KNOW-HOW DELIVERED

AMMONIA REVAMP

KB

R T

EC

HN

OL

OG

Y

Make the Future Happen Faster

Owners of older ammonia plants now confront many challenges rising feedstock prices, growing global demand, a changing regulatory landscape, and competition from larger, more energy-efficient plants. Building a new plant carries hefty capital costs. It can disrupt operations as you transition to the new facility. It takes time. So many plant owners debottleneck existing facilities instead of building new capacity and they call on KBR Technology.

Our know-how is there to help when your facility is a revamp candidate. If you own a 1970s or 1980s-era plant that has never been substantially revamped, KBR revamp projects can increase plant capacity by 25-50%.

Is capacity utilization low due to natural gas supply curtailment, or the uncertainty of future supply? Do you need to reduce your operations dependence on natural gas by substituting alternative fuels? Do not reharp your furnace or replace reformed gas waste heat boiler. KRESTM revamps help you consume less than 6.4 Gcal/t natural gas.

Do you want to produce HP steam in the synthesis loop of your 1970s-vintage plant? Our Ammonia Converter Upgrade technology does this and helps modernize plant processes at the same time.

A KRES revamp solution can extend reformer and waste heat boiler tube life, further improving plant reliability and increasing flexibility. The KRES reforming system also generates less

flue gas than other systems, which results in reduced NOx emissions so you can meet more stringent regulations and reduce your environmental footprint.

KBR ammonia revamp projects help you achieve productivity and economic improvements within efficient schedules, along with proven reliability.

HOW

AMMONIA CASE 1

SITuATION:

Two natural gas-based 1520 MT/D ammonia plants had been in continuous production since 1985. These plants were designed by KBR. The owners opted for a revamp of the plants to increase capacity and reduce energy consumption.

SOLuTION:

Install Purifier technology to achieve lower operating costs, extend asset life and achieve lowest proven energy consumption of any competing solution.

RESuLTS:

Maximizeeconomiccapacityincrease to 1,890 metric tons per day (MTPD)

Reduceenergyconsumptionfrom 8.03 Gcal/t (LHV) to 7.69 Gcal/t

Unmatched Experience Matched to Your Demand

Partner with KBR to optimize your efficiency and capitalize on market opportunities. There is a reason we have become the first name in ammonia technology. A leading ammonia licensor and innovator since 1943, we have licensed more than 200 ammonia plants. We have completed more than 150 revamp studies and 100 ammonia revamp projects, including 30 process revamps and 48 furnace revamps between 1990 and today.

No other company can match KBRs experience, or the depth and variety of our proprietary process technology portfolio. Our dependable ammonia plant revamp solutions yield proven capacity increases in older plants, reduce energy requirements on a per-ton-of-ammonia basis and achieve attractive project paybacks, some in as few as 3-5 years.

Assess, Identify and Improve

Your plant is not like any other. In fact, its very likely that your plant is quite different than the one that was commissioned. Over years of operation modifications get made. Parts wear out and get replaced. Feedstock mixes change. Thats why every KBR revamp project begins with a thorough process study of your entire plant.

Using sophisticated evaluation tools and decades of hands-on ammonia experience, the KBR study team conducts a process study, simulating your current operation to determine sustainable capacity, pinpoint bottlenecks, assess energy consumption and equipment performance and identify areas of improvement.

Some facilities opt for abbreviated studies using data gathered by their own onsite plant engineers. No matter the approach, a number of revamp process options will be considered and the costs and benefits of each option carefully weighed to find the most cost-effective solution for your requirements. KBR has experience revamping not only KBR plants but also non-KBR technology plants. We typically find more improvement opportunities in non-KBR plants.

HOW

AMMONIA CASE 2

SITuATION:

A Chinese chemical company had been operating a conventional KBR Technology-based 1000 MTPD ammonia plant since 1978. The plant was actually producing up to 1070 MTPD ammonia but was facing regular natural gas supply curtailments that negatively affectedcapacityutilization.

SOLuTION:

A KRES+ATR revamp replaced the existing primary reformer and secondary reformer, allowing the operator to use coal to generate steam for the process, thus reducing the natural gas requirements.

RESuLTS:

Naturalgasusagereducedfrom 9.2 to 6.5 GCal/MT

Upto29%highercapacityutilization during natural gas curtailment yielding significant greater ammonia production

13%higherCO2productionfrom theammoniaplant,maximizingthe conversion of ammonia to urea

Amoreflexibleandrobustoperation with high reliability as a result of eliminating the primary reformer furnace

Lowercapitalcostdueto mechanically simple construction fabricated locally with assistance from KBR

Successfulcontinuousoperation since 2003

KB

R T

EC

HN

OL

OG

Y

KBR AMMONIA PROCESS TECHNOLOGIES

KBR ammonia revamp solutions are customized for

your plant and your revamp targets. Whether your

goal is to increase plant capacity, reduce energy

consumption, decrease maintenance costs or meet

new environmental standards, we offer flexible

revamp solutions to meet the challenge. Based on

our proprietary ammonia technologies, our revamp

technologies have been tested and proven over years

of commercial application in plants worldwide.

KBRs conventional ammonia plant revamp process utilizes a conventional flow schemeconsisting of a steam methane reformer combined with a secondary reformer producing the standard stoichiometric hydrogen/nitrogen ratio synthesis gas to increase capacity and successfully optimize energy consumption. This option delivers:

Increased capacity up to 50% for 1970s-1980s era plants

Increased capacity up to 15-20% for newer plants

Decreased energy consumption

Increased revenues and reduced operating costs

KRESTM (KBR Reforming Exchanger System) revamp, our proprietary system for synthesis gas reforming, delivers a reliable, maintenance-free operation with decreased capital costs, reduced operating costs and lower emissions. KRES can be used to increase or replace syngas production capacity from an existing Steam Methane Reformer (SMR) with minimum downtime. In a total SMR replacement, feed+fuel consumption of natural gas can be reduced up to 30% while allowing a less expensive fuel, such as coal, to generate the steam needed for the process.

KRESTM technology upgrades the SMR to a lite reformer. Energy substitution to an alternative source is maximized. Feed+fuel consumption of natural gas is reduced so that a plant could produce 30-50% more ammonia on a sustained basis by using a less expen-sive and easily available source of energy, such as coal, to generate the steam needed to substitute energy to the process. KRES is a solution for plants forced to re-duce capacity utilization due to natural gas curtailment. It may be used to maintain or increase the ammonia capacity by reducing dependency on natural gas supply by up to 50%.

PurifierTM revamp, KBRs proprietary cryogenic Purifier process, removes all the methane and 60% of the argon leaving a nearly inert-free syngas, reducing capital and operating costs vs other conventional solutions while increasing capacity and plant reliability. Used alone or in combination with a KRES revamp, our Purifier process can increase plant capacity up to 50% and combined with other improvements can reduce plant energy consumption.

Ammonia Converter Upgrade revamp: More than 150 KBR and other similar (e.g. GIAP) ammonia plants built in the 1970s use vertical cold wall ammonia synthesis converters with a heat exchanger at the top. KBR now offers a special technology which allows the generation of high pressure steam in the synthesis loop by carrying a simple modification on the internals of this converter. These plants are inherently energy inefficient as they do not generate HP steam in their synthesis loop. This KBR technology can bring the energy efficiency of your plant closer to that of the modern plants. The tech-nology applies to all the synthesis loops, irrespective of their current revamp status.

Operators throughout the world are revamping their plants using our proprietary KRES and Purifier to increase capacity and reduce energy consumption.

KB

R T

EC

HN

OL

OG

Y

KBR PROPRIETARY AMMONIA EQUIPMENT

Low-cost, energy-efficient technology offers your

ammonia plant measurable performance advantages.

Proven over time in multiple installations, our

proprietary ammonia equipment (combined with our

innovative processes) offers the flexibility, reliability

and workhorse performance that gives our revamp

clients a competitive edge. Licensed through our

preferred vendors and contractors, KBR equipment

is designed to meet the specifications and project

requirements of modern ammonia producers for

safety, low operating costs and superior uptime.

KBR Top-Fired Steam Methane Reformer (SMR) overcomes many of the mechanical design challenges in primary reforming to yield lower energy consumption and record-setting reliability in more than 200 ammonia, methanol and hydrogen plants worldwide.

KBR Reforming Exchanger System (KRESTM) replaces a primary reformer with a fired feedgas preheater, an autothermal reformer (ATR) and a reforming exchanger in a reliable open-ended tube design. It delivers lower CAPEX, operation and maintenance costs with smaller plot requirements. Reforming exchanges can also be used separately to debottleneck a conventional steam-methane reformer.

PurifierTM Cryogenic Syngas Purification is a simple design consisting of a compact core exchanger, a cryogenic column with a built-in condenser and a feed gas expander. The KBR Purifier provides high-purity synthesis gas, precise control of H2/N2 ratios and provides the benefit of mild reforming temperatures leading to lower operating costs, longer catalyst tube life and the lowest proven energy consumption as low as 6.5 Gcal/MT.

KBR Reformer Gas Waste Heat Boiler features a vertical, natural-circulation, watertube, floating-head design with a removable WHB tube bundle. The KBR design provides lower initial costs, higher reliability and less maintenance than fired-tube boiler designs.

Horizontal Ammonia Synthesis Converter for conventional magnetite ammonia synthesis loops consists of two or three reaction stages, each with vertical downward flow in the catalyst beds. Intercoolers between the reaction stages provide feed gas preheating leading to maximum conversion and heat recovery. The KBR horizontal converter also features a removable basket that can be rolled out of the converter on tracks for easier loading and unloading of catalyst.

Single-bed Vertical, Radial-flow Magnetite Ammonia Converter features a separate converter vessel consisting of a magnetite catalyst bed with or without an internal heat exchanger. This converter is typically used downstream of the main converter to boost per pass ammonia conversion to maximize capacity as well as energy efficiency.

KB

R T

EC

HN

OL

OG

Y

KBR Technology Services and Support

Expert KBR support ensures lasting success of ammonia revamp projects.

Once the revamp option is defined and selected during the study phase, the KBR design team will develop the basic engineering design package (BED).

KBR engineers carefully consider every aspect of the project from critical equipment and systems to start up and shutdown to ensure the most reliable solution. With the BED package, clients then select a local detailed engineering contractor to execute procurement and construction of the project. KBR clients continue to receive technical support from concept to reality. A team of KBR ammonia experts is available to provide complete on-site commissioning and start-up services.

Advanced Process Control (APC) systems from KBR help make certain you maintain smooth operations for years to come. Advanced process automation tools enable performance improvements by continuously operating the unit at specified design limits and constraints. In addition to control applications, KBR APC systems deliverreal-time performance indicators that report on the health of the plant. Using this ongoing monitoring to take proper corrective actions at the appropriate time, operators can maintain productivity and profitability.

Operator Training Simulators (OTS) improve the operators understanding of plant operation prior to startup and help them maintain their competency level over time. OTS incorporates KBRs in-depth knowledge of the technology customized to the flowsheet process of each plant, providing a realistic training experience for startup, operation and shutdowns, as well as emergency conditions and malfunctions.

The availability of KBR expertise plays a significant role in assuring safe operation, lower operating costs and superior onstream time that are crucial to long-term productivity.

AMMONIA CASE 3

SITuATION:

An ammonia plant in India had reached the limits of its economic capacity. Designed to produce 1,500 MT/D, it was running at highest capacity. The owners decided to revamp the existing plant to increase capacity and lower total energy consumption.

SOLuTION:

Install KRES in parallel with the existing SMR and upstream of secondary reformer to increase capacity, reduce emissions and enhance plant energy efficiency by fully using the capacity of theexistingISBLandOSBLequipment.

RESuLTS:

Reducedenergyconsumptionfrom 7.45 Gcal/t (LHV) to 6.96 Gcal/t resulting in lower production costs

Increasedcapacityfrom1,510MT/D to 1,940 MT/DHOW

KB

R T

EC

HN

OL

OG

Y

Every day, reliable, commercially proven KBR ammonia process solutions improve productivity and improve lives around the globe. We look forward to talking with you about the ways we can help your world work better.

KNOW-HOW DELIVERED

www.kbr.com/ammonia

Houston Beijing Dubai Leatherhead Moscow New Delhi Singapore

2011 KBRK10106 08/11