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Ammonia Technology for Tomorrow

The best people and technologiesdelivering the right solutions.

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

For syngas preparation, we offer:Conventional Reforming KBR steam-methane primary reformer operating at high pressure coupled with secondaryreforming 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-freesynthesis 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 usesruthenium on a graphite base. This catalyst is up to 20 times more active than iron catalyst, which allows the loop pressureto 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 haslicensed 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 atlarge capacities. The plant in China is the second KRES unit. The first KRES unit has been on-stream in Canada at a capacityof 350 t/d since 1994. KBR offers KRES for new plants in combination with its Purifier technology, which eliminates the needfor 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.

HH

NH

KAAPplus ProcessKBR 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 technologiesand their benefits to the ammonia producer are summarized in the following paragraphs.

AIR

FEED

SULFURREMOVAL

KRES

PROCESSHEATER

METHANATOR

CARBONDIOXIDE

REJECT GASTO FUEL

DRYERS

CO2STRIPPER

CO2ABSORBER

PURIFIER

KAAPAMMONIA

CONVERTER

SYNTHESIS GAS COMPRESSOR

SYNLOOP RECYCLE

AUTOTHERMALREFORMER REFORMING

EXCHANGER

LT SHIFT

MP STEAM

CONDENSATESTRIPPER

UREA PROCESS CONDENSATE

CLEAN CONDENSATETO BFW SYSTEM

REFRIGERATION COMPRESSOR

WARMAMMONIAPRODUCT

COLDAMMONIAPRODUCT

RECYCLE

UNITIZED CHILLER

PURGE

AMMONIA SEPARATOR

HT SHIFT

STEAM

RAW SYNTHESIS GAS

SYNLOOP PURGE

MAKEUP SYNTHESIS GAS

AIR COMPRESSOR

KRESKBR Reforming Exchanger System (KRES) eliminates the primary reformer resulting in the reduction of plantcapital cost. The radiant tubes of a traditional firedreformer are replaced with a unique and robust shell andtube reforming exchanger. The open-ended tubes arepacked with conventional reforming catalyst. Heat to drivethe reforming reaction in the tubes is externally suppliedby 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 ATRis fed excess process air, usually about fifty percent morethan required for nitrogen balance.

PurifierKBR’s cryogenic Purifier technology simultaneouslyremoves impurities from the synthesis gas and adjusts thehydrogen to nitrogen ratio to 3:1. It also serves as a purgegas recovery unit as purge gas rejected from the synthesisloop is passed through the Purifier. The Purifier removesall the methane and most of the argon by washing themout 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 lowerreforming temperatures, which provide energy savings.

• Providing a very clean makeup gas to the synthesis loopallowing 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, becauseminor variations in methane, carbon monoxide and carbon dioxide slips will not reach the synthesis loop.

KAAP SynthesisIn 1992 the first commercially produced ammonia usingKBR Advanced Ammonia Process (KAAP) technology wassynthesized at the Methanex (formerly Pacific Ammonia)plant in Kitimat, British Columbia, Canada. This revolutionin ammonia technology was the result of a retrofit of anexisting plant with a new ammonia converter filled withKAAP catalyst. KAAP catalyst, which uses ruthenium on astable 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 toabout 90 bar. In 1998 two grassroots KAAP plants producing1850 t/d ammonia began operating in Trinidad. A thirdKAAP plant in Trinidad started up in 2002 and a fourthbegan operating in 2004.

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 tenpercent and energy consumption is reduced by 0.1 to 0.2Gcal/ton, when compared with designs offered by otherlicensors. KAAPplus, which combines commercially provenKRES, Purifier, and KAAP technologies, is the ammoniatechnology for tomorrow.

KAAPplus - Delivering technology benefits to our Clients...

Fired Reformer KBR has been an active leader inreformer furnace design for manyyears. Our fired steam-methanereformers have been installed inmore than 200 ammonia, methanoland hydrogen plants worldwide.Primary reforming presents complexmechanical design problems.

The preheated feed is distributed to catalyst tubes suspended in the radiant section. The burners are located between the rows of tubesallowing the tubes to be heated fromboth sides. The firing is downwardsfrom the top of the firebox providinga 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 coupledwith a gas turbine that drives the aircompressor. In this arrangement the gas turbine exhaust is used as preheated combustion air for the reformer radiant section.

KRES ReformingKBR Reforming Exchanger System(KRES) is a reliable proprietary tech-nology 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.

Design features include:• Open-ended tubes that hang from a

single tube sheet at the cold end tominimize expansion problems.

• No direct firing, therefore no hotspots will occur on the tubes.

• Removable top head for easy accessfor catalyst loading.

• Removable tube bundle for easymaintenance.

Advantages of KRES compared to atraditional 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 plantsteam system due to reduced steamgeneration.

• Decreased operation and maintenance costs.

• Smaller plot space required.• Lower emissions.

KBR’s Ammonia Equipment TechnologyThe 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 developedbased on all these factors to better serve our Clients and provide them a competitive advantage.

Tubesheet CombinedReformed Gas

Feed Gas & Steam

AutothermalReformerEffluent

Open EndedTubes

Distributor

Catalyst FilledReformer Tubes

RefractoryLining

KBR Reforming Exchanger

Waste Heat BoilerHeat 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 designfor this challenging heat exchange service. We offer a vertical, natural-circulation, water-tube, floating-headdesign with refractory lining. KBR's waste heat boilerdesign has a low initial cost and is highly reliable and easy to maintain. The bundle is removable, unlike bundlesin a fired-tube design.

PurifierKBR’s Cryogenic Purifiertechnology is a simple systemconsisting of three pieces ofequipment: the feed/effluentexchanger, the column withits built-in condenser, and theexpander. These items andthe connecting piping areenclosed in a cold box,which is filled with perliteinsulation. The exchanger is a plate fin type made of

aluminum. The column operates in the range of minus170˚C to minus 200˚C and the integral condenser is a shelland tube design. The expander is a compact, low-speed unitthat typically is coupled to a generator to recover power.A 2000 ton/day ammonia plant requires an expanderwith a capacity of about 200 kW.

KAAP SynthesisConverterKBR's Advanced AmmoniaProcess (KAAP) ammonia synthesis converter uses onestage of traditional magnetitecatalyst, followed by threestages of KAAP catalyst. All ofthe catalyst beds are radial-flow for low pressure drop.Intercoolers are locatedbetween the catalyst beds formaximum conversion andheat recovery. The proprietaryKAAP catalyst consists ofruthenium on a stablegraphite carbon base.

It is the first major advance in catalyst technology since theoriginal BASF ammonia plant started up in 1913. The KAAPcatalyst has an activity up to twenty times higher than

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

Horizontal Synthesis ConverterFor conventional (non-KAAP) synthesis loops, KBR offersits horizontal synthesis converter. The horizontal ammoniasynthesis converter contains two or three reaction stages,each with vertical downward flow in the magnetite catalystbeds. Intercoolers are provided between the catalyst bedsfor maximum conversion and heat recovery.

The catalyst basket can be removed from the convertershell for catalyst loading and unloading. A heavy crane isnot needed to lift the catalyst basket out of the converteras it can be rolled out on tracks.

Unitized ChillerThe Unitized Chiller is a specially designed, multi-streamheat exchanger that cools the effluent from the ammoniasynthesis converter with recycled gas and boiling ammoniarefrigerant at several temperature levels. In doing so,the Unitized Chiller combines several heat exchangers,compressor knockout drums and interconnecting pipinginto one piece of equipment. This design saves pressuredrop in the synthesis loop and reduces capital cost.

Plant Safety and ReliabilityKBR 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 stagesof 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 andrequire 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 dayswere obtained.

• A Netherlands ammonia plant using KBR technology produced more than 15,000,000 tons of ammonia, which is aworld 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 achievehigher capacity and lower energy consumption.

Environmental ProtectionKBR 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 reformingsystem, 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 CondensateKBR'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.

KICSKBR’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 condensatehydrolyzer/stripper and eliminates several pieces of equipment, avoids plant effluents, and saves capital and maintenance cost.

Advanced Process AutomationAdvanced Process ControlKBR offers Advanced Process Control (APC) systems as part of our ammonia technologyand has successfully implemented them on a number of projects. APC systems havedemonstrated 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 maintenancerequirements 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 controlstrategies 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 SimulatorsKBR 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 fullyincorporates our proprietary knowledge of the technology and plant operation. The model iscustomized to the flowsheet process conditions of each plant and provides the operator withrealistic 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 tothe actual plant. Depending on Clients’ needs, functionality can range from a system designedexclusively 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 ServicesKBR is a leading international, technology-based engineering, construction and maintenance contractor. Our approach toproject execution is based on a company-wide commitment to quality management. We maintain close communicationswith 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 tothe 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 TechnologyKBR was formed in 1998 by a merger of The M. W. Kellogg Company and Brown & Root Inc. Brown & Root had previouslyacquired 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 thatwe have designed and constructed are recognized worldwide for superior performance and serve as a cornerstone of thenitrogen fertilizer industry, which is increasingly vital for feeding the growing global population. Our continuing commitmentto 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 thatproduce more ammonia than plants designed by all other companies in the industry. An important contributor to planteconomics is economy of scale. Today’s largest ammonia plants produce more than 2000 metric tons per day (mtpd) ofammonia. 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, safetyand environment, technological improvement, plant reliability, and most importantly, Client service. These commitmentsprovide 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/economicstudies through project execution, project commissioning and start-up, contract operation and maintenance, and advanceprocess 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 ExperienceCLIENT 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 Headquarters601 JeffersonHouston, Texas 77002Tel: 713.753.2000Fax: 713.753.2541www.halliburton.com/ammonia

Worldwide Headquarters4100 Clinton DriveHouston, Texas 77020P.O. Box 3Houston, TX 77001-0003Phone: 713.753.3011

www.halliburton.com

K0670_1 08/04 Printed in the U.S.A.

© 2004 Kellogg Brown & Root, Inc.

a Halliburton company

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