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Efficient Ammonia Production: Jim Gosnell 13 October 2005 Hydrogen Conference Argonne National Laboratory
Efficient Ammonia Production: Jim Gosnell 13 October 2005 Hydrogen Conference Argonne National Laboratory
Efficient Ammonia Production: Jim Gosnell 13 October 2005 Hydrogen Conference Argonne National Laboratory
Jim Gosnell
13 October 2005
Hydrogen Conference
Argonne National Laboratory
Topics to be Covered
Overview of KBR Activities
Ammonia Supply & Demand
History of Ammonia Manufacture
Ammonia Plant Market Trends
Current Manufacturing Technology
Ammonia from Renewable Energy
Summary
Organization
Halliburton Company
(Energy Services)
Overview
Organization (Contd)
Process Technology
Development
Licensing
Engineering
Procurement
Construction
Operations
Maintenance
Government &
Infrastructure Division
CFO
Legal
Largest
government
logistics & services
contractor with
premier worldwide
civil infrastructure
capabilities
Administration
Baku
Aberdeen
Greenford
Calgary
Leatherhead
Algiers
Yokohama
Houston
Singapore
Monterrey
Indonesia
Muscat
Cairo
Doha
Perth
Rio de Janeiro
Johannesburg
= Operating/Execution Centers
= Joint Venture Alliances
Jakarta
Gas Monetization
Petrochemicals
Refining
Syngas
Methanol
Hydrogen
GTL
Urea
Ammonia
Other
Fertilizers
Topics to be Covered
Overview of KBR Activities
Ammonia Supply & Demand
History of Ammonia Manufacture
Ammonia Plant Market Trends
Current Manufacturing Technology
Ammonia from Renewable Energy
Summary
Sulfuric acid
Ammonia
Urea
Ethylene
Chlorine
Soda
Methanol
167
142
121
105
50
43
35
Ammonia Uses
Fertilizers
82%
Other Uses
18%
explosives
fibers
resins
animal feed
M illions of hectares
1,400
1,200
Rest of World
Southwest Asia
Socialist Asia
FSU
Europe
North America
1,000
800
600
400
200
0
1980
1990
2000
World Population
8,000
7,000
Millions
6,000
5,000
4,000
3,000
2,000
1,000
0
1980
Industrialized
1990
2000
EE & FSU
China
Source: EIA
2010
India
2020
Rest of World
MILLIONS of MT/YEAR
185
175
165
2005-2010 = 2.2%/year
155
145
135
125
2000
2001
2002
2003
2004
2005
YEAR
2006
2007
2008
2009
2010
MILLIONS of MT/YEAR
185
Installed Capacity
175
Capacity
165
155
Demand
145
Demand
135
125
2000
2001
2002
2003
2004
2005
YEAR
2006
2007
2008
2009
2010
13%
14%
12%
46%
3%
5%
7%
ASIA
China
India
Indonesia
All other
27%
8%
4%
7%
PERCENT EXPORTED
13.5%
13.0%
12.5%
12.0%
11.5%
11.0%
2000
2001
2002
2003
2004
2005
YEAR
2006
2007
2008
2009
2010
+4.9
-2.9
-5.4
-1.5
-0.1
+1.1
+3.9
(Fertecon)
400
350
300
250
Extreme volatility in
US gas prices
PCS closes
Trinidad capacity
due to lack of gas
price agreement
200
150
100
Bahrain plant o/s 1985
50
0
70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 0 1 2 3 4
Current $/tonne
300
250
200
150
100
50
0
1995
2005
2010
Topics to be Covered
Overview of KBR Activities
Ammonia Supply & Demand
History of Ammonia Manufacture
Ammonia Plant Market Trends
Current Manufacturing Technology
Ammonia from Renewable Energy
Summary
2NH3
Discovery of Hydrogen
Described by Robert Boyle in 1671
Fe + H2SO4
FeSO4 + H2
Recognized as an element in 1766 by Henry
Cavendish
Named by Antoine Lavoisier in 1783 after he
discovered its ability to generate water
2H2 + O2
2 H2 O
H2 + CO + CH4
3H2 + CO
Process
Reaction
Approximate
Relative
Energy
Consumption
Water electrolysis
2H2O 2H2 + O2
300%
Coal gasification
170%
CH + 2H2O 2 H2 + CO2
135%
Naphtha reforming
104%
100%
YEAR
1784
1904
1908
1908 - 1922
1910
1914
1927
2005
19
20
19
30
19
40
19
50
19
60
19
70
19
80
19
90
20
00
20
10
20
20
20
30
20
40
20
50
Population (Billions)
10
9
8
7
6
5
4
3
2
1
0
300
250
200
``
Year
150
100
50
Million Tons/Year of N2
Topics to be Covered
Overview of KBR Activities
Ammonia Supply & Demand
History of Ammonia Manufacture
Ammonia Plant Market Trends
Current Manufacturing Technology
Ammonia from Renewable Energy
Summary
Gcal/mt - LHV
10
9
8
7
6
5
THEORETICAL MINIMUM
1940
1950 1960
1970
1980
1990
2000
Thousand MTPD
12
10
Source: KBR
LA
ME
IN - AF
APAC
Europe
NA
8
6
4
2
0
85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04
Year of Award
M etric Tons/Day
2000
1500
1000
500
0
1950s
1960s
1970s
1980s
1990s
2000s
MT/D
2000
1000
2X
2X
0
1960 1965
1970 1975
Year
2000
2005
Relative $/MT
100%
90%
80%
70%
60%
1
1.5
2.5
Capacity Factor
3.5
Topics to be Covered
Overview of KBR Activities
Ammonia Supply & Demand
History of Ammonia Manufacture
Ammonia Plant Market Trends
Current Manufacturing Technology
Ammonia from Renewable Energy
Summary
Process Air
Carbon
Dioxide
Natural
Feed
Gas
Treatment
Feed
Syngas
Production
Syngas
Purification
Synthesis
Loop
Ammonia
Condensate
Steam
Steam & Water
System
Make-up
Water
Chemical Reaction
Favorable
Conditions
Primary Reforming
Secondary
Reforming
Low temperature
High steam/CO
Low temperature
High steam/CO
Equipment
Features
Primary Reforming
Catalyst-packed tubes in a
furnace
Nickel catalyst
Secondary Reforming
Refractory-lined pressure
vessel
Nickel catalyst
Pressure vessel
Iron-chrome
catalyst
Pressure vessel
Copper-zinc
catalyst
Primary Reforming
Fuel
To Feed
Treatment
Feed
Air
Reformer
Outlet
700
oC
BFW
Steam
ID Fan
Mixed Feed
Superheated Steam
Secondary Reforming
Excess Air
Primary
Reformer
Effluent
700 oC
100-125 bar
Steam
870 oC
BFW
To High
Temperature
Shift Reactor
Shift Conversion
Syngas 370 C
from
Boiler
200 C
Low
Temperature
Shift Reactor
High
Temperature
Shift Reactor
430 C
240 C
Shifted
Syngas
to CO2
Removal
Separator
35 C
BFW Heating &
Steam Generation
Water
Cooler
Process
Cond.
Description
CO2
Removal
Physical Dissolution
or Chemical Reaction
Methanation
Drying
Physical Adsorption to
remove water & CO2
Cryogenic
Purification
Separation of argon,
residual CH4 and excess
N2 from syngas
Favorable
Conditions
Low temp &
High pressure
280 - 350C
2 - 4 C
-180 C
Equipment
Features
Absorb/regen
Contact syngas with
columns with solution solution over packing
circulation pumps
Nickel catalyst
Drying
Cryogenic
Purification
Aluminum, generator
brake, trays, set H/N =
3.0
Syngas Purification
CO2
Regenerator
CO2
Dryers
CO2 Methanator
Absorber
Pure, Dry
Syngas to
Compressor
CW
Raw
Syngas
from
Shift
Process
Condensate
to Stripper
Cryogenic
Purifier Waste Gas
to Fuel
NH3
Synloop
Purge
Syngas to
2 C Compresso
2C
-182 C
Syngas
from
Dryers
H2
N2
CH4
A
4C
Vol%
62-68
30-35
2-3
~0.6
H2/N2 = 3
Inert <0.3%
Description
Favorable
Conditions
Synthesis
Heat
Recovery
High T
Product
Recovery
Equipment
Features
Synthesis
P = 90 175 bar
T = 400 - 500 C
Heat
Recovery
Proprietary
design
Product
Recovery
Compression
refrigeration system
Ammonia as the
refrigerant
2C
31.6 bar-a
93 bar-a
Steam
& BFW
Let Down
Drum
HP BFW
-18 C
Ammonia
Reactor
Unitized
Chiller
CW
Refrigeration System
Condenser
Refrigeration
Compressor
Ammonia
Accumulator
NH3
from
Letdown
Drum
HP Case
LP Case
-33 C
0 bar-g
Unitized Chiller
Warm NH3
Cold
NH3
Ammonia Converter
KAAP Catalyst
Topics to be Covered
Overview of KBR Activities
Ammonia Supply & Demand
History of Ammonia Manufacture
Ammonia Plant Market Trends
Current Manufacturing Technology
Ammonia from Renewable Energy
Summary
Circulation
& Refrigeration
Compressors
Air
Sep
Unit
N2
Ammonia Ammonia
Synthesis
Loop
Air Compressor
Water
Elect.
Cells
100 bar-g
H2
O2
Material Balance
(tons/ton of ammonia assumes no losses)
IN
Air
1.09
Water
1.59
OUT
Ammonia
1.00
Oxygen
Argon
1.67
0.01
TOTAL
2.68
2.68
390
Pump
Electrolytic cells
TOTAL
8
7000 9000 (1)
~7400 9400
6.4 8.1(1)
-0.6
5.8 7.5
2150 kcal/kWh(2)
Electricity (1)
6.4
16.0
Heat recovery
-0.6
-0.6
TOTAL
5.8
15.4
$259 (1)
2
-42
-24
TOTAL
(1) Based on 3.5 kWh/Nm3 of H2
$195
Topics to be Covered
Overview of KBR Activities
Ammonia Supply & Demand
History of Ammonia Manufacture
Ammonia Plant Market Trends
Current Manufacturing Technology
Ammonia from Renewable Energy
Summary
1970s a decade
of rapid capacity
expansion
40%
35%
30%
25%
20%
15%
10%
5%
0%
Gcal/mt - LHV
1950s
1960s
1970s
1980s
1990s
THEORETICAL MINIMUM
2000s
1980s a decade
of reduced energy
consumption
Thousand MTPD
12
10
LA
ME
IN - AF
APAC
Europe
NA
8
6
4
2
1990s a decade
of moving
projects to low
gas cost areas
85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04
Year of Award
Metric Tons/Day
2000
2000s a decade
of increased
plant capacities
1500
1000
500
0
1950s
1960s
1970s
1980s
1990s
2000s
MILLIONS of MT/YEAR
185
175
165
155
145
135
125
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
YEAR
This will drive ammonia prices down towards their historic average
of about $150/mt
THANK YOU