Reforming KAAP process

KRES [Kellogg reforming exchanger system] A reforming process for providing syn-gas to the KAAP process. 

The KRES (Kellogg Reforming Exchanger System) is a reforming process that provides syngas to the KAAP process. The KAAP (Kellogg Advanced... 

M. W. Kellogg has also suggested a process (the KAAP process) based on a new catalyst [928, 949]. This technology has been used in a revamp project where a new reactor was installed downstream of the existing reactor in an ammonia synthesis loop (see Sect. 6.4.3.4). In addition, more radically new process schemes deviating from the traditional route have been described. An example is a scheme based on so-called parallel reforming [30,32,120,121] and a low pressure loop with ammonia recovery by water absorption [769]. None of these new developments have been implemented in practice. 

Another key feature of this new process is the patented KBR Reforming Exchanger System (KRES), which eliminates the need for the directly fired primary reformer furnace (fig. 6.11). This reduces capital costs by 5-8%, and emissions of NO and CO2 by 70-75%. The first KAAP process was installed for the Ocelot Ammonia Company s (now Pacific Ammonia Inc.) retrofit of its plant in Kitimat, British Columbia, in 1992 and when the first two new KAAP plants (for Farmland Misschem and PCS Nitrogen) were completed at Point Lisas, Trinidad, in July 1998, they became the world s largest ammonia facilities (each at 1,850 t/day) to date. ... 

KAAP [Kellogg advanced ammonia process] The first high-pressure process developed for synthesizing ammonia from its elements which does not use an iron-containing catalyst. The reformer gas for this process is provided by the KRES process. The catalyst was developed by BP it contains ruthenium supported on carbon. Developed by MW Kellogg Company in 1990 and first installed by the Ocelot Ammonia Company (now Pacific Ammonia) at Kitimat, British Columbia, from 1991 to 1992. Another plant was installed at Ampro Fertilizers in Donaldsonville, LA, in 1996. 

Description The key steps in the KAAP plus process are reforming using the KBR reforming exchanger system (KRES), cryogenic purification of the synthesis gas and low-pressure ammonia synthesis using KAAP catalyst. 

KAAP plus An improved version of KAAP, announced by Kellog Brown Root in 1999. It combines the features of the KBR Advanced Ammonia Process, the KBR Reforming Exchanger System, and the KBR Purifier technology. The catalyst is the same as that used in KAAP. In 2003, more than 200 large-scale plants were operating or had been contracted. 

Pig. 9.12 Flow-sheet for KBR advanced ammonia process 1-Air compressor 2,12,28,33,34-Cooling 3-Feed gas compressor 4-Waste heat boiler 5-Primary reformer 6-Secondary reformer 7,9,11,15,20,22,26,27,30-Heat recovery 8-HTS 10-LTS 16-Condensate stripper 17-C02 absorber 18-C02 stripper 21-Methanator 24-Dryer 25-Synthesis gas compressor 29-KAAP ammonia converter 32-Refrigeration compressor. 

---