Fertilizer Production Harnessing Technological...
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Fertilizer Production Harnessing Technological Innovation
John Derbyshire
President, Technology and Consulting
KBR Inc., Houston, Texas, USA
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Energy Efficiency
Reliability Safety
Environmental Compliance
Production Management
The Role of Technology in Fertilizer Manufacturing
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ENERGY
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Energy Saving Technology
Vintage Ammonia Plants (1960s, 70s,80s)
>10 Gcal/T ammonia (LHV)
Revamp technology targets
7+ Gcal/T ammonia (LHV)
KBR grass-root plants
6.2+ Gcal/T ammonia (LHV)
Theoretic minimum Ammonia Plant 4.97 Gcal/T ammonia (LHV)
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Improved Converter Design
Higher conversion reduces refrigeration duty
Improved CO2 Removal System
Reduced CO2 Slippage and low energy requirements
Energy Saving Technology
Improved Reforming
Reduced heat loss and pressure drop
Highly Efficient Machinery trains
Compressors and turbines use less steam and also reduced fuel consumption
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Example: Ammonia Revamp in Asia
Before Revamp
•Energy 8+ Gcal/MT
•Capacity 1600MTPD
After Revamp
• Energy 7.35Gcal/MT
• Capacity 2000 MTPD
Energy Reduces by
˜ 10%
Capacity Increased by 25% Project IRR = >20%
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RELIABILITY
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Ammonia Plant Reliability
Peace of mind
Target Continuous Days Operation
>1200 days
Target on-stream Factor
97%
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What is 1% More Reliability Worth?
3000 MT/day Name Plate 354 Days
1% more = 30 MT/day 354 Days
Assume Ammonia Price = $400/MT Additional Annual Revenue = >$4.2 Million
Example: Assume Plant is producing at Name Plate Capacity
Reliability of Process and Equipment is the Key
Assume 97% Utilization rate = 354 days /year
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Reliability in Fertilizer Plants
Production on-stream factor hurt by reliability factors of the following in ammonia plant
• Rotating Machinery
• Reformer
• Waste Heat Boiler
• Other Critical Equipment
Reduce Asset downtime with Preventive maintenance
• Proactive asset management
• Early detection of potential problems
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Changing the World of Maintenance
1930 1940 1950 1960 1970 1980 1990 2000 2015
The Next Generation of
Maintenance Management
• More and Better Hand
Tools to Fix
Breakdowns
• Planned Maintenance
• Scheduled Overhauls
• CMMS for Improved
Efficiency and Control
• Reliability Assessment
• Business Risk
Prioritization
• Reliability-Centered
Maintenance (RCM)
• Condition Monitoring
• Asset Performance
Management System
New Technologies and Practices
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Example: Asset Performance Management (APM) System
Reliability & Integrity Mgt.
Asset Performance Mgt. System
Data Analysis Expert Diagnostics Alarm Settings
EAM/CMMS Automated Work Requests Diagnostics Recommendations
CMMS
Data Sources
Inspection Reports
Operator Rounds
Vibration
Process / Performance
Lubricant Tests
Thermography
Collected By:
Operators
Maintenance Craft
Technical Personnel Knowledge From Experienced
Plant Personnel & RCM Analysis
Work Orders
Training
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ENVIRONMENTAL
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Environmental Related Challenges for Fertilizer Plants
Green House Gases (GHG) emissions reduction
• Carbon dioxide CO2 emissions
Pollutant reduction
• Nitrogen oxides (NOx) emissions
• Sulfur oxides (SOx)
Reduce Particulate emissions
Protect water quality
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Technology Enabling Environmental Compliance for Fertilizer Plants
• Improved Reformer Design
• Reduced CO2 emissions
GHG Gases
• Reduced NOx emissions
• Implementing SCR
• Low NOx burner design
Pollutant Emission
• Prilling Tower design
• Granulator design
• Improved Scrubber
Particulate Matter Emission
• Reduced toxicity
• Water converted back to Process steam
Water Quality
• Reuse Condensates and Waste water
• High Pressure Condensate stripper reduce water usage
Water Usage
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SAFETY
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Safety
Culture Systems
• Corporate Policies • Best Practices • Regulatory Compliance • Safety Monitoring &
Recording • Culture Development
Operator Training Simulator • On job Training • Classroom Training • Upgrade and Retrofits
Process Automation Technologies • Performance Monitoring
systems • Safety Instrumented
Systems
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Example: Operator Training Simulator Life Cycle Modeling
Whole plant dynamic model
for Operations Support
Dynamic modeling for
Plant Design & Engineering
‘Virtual’
Plant
Environment
(OTS)
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Example – Safety Instrumented System
Sensors
Logic Box
Control Elements
Pressure Temperature Flow Other conditions
Process Control System
Valve actuators, Safety relays
Real time safety enabled for Process and Equipment
Decides safe state or not
Automated logic determines action
Implement the action determined by logic system
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PRODUCTION MANAGEMENT
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Production Management System
Production Operations
Management
Data Collection &
Historization
Mass & Energy Balance
Dashboard & KPI’s
Production Optimization
Operations Advisory & Logs
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Basic Production Management
ERP
DCS
Distributed Control Systems
Enterprise Resource Planning
Data Collection &
Historization
Mass & Energy Balance
Dashboard & KPI’s
Production Optimization
Operations Advisory & Logs
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Full Scope Production Management
Enterprise Resource Planning
Accounting Human Resources Supply Chain Management
DCS Remote Instruments/Equipment DCS/ PLCs Emergency Shutdown Systems
Process Historian Inventory
Management
Performance
Management
Operator Training
Inspection Warehousing Operator Logbook Asset
Management
Quality
Management
Engineering
Design
Analysis
Energy Monitoring
Planning &
Scheduling
Yield Accounting HS&E
Management Work Orders Maintenance
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KBR Ammonia Technology – Superior Performance
• Low energy consumption of 6.5 Gcal/MT
• Reduced CO2 and NOx emissions Energy Advantage
• Greater than 97% availability
• Typical 3-4 years runs without maintenance turnarounds
• Flexibility and greater stability
Ease of Operation
• Synthesis equipment 10-15% smaller
• Up to 30% less reformer tubes in radiant section, fewer burners
• Plot plan is 25-30% smaller
CAPEX Advantage
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Questions