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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 >>>

Preliminary Programme Monday 24 February Day Zero

09:00-17:00 07:30-17:00 15:00 18:30 Pre-Conference Workshop Pre-Conference Site Visit to Borealis Grand Quevilly Exhibition & Registration open Registration sponsored by Welcome Reception sponsored by
UREA & NITRIC ACID RESISTANT STAINLESS STEELS www.gemac.com

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

Tuesday 25 February Day One

08:00 Exhibition & Registration open

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

E: conferences@crugroup.com | T: +44 20 7903 2444 | F: +44 20 7903 2172

Organised by CRU Events

Nitrogen + Syngas 2014

24-27 February 2014, Marriott Rive Gauche, Paris, France

Pre-Conference Site Visit to Borealis Grandpuits Plant, Monday 24 February

The Borealis Grand-Quevilly site manufactures fertilizers for agriculture and industrial intermediates that are used in the production chain of nitrogen fertilizers and in other industries (metallurgy, food processing etc.). With a workforce of 340 staff, the Grand-Quevilly site has a production capacity of over 3.3 million tons per year. The Grandpuits plant production units operate continuously. Borealis is investing heavily in the Grand-Quevilly site, as demonstrated by the recent inauguration of the Nitric 8 unit. Borealis is also developing close ties with other companies, such as the German Linde group, whose CO2 liquefaction unit on the site recycles the CO2 released by the plant for industrial uses. Places for the site visit are strictly limited. Please contact conferences@crugroup.com to request further details.

Technical Programme - Tuesday 25 February

Auditorium sponsored by Session 1: Ammonia Catalyst Developments 14:00 A New Industry Benchmark for Ammonia Production J. Jnsson (Haldor Topse A/S) For more than half a century Topse has set the standard for catalysts and technology in ammonia plants. Signicant efforts are invested in research and development to ensure continuous improvement in efciency, reliability and sustainability. This year, the introduction of a truly groundbreaking product from Topse will set a new industry benchmark for ammonia production. 14:30 Better Understanding of Chemical Reactors N. Ringer (Clariant) In spite of technological improvements which have improved their physical integrity, activity and selectivity, catalysts used in ammonia plants can only full their expected operating life if they are correctly loaded, particularly in installations using layers of different catalyst particles and inert shapes. Examples will be given of what can go wrong in a plant turnaround. 15:00 Ammonia Synthesis Converter Catalyst Unloading: Methodologies and Challenges M. Mohammadian (OCI Nitrogen) Ammonia synthesis catalyst typically lasts around 15 years but may have to be unloaded earlier for repair or replacement of the internals, for example. Its pyrophoric character, the large inventory, and the complexity of the converter internals pose special problems which inuence techniques for unloading both vertical and horizontal converters, as discussed in this paper. 15:30 Q&A 17:30 Q&A 15:45 Networking break sponsored by 17:45 Close of Day One 17:45 Drinks Reception Co-sponsored by Session 2: Synthesis gas generation 16:15 Cracking of Alloy 800H Reformer Riser C. Thomas (Quest Integrity Group) Root cause analysis revealed that cracks in the Alloy 800 transition pieces of the riser tube in a Kellogg reformer were the result of stress relaxation cracking, adding to a growing body of evidence that calls into question the generally held belief that austenitic alloys do not require post-weld heat treatment. 16:45 The Truth about Microalloys Additions in Reformer Tubes B. Fournier (Manoir Industries) H. Chasselin (Manoir Industries) Microalloys have become an industry standards in the supply of reformer tubes, however, the selection of those alloying elements so important for creep resistance have evolved signicantly. The paper will tackle about impact of microalloying elements, their respective impacts on the creep resistance of the alloy and the relationship between micro additions and the general chemical composition. 17:15 Improvements in Reformer Monitoring by InTube Temperature Measurement P. Murray (Johnson Matthey) This paper reviews the benets of the use of CatTrackers in different designs of reformers to measure in-tube process gas temperatures in steam reformers and help prevent overring and its potentially catastrophic results. CatTracker technology can also be of benet in other reactors in synthesis gas plants and examples of this will also be reviewed.

N.B. Programme is provisional and subject to change

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Fertilizers &Chemicals

Technical Programme - Wednesday 26 February

Auditorium sponsored by

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.

E: conferences@crugroup.com | T: +44 20 7903 2444 | F: +44 20 7903 2172

Organised by CRU Events

Nitrogen + Syngas 2014

24-27 February 2014, Marriott Rive Gauche, Paris, France

Technical Programme - Wednesday 26 February Stream One

systems with electronic ones, and enhancing cooling of the bearings. In one case plant capacity was raised from 1,360 t/d to 2,000 t/d. 11.45 Improved Reformed Gas Waste Heat Boiler Design Enhances Ammonia Plant Reliability M. Gandhi (KBR) There are more than 150 ammonia plants in the world still using multiple-shell bayonet tube waste heat boilers for cooling the reformed gas. These are now causing downtime and increasing maintenance costs. KBR now offers a revamp package using a single-shell oatinghead water tube boiler which has been a feature of its new plant designs since the 1980s. 12.15 Co2 Stripper Column Efuent System: Mechanical Application Employing Innovative Technology P. Minola (Saipem) This paper will present the design enhancements of two efuent piping systems for use in CO2 stripper columns in Ammonia plants. 12.30 Q&A 12.45 Networking Lunch Session 3A: Panel Discussion: Ammonia Revamps 14:00 Technological Engineering: The Most Efcient Way to Enhance the Performance, Reliability and Capacity of Your Ammonia Plant and Raise its Technological Level to State of the Art S. Panza (Casale Group) Syngas Turbocompressor Unit Modernization Projects for Ammonia Production Increase A. Lubimov (Entechmach LLC RPC) Lifecycle Solution to Enhance Availability and Reliability of Urea Plants D. Ishikawa (Toyo Engineering Corp.) 15.15 Networking break sponsored by

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

N.B. Programme is provisional and subject to change

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Fertilizers &Chemicals

Technical Programme - Wednesday 26 February Stream One

Session 4A: Environmental Efciencies 15.45 Forty Years Experience in Engros Total Recycle Urea Plant No 1 C. G. Abbas (Engro Fertilizers Ltd) Originally designed as a 515-t/d plant , Engros No 1 urea plant was revamped to its present capacity of 780 t/d with upgraded venting systems. In its 40-year history some fairly major emergencies have arisen. The paper describes these and their remedies. 16.15 Signicant Ammonia Recovery from Urea Plant LP Section Off-Gases S. G. Gedigeri (Oman India Fertiliser Co.) An entirely in-house designed ammonia recovery system is saving a total of about 55 t/d of ammonia from being ared in the off-gases from OMIFCOs two urea plants. The new system paid for itself in under 90 days and has improved the plants environmental performance. 16.45 Synergistic Methanol Abatement System in an Ammonia-Urea Production Complex N. Zeevi (Petrokemija Plc) Methanol an unwanted by-product of the LT shift stage in an ammonia plant is rejected in the carbon dioxide and has environmental and operational ill-effects. The paper describes a system for minimizing methanol generation and its benecial effect on the operation and economics of an ammonia-urea complex. 17.15 Q&A 17.30 Close 17:30 Drinks Reception sponsored by

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

N.B. Programme is provisional and subject to change

E: conferences@crugroup.com | T: +44 20 7903 2444 | F: +44 20 7903 2172

Organised by CRU Events

Nitrogen + Syngas 2014

24-27 February 2014, Marriott Rive Gauche, Paris, France

Technical Programme - Thursday 27 February

Auditorium 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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Fertilizers &Chemicals

Technical Programme - Thursday 27 February

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

N.B. Programme is provisional and subject to change

E: conferences@crugroup.com | T: +44 20 7903 2444 | F: +44 20 7903 2172

Organised by CRU Events