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Design, Commissioning & Operation of Largest KBR Reforming Exchanger System (KRES) Disclosure Number: IPCOM000217666D
Publication Date: 2012-May-10

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Page 01 of 14

KBR Paper# 1910

Design, Commissioning & Operation of Largest KBR Reforming Exchanger System (KRES)


Shen Xize, Xu Xiaojun, Feng Wei

Liaoning Huajin Tongda Chemicals Co, Panjin (P.R. China)

Shashi Singh, Avinash Malhotra

KBR, Houston, Texas, USA

Prepared for publishing in the "Nitrogen & Methanol" A Magazine from British Sulfur

Copyright KBR

March 2005

Page 02 of 14

Design, Commissioning & Operation of Largest KBR Reforming

Exchanger System (KRES)


Liaoning Huajin Tongda Chemicals Co. Ltd. has been operating a conventional KBR technology based 1000 MTPD ammonia plant since 1978 at Panjin City in Liaoning province China. The plant has been facing a natural gas supply curtailment leading to very low capacity utilization and reduced production. In 2001 Liaohe awarded KBR a contract to supply technology and a basic engineering design package for a project to revamp this plant to reduce its dependence on natural gas by up to about.29% [natural gas consumption reduction from 9.15 to

6. 47Gcal/MT].

In this project, KRES replaced an existing fired reformer to significantly reduce the plant's natural gas requirement. An off-site coal fired package boiler was provided to maintain steam balance. An offsite oxygen package unit was also added to supply enriched 02 for refon'ning. Beside increased capacity utilization of the ammonia plant and reducing their overall natural gas bill, Liaohe also expected to increase production C02 by 13% and thus achieve higher urea production.

The KBR Reforming Exchanger System - KRES and Autothermal Reforming - ,~TR is a simple heat exchanger based steam reforming process used for generation of ammonia synthesis gas. In a conventional ammonia technology, waste heat exiting the secondary reformer is involuntarily recovered by raising steam in a waste heat boiler. Raising steam, a lower grade energy carrier, from this high grade waste heat is not thermodynamically as sound as recovery in KRES at 1000 - 700 degC. KRES technology recovers the high grade waste heat within the reformer system (reforming exchanger) for raising additional reformed gas.

The Liaohe's KRES unit is based on a significantly improved version of the original design used for the Ist time at Methanex's ammonia plant at Kitimat, Canada in 1994. It has several optimized and enhanced features incorporated making it more affordable and very compact.

The commissioning and operating experience at Panjin has re-confirmed all the outstanding attributes of KRES known from the first unit at Kitimat. All the technology enhancements, including scalability, have performed as foreseen. The unit is very user friendly and flexible and it adapts well to varying throughput requirements. KRES offers a proven and superior technology altemative to the conventional fired tube fumace type reformer. Ammonia producers can incorporate this technology to signit-~cantly reduce their dependence on natural gas, expand their production capacity, i...