Programme

Programme
Sponsors:
Monday, 23 February
Workshop registration and refreshments
08:00 – 09:00
“Operating, maintaining and revamping urea plants”
09:00 – 17:00
Conference registration and exhibition open
Welcome Reception sponsored by Gemaco
15:00 – 19:30
18:00 – 19:30
(Registration for workshop participants only)
Pre-Conference Workshop (separately bookable at extra charge)
Tuesday, 24 February
Registration desk open sponsored by Toyo Engineering
Exhibition open
Commercial programme
Refreshment break sponsored by Stamicarbon
Commercial programme
Lunch sponsored by ThyssenKrupp Industrial Solutions
Technical programme
Refreshment break sponsored by Stamicarbon
Technical programme
Drinks Reception in Exhibition Area
sponsored by Entechmach
08:00 – 19:00
08:00 – 19:00
09:00 – 10:30
10:30 – 11:00
11:00 – 12:30
12:30 – 14:00
14:00 – 15:30
15:30 – 16:00
16:00 – 17:30
17:30 – 19:00
Wednesday, 25 February
Registration desk open sponsored by Toyo Engineering
Exhibition open
Technical programme
Refreshment break sponsored by Stamicarbon
Technical programme
Lunch sponsored by Casale/Clariant
Technical programme
Refreshment break sponsored by Stamicarbon
Technical programme
Drinks Reception in Exhibition Area
co-sponsored by BD Energy, Ortash and SBN
08:30 – 17:30
08:30 – 17:30
09:00 – 10:30
10:30 – 11:00
11:00 – 12:30
12:30 – 14:00
14:00 – 15:30
15:30 – 16:00
16:00 – 17:30
17:30 – 19:00
Thursday, 26 February
Registration desk open sponsored by Toyo Engineering
Exhibition open
Technical programme
Refreshment break sponsored by Stamicarbon
Technical programme
Lunch
Technical programme
08:30 – 15:30
08:30 – 15:30
09:00 – 10:30
10:30 – 11:00
11:00 – 12:30
12:30 – 14:00
14:00 – 15:30
This conference is an open forum and the content of papers and presentations given by guest authors
and speakers from companies other than CRU and its subsidiaries and any opinions expressed therein
are the responsibility of the authors and speakers concerned and are not endorsed by CRU Events.
CRU Events disclaims all liability for any tort or damage arising out of any statement or opinion made in
any paper or presentation by any guest author or speaker.
Organised by CRU Events
Monday, 23 February
08:00
Workshop registration and refreshments (Registration for workshop participants only)
09:00 Pre-conference Workshop “Operating, maintaining and revamping urea plants”
- 17:00 facilitated by UreaKnowHow.com
- How to prevent detrimental corrosion phenomena in HP equipment and piping
- Safety incidents in the urea industry
- Doing repairs on high pressure equipment items
- Revamping technologies for urea plants
- How to assure a first-class urea product
Mark Brouwer, Owner, Director, UreaKnowHow
Jo Eijkenboom, Director, UreaKnowHow
Giel Notten, Corrosion and Materials Consultant, NTT Consultancy
George van Bommel, Sr. Energy & Process Engineer, Sr. Consultant Fertiliser & Commissioning
Only for delegates who pre- booked a place for the workshop – separately bookable and at additional charge
15:00
Registration
Sponsored by Toyo Engineering
15:00
Exhibition open
18:30
Welcome Reception (Exhibition Area)
Sponsored by Gemaco
Tuesday, 24 February
08:00
Welcome Coffee
Sponsored by Stamicarbon
08:00
Registration
Sponsored by Toyo Engineering
Conference Auditorium
Sponsored by Casale and Clariant
09:00
Welcome from CRU
Global Outlooks
SESSION CHAIR: TBC
09:00
Global Gas Outlook
- Global pricing outlook
- Regional snapshots: European dependence on Russian gas
- How will shale and other unconventional gas resources impact the global market?
James Henderson, Senior Research Fellow, Oxford Institute for Energy Studies
09:30
The Outlook for Nitrogen: China Syndrome
- 2014 in review: Cheap coal and a liberal export policy help China export record volumes of urea.
- How sustainable are Chinese exports at the 10 million tonne level? And how marginal is Chinese supply?
- Cost competiveness: The impact of gas market reforms and a depressed coal price on global nitrogen
margins
- The first world scale US nitrogen plants will be commissioned later this year (2015). How will they affect
US nitrogen supply and Atlantic trade?
- The case for Indian subsidy reform
Alistair Wallace, Senior Consultant, CRU
Organised by CRU Events
Tuesday, 24 February
10:00
Global Methanol Outlook
- Global methanol balance to 2012
o Main drivers
o Regional balances
- Methanol use and economics
- Methanol pricing and margins
Mark Berggren, Managing Director, Methanol Market Services Asia (MMSA)
10:30
Refreshment & Network Break
Sponsored by Stamicarbon
11:00
Managing risks to promote investments and enhance competitiveness in the fertilizer industry
- Sources of funding: traditional major funding models
- Where IFC is underwriting investment
- Options for funding plants where rational funding isn’t possible
- Mitigating risk for investors around the world
- Who is investing in agriculture and fertilizer projects and where?
Anil Chandramani, Chief Investment Officer & Global Sector Lead, Chemicals & Fertilizers, International
Finance Corporation (IFC)
11:30
The geopolitical outlook for Russia and the Middle East – possible trajectories
- The political and economic outlook for Russia and the implications for business
- The near-term trajectory of the Middle East crisis and scenarios for the future
- Doing business in an increasingly volatile geopolitical world
Charles Hecker, Global Research Director, Control Risks
12:00
The FSU outlook for fertilizer demand and production
Mikhail Penkov, Head of Dept. for Planning and Analysis, URALCHEM OJSC
12:30
Lunch
Sponsored by ThyssenKrupp Industrial Solutions
Technical programme:
Session 1: Front-end Syngas technology and operations
14:00
New generation purification catalyst technology
As the use of new hydrocarbon feedstock increases as new wells are utilised, so too does the potential for
increased impurities. This paper will cover various purification catalysts that have been used in Middle Eastern
Ammonia and Methanol plants to avoid downstream catalyst failure and plant shut down.
Prasant Kumar, Technical Service Manager, Clariant Middle East Bahrain Branch
14:30
Online asset management 24/7
This paper will demonstrate a system for continuous monitoring of process tubes for temperature variations
and tolerances within the reformer. The results can be analysed, giving operators the necessary information to
adjust furnace conditions to operate within the integrity operating window.
David Schmitt, President, Increase Performance
15:00
Innovative in-situ refractory repair and dry out with steam after sudden transfer line refractory
This paper documents an incident of a potential catastrophic failure of a transfer line. A complex maintenance
procedure was developed to deal with the transfer line refractory repair, which included inspection analysis
using video-scopy and thermography. Safe handling of the transfer line bulging, and issues faced during the
transfer line repair and dry-out will be shared.
Syed Ali Raza Sani, Operations Engineer, Engro Fertilizers Limited
Asim Rasheed Qureshi, Unit Manager Operations – Ammonia2 Plant, Engro Fertilizers Limited
Organised by CRU Events
Tuesday, 24 February
15:30
Refreshment & Network Break
Sponsored by Stamicarbon
Session 2: Syngas generation
16:00
Foil supported catalysts deliver high performance in steam reformers
This paper presents a foil supported steam reforming catalyst system, currently in use in two steam reformers
in Turkey and Mexico. Catalyst-coated foil structures in the reformer tube improve heat transfer by continually
directing the flow towards the tube wall. The paper will provide performance curves that demonstrate heat
transfer that is 35% better than pellets at the same pressure drop. Results from internal testing and operating
plants will also be shared.
William Whittenberger, Site and Technology Director - Refineries Business, Johnson Matthey Process
Technologies, Inc.
16:30
Extended survey of a steam reformer charged with high activity catalysts
An extended performance evaluation of the steam reformer was conducted following the replacement of the
primary reformer catalyst. A thorough steam reformer survey using infrared thermography, which assessed
both process and flue gas, provided detailed insight into actual reformer operation and identified opportunities
for enhancing performance.
Nenad Zečević, Member of the Board, Petrokemija d.d.
Jovica Zorjanovic, Sales Account Manager - Syngas EMEA, Clariant
17:00
Novel transitional metal catalyst for synthesis gas production from CH4/CO2-rich gas mixtures
Using CO2 instead of steam for reforming methane yields a synthesis gas with a low H2:CO ratio, suitable for
some organic chemical syntheses, but existing catalysts are highly susceptible to carbon fouling. NIC’s new
catalyst remains coke-free over a wide range of CH4/CO2 mixtures, including biogas, which has a
considerable global warming potential if not captured.
Dr. Gasan Osojnik, Researcher, National Institute of Chemistry (Slovenia)
17:30
Close of day one
17:30
After-Session Drinks Reception (Exhibition Area - dress code casual)
Sponsored by Entechmach
Organised by CRU Events
Wednesday, 25 February
08:30
Welcome Coffee
Sponsored by Stamicarbon
08:30
Registration
Sponsored by Toyo Engineering
Conference Auditorium
Sponsored by Casale and Clariant
Stream A: Session 3a:
Methanol operations
Stream B: Session 3b:
Materials & construction
09:00
Experience in optimising ATR performance
with high stability KATALCOJM catalysts
Autothermal reforming is becoming more
prevalent in methanol plants, however, due to the
severe operating conditions encountered, a
number of problems are often experienced. This
paper presents a case study where the time
between catalyst skims has been extended from
every 2 years to 7 years before discharge and
replacement with fresh material.
Kevin Mowbray, Technical Sales Manager,
Johnson Matthey
09:00
A new metal dusting resistant nickel alloy
with exceptional fabricability and thermal
stability
Metal dusting is a catastrophic corrosion attach
resulting in the disintegration of alloys after
elevated temperature exposures in
carbonaceous atmosphere containing H₂, CO,
CO₂ and H₂0 gas mixtures. A new Ni-Cu-Mo-Cu
based solid-solution-strengthened wrought alloy
has been recently developed to resist against
metal dusting corrosion attack. In this paper,
three characteristics of the alloy, metal dusting,
thermal stability and weldability will be presented.
Vinay Deodeshmukh, Market Manager, Haynes
International Inc.
09:30 Advanced process control on a methanol
plant: Results and benefits
Many integrated syngas plants have combined
process and utility plants using natural gas as the
feedstock for both the product and energy
generation. This case study will demonstrate how
a methanol plant continually optimises the yield
of methanol from the process so as to increase
methanol production without increasing the
feedstock to the plant, and in turn reducing CO2
emissions.
Kieron Lennox, Regional Manager, IPCOS
Middle East & North Africa
09:30
Receiving the right amount and right quality
materials in time as promised
Urea and nitric acid plants require specially
alloyed materials of construction in order to
ensure a safe and reliable operation. This paper
will elaborate on the specific material quality
requirements in various urea process
technologies, including Stamicarbon, Saipem,
Casale, and TEC licences, and will include
historical perspectives. Several references will be
presented in detail together with feedback from
end users.
Jean-Marc Sluyters, CEO, Gemaco S.A.
Giel Notten, Corrosion Materials Consultant NTT
Consultancy
10:00
10:00
High-temperature hydrogen attack –
recommendations of the US Safety and
Hazard Board
High temperature hydrogen attack (HTHA) is a
damage mechanism that has the potential to
cause catastrophic failure of low alloy steel
processing plant, which was illustrated by the
incident at Tesoro Anacortes Refinery in 2010.
This paper reviews the findings of the Tesoro
Anacortes incident report and describes the
impact that adoption of the US Chemical Safety
Board recommendations will have on the
requirements for inspection to ensure integrity of
Innovative solutions for methanol and
formaldehyde production: A
Chemanol/Topsøe case story
This joint presentation between Chemanol and
Topsøe will highlight the experiences Chemanol
has had operating and expanding both their
methanol and UFC-85 plants, including six
capacity expansion projects and vertical
diversification expansions into upstream
methanol production.
Khalid Moharrum, General Manager,
Operations, Chemanol
David J. Bray, Product Manager, Shift Catalysts,
Organised by CRU Events
Haldor Topsøe A/S
carbon steel equipment in hydrogen service in
the syngas industry.
Charles Thomas, Principal Consultant, Quest
Integrity Group
Wednesday, 25 February
Wednesday, 25 February
10:30
10:30
Refreshment & Network Break
Sponsored by Stamicarbon
Session 4a: CO2 removal and
ammonia operations
11:00
Lessons learnt to extend the life and
reliability of molecular sieve beds in two large
ammonia plants
After the premature replacement of four charges
of Molecular sieves in two large Ammonia plants,
a detailed study was commissioned to analyse
for all possible causes of premature highpressure drop build up resulting in the significant
reduction of the life span of the beds. This paper
will share the lessons learnt.
V K Arora, Director – Process& Operations, KPI
(Kinetics Process Improvements Inc.)
11:30
Improved efficiency and lifetime reliability
with new hydraulic energy recovery design
for CO2 removal in ammonia plants
The CO2 removal in NH3 production is a
significant contributor to overall plant energy
consumption. The pressure difference between
the absorber and stripper represents an
opportunity for recovery. This paper presents a
new energy recovery solution with simplified
design, with high reliability and efficiency across
a wide range of operating conditions.
Andrea Gains-Germain, Director of New
Product Development, Energy Recovery
12:00
Reevaluating Advanced Control of the
Ammonia Process
Advanced control schemes, have been used
since the early 1970’s for ammonia plants. Over
the decades the tools have changed somewhat
but the goals and techniques have not. This
paper will take a fresh look at the problem being
addressed by optimization – variability – and new
techniques for solving the problem. The paper
will also show how plant personnel can evaluate
the economic impact of improvements in control.
James Gremillion, Agrichem Program Lead,
Emerson Process Management
12:30
Lunch
Organised by CRU Events
Refreshment & Network Break
Sponsored by Stamicarbon
Session 4b: Nitric acid catalysts
11:00
Minimize the total cost of ownership for the
customer with Heraeus catalytic systems
Heraeus offers two nitric acid catalyst gauze
systems aimed at saving operators’ costs. FTCHR is designed to minimize N2O formation and
can be supplemented, if necessary, with a
secondary N2O abatement catalyst to minimize
GHG liability. FTC-LL is designed to minimize
platinum losses, one of the most significant
operating cost elements.
Oliver Henkes, Senior Application Engineer,
Heraeus Materials Technology GmbH & Co.
KG
11:30
Rewriting the definition of clean
Platinum loss due to volatalisation and
mechanical losses is a significant cost
component in nitric acid production. This paper
will demonstrate a new technology which
provides a non-aggressive treatment of
superheaters and boiler sections to remove and
recover oxidised PGM’s.
Torsten Bünnagel, Principal Product Specialist Nitro Technologies, Johnson Matthey
12:00
Future improvements based on multi-layer
gauze technology in ammonia oxidation
Umicore has developed knitting technology for
creating sophisticated integrated threedimensional multi-layer ammonia oxidation
catalyst gauzes with superior mechanical
strength, activity and selectivity, lower overall
gauze weight and better metal-loss performance.
Christian Goerens, Manager Applied
Technology, Umicore AG & Co. KG (Platinum
Engineered Materials)
12:30
Lunch
Wednesday, 25 February
Wednesday, 25 February
Session 5a: Ammonia operations
Session 5b: Urea technology
14:00
Detection and localization of leakages in
toxic/flammable chemicals pipelines using
distributed fibre optic sensors
Pipeline leakages can have many different
origins and causes. This paper will present the
system architecture and installation of a fibreoptical distributed sensing system at an ammonia
production, storage and processing site. Results
of simulated leakage detection tests and longterm operation in normal operating conditions will
also be shared.
Roberto Walder, Sales Manager, Smartec SA
14:00
Latest trends in urea process technologies
A bird’s-eye view of the various commercial urea
processes, their historical and projected future
share of the urea plant market worldwide,
experience in the latest examples, and trends in
their process and materials technology.
Mark Brouwer, Director, UreaKnowHow.com
14:30
Case studies for reliable performance in an
ammonia plant
Referencing two heat exchanger design cases,
this paper will highlight industrial experience for
modified in-house design of the exchangers. This
resulted in simplified design for reliable operation
and improvement in process and ease of
maintenance at an optimum cost.
AP Shah, Vice President (Project Development),
Gujarat State Fertilizers & Chemicals Limited
14:30
Improving energy efficiency and enhancing
capacity of a urea unit through installation of
a Vortex Mixer in the urea reactor
Based on diligent study of the hydrodynamics of
urea reactors, NIIK has successfully installed
vortex mixers in the reactors of seven urea
plants, improving conversion of incoming
ammonia and carbon dioxide feeds to
ammonium carbamate and concomitantly
improving plug flow through the reactor.
Alexander Vorobjev, Senior Research
Engineer, NIIK (R&D Institute of Urea)
15:00
Sharing experiences of handling various
critical emergencies in a major fertilizer
complex
This paper will share the experience of handling
critical emergencies including: total outage
incidents of power, DCS, NG feedstock and fuel
supply; and major leaks of ammonia, chlorine
and hot potassium carbonate solution. The
actions taken to control and manage the
incidents will be shared.
Pothamsetti Harinarayana Reddy, Deputy
General Manager – Production - Nagarjuna
Fertilizers and Chemicals Limited
15:00
How rigorously plant modeling can advance
your urea business
Complex physical phenomena in the carbamate
and urea reaction give serious deviations when
applying traditional modeling tools. Over the
years, Stamicarbon has continuously improved
the thermodynamics of its models reaching a
point where accurate plant modeling is possible.
These products range from off-line applications
through real time optimizers (RTO), total plant
monitoring systems (TPM) operator training
systems (OTS) and finally SIRIUS@MAX®.
Luc Dieltjens, Senior Process Control Engineer,
Stamicarbon
15:30
Refreshment & Network Break
Sponsored by Stamicarbon
15:30
Refreshment & Network Break
Sponsored by Stamicarbon
Session 6a: Ammonia revamps
Session 6b:
Urea granulation technology
16:00
16:00
Increase of production capacity of existing
ammonia plants
This paper investigates the technical and
economic feasibility of a concept for a 30%
capacity increase in existing FSU plants. It will
detail how reforming capacity is increased by
adding an autothermal reformer, while capacity is
added to the ammonia synthesis by TKIS’ Dual
Pressure Process.
Organised by CRU Events
High speed drum granulation technology as a
method for urea unit capacity increase and
urea quality improvement
High sped drum granulation technology offers
multiple opportunities within a urea plant. This
paper will demonstrate how the technology can
be applied to prills fattening using urea melt,
resulting in improvements to the average size
and strength of the prills.
Dr Klaus Noelker, Head of Process Department,
Ammonia & Urea Division, ThyssenKrupp
Industrial Solutions
Natalia Kargaeva, Head of International Affairs
Department, NIIK (R&D Institute of Urea)
Wednesday, 25 February
Wednesday, 25 February
16:30
Successful ammonia plant revamping; A
model for future plant modernisation
This case study will present an overview of the
main interventions and results of a deep revamp
of a Russian ammonia plant based on GIAP and
TEC technologies that has resulted in an
increased capacity from 1350 to 2000MTD.
Sergio Panza, Syngas Process Manager,
Casale SA
16:30
Experience from Urea Plant Revamp at
Egyptian Fertilizers Company
Drawing on the experience of revamping two
EFC urea plants, this presentation will showcase
how a 17% capacity increase was achieved
through the installation of additional reactor
volume stripping, evaporation and condensation
capacity.
Stephan Buss, ThyssenKrupp Industrial
Solutions
17:00
Leading ammonia capacity upgrade
technologies
This paper discusses various capacity upgrade
technologies for each unit operation in ammonia
production, including reforming capacity
increases via CO2 removal solvent upgrades or
change-outs, ammonia synthesis reactor and
refrigeration system upgrades using a variety of
KBR technologies.
Mahesh Gandhi; Sr Process Manager, KBR
Technology
17:00
Optimized fluid-bed urea granulation process
minimizes capital investment and energy
consumption and improves product quality
GGT’s CRG (Cold Recycle Granulation)
technology was successfully brought into
operation in 2013 in a 3,000-t/d urea plant in
China. Operating with a lower fluidized-bed level,
special hydraulic urea solution sprays and slow
cooling of the product reduces the height and
CAPEX of the plant, cuts air consumption and
OPEX, and improves product quality.
Wang Wei; Director, Green Granulation
Technology
Ken Monstrey, Process Developer, Green
Granulation Technology
17:30
Close of day two
17:30
Close of day two
17:30
After-Session Drinks Reception (Exhibition Area - dress code casual)
Co-sponsored by BD Energy, Ortash, SBN
Organised by CRU Events
Thursday, 26 February
08:30
Welcome Coffee
Sponsored by Stamicarbon
08:30
Registration desk
Sponsored by Toyo Engineering
Conference Auditorium
Sponsored by Casale and Clariant
Stream A:
Session 7a: Compressors
Stream B:
Session 7b: Urea operations and
Fertilizer Finishing
09:00
Repair and modernization of chemical
compressor equipment
Revamping is vital for the nitrogen and methanol
industries of the former Soviet states, but often
that changes the operating conditions of the
compression equipment, resulting in increased
vibration. The paper describes modifications to
the seals, bearings and flow channels of existing
compressors which mitigate the problem and,
furthermore, improve their efficiency.
Martsynkovskyy Vasyl, Director, TRIZ Ltd
(LLC)
09:00
Operation of the world’s largest single train
urea plant with leaking Medium Pressure
Decomposer (MPD)
Following a leak in the MPD exchangers, which
resulted in a sudden increase in conductivity of
the steam and condensate system, and
subsequent increase in steam consumption in
the vacuum section, actions were taken to
enable continued plant operation until planned
outage. Issue faced during the continued
operation, actions taken during the plant
turnaround and failure analysis will be shared.
Asim Qureshi, Unit Manager Operations –
Ammonia2 Plant, Engro Fertilizers Limited
Syed Usman Ahmed, Urea Operations
Engineer, Engro Fertilizers Limited
09:30
Managing unforeseen oil flow across
modified syngas compressor oil seals to
minimize production loss
Modified oil seals fitted to FFCL’s high-pressure
syngas compressor to counter a vibration
problem were found after start-up to pass an
excessive amount of sweet oil beyond the
capacity of the seal oil supply pump. The paper
describes how the plant was kept in operation
until the OEM came up with a solution.
Ahsan Sarfraz, Section Head Offsite & Utilities,
Fatima Fertilizer Company Limited
Muhammad Hashim, Senior Production
Engineer, Fatima Fertilizer Company Limited
09:30
2005 – 2015: The first decade at the OMIFCO
Fertilizer Complex
The Greenfield OMIFCO complex was
successfully commissioned in 2005. This paper
will provide a retrospective of the experience in
operation, maintenance and engineering
programmes to improve the safety and capability
of the complex.
Alberto Carlo Serrafero, Urea Process
Manager, Saipem - Snamprogetti™ Urea
Technology
S.G. Gedigeri, CEO, OMIFCO
10:00
The latest designs and the proven
achievements for synthesis gas compressor
drive steam turbine modernisation
This paper introduces the latest designs with
high performance and reliability for syngas
turbine modernisation, where the turbine blade
has been designed for high speed and high
output power. A case study on the features of a
syngas compressor train recently installed on an
ammonia plant will be referenced.
10:00
Project Cool: Cooling CAN in shell and tube
heat exchanger
Gert-Jan de Geus, CEO, OCI Nitrogen
Organised by CRU Events
Norihito Fujimura, Senior Engineer
Norihisa Wada, Senior Adviser, Technology
Mitsubishi Heavy Industries Compressor
Corporation
Thursday, 26 February
Thursday, 26 February
10:30
10:30
Refreshment & Network Break
Sponsored by Stamicarbon
Refreshment & Network Break
Sponsored by Stamicarbon
Session 8a: Energy efficiency
Session 8b: Urea operations II
11:00
Use multi-stage integrated chilling to
increase ammonia production
This paper will present a new approach with
multi-stage chilling to de-bottleneck the limiting
process air compressor along with the other two
major compressors as well as the reforming
section to increase the ammonia plant capacity
with improved energy efficiency, which achieved
an additional 10% plant capacity with improved
energy efficiency in excess of 10%.
VK Arora, Director – Process& Operations, KPI
(Kinetics Process Improvements Inc.)
11:00
Prevention of a potential catastrophic failure
of a high pressure condenser in a urea plant
Leakages from the tube to tubesheet joints were
a frequent occurrence in a high pressure
carbamate condenser installed in a urea plant.
Subsequent inspection revealed improper repair
works as the primary cause. This paper will detail
the inspection and subsequent repair
procedures.
Roberto Gorza, Senior Mechanical Engineer,
Casale SA
11:30
Linde Ammonia Concept (LAC™) for
complete conversion to urea
Linde’s second generation LAC™ combines
proven process steps in such a way as to provide
flexibility in the H2/CO2 ratio in the synthesis
gas, allowing urea output to be maintained at a
constant level with or without production of
additional ammonia for other purposes.
Bernd Kandziora, General Manager Sales,
Linde AG Engineering Division
11:30
Urea stripper prototype repairs using micro
TIG welding
After 4 years of operation, initiation of typical
urea stripper issues relating to corrosion at tubeto-tube sheet joints and inner surface of tubes
near HAZ was recorded during inspection.
Successful prototype Micro-TIG welding repair
was employed to extend the life of a urea
stripper, enabling deferment of major capital
investment, and helped to maintain higher than
expected service factor of the equipment.
Muhammad Asad Waheed, Maintenance
Manager, Engro Fertilizers Limited
Omair Mazhar Qureshi, Warehouse & Contracts
Unit Manager, Engro Fertilizers Limited
12:00
Energy efficiency study & energy
management system for an ammonia plant
This paper presents the results of a
comprehensive energy efficiency study carried
out for an ammonia production site. As a
consequence of the assessment and analysis
carried out by DVA Energy Services, a number of
projects have been identified, each achieving
energy efficiency improvements, which are
expected to significantly reduce energy
consumption at the site.
David Velázquez, General Director, DVA Global
Energy Services sl
12:00
Practical solutions on operational trouble
cases
Due to high corrosiveness of ammoniacarbamate produced in the synthesis section of
urea plants, corrosion resistant materials have
historically been used. However, corrosion
related damage is still common over long-term
operation. This paper describes Toyo’s
experience of several instances of corrosion
related damage, the investigation undertaken to
identify the root causes, and the practical
solutions applied to rectify the damage.
Masashi Takahashi, Engineering Technology
Division, Toyo Engineering Corporation
12:30
Lunch
12:30
Lunch
Organised by CRU Events
Thursday, 26 February
Thursday, 26 February
Session 9a: Ancillary operations
Session 9b: Case studies from the
former Soviet Union
14:00
Incorrect level configuration of steam drum
can cause multiple issues at ammonia plant
Correct level measurement in the steam drum is
of extreme importance for smooth plant
operation. Incorrect measurement can case HTS
catalyst deterioration, BFW Turbine seal failure
and scaling in the steam header. This paper will
describe the root causes of incorrect level
measurement and the corrective actions taken to
avoid such a failure in the future.
Muhammad Azhar Malik, Production Manager,
Engro Fertilizers
14:00
Optimal integration of Topsøe’s ammonia,
methanol and hydrogen technologies at
Shchekinoazot, Russia
Shchekinoazot, replaced its old plant with new
production unit based on a two-step reforming
front-end with a capacity of 450,000 MTPY,
which was commissioned in 2011. This paper will
share operating experience from the 3+ years of
operation. The commission of a of a new 26,000
NmH3/h capacity hydrogen plant and new project
for the co-production of ammonia and methanol
which will add 130,000 MTPY of ammonia
capacity to the existing complex will also be
shared.
Maria Yanovskaya, Group Manager,
Technology, Haldor Topsøe ZAO
Anatoliy Surba, General Director, Plant
Shchekino Azot
14:30
High biological growth and air recirculation
caused significant performance deterioration
of cooling tower
This case study will discuss an incident where
sudden performance deterioration and drastic
increases in supply and approach temperature
occurred in a cooling tower, causing serious load
limitations in downstream plants. The paper will
highlight the analysis employed to pinpoint the
issue, and the hardware changes implemented to
overcome the issue.
Zubair Talhar, Process Engineer, Fatima
Fertilizer Company Limited
Ahsan Sarfraz, Section Head Offsite & Utilities,
Fatima Fertilizer Company Limited
14:30
Tatarstan Mendeleevsk fertilizer complex is
ready for start-up
A new large-scale fertilizer complex, comprising
of a 2050 T/D ammonia plant and a 2050 T/D
urea synthesis and granulation with coproduction of methanol of 667 T/D, is expected to
successfully commission in Q2 2015. This paper
will provide a detailed account of the key
milestones and lessons learnt.
Kinya Ishizawa, Mitsubishi Heavy Industries
Ltd
15:00
CO2 Management: From production
enhancement to energy storage
CO2 from flue gases constitutes a value product
when recycled as chemical feedstock or used for
other value chain applications. This presentation
will discuss the use of CO2 for urea and
methanol production enhancement as well as its
valorization in the production of Synthetic Natural
Gas (SNG) utilizing hydrogen available from
excess renewable resources.
Gianluca Di Federico, Business Sales Manager,
ALSTOM Carbon Capture GmbH
15:00
Increase of capacity by 35% and efficiency
raise of the technological air centrifugal
compressor 101J in ammonia production
Aleksandr Liubimov, Leading Specialist on
Centrifugal Compressors, Entechmach RPC
LLC
15:30
Close of conference
15:30
Close of conference
Organised by CRU Events