KBR's PURIFIERplus™ ammonia process combines proven and reliable technologies for the manufacturing of ammonia from our proprietary KRES™ (KBR Reforming Exchanger System), Purifier™ and horizontal ammonia synthesis converter to produce a synergistic, lower cost process that eliminates the need for an air separation plant and a primary reformer.
KBR's new PURIFIERplus™ ammonia process combines KRES™ and Purifier™ technologies in one flowsheet.
While KRES™ and Purifier™ provide significant cost savings and operational efficiencies separately, combining them in PURIFIERplus™ allows for further economic gains. The benefits of the Purifier™ process include:
KBR KRES™ Exchanger
KRES™ is a proprietary heat exchanger-based steam reforming technology consisting of a fired preheater, an autothermal reformer (ATR) and a reforming exchanger. KRES™ takes the place of a conventional primary reformer by feeding excess air, natural gas feed and steam to the ATR and feed and steam in parallel into the upper end of the robust, shell-and-tube reforming exchanger. The compact ATR and reforming exchanger in combination with the fired preheater take up much less plot space than a conventional fired steam methane reformer.
The tubes in the KBR reforming exchanger are open-ended and hang from a single tube sheet at the inlet cold end to minimize expansion problems. They are packed with a conventional reforming catalyst, which can be easily loaded through a removable top head. The tubes are accessible and removable as a bundle for maintenance. This simple, proprietary design has proven to be extremely reliable and maintenance-free in commercial operation since 1994.
Read more about KBR Reforming Exchanger System (KRES™).
KRES™ Exchanger as installed at an ammonia plant in British Columbia, Canada
Downstream of the KRES™ unit, KBR's cryogenic Purifier™ process simultaneously removes impurities and adjusts the hydrogen to nitrogen ratio to 3:1. The system accepts purge gas from upstream, thus eliminating the need for a separate purge gas recovery unit.
The Purifier™ system consists of:
All items and the connecting piping are welded and enclosed in a perlite-insulated cold box.
KBR proprietary cryogenic purification technology removes methane, argon and excess nitrogen from synthesis gas and allows use of air instead of oxygen in the reforming section of the ammonia plant, eliminating the need for an expensive air separation unit.
Read more about KBR's Purifier™ Cryogenic Syngas Purification.
For conventional magnetite synthesis loops, KBR offers its horizontal ammonia synthesis converter. Inter-stage coolers between the catalyst beds provide for maximum conversion and heat recovery.
For conventional magnetite ammonia synthesis loops, KBR offers its horizontal ammonia synthesis converter. The converter contains two or three reaction stages, each with vertical downward flow in the magnetite catalyst beds. Intercoolers are provided between the catalyst beds for maximum conversion and heat recovery.
The catalyst basket is easily removed from the converter shell for catalyst loading and unloading. The basket can be rolled out of the horizontal converter vessel on tracks, thus avoiding the need for a heavy, expensive crane.
Read more about KBR's Horizontal Synthesis Converter.