low energy
Purifier design
technology

1960 1970 1980 1990 2000 2010

600 t/d 1000 t/d 1000 t/d 1300 t/d 1800 t/d >2200 t/d
> 10 Gcal/t 9-10 Gcal/t 8-9 Gcal/t 7-8 Gcal/t 6.5-8 Gcal/t 6.3-8 Gcal/t

Older plants (60’s - 90’s) need to be revamped to compete with

modern, larger & more energy efficient plants

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 Typical Revamp Objectives
Owners want to revamp their plants in order to:
– Improve profitability by lowering specific cost of
production
• Capacity Increase
• Energy Savings
• Both
– Improve reliability
– Change feedstock
– Maintenance
M i t related
l t d e.g. furnace
f re-harp,
h waste
t heat
h t
boiler replacement
– Comply with new environmental regulations
– Less capital outlay & schedule than new plant

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KBR Revamp Experience

»Executed more than 80 revamp projects, plus

numerous other furnace revamps
»Plant capacities have ranged from 90 to 2000 t/d
»Done over 150 paid revamp studies

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 Recent Revamp Projects
Client Location Type Description Online
PakArab Pakistan KRES Cap. & Energy 2012
j
Huajin China Conventional Cap. & Energy
gy 2012
NFL India Purifier Feedstock 2012
Al Bayroni KSA Conventional Energy 2010
Kribhco #1,#2 India Purifier Cap. & Energy 2011

Zuari India Conventional Cap. & Feed 2011

Chambal #1 India KRES Cap. & Energy 2009

Chambal #2 India KRES Cap. & Energy Delayed

Daqing China Conventional Capacity 2006

Lutianhua China Conventional Cap. & Energy 2005

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Revamp Options
»Conventional
– Open art, undifferentiated
– No major change to process scheme
– Limited benefits, has drawbacks

»KBR Technology Based

– Proprietary KBR technology
– Larger benefits with fewer drawbacks
– Cost-effective, more value to client

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 Agenda

• Introduction
• Conventional Revamp Options
• KBR Technology based Revamp Options
• Recommended Execution Approach
• Case Studies
• Conclusions

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Sections in an Ammonia Plant

Process Air CO2

Natural NH3
Gas Syngas Syngas Synthesis
Production Purification Loop

Condensate
Steam

Steam &
Water System

Make-up Water

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 Conventional Revamp Options for
Syngas Production Section
Option Reduce Energy Increase
Capacity
Preheat combustion air X
Chill process air
i to
t compressor suction
ti X
Higher process air pre-heat X
Higher mixed feed pre-heat X X
Reduce steam/carbon ratio X X
Increase diameter of reformer tubes X
Add row of reformer tubes (KBR furnaces) X
Add Pre
Pre-reformer
reformer X X
Add steam superheater burners X X
Modify air compressor internals X X
Parallel equipment as needed X
HP Condensate Stripper X X

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Conventional Revamp Options for

Syngas Purification Section
Option Reduce Increase
Energy Capacity
Change CO2 removal solvent X X

Modify/change activator X
Upgrade tower packing X X
Parallel equipment as needed X X
Add hydraulic turbine X

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 Conventional Revamp Options for
Synthesis Section
Option Reduce Increase
Energy Capacity
Add syngas dryers X X
Chill syngas compressor suction X

Converter basket retrofit X X

Add new converter X X
Add purge gas recovery unit X X
P ll l equipment
Parallel i t as needed
d d X
Improve heat recovery X X
Modify syngas compressor internals X

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Conventional Revamp Options for

Utility Section/Miscellaneous
Option Reduce Increase
Energy Capacity
Change turbine internals X X
Improve heat recovery X X

Power recovery X
Raise steam superheat temperature X X
Modify pump rotors X

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Typical Issues with Conventional Revamps

» Increased pressure drop in plant – reduces

energy efficiency
»Increased steam production – no choice
» More severe conditions e.g. furnace tubes,
WHB - increased risk of failure, lower
reliability
» Capacity
C it iincrease is
i limited
li it d for
f newer plants
l t

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Agenda

• Introduction
• Conventional Revamp Options
• KBR Technology based Revamp Options
• Recommended Execution Approach
• Case Studies
• Conclusions

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 KBR Technology for Revamps
» KRESTM: KBR Reforming Exchanger System
- KRES-SMR
- KRES-ES
- KRES-ATR
» PurifierTM
» Improved Synloop Heat Recovery

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KRES – SMR Revamp Scheme

Reforming Exchanger
(New Item)
~
~

To Heat
Mixed Recovery
Feed

Air

Primary Secondary
Reformer Reformer

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 KRES-ESTM Revamp Scheme
Reforming Exchanger
(New Item)

~
To Heat
Mixed Recovery
Feed

O2

Air

Primary Secondary
Reformer (LITE) Reformer

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KRES-ATR REVAMP

Excess Air
or
Enriched Air

Natural Gas
Plus Steam

Autothermal Reforming
Reformer Exchanger
Process (MODIFIED (NEW)
Heater SECONDARY
(NEW) REFORMER)
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 KRES Heat Curve

Heat used for

1000 reforming
Temperature, oC

Heat used for

steam generation

370
325
HP Steam

Heat Duty

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Reforming Exchanger Features

» 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

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Reforming Exchanger – Tube Bundle

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Reforming Exchanger – Tube Bundle

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 KRES Experience

Client Country ∆ MTPD Year

Chambal #1 India +430 2009

Chambal #2 India +400 Delayed

Ballance New Zealand +90 Delayed

Liaohe China +330 2003

Methanex Canada +105 1994

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KRES Revamp at Liaohe, China

KRES
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 KRES Plant at Methanex, Canada

Title

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Benefits of KRES based Revamps

» KRES increases reforming capacity by about 25%
» Expensive furnace modifications avoided
» Better use of high grade heat
» Reduces furnace emissions
» Parallel installation reduces pressure drop
» Simple Revamp – KRES can be installed while plant is
in operation & tie-ins completed in short turnaround
» Reduces severity on waste heat boiler
» Lost
L t steam
t production
d ti can replaced
l d using
i cheaper,
h
alternative energy sources or by other efficiency
improvements

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 PurifierTM Revamp Option
» Can be used to increase capacity by up to 50% and reduce
energy consumption
» Best suited if bottlenecks are furnace & synthesis loop
» Uses excess air in secondary reformer
» Milder conditions for primary reformer – extends tube life
» New cryogenic purification step
» New parallel process air compressor
» Milder conditions for WHB
» Increases CO2 production
» Clean, dry syngas debottlenecks synthesis loop & extends
life of synthesis catalyst

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Conventional Process
Severe Reformer
Conditions
Air Flow Fixed
Stoichiometric Air

Feed Primary Shift & Methanation Com- Magnetite

Secondary
Reformer Reformer CO2Rem & Dryers pression Synthesis
NH3
Steam Product
Purge Gas
Recovery
To Fuel Loop
Purge
T=815 oC T=1000 oC
CH4
11%~ CH4 ~0.3% H/N = 3
Inerts > 1~1.5%

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 Typical Purifier™ Process

Mild Reformer
Excess Air Methanation
Conditions
Recycle Purge
& Dryers
D

Feed
Primary Secondary Shift & Methanation Com-
Purifier Synthesis
Reformer Reformer CO2 Rem & Dryers pression
NH3
Steam
Product
To Fuel (includes
excess N2 & CH4)

H2/N2=3
T= ~ 700 oC Inerts<0.27%
CH4 = 25% T= 900 oC H2/N2 ~ 2.0
CH4 = 2%

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PurifierTM
Syngas to
Waste Gas 2 oC 2 oC Compressor
to Fuel

-182 oC
H2/N2 = 3.0
Syngas oC Inerts < 0.3%
4
from
Dryers

vol%
H2 62-68
N2 30-35
CH4 2-3
Ar ~ 0.6

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Cryogenic Purifier™ in a Recent Plant

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Comparison of Process Parameters with

Purifier Revamp Option
Original Conventional Purifier Revamp
Plant Revamp
Capacity MTPD 1350 1800 1890
Primary Reformer
Mix Feed T, oC 510 537 438
Outlet T, oC 820 810 706
Steam/Carbon 3.5 3.0 2.7

Secondary Reformer
Process Air T, oC 468 480 453
Methane Exit, mol% 0.32 0.27 1.72
Outlet T, oC 1002 972 885

Synthesis Loop
CH4 in MUG, mol % 0.83 0.97 none
Inerts in MUG, mol% 1.15 1.27 0.19
Loop P, kg/cm2(g) 210 181 178

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 Improved Synloop Heat Recovery

»Applicable to vertical, cold wall, bottle type

converters
»Simple proprietary modification to ammonia
converter
»Synloop heat recovery to HP steam rather than
HP BFW
»Additional low grade heat recovery in BFW
»Energy savings of 0.2-0.3 Gcal/t

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Scheme before Revamp

All
Smaller 121-C, WHR by
Large duty 122- BFW
C inside Heating
Converter

Unable to
Raise HP
Steam,
MP Steam
Inefficient..

L
Lower Feed
F d
Temperature, Many
limited by Retrofitted
Converter Basket
shell design

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 Scheme after Revamp
Converted Gas to 1123-CA
Cooling & Chilling
NEW WHB- New WHB
~ 123-C Optional
BFW HEATER HP HP
150 – 170 C ~STEAM ~STEAM
1123-C
NEW WHB
WHB-

~
Recycle+
BFW Required High Grade
Make-up Waste Heat
Gas 121-C 130 – 155 C
445 – 460 C
CONVERTER 122-C
FEED/EFFLUENT
EXCHANGER Flow Split:
Quench 52-40% 122-C removed,
Main 48-60% 105-D modified

New External
122-C
C
105-D
105 D
SYNTHESIS
CONVERTER

102-B
START-UP
HEATER

Shaded Equipment: New/Modified

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Which Revamp Option?

Q. Which revamp option is the best one for my plant?

A. Need to do a Process Study to find the answer

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 Agenda

• Introduction
• Conventional Revamp Options
• KBR Technology based Revamp Options
• Recommended Execution Approach
• Case Studies
• Conclusions

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Recommended Execution Approach

» Revamps can be complex engineering tasks

» KBR believes in a phased approach for successfully

implementing revamp projects

¾Phase I – Process Study

¾Phase II – Basic Engineering

¾Phase III – EPC

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 Phase I - Process Study

»Data Collection visit

»Process Simulation

»Screening of Revamp Options

»Cost Estimates (± 30%)

»Revamp Study Report

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Why a Process Study?

»There are no duplicate plants – every plant is
unique in terms of
– Process design
– Feed & utility conditions
– Ambient conditions
– Modifications made
– Extent of equipment deterioration
»Benchmark current plant performance and
identify bottlenecks
»Compare different revamp options
»Reduce risk of the revamp project

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 Phase II - Basic Engineering

»Develop a Basic Engineering Design (BED)

package
»Define new & modified equipment
»Develop P&ID & define inline instruments
»Conceptual Plot Plan

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Phase III – EPC

»Carry out Detailed Engineering

»Procurement of new equipment
»Construction
»Tie-ins & re-start
»Plant performance test

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 Agenda

• Introduction
• Conventional Revamp Options
• KBR Technology based Revamp Options
• Recommended Execution Approach
• Case Studies
• Conclusions

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Case Study 1 – Conventional Revamp

»Yuntianhua Ammonia Plant, China

»Base case capacity ~ 1000 t/d
»Capacity increase to 1500 t/d
»Energy consumption about the same
»Maintain high reliability
»Conventional revamp option implemented

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 Yuntianhua Revamp Features
» Modified Feed Gas Compressor Driver & Suction Drum
» New Parallel Air Compressor & Motor
» Reformer convection section coils modified
» Modified Secondary Reformer burner
» Shift reactors converted to radial flow
» LTS guard bed in parallel to main LTS bed
» Packing upgrade in CO2 absorber & stripper
» Syngas compressor & turbine upgraded
» Molecular sieve driers added – wet loop to dry loop
» Converter basket upgraded
» PGRU upgraded

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Yuntianhua Revamp Results

Base
ase Target
a get Actual
ctua

Capacity, mt/d 1148 1500 1508

Energy, Gcal/t (LHV) 8.20 8.20 8.04

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 Case Study 2 – KRES-SMR Revamp

»Chambal Fertilizers & Chemicals Ltd. (CFCL),

India operates 2 ammonia plants, each 1500 t/d
Pl t 1 is
»Plant i a Haldor
H ld Topsoe
T plant
l t
»Revamp target for Plant 1 was 2000 t/d
»Client selected KBR revamp option with
Reforming Exchanger
»Phase 1 of revamp completed in 2009
»Revamped plant is in successful operation

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CFCL Revamp Features

Phase 1:
– Reforming Exchanger added in parallel to existing
Primary Reformer
– Minor upgrades
pg to Primary
y Reformer
– Replaced Secondary Reformer
– New add-on KBR radial ammonia converter & HP steam
boiler

Phase 2:
– HTS & LTS modification
– CO2 removal upgrade from G-V to aMDEA
– Syngas compressor/turbine upgrade
– New auxiliary process air compressor
– New molecular sieves – wet loop to dry loop piping
change

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 CFCL Revamp

PRIMARY
REFORMER

REFORMING
EXCHANGE
R

Successful
RG Integration &
WHB Tie-in

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CFCL Revamp Results

Base Phase-1 Phase-2

Ammonia Production, t/d 1600 1781 2000
NG Feed+Fuel, Gcal/t 7.84 7.36 7.33
Feed+Fuel+Power, Gcal/t 7.88 7.60 7.31

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 Case Study 3 – KRES-ATR Revamp

»Liaohe in Panjin, China owns KBR ammonia

plant, 1978 vintage
g
»Base case capacity was 1070 t/d
»Plant was facing natural gas shortage
»KRESTM revamp option was successfully
implemented in 2003

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Liaohe Revamp Features

» New Reforming Exchanger

» New Process Heater
» Existing Primary Reformer demolished
» New Secondary Reformer, Waste Heat Boiler, Steam
Superheater, Steam Drum
» Equipment removed was reused in plant elsewhere in
China
» CO2 removal unit upgrade to UOP ACT-1
» New coal-fired boiler in OSBL
» New Air Separation Unit (ASU) in OSBL

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 Liaohe KRES in Fabrication

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Liaohe Primary Reformer Removed

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 Liaohe Revamp Results

Gcal/t Before Revamp After Revamp

Feed 54
5.4 62
6.2

Fuel 3.8 0.3

Total Natural Gas 9.2 6.5 [29% less]

Coal Fired & Other

0.00 2.1
C dit ((net)
Credits t)
Total (excl. ASU) 9.2 8.6

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Conclusions
»There can be a strong business case for older
plants to revamp to perform closer to current
world standards
C ti
»Conventional l andd KBR technology
t h l based
b d
revamp options available
»KBR technology based options bring more
value to a revamp project
»Revamp study is essential to identify best
revamp option
»KBR has vast, proven experience and is
particularly well qualified to execute revamp
projects

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THANK YOU

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