Rehabilitation project of the Egyptian Chemical Industries Company (KEMA) to work with natural gas technology

• To comply with environmental laws and regulations
• To provide electricity currently consumed in electrical analysis of water (150 MW / hour) and export to the main network
• To add a new product (fertilizer Urea 46 g 5% Azut) with a capacity of 530 thousand tons / year
• To raise the current production capacity of ammonium nitrate (agricultural and industrial) from 100 thousand tons / year to 220 thousand tons / year

Rehabilitation of Kima Fertilizers Company (Ammonia-Urea) in Aswan Governorate
In order to fill the gap in the fertilizer markets, in addition to the establishment of a full industrial city in Aswan, which contributes to the creation of jobs in Upper Egypt, and after the aging of the current plant, which is about to stop. About 11.6 billion pounds, equivalent to 738 million 500 thousand dollars according to the exchange rates at the time. The project is built on an area of ​​60 acres and provides nearly 3700 direct and indirect job opportunities
In Upper Egypt.
The project aims to produce 1220 tons of ammonia, of which 900 tons of urea are produced daily at the new Kima plant with a total of 570 thousand tons / year and 300 tons of ammonia go to the old factory to produce 120 thousand tons / year of low and high density ammonia nitrate, 100 thousand tons / year of fertilizer Nitrogen ammonium nitrate
The use of natural gas instead of electricity contributed to saving 150 MWh for the national grid. The application of all environmental requirements using modern technological systems to preserve the environment.

Kima Factory 2
Kima Factory Components /
Kima plant consists of three sectors
Facilities and services
Ammonia Factory
Urea plant and packing station
I. Facilities and Services
Include both
Natural gas filtration and reduction plant in order to meet the plant's natural gas needs of 1,200,000 m3 / day at 25 bar pressure.
Water treatment plant in order to produce water for various industrial processes, such as cooling water - desalinated water to produce steam required for factories.
Nitrogen production unit - to produce 600 m3 / h nitrogen required for disinfection, industry and start-up.
Unit for the production of air processes and devices and the purpose of producing air for cleaning and operation of equipment on site.
(1)

Electricity production plant with the purpose of producing 27.2 MW / h to meet the needs of the factory of self-electricity and export the surplus to the old plant.
Cooling towers - to provide the water needed to cool various industrial processes in the ammonia and urea plant.
Diesel station - contains (2) diesel capacity of each 2.5 MW to meet the needs of factories of electricity in case of emergency and power outages.
Fire water network - to secure factories in case of fire.
Central laboratories - A factory has been established on the latest level with different devices to carry out the required analyzes of industrial processes and control the quality of the final product.
Linking station between the new factory and the old factory. There is a network between the manufacturers to supply the old factory with its needs of ammonia, steam, treated water, air of equipment and processes, electricity.
11 - the main control room is the follow-up and control of industrial processes and remote control and the operation of various production units.
Second: Ammonia factory
It includes three phases /
Desulphurization stage of natural gas.
(2)
The stage of synthesis gas production (nitrogen and hydrogen). This is done by cracking natural gas in the primary and secondary transformers with air pumping as a source of nitrogen in the secondary transformer through the process air compressor, which is managed by a gas turbine. This is one of the new ways to save energy consumption for ammonia plants.
Phase of synthesis gas purification (carbon compounds - argon - methane)
Through the following stages:
Convert co to co2 in two units (HT - L T).
CO2 removal unit.
Methanitor unit to convert CO, CO2 to methane.
Drying phase of natural gas.
Phase of gas purification and adjust the ratio of nitrogen to hydrogen to (1: 3)
Anavar Compressors:
It includes 4 compressors (compressor of carbon dioxide used in urea industry - natural gas compressor - synthetic gas compressor - liquefaction compressor for ammonia gas) in order to raise the gas pressure to the required operating pressures.
(3)
Synthesis of ammonia:
It is carried out inside the ammonia reactor through the reaction of hydrogen with nitrogen at a pressure of 155 bar in the presence of a catalyst to produce 1200 tons of ammonia per day. This reactor is part of the modern technology applied for the first time in Egypt.
Condensing, separation and storage unit The ammonia is condensed, separated and stored inside the main ammonia tank which has a capacity of 10,000 tons of ammonia. It sends 900 tons of ammonia to the urea plant and 300 tons of ammonia to the old plant.
III / Urea plant
It consists of:
Urea Synthesis Unit: It is carried out by introducing ammonia with carbon dioxide at 145 bar pressures in Pool Reactor to produce urea solution.
Disassembly and recovery of unreacted gases with a view to obtaining a concentration of urea solution of 72%.
Phase II concentration: It consists of two stages to reach the concentration of urea solution to 98%.
(4)
Granulation stage: The urea solution is converted into urea granules with a size of 2-4 mm which is the final product of the plant at a concentration of 46.20%.
Storage and Packing Unit: where the final product is cooled and sent to the filling station, which consists of 6 conveyor belts for packing 240 tons / hour by rail and transport vehicles. In case of stopping the filling station, the product is sent to the main store with a capacity of 50,000 tons.

The movement of the project "Ammonia and Urea" until 31/5/2019

Financing segments:

• Initial tranche: Facilitation of US $ 292.3 million, including interest paid and commission fees
• Second tranche: Facilitation of EGP 1,920 billion, including interest paid, fees and commissions

Summary of the most important financing conditions:

Duration of funding

• 8 years to the US dollar slide
• 8 years for the Egyptian pound

Investment cost

The investment cost of the ammonia and urea project is estimated at LE 11.638 billion

Total expenditure on the project until 31/5/2019 estimated at 9,677 billion pounds

The total outstanding expenses for the project as at 31/5/2019 is estimated at LE 1,861 billion

Banks lending

• Bank of Egypt, National Bank of Egypt, Banque du Caire, Arab African International Bank, BLOM Egypt Bank and Real Estate Bank
• Credit facilities account for 62% of the total investment cost of the project
• The equity ratio is 38% of the total investment cost of the project

The overall position of the project

The investment cost of the project "Ammonia and Urea" and the balance until 31/5/2019

 Movement of funding sources of the project "Ammonia and Urea" until 31/5/2019

With the knowledge that 183 million Egyptian pounds were disbursed during June 2019

The main financial indicators of the new project

• The company's revenues are expected to reach 2.2 billion pounds in the first year of operation 2019/2020 and revenue is expected to rise to LE 4 billion by 2026/2027. The use of modern technology will lead to lower operational costs and increase profit.