KAAP™ Ammonia Synthesis Converter

KAAP Ammonia Converter as installed at an 1850 MTPD grassroots ammonia plant in Trinidad. Click to Enlarge

KBR's Advanced Ammonia Process (KAAP™) ammonia synthesis converter uses one stage of traditional magnetite catalyst, followed by three stages of KAAP™ catalyst. All of the catalyst beds are radial flow for low pressure drop. Intercoolers are located between the catalyst beds for maximum conversion and heat recovery. The proprietary KAAP™ catalyst consists of ruthenium on a stable, high-surface-area graphite carbon base. KAAP™ catalyst contains a precious metal (ruthenium) and, thus, costs more than conventional magnetite catalyst.

KAAP™ Catalyst is the first major advance in catalyst technology since the original BASF ammonia plant started up in 1913. The KAAP™ catalyst has an intrinsic activity ten to twenty times higher than conventional magnetite catalyst. This allows operation at 90 bar synthesis loop pressure, which is one-half to two-thirds the operating pressure of a conventional magnetite ammonia synthesis loop. At this low pressure, only a single-casing synthesis gas compressor is needed and pipe wall thicknesses are reduced. This results in savings in plant capital equipment and operating costs.

KAAP™ Catalyst is manufactured and its operating performance is guaranteed by BASF Catalysts LLC under exclusive license to KBR.