PRE-COMMISSIONING / COMMISSIONING / INITIAL START-UP

The following are the major start-up milestones achieved during the pre-commissioning and
commissioning of the plant.

Date Activity
Beg of Aug. 1999 Steam flushing started
09 Jan. 1999 Air flushing started
13 Dec. 1999 Primary reformer catalyst loading started (completed 17 Dec. 1999)
15 Nov. 1999 Ammonia converter catalyst loading started (completed 02 Dec. 1999)
24 Jan. 2000 First ignition of burners in primary reformer (drying purpose)
19 Feb. 2000 First process steam and natural gas feed to primary reformer
23 Feb. 2000 Secondary reformer ignited
26 Feb. 2000 Low temperature shift reactor put into operation
27 Feb. 2000 Process gas feed to MDEA section
15 Mar. 2000 Methanator put into operation
26 Mar. 2000 Synthesis gas compressor started
29 Mar. 2000 Ammonia refrigeration compressor started
29 Mar. 2000 First ammonia product sent to storage

As the steam supply from outside battery limit was not stable in respect of continuity and
quantity, the steam flushing was suspended many times and resulted in long time lag between the
start of steam flushing and air flushing. However, as can be seen from the above list of
milestones, the contractor, Mitsubishi Heavy Industries, by means of an extremely tight planning
recovered the loss caused by the steam flushing and managed to put the entire unit on stream
within a period of approximately 40 days after the first process steam and natural gas had been
fed into the primary reformer in spite of the time loss caused by the replacement of one complete
dry gas seal unit for synthesis gas compressor.

START-UP DELAYS

The overall project schedule has been successfully met and that the first product was obtained 34
months from the effective date of the contract eventhough some delays did occur during the
initial start-up.

During the start-up of the Process Air Compressor, which was scheduled to be put in service for
air flushing of the process gas pipings, a heavy vibration problem in the Compressor was
encountered. Due to insufficient flushing in the oil system, small foreign particle remaining in
the lubrication piping system was the principal cause of the vibration.

Initially the MDEA Semi-lean solution pumps were suffering due to a damage in the shaft
bearing. With the newly installed shaft bearing relieving fully the radial thrust, the trouble have
been corrected.

One of the intercoolers had an acoustic resonance problem and full load was not achieved during
the pre-commissioning stage. After the addition of a longitudinal baffle during the short period
shutdown prior to the process start-up, the noise and vibration caused by the acoustic resonance
disappeared entirely at full load operation.

Minor things have also been experienced, however, they never reached to serious constraints and
the cooperative effort by the contractor, MHI and the owner, KPA, resolved each problem
diligently and patiently.
PERFORMANCE - PROCESS

40 days after feed gas and steam were introduced to the primary reformer, the first drop of
ammonia have been delivered to the storage. On-spec 99.8 wt% product was achieved two days
after while the reduction of the S-50 synthesis catalyst was conducted simultaneously.

An average of 104% production rate has been achieved since then. The largest production
capacity demonstrated was 2,100 MTPD which is the largest ever commercially recorded.

The product quality for ammonia was quite acceptable and exceeded the specification of 99.8
wt% even for the reduction period of S-50 ammonia converter. Oil content was around 2-3 ppm
wt. For the byproduct CO2, nothing wrong was observed with regard to the quality and always
exceeded the specification of 99.0 vol% dry.

The energy consumptions inside the battery limit of the plant were all within the guaranteed
value. As fluctuation in the natural gas composition was observed, a higher setpoint on the
process steam was settled. However, the natural gas consumption of 6.6 Gcal (LHV)/m-ton with
credit for steam export and utilities has been achieved.

Steam export from the Plant was around 0.45 m-tons/m-ton which exceeded the expected value.

Electric power consumption of 22 kWh/m-ton was achieved with motor driven machineries such
as two IDFs, one semi-lean pumps (partially covered by power recovery turbine), recycle gas
compressor and utility pumps.

PERFORMANCE - HSE

Some parameters regarding the environmental control have been measured as an additional
program of the KPA plant evaluation.

The plant component are all plotted and accommodated in a very confined area and close to the
adjacent plant, noise level at the process plant battery limit was around 80 dB(A).

Neither SO2 nor NOx emission measured at the battery limit exceeded 5 ppm.

Safety records have reached 5,765,978 Work Hours total without Lost Time Accident.

CONCLUSION

The challenging job of establishing the large scale ammonia plant was successfully proved by the
design, construction and operation of the KPA plant. This successful result may force other plant
owners to eager towards the larger production capacity in single-line unit based on tubular
reforming.

ACNOWLEDGE

The plant commissioning was carried out by well trained operators supplied by KPA who have
rich experience in PT. Pupuk Kaltim existing plants. Thanks to them, the world largest
production capacity have been demonstrated successfully.