Improve Efficiency of Ammonia Plants · Additional ammonia gain from premium product 1,900,000 USD LK-823 LK-853 FENCE ... Topsoe Shift Converter Bottom Support Grid ...

word(s) in header by

changing the Open

Sans (Headings)

1

Leading the way forward for the fertilizer industry

GPCA – Dubai – September 2016

Achraf Bergui M.Sc. - Haldor Topsoe

Innovative Solutions to Improve Efficiency of Ammonia Plants

2

1 week extra of Production ?

3

Plant Efficiency The catalyst, Process and Human Factor

4

“Over the years, investments have

produced important improvements”

Case story: Premium LTS catalystExtra ammonia production achieved

5

LK-853 FENCE™Optimized use of natural resources

Catalyst age (months)

CO

Slip

, dry

mo

l%

3024181260 36

Additional ammonia gain from premium product

1,900,000 USD

LK-823

LK-853 FENCE™

Premium pay back114,000 USD

Different SOR inlet temperatures due to temperature limitations

6

LK-853 FENCE™An investment in added value

4210 MT = 2,5 days of production

Cost Gain Extra Ammonia (MT)

Premium for catalyst $114,000 - -

0-12 months 0 0 0

12-24 months 0 $531,000 1180

24-36 months 0 $1,363,500 3030

Net Present Value: $1,350,000

8

Pre-Project ConfigurationsTopsoe Shift Converter Bottom Support Grid – Case Study

9

Topsoe Shift Converter Bottom Support GridDesign

10

SOR8 kPa

36% Reduction in Pressure Drop

Topsoe Shift Converter Bottom Support Grid – Case Study

Emergency Shutdown

Post-Project Performance - HTS

11

Post-Project Performance - LTS

SOR23 kPa

50% Reduction in Pressure Drop

Topsoe Shift Converter Bottom Support Grid – Case Study

12

Decreasing cost by upgrading technologyUpgrading old design in order to save money

• Challenge• Decreased pressure drop over

• Significantly decreased the need of support balls

• Combined savings: 80,000 USD/year

13

Plant efficiency and reliabilityCan you improve efficiency and reliability?

Efficiency

Reliability

Best in classMany shutdowns

Average

Low efficiencyWorst in class

Work

towards best-in-classperformance

14

TWT measurementsWhy is accuracy important

-20°C +20°C

~2% lost production

<50% reduced tube lifetime

2% ~ 7 days of production

Design TWT

How well do you know your temperatures?

15

Economical benefit : Number of unplanned stopsImproving the on-stream factor with Priority Agreement

2,8 days fewer unplanned stops per year

0

1

2

3

4

5

6

Customer 1 Customer 2 Customer 3 3rd party

benchmarking

Combined, Topsoe

customers

Ave

rag

e n

um

be

r o

f u

np

lan

ne

d

sto

ps

pe

r ye

ar

16

Are you saying yes to added value?Premium products and services from Topsoe

“You miss 100 % of the shots you don’t take”

-Wayne Gretsky

17

Thank YouTo find out moreor get in contact

www.topsoe.com

follow us on: