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Scale-Up of an Ammonia Synthesis Catalyst System Disclosure Number: IPCOM000218544D
Publication Date: 2012-Jun-05
Document File: 10 page(s) / 1M

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The Prior Art Database

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S. KNEZ, M.W. Kellogg Company, Houston, Texas

P. SHIRES, M.W. Kellogg Company, Houston, Texas

S. TENNISON, British Petroleum Limited, Sunbury-on-Thames,Middlesex


This paper will highlight some of the critical paths and decision networks involved in the successful development and scale-up of a novel ammonia synthesis catalyst system. The Kellogg Advanced Ammonia Process (KAAP) is based on this new catalyst and represents the first major change in ammonia synthesis catalyst technology since the

magnetite catalyst-based ammonia rocess was encompassed both catalyst development and its subsequent process implementation. The catalyst development required the complete development/scale-up of a proprietary catalyst support manufacturin process and scale-up of

                     The successful process implementation required investigation of catalyst operating conditions and reactor designs to most effectively utilize the unique characteristics of the new catalyst.

Criteria for the desi n of a 3 MTPD Process Demonstration Unit QPDU) are also discussed. This PDU verified the bench/pilot-scale derived kinetic model over a range of conditions using

            as pan ot tne scale-up of catalyst support manufacturing technology and catalyst production scale-up.

The upcoming KAAP retrofit will represent the commercial implementation of the KAAP scale-up of a technology resulting from a twelve-year joint development program between British Petroleum Ltd. and The M.W. Kellogg Co. This paper will discuss the importance of assembling a joint oversight committee to monitor, review and recommend to the management of both companies a consensus course of action during the critical developmenVscale-up phases of the project to meet the overall program goals.

developed in 1913. The scope oPthe project

the impregnation tecgh nology.

                   all of 1992 at Ocelot Ammonia Company, in Kitimat, British Columbia, Canada. The technology will be

implemented as a retrofit into the existing ammonia plant allowing for a 40%increase in ammonia production capacity.

The approachin commercial implementation of between catalyst developer, British Petroleum

BP)and process developer, The M.W. Kellogg

L0.(MWK). This paper will also attempt to illustrate the role -and importance of the Joint

Development Committee (JDC) as a decision- makina team tttrougb all phases nf *?

development and scale-up. The course of commercialization althou h well-planned did

and problems. The successful development of KAAP was chiefly the product of commitment by the companies and individuals, hard-work, and a fundamental understanding of the technical challenges associated with catalyst development.

KAAP evolved


om a synergistic cooperation

present the developers wR unexpected avenues


Globally, ammonia is the largest synthetic chemical in value and the second largest in quantity. It is the most im ortant chemical on which human life depen




The co...