UPDATED: 12/10/2017 — see Change Log

OWNER: Koch Fertilizer Enid LLC (Koch Industries Inc)
PROJECT: Nitrogen fertilizer plant, ammonia expansion, urea brownfield[memberful does_not_have_subscription=”1314-ammonia-industry-annual-subscription,1311-ammonia-industry-monthly-subscription,3338-ammonia-industry-30-day-subscription”]

EXISTING PLANT:
COST (reported): [none given]
JOB CREATION: 130 permanent — see Job Openings [LINK]
START-UP DATE (reported): 1974

EXPANSION:
COST (reported): $1.3 billion
JOB CREATION: 120 permanent, 2,800 peak temporary — see Job Openings [LINK]
START-UP DATE (reported): 2017

CAPACITY	USGS[1]	COMPANY[2]	PERMIT[3]	ADJUSTED[4]
Ammonia	930,000 mtpy	[none given]	[Membership required]	[Membership required]
Units: stpd, stpy, mtpd, mtpy = short/metric tons per day/year. [1] United States Geological Survey (USGS) Mineral Yearbook, Nitrogen gives capacity in metric tons per year, calculated as “engineering design capacity adjusted for 340 days per year of effective production capability,” rounded to three significant digits. Source: most recent year, Table 4: Domestic Producers of Ammonia, http://minerals.usgs.gov/minerals/pubs/commodity/nitrogen/. [2] Koch has not published capacity information. [3] [Membership required]. Sources: linked below. [4] [Membership required]. See Methodology.

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SUMMARY STATUS: Construction Phase
Koch is expanding its Enid plant, the “single largest project investment in company history,” increasing capacity on both ammonia lines, debottlenecking the existing urea plant, and building a new urea plant. The ground-breaking took place in October 2014; the project is slightly behind schedule, but construction was expected to be complete in 2017.

EXISTING PLANT:
COST: $30+ million in 1972
JOB CREATION: 130 permanent — see Job Openings [LINK]
START-UP DATE: 1974 ammonia, 1980 urea, 1990 UAN

EXPANSION:
COST: $1.3 billion
JOB CREATION: 120 permanent, 2,800 peak temporary — see Job Openings [LINK]
START-UP DATE: 2017
LIKELIHOOD: Likely — see Methodology

CAPACITY	USGS[1]	COMPANY[2]	PERMIT[3]	ADJUSTED[4]
Ammonia	930,000 mtpy		Existing: 3,200 stpd Post-expansion: 3,600 stpd	Existing: 1,059,592 mtpy Expansion: +132,449 mtpy Post-expansion: 1,192,041 mtpy GROSS
Urea		Brownfield: 900,000 stpy	Existing: 1,550 stpd Brownfield: 2,425 stpd	Existing: 513,240 mtpy Brownfield: +802,972 mtpy Post-expansion: 1,316,212 mtpy GROSS 1,122,505 mtpy, granular
UAN				107,615 mtpy
Units: stpd, stpy, mtpd, mtpy = short/metric tons per day/year. [1] United States Geological Survey (USGS) Mineral Yearbook, Nitrogen gives capacity in metric tons per year, calculated as “engineering design capacity adjusted for 340 days per year of effective production capability,” rounded to three significant digits. Source: most recent year, Table 4: Domestic Producers of Ammonia, http://minerals.usgs.gov/minerals/pubs/commodity/nitrogen/. [2] Koch has not published capacity information. [3] Permit documents for this site give capacity in short tons per day. Sources: linked below. [4] Adjusted Capacity is in metric tons per year assuming operations for 365 days per year; based on Permitted Capacity; Urea granulator capacity constrains urea capacity at 3,390 stpd; UAN capacity is computed from Nitric Acid capacity of 118 stpd. See Methodology.

FEEDSTOCK: Natural gas
END PRODUCTS: Ammonia, Urea, DEF, UAN, CO2

RESEARCH NOTES:
The $1.3 billion expansion at Enid, which represents Koch Industries’ “single largest project investment in company history,” will increase production capacity at the two existing ammonia lines and the urea plant, as well as build a new urea plant with a capacity of 900,000 stpy.

In April 2017, local news reported that the construction phase would be “wrapping up by the end of the year.” And again, in October 2017, local news reported that “the majority of construction and commissioning activities are expected to wrap up by the end of the year.”

In February 2017, local news had reported that “the plant is in the process of commissioning several upgrades and new facilities, including a tertiary water treatment facility.” In December 2017, the Enid plant manager described this water treatment project as “an ideal example of how public and private institutions can work together for a cleaner environment and more efficient use of valuable resources,” when it won the Oklahoma Water Resources Board’s inaugural “Water for 2060 Excellence Award.”

Back in 2012, Koch had announced that engineering company Black & Veatch would “help develop” projects across Koch’s North American plants, to increase capacity by “more than two million tons annually,” “through production enhancements and new capacity investments.” As a result, in May 2013, Koch announced the Enid expansion.

KBR won the EPC contract for the urea brownfield, which will be built by Stamicarbon, and for the ammonia line expansions, splitting duties for the rest of the expansion projects with Black and Veatch.

The expansion project includes a series of revamps on the two ammonia lines, increasing capacity on Lines 1 and 2 from 1,600 stpd each to 1,700 stpd and 1,900 stpd respectively, while retrofitting SCR deNOx on Line 2. The existing urea plant will also be revamped, but only to “allow the No. 1 Urea Plant to perform up to its permitted design capacity” of 1,550 stpd (on average, or 1,600 stpd short-term).

The brownfield urea plant will have a capacity of 2,425 stpd, bringing the total gross urea capacity at Enid to 3,975 stpd – however, the site’s capacity for granulated urea will be constrained at 3,390 stpd, which includes the output from both urea plants. Up to 114 stpd of the urea would be required for UAN production, leaving a maximum of 471 stpd available for production of DEF.

The Enid site also includes a carbon dioxide plant. CO2 from ammonia production is either consumed in urea and UAN production, sold (either trucked to Linde as food-grade CO2, or sent in a pipeline to Merit for EOR), or vented to the atmosphere. Before the expansion, air permits capped site-wide greenhouse gas emissions at 1,424,516 stpy CO2e, however, this number rises to 2,578,699 stpy CO2e after the expansion.

Fertilizer is shipped from the site by rail and truck; additionally, ammonia is shipped out by pipeline.

Farmland Industries built the ammonia plant at Enid in 1974, using technology from M. W. Kellogg. The original plant had a capacity of 385,000 stpy; it outperformed its rated capacity of 1,000 stpd to reach production of 1,200 stpd. Two years later, Farmland added a second M. W. Kellogg ammonia plant of the same capacity.

In 1980, Farmland started up a Forster Wheeler urea plant, which was revamped in 2007-2009 increasing its capacity from 127,000 stpy to roughly 600,000 stpy.

In 1990, Farmland started UAN production, using Weatherly nitric acid (NA) and ammonium nitrate (AN) plants, both of which were built in 1968 and relocated from Kennewick, WA. The site’s UAN production capacity is not published, but is constrained by NA and AN production capacities, which are respectively 118 stpd (as 110% HNO3) and 176 stpd (as 75.5% AN).

Farmland filed for Chapter 11 bankruptcy protection in 2002, and Koch Nitrogen purchased the Enid plant at auction in 2003, paying $171 million for it and three other plants, including Beatrice, NE, Dodge City, KS, and Fort Dodge, IA, and a dozen terminals.

Koch Industries Inc recently reorganized its corporate structure: Koch Fertilizer Enid LLC is now a subsidiary of Koch Fertilizer LLC, which is a subsidiary of Koch Ag & Energy Solutions LLC.[/memberful]

View larger map with all ammonia plants.

ADDRESS: 1619 South 78th Street, Enid, Oklahoma, 73701, United States

WEBSITE: http://www.kochind.com/
WEBSITE: http://www.kochagenergy.com/
WEBSITE: http://www.kochfertilizer.com/

REGULATORY SOURCES:

• USGS: Minerals Yearbook, Nitrogen [RECENT / ARCHIVE]
• EPA Emissions data: Greenhouse Gas Emissions from Large Facilities: Koch Fertilizer Enid [LINK]
• Risk Management Plan: Right to Know Network: Koch Fertilizer Enid [LINK]
• Permit Documents: Oklahoma DEQ Final Issued PSD Permits [LINK / DOC]

NEWS SOURCES:

• 12/06/2017: Black & Veatch press release: Black & Veatch work on $1.3B Koch Fertilizer plant expansion contributes to water award [LINK]
• 10/15/2017: Enid News: Koch expansion nears completion [LINK]
• 04/12/2017: Tulsa World: $1.3B expansion of Koch fertilizer plant in Enid to be completed in June [LINK]
• 02/25/2017: Enid News: Koch Fertilizer expansion continuing east of Enid [LINK]
• 01/01/2017: Koch News: Shades of gray (water) [PDF]
• 05/10/2016: Enid News: Enid Rotary Club hears Koch Fertilizer update [LINK]
• 12/28/2015: Enid News: Expansion could impact Enid residents’ air quality for the better [LINK]
• 08/23/2015: Enid News: Plant expansion on track [LINK]
• 06/23/2015: Koch Industries press release: Delivering DEF [LINK]
• UNDATED: Koch Industries, fact sheet: Enid, OK [PDF]
• 02/13/2015: Koch Industries press release: Koch Nitrogen Launches Enid Project Website [LINK]
• 02/2015: Koch News: Koch’s largest project: Enid expansion [PDF]
• UNDATED: KBR project profile: Koch Enid Plant Expansion [PDF]
• 09/30/2014: Black and Veatch press release: Black & Veatch to Provide Engineering Services for $1.3 Billion Fertilizer Plant Expansion [LINK]
• 10/09/2014: Enid News, local news story: Koch Industries: ‘Single largest project’ [LINK]
• 10/06/2014: Enid News, local news story: A crush of workers is coming [LINK]
• 09/02/2014: KBR press release: KBR Awarded EPC Services Contract for Koch Nitrogen Urea Expansion [LINK]
• 08/06/2014: Koch Industries press release: Koch Nitrogen to Begin Construction on $1.3 Billion Expansion Project [LINK]
• 12/05/2013: Koch Industries press release: Koch Fertilizer Announces New Holding Company and Leadership Changes [LINK]
• 06/10/2013: Stamicarbon press release: Koch Nitrogen Selects Stamicarbon’s Urea Technology for its Expansion in Enid, Oklahoma [LINK]
• 05/15/2013: Koch Industries press release: Koch Nitrogen to Build New Urea Plant and Increase Production in Enid Oklahoma [LINK]
• 05/14/2012: Koch Industries press release: Koch Fertilizer to Develop Projects for Production Increase [LINK]
• 05/14/2012: Koch Industries press release: Koch Investing, Adding Jobs at Enid Plant, Around Fertilizer Business [LINK]
• 03/28/2003: Associated Press news story: Koch buys Farmland fertilizer assets [LINK]