2 24th AFA IInt’l. Te echnical F Fertilizerss Confere ence
Session I
S Sessio on I
Chairp person: Samii AMARNEH QES Man nager – T The Arab Potash C Company y
1
DAP P & Phosph horic Acid P Plant Improvement Mr. John Wingg - Phosphate Consultannt
JJohn Wing, P.E.
U USA
2
Phossphate Plan nt Yield Com mparisons Mr. R Richard D. Harrison – Process Suppervisor / Feertilizer Connsultant
P PegasusTSII Inc.
U USA
3
Noveel Large Sccale Energy Efficient T Technology ffor Urea Prodduction Mr. R Rinat Anderrzhanov, Deeputy Technnical Directoor of Innoviiations
R R&D Instittute of U Urea
R Russia
4
Guaranteed (Riisk Free) En nergy Savin ngs in Wateer and Steam m Systeems through gh Avanceon n's Propriettary "iwaterr" & “iboileer” Mr. A Armaghan Y Yusuf – Bussiness Manaager
A Avanceon
P Pakistan
5
Utillization of S Satellite Imaage To Imprrove Solar Ponds P Prodduction Mr.: Zaid Halassah - Seniorr Chemist
APC C
JJordan
24 4th AFA In nt’l. Tecchnical Fe ertilizers Conference D DAP & PH HOSPHORIIC ACID PL LANT IMP PROVEMEN NTS ng - Phosp phate Conssultant Mrr. John Win John Wing, P.E E. - USA Abstrac ct: A selecttion of attra active mod difications a are describ bed, based on successsful projeccts. DAP inn novations include: D Dual Mole R Reactor-Grranulator A Acid Scrubb bing B BFL Vaporiizer/Scrubb ber - Vaporizes all am mmonia witth free hea at from air le eaving th he reactor--granulatorr acid scrub bber. This unit provid des a 3rd sttage of sscrubbing – potentially eliminatin ng need fo or any tail-g gas scrubbe er. P Product Screen Diverrter System ms – easy capacity c inccrease A Automated Recycle C Control - co ontinuouslyy monitors recycle r parrticle size a and a adjusts process to kee ep size in m mid-range.. D Dual diame eter reactorr (pre-neutralizer) P Pipe Reactor C Cooler Air C Chiller T Tran-Tech Product Co ooler Phosphoric Acid p plant projeccts to consider include e: C Conversion n from Dihyydrate to Hemi: Make es acid at 4 42% concen ntration vs. ~27% N No need for most eva aporation. Usually U no rock grinding is need ded. C Conversion n to Hemi-D Di – similarr benefits plus p 98.5% recovery & clean gyp psum U Utilize gypssum – man ny ways to make gypssum an assset rather tthan liabilityy R Recover uranium – m major investtment with high profit potential R Recover flu uosilicic aciid – high-purity grade e for AlF3 fe eed A variety off profitable uses for p phosphogyp psum A Advances in dry gypssum stackin ng P Purify phossphoric acid d to techniccal or food grade Project manageme ent and sta art-up issue es are disccussed
Session I
24th AFA Int’l. Technical Fertilizers 2 F s Confere ence P Phosphate e Plant Yielld Comparrisons Rich hard D. Ha arrison – Prrocess Sup pervisor / F Fertilizer Co onsultant PegasusTSI In nc. - USA
Abstrac ct: Introducction - PegasusTSI Core C Busine ess Activitie es Estimated Range of P2O5 Losses to G Gypsum Sta acks Processs Changes to Reduce e Phosphatte Losses: ◦ Eliminate off-site e discharge es ◦ Reducce phospha ate flow to gypsum sttack ◦ Identiffy opportun nities to reccycle proce ess water ◦ Redire ect fresh wa ater make--up to gypssum stack Processs Alternativves 1. Site selection s and climate conditionss - typical p plants, Florrida and N. Africa 2. Open n Circuit Prrocesses – no recove ery of pore moisture P P2O5 3. Close ed Circuit P Processes – some recovery of p pore moistu ure P2O5 4. Proce ess Water Recycling 5. High Strength F Fluoride Re ecycle 6. Impro oved Wash hing and/orr Double Fiiltration 7. Non-C Contact Evvaporator C Condenserr Cooling 8. Calcination
Session I
2 24th AFA Int’l. Te echnical F Fertilizerrs Confere ence Novel L Large Scalle Energy E Efficient T Technolog gy for Urea a Productiion Mr. Rinat R Ande erzhanov, D Deputy Tecchnical Dire ector of Inn noviations R&D Ins stitute of U Urea – Rus ssia
Abstrac ct: R&D Institute of Urea U is a leading en ngineering company focused o on the devvelopment of ed producttion techno ologies tha at help our custome ers to cut ttheir energ gy and fee edadvance stock co osts, impro ove safetyy and ecolo ogy efficiency. R&D Institute o of Urea is an owner of propriettary license es and “kn now-hows” for the m majority of urea u techn nologies allowing us to offer sta ate of the a art solutionss to increase plant prroductivity. By the present m moment we have de eveloped technologie t es for con nstruction of low-sca ale (URECO ON 2006®) and avera age-scale (URECON N 2007®) urea plants.. To be a able to pro ovide comp plete service and to be on the e edge of modern tre ends in urrea industryy we’ve devveloped an n energy-effficient technology fo or constructtion of larg ge-scale urrea plants (ccapacity ovver 2000 tp pd) that corresponds to the pressent enviro onment and d operation nal effective eness requ uirements. The keyy features o of our adva anced technology are e: - Synthesis reacto or operate es at 200 b bars and is equipped with a set s of interrnal device es, including Vortex M Mixer, Long gitudinal Se ectioning E Element and d Trays. melt separation at se everal stages during tthe synthe esis reactio on helps to reduce he eat - Urea m losses and a increasse the efficciency of diistillation process. - Stripping distillattion in CO2 2 flow at 9 90 bars allo ows achievving higher process performance e operating g period of the strippe er due to le ess wearing g service cconditions. and prolonging the merged carrbamate co ondenser o operating a at 90 bars provides e efficient reccuperation of Subm the proccess internal heat to g generate 3 Bar steam m. - Doub ble-stage melt distillation red duces the equipmen nt costs compared with oth her technolo ogies. ment lay-ou ut as a result of the ssynthesis a and HP disttillation units working at - Simpliffied equipm differentt pressure.. Thus, the e HP equipment can b be position ned at a low wer height that reducces investm ment and co onstruction and assem mbly costs for the ere ection of a urea unit. nstitute of U Urea techn nology can be used fo or the consstruction of a new urea Innovatiive R&D In unit as w well as forr the rehab bilitation of an existing g plant with total liqu uid recycle process, but b for it to be the mo ost rational investmen nt there should be at least 2 un nits at a pla ant. Capaccity es up to 60 0% and ene ergy costs deplete su ufficiently (reaching 5 50% for steam). increase R&D Insstitute of Urea U univerrsal techno ology for la arge capaccity units iss a compettitive solution for urea a production n providing g perfect op perational and econo omical perfo ormance
Session I
24th AFA Int’l. Te 2 echnical Fertilizer F rs Conference Gu uaranteed (Risk Free e) Energy Savings in n Water an nd Steam Systems through t Avan nceon's Prroprietary "iwater" & “iboiler”” Mr. Armaghan Yusuf – Business Manager M Ava anceon – P Pakistan
Abstrac ct: Water a and steam systems are big enerrgy cost ce enters in a fertilizer plant. Everyy facility takkes necessa ary measu ures to minimize the e energy consumption in orde er to bette er align w with corporate objectives of impro oved qualitty, profitability and en nvironmentt sustainability. er certain q questions d do arise wh hile initiating energy ssavings pro ojects, som me are; Howeve Who gu uarantees the savingss and what if savings are not acchieved? Will my manufactu uring proce ess be distu urbed? Project Involves high capital investmen nt!!! I need a specific ROI or IRR R to investt; Energy o optimization is not myy businesss and am n not sure if I can manage it to ach hieve my financial go oals. Avanceon, a US based syystem integrator and d energy m manageme ent compa any, offerss a uce energ gy consum mption in water w and d steam ssystems w with unique partnership to redu ely no finan ncial risk to o customerrs. absolute The paper brieflyy describess Avanceo on’s “iwate er” and “ib boiler” pacckages, the e concept of guarantteed (no rissk) savingss, and dettails of projjects at En ngro Fertilizer Limited d and Nesstle Pakistan n respectivvely. Utiliza ation of Sa atellite Ima age to Imp prove Sola ar Ponds Production P n Mr. Zaid Halaseh/ S Senior Che emist APC – Jo ordan Abstrac ct: The use of satellite iimages is wiidely used inn many applications all around the world. Thiss paper revieews the usagee of satellitee imagery to improve thee efficiency of the contrrol and increease the prodductivity of the solar ponnds system at the Arabb Potash Coompany that used to prooduce Carnaallite ( the raw martial of potash). d therm mal Satellite images weree processed using special software like Infograagh and Irdasss to have density, and depthh profiles which w used too improve thhe process coontrol and ppredict for fuuture actionss. The data aand the final images weree saved in sppecial softwaare as an arcchiving and ccomparison system (ArccMap GIS) Infrared layer of the image was used to checck for seepaage of the brrine from thee solar pondds and to loccate the areas of any susppect sink holees. The mainn benefits off processing the satellite images for the t Arab Pottash companny are: 1. Improvve the proceess control off the solar poonds system m. 2. Plan thhe salt dredgging works inn the solar ppond system by calculatinng the salt ggrowth in eacch subarea, locatinng any closeed area arounnd high denssity brine annd evaluate thhe dredged aareas. 3. Locatiing any suspected sinkhoole (coordinaates) and thee risk of thesse sinkholes on the systeem and the dikes. 4. Locatiing the reverrse flow of thhe brine in thhe solar ponnds system annd set the rigght solution for this phenoomenon.
Session I
S Sessio on II
Chairp person: Mr. John Wing Phospha ate Consu ultant– JJohn Wing P.E. - U USA
1
The major ressearch activvities of the Research In Institutes forr Fertilizers (JS SC “NIUIF”) Mrr. Yuri Cherrnenko – Geeneral Direcctor
JSC “N NIUIF” R Russia
2
FS SA Neutralizzation with Calcium C Compounds Mrr. Salah Albuustami - Prrocess Enginneer
JACOB BS
U USA
3
Caatalysts for S Sulphuric A Acid and Am mmonia Plaants Mrrs. Ayten Y Y. Wagner – Arae Man nager – Catyylest Deevision Mrr. Henrik Laarsen - Geneeral Manageer, Marketinng & Sales Synnthesis
Haldorr Topsoee
D Denmark
4
IJC C Experiencce on Revam mping of Su ulfuric Acidd and Phosphoric Accid Plants Mrr. AWINASH H PESHWE,, PLANT HE EAD
IJC
Jo Jordan
5
Repplacement of o High Prressure Scru ubber in SA AFCO-II Urrea Plant Mrr. Bellary M Muhammad U Usman – Maaintenance Supperintendennt
SAFCO O
S. Arabia
2 24th AFA Int’l. Technical F Fertilizerss Confere ence The m major resea arch activiities of the e Research Institute es for Ferttilizers (JS SC “NIUIF””) M Mr. Yuri Che ernenko – General Director D JSC C “NIUIF” - Russia
Abstrac ct: The paper describess the main research acctivities of Russian R Research Insttitute for Feertilizers (JS SC “NIUIF””) and showss technologiical processees developedd by this Institute that hhave been im mplementedd at Russian mineral m fertiilizers plantss and plants located in thhe former Sooviet Union sstates
FSA N Neutralizattion with C Calcium Co ompounds s Mrr. Salah Alb bustami - Process Engineer J JACOBS – USA
Abstrac ct p g emissionss, phospha ate As environmental regulations continue to restrict chemical processing perators w will eventually be re equired to neutralize e fluoride w waste matterials. Mo ost plant op phospha ate plants currently use direcct contact barometriic condenssers with recirculating cooling pond wate er that is ssaturated with w fluorid de salts. M Most of thiss fluoride iis allowed to precipita ate as the recirculating water ccools in large cooling g pond sysstems. Wh hen forced to treat flu uoride con ntaminated water, ph hosphate producers p typically use u lime or o limestone neutralizzation prio or to disch harging efffluent. A better b envvironmental alternativve is to use scrubbe ers to remo ove fluoride es as fluosilicic acid p prior to con ndensing th he vapors iin baromettric condenssers. If a m market can nnot be fou und for the e fluosilicicc acid, it ca an then be e neutralized with phosphate ro ock to produce a we eak phosp phoric acid. This tech hnique is not curren ntly used be ecause it is not profiitable. Thiss paper discusses F Fluosilicic A Acid neutra alization w with several calcium co ompounds such as ph hosphate rock, r lime and a limesto one.
S Session III
24th AF FA Int’l.. Technical Fertilizzers Confference
Session n II
Catalysts for C f Sulphu uric Acid a and Ammo onia Plants s M Mr. Henrik k Larsen – General Manager M , Marketing g & Sales S Synthesis s Mrs. Ayten Y. Wagner – Area Man nager – Ca atylest Dev vision Haldor T Topsoe – D Denmark Abstrac ct: The firsst Part of this t paper describess case storries disclossing some e of the op perating experien nce we havve gained on VK69 and a VK-701 1 LEAP5TM M. For many sulphurric acid pla ants the bo ottleneck ffor prolong ged operatting time between b Mr. Henrrik Larsen plant sh hutdowns iss the scree ening requiirement of Bed 1 due e to increassed pressu ure drop build-up p caused byy plugging by dust prresent in th he feed gass. An imprroved prote ection against pressu ure drop bu uild-up can be obtaine ed by the use u of a dust pro otection ca atalyst in the top of Bed 1. In 2007 Top psee introd duced a ne ew dust protectio on catalystt in the sha ape of a 25-mm Daissy. Installa ation of a 1 15 cm top layer of this uniq que VK38 dust prote ection cata alyst resultts in a dou ubling of th he operatin ng time between n screening gs comparred to the 12 1 mm Daisy. Conseq quently, the number of timeconsum ming and exxpensive sh hutdowns ffor catalystt screening g is reduced and at th he same time significcant saving gs in blow wer energy result from m the lowe er pressurre drop. o 80 installlations with h 25 mm Daisy D dust p protection catalyst c 1oday, 4 years latter, close to are in operating arround the w world. Mrs.Ayten n Y. Wagner The seccond part o of this pape er discloses actual op perating exxperience o obtained fro om one of our 25-mm daissy dust protection insttallations. Advanc ced Reform ming Tech hnology fo or Ammonia Plants Haldor Topsoe AffS (Topsoe e) suppliess a full ran nge of refo orming tecchnologies which also o includess heat exgy. The Ha aldor Topssoe Exchan nge Reform mer (HTER R) technolo ogy is app plicable to change reforming technolog echnologiess such as ssyngas, hyydrogen. methanol, m an nd ammon nia. many te This paper describes how th he HTER ttechnologyy .is adopte ed in an ammonia pllant and what w benefits can be offered to the amm monia indu ustry. For a new amm monia plant, impleme enting the H HTER redu uces the siize Of the and due to o high reforrming temp perature sttill retains a low meth hane slippa age, which is crucial primary reformer a monia produ uction. for amm Variou us options are availab ble for a ca apacity incrrease in the e front-end d of an amm monia com mplex. Out of o these conve ective gas heated refo orming sta ands out ass an attractive option from both a technical as well ass a cost effective perspectivve. The Halldor Topsie e exchange e reforme er (HTER) ttechnologyy is a prove en revamp option wh here a capacity increase of 20 --25 % can easily be achieve ed, while the methane e leakage iss retained at a low level. The HTER teleology has now w been in ssuccessful commercial operatio on since: ea arly 2003. A full size industrial amped with h an HTER R installed d downstream m of an Au uto thermall Reformer (ATR), this has unit hass been reva resulted d in a 33% increase in n reforming g capacity.
2 24th AFA IInt’l. Te echnical F Fertilizerss Confere ence
Se ession II
IJC E EXPERIENCES ON R REVAMPIN NG OF SUL LFURIC AC CID AND P PHOSPHO ORIC ACID D PLANT TS Mrr. AWINAS SH PESHW WE, PLANT T HEAD IJC – Jorrdan Abstrac ct: Freque ent failure e of High P Pressure Scrubber in SAFCO O-II Urea Plant cau used continu uous prod duction los ss. After several shut downs and repa airs equip pment reliability could not be e achieve ed to operrate the p plant at de esigned parameter p rs.
In orderr to overcom me the challlenge on plant reliability, SAFCO Manageme ent decided d to take the e challenge e to replace e the equipment with h upgraded material in n May 2011. Manufac cturing of new Scrubbe er, Air lifting of 65 T new Scrubbe er and repla acement wa as done suc ccessfully in n short time to put the plant back in o operation.P Paper Conte ent ( not lim mited to the e below, few w more poin nts may be added) 1. OBJEC CTIVE 4. PRE-SD PREPARTIONS S 5. EXECUTION 2. PROJE ECT SCOPE E N (SD PHAS SE) 6. SUCCESS VALUE 3. CHAL LLENGE IN H HAND V 7. SUCCESS STORY S of any pro ocess is limitted by the low west capacityy steps in the e process. enecking like waste heat b boiler limitatio on, sulfur flow w restrictionss, inadequacyy in cooling ssystems & Our IJC’ss experiencess on debottle proposal of capacity enhancemen e t with improvved efficiencyy are discusssed.
Replacement off High Pre essure Scrrubber in SAFCO-II Urea Plan nt M ntendent Mr.. Bellary Muhammad Usman – Maintenan ce Superin AFCO - S. Arabia SA
Abstrac ct The Ind do Jordan Chemicalss Companyy is commiitted for itss continual improvem ments in bo oth operatio onal and safety fielld at its Eshidiya ccomplex ccomprising of sulfurric acid and phospho oric acid pllants. IJC is having h 200 00 MTPD sulfuric a acid plant based on Monsanto o’s Double e Conversion Double Absorption n process and 700 M MTPD of P2 2O5 phosp phoric acid d plant bassed on Hyd dro Agri’s ssingle stag ge hemihyd drate proccess. Both h the proce esses are in operattion with ffull capacityy since its commissio c oning. Normallly the proccess plantss will have 10-15% extra margin than the e nameplate capacitie es. We see e lots of plants are e expande ed to high her capacitties throug gh modern nization and optimiza ation. Debottleneckin ng for incre emental ca apacity costs less th han the ne ew plant and only it re equires corrrect evaluation studies. enecking iss like remo oving the w weakest link in a chain, maximu um producction capaccity Debottle of any p process is llimited by tthe lowest capacity stteps in the process. Our IJC C’s experie ences on debottlene ecking like e waste h heat boiler limitation, sulfur flo ow restrictio ons, inade equacy in cooling ssystems & proposal of capaccity enhancement w with improve ed efficienccy are discu ussed.
Se ession III
Chairp person: Mr. S Saed BOK KISHA P Plant Ma anager - Ruwais F Fertilizer Industrie es (Fertil)) U UAE
1
Meeeting enviroonmental isssues facingg new and eexisting ureaa Flu uid –bed Graanulation w with Plants Mr.. Harald Fraanzrahe – P Process Mannager
Uhde F Fertilizer Netherlan nds Technoology B. V.
2
Revvamping off a Conventiional Total R Recycle Ureea Plant Mr.. Narayansaamy Selvaraj aj – Head off Urea -1 Pllant
QAFC CO
Qatar
3
Besst-practice on o RBI drivven Integrityy Assurancee from Con ncept to Impplementatioon Mr.. salah Abduulaziz Zainaaldin - Senioor Inspection Engineer (Deesignated).
GPIC
Bahrain
4
Heaalth, Safety and Enviroonment in Fertilizer F In ndustry Storry behind A APC Successs in achieviing 40000000 MHW Frree of LTI-s L Mr.. Sami Amarrneh/ QES M Manager
2 24th AFA Int’l. Technical F Fertilizerss Confere ence
APC
Jordan
Session IIII
Meetin ng environ nmental is ssues faciing new an nd existing g urea Flu uid –bed G Granulation n with Plants Mr. Harald Frranzrahe – Process M Manager Fertilizer T Technology B. V. – N Netherland ds Uhde F
Abstrac ct: In recent years m many environmental regulation ns have be een amen nded by th he regulato ory ed to a sign nificant red duction in the permisssible emisssion levels for bodies. This has le ammonia and urea dust for new urea fluid-bed granulation g n plants. Bu ut existing plant operrators are also faced d with the e demands from their environme ental autho orities to red duce their emissions to the envvironment. While th he reductio on of dust emissionss can be a achieved b by using sccrubbing ssystems wiith higher separation n efficienccy, reducin ng ammonia a emission ns in a urea a granulatio on plant is more com mplicated. In n principle significantt ammonia reductio ons can b be achieve ed by insta alling acidic scrubbing system ms well kn nown in th he fertilizerr industryy. In NPK or AN plan nts the ressulting blee ed stream ffrom the accidic scrub bber can be e reintrodu uced into th he processs without any difficu ulty, as in th hese plantts the bleed d contains componen nts which a are alreadyy present in n the plantt For a urea fluid-bed g granulation plant the ssituation iss more com mplicated. In this case e the bleed d and the product. F e acidic sccrubber con ntains com mponents w which cann not be proccessed in a standard d urea synthesis and d from the evapora ation plant and which until now a are usuallyy not part o of the produ uct specificcation. The ble eed from th he ammon nia scrubbe er must be e processe ed in some way. Th his processsing can b be done in n various ways. In accorrdance with our commitment to o improve our o fluid-be ed granula ation process UFT ha as developed optionss for achie eving amm monia emission reducctions from urea fluidb bed granula ation plantss. With UF FT's Ammo onia Conve ert Techno ology the acidic a bleed d from the ammonia scrubber has been successfull integrated into the e granulatio on process. In this p paper vario ous availab ble and industrially prroven optio ons for gran nulation pla ant operato ors are pre esented. In n especia ally UFT´s p proprietaryy Ammonia Convert Technology, which h combiness minimize ed ammonia a emission ns with redu uced produ uction cost will be discussed.
2 24th AFA Int’l. Te echnical F Fertilizerrs Confere ence
Session IIII
R Revamping g of a Con nventional Total Rec cycle Urea a Plant Mr. Narrayansamyy Selvaraj – Head of Urea U -1 Pla ant Q QAFCO – Qatar Q
Abstrac ct: In July 2 2007 Qatar Fertilizer Company (QAFCO) and Urea Casale (US SCA) signe ed a contra act for revamping of th he Total Recycle urea plant (To oyo technology) locatted in Mesa aieed, Qata ar. ginal capa acity of the e QAFCO Urea-1 pla ant was 10 000 MTD; the plant used to ru un, The orig before revamping, r , at a capacity of 1320 MTD. The sco ope of the Revamp project wa as to integrate the U Urea-1 plan nt with a n new 60,000 0 t/y Melam mine plantt designe ed with Eurrotecnica te echnology.. The revam mping wass aimed at increasing the urea ssynthesis ccapacity up p to 1610 MTD (abo out 30% inccrease in capacity) c hieved by u utilizing the e recycle Carbamate fflow comin ng from the e Melamine e The incrrease in plant capacity was ach plant (about 50% increase in n Carbama ate flow to the t synthesis loop co ompared to o the stand alone plan nt). Casale e opted fo or revamping the syn nthesis unit with its High H Efficie ency Comb bined (HEC C) process to improve the CO2 2 converssion and m minimize the e modificattions in the e downstre eam section ns. This invvolved insttalling Four new high h pressure equipme ents i.e Se econdary re eactor, Strripper, Carrbamate co ondenser and a Mixing g Tee. In addition a to o this, the e HP Carba amate pum mps were re eplaced fro om reciproccating pum mps to Centtrifugal pum mps, to cop pe with the e increase ed Carbam mate flow. Beside the Melam mine integrration, the other majo or objectivve of the U Urea-1 reva amp projecct was envvironmentall improve ement to elliminate the ammonia a and urea a emissionss from Ure ea-1 plant tto the sea.. To achievve this, the e crystallizzer was re eplaced witth an evap poration se ection and a brand ne ew process condenssate treatm ment unit off capacityy 65 MT/h was installed. The tre eated cond densate fro om this uniit is suitable for use a as Boiler F Feed Waterr (after pa assing thro ough Polish hing Unit) The pro oject was executed using EP & C strate egy. Urea Casale w was responsible for the Basic & Detailed d Enginee ering, Proccurement p part of the P Project. An nother conttract was ssigned with h a local co onstruction contractorr Qatar C Construction n Company (Qcon), ffor executin ng the construction part. p Urea Casale C provided site a assistance e during cconstruction and also o Supervisio on during ccommissioning and start up of the plant. The pro oject involved making g around 45 50 Tie-ins. 80% of the construcction work w was carried d out with tthe Urea-1 plant wa as running. The rema aining 20% % job was completed in a shutdo own lasting g 26 days. The T complete projectt was exe ecuted with h a very go ood safety rrecord. ant is over. This is a successfull revamp p project, havving met alll The perrformance test of the revamped Urea-1 pla its revam mp objectivves.
2 24th AFA Int’l. Te echnical F Fertilizerrs Confere ence
Session IIII
B Best-prac tice on RB BI driven In ntegrity Assurance from Conce ept to Impllementatio on Mr. Nader A.Rahim - Inspe ection Superintenden nt GPIC – Ba ahrain
Abstrac ct: nt years, th he applicab ble Legislattion in a nu umber of co ountries pe ermits greater flexibilitty In recen in the setting s of inspection strategiess (inspectio on intervalss, methodss and cove erage) for pressure equipmentt and oth her static p plant itemss, through the use off RBI (Riskk Based In nspection) technolog gy. It is a ttechnologyy processs which, wh hen correcttly applied,, is used to o formally o optimize inspection e efforts for e each static equipmentt items off plant, whiilst minimizzing equipm ment failure e risks caused by the e relevant d deterioratio on mechanisms. This paper outline es a reliable and pro oven RBI d driven equipment inte egrity assu urance proccess best-practice in n application n and. The paper a also descrribes the challengess faced b by GPIC during d the e RBI tecchnology a impleme entation an nd actual integration i of the same into th he existing systems, together w with the RB BI benefitss which h have been achieved tto date. Wh hen this te echnology is impleme ented at an ny plant site e, it has be een shown n to delive er ….. _ Enhan nced integrrity _ More focused inspection strategies _ mainte enance control strate egies to red duce equip pment failurre risks _ Improved ‘workin ng togethe er culture’ ure technica al corporatte memory _ Captu
2 24th AFA Int’l. Te echnical F Fertilizerrs Confere ence
Session IIII
Health, Sa afety and Environm E ent in Fert rtilizer Indu ustry Story be ehind APC C Success s in achiev ving 40000 000 MHW F Free of LT TI-s Mr. Sami Amarneh/ QES Manage er APC – Jordan
Abstrac ct: 1. Paper Summary: achieving 44000000 MH HW in APC ffree of LTI-ss during the period from m Feb-02- 2011 till September-0 S 08 by applyinng Safety Leeadership annd Managem ment methodoologies whicch significanntly conttributed in ellevating the level of safeety performaance to a worrld class level. 2. Detaileed Slides Cooverage: 2.1. Appllying a safetty managemeent system aaccording to the best andd recent interrnational saffety standardd-(OHSAS180001:2007). 2.2. Instillling , growiing and sustaain a vibrantt safety cultuure that emplloys all APC C employeess in a continuuous proactive safety dynaamics by appplying the cooncept of „C Council driveen Safety Maanagement” by conductiing „so far” 5 safety foruums out of 8 schheduled foruums for 20111. These foruums are attennded by 2000 employees at each foruum from mannagement em mployees and non-manageement emplooyees. The G GM, DGM-s and the deppartments‟ managers m atteend these em mployees andd they are heavvily involvedd in them thrrough robustt designed prresentations that enhancce the safety culture in thhe company.. The presentations in each forum are publisheed in a bookklet and a coppy is distribuuted to each employee after each forrum. c in the company bby preparingg a speech prresented by tthe 2.3. Usinng the safety culture in Isslam to servee the safety culture Com mpany Religiious Guidannce Head andd presenting it at each foorum. This prractice is unnprecedentedd and it is exclusively appllied by APC. 2.4. Appllying the conncept of “Inccident Recalll Techniquee” at the safeety forums deesigned for our o Truckingg drivers (3 out of 4 havee already beeen conductedd in 2011); aat these foruums we ask thhose driverss who encounntered dangeerous drivingg situations, in which w they haave done som mething to ccontrol the riisk and accoordingly theyy have succeeeded to prevvent the incident from occuurrence, to present these situations inn front of othhers‟ driverss (about 2000 attendees). Through thiis practice; tthe hazards and risks are efffectively com mmunicated to other drivvers as well as the operaational ways of effectivelly controllinng them. mness princiiple in selectting those feew superintenndents to preesent their saafety presenntations at the 2.5. Usinng the random supeerintendents‟‟ safety foruums (2 out of 4 have alreeady been coonducted in 2011). 2 This practice creaates the needded motiivation at eaach superinteendent to be up to his ressponsibilities as each of them will exxpect that m may be he willl be one of those who will be b selected too give the prresentation. The superinntendent pressentation adddresses the aactual perform mance on ween the acttual perform mance and the set his aannual safetyy objectives and the actions he took to eliminatee the gap betw objeectives. 2.6. Deveeloping and implementinng an effectiive safety procedure to m monitor, conntrol and impprove the saffety perform mance of our servvice providerrs. 2.7. Appllying a Worlld Class Safe fety Incentivees Scheme. 2.8. Effecctive Managgement Revieew Meetingss.
Se ession n IV
Chairp person: Mr. M Mejbel AL LSHAMMERI HSE Manager – PIC Kuwait
1
10 Years of Saafurex Expeeriences in Stamicarboon Urea Plaants Mrr. Joost Roees – Acqisitiion Manageer Mechaniical Engineeer
Stamicarrbon
Neth herlands
2
Cap apacity Increease of Ureea Plants Mrr. Thomas K Krawczyk – Senior Proocess Engin neer
Uhde Gm mbH
Gerrmany
3
M.P P. Boiler Su uper Heaterr Coil Failu ure and Repplacement Mrr. Adel Moh hammad Al Wahedi - M Mechanicall Engineer
FERTIL L
UAE E
4
Caarbon Dioxid ide Recoveryy Plant at G GPIC – A Su ustainable O Option Mrr. Jamal Alii Al Shawooosh - Methaanol Plant Superintend S dent
GPIC
Bah hrain
5
Latest improvements in IIndirect Coooling Techn nology for G Granular Fertilizer Mss. Marietta Mansvelt M - Technical S Service Man nager
Solex Thermall Science Inc. I
Can nada
24 4th AFA In nt’l. Tecchnical Fe ertilizers Conference
Se ession IV
10 Ye ears of Saffurex Expe eriences in n Stamica arbon Urea a Plants Mr. Jo oost Roes – Acqisition n Managerr Mechaniccal Enginee er Stamicarbo on – Nethe erlands Abstract : To comb bat the seve ere carbama ate corrosion conditionss prevailing in the synth hesis sectio on of urea develop in 1 plants, S Stamicarbon n started to d 1992 togeth her with San ndvik Swede en a new sta ainless steel gra ade named S Safurex®. S Safurex® is a super duplex materiall having sup perior corrossion resistantt properties,, even at ve ery low conte ent of passivation air. The T materia al is proprietary and solely inttended for ® Stamicarbon urea plants. p The m material wass introduced d in the marrket in 1996 6 and in 199 98 the first Safurex S equ uipment ® plant to replace deprecciated equipment. In 2006 Safurex became th he standard d were insstalled in exiisting urea p construcction materia al and since e then severral Stamicarrbon grass root r urea plants have b been commiissioned or are under co onstruction h having a complete syntthesis sectio on in Safure ex® materiall. This allow ws to reduce e the passivation air from 0.6 vol % (whicch is advise ed for non S Safurex® plants) to as lo ow as 0.1 % %.
he past 10 yyears over 1 190 pieces o of Safurex® equipment have been manufacturred or are under constrruction During th varying ffrom high prressure vesssels like Urrea Reactor, Pool Cond denser, Poo ol Reactor, H HP Carbama ate Conden nser, HP Scrubbe er, including HP piping a and accesso ories such a as (control) valves, HP ejector and d safety valvves. Several inspectionss have been performed by Stamica arbon on Sa afurex® equipment since e 1998 and experience es will be shared a and compared with the corrosion b behavior of tthe tradition nal stainlesss steels used d in urea syynthesis secctions like 316L L UG and X X2CrNiMo 25 5-22-2. First an o overview wiill be presen nted on typical corrosio on forms wh hich occur in n the synthe esis section observed over o the past 40 years y in non n Safurex® p plants. Subssequently th he corrosion n behavior o observed in more than 40 inspecte ed Safurex® vessels wiill be discusssed. The Superior corrrosion resisttance of Safurex® is cle early demon nstrated, even at very low concentration of passiivation air th he synthesiss section.
C Capacity In ncrease off Urea Plants Mr. Thomas Krawczykk – Senior Process Engineer Uhde Gm mbH – Germ many Abstract : In a typ pical natural-gas based ammonia / urea comp plex, there is a surpluss of ammon nia which is not convverted to ure ea due to a limited ava ailability of C CO2. Often,, the desire for an incre ease of the urea pro oduction capacity come es togetherr with the re equirement to convert all ammon nia to urea. Thus alsso modificattions in the ammonia plant p are neccessary. Th he presentation discussses several options for urea pla ant revamp ps, including g the modiffications on n the ammo onia and CO2 side. It olutions, m making reference to a actual proje ects under providess exampless for the ttechnical so impleme entation.
24 4th AFA In nt’l. Tecchnical Fe ertilizers Conference
Se ession IV
M.P. BO OILER SUP PER HEAT TER COIL F FAILURE A AND REPA ALCMENT T Mr. A Adel Mohammad Al W Wahedi - Mechanica M l Engineer FERT TIL – UAE E Abstrac ct: FERTIL L operates a 1300 MT TPD Amm monia Plantt and 2300 0 MTPD Grranulated Urea U Pant with related utilitie es in Ruw wais, Abu-D Dhabi, UA AE. The Utilities Plan nt has two o Medium Pressurre steam b boilers (B-5 5501 A&B) fabricated d and supp plied by M//s Mitsubisshi, Japan. The boiler was in service s forr 25 years w without anyy problem. Boiler details:
T Type of Boile er : Mitsubh hishi 36VP-1 18W T Tag numberr: B-5501 A & B E Evaporation (MCR) Cap pacity : 140 MT per hou ur D Design Presssure : 48 Kg g/cm2G O Operating prressure: 40 Kg/cm2G S Steam Temp perature: 42 20 Deg C F Feed water Temperatur T re : 120 Deg gC F Fuel Fired: Natural N Gass N Number of B Burners- 2 ( front side) C Commission ning Year : 1 1983
In the p past 28 yea ars during all a turnarou unds, the b boilers werre inspecte ed by third party inspection age ency and during the year 2005 boile er integrityy study w were carried by M/s MHI, Jap pan the Original O Eq quipment Manufacturer, and d concluded d that boile er is in satissfactory co ondition. During A April 2008,, while utilizzing the plant shut do own opporrtunity, routtine inspecction of the e Medium P Pressure Boiler (B B-5501A) was w carried out. Watter dripping g was seen from its super hea ater tube ba ank. Sub bsequent hydro-te est of the b boiler revealed leaka age from th he super he eater coils. The leakk was from m three coils out of the total 28 coils. T The leak was w from th he inner sid de of bend in the coil assembly. Generallyy, the inspe ection of the coilss at this lea ak location is not possible by co onventional NDT meth hods due tto in-accesssibility. Due to non-availa ability of sp pare coils / resourcess, and to minimize m th he down tim me, the lea aky coils w were cut, gged at the e headers. Final hydrro-test wass done and d the boilerr was taken n in to servvice and removed and plug 5 load. Additional monitoring g facility wa as provided d to ensure e the safe operation o o of the boile er. kept at 50% on the failu ure, and long service e life of the e boilers, it was decid ded to repla ace the su uper heaterr coils in Based o both bo oilers and accordingly a y the mate erials were e procured from the Original Equipment Manufactu urer, M/s Mitsubisshi, Japan and replaccement was done durring the yea ar 2009. This pap per describe es the seque ence of activvities during g the leak re epair, action n plan for prrocurement of the coils,, super heater co oil replacem ment jobs, th he failure invvestigation of the leakyy coil carried d out, usage e of advanced inspectio on techniqu ues to inspect in-accesssible
24 4th AFA In nt’l. Tecchnical Fe ertilizers Conference
Se ession IV
locations. M Material o of the super heater: 2¼ Cr 1 Mo stteel. Dettailed y and ana alysis ind dicated tthat the le eak was due to in nternal th hinning study caused by caus stic attack Carbon n Dioxide Recovery y Plant at G GPIC – A S Sustainablle Option mal Ali Al Shawoosh S – Methano ol Plant Sup perintendent Mr. jam GPIC C – Bahrain n Abstrac ct: The Gu ulf Petrocchemical In ndustries Co. (GPIC) owns and operrates an integrated petrochemical pro ocessing co omplex com mprising 12 200 MTPD each of single stream m Ammon nia and Me ethanol plants, commissioned in 1985 and 1700 MTPD off single sttream Ure ea plant, 1998.In the commisssioned in 1 e original d design philosophy of 1985, 275 5 MTPD of Carbon Dii-oxide (CO O2) from Ammon nia plant was utilized to producce 120 MTPD of metthanol (tota al being 12 200 MTPD D) and the balance CO2, 10 015 MTPD from Amm monia Plant was vente ed to the atmosphere a e. Howeve er, after the e commisssioning of th he Urea plant in Janu uary 1998,, all the CO O2 produce ed in the A Ammonia plant wa as utilized for urea production. This led to o the reducction in me ethanol pro oduction byy about 120 0 MTPD as no fu urther CO2 was availa able to ach hieve desig gn capacityy of 1200 M MTPD of methanol. Purely ffor environmental con nsideration ns and in o order to briing the me ethanol pro oduction ba ack to 1200 0 MTPD level an nd also to ttest maxim mum capaccity of Urea a plant thatt can be acchieved ab bove its no ormal capacity with addition nal CO2 frrom CDR plant and at the sa ame time cut down on green n house gas release e to the environm ment; GPIC C installed a Carbon Di-oxide e Recoveryy (CDR) pla ant (450 M MTPD capacity of CO2 2) as it wass seen as a very viab ble and susstainable option to o enhance methanol production n without th he need forr additional natural ga as.
ovements in Indirectt Cooling Technolog gy for Gra anular Ferttilizer Lattest impro nical Servicce Manager Ms. Mariietta Mansvvet- Techn Solex Thermal S Science Inc. – Canad da Abstra act: Since moore than 20 years, Solexx indirect coooling technnology has ffound it’s pllace in the fertilizer f industry and provenn it’s reliabillity in more than 120 innstallations ffor all typess of fertilizeer. During the t last few years new developmen d nts have beenn made baseed on intenssive researchh work to improve the operatioon performaance with thhe target of “ no caking – no cleaniing”. Installaations in Middle E East, India aand other coountries are the living pproof of Soleex’s capabillity to modeel the operatinng conditionns to meet thhe reality. Solex waants to sharee this experiience and prresent their latest technnology, whicch ensures operator o friendly equipment as well as providing p thee most cost effective soolution to coooling fertiliizer.
S Sessio on V
Chairp person: Dr. A Abdelhak KABBAB BI Head of De ept. Environmenttal– OCP P M Morrocco 1
Poort worker ddevelopmentt programm me Isssa Awad HA ASAN - Bussiness Deveelopment Manager Ma -
JJNSL
Jordan n
2
An nalysis of Saafety Perforrmance of IIndian Fertiilizers Plants Mrr. Manish G Goswami - Dy. D Chief (T Technical)
F FAI
India
3
Coommissionin ng and Revaamping Ferrtilizer Plan nts Through h an Obbjective Orieented Approoach Mrr. Gian Piettro Testa – Consultant C for Saipem m (Italy) - Bu usiness Deevelopment Manager O O.V.S (Italy))
K K&T
Monacco
4
En nvironmentaal friendly w way of spen nt catalyst reecycling Mrr. Clemens K Kuhnert - Area A Managger Middle East & Afrrica
N Nickelhüttee A Aue GmbH H
Germany
5
An new approaach for Ureaa Plant Opttimization using u Advan nced Proocess Contrrol Mrr. Christiaaan Moons – Sales Direcctor Mrr. Luc Dieltj tjens - Proceess Engineeer
IIPCOSS Stamicarboon
Belgium m
24 4th AFA In nt’l. Tecchnical Fe ertilizers Conference
Se ession V
Analysis of Sa afety Perfo ormance of o Indian F Fertilizers Plants Mr. M Manish Gosswami - Dyy. Chief (Te echnical) FAI - Ind dia Abstrac ct: FAI hass been con nducting sa afety surve ey of fertiliser plantss for the pa ast severa al years to assess the status of the safe ety perform mance of the industry as a whole e and to he elp fertiliserr plants imp prove theirr performan nce to esta ablish a safe and hea althy workin ng environment. The present survey was w carried d out for 31 ammonia a-urea and d NP/NPK complex fe ertiliser pla ants for a p period of fivve years for the yyears 2005 5-2010. Th he paper provides the e results off analysis of o accidentt data with respect to o various safety p parameterss viz. incide ence rate, severity ra ate and fata ality rate. The analyssis also ide entifies the e causes of incide ents and ffatalities an nd plant a areas prone e to incide ents so tha at plant ma anagemen nt can address the issues to t minimize e the occurrrence of in ncidents.
ONING AN ND REVAM MPING FER RTILIZER P PLANTS T THROUGH H AN COMMISSIO OB BJECTIVE ORIENTED D APPROA ACH” an Pietro T Testa – Consultant fo or Saipem ((Italy) - Bussiness Devvelopment Manager Mr. Gia O.V.S (Italy) K K&T – Monaco Abstrac ct: The pap per brings o out how the strategy and road m map has to o be develo oped to com mplete the very cha allenging w world class projects a along with the implementation off revamping ones. Theorettical aspeccts and the e straight im mplementa ations of the principle es are focu used and highlighted h in order to provid de tools to accomplissh the different expecctations tha at all the invvolved Enttities have in mind to make bu usiness an nd to fulfil ccommitmen nts. nto which the activitties are co onfined, is considere ed the basse for gettiing resultss and its The framework, in eparing actiion plans a and correcttive ones. dynamicc structure the main ttool for pre ude and ca apability to carve out strategies and to pro ovide a surre focal poiint for the P Project’s Leadersship’s attitu successs are considered. de availablle to make the issuess more und derstandable and fam miliar. Examples are mad
24 4th AFA In nt’l. Tecchnical Fe ertilizers Conference
Se ession V
En nvironmen ntal friendlly way of s spent cata alyst recyc cling Mr. Cllemens Kuhnert - Are ea Manage er Middle East E & Africca elhütte Au ue GmbH – Germany y Nicke Abstrac ct:
W Why it is im mportant to recycle me etal R Recycling S Saves the E Earth m metals are precious natural n reso ources of th he Earth. M Metal deposits are no on renewable resources that will run out if exp ploited at th he presentt rate. E Example: NHA N recycled 3300 t o of nickel instead of th he deep impact in the e environme ent to explore 230 0 000 t of ore e. (average e Ni 1,45%)) R Recycling S Saves Energy Itt takes lesss energy to o melt down waste metal and re ecycle it tha an it does tto produce new meta al R Recycling H Helps Mitig gate Globall Warming and Reducce Pollution U Using recyccled metal reduces CO2 C emissions and air pollution.. By saving g energy in industrial p production through re ecycling, the e greenhou use gas em missions fro om factorie es and indu ustrial plan nts are le essened. R Recycling R Reduces Waste W Products in Lan ndfills B By recycling g, we can llessen the waste matterials thatt are placed d into landffills and we e are able tto make th he most ou ut of these materials Reduces th he amountt of metal g going to lan ndfill as desspite a gro owing a awareness of the valu ue in recycling metal, R Recycling H Helps you S Save Mone ey R Recycling p provides wa ays to save e money. With W selling g spent cattalyst you will w benefit on the reccycling ssystem.
A ne ew approa ach for Ure ea Plant O Optimizatio on using A Advanced Process P C Control Mrr. Christiaa an Moons – Sales Dire ector M Mr. Luc Dieltjens - Pro ocess Engin neer n – Belgiu um IPCOS-Sttamicarbon Abstrac ct: Producttion manag gers of ure ea plants a are under pressure to o maximize profitability due to global ccompetition n, tightenin ng legislation on eco osphere lo oad, and ffluctuation of oil/gas prices. T The joint S Stamicarbon n-IPCOS S Sirius@Max optimizattion solutio ons for urea a plants relieve tthese presssures and d increase the plant efficiency. Optimizing g urea plants often m means ma aximizing the prod duction and d/or minimiizing the energy conssumption. This paper describ bes how th he combination of Sttamicarbon n's urea prrocess know-how tog gether with IPCOS' model p predictive ccontrol tech hnology is used to continuously push the p plant opera ation to the e limits. Sirius@ @Max optim mizes the operation o o of the Urea a plant minute by min nute, everyy hour of th he day, ressulting in improve ed reliabilitty of the o operation a and guaran nteeing tha at the high hest possiible producction level can be maintain ned under all circumsstances.