Professional Documents
Culture Documents
Agenda
Conventional Process
Set air
rate here
Steam
So H/N = 3 here
CO2
Air
PRIMARY
REFORMER
WHB
SHIFT &
CO2 REM
SECONDARY
REFORMER
METHANATION
& DRYERS
COMPRESSION
MAGNETITE
SYNTHESIS
NH3
Product
PURGE GAS
RECOVERY
ToFuel
T = ~1000 C
CH4=~0.35%
Natural
Gas
T = ~810 C
CH4=~11-12%
LoopPurge
P = 150-200
bar
H/N=2
CH4
~2-3%
H/N=2
Steam
CO2
ExcessAir
PRIMARY
REFORMER
RecyclePurge
SECONDARY
REFORMER
WHB SHIFT
& CO2 REM
METHANATION
& DRYERS
PURIFIER
COMPRESSION
ToFuel
T = 710 C CH4
CH4 ~27-29%
Natural
Gas
SYNTHESIS
NH3
Product
P = 155 bar
T = 890 C CH4
CH4~1.5-2.5%
2C
2C
180C
Syngas
from
Dryers
H2
N2
CH4
A
4C
Vol%
6268
3035
23
~0.5
Syngasto
Compressor
H2/N2=3
Inert<0.3%
H2
Purified
Syngasto
Compressor
Syngas
FromDryers
Generator
Expander
HIC
HIC
FeedEffluent
Exchanger
Rectifier
Nitrogen
Equipment Includes
Feed/Effluent
exchanger
Column
Cold Box Enclosure
Expander/Generator
(non proprietary)
Agenda
Fuel
Gas Turbine
Process Air
to
Secondary
Reformer
GTE
525 C
Radiant
Section
To Feed
Treatment
Feed
Air
Reformer
Outlet
710 oC
HP
BFW
Steam
ID Fan
Mixed Feed
Superheated Steam
Excess Air
No metal parts
Primary
Reformer
Effluent
710 oC
890oC
To Reformed
Gas Boiler
Purifier
Conventional
65%
125
55,000
66%
12-25
85%
10+
710
25-30%
100%
110
76,000
100%
~10
100%
<5
800-840
10-12%
Purifier
890
1.7
Conventional
1000
<0.3
125 bar
328 C
KBR Proprietary
Natural circulation
floating head design
Removable bundle
Syngas from
Secondary
Reformer
890
oC
360 C
Cooled
Syngas to
Shift
Steam to
superheat coil
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
Norway
1999
Zepu
China
2000
600
CNC
Trinidad
2002
1850
CNOOC
China
2003
1500
Location
Start Up-Year
Capacity
N2000
Trinidad
2004
1850
PIM2
Indonesia
2004
1200
Kujiang 1B
Indonesia
2005
1000
BFPL
Australia
2006
2200
EBIC
Egypt
2009
2000
MHTL
Trinidad
2009
1850
Jianfeng
China
2010
1500
Pequiven, Moron
Venezuela
U/C
1800
Pequiven, Jose
Venezuela
U/C
1800
Venezuela
U/C
1800
Matix
India
U/C
2200
Location
Start Up-Year
Capacity
Matix
India
U/C
2200
Petrobras
Brazil
U/C
2200
Jaypee
India
U/C
2200
Argentina
U/C
1500
BCIC
Bangladesh
U/C
1000
Kima
Egypt
U/C
1320
IFC
USA
U/C
2200
EPCL
Nigeria
U/C
2300
PAU
Indonesia
U/C
1900
Pusri
Indonesia
U/C
2200
Dyno Nobel
USA
U/C
2300
Shift Conversion
370 C
210 C
Syngas from
Boiler
Low Temperature
Shift Reactor
High Temperature
Shift Reactor
430 C
To CO2
Removal
230 C
Separator
BFW Heating &
Steam
Generation
70
Water
Cooler
Process
Cond.
Syngas to
Methanator
CO2@~0.6barg
LP Flash
Column
HP Flash
Column
Absorber
Stripper
Hydraulic
Turbine
Syngas
from LTS
LP Steam or
HP BFW
Reboiler
Demin
Water
Process
Cond.
Location
Year
System
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
Location
Year
Capacity mtpd
Pequiven, Moron
Venezuela
U/C
1800
Pequiven, Jose
Venezuela
U/C
1800
Pequiven, PN
Venezuela
U/C
1800
Matix
India
U/C
2200
Argentina
U/C
1500
Petrobras
Brazil
U/C
2200
Jaypee
India
U/C
2200
Kaltim 5
Indonesia
U/C
2700
Location
Year
Capacity mtpd
BBCI
Bangladesh
U/C
1000
Kima
Egypt
U/C
1320
IEPCL
Nigeria
U/C
2300
IFC
USA
U/C
2300
YPFB
Bolivia
U/C
1200
Pusri IIB
Indonesia
U/C
2000
PAU
Indonesia
U/C
1900
Dyno Nobel
USA
U/C
2300
Waste Gas
to Fuel
Methanator
4 oC
Syngas
from
CO2 Absorber
CW
NH3
Pure, Dry
Syngas to
Compressor
Synloop
Purge
Process
Condensate
to Stripper
2C
2C
-180 C
Syngas
from
Dryers
H2
N2
CH4
A
4C
Vol%
62-68
30-35
2-3
~0.5
Syngas to
Compressor
H2/N2 = 3
Inert <0.3%
H2
Purified
Syngasto
Compressor
Syngas
FromDryers
Generator
Expander
HIC
HIC
FeedEffluent
Exchanger
Rectifier
Nitrogen
Equipment Includes
Feed/Effluent
exchanger
Column
Cold Box Enclosure
Expander/Generator
(non proprietary)
Conventional
Purified Syngas
Percent Inert
Moisture
CO2
<0.3
dry
0
>1
wet syngas
5-10 ppm
PG H2 Recovery
Integral
Separate Unit
Complex
Reduced Production
or Shutdown
Synthesis Loop
Syngas
from
Purifier
HP
Steam
Synloop
Purge
Syngas
Compressor
2C
31 bar
BFW
Refrigeration
Compressor
155 bar
Unitized
Chiller
Horizontal
Converter
Let Down
Drum
CW
To Ammonia
Accumulator
HP
Separator
BYPASS
INLET
OUTLET
BED 3B
BED 3A
BED 2
BED 1
MAIN
INLET
Flange
TI
Basket Removal
Expensive overhead crane not needed
Basket rolls out on tracks
Location
Start Up-Year
Capacity
Nihon
Japan
1971
1650
Sherritt-Gordon
Canada
1983
1000
UCAM
Netherlands
1984
1360
Ocelot
Canada
1986
545
Koch Nitrogen
USA
1986
1530
NCFC
Saudi Arabia
1988
1500
Kemira Oy
UK
1989
825
SCW
China
1990
600
Pusri 1B
Indonesia
1992
1350
Gresik
Indonesia
1993
1350
Korashan
Iran
1995
1000
Inner Mongolia
China
1997
1000
Jiu Jiang
China
1997
1000
Location
Start Up-Year
Capacity
Lanzhou
China
1997
1000
Pak-American
Pakistan
1997
600
Chambal
India
1999
1350
Zepu
China
2000
600
CNOOC
China
2003
1500
PIM2
Indonesia
2004
1200
Kujiang 1B
Indonesia
2005
1000
BFPL
Australia
2006
2200
Jianfeng
China
2010
1500
Pequiven, Jose
Venezuela
U/C
1800
Venezuela
U/C
1800
Location
Start Up-Year
Capacity
Venezuela
U/C
1800
Matix
India
U/C
2200
Petrobras
Brazil
U/C
2200
Jaypee
India
U/C
2200
TDF
Argentina
U/C
1500
Kaltim 5
Indonesia
U/C
2700
BCIC
Bangladesh
U/C
1000
Kima
Egypt
U/C
1320
IEPCL
Nigeria
U/C
2300
IFC
USA
U/C
2200
PAU
Indonesia
U/C
1900
Pusri 2
Indonesia
U/C
2000
Ammonia
Accumulator
HP Case
LP Case
NH3 from
LetdownDrum
Unitized Chiller
30-40oC
-33oC
To Refrigeration Compressor
From NH3
Converter
RECYCLE To
GASSyngas
Compressor
Ammonia
Product
Operator friendly
Location
Start Up-Year
Capacity
Ocelot
Canada
1986
545
Kemira Oy
UK
1989
825
SCW
China
1990
600
Pusri 1B
Indonesia
1992
1350
Gresik
Indonesia
1993
1350
Korashan
Iran
1995
1000
Inner Mongolia
China
1997
1000
Jiu Jiang
China
1997
1000
Lanzhou
China
1997
1000
Pak-American
Pakistan
1997
600
PLNL
Trinidad
1998
1850
PCS Nitrogen
Trinidad
1998
1850
Location
Start Up-Year
Capacity
Zepu
China
2000
600
CNC
Trinidad
2002
1850
CNOOC
China
2003
1500
N2000
Trinidad
2004
1850
PIM2
Indonesia
2004
1200
Kujiang 1B
Indonesia
2005
1000
BFPL
Australia
2006
2200
EBIC
Egypt
2009
2000
MHTL
Trinidad
2009
1850
Jianfeng
China
2010
1500
Pequiven Moron
Venezuela
U/C
1850
Pequiven Jose
Venezuela
U/C
1800
Location
Start Up-Year
Capacity
Pequiven PN
Venezuela
U/C
1800
Matix
India
U/C
2200
Petrobras
Brazil
U/C
2200
Jaypee
India
U/C
2200
Kaltim 5
Indonesia
U/C
2700
BCIC
Bangladesh
U/C
1000
TDF
Argentina
U/C
1500
Kima
Egypt
U/C
1320
IEPCL
Nigeria
U/C
2300
IFC
USA
U/C
2200
PAU
Indonesia
U/C
1900
Pusri 2
Indonesia
U/C
2000
yes
>18
3%
Conventional
240-300
100-130
no
10
8-12%
Agenda
Location
Year
MTPD
Unocal
USA
1966
680
Kemira
Netherlands
1968
1360
First Miss
USA
1968
900
Asahi
Japan
1971
900
Yara # C
Netherlands
1971
900
PCS N2
USA
1978
1360
BASF
Germany
1982
1360
Yara # D
Netherlands
1984
1500
Yara # E
Netherlands
1987
1750
Yara TR2
Trinidad
1988
1360
Location
Year
MTPD
Jinxi
China
1993
1000
Jianfeng
China
1993
1000
Sichuan
China
1995
1000
Sinopec/UGPW
China
1997
1000
Safco
Saudi Arabia
1999
1500
CNOOC
China
2003
1500
BFPL
Australia
2006
2200
Jianfeng
China
2010
1500
Pequiven Jose
Venezuela
U/C
1800
Venezuela
U/C
1800
Plant
Location
Year
MTPD
Kribhco Revamp # 1
India
2012
1890
Kribhco Revamp # 2
India
2012
1890
NFL
India
U/C
950
Matix
India
U/C
2200
Jaypee
India
U/C
2200
Argentina
U/C
1500
Petrobras
Brazil
U/C
2200
Location
Year
MTPD
Kaltim 5
Indonesia
U/C
2700
BCIC
Bangladesh
U/C
1000
Kima
Egypt
U/C
1320
IEPCL
Nigeria
U/C
2300
IFC
USA
U/C
2200
YPFB
Bolivia
U/C
1200
Pusri IIB
Indonesia
U/C
2000
PAU
Indonesia
U/C
1900
Dyno Nobel
USA
U/C
2300
Gcal/mt - LHV
10
9
8
7
6
5
THEORETICAL MINIMUM
1970
1975 1980
1985
1990
1995
2000
6.06
1.72
7.78
-1.52
6.26
0.27
6.53
Gcal/MetricTonofNH3(LHV)
Natural Gas
Measured
Expected
Feed
6.25
6.32
Fuel
1.93
1.91
Subtotal
8.18
8.23
Export Steam
-1.72
-1.75
Net
6.46
6.48
Electricity
0.03
0.03
Total Energy
6.49
6.51
Longest run
Non-KBR Plants
90.6%
385 days
KBR Conventional
92.7%
432 days
KBR Purifier
94.2%
624 days
All Plants
91.5%
424 days
Agenda
OWNER
LICENSOR/EPC
CONTRACTOR
Phase 1 TENDER
PERIOD
At Tenderers Cost
ANALYSE/
NEGOTIATE/
AWARD
PHASE 2 EXECUTION
PERIOD
MANAGE AND
CONTROL
PHASE 3 EXECUTION
PERIOD
ENGINEERING
PROCUREMENT
(IF REQUIRED)
OPEN BOOK
ESTIMATE
CONVERT TO
LUMP SUM
Reimbursable
ENGINEERING
PROCUREMENT
CONSTRUCTION
COMMISSIONING
Lump Sum
OWNER
LICENSOR
ANALYSE/
NEGOTIATE/
AWARD
Phase 1 BED/FEED
- License Fee Agree
ANALYSE/
NEGOTIATE/
AWARD
PHASE 1 AWARD PHASE
ISUUE ITB TO
SELECTED
CONTRACTORS
PROCUREMENT
(LLI)
SELECT
CONTRACTOR
AWARD LUMPSUM
CONTRCT
FIXED FEE
Reimbursable
ENGINEERING
PROCUREMENT
CONSTRUCTION
COMMISSIONING
Lump Sum
Comparison of Options
Option A
Option B
Option C
Option D
Select
Technology First
Yes
Yes
Yes
No
Description of
EPC Phase
Cost Plus or
Reimbursable
OBE converted
to LSTK
TIC
Lowest
Medium
Medium (-)
Highest
Schedule
30~32 months
32~34months
34~36 months
+ 48 months
Quality
Highest
Highest (-)
Medium
Medium
Owners Risk
Highest
Medium (-)
Medium
Lowest
Agenda
Summary