Urea Plant

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

Air Blown Reformer
OMIFCO,(a)
OMAN

Air Blown Reformer
FERTINITRO,(a)
VENEZUELA

Air Blown Reformer
PROFERTIL,(a)
ARGENTINA

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

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
Under Exec.
UFT
2x 3850
FEED
Under Exec.
UFT
2050
Under Exec.
Engineering / Procurement / Construction
Under Exec.
Gas-to-Liquids
(Sasol, Chevron,
Haldor Topse A/S)
2 x 17000 BPSD
17

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
Under Exec.
License / PDP / Engineering / Tech. Assistance
Under Exec.
Under Exec.
License / PDP / Engineering / Tech. Assistance
Under Exec.
UFT
3850
Under Exec.
UFT
3850
Under Exec.
Under Exec.
Under Exec.
Under Exec.
Under Exec.
Under Exec.
Methanol
(Haldor Topse A/S)
10000
Front End Engineering
19

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
2011
21

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
2009
23

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
2004
25

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
2002
2002
27

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
Licenses / Engineering / Procurement / Construction
2001
2001
2001
29

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
2001
2000
1999
1999
1999
1999
1999
31

PROJECT REFERENCES
Technologies
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.
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

License
Plant (License)
Capacity T/D
Capacity T/D
Methanol (Kvaerner)
from 2000 to 2250
1998
1998
License / Engineering / Supervision
1998
Engineering / Procurement / Constr. Mngmt
1998
1997
1997
1997
1996
1996
1996
1996
1996
1996
1996
1995
33

PROJECT REFERENCES
Technologies
Country,
Location
India, Babrala, U.P.
License
Snamprogettitm
Capacity T/D
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
NAGARJUNA FERTILIZERS AND CHEMICALS Ltd.
Italy, Ferrara
34
ENICHEM AGRICOLTURA S.p.A.
1700
Haldor Topse
A/S, Giammarco
Vetrocoke
900
1500

License
Plant (License)
Capacity T/D
Capacity T/D
Methanol (Ici)
2000
Deep Hydrolysis
(SnamprogettiTM)
1700
1995
1995
1994
Engineering / Procurement / Constr. Mngmt
1994
1993
1993
1993
1992
1992
1992
1992
1992
35

PROJECT REFERENCES
Technologies
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)
Venezuela, Zulia
PEQUIVEN
India, Aonla, U.P.
India, Jagdishpur, U.P.
INDO GULF Co., 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

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)
1991
1991
1990
1990
1990
1989
1989
1988
1988
1988
Engineering Services
1988
1800
3000
37

PROJECT REFERENCES
Technologies
Country,
Location
License
Urea
Snamprogettitm
Capacity T/D
Technology
Capacity T/D
Pakistan, Multan
PAKARAB FERTILIZERS Ltd.
300
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.
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

License
Plant (License)
Capacity T/D
Capacity T/D
Methanol (Ici)
Ammonium Sulphate
(Struthers Wells)
1000
366
1986
1985
1985
1985
1985
1984
1983
1983
1983
1983
Licence / Engineering / Procurement
1982
1982
1982
1982
39

PROJECT REFERENCES
Technologies
Country,
Location
License
Snamprogettitm
Capacity T/D
CIS, Togliattigrad
TOGLIATTI AZOT
Pakistan, Mirpur Mathelo
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
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

License
Plant (License)
Capacity T/D
Capacity T/D
Ammonium
Sulphate (Ici)
Calcium Nitrate
(Pintsch Bamag)
1982
1980
1980
1980
1980
1979
1979
1979
1978
1977
1976
1975
1974
1973
1400
200
41

PROJECT REFERENCES
Technologies
Country,
Location
Italy, Manfredonia
License
Snamprogettitm
Capacity T/D
Haldor Topse
A/S, Giammarco
Vetrocoke
Urea
1200
Technology
Capacity T/D
1000
Venezuela, Moron
SERVIFERTIL
750
Italy, Nera Montoro
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
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

License
Plant (License)
Capacity T/D
Capacity T/D
NPK (Dorr Oliver)
920
1972
1972
1971
1971
1971
1971
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
INDO GULF Co., Ltd.
SnamprogettiTM
SnamprogettiTM
Iraq, Khox Al-Zubair
STATE COMPANY OF FERTILIZER
SnamprogettiTM
SnamprogettiTM
India, Hazira, Gu.
SnamprogettiTM
India, Babrala, U.P.
SnamprogettiTM
China, Hejiang, Sichuan
SICHUAN TIANHUA Co., Ltd.
SnamprogettiTM
NAGARJUNA FERTILIZERS AND CHEMICAL CORP.
SnamprogettiTM
India, Aonla, U.P.
SnamprogettiTM
India, Bharuch, Gu.
SnamprogettiTM
India, Gadepan, Ra.
CHAMBAL FERTILIZERS AND CHEMICALS Ltd.
SnamprogettiTM
SnamprogettiTM
SnamprogettiTM
Pakistan, Mirpur Mathelo
SnamprogettiTM
India, Namrup
HINDUSTAN FERTILIZER COMPANY Ltd.
Montedison
India, Namrup
HINDUSTAN FERTILIZER COMPANY Ltd.
Montedison
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.
SnamprogettiTM
INDO GULF Co., Ltd.
SnamprogettiTM
Canada, Red Water, Alberta
AGRIUM U.S. Inc.
SnamprogettiTM
SnamprogettiTM
Spain, Puertollano
EMPRESA NACIONAL DE FERTILIZANTES S.A.
SnamprogettiTM
Germany, Brunsbttel
YARA BRUNSBUTTEL GmbH
SnamprogettiTM
India, Bharuch, Gu.
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
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
India, Talcher
1500
1979
India, Sindri
1000
1979
India, Haldia
500
1979
TECHMASHIMPORT
Ukraine, Gorlovka
1500
1979
India, Nangal
1000
1978
MONTEDISON
Italy, Ferrara
1500
1977
50
COMPANY
LOCATION
CAPACITY t/d Urea
START-UP
India, Nampur
1000
1976
India, Rarauni
1000
1976
KIROVAKAN CHIM
Russia, Kirovakan Chim
54
1973
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
700
1968
MONTEDISON
450
1967
VETROCOKE
Italy, Porto Marghera
250
1967
NEYVELI LIGNITE
India, Neyveli
500
1965
C.N.A. (Compagnie
The Netherlands
330
1965
51

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
200
1962
C.N.A. (Compagnie
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

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
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.
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02.

AMMONIA-UREA AND SYNGAS-BASED PRODUCTS

People, Skills, Equipment.

SAIPEM ENGINEERING & CONSTRUCTION 6

SNAMPROGETTItm UREA TECHNOLOGY

AMMONIA-UREA AND SYNGAS-BASED

UREA PLANTS BASED ON CONVENTIONAL

OTHER FERTILIZERS, RELATED UNITS

Saipem has a strong bias towards oil

Ever since its initial steps in the fifties

and numerous project execution

installation; also revamps, upgradings,

Saipem therefore offers a complete

(*) Until Dec. 31, 2010

We have designed and built hundreds

(*) Until Dec. 31, 2011

production of 3,558 Tons per Day

Continuous Urea Technology

Moron Fertilizer Complex - Venezuela 1972

In addition to a large number of

Among other technological novelties,

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

Primary and secondary

Primary and secondary

Primary and secondary

Primary and secondary

Primary and secondary

One step reformer

Synthesis including Nitrogen

Saipem today is a market leader in

AMMONIA-UREA AND SYNGAS-BASED

Saudi Arabia, Al Jubail

SAUDI ARABIA FERTILIZER Co. SAFCO-5

China, Ordos, Inner Mongolia

ORDOS YIDING COAL CHEMICAL Co, Ltd.

PETRONAS CHEMICAL FERTILISER SABAH Snd. Bhd.

Gabon, Port Gentil

GABON FERTILIZER COMPANY

Nigeria, Agenebode, Edo State

DANGOTE FERTILIZER Ltd.

CHEVRON NIGERIA Ltd. (CNL)

ESCRAvOS GAS-TO-LIqUIDS PROjECT - NIGERIA

License / PDP / Tech. Assistance

Licenses / PDP / Tech. Assistance

License / PDP / Tech. Assistance

License / PDP / Tech. Assistance

Engineering / Procurement / Construction

AMMONIA-UREA AND SYNGAS-BASED

HABAC NITROGENOUS FERTILIZER & CHEMICALS

TATA (FERTILIZER DIVISION) CHEMICALS Ltd.

China, Hefei, Anhui

CNSG ANHUI HONG SIFANG Co., Ltd.

India, Panagarh, West Bengala

MATIX FERT. & CHEM. Ltd.

Peru, San Juan De Marcona

QATAR FERTILIZER COMPANY QAFCO-6 Project

China, Fugu, Shaanxi

SHAANXI POPULAR JURASSIC (GROUP) Co., Ltd.

China, Jungar, Inner Mongolia