The year 2020 will be remembered as an uncertain, demanding and challenging year. When faced with a global pandemic, companies have adopted new approaches and remote inspection, monitoring and training using the latest digital tools has been key for the successful completion of projects. Stamicarbon, Casale and KBR share some of their experiences of the past year.
NOx emissions from chemical processes such as steam methane reforming contribute to air pollution. The chemical industry is required to take steps to lower such emissions. Technology, developed for related industries, can be designed and optimised to reduce NOx emissions from steam methane reformers. Emission control experts can use a combination of modelling and experience to guide plant operators in recommending and designing optimum, sometimes tailor-made solutions. In this article different options are discussed including low NOx burners, selective catalytic reduction, selective non-catalytic reduction and high emissivity ceramic coatings.
Johnson Matthey (JM) has secured a multiple licence for China’s Ningxia Baofeng Energy Group’s latest project to develop five of the largest single train methanol plants in the world. Located at Baofeng’s Ordos City complex in Inner Mongolia, the five plants each have a planned capacity 7,200 t/d. Under the agreement Johnson Matthey will be the licensor of all five plants and supplier of associated engineering, technical review, commissioning assistance, and catalyst. The plants will take synthesis gas as a feed and use JM radial steam raising converters in a patented series loop. Within the design, there is potential for 1-2% more feedstock efficiency over the life of the catalyst. Thanks to JM’s methanol loop synthesis technology, the plants will provide enhanced energy savings along with low OPEX, CAPEX and emissions. When complete, the plants will represent JM’s 13th operating license in China for a mega-scale plant (>5,500 t/d) and the fourth JM methanol design licensed by Ningxia Baofeng Energy.
The following case studies describe serious incidents associated with leak detection system failures. Incident 4 relates to the failure of the active pressurised leak detection system for the loose liner of a urea reactor and Incident 5 relates to a passive leak detection system which failed to work leading to serious corrosion of the carbon steel wall of the HP scrubber.
Part 1 of a two part look at a potential sustainable future for the nitrogen industry, looking at sustainable nitrogen management and nutrient use efficiency.
Building on its long experience and leading position within global ammonia production, logistics and trade, Yara says that it aims to capture opportunities in green shipping, agriculture and industrial applications; a market expected to grow by 60% over the next two decades. A major first step includes plans to fully electrify its ammonia plant at Porsgrunn, Norway, with the potential to cut 800,000 t/a of CO 2 , equivalent to the emissions from 300,000 passenger cars.
Alistair Wallace, Head of Fertilizer Research, Argus Media, assesses price trends and the market outlook for nitrogen.
Ammonia supplies have been curtailed by production shutdowns, including Kaltim and PT PAU in Indonesia, SABIC and Ma’aden in Saudi Arabia, Sorfert in Algeria and Chinese gas-based producers. There have also been gas curtailments in Iran and Trinidad.
Process and simulation models can be valuable tools when troubleshooting to solve operational issues in sulphur recovery units. Two examples are provided. In the first case study it is shown how a tuned model was useful in troubleshooting an SRU that was experiencing lower than expected recovery efficiency and apparent channelling in the first catalytic converter. In the second case study an SRU simulation tool is used to investigate sulphidic corrosion in a waste heat boiler.
Continuing rationalisation in China’s phosphate industry has been reducing demand for sulphur and sulphuric acid at the same time that the country is producing more of both.