Ammonia Revamp: KBR Response for Modern-Day Challenges
In this whitepaper, KBR’s Volodymyr Oliynyk, Alexander Ivanov and Daragh Blennerhassett examine how with new construction costs exceeding $700 million to $1 billion, revamping existing ammonia plants offers a cost-effective solution.
Upgrades such as advanced equipment, optimized process schemes, and modern control systems improve efficiency, reliability, and safety—ensuring long-term viability and supporting global food security.
Industry overview and KBR’s role in revamps
At present, approximately 495 ammonia plants are in operation worldwide, with more than 350 built between the 1960s and 1990s. Many of these still rely on outdated technologies, leading to lower energy efficiency and higher carbon emissions. In the current market with high energy prices, construction cost, and growing demand for ammonia-based fertilizers, it presents a significant opportunity for revamping; the process of upgrading and modernizing existing plants to enhance their performance.
KBR is a global leader in ammonia revamps, having over 200 revamp projects executed at different engineering stages, starting from feasibility studies and extending to basic and detailed engineering, proprietary equipment supply, and commissioning support. This extensive experience positions KBR as a key partner for plant operators looking to improve efficiency, increase capacity, and transition toward sustainable ammonia production.
KBR revamp philosophy
KBR’s approach for successful execution of a revamp project is based on the application of innovative and proven technical options together with deep understanding of the technologies and processes at the revamping plant.
There are two approaches that can be applied when executing an ammonia revamp project:
Extensive: Focuses on increasing capacity to achieve higher output. It typically involves adding more resources, equipment, or expanding infrastructure.
Intensive: Relies on optimization, efficiency, and process improvements without significantly increasing physical infrastructure.
These approaches may be applied independently – extensive primarily for capacity increase and intensive for energy efficiency enhancement.
KBR’s execution strategy towards complex revamp projects is based on the utilization of both extensive and intensive approaches to achieve the project’s operation performance targets within the budget.
Any revamp project has these specific phases of development. These include:
- Feasibility study or process evaluation
- Proprietary engineering design or project design documentation
- Detail design
- Equipment supply
- Construction, commissioning and startup
KBR’s proprietary technologies and equipment
In every revamp project, KBR evaluates the use of proven open art engineering solutions and also differentiated proprietary KBR technologies. KBR has developed unique, proprietary technical solutions and equipment designs. These technologies have been successfully implemented in the ammonia industry and confirmed by long-term reliable operation.
KRES™ – KBR Reforming Exchanger
This technology was developed by KBR in the 1990s and is based on the utilization of KBR-designed unique equipment—KRES, that allows reforming the hydrocarbon feed using high grade-heat of converted gas after the secondary reformer and without direct fuel firing. KBR offers this process for implementation to ammonia plants where such high-grade heat is available.
The application of the KRES can be in the following scenarios:
Grassroots plants: Installed in parallel to the SMR + secondary reformer section allowing reduction in fuel burning in the SMR and subsequently on CO2 emissions. This option is very attractive for “blue” ammonia or standalone ammonia production facilities where no extra steam is required.
Revamping plant: Installed in parallel to the existing SMR + secondary reformer section, it allows production of up to 130% of SMR capacity. This option is good for capacity increase projects as it does not require significant modifications in the existing SMR and the majority of the work can be completed outside of the turnaround. The KRES technology also provides some energy reduction in the fuel for the reformer between 0.03 to 0.05 Gal/MT.
Waste Heat Boiler – 101-C
KBR’s floating head boiler design has been successfully used since 1983 at all new ammonia plants, replacing the old-style bayonet boilers. The unique feature of this boiler is its water-tube cooled, floating head design with natural circulation and hot gas on the shell side. The new 101-C design also can be implemented at conventional technology plants by replacing old types of boilers 101-CA, 101-CB and 102-C with a single unit.
KBR implemented these boilers to replace outdated waste heat boilers during several revamps of ammonia plants. It helps avoid complications with operational reliability and routine replacement within the normal turnaround schedule. The new integrated 101-C design can also be installed within the existing footprint of the existing equipment in certain facilities.
There is no need to change the existing steam drum to just reconnect existing risers to the new boiler.
Purifier®
KBR’s Purifier and PurifierPlus flowsheets represent the most energy-efficient ammonia processes available in the market. The lowest recorded net energy consumption — 6.25 Gcal/MT — was achieved at a Purifier plant operated by CFCL in India.
Together with opex benefits, this technology provides the lowest capex at the construction, by reducing the sizes of the equipment in the reformer section and a synthesis loop that operates without inerts, avoiding the costs for HRU equipment. It is estimated that capex reduction is about 6-8% of the ammonia project total installed cost (TIC).
Ammonia Converter – 105-D
Since the introduction of the first ammonia plant, KBR has consistently utilized proprietary designs for ammonia converters. Over the years, KBR has developed multiple multi-bed configurations, including both vertical and horizontal designs, each offering distinct benefits based on factors such as technology selection, plant capacity, plot plan constraints, and client preferences for maintenance.
In general, KBR recommends vertical converters for plants with capacities below 2,000 MTPD, while horizontal converters are suitable for capacities up to 6,000 MTPD using a single horizontal unit.
For revamp projects, KBR may propose the addition of a single-bed, cold-wall design add on converter. Installed in series with the main converter, this proven design functions as an additional catalyst bed, enabling ammonia conversion rates of 21-24%. This approach increases synthesis loop capacity without requiring major investments in expanding existing equipment.
Unitized Chiller – 120-C
This unique KBR equipment integrates the functions of several components typically used in conventional ammonia plant refrigeration systems. It features multiple compartments, where liquid ammonia evaporates at different pressures and temperatures, combined with a central coaxial tube bundle.
Such a design allows drastic reduction in pressure drop for the recycled gas and saves energy during the recycle stage of synthesis gas compressor. This is a standard piece of equipment for all KBR design ammonia plants since the 90s but can be considered as a possible revamp option for substantial energy reduction.
KBR sustainability and carbon reduction revamps
With increasing emphasis on sustainable operations, ensuring food security has created a complex affordability challenge in a commoditized market.
KBR’s ammonia revamp business provides the following advanced solutions:
- Substitution of fossil feedstock with renewable sources
- Conversion of fossil-fuel-based ammonia plants into “green” operations
- Implementation of post-combustion capture technologies for carbon sequestration, utilization, or urea upgrades
In essence
KBR’s leadership in ammonia technology is built on decades of experience designing and executing grassroots ammonia plants.
KBR takes a flexible, client focused approach to every revamp, beginning with a detailed assessment of plant objectives and real operating conditions. From feasibility and process studies through open art technology assessment, proprietary equipment design and detailed engineering, KBR ensures that every solution is technically sound and commercially optimized. Once engaged, KBR supports the full project lifecycle ensuring seamless execution and predictable results.
With proven experience in capacity expansion, energy efficiency improvements, and sustainability driven upgrades, KBR offers comprehensive, high value revamp solutions that help operators maximize the performance and longevity of their ammonia assets.
