Anda di halaman 1dari 58

02.

2012

AMMONIA-UREA AND SYNGAS-BASED PRODUCTS

AMMONIA-UREA
AND
SYNGAS-BASED
PRODUCTS
ENGINEERING AND CONSTRUCTION
PROJECT REFERENCES

People, Skills, Equipment.


Saipem S.p.A.
Via Martiri di Cefalonia, 67 - 20097 San Donato Milanese, Milan - Italy
Tel. +39.02.520.1 - Fax +39.02.520.44415
saipem.com - A subsidiary of Eni S.p.A.

spm_UREAre_Cdorso_12_02_02.indd 1

03/02/12 09.56

AMMONIA-UREA
AND
SYNGAS-BASED
PRODUCTS

INDEX

Saipem TODAY

SAIPEM ENGINEERING & CONSTRUCTION 6


Ammonia-Urea
and Syngas-based Products

SYNGAS PRODUCTIONCAPACITY

12

SNAMPROGETTItm UREA TECHNOLOGY


INTHEWORLD

14

AMMONIA-UREA AND SYNGAS-BASED


PROJECT REFERENCES

16

SNAMPROGETTItm UREA
TECHNOLOGY Revamp references

44

UREA PLANTS BASED ON CONVENTIONAL


AND I.D.R. PROCESSES

50

OTHER FERTILIZERS, RELATED UNITS


AND GAS-BASED PRODUCTS

56
3

Saipem
today
Saipem today is a world leader in the global supply
of engineering, procurement, project management,
construction AND DRILLING services with distinctive
capabilities in the design and execution of large-scale
offshore and onshore projects.

Saipem has a strong bias towards oil


and gas frontiers, namely activities
in harsh and remote areas, in deep
waters as well as in extremely cold and
hot environments, applying significant
technological competences in many
diverse fields such as gas monetization
and heavy oil exploitation.
Saipem is organized in two Business
Units: Engineering & Construction
and Drilling.

Saipem
ENGINEERING & CONSTRUCTION
FOLLOWING AN AGGRESSIVE GROWTH STRATEGY, WHICH INCLUDED
IN THE LAST DECADE THE ACQUISITION OF MANY CONSTRUCTION,
TECHNOLOGY AND ENGINEERING COMPANIES, MOST PROMINENTLY
OF SNAMPROGETTI, BOUYGUES OFFSHORE, SOFRESID AND MOSS
MARITIME, SAIPEM HAS BECOME ONE OF THE WORLD LARGEST
AND MOST COMPLETE ENGINEERING AND CONSTRUCTION COMPANIES
IN THE GLOBAL OIL AND GAS MARKETS, ONSHORE AND OFFSHORE.

Ever since its initial steps in the fifties


as the construction division of Snam,
the pipeline company of the Eni Group
in Italy, Saipem has pursued
a systematic growth strategy, based
on the development of internal assets,
expertise and skilled resources, as well
as on the acquisition of other players
with their own asset bases, such as
Micoperi in late eighties, and many
others.
In the last decade, Saipem has
continued its growth by acquiring
Bouygues Offshore and Sofresid in
France, Moss Maritime in Norway, Idpe
in India and Snamprogetti in Italy,
and by carrying out a multibillion
investment program into the expansion
of its offshore construction and drilling
fleets. Since the year 2000, Saipems
market capitalization has grown more
than sixfold and its revenues tenfold.(*)
The organizational integration of
this considerable asset base, namely
the network of engineering centres,
fabrication and support yards in several
continents as well as the offshore
construction fleet, has been completed
gradually over the years - most recently
with the creation of a unified Business
Unit Engineering & Construction,
an entity with over 30,000 employees
(excluding corporate and BU Drilling
staff) from over 100 nationalities,
with over 60 permanent establishments

and numerous project execution


centres around the globe, and with
yearly revenues exceeding 10 billion /y;
all held together by outstanding project
management skills.
Through the involvement of our global
EP(I)C hubs in Milan, Rome and Fano
(Italy), Paris (France) and Chennai
(India), which operate in connection
with a growing number of medium size
and smaller regional engineering
and project execution centres
employing altogether over 7,000
engineers, Saipem balances high
project execution quality with a
competitive cost and - most importantly
- with a major emphasis on local
know-how and content.
This well-integrated multicenter
approach provides a consistent design
and robust execution philosophy
on all our projects worldwide.
Top priority is provided throughout
to all HSEQ aspects.

installation; also revamps, upgradings,


maintenance, decommissionings,
reclamations and decontaminations.
Saipem today operates in virtually every
world market, often in remote locations
with harsh environmental conditions
and challenging logistics, leveraging
on its proven experience across the
most significant product lines in the
oil and gas production onshore,
offshore, in deepwater; gas and oil
transportation via offshore and onshore
pipeline systems; midstream, refining,
chemicals, power generation from fossil
as well as from renewable sources;
environmental industries, maritime
works and infrastructure.
This new series, therefore, outlines
Saipems integrated references
in engineering and construction
markets offshore and onshore,
according to individual business
and technology lines.

Saipem therefore offers a complete


range of project definition
and execution services, offshore
and onshore, particularly for
the complex mega-projects required
by the market today: from feasibility
and conceptual studies to complex
integrated solutions combining design,
engineering, procurement, field
construction, fabrication and offshore

(*) Until Dec. 31, 2010


7

Ammonia-Urea
and Syngas-based Products
The industrial application
of syngas-based chemical
processes has been one of the
stalwarts of Snamprogetti,
recently integrated into Saipem,
almost since its earliest days
many decades ago.

We have designed and built hundreds


of plants, including more than twenty
fully integrated complexes, in every
remote corner of the world, mostly
based on the world leading and
proprietary licensed SnamprogettiTM
Urea Technology as well as on third
party syngas generation, ammonia
and methanol synthesis technologies.
In the Ammonia-Urea process
sequence, Saipem is a recognized
world leader:
127(*) Urea Technology licensed
plants.
In the quest for the economies of
scale, following the design and
construction of the largest single
train urea unit in operation for a
long time (Profertil, Bahia Blanca
Fertilizer Complex in Argentina),
which achieved an average yearly

(*) Until Dec. 31, 2011


8

production of 3,558 Tons per Day


(T/D) in 2006 and has become
the reference for the subsequent
design and construction of todays
biggest single train urea plants,
at the end of 2010 Saipem has
completed and put on stream the
world largest single train unit,
namely the Daharki Ammonia-Urea
Complex for Engro in Pakistan,
with the design production capacity
of 3835 T/D of urea. Three more
such units, with the capacity of
3850 T/D, are at various stages of
design and construction in Qatar
and in India.
Design and construction in 20022005 of the largest ammonia-urea
single project, namely Omifco in
Oman, with the total urea design
capacity of 5,060 T/D; in 2008 the
plant achieved the capacity peak of
6,000 T/D.

Continuous Urea Technology


improvements and upgrading.
To name just a few most recent
achievements:
- the new OmegabondTM Advanced
Tubing Technology (Ti/Zr
metallurgically coextruded) for
improved stripper performance
developed in collaboration with
ATI WahChang;
- focus on plant reliability and
availability concepts applied on
the 5,000+ T/D single train for
which a design is available;
- the adoption of continuously
improved environmental impact
reduction and energy saving
schemes.

Moron Fertilizer Complex - Venezuela 1972

10

In addition to a large number of


integrated ammonia-urea complexes
based on natural gas and light
naphthas as feedstocks, in 2002
Saipem has placed on stream in
Nanjing, P.R. China, a complex
utilizing coal-like Eureka pitch as
feedstock. This feedstock is gasified
by means of a GE (former Texaco)
gasification technology to produce
syngas, subsequently converted into
1,000 T/D of ammonia and 1,700 T/D
of urea.
Our project reference list has been
enriched with the award a few
years ago of the multibillion
Gas-to-Liquids project in Escravos,
Nigeria from Chevron Nigeria Ltd., to
be started up shortly.
The goal of this new investment is
the conversion of natural gas into
33,000 BPSD of top quality middle
distillates for transportation fuels
via the new process technology
licensed by Sasol. The first steps in
the process sequence, namely the
syngas production, are based on a
technology which is very similar to the
one applied in large scale ammonia
and methanol synthesis.

Among other technological novelties,


this project will see one of the first
applications on a very large scale of
Haldor Topses ATR Auto Thermal
Reformer process technology. With
a capacity of 560,000 Nm3/h of each
of the two ATRs, this will be one of
the largest syngas production units in
the world.
Saipem has been traditionally a
leading player in the design and
execution of Methanol Synthesis
plants, based on different process
technologies, with the more recent
focus on Haldor Topses e.g.
the 3,000 T/D Bandar Imam plant in
Iran a world class plant at the time
of its start-up in 2004 and, more
recently, the Front End Design of the
10,000 T/D VIVA Methanol Project in
Nigeria. This last one could become
the largest methanol synthesis and
syngas generation plant ever built.

11

Syngas Production
Capacity
Syngas Production Capacity
in Recent Saipem Designs.

Syngas Generation
Technology

Syngas Production Capacity per Train (dry basis), kNm3/h

Project

N. Type

VIVA METHANOL,(b)
NIGERIA

ATR

ESCRAVOS GTL,(c)
NIGERIA

ATR

QAFCO 5,(a)
QATAR

Primary and secondary


Air Blown Reformer

ENGRO,(a)
PAKISTAN

Primary and secondary


Air Blown Reformer

OMIFCO,(a)
OMAN

Primary and secondary


Air Blown Reformer

FERTINITRO,(a)
VENEZUELA

Primary and secondary


Air Blown Reformer

PROFERTIL,(a)
ARGENTINA

Primary and secondary


Air Blown Reformer

BANDAR IMAM,(b)
IRAN

One step reformer

NANJING,(a)
CHINA

Gasifier

(a) Ammonia
(b) Methanol

200

Synthesis including Nitrogen

Synthesis
(c) Gas-to-Liquids
12

100

300

400

500

600

700

800

900

1000

1100

13

SNAMPROGETTI
UREATECHNOLOGY
INTHEWORLD
TM

CANADA

SPAIN

U.S.A.

ALGERIA
MEXICO

TRINIDAD
& TOBAGO

NIGE

VENEZUELA

G
PERU

Saipem today is a market leader in


the ammonia-urea process chain, with
127 snamprogettiTM Urea Technology
licenses worldwide, with more than 20
integrated ammonia-urea complexes
and numerous individual process units
designed and built in every continent.
Saipem holds a leading share of the
total installed capacity worldwide.
14

ARGENTINA

RUSSIA
TATARSTAN
GERMANY
KAZAKHSTAN
AUSTRIA
ITALY
BULGARIA
IRAQ
SAUDI ARABIA

IRAN

PAKISTAN
BAHRAIN
QATAR

OMAN

P.R. CHINA
BANGLADESH

INDIA

VIETNAM

ERIA

GABON

SOMALIA

INDONESIA
MALAYSIA

15

AMMONIA-UREA AND SYNGAS-BASED


PROjECT REFERENCES
Saipem iS THe OWNeR OF THe
SNampROGeTTiTm URea TeCHNOLOGY.
Location

Technologies

cLient

Country,
Location

ammonia
License

Urea
Snamprogettitm

Capacity t/D

technology

Capacity t/D

Saudi Arabia, Al Jubail

SAUDI ARABIA FERTILIZER Co. SAFCO-5

3250

China, Ordos, Inner Mongolia

ORDOS YIDING COAL CHEMICAL Co, Ltd.

1740

Malaysia, Sabah

PETRONAS CHEMICAL FERTILISER SABAH Snd. Bhd.

3500

Gabon, Port Gentil

GABON FERTILIZER COMPANY

3850

Nigeria, Agenebode, Edo State

DANGOTE FERTILIZER Ltd.

Tatarstan, Mendeleevsk

AMMONI

Nigeria, Escravos

CHEVRON NIGERIA Ltd. (CNL)

2x 3850
2050

ESCRAvOS GAS-TO-LIqUIDS PROjECT - NIGERIA


In addition to being one of the first applications of the Gas-to-Liquids technology on a world-class scale
(process technologies by Sasol, Chevron, Haldor Topse and others), the design and construction of this
complex had several elements of originality, such as the harsh and remote site environment.
In order to simplify local construction on the site in Escravos, Nigeria, many plant sections were designed
and built in an U.A.E. fabrication yard as modules, then shipped to the site.
Modularization design: the biggest Saipem modularized plant of all times (pipe rack modules of over
1,000 tons each, process modules of over 2,000 tons each)
Erection - Reactors Size: World Class Record 2008

16

GranULation
License

others

on stream

Plant (License)
Capacity t/D

UFT

scope of work
Capacity t/D

3250

Licences/Engineering/Procurement/Supervision

Under Exec.

License / PDP / Tech. Assistance

Under Exec.

UFT

3500

Licenses / PDP / Tech. Assistance

Under Exec.

UFT

3850

License / PDP / Tech. Assistance

Under Exec.

UFT

2x 3850

FEED

Under Exec.

UFT

2050

License / PDP / Tech. Assistance

Under Exec.

Engineering / Procurement / Construction

Under Exec.

Gas-to-Liquids
(Sasol, Chevron,
Haldor Topse A/S)

2 x 17000 BPSD

17

AMMONIA-UREA AND SYNGAS-BASED


PROJECT REFERENCES

Technologies
Location Client Ammonia
Country,
Location
Vietnam, Bac Giang

License

Urea
Snamprogettitm

Capacity T/D

Technology

Capacity T/D

HABAC NITROGENOUS FERTILIZER & CHEMICALS


COMPANY Ltd.

1000

India, Babrala

TATA (FERTILIZER DIVISION) CHEMICALS Ltd.

3850

China, Hefei, Anhui

CNSG ANHUI HONG SIFANG Co., Ltd.

1000

India, Panagarh, West Bengala

MATIX FERT. & CHEM. Ltd.

3850

Peru, San Juan De Marcona

CF INDUSTRIES Inc.

3850

Qatar, Mesaieed

QATAR FERTILIZER COMPANY QAFCO-6 Project

3850

China, Fugu, Shaanxi

SHAANXI POPULAR JURASSIC (GROUP) Co., Ltd.

1760

China, Jungar, Inner Mongolia

INNER MONGOLIA TALENT CHEMICAL FERTILIZER Co., Ltd.

1760

Algeria, Arzew

ALGERIA OMAN FERTILIZER COMPANY

Vietnam, Ca Mau

PETROVIETNAM

2385

Vietnam, Ninh Binh

VIETNAM NATIONAL CHEMICAL CORP. (VINACHEM)

1760

Nigeria,
Lekki Peninsula (Lagos)

VIVA METHANOL

18

2x 3500

Granulation Others Scope of work On stream


License

Plant (License)
Capacity T/D

Capacity T/D
License / PDP / Tech. Assistance

Under Exec.

License / PDP / Engineering / Tech. Assistance

Under Exec.

License / PDP / Tech. Assistance

Under Exec.

License / PDP / Engineering / Tech. Assistance

Under Exec.

UFT

3850

Licenses / PDP / Tech. Assistance

Under Exec.

UFT

3850

Licenses / PDP / Tech. Assistance

Under Exec.

License / PDP / Tech. Assistance

Under Exec.

License / PDP / Tech. Assistance

Under Exec.

License / PDP / Tech. Assistance

Under Exec.

License / PDP / Tech. Assistance

Under Exec.

License / PDP / Tech. Assistance

Under Exec.

Methanol
(Haldor Topse A/S)

10000

Front End Engineering

19

AMMONIA-UREA AND SYNGAS-BASED


PROjECT REFERENCES

Technologies
Location

cLient

Country,
Location
Qatar, Mesaieed

China, Korla, Xinjiang Uyugur

ammonia
License

Urea
Snamprogettitm

Capacity t/D
QATAR FERTILIZER COMPANY QAFCO-5 Project

Haldor Topse
A/S

2x 2300

PETROCHINA TARIM PETROCHEMICAL COMPANY

qAFCO 5 FERTILIzER COMPLEX - qATAR


The Qafco 5 Fertilizer Complex, with a total capacity of 4,600 T/D of ammonia partially
converted into 3,850 T/D of granular urea, will be the largest single train urea project
inside the largest fertilizer complex in the world.
The project is also characterized by a common utilities and offsites complex to feed
subsequent development of Qafco as fertilizer producer as well as by an excess of
ammonia production capacity for other applications.

20

technology

Capacity t/D
3850
2640

GranULation
License

scope of work

on stream

Plant (License)
Capacity t/D

UFT

others

3850

Capacity t/D
Licenses / Engineering / Procurement / Supervision

2012

License / PDP / Tech. Assistance

2011

21

AMMONIA-UREA AND SYNGAS-BASED


PROjECT REFERENCES

Technologies
Location

cLient

Country,
Location
Pakistan, Daharki

Oman, Sohar

ammonia
License

Urea
Snamprogettitm

Capacity t/D
ENGRO FERTILIZERS Ltd.(EFL)
(formerly ENGRO CHEMICAL PAKISTAN Ltd.)

Haldor
Topse A/S

2194

Sohar International Urea & Chemical Industries SAOC


(SIUCI)

DAHARkI AMMONIA-UREA COMPLEX - PAkISTAN


The Daharki Ammonia-Urea Complex, with an ammonia capacity of 2,194 T/D and
an urea capacity of 3,835 T/D, is today the largest single train urea plant on stream
in the world. The complex is characterized by the world tallest urea prilling tower.

22

technology

Capacity t/D
3835
2x 1750

GranULation
License

others

scope of work

on stream

Plant (License)
Capacity t/D

Capacity t/D
License / Engineering / Procurement / Supervision

2010

License / PDP / Tech. Assistance

2009

23

AMMONIA-UREA AND SYNGAS-BASED


PROjECT REFERENCES

Technologies
Location

cLient

Country,
Location
Oman, Sur

Iran, Bandar Imam (Razi)

ammonia
License

Snamprogettitm
Capacity t/D

OMIFCO

Haldor Topse
A/S, Giammarco
Vetrocoke

Urea
technology

Capacity t/D

2x 1750

2x 2530

PETROCHEMICAL INDUSTRIES DEVELOPMENT


MANAGEMENT Co.

OMAN INDIA FERTILIzER COMPLEX - OMAN


At the time of the start-up in 2005, the Omifco Fertilizer Complex was the largest ammonia-urea project in
the world, supplying granular urea. The plant was implemented under limited recourse of project financing,
including the involvement of Italian and French ECA.
The project was built quickly and started up smoothly:
First gas into the ammonia plant 32 months after project financial closure,
35 months after EpC contract signature
First production in 18 days and 1 day for ammonia-urea train one; 12 days and 1 day for train two

24

GranULation
License

others

scope of work

on stream

Plant (License)
Capacity t/D

UFT

2x 2530

HydroAgri

1800

Capacity t/D

Utilities & Offsites

License / Engineering / Procurement / Construction

2005

Engineering / Procurement / Construction

2004

25

AMMONIA-UREA AND SYNGAS-BASED


PROjECT REFERENCES

Technologies
Location

cLient

Country,
Location

License

Urea
Snamprogettitm

Capacity t/D

Iran, Bandar Imam

FANAVARAN PETROCHEMICAL Co.

Vietnam, Phu-My

PETROVIETNAM

China, Nanjing, Jiangsu

SINOPEC NANJING CHEMICAL INDUSTRIAL Co., Ltd.

Indonesia, Bontang-Utara

ammonia

Capacity t/D

2200
Haldor Topse
A/S,Texaco,
Linde, Ici

1000

P.T. PUPUK KALIMANTAN TIMUR

BANDAR IMAM THIRD METHANOL PLANT - IRAN


At the time of the design in 2001, the Bandar Imam Third Methanol was the largest
methanol project in the world, supplying methanol high quality grade (AA).

26

technology

1750
1725

GranULation
License

others

scope of work

on stream

Plant (License)
Capacity t/D

Capacity t/D
Methanol
(Haldor Topse A/S)

3030

License / Engineering / Procurement

2004

License / Basic / Tech. Assistance

2004

License / Engineering / Procurement

2002

License / Basic / Tech. Assistance

2002

27

AMMONIA-UREA AND SYNGAS-BASED


PROjECT REFERENCES

Technologies
Location

cLient

Country,
Location
Bahia Blanca, Argentina

ammonia
License

Snamprogettitm
Capacity t/D

PROFERTIL S.A.

Haldor Topse
A/S, Basf

Urea
technology

2050

Capacity t/D
3250

China, Hefei, Anhui

HEFEI SIFANG GROUP

400

China, Qingzhen, Guizhou

GUIZHOU FERTILIZER Co., Ltd.

400

BAHIA BLANCA FERTILIzER COMPLEX - ARGENTINA


At the time of completion in 2001, the Bahia Blanca Fertilizer Complex included the
largest single train urea plant in the world, with the design granular urea production
capacity of 3,250 T/D.
It was the first plant to break the 3,000 T/D production target in single stream urea.
In 2006 it produced 1,280,718 tons in a full year of operation, achieving in 360 days of
operation an average daily production of 3,558 T/D, with a maximum peak of 3,700 T/D.

28

GranULation
License

others

on stream

Plant (License)
Capacity t/D

HydroAgri

scope of work

2x 1850

Capacity t/D
Utilities & Offsites

Licenses / Engineering / Procurement / Construction

2001

License / Basic / Tech. Assistance

2001

License / Engineering / Procurement

2001

29

AMMONIA-UREA AND SYNGAS-BASED


PROjECT REFERENCES

Technologies
Location

cLient

Country,
Location
Venezuela, Jose

ammonia
License

Urea
Snamprogettitm

Capacity t/D
FERTINITRO C.E.C.

Haldor Topse
A/S, Giammarco
Vetrocoke

2x 1800

technology

Capacity t/D

2x 2200

China, Huainan, Anhui

ANHUI HUAINAN CHEMICAL GROUP Co., Ltd.

900

China, Anyang, Henan

ANYANG CHEMICAL INDUSTRIAL GROUP Co., Ltd.

600

China, Hechi, Guangxi

GUANGXI HECHI CHEMICAL Co., Ltd.

400

China, Huaxian, Shaanxi

SHAANHUA FERTILIZER Co., Ltd.

400

China, Pingdingshan, Henan

PINGDINGSHAN FEIXING CHEMICAL GROUP Co., Ltd.

400

Malaysia, Gurun, Kedah

PETRONAS FERTILIZER Sdn Bhd

jOSE FERTILIzER COMPLEX - vENEzUELA


With the design production of 4,400 T/D of urea in two lines, the Jose Fertilizer
Complex is still today the largest ammonia-urea complex in Latin America.

30

1800

GranULation
License

others

on stream

Plant (License)
Capacity t/D

HydroAgri

scope of work

2x 2200

Capacity t/D

Utilities & Offsites

License / Engineering / Procurement / Construction

2001

License / Engineering / Procurement

2000

License / Engineering / Procurement

1999

License / Engineering / Procurement

1999

License / Engineering / Procurement

1999

License / Basic / Tech. Assistance

1999

License / Basic / Tech. Assistance

1999

31

AMMONIA-UREA AND SYNGAS-BASED


PROJECT REFERENCES

Technologies
Location Client Ammonia
Country,
Location

License

Urea
Snamprogettitm

Capacity T/D

Technology

Capacity T/D

Bahrain, Sitra Island

GULF PETROCHEMICAL INDUSTRIES Co.

China, Zhanyi, Yunnan

YUNNAN ZHANYI CHEMICAL Co., Ltd.

India, Kakinada, A.P.

NAGARJUNA FERTILIZERS AND CHEMICAL CORP.

Venezuela, Jose

SUPERMETANOL CA

China, Lanzhou, Gansu

PETROCHINA LANZHOU PETROCHEMICAL Co.

India, Phulpur, U.P.

INDIAN FARMERS FERTILIZERS COOPERATIVE Ltd.

2x 1100

India, Vijaipur, M.P.

NATIONAL FERTILIZERS Ltd.

2x 1100

China, Chishui, Guizhou

GUIZHOU CHITIANHUA GROUP Co., Ltd.

China, Dongfang, Hainan

CNOOC CHEMICAL Ltd.

1765

China, Hejiang, Sichuan

SICHUAN TIANHUA Co., Ltd.

1765

China, Hohhot, Inner Mongolia

INNER MONGOLIA TIANYE CHEMICAL GROUP Co., Ltd.

1760

China, Jining, Shandong

JINING CHEMICAL FERTILIZER PLANT

China, Jiujiang, Jiang-Xi

SINOPEC JIUJIANG PETROCHEMICAL COMPANY (JPC)

India, Aonla, U.P.

INDIAN FARMERS FERTILIZERS COOPERATIVE Ltd.

China, Baoji, Shaanxi

SHAANXI BAOJI NITROGEN FERTILIZER PLANT

32

1700 (941
uninterrupted
production days
between
turnarounds)
400
Haldor Topse
A/S, Giammarco
Vetrocoke

900

1500

1760

500

400
1760
2x 1100
400

Granulation Others Scope of work On stream


License

Plant (License)
Capacity T/D

Capacity T/D

Methanol (Kvaerner)

from 2000 to 2250

License / Basic / Tech. Assistance

1998

License / Basic / Tech. Assistance

1998

License / Engineering / Supervision

1998

Engineering / Procurement / Constr. Mngmt

1998

License / Engineering / Procurement

1997

License / Basic / Tech. Assistance

1997

License / Basic / Tech. Assistance

1997

License / Basic / Tech. Assistance

1996

License / Engineering / Procurement

1996

License / Engineering / Procurement

1996

License / Engineering / Procurement

1996

License / Basic / Tech. Assistance

1996

License / Engineering / Procurement

1996

License / Basic / Tech. Assistance

1996

License / Basic / Tech. Assistance

1995

33

AMMONIA-UREA AND SYNGAS-BASED


PROJECT REFERENCES

Technologies
Location Client Ammonia
Country,
Location
India, Babrala, U.P.

License

Snamprogettitm
Capacity T/D

TATA (FERTILIZER DIVISION) CHEMICALS Ltd.

India, Shahjahanpur, U.P.

KRIBHCO SHYAM FERTILIZERS Ltd. (KSFL)

India, Gadepan, Ra.

CHAMBAL FERTILIZERS AND CHEMICALS Ltd.

Haldor Topse
A/S, Giammarco
Vetrocoke

Urea

1350

Technology

Capacity T/D

2x 1125
2x 1100

Haldor Topse
A/S, Giammarco
Vetrocoke

1350

2x 1125

Venezuela, Jose

SUPERMETANOL CA

China, Fuling, Sichuan

CHONGQING JIANFENG CHEMICAL COMPLEX

1750

China, Jinxi, Liaoning

JINXI NATURAL GAS & CHEMICAL Co., Ltd.

1760

Pakistan, Goth Machhi

FAUJI FERTILIZER COMPANY Ltd.

Haldor Topse
A/S, Basf

1100

1925

Bangladesh, Tarakandi

JAMUNA FERT. COMPANY Ltd.

China, Luoyang, Henan

LUOYANG ZHONGHAO CHEMICAL INDUSTRIAL Co., Ltd.

400

China, Yuanping, Shanxi

SHANXI YUANPING CHEMICAL INDUSTRY Co., Ltd.

400

India, Kakinada, A.P.

NAGARJUNA FERTILIZERS AND CHEMICALS Ltd.

Italy, Ferrara

34

ENICHEM AGRICOLTURA S.p.A.

1700

Haldor Topse
A/S, Giammarco
Vetrocoke

900

1500

Granulation Others Scope of work On stream


License

Plant (License)
Capacity T/D

Capacity T/D

Methanol (Ici)

2000

Utilities & Offsites

Deep Hydrolysis
(SnamprogettiTM)

1700

License / Engineering / Supervision

1995

License / Basic / Tech. Assistance

1995

License / Engineering / Supervision

1994

Engineering / Procurement / Constr. Mngmt

1994

License / Basic / Tech. Assistance

1993

License / Basic / Tech. Assistance

1993

License / Engineering / Procurement / Construction

1993

License / Basic / Tech. Assistance

1992

License / Basic / Tech. Assistance

1992

License / Basic / Tech. Assistance

1992

License / Basic / Tech. Assistance

1992

Engineering / Procurement / Construction

1992

35

AMMONIA-UREA AND SYNGAS-BASED


PROJECT REFERENCES

Technologies
Location Client Ammonia
Country,
Location

License

Urea
Snamprogettitm

Capacity T/D

Technology

Capacity T/D

China, Beijing

BEIJING CHEMICAL EXPERIMENTAL PLANT

400

China, Xuanhua, Hebei

HEBEI XUANHUA FERTILIZER GROUP Co., Ltd.

400

China, Puyang, Henan

HENAN ZHONGYUAN DAHUA GROUP Co., Ltd.

1760

Italy, Nera Montoro

TERNI INDUSTRIE CHIMICHE S.p.A.

Saudi Arabia, Al Jubail

NATIONAL CHEMICAL FERTILIZER Co. (IBN AL-BAYTAR)

Bahrain, Sitra Island

GULF PETROCHEMICAL INDUSTRIES Co.

Venezuela, Zulia

PEQUIVEN

India, Aonla, U.P.

INDIAN FARMERS FERTILIZERS COOPERATIVE Ltd.

India, Jagdishpur, U.P.

INDO GULF Co., Ltd.

India, Vijaipur, M.P.

NATIONAL FERTILIZERS Ltd.

United Kingdom, Immingham

NORSK HYDRO FERTILIZERS Ltd.

36

1500
Uhde

from 1000 to
1200

Haldor Topse
A/S, Benfield
(UC)

1350

2x 1100

Haldor Topse
A/S, Giammarco
Vetrocoke

1350

2x 1100
2x 1100

Granulation Others Scope of work On stream


License

Plant (License)
Capacity T/D

Kaltenbach
Thuring S.A.

Capacity T/D

400

Methanol (Ici)

from 1000 to 1200

Deep Hydrolysis
(SnamprogettiTM)

2x 1200

Ammonium Nitrate
(HydroAgri)
Calcium Ammonium
Nitrate Granulation
(HydroAgri)

License / Basic / Tech. Assistance

1991

License / Basic / Tech. Assistance

1991

License / Engineering / Procurement

1990

Engineering / Procurement / Construction

1990

License / Basic / Tech. Assistance

1990

License / Engineering / Procurement

1989
1989

License / Engineering / Supervision

1988

License / Engineering / Procurement

1988

License / Engineering / Supervision

1988

Engineering Services

1988

1800

3000

37

AMMONIA-UREA AND SYNGAS-BASED


PROJECT REFERENCES

Technologies
Location Client Ammonia
Country,
Location

License

Urea
Snamprogettitm

Capacity T/D

Technology

Capacity T/D

Pakistan, Multan

PAKARAB FERTILIZERS Ltd.

300

Bahrain, Sitra Island

GULF PETROCHEMICAL INDUSTRIES Co.

India, Hazira, Gu.

KRISHAK BHARATI COOP. Ltd.

4x 1100

India, Thal Vaishet, Ma.

RASHTRIYA CHEMICALS FERTILIZERS Ltd.

3x 1500

Somalia, Mogadishu

MINISTRY OF NATIONAL PLANNING

Mexico, Pajaritos

AGRO NITROGENADOS S.A.

Bulgaria, Vratza

CHIMCO

Canada, Red Water, Alberta

AGRIUM U.S. Inc.

Spain, Castellon de la Plana

PROQUIMED

Uhde

1000

150
1500
600
1500

Trinidad and Tobago, Point Lisas PCS NITROGEN

1620

India, Bharuch, Gu.

GUJARAT NARMADA VALLEY FERTILIZERS Co., Ltd.

1800

India, Trombay, Ma.

RASHTRIYA CHEMICALS FERTILIZERS Ltd.

Libya, Marsa El Brega

Mexico, Pajaritos

38

NATIONAL PETROCHEMICAL Co. (NAPETCO)

AGRO NITROGENADOS S.A.

Haldor Topse
A/S, Benfield
(UC)

900

1000

Haldor Topse
A/S, Benfield
(UC)

1000

1500
1500

Granulation Others Scope of work On stream


License

Plant (License)
Capacity T/D

Capacity T/D

Methanol (Ici)

Ammonium Sulphate
(Struthers Wells)

1000

366

License / Basic / Tech. Assistance

1986

Engineering / Procurement / Construction

1985

License / Engineering / Supervision

1985

License / Engineering / Supervision

1985

License / Basic / Tech. Assistance

1985

License / Basic / Tech. Assistance

1984

License / Basic / Tech. Assistance

1983

License / Basic / Tech. Assistance

1983

Engineering / Procurement / Construction

1983

License / Engineering / Procurement

1983

Licence / Engineering / Procurement

1982

License / Engineering / Procurement

1982

Engineering / Procurement / Construction

1982

License / Basic / Tech. Assistance

1982

39

AMMONIA-UREA AND SYNGAS-BASED


PROJECT REFERENCES

Technologies
Location Client Ammonia
Country,
Location
Pakistan, Goth Machhi

License

Snamprogettitm
Capacity T/D

FAUJI FERTILIZER COMPANY Ltd.

CIS, Togliattigrad

TOGLIATTI AZOT

India, Phulpur, U.P.

INDIAN FARMERS FERTILIZERS COOPERATIVE Ltd.

Pakistan, Mirpur Mathelo

FAUJI FERTILIZER COMPANY Ltd.

Haldor Topse
A/S, Benfield
(UC)

Urea

1000

Technology

Capacity T/D

1725
2x 1500
1550

Haldor Topse
A/S, Benfield
(UC)

1000

1740

USA, Borger, Texas

AGRIUM U.S. Inc.

CIS, Novomoskovsk

NOVOMOSKOVSK AZOT

1500

Germany, Bsterreichische

YARA BSTERREICHISCHE GmbH

1000

Iraq, Khor Al-Zubair

MINISTRY OF INDUSTRY AND MINERALS

Italy, Manfredonia

ENICHEM AGRICOLTURA S.p.A.

1000

Austria, Linz

AGROLINZ MELAMIN GmbH

1000

Iraq, Basrah

MINISTRY OF INDUSTRY AND MINERALS

1300

USA, Memphis, Tennessee

PCS NITROGEN

1000

USA, Lawrence, Kansas

FARMLAND FERTILIZER/Ag CHEMICAL

Italy, Ravenna

ANIC S.p.A.

40

250

2x 1600

600

Granulation Others Scope of work On stream


License

Plant (License)
Capacity T/D

Capacity T/D

Ammonium
Sulphate (Ici)
Calcium Nitrate
(Pintsch Bamag)

License / Engineering / Supervision

1982

License / Engineering / Procurement

1980

License / Engineering / Supervision

1980

License / Basic / Tech. Assistance

1980

License / Basic / Tech. Assistance

1980

License / Engineering / Procurement

1979

License / Basic / Tech. Assistance

1979

License / Basic / Tech. Assistance

1979

License / Engineering / Supervision

1978

License / Basic / Tech. Assistance

1977

License / Basic / Tech. Assistance

1976

License / Basic / Tech. Assistance

1975

License / Basic / Tech. Assistance

1974

License / Basic / Tech. Assistance

1973

1400
200

41

AMMONIA-UREA AND SYNGAS-BASED


PROJECT REFERENCES

Technologies
Location Client Ammonia
Country,
Location
Italy, Manfredonia

License

Snamprogettitm
Capacity T/D

ENICHEM AGRICOLTURA S.p.A.

Haldor Topse
A/S, Giammarco
Vetrocoke

Urea

1200

Technology

Capacity T/D

1000

Venezuela, Moron

SERVIFERTIL

750

Italy, Nera Montoro

TERNI INDUSTRIE CHIMICHE S.p.A.

300

Mexico, Minatitlan

FERTIMINA S.A.

750

Spain, Puertollano

EMPRESA NACIONAL DE FERTILIZANTES S.A.

300

Syria, Homs

GENERAL ORGANIZATION FOR EXECUTING


INDUSTRIAL PROJECTS (GOEIP)

Italy, Gela

ENICHEM AGRICOLTURA S.p.A.

Russia, Tula

V/O TECHMASHIMPORT

Italy, Pisticci

ANIC S.p.A.

Romania, Victoria

INDUSTRIAL IMPORT

42

Ici

150 MT/D
70

Air Liquide,
Ammonia Casale

430

Granulation Others Scope of work On stream


License

Plant (License)
Capacity T/D

Capacity T/D

NPK (Dorr Oliver)

920

License / Engineering / Supervision

1972

Engineering / Procurement / Construction

1972

License / Engineering / Supervision

1971

License / Engineering / Procurement

1971

License / Engineering / Procurement

1971

Engineering / Procurement / Construction

1971

License / Engineering / Procurement

1966

Methanol
(Ammonia Casale)

from 720 MT/D

Engineering / Procurement

1966

Methanol
(Ammonia Casale)

170

Engineering / Supervision

1964

Methanol
(Ammonia Casale)

90

Engineering / Procurement

1963

43

Snamprogetti
Urea Technology
Revamp references
TM

With the objective of improving the economics


and environmental impact of plants built earlier mostly
on SnamprogettiTM Urea Technology, Saipem has introduced
several NEW solutions in order to expand their production
capacity, modernize their hardware and enhance
their operability and reliability.

Main revamp undertakings:


Updated process scheme
Energy optimization
Improvement of product quality
Reduction of emissions
Improved metallurgy
Saipem has developed a successful
revamp methodology to meet clients
expectations:
Continuous assistance during the
development of the project and the
lifetime of the plant.
Identification of clients needs
through feasibility studies.
Definition of the appropriate and
economically viable revamp process
scheme.
44

Development of a process
design package and supply of
the relevant services (licensor
technical assistance during detailed
engineering, commissioning and
start-up) to allow an effective
implementation.
Based on this approach, almost
twenty revamps have been
implemented during the last few
years, mainly in India, Pakistan and
P.R. China, resulting in a typical
capacity increase between 30 and
70%, as well as in a significant
reduction in energy consumption.

45

SnamprogettiTM
Urea Technology
Revamp references

Location Client ORIGINALPROCESS O


Country,
Location
India, Jagdishpur, U.P.

INDO GULF Co., Ltd.

SnamprogettiTM

India, Thal Vaishet, Ma.

RASHTRIYA CHEMICALS FERTILIZERS Ltd.

SnamprogettiTM

Iraq, Khox Al-Zubair

STATE COMPANY OF FERTILIZER

SnamprogettiTM

India, Vijaipur, M.P.

NATIONAL FERTILIZERS Ltd.

SnamprogettiTM

India, Hazira, Gu.

KRISHAK BHARATI COOP. Ltd.

SnamprogettiTM

India, Babrala, U.P.

TATA (FERTILIZER DIVISION) CHEMICALS Ltd.

SnamprogettiTM

China, Hejiang, Sichuan

SICHUAN TIANHUA Co., Ltd.

SnamprogettiTM

India, Kakinada, A.P.

NAGARJUNA FERTILIZERS AND CHEMICAL CORP.

SnamprogettiTM

India, Aonla, U.P.

INDIAN FARMERS FERTILIZERS COOPERATIVE Ltd.

SnamprogettiTM

India, Bharuch, Gu.

GUJARAT NARMADA VALLEY FERTILIZERS Co., Ltd.

SnamprogettiTM

India, Gadepan, Ra.

CHAMBAL FERTILIZERS AND CHEMICALS Ltd.

SnamprogettiTM

India, Phulpur, U.P.

INDIAN FARMERS FERTILIZERS COOPERATIVE Ltd.

SnamprogettiTM

India, Phulpur, U.P.

INDIAN FARMERS FERTILIZERS COOPERATIVE Ltd.

SnamprogettiTM

Pakistan, Mirpur Mathelo

FAUJI FERTILIZER COMPANY Ltd.

SnamprogettiTM

India, Namrup

HINDUSTAN FERTILIZER COMPANY Ltd.

Montedison

India, Namrup

HINDUSTAN FERTILIZER COMPANY Ltd.

Montedison

India, Thal Vaishet, Ma.

RASHTRIYA CHEMICALS FERTILIZERS Ltd.

SnamprogettiTM

46

ORIGINALNOMINAL CAPACITY CAPACITY AFTER REVAMPING On stream


(MT/D)

(MT/D)

Year

2x 1500

2x 1700

Under Exec.

1900

2300

Under Exec.

2x 1600

2x 2080

Under Exec.

4x 1100

2x 1515 and 2x 1615

Under Exec.

4x 1300

4x 1660

Under Exec.

2x 1125

2x 1900

Under Exec.

1765

2300

Under Exec.

2x 1500

2x 2350

2009

4x 1100

4x 1515

2008

2350

2350 energy efficiency improvement

2008

2x 1125

2x 1750

2008

1550

2115

2008

2x 1100

2x 1515

2008

1740

2175

2008

2x 500

2x 500

2005

1167

1167

2002

3x 1500

3x 1900

2002

47

SnamprogettiTM
Urea Technology
Revamp references

Location Client ORIGINALPROCESS O


Country,
Location
India, Hazira, Gu.

KRISHAK BHARATI COOP. Ltd.

SnamprogettiTM

India, Jagdishpur, U.P.

INDO GULF Co., Ltd.

SnamprogettiTM

Canada, Red Water, Alberta

AGRIUM U.S. Inc.

SnamprogettiTM

Pakistan, Goth Machhi

FAUJI FERTILIZER COMPANY Ltd.

SnamprogettiTM

Spain, Puertollano

EMPRESA NACIONAL DE FERTILIZANTES S.A.

SnamprogettiTM

Germany, Brunsbttel

YARA BRUNSBUTTEL GmbH

SnamprogettiTM

India, Bharuch, Gu.

GUJARAT NARMADA VALLEY FERTILIZERS Co., Ltd.

SnamprogettiTM

Pakistan, Multan

PAKARAB FERTILIZERS Ltd.

Inventa

USA, Memphis, Tennessee

PCS NITROGEN

SnamprogettiTM

USA, Lawrence, Kansas

FARMLAND FERTILIZER/Ag CHEMICAL

SnamprogettiTM

Austria, Linz

AGROLINZ MELAMIN GmbH

SnamprogettiTM

Italy, Nera Montoro

TERNI INDUSTRIE CHIMICHE S.p.A.

SnamprogettiTM

48

ORIGINALNOMINAL CAPACITY CAPACITY AFTER REVAMPING On stream


(MT/D)

(MT/D)

Year

4x 1100

4x 1300

2001

2x 1100

2x 1500

2001

1500

2100

1996

1725

2105

1992

300

400

1991

1000

1400

1990

1800

2350

1990

150

300

1986

1000

1250

1983

600

720

1982

1000

1300

1980

300

360

1980

49

UREA PLANTS BASED on


conventional and i.d.r. PROCESSes
SAIPEM IS THE OWNER OF THE FORMER
MONTEDISON UREA TECHNOLOGy.
COMPANY

LOCATION

CAPACITY t/d Urea

START-UP

ZAKLADY AZOTOWE PULAWY

Poland, Pulawy

1700

1994

AGRIMONT

Italy, Ferrara

1700

1989

C.N.C.C.C.

China, Luzhou

750

1988

TECHMASHIMPORT

Russia, Berezniki

1500

1982

QUIMIGAL

Portugal, Lavradio

Rev. to 270

1982

FERTIMONT.

Italy, San Giuseppe di Cairo

300

1981

TECHMASHIMPORT

Russia, Kemerovo

1500

1981

THE FERTILIZER CORP. OF INDIA Ltd.

India, Ramagundam

1500

1979

THE FERTILIZER CORP. OF INDIA Ltd.

India, Talcher

1500

1979

THE FERTILIZER CORP. OF INDIA Ltd.

India, Sindri

1000

1979

THE FERTILIZER CORP. OF INDIA Ltd.

India, Haldia

500

1979

TECHMASHIMPORT

Ukraine, Gorlovka

1500

1979

THE FERTILIZER CORP. OF INDIA Ltd.

India, Nangal

1000

1978

MONTEDISON

Italy, Ferrara

1500

1977

50

COMPANY

LOCATION

CAPACITY t/d Urea

START-UP

THE FERTILIZER CORP. OF INDIA Ltd.

India, Nampur

1000

1976

THE FERTILIZER CORP. OF INDIA Ltd.

India, Rarauni

1000

1976

KIROVAKAN CHIM

Russia, Kirovakan Chim

54

1973

THE FERTILIZER CORP. OF INDIA Ltd.

India, Durgapur

1000

1973

THE FERT. & CHEM. TRAVANCORE

India, Cochin

1000

1973

C.N.A. (Compagnie
Neerlandaise de lAzote)

The Netherlands, Sluiskil

1100

1970

MONTEDISON

Italy, Castellanza

450

1968

C.N.A. (Compagnie
Neerlandaise de lAzote)

The Netherlands, Sluiskil

700

1968

MONTEDISON

Italy, San Giuseppe di Cairo

450

1967

VETROCOKE

Italy, Porto Marghera

250

1967

NEYVELI LIGNITE

India, Neyveli

500

1965

C.N.A. (Compagnie
Neerlandaise de lAzote)

The Netherlands

330

1965

51

UREA PLANTS BASED on


conventional and i.d.r. PROCESSes

COMPANY

LOCATION

CAPACITY t/d Urea

START-UP

NISSAN CHEM.

Japan, Toyama

60

1965

IND. COLOMBIANA DE FERTILIZANTES

Colombia, Barranca

30

1964

OESTERREISCHICHE STICKSTOFFWERKE

Austria, Linz

80

1963

MINISTRY OF MINES FERT. CORP.

Iran, Shiraz

120

1963

MONTEDISON

Italy, Novara

70

1963

MONTEDISON

Italy, Novara

43

1963

UNIAO FABRIL AZOTO

Portugal, Lisboa

150

1963

IST. VENEZOLANO DE PETROQUIMICA

Venezuela, Moron

50

1963

OFFICE NATIONAL IND. DE LAZOTE

France, Toulouse

200

1962

PIERREFITTE STE GENERALE


DENGRAIS ET PRODUITS CHIMIQUES

France, Pierrefitte

120

1962

AZOLACQ

France, Pardies

120

1962

VETROCOKE

Italy, Porto Marghera

125

1962

C.N.A. (Compagnie
Neerlandaise de lAzote)

The Netherlands, Sluiskil

200

1962

C.N.A. (Compagnie
Neerlandaise de lAzote)

The Netherlands, Sluiskil

180

1962

52

COMPANY

LOCATION

ARMOUR

U.S.A., Cherokee

SUN OLIN CHEM.

CAPACITY t/d Urea

START-UP

45

1962

U.S.A., North Claymont

200

1960

SPENCER CHEM.

U.S.A., Henderson

100

1959

FINALENS

France, La Bass

70

1959

BEFU CHEM.

Japan, Befu

100

1959

OESTERREISCHICHE
STICKSTOFFWERKE

Austria, Linz

40

1958

SINDRI FERTILIZERS

India, Sindri

70

1958

MITSUBISHI CHEM.

Japan, Kurosaki

60

1958

TOKAI AMM. SULPH.

Japan, Yekkaichi

200

1958

MITSUBISHI CHEM.

Japan, Kurosaki

60

1957

UBE IND.

Japan, Ube

100

1957

NISSAN CHEM.

Japan, Toyama

50

1957

SPENCER CHEM.

U.S.A., Vicksburg

30

1957

OFFICE NATIONAL IND. DE LAZOTE

France, Toulouse

100

1956

MONTEDISON

Italy, Ferrara

200

1956

53

UREA PLANTS BASED on


conventional and i.d.r. PROCESSes

COMPANY

LOCATION

CAPACITY t/d Urea

START-UP

MITSUBISHI CHEM.

Japan, Korodaki

60

1956

KIOWA HAKKO

Japan, Ube

80

1956

SHELL CHEM.

U.S.A., Ventura

100

1956

NISSAN CHEM.

Japan, Toyama

50

1953

MONTEDISON

Italy, Ferrara

100

1953

MONTEDISON

Italy, Novara

120

1953

STAATSMIJINEN

The Netherlands, Lutterada

1945

HOLZVERZUCHERRUNGS

Switzerland, Ems

10

1945

MONTEDISON

Italy, San Giuseppe di Cairo

30

1939

STOCK, SUPERFOSFAT

Sweden, Ljiungavark

1938

MONTEDISON

Italy, Novara

1935

54

55

OTHER FERTILIZERS,
RELATED UNITS
AND GAS-BASED PRODUCTS
SAIPEM HAS FURTHER REFERENCES IN
DESIGNING AND BUILDING PLANTS TO
PRODUCE OTHER FERTILIZERS
AND ASSOCIATED PRODUCTS.

Ammonium Nitrate
Ammonium Sulphate
Granulated Calcium Ammonium Nitrate
CO Production
DiAmmonium Phosphate (DAP)
Hydrogen Production
Nitric Acid
NPK
Phosphate Granulation
Phosphate Rock Grinding
Phosphoric Acid
Sulphuric Acid
Triple Super Phosphate

56

02.2012

AMMONIA-UREA AND SYNGAS-BASED PRODUCTS

AMMONIA-UREA
AND
SYNGAS-BASED
PRODUCTS
ENGINEERING AND CONSTRUCTION
PROJECT REFERENCES

People, Skills, Equipment.


Saipem S.p.A.
Via Martiri di Cefalonia, 67 - 20097 San Donato Milanese, Milan - Italy
Tel. +39.02.520.1 - Fax +39.02.520.44415
saipem.com - A subsidiary of Eni S.p.A.

spm_UREAre_Cdorso_12_02_02.indd 1

03/02/12 09.56