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)un,2022
pakarab POSITION PAPER
Ammonia Plant Capacity Revamp
Date: 2-lth

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POSITION PAPER
On

PFL AMMONIA PLANT

cAPACtTy REVAMP (TARGET 1150 MTPD)

Prepared by Reviewed by Signed by

Mubasher Mohsin Ali
Naeem Fareed Shahbaz Ali Ali Abrar AbdulGhaffar Abdul Nasir
Javaid Afzal
Sr. Process Snr. Process
Engineer _ Enginqqr DBN fi\^, DM-TSD DM-Maintenqnce SPM SM-DBN & REAP

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 POSITION PAPER Date: 27rh Jun,2022
Fakarab
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Ammonia Plant Capacity Revamp Page 2of4

Executive Summary:
Ammonia plant of Pakarab Fertilizers Ltd. (PFL), [t/ultan Pakistan was designed by ttl.
W. Kellogg Ltd (IUWKL) for a nameplate capacity of 910 [\4TPD (original) and 960
TUTPD (with PGRU) and was commissioned in November 1978. Design Energy Index
of Ammonia plant was 9.15 GCal/lVeT.

Aiming energy conservation of Ammonia Plant, following two projects were identified
to increase PFL profitability and sustainability by decreasing gas consumption through
improvement of overall energy index of Ammonia plant by 0.5 Gcal/MeT:

1 Primary Reformer (101-B) Furnace Convection Section modification for flue gas
waste heat recovery
2 Catacarb Revamp for stripping index improvement

KBR was engaged to investigate for further energy saving potential and KBR presented
some low CAPEX and some mid-range CAPEX energy saving ideas which are
presented below in Table -1 and Table-2.

Profitability and IRR of further energy conservation projects is linked with capacity
enhancement of Ammonia Plant, therefore, all future equipment replacement shall be
done targeting plant capacity of 1 150 MTPD

Background

Low CAPEX Energy Saving:

tM/S KBR was engaged to integrate all above modifications and calculate the overall
energy gain acquired because of these modifications and propose any other low
CAPEX energy saving ideas. KBR suggested Low CAPEX ldeas are as below:
Table-l Low CAPEX Energy Saving ldeas

Conversion of Conventional Relief Valves

1 (RV) 102-Cl to Pilot Operated to save 225,000 0.015
pressure energy
Prepared by Reviewed by Signed by
Mubasher Mohsin Ali
Naee6q19g6 Shahbaz Ali Ali Abrar AbdulGhaffar Abdul Nasir
Javaid Afza I

Sr. Process Snr. Process

DM-Maintenancl SM.DBN & REAP
Engineer Engingpr DBN hh,\\ DM.TSD SPM

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 pakarab POSITION PAPER
Ammonia Plant Capacity Revamp
Date 27th Jun,2022

ffinllilllR\ Ulilm il [$ Page 3of4

Addition of Refrigeration Compressor (105-

2 J) Discharge Cooler (1124-C) to reduce load 700,000 0.014
on 105-J

Stripped LP Condensate heat recovered to

3 300,000 0.01
demineralized water

Ammonia Recovery from Refrigeration

4 350,000 0.01
System (109-F and 107-F) Purges

Addition of Suction Chiller to Synthesis Gas

5 460,000 0.01
Compressor (103-J)

2.035 0.059
6 Total Energy Gain with lnstalled Cost
M.USD Gcal/MT

Mid-Range CAPEX Energy Saving:

Aftenarards, KBR shared some other energy saving options of medium-range CAPEX as
below:

Table-2 Mid-Range CAPEX Energy Saving ldeas

Medium-Range CAPEX Options

1
Conversion of existing wet loop
configuration to dry loop
2,500,000, - 0.12-0.15
3,500,000

2 Additional Convertor (1 105-D) 11,000,000 0.25

Parallel Radial flow LTS and Guard
3 NA Reliability
beds

4
in-erricient turbines 3,400,000 NA
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ln detailed discussions, KBR emphasized to plan for capacity revamp in order to gain
energy conservation as no further energy conservation is achievable without capacity
enhancement.

Prepared by Reviewed by Signed by

Mubasher Mohsin Ali
Naeem (reed Shahbaz Ali AliAbrar Abdul Ghaffar Abdul Nasir
Javaid Afzal
Sr. Process
Engineer
Snr. Process
Enginee.r DBN e{ DM-TSD DM-Malntenance
ASPM SM-DBN & REAP

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 POSITION PAPER Date 27th Jun,2022
Fakarah
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Ammonia Plant Capacity Revamp Page 4of4

Concl usion/ Recommendations :

KBR feedback pertaining to reduction of Ammonia plant energy index beyond above
proposed modifications were presented in tt/RlV. Potential growth options were also
discussed to assess the target future capacity. Based on guidelines received from CEO
during tVlRtM dated 14th June, 2022 scope of KBR study will be developed covering
following;

KBR Scope
. Revamp upto 1 ,150 MTPD capacity with target Energy Index of 7 .B Gcal/tMT.
. Minimum achievable Energy Index without capacity revamp integrating solutions
covered under Feasibility study conducted in 2021.

Design Basis for Future Replacements

. All future equipment replacements shall be made targeting plant capacity of 1150
MTPD.

Attachments:

1. MOM of MRM dated 14th June 2022.

2. MOM of meeting with UM Process (West) and SH Ammonia regarding target capacity
finalization.

Prepared by Reviewed by Signed by

Mubasher Mohsin Ali
Naeem Fareed Shahbaz Ali Ali Abrar Abdul Ghaffar Abdul Nasir
Javaid Afzal \
Sr. Process
Engineer
Snr. Process
EngineqrlDBN f],\ DM-TSD DM-Maintenance SPM SM-DBN & REAP

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 Attachment # 1

MOM of MRM Dated: 14th June 2022.

 Attachment # 2
MOM of Meeting with UM Process West and SH Ammonia Operation