Koch Nitrogen's Enid Facility Expansion, Oklahoma, United States of America

The new urea plant at Enid will have an annual production capacity of 900,000t.

Koch Nitrogen broke ground on a $1.3bn expansion of its fertiliser plant located east of Enid, Oklahoma, in October 2014.

The project involves the revamping of certain existing production processes of the facility and construction of an integrated new urea plant at the same site. Overall, the project is expected to increase the annual production capacity of the fertiliser plant by more than one million tonnes.

The expansion will generate 1,000 new jobs during construction phase and 50-60 additional permanent jobs when it comes online in 2016. The existing facility employs 140 people.

Details of the existing fertiliser production facility at Enid

The new fertiliser plant will produce between 1.5 and two million metric tons of ammonia, urea and urea ammonium nitrate (UAN) a year.

The existing fertiliser plant at Enid came online in 1974. Koch Nitrogen acquired the facility from Farmland in 2003. It currently produces ammonia, UAN (liquid fertiliser) and granular urea. A recent development at the site involved the construction of a 10,000ft² control centre, completed in 2011, which enabled the plant operations to be fully automated.

Enid fertiliser plant expansion project details

The initial planning works for the current project started in 2012, and the new urea plant will have an annual production capacity of 900,000t. The existing ammonia production facilities will be improved to increase efficiency and their production capacity. An additional 90,000t of urea storage facilities will also be added as part of the project.

A new urea plant will produce diesel exhaust fluid (DEF), which is a high-purity urea solution that reduces the nitrogen oxide content in the exhaust emissions of diesel engines.

Associated project activities include the upgrade of the wastewater treatment facilities, construction of two electric power substations including power interconnections, and construction of an additional high-speed truck and rail loading facilities.

Stamicarbon's licenced technologies for the project

"The project is expected to increase the annual production capacity of the fertiliser plant by more than one million tonnes."

The new urea plant will feature urea melt and granulation facilities, implementing technologies licensed by Stamicarbon. A urea melt facility will implement Stamicarbon's Urea2000Plus Pool Reactor technology, which integrates a medium pressure adiabatic flash separator. Proprietary Safurex stainless steel for construction of the high pressure urea equipment is also being supplied by the company.

A granulation facility will implement Stamicarbon's fluid bed granulation technology. Stamicarbon's proprietary urea dust and ammonia acid scrubbing equipment will also be installed at the plant.

Contractors involved with the fertiliser plant expansion

Conceptual design for the expansion project including the definitive project cost estimate was provided by Black & Veatch, which was awarded the contract in May 2012. The company was further awarded a contract in September 2014 to provide engineering and procurement services for the existing two ammonia plant expansions including the utility and infrastructure improvements.

KBR has been awarded the engineering, procurement and construction (EPC) contract for the new urea plant. The company is also providing construction management services for the overall project. The respective contracts were awarded in September 2014.

Marketing commentary for Koch Nitrogen

Koch Nitrogen and Koch Fertilizer Canada are affiliates of Koch Fertilizer, which is an indirect subsidiary of Koch Industries. Koch Fetilizer and its affiliates operate nitrogen based fertiliser plants in the US, Canada, Trinidad and Tobago. They also operate state-of-the-art terminals in the US, Canada, Mexico, Brazil, Australia, France and the UK, supplying globally more than 13 million tonnes of fertiliser products annually.

NRI Energy Technology