www.nitrogensyngas.

com

Fertilizers
&Chemicals

Pre-Conference Full Day Workshop Monday 24 February, 09:00 17:00

Improving Safety, Reliability and Performance
of Urea Plants

- How to assure a rst class urea product

Organised by UreaKnowHow.com

- 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

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

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

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

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

Session 2: Synthesis gas generation

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.

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.

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.

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.

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

N.B. Programme is provisional and subject to change

Book now! Online: www.nitrogensyngas.com

www.nitrogensyngas.com

Fertilizers
&Chemicals

Technical Programme - Wednesday 26 February

Auditorium sponsored by

Stream One

Stream Two

Session 1A: Synthesis Gas Generation & Purication

Session 1B: Urea Equipment

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.

09:00 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 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.

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

10:30 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

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.

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 - Wednesday 26 February

Stream One

Stream Two

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 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.

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.

12.15 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

12.30 Q&A

12.45 Networking Lunch

12.45 Networking Lunch

Session 3A: Panel Discussion: Ammonia Revamps

Session 3B: Panel Discussion: Safety

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)

14:00 Safe Reduction of ShiftMax 217 at Low

Temperature
W. Kaltner (Clariant)

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

N.B. Programme is provisional and subject to change

Book now! Online: www.nitrogensyngas.com

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

www.nitrogensyngas.com

Fertilizers
&Chemicals

Technical Programme - Wednesday 26 February

Stream One

Stream Two

Session 4A: Environmental Efciencies

Session 4B: Methanol Technology

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.

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 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

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

Stream Two

Session 1A: Measurement & Monitoring

Session 1B: Nitrates & Nitric Acid

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.

09:00 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 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

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.

Book now! Online: www.nitrogensyngas.com

www.nitrogensyngas.com

Fertilizers
&Chemicals

Technical Programme - Thursday 27 February

Stream One

Stream Two

Session 2A: Ammonia Operations & Maintenance

11:00 Q&A

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.

11:15 Networking break

sponsored by

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

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