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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
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“Over the years, investments have
produced important improvements”
Case story: Premium LTS catalystExtra ammonia production achieved
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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
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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
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SOR8 kPa
36% Reduction in Pressure Drop
Topsoe Shift Converter Bottom Support Grid – Case Study
Emergency Shutdown
Post-Project Performance - HTS
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Post-Project Performance - LTS
SOR23 kPa
50% Reduction in Pressure Drop
Topsoe Shift Converter Bottom Support Grid – Case Study
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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
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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
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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?
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Economical benefit : Number of unplanned stopsImproving the on-stream factor with Priority Agreement
2,8 days fewer unplanned stops per year
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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
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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