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Nitrogen 2014 Programme 25 Oct
Nitrogen 2014 Programme 25 Oct
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Fertilizers &Chemicals
Pre-Conference Full Day Workshop Monday 24 February, 09:00 17:00 Improving Safety, Reliability and Performance of Urea Plants
- 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 rst class urea product Organised by UreaKnowHow.com
N.B. This is a separately bookable event. Special price for delegates attending the conference + workshop. See back page for details >>>
10:30 Networking break sponsored by Product stewardship 11:00 Product stewardship and the nitrogen industry - Product stewardship: engaging with policy makers on legislative issues - Product safety and industry reputation - Increased nutrient use efciency: agronomically viable alternatives Rosemary OBrien, Vice President, Public Affairs, CF Industries Feedstock Scenario 11:30 Global Gas Outlook: Supply, Demand and Changing Flow Dynamics - Global pricing outlook - Regional snapshots - How will shale and other unconventional gas resources impact? Speaker tbc 12:30 Methanol Fuel Drivers: Public Policy, Economics, Energy and the Environment - Key drivers leading the resurgence of interest in methanol fuels: - Public Policy directives - Energy efciency gains - Positive economics - Environmental benets Gregory Dolan, Executive Director Americas/ Europe, The Methanol Institute 12:45 Networking Lunch sponsored by
N.B. Programme is provisional and subject to change
Commercial Programme
Auditorium sponsored by 08:50 Welcome from CRU Nick Edwards, General Manager, Fertilizers, CRU Global & Regional Outlooks 09:00 Mega Trends in the Nitrogen Industry - Market oversupply - Chinese export potential - Sub-Saharan Africa nally? - Commodity gas - Investment: Where next? Alistair Wallace, Senior Consultant, Nitrogen, CRU 09:30 Panel Discussion: Africa as an emerging market for Nitrogen investment - Long and short-term investment prospects - Current fertilizer scenario in Africa - Upcoming project details - Demand drivers: examining the agricultural potential of the region Alexander Singleton, Consultant, CRU Murari Mohan Rakshit, General Manager, Fertilizer Division, Olam International Speaker tbc, KBR Technologies Speaker tbc, International Finance Corporation
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Fertilizers &Chemicals
Stream One
Session 1A: Synthesis Gas Generation & Purication 09:00 Operational and Performance Improvements in Foster Wheeler Terrace Wall Reformers R. Basse (Foster Wheeler Fired Heater Division) Many improvements have been made in the terrace wall primary reforming furnace since its introduction in the early 1960s, resulting in greater reliability and easier operation and maintenance, as feedback from plants built in recent decades attests. Many of them can be retrotted in existing furnaces, while modularization has also reduced construction time for new units. 09:30 Operating Experience in a BASF aMDEA Carbon Dioxide Removal System M K. Butt (Engro Fertilizers Ltd) Engro recently commissioned very successfully a CO2 removal system using BASFs aMDEA process. The paper describes the companys experience during precommissioning, commissioning and normal operation and describes some modications made in response to particular incidents. 10:00 Economics of Ammonia Production from OffGases V. K. Arora (Kinetics Process Improvements, Inc.) The relative merits, energy efciency and economics of producing ammonia from off-gases from sources such as methanol, carbon monoxide and ethylene plants will be compared, taking account of the various available techniques for purifying the synthesis gas and of environmental benets. A specic case study will be presented. 10:30 Q&A 10:45 Networking break sponsored by Session 2A: Ammonia Plant Modernisation 11:15 Modernization Technologies for Synthesis Gas Compressor Drive Steam Turbines to Increase Efciency, Operability and Reliability N. Fujimura (Mitsubishi Heavy Industries Compressor Corporation) The turbine drives for ammonia synthesis gas compressors can be upgraded very substantially while retaining the original casing for example, by changing the design of the blades, replacing mechanical steam governing
N.B. Programme is provisional and subject to change
Stream Two
Session 1B: Urea Equipment 09:00 Design Evolution of the Urea Reactor A. C. Serrafero (Saipem Snamprogetti Urea Technology) As one of the key equipment items in the HP section of the urea plant, the Snamprogetti Urea Technologys reactor is under constant development. The paper will trace this development over the years, analyse reactor experience and describe an innovative technique for site assembly recently applied in a large-size plant. 09:30 Granulation Technologies: A Remarkable and Proven Way to Substantially Enhance Urea Plant Capacity A. Scotto (Casale Group) A report on the rst implementation in China of Casales proven Split Flow / Full Condenser advanced technology for upgrading urea solution plants and its new Vortex Granulation technology for increasing the output of urea prilling units and improving the quality of the product. 10:00 Equipment Management: Effective Solutions A. Chirkov (NIIK) Each year NIIK inspects 10-20 urea plants, with a total count of the inspected items exceeding 5500, diagnosing corrosion and evaluating technical condition of the equipment, using the full range of inspection techniques appropriate to each. This kind of comprehensive approach to equipment management is needed to assure best performance and reliable operation of production units. 10:30 Q&A 10:45 Networking break sponsored by Session 2B: Urea Finishing 11:15 Improving Prill Product Quality and Reducing Emissions from Urea Prill Towers A. J. Cadena (Graham Corporation) The amount and, therefore, the cost of the formaldehyde added to improve the inherently poor crushing strength of prilled urea depend on the moisture content of the melt, which in turn depends on the vacuum maintained in the evaporator. The paper examines causes of poor vacuum performance and ways of overcoming them.
Stream Two
11.45 High-Efciency Scrubbing Technology for Urea Granulator Exhaust W. Dirkx (Stamicarbon BV) Stamicarbon and EnviroCare have developed a highly efcient ve-stage scrubber technology, which is now integrated with Stamicarbons second-generation uidized-bed urea granulation technology. It comprises acid scrubbing to capture ammonia as ammonium sulphate and highly efcient mist elimination for submicron and condensable particulates. 12.15 New Urea Plant Construction in the USA: Plan to Use Indirect Coolers to Reduce Energy Consumption P. Moran (Solex Thermal Science Inc.) Indirect product coolers cost substantially less to run than the familiar uidized-bed type on account of their substantially lower energy consumption and could thus provide economic benets to the companies now launching urea projects in the USA to exploit the shale gas boom. The paper will discuss design aspects and CAPEX and OPEX considerations. 12.30 Q&A 12.45 Networking Lunch Session 3B: Panel Discussion: Safety 14:00 Safe Reduction of ShiftMax 217 at Low Temperature W. Kaltner (Clariant) Implementation of the API RP 584 Integrity Operating Windows Methodology at the Gibson Island Ammonia Manufacturing Plant C. Thomas (Quest Integrity Group) 15.15 Networking break sponsored by
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Stream Two
Session 4B: Methanol Technology 15.45 Proven Autothermal Reforming (ATR) Technology for Modern Large-Scale Methanol Plants P. J. Dahl (Haldor Topse A/S) ATR offers distinct benets as a large-scale source of methanol synthesis gas. It operates at a low S/C ratio and produces a synthesis gas with a suitable composition for methanol synthesis; and a single ATR can supply a 10,000+ t/d methanol plant. This paper describes Topses experience, and comments on process conditions, catalysts and design requirements. 16.15 Methanol Synthesis from Carbon Dioxide: Comparison of Novel Possible Process Schemes M. Bahmani (Petrochemical Research and Technology Company, National Petrochemical Company) Although CO2 rather than CO appears to be the chief reactant in the synthesis of methanol, a pure H2/CO2 mixture does not give good yields because the CO2 adversely affects the catalyst. But, as PRTC researchers have found out, methanol can be made from an H2 / CO2 mixture if it is rst subjected to the reverse water gas shift reaction in a separate reactor. 16.45 Application of ALSTOMs Chilled Ammonia Process in the Methanol Industry P. Arnold (Alstom Carbon Capture GmbH) G. Di Federico (Alstom Carbon Capture GmbH) Originally designed for the power industry, the chilled ammonia process is especially suitable for providing supplementary CO2 feed to a gas-based methanol plant as it uses ammonium carbonate solution as the solvent for absorbing ue gas CO2. This is much cheaper than the amine solutions used in other processes and does not contaminate the CO2 with VOCs. 17.15 Q&A 17.30 Close 17:30 Drinks Reception sponsored by
Stream One
Session 1A: Measurement & Monitoring 09:00 Lasers Enhance Safety and Environmental Performance in Ammonia and Urea Plants H. Adam (Boreal Laser Inc.) Laser gas detection is a high-resolution measurement technique which gives a gas-specic response that greatly reduces the risk of both missed detection and false alarms. This paper presents experience and data from the successful implementation of Boreal Laser ammonia monitors in a variety of applications in ammonia and urea plants. 09:30 Benets of Clamp-on Ultrasonic Mass Flow Meters for Optimization of Urea Production Processes J. Wylamrzy (FLEXIM GmbH) Being non-intrusive, the external ultrasonic ow metering device described does not increase the risk of corrosion or leaks and can be tted simply by clamping it onto a pipe or vessel. 10:00 Reliable Sampling and Analysis of Raw Syngas P. Van Vuuren (Kaiser Analytics) On-line analysis is problematic if it depends on the transmission of a sample of a hot process gas containing condensable or solidiable components to a remote analyser. In the system described in this paper the sensor of the analyser is located on the process gas line and transmits a signal to the analyser through a bre-optic line. 10:30 Q&A 10:45 Networking break sponsored by
Stream Two
Session 1B: Nitrates & Nitric Acid 09:00 New Developments Down to the CORE T. Buennagel (Johnson Matthey Noble Metals) In the economy of today nitric acid producers are obliged to run their plants at peak output from the outset of the campaign. This places unprecedented demands on the catalyst. Drawing on improved understanding of the chemical reactions involved, Johnson Matthey has developed EcoCat CORE with the exibility to operate at full efciency from the very start. 09:30 Fluidized Drum Granulation Technology and its New Industrial Application for Calcium Ammonium Nitrate S. Valkov (SNC-Lavalin) SNC-Lavalin provided a new 1,335-t/d CAN plant using a uidized-drum granulator to replace SASOLs old pugmill-based plant, which was basically worn out. The paper sets out the reasons for the choice of this technology and describes the process, the project and problems during commissioning. In July this year the plant achieved 112% of rated capacity. 10:00 Heraeus Technical Service Portfolio for Nitric Acid Plants T. Keller (Heraeus Materials Technology GmbH & Co. KG) Good back-up service from the catalyst supplier is vital for a nitric acid plant operator in case of unexpected problems involving the catalyst gauzes that he might not be able to deal with alone. The paper provides examples of ways in which Heraeus is able to troubleshoot catalyst problems and help minimize their clients production losses. 10:30 A unique system for purication of contaminated condensates for any ANS Process J.F. Granger (Borealis Chimie) J.B. Peudpiece (Borealis Chimie) Borealis Chimie SAS has developed, installed and is operating technology to purify the ANS process condensate produced by different ANS Processes. This technology is currently in operation in plants were the neutralization reaction is carried out at atmospheric pressure and at higher pressure; up to 5 bars; and with a production capacity from 250 to 1800 MTPD without consumption of imported energy. As a result of the treatment, most of the Process condensate can be released with an AN content below 50 mg/l.
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Stream One
Session 2A: Ammonia Operations & Maintenance 11:15 Unique BMR Experience of 25-Year-Old Second-Hand Ammonia Plant S. Z. Ali (Fauji Fertilizer Co.) Acquired by FFC in 2002, the former Pak-Saudi Fertilizers nitrogen complex had a poor record in all respects - operation, maintenance, environmental and energy-efciency. The paper describes how FFC set about rectifying these problems, raising the capacity by 25%, reducing energy consumption by around 10% and conforming to all environmental standards. 11:45 Inadequate Preservation Resulted in Major Issues at Ammonia Plant A. R. Qureshi (Engro Fertilizers Ltd) The restart of Engros ammonia plant after a 6-month interruption in gas supply was delayed by unexpected corrosion problems in various parts of the plant. This prompted a critical review of the companys procedures for mothballing the plant and monitoring its condition during the period of the shut-down. 12:15 Unique Experience in Handling and Solving Heavy GV Solution Carry-over Problem in Ammonia Plant P. Harinarayana Reddy (Nagarjuna Fertilizers & Chemicals Ltd) The paper catalogues a number of measures employed to cure a persistent serious problem with solution carryover from the GV CO2 removal unit serious because the organic activators from the GV solution ended up in the process water stripper off-gas, which was being fed to the primary reformer. 12.45 Q&A 13.00 Networking Lunch 14.30 Close of conference
Stream Two
11:00 Q&A 11:15 Networking break sponsored by Session 2B: Urea Operations & Maintenance 11:45 Challenges Encountered During Early Operation of a 3,835-t/d Urea Plant M. Mukhtar (Engro Fertilizers Ltd) Successfully commissioned in 2010, Engros new urea plant had to be idled in 2011 for lack of natural gas, and when it reopened in 2012 it was operating on lower-grade gas from an alternative source. The major challenges faced during its early operation will be highlighted. 12:15 Features of Final Cooler Maintenance in Synthesis Gas Compression Units in Fertilizer Plants Case Study A. M. Mosbah (Abu Qir Fertilizers & Chemical Industries Co.) The performance of the nal cooler in the make-up gas supply has a direct impact on the efciency of the synthesis loop. Abu Qir has tackled repeated problems with leaking tubes by mechanical tube plugging, regular chemical washing and closer monitoring to provide early warning of tube fouling and initiate preventive maintenance. 12:45 Troubleshooting Urea Load Limitation How Misleading the Process Indications Could Be A. Munem Alnajjar (Gulf Petrochemical Industry Co.) Malfunctioning of a replacement HP carbamate ejector installed during the 2010 turnaround was initially thought to be to blame for a capacity-limiting problem that developed 18 months into the operating campaign. But at the 2012 turnaround the cause was found to be something completely different. The paper tells the story. 13.15 Q&A 13.30 Networking Lunch 14.30 Close of conference