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Retrofit of an Agrico Chemical Co. NH3 Converter via the MWK Vertical Split Flow Basket Modification

IP.com Disclosure Number: IPCOM000218709D
Publication Date: 2012-Jun-06
Document File: 29 page(s) / 1M

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The IP.com Prior Art Database

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This is the abbreviated version, containing approximately 12% of the total text.

Page 01 of 29

MODERNIZATION OF AN AGRICO AMMONIA CONVERTER VIA THE
KELLOGG VERTICAL SPLIT-FLOW BASKET MODIFICATION

    R. G. Howerton Agrico Chemical Company

S. A . Noe


The M. W. Kellogg Company

   PRESENTED AT THE 1988 AMMONIA SYMPOSIUM SAFETY IN AMMONIA PLANTS AND RELATED FACILITIES

AMERICAN INSTITUTE OF CHEMICAL ENGINEERS DENVER, COLORADO

AUGUST 1988

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Page 02 of 29

ABSTRACT

A report on Agrico's ammonia converter basket modification is presented. Various aspects of the retrofit of Agrico's plant No. 2 at the Verdigris, Ok. complex are discussed including field

construction, analysis o f preliminary test data, a n d final

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performance after incorporating improved temperature control features.


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Page 03 of 29

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MODERNIZATION OF AN AGRICO AMMONIA CONVERTER V I A THE
KELLOGG VERTICAL SPLIT-FLOW BASKET MODIFICATION

     R . G . Howerton A g r i c o Chemical Company

S , A , Noe


The M. W . K e l l o g g Company

W i t h t h e c u r r e n t s t a t e o f t h e ammania m a r k e t , emphasis has been p l a c e d on revamping e x i s t i n g p l a n t s w i t h l o w c o s t r e t r o f i t schemes w h i c h p r o v i d e s h o r t p a y o u t p e r i o d s t h r o u g h r e d u c e d e n e r g y c o n s u m p t i o n . O f t h e s e schemes, one o f t h e most a t t r a c t i v e r e t r o f i t o p t i o n s i s t o p e r f o r m an i n - s i t u revamp o f an e x i s t i n g ammonia c o n v e r t e r b a s k e t t o p r o v i d e i n c r e a s e d c o n v e r s i o n and reduced p r e s s u r e d r o p . S i n c e r e t r o f i t t i n g a c o n v e r t e r n e c e s s a r i l y r e q u i r e s r e p l a c e m e n t o f t h e e x i s t i n g c a t a l y s t c h a r g e , t h e economics a r e p a r t i c u l a r l y a t t r a c t i v e when t h e r e t r o f i t c o i n c i d e s w i t h a s c h e d u l e d c a t a l y s t change-out.

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INTRODUCTION



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The Agrico Chemical Company's Verdigris, Ok. fertilizer complex includes two worldscale ammonia plants built by The M. W . Kellogg Company. Plant no. 1 i s a nominal 1000 STPD plant originally started-up i n 1 9 7 5 while plant no. 2 is a nominal 1150 STPD plant brought on stream in 1977. Agrico operates both plants at production rates o f 20 to 30% above nameplate capacity. Excellent on-stream factors were highlighted in 1 9 8 6 when plant N o . 2 completed a record setting run of 25 munths of cont-inuotts ammonifa production.

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prompting Agrico t o begin planning for a turnaround in 1986 to take corrective measures. Since inspecting the converter internals would

0 require unloading the catalyst charge, the decision was made to modernize the converter by performing an in-situ converter retrofit.

In March 1986, after evaluating the three competing proposals, Agrico awarded Kellogg a lump-sum turn-key contract for performing the converter retrofit. External to the converter, the only modification required t o realize the energy savings is t o install a s...