K-Green™: KBR'S Green Ammonia Technology

K-GreeN™
KBR’s Green Ammonia Technology

KBR WEBINAR, June 18 2020
©2019 KBR Inc. All Rights Reserved.

Presenters
Paolo Brunengo is Director, Ammonia & Syngas technology, KBR.
Based in London, he is responsible for business development for ammonia revamp projects and K-
Green, KBRs Green Ammonia technology.
Paolo joined KBR in 2019 and has 22 years of industry experience across various companies including
Casale, Johnson Matthey, Maire Tecnimont.
Paolo studied B.A.Sc. in Chemical Engineering from MIP-Politecnico Di Milano, Italy and master’s
degree in Engineering Technology from ENSTA ParisTech, France.
Akhil Jain Nahar is Senior Technical Professional Leader, Ammonia & Syngas technology, KBR.
Based in Delhi NCR, he is responsible for business development for ammonia projects in India
and Asia region.
Akhil join KBR in 2010 and has 18 years of industry experience. Before KBR, he has worked with
Rashtriya Chemicals and Fertilizers Ltd and Technip KT India Ltd.
Akhil did his bachelors’ degree in Chemical Engineering from University of Pune, India.
2 K-GreeN™ | KBR Green Ammonia Solution | Webinar Jun 2020 Proud history, bright future.
Agenda
▪ Green Ammonia: what is it?
▪ Why Green Ammonia?
▪ Producing Green Ammonia today: challenges and
opportunities
▪ K-GreeN™: KBR solution for
Green Ammonia:
▪ Pilot/demonstration scale
▪ Commercial scale
▪ Conclusions
▪ Q&A
World Leader in Ammonia Technology
KBR
▪ $5.6 bn Revenue 2019, 37000 employees, 80+ Countries
▪ Licensed 242 grassroots ammonia plants since 1950.
▪ More than 50% of world’s ammonia produced using KBR’s
ammonia process
▪ Since 2000, KBR has licensed 38 new grass root ammonia plants (24
based on Purifier™ technology)
2019 records
World’s Largest Single World’s Most Efficient World’s Most Reliable

Train Plant – 2,890 tpd Plant – 6.27 Gcal/ton, Plant – over 5 years
(2,982 tpd achieved), Chambal, India continuous operation
EuroChem, Russia at Yara, Netherland
Ammonia Manufacturing: The Basics
▪ Ammonia is synthesized from hydrogen and nitrogen by the Haber-Bosch process @ 90-200 bar, 350-500 °C:
3𝐻2 + 𝑁2 ⇌ 2𝑁𝐻3
▪ Nitrogen source is always air (~78% N₂), directly or after separation (ASU)
▪ Hydrogen source has varied over the years, at present mainly based on natural gas or other fossil fuels like
fuel oil, naphtha, coal:
Process Reaction approx. relative energy required

Methane Reforming 𝐶𝐻4 + 2𝐻2 𝑂 → 4𝐻2 + 𝐶𝑂2 100%
Naphtha Reforming 𝐶𝐻2 + 2𝐻2 𝑂 → 3𝐻2 + 𝐶𝑂2 102%
Heavy fuel oil Reforming 𝐶𝐻 + 2𝐻2 𝑂 → 2½𝐻2 + 𝐶𝑂2 135%
Coal gasification 𝐶 + 2𝐻2 𝑂 → 2𝐻2 + 𝐶𝑂2 170%
Water electrolysis 2𝐻2𝑂 → 2𝐻2 + 𝑂2 300%
Green Ammonia: What Is It?
Grey/Brown Ammonia Blue Ammonia

Produced from fossil fuel via carbon Grey Ammonia whose CO₂ emitted during
intensive processes, currently the production is sequestrated via carbon
predominant way capture and storage (CCS) technology or
planting of trees to make carbon neutral
Renewable ammonia Green Ammonia
Produced via biogas, bio-methane or Low or zero carbon-emission Ammonia,

biomass gasification produced via electrolysis of water using
renewable-based electricity
Green Ammonia: Why?
▪ 80% of global
Ammonia
production currently
used to produce
fertilizers
▪ Ammonia
production currently
accounts for around
1.8% of global CO₂
emissions(1)
▪ Grey/brown
Ammonia process is
the largest carbon (1)
dioxide emitting
chemical industry (1) Ammonia: zero-carbon fertiliser, fuel and energy store, Issued: February 2020, The Royal Society
process(1)
Green Ammonia: Why?
T O D AY TOMORROW
Green Ammonia applications can grow beyond the current applications and support the energy transition towards
lower/zero carbon fuels
▪ Shipping fuel
▪ Energy storage The transition has started already
▪ Power source
Green Ammonia: Why?
Decarbonisation>>> As fertilizer:
▪ Stable growth driven by population and GDP
As chemical feedstock:
▪ Multitude of applications, growth
outpaces fertilizers
As energy carrier – fuel:
▪ Energy import from high solar/wind regions
(e.g. Japan from Australia by 2030)
▪ Shipping industry (e.g. Scandinavia, UK)
▪ Ammonia engines possible but hydrogen
more likely
Energy Transition>>> ▪ Ammonia has storage benefits over

hydrogen/methanol
Producing Green Ammonia Today: Challenges/Opportunities
H₂ Storage
Only a fully integrated solution is capable to optimize the operating level and energy storage options to
manage the intermittent nature of renewable energy supply
Producing Green Ammonia Today: Challenges/Opportunities
Cost comparison of Ammonia production(1)
▪ “Cost range” refers to the range of total levelised
costs across regions
▪ The lower end of the cost range is disaggregated
into cost categories
▪ Electrolysis assumptions:
▪ Powered by 100% renewable electricity
▪ ‘Feedstock cost’ is the electricity for the
electrolyzer
▪ ‘Fuel cost’ is additional electricity for the air
separation unit, synthesis loop, etc.
(1) Ammonia: zero-carbon fertiliser, fuel and energy store, Issued: February 2020, The Royal Society
K-GreeN™: KBR Solution for Green Ammonia
▪ Complete green Ammonia plant: from electrolyzer ▪ Trouble-free project execution by evaluating:
to Ammonia ▪ Minimum economic turndown capacity
▪ Low-cost add-on electrolyzer unit to existing ▪ Flexibility in ramp-up/ramp-down
Purifier™ Ammonia plant with no ASU or
▪ Impact assessment on economical feedstock
synthesis loop modifications required to produce
and product storage requirements
green Ammonia
▪ Proprietary equipment and catalyst
▪ Unsurpassed Ammonia synthesis plant reliability,
with lowest energy consumption at lower capital ▪ Life cycle support through KBR’s plant operations
cost (due to lower equipment count) management system Ammonia InSite® and KBR
technical services
▪ Various capacities:
▪ Demonstration units (<200 MTPD)
▪ Small-size green Ammonia plants
(200 - 600 MTPD)
▪ Large-scale green Ammonia plants
(600 - 6,000 MTPD)
K-GreeN™: Demonstration Scale Ammonia Plant
Power
H₂
Storage
Electrolysers
H₂O H₂
system Refrigeration
Compression Refrigeration
compressor
Chilling
N₂ system system
Converter system
O₂
NH₃
Converter
ASU
system
Air
Synthesis Loop
K-GreeN™: Demonstration Scale - Advantages
▪ Can be designed with range of pressure to suite the client/site needs
▪ Minimum number of equipment to minimize the Capex
▪ Proven Ammonia Converter Design – cold wall design
▪ Customized to operating condition of Ammonia Product
▪ Can be modularized for easy construction
▪ No Liquid or Vapor Effluent Generation
▪ No steam generation equipment or any steam export from plant
▪ Capable of Turndown for optimum utilization
▪ Fully integrated scheme
K-GreeN™: Large Scale Ammonia Plant
Power
H₂
Storage
Electrolysers Refrigeration
H₂O H₂
system
Compression Refrigeration
compressor
Chilling
system system
N₂ system
Steam Gen.
O₂
NH₃
Converter
ASU
Converter
Air Synthesis Loop Scope
K-GreeN™: Large Scale – 3Bed Horizontal Intercooled Converter
Man ways
BYPASS
INLET
OUTLET BED 3B BED 3A BED 2 BED 1
MAIN INLET
Flange TI
Single converter up to 6000 mtpd Ammonia plant
▪ Cold Wall Design
▪ Made of 1.25 Cr
▪ Less prone to cracking than hot wall designs
▪ Lower loop pressure drop
▪ Lower energy consumption & operating cost
▪ Easy Basket Removal
▪ Basket rolls out on tracks
▪ No need for expensive overhead crane
▪ Well-proven
▪ 20+ converters in operation/design
Man ways
BYPASS
INLET
OUTLET BED 3B BED 3A BED 2 BED 1
MAIN INLET
Flange TI
Single converter up to 6000 mtpd Ammonia plant
K-GreeN™: Large Scale – Unitized Exchanger System
NH₃
REFRIGERANT To Refrigeration Compressor
~ ~ ~
Refrigerant
From NH₃
Converter
To Syngas
Ammonia
Compressor
RECYCLE GAS Product
K-GreeN™: Large Scale – Unitized Exchanger System
▪ Replaces several chillers, recycle exchangers
and separators
▪ Number of stages = 2 – 4
▪ Reduces expensive HP pipe & fittings
▪ Lowers loop pressure drop
▪ Uses less plot area
▪ Ease of operation
▪ 50+ Unitized Chillers operating or in design
K-GreeN™: Large Scale Ammonia Plant - Advantages
▪ Well proven design
▪ Steam Generation - Superheated steam generation making loop energy efficient
▪ No start-up boiler required
▪ Summary
▪ Fewer number of equipment ➔ Reduced capital cost (capex)
▪ Reduced amount of bulk materials ➔ lower capex
▪ Reduced construction works ➔ lower capex
▪ lower loop pressure drop ➔ Reduced operating cost (opex)
▪ fewer pieces of equipment ➔ Reduced maintenance cost associated
▪ Robust and Reliable Steam Generation and Superheating with Process Gas
K-Green™: Green Ammonia From Existing Plants
▪ Possible to produce up to 7% of existing plant capacity as Green Ammonia
▪ Renewable H₂ used for either increasing the capacity or Syngas substitution
▪ Minimum to NO changes required to existing plant
▪ Easy to implement
▪ Capacity can be varied as per H₂ availability ➔ NO requirement of H₂ storage
▪ Technically feasible
▪ Existing plants with PurifierTM technology are better positioned to produce green
Ammonia with limited modification
K-GreeN™: Conclusions
▪ Green Ammonia - towards a sustainable, carbon-free economy:
▪ Low or zero carbon-emission fertilizers
▪ Supporting the energy transition
▪ as storage and carrier for green hydrogen (well proven, cost-competitive and reliable infrastructure)
▪ used directly as a green fuel or fuel additive
▪ K-GreeN™ - KBR solution for green Ammonia
▪ combines unsurpassed Ammonia synthesis plant reliability and efficiency with best-in-class electrolyzers and air
separation technologies
▪ provides high level of operational flexibility with integrated buffering of hydrogen to maximize the value of
intermittent renewable power supply
▪ KBR can develop dynamic models with various level of hydrogen/Ammonia production and storage to cope with
availability of renewable energy, cost of alternative energy and permitting requirements
▪ KBR can help to convert into green Ammonia part of existing plants’ production with minimum modifications

K-Green™: KBR'S Green Ammonia Technology

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K-GreeN™

KBR’s Green Ammonia Technology

©2019 KBR Inc. All Rights Reserved.

World’s Largest Single World’s Most Efficient World’s Most Reliable

Process Reaction approx. relative energy required

Grey/Brown Ammonia Blue Ammonia

Renewable ammonia Green Ammonia

Produced via biogas, bio-methane or Low or zero carbon-emission Ammonia,

Energy Transition>>> ▪ Ammonia has storage benefits over

▪ Minimum number of equipment to minimize the Capex

▪ Proven Ammonia Converter Design – cold wall design

▪ Customized to operating condition of Ammonia Product

▪ Can be modularized for easy construction

▪ No Liquid or Vapor Effluent Generation

▪ No steam generation equipment or any steam export from plant

▪ Capable of Turndown for optimum utilization

▪ Fully integrated scheme

OUTLET BED 3B BED 3A BED 2 BED 1

OUTLET BED 3B BED 3A BED 2 BED 1

▪ Reduces expensive HP pipe & fittings

▪ Lowers loop pressure drop

▪ Uses less plot area

▪ 50+ Unitized Chillers operating or in design

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