Join Us for an Unforgettable Day on the Green!  

Mark your calendars! On Monday, March 31, we’re hosting an exciting Golf Tournament at Battle Creek Golf—a perfect blend of competition, camaraderie, and fun.

Tournament Details:

Location: Battle Creek Golf

Checkin and Warmup: 12:00 PM

Shotgun Start: 1:00 PM

Buffet & Awards Ceremony: 5:00 PM

Want to Get Involved? We have exclusive sponsorship opportunities available! If you're interested, you can download the sponsorship packages here or email michelle.bingham@crugroup.com for more information.

Secure Your Spot:

• Individual Entry: $150 per person (includes golf + buffet)
• Team Entry: $500 for a team of 4 players
• Guests & Spouses: Join us for the buffet at just $25

Spots are limited and available on a first-come, first-served basis, so don’t wait—grab your clubs and get ready for an amazing day on the course!

Will cover the applicable elevated temperature damage mechanisms, how to avoid them & how to prolong the life of critical components such as catalyst tubes, manifolds & pigtails.

This workshop is appropriate for anyone who has responsibility for a steam methane reformer including Plant leaders, Process engineers, Mechanical Integrity engineers, Fixed Equipment Inspectors.

This tutorial is set up to provide an overview of API 612 special purpose steam turbines and API 617 Ch2 multi-stage compressors. We will review typical maintenance cycles and predictive approaches to extend outages and minimize downtime. This will be focused on the ammonia industry (Syngas, NH3 Ref, Process Air, Natural Gas booster, recirculator, etc). Case studies will be of focus as we believe operations/maintenance will take strong interest in this portion.

• Importance of regular inspections and diagnostics for early issue detection and extending operation.
• Typical failure modes and maintenance strategies for turbines and compressors.
• Case study 1: Weld repair on a compressor rotor (i.e., laser weld repairs on DGS, hydraulic coupling).
• Case study 2: HVOF coating application for compressor rotor repairs. (Impellers Bores, Eye OD’s and journals).
• Case study 3: Turbine disc weld buildup repairs using upgraded materials to enhance resistance to stress corrosion cracking.

The design of a steam methane reformer (SMR) furnace is typically based on ideal, uniform heat transfer.  Real life is rarely ideal, though.  And many SMRs have been operating for 30, 40, 50 years or more, often at a capacity that is significantly higher than original – hardly ideal anymore.  Therefore, this training looks at:          

• How do you design an SMR for improved reliability?
• What can you do if your SMR suffers from non-uniformity?

BD Energy Systems has designed and revamped dozens of SMRs to address these issues, among other design challenges.  This presentation will include real-life examples from the speakers’ experience.

Structural resonance is a condition that is often misdiagnosed and commonly goes undiagnosed, resulting in persistent high amplitude vibration issues for long periods of time. Resonance is difficult to resolve without the proper engineering approach, as changes that may move a resonant mode out of excitation can move a different mode into an excitation range.

This presentation will introduce the audience to methods for diagnosing and resolving resonance by discussing a case study that includes:

• Initial vibration data and what specifically indicated resonance as having a high probability as a causal effect
• Field testing methods and analysis to identify resonant modes
• Experimental modal analysis and how it was used to test prospective modifications for effectiveness
• Acceptable separation margins between resonant modes and excitation forces
• Solution implementation and post-implementation vibration data

Overview

Potassium carbonate (pot carb) CO2 Removal Training Course is designed for all aspects of plant personnel working with pot carb CO2 removal systems in syngas plants. The course will empower your stakeholders to apply more effectively the knowledge acquired to better manage specific operating and maintenance issues that plant personnel face daily.

Training Seminar Objectives

The training course is directed toward improving the level of process understanding among plant management, engineers, operators, maintenance, laboratory, and HSE personnel involved with pot carb systems. This course will assist all attendees in more effectively applying the knowledge gained on analytical and operational parameters to make better decisions to manage common operating and maintenance issues. how to coordinate their efforts to achieve the best long-term performance of critical equipment such as absorbers, flash vessels, heat exchangers, filters, & strippers, and to identify opportunities and best-practice guidelines.

Who Should Attend?

Target Group: Plant Management, Engineering, Operations, Reliability, Maintenance and Health, Safety & Environmental personnel in Ammonia, Methanol, Hydrogen, & other syngas plants that use pot carb for CO2 removal.

This training workshop will combine presentation and interactive discussion on the topic of High Pressure Boiler Operation, Troubleshooting and Metallurgical Failure Analysis.  Sr. Boiler Specialist, Ray Titsing, will cover best practices for boiler operation and chemistry while Sr. Metallurgist, Mel Esmacher, will enhance the audiences’ understanding of failure mechanisms when best practices are not followed.  In addition to detailed presentation-based descriptions of key aspects of component failure in these systems, hands-on samples will be provided to reinforce understanding of common failure modes, and to help drive interactive discussion.  Discussion will include typical steps that can be taken to prevent these failures from occurring.

This training session builds on the basic training provided by Kinetix on the design and operation of hot potassium carbonate solvent based (Benfield, Catacarb, Vetrocoke, LRS-10) gas purification units. It should be of interest to owners and operators who are new to this technology, and to those wanting to refresh themselves on the technology. In the last 50 years there have been numerous safety and reliability related incidents in hot potassium carbonate units: explosions in storage tanks, corrosion, excessive solution foaming, heat exchanger fouling, improper column level control, reverse flow through pumps, and high-pressure vessel vapor blow-through. The purpose of this training is to raise risk awareness by reviewing the learnings from these incidents, with the objective of preventing them from occurring again.

Industrial water systems exist so that necessary chemical, mechanical and biological processes can be conducted to reach the desired outcome. Fouling can occur even in industrial water systems treated with the best water treatment programs currently available. Evaporative cooling water systems are particularly prone to fouling, which can be inorganic, organic, or microbiological in nature.  This fouling occurs by a variety of mechanisms and if allowed to progress, the system can suffer from decreased operational efficiency, premature equipment failure, lack of water quality control, and increased health-related risks associated with microbial fouling. Periodic cleaning of inorganic and organic debris or disinfection of the water system has a limited effect and serves only as a partial solution to the management of bio-foulants.  This training covers best practices for microbial management in cooling waters, particularly in ammonia plants. Topics will include microbiology of CW systems, technologies for microbial monitoring & management, highlighted by real world examples.

• Types of cooling water systems
• Why is microbial management important in water systems?
• Microbial ecosystems in cooling waters systems
  • Types
  • Habitat
  • Growth requirements
  • Ecology in Ammonia plant cooling water systems
• Biofilms
  • What are biofilms
  • Why worry about biofilms
  • Biofilm management
  • Real world examples of problems due to biofilms
• MIC – Microbiologically Influenced Corrosion
  • What is MIC
  • Why be concerned about MIC
  • Real world examples
• Microbial Management – Performance Standards
  • What are the objectives of microbial management
  • What are the treatment options
    • Chemical types
      • Pros and Cons
    • Application methods
    • Monitoring methods
      • Chemical
      • Microbial
  • How is success measured?
  • Treatment strategy overview
    • What is the Most Effective Technology (MET)
• Microbial Management – Health Standards
  • Brief overview
  • Real world example tied back to performance standard

presented by CRU

When the US Inflation Reduction Act (IRA) was signed into law in August 2022 it marked a step change in climate investment. Two years on, $161bn has been invested into clean energy production and industrial decarbonization. The IRA offers much needed incentives designed to support the acceleration and deployment of low carbon hydrogen, sustainable aviation fuel and clean energy.

One key provision, the IRA’s 45V production tax credit, offers up to $3/kg hydrogen potentially creating the environment for economically viable hydrogen projects. However, the delay to the treasury guidance being published has created uncertainty and slowed project execution. Meanwhile, 45V has set a benchmark for hydrogen subsidies driving global competition that has facilitated the creation of new support schemes, e.g. the EU Hydrogen Bank and Canadian investment tax credits.

In the US, major clean hydrogen and ammonia projects are already underway and the US DOE has committed $7bn towards establishing regional hub projects. Many US projects are looking at exporting overseas, especially to customers in locations where further subsidies could be incorporated into the business model, e.g. Japan. This creates opportunities and threats as low carbon products compete to capture subsidies and satisfy a limited global demand. While the IRA provides substantial financial support, it has been criticized for lacking clarity on some aspects of hydrogen certification, including how “clean” hydrogen is defined, measured and verified. Furthermore, the IRA has been successful at attracting capital into the US but one of the biggest barriers to progressing large scale projects in the pipeline is securing offtake, which the legislation does less to support. This presentation will reflect on the global impact of the IRA two years on and examine the opportunities and challenges which are still present.  

One cannot argue that industrialization, with its carbon emissions and associated average atmospheric temperatures have steadily increased since the 1950s. This trend, if unchanged, will result in higher sea levels and unlivable temperatures around the equator over the coming years. To address this threat, companies, and society as a whole need to be creative on finding ways to reduce carbon emissions while still providing the needs of society, like food, heat, power, and mobility. This challenge will require financial support, innovation, risk taking and policies that can set the pace to which companies and countries must act.  

At LSB Industries, we work diligently to maximize the long-term value of the company for all our stakeholders - particularly our employees and the residents of the communities in which we operate – as well as society and the environment. Every decision we make is framed and guided by our core values, purpose and vision. We create products that improve the quality of life for current and future generations and are working towards becoming a leader in the energy transition in the chemical industry through the production of low and no carbon products that build, feed and power the world.

In the evolving manufacturing ecosystem, operations excellence is no longer defined solely by process efficiency—it now hinges on a harmonious blend of technology, people, and culture. Digital transformation acts as a pivotal enabler, driving innovation, agility, and sustainable growth. By adopting advanced tools such as IoT, AI, predictive analytics, and cloud platforms, manufacturers can unlock real-time insights, optimize operations, and proactively adapt to challenges.

At Caravel Solutions, we believe that technology is only as transformative as the people who use it. Our approach to operations excellence centers on empowering individuals and cultivating a culture of ownership and innovation. By fostering ownership, collaboration, upskilling teams, and instilling a mindset of continuous improvement, we ensure that people are at the center of every transformation initiative.

Operations Excellence is not just about process and tools but rather about inspiring a workforce to reimagine what is possible. When paired with an inclusive and adaptive organizational culture, it drives sustainable improvements that extend beyond the production floor. Through this synergy of people, culture, and technology, Caravel Solutions inspires manufacturing leaders to embrace operational excellence as a shared vision, unlocking new levels of performance and innovation.

An unexpected fire occurred two weeks after start-up of a hydrogen plant following a Major Plant Turnaround. The fire occurred beneath the furnace box as a result of loss of containment from a radiant section process gas tube. In this presentation we will share the sequence of events leading up to the fire, the and the damage caused by the fire. Most importantly we will review the incident investigation results and how they have been applied to prevent recurrence.

presented by HRST Inc.

An SMR convective waste heat boiler (WHB) evaporator is critical for reducing flue gas temperatures for emission equipment and generating steam for the SMR and downstream processes, making it a reliability must run piece of equipment at any plant. Leaking or failed evaporator tubes can result in lengthy forced outages, with tube replacement oftentimes being difficult, time consuming, and costly due to lost production.

Unlike the WHB’s superheater or economizer, the boiler’s evaporator tubes rely on two-phase steam/water mixtures and boiling heat transfer to keep their operating temperature in check. When either a poor flow regime or lack of boiling heat transfer occurs, the metal temperature can rapidly increase above its design parameters and rapid degradation of the tube wall can occur.

Boiler evaporator tube failure mechanisms typically stem from an issue with internal flow regimes causing stratification of flows, poor circulation resulting in chemical concentration, or a combination of the two along and high heat flux/metal temperatures excursions above the intended design. Incorrect flow regimes and circulation issues can lead to under deposit corrosion (UDC) or caustic gouging, whereas complete flow separation (stratification) may lead to dry-out and short- or long-term overheating of the tube material.

This presentation will focus on helping plant personnel understand how poor circulation and flow regimes in boiler evaporator tubes can lead to failures, what those failure mechanisms are, and how to address them through interim operational changes or design modifications. Topics discussed will include:

• Evaluating the tube flow regime in horizontal vs. vertical orientation tube applications
• How correct tube, downcomer/feeder piping, and riser pipe sizing can affect circulation of the boiler circuit
• Importance of adequate gas-side baffling and corbels
• Tube failure mechanisms related to flow regimes and evaluation
• Chemistry’s role in accelerated tube failures
• Corrective operational or design changes to prevent tube failures

Case studies involving water-tube boiler evaporators in SMR WHBs will be discussed, including both vertical and horizontal tube orientations in natural and forced circulation applications.

In 2005, a multiple tube failure in a hydrogen plant reforming furnace occurred in a Chevron refinery.  This event occurred during a start-up of the hydrogen plant following a turnaround. The tube failures were related to severe overheating and incipient grain boundary melting.  This presentation will review root causes and recommendations to prevent future events.  This event highlights the importance of having and following well written procedures, recognizing and mitigating risk, and the risk associated with transient states of units. 

This presentation will provide details on a tube failure and subsequent lessons learned.  It also highlights that plants are very vulnerable to incidents during transient conditions. 

A European ammonia plant, has successfully restarted following a revamp of the process gas cooling section, executed by Casale. Casale replaced the outdated 101-CA/B and 102-C boilers located downstream of the secondary reformer with three new double-tube type boilers supplied by Arvos.

This presentation details the installation of the new Casale-Arvos boilers and the plant’s successful start-up after the steam generation system upgrade. The new boilers were installed in the same location as the previous ones, minimizing investment costs and plant modifications. The more robust and reliable design of the Casale-Arvos boilers has resulted in enhanced overall performance and reliability of the ammonia plant.

presented by John Zink

This presentation explores the transformative potential of hydrogen as a fuel for the reforming and refining industries, with a focus on its role in reducing CO2 emissions, impact on burner design and operations. It examines hydrogen’s combustion characteristics and the technical challenges involved in transitioning to hydrogen firing, particularly in high-temperature applications. 

Hydrogen firing offers a pathway to CO2-free combustion, enabling diffusion burners to operate with 100% hydrogen while reducing CO emissions. However, the presentation also addresses key operational challenges, such as managing NOx emissions with advanced burner technologies like ultra-low NOx systems. It also highlights hydrogen’s unique properties which introduce operational and reliability risks ultimately necessitating advantage burner designs and philosophies for reliable operation. 

By presenting both the opportunities and complexities of hydrogen firing, this session offers a balanced perspective on key burner design criteria needed for greater success in the journey to integrate hydrogen into existing processes. The ability to retrofit systems and reduce CO2 emitted through innovative burner designs, making hydrogen firing a compelling option for industries committed to all emissions (not just carbon) reduction and regulatory compliance. 

presented by LG Water

Climate change and global warming are pushing society to find and use low-footprint carbon emission technologies urgently in order to stop or slow down this trend. One of the main consequences of this situation is water scarcity due to extended drought, particularly S one of the most sensible areas which is suffering the consequences.

Hydrogen could be indispensable for changing this trend. It can be used as fuel for internal combustion engines without producing carbon dioxide, the main contributor to global warming. The production of hydrogen can come from different chemicals, and depending on which one is used, it can be grey, blue, turquoise, or green. Green hydrogen is produced by the electrolysis of water, splitting water into hydrogen and oxygen using only electricity from renewable energy sources. In order to produce hydrogen through electrolysis, ultrapure water is required. Ultrapure water is defined as water with normally an electrical conductivity of less than 1 µS/cm. It is estimated that 9 kg of ultrapure water is needed to produce 1 kg of H2. Ultrapure water is produced from all different water sources, such as groundwater, city water, surface water, wastewater, and seawater. Among all the potential technologies for treating water, reverse osmosis (RO) is one of the main ones for demineralization or desalination processes involved in producing ultrapure water.

Within the syngas plant, blue hydrogen from ammonia is a key process requiring high purity water to maintain equipment integrity and longevity. One of the key challenges is maintaining sufficient high-quality water in order to RO is one of the most efficient technologies for desalination. Nevertheless, it is a process with a high requirement of energy consumption, particularly for seawater. Therefore, optimizing the energy consumption in RO will improve the overall OPEX cost of the hydrogen production facility.LG Nano H2O manufactures RO membranes that incorporate the patented technology Thin-Film Nanocomposite (TFN). The membranes combine a competitive permeability with very high salt rejection offering superior permeate water quality with potential energy savings in SWRO(seawater RO) & BWRO(Brackish Water RO) operation. TFN membranes for seawater can reach up to 99.89% rejection with similar permeabilities to other membrane technologies. It can help to optimize the overall energy consumption of the water treatment process for the production of ultrapure water. This paper will show key points to consider when expanding your demineralized water plant especially the RO’s which provide the bulk of the work in the demineralization process.

This presentation intends to cover our carbon capture and utilization (CCU) project at its Clear Lake, Texas, site as part of its Fairway Methanol joint venture with Mitsui & Co., Ltd. The project was commissioned and is expected to capture 180,000 metric tons of CO2 industrial emissions and produce 130,000 metric tons of low-carbon methanol per year.

Ammonia has been widely used in fertilizers and industrial applications. In recent years, with the increasing momentum toward carbon neutrality, expectations for low-carbon emission (decarbonization) are also becoming prevalent in conventional ammonia plants.  

Mitsubishi Heavy Industries Compressor Corporation (MCO) has intensive experience manufacturing synthesis gas compressors (hereinafter referred to as syngas compressor) and associated steam turbine drivers (hereinafter referred to as syngas turbine) used in fertilizer plants with operating capacities up to 3,670 ton/day. We have utilized this experience in modernizing numerous syngas compressors & turbines which are in operation for the last 30 to 40 years. Based on this experience, this study introduces the case of a carbon footprint-based syngas compressor train modernization project.  

In ammonia plants, some historic factories have low production capabilities due to the use of outdated low efficiency compressors. Replacing those with the latest best available, current compressor technology not only expands the plant capacity, but also can help customers to improve their OPEX via increased efficiency. When upgrading an existing plant, it is preferable to minimize the scope of modification in order to keep the overall investment costs low. Based on our vast experience in footprint replacement (i.e., having delivered more than 350 units and technologies), we are capable to propose optimization or minimalize the scope of modification according to the existing plant conditions or based on customer requests. For example, in case of plant capacity expansion project, applying conventional design may result in larger size of compressor, and thus modification of existing concrete foundation would be necessary. On the other hand, available period for the revamping or replacement work is usually limited since the work must be done during plant turnaround period and evaluation of soundness for existing old foundation is quite difficult. However, by applying MCO’s unique customized design, the new compressor can be arranged to fit within the existing foundation, minimizing the modification scope of the entire project and supporting customers in maximizing their return on investment.  

Regarding steam turbine, in the past, two tandem turbines were used since there was no suitable blade especially for last stage (at low pressure section). However, as technology for turbines continued to advance, our experience has made it possible to replace the existing complex system with a simpler single turbine system. The benefit of this upgrade includes lower overall replacement costs (CAPEX) due to reduced piping, coupling, casing, and engineering costs, as well as lower maintenance costs (OPEX) due to reduced capital spare parts (such as rotors), 2-year spare parts, and overhaul costs, among other things. Less bearing loss, steam leakage, and pressure loss in the piping are some of the additional benefits to save steam, which contributes to the reduction of CO2 emissions and the achievement of sustainable development objectives.  

The risks associated with this kind of revamp are also discussed in this study and the associated countermeasures are explained. Furthermore, the lessons learned during execution of a project of this sort are also elaborated.  

In conclusion, there has been a recent trend toward increasing the productivity and carbon efficiency of current plants. And we believe that this study can serve as a reference for anyone associated with these plants. In addition, we hope this can educate new plant stakeholders regarding potential opportunities involved in design of a new plant.

Koch Methanol’s MegaMethanol™ facility in Louisiana was commissioned and began production in 2021. The plant was designed based on pipeline natural gas, which is widely accessible in this region and the most common feedstock for large-scale methanol production in the Americas. In 2023, Koch successfully implemented a carbon-rich feedstock pipeline that led to increased methanol production as well as a reduction in operating cost. This paper will discuss how Koch led a methodical approach, in collaboration with the expertise of the licensor and Clariant, to evaluate the risk to equipment and catalyst, develop new operating control envelopes to safely implement the project and optimize the plant. 

Many industries are looking for opportunities to remove carbon emissions from their current and future operations to meet their company’s sustainability targets and improve the environment. Currently, companies are asking how much carbon reduction is necessary to classify my product as “blue” and what technologies need to be employed. Acid gas removal units (AGRU) using amine technology is a proven method for separating CO2 from both process gases and flue gas streams. Both gas streams require tailored AGRU designs to optimize for specific operational challenges. Often CO2 removal from both source is necessary to qualify. This presentation will focus on the utilization of amine acid gas removal technologies to treat process gases and flue gases which would apply in a variety energy industries to provide cleaner fuel for the future.

Plant operations and mechanical integrity engineers working jointly with steam methane reformer experts to complete a deep dive analysis on catalyst tube inspection data, to gain a better understanding of:

• Furnace heat balance Impact of flue gas exit tunnel design
• Impact of operational issues such as steam: carbon ratio
• Impact of catalyst crushing on tube life
• Impact of burner management and flame impingement on tube life
• Impact of tube manufacturing tolerances and QA/QC on tube life  

2. Using the outcomes from this analysis to create a ‘tube harvesting program’, which ensures that only those tubes which are approaching end of life are changed out during the turnaround, avoiding the need for completing a full re-tube during a turnaround window.  

Catalyst tubes are essential in hydrogen production and are widely used in industries such as fuel refining, fertilizer manufacturing, and specialty gases. These tubes operate under extreme temperature and pressure conditions, necessitating the use of high-temperature-resistant materials. The reformer furnace, a complex system that includes catalyst tubes, burners, valves, heat exchangers, fans, and engines, is prone to failures, particularly in the radiant section where creep is the primary damage mechanism. Catalyst tubes are designed following the API-530 standard, with a typical service life expectancy of 100,000 hours (~11.4 years) under specified operating conditions. However, variations in these parameters can cause the tubes' service life to range from 30,000 to 180,000 hours. This study examines catalyst tubes that were in operation for 10 years at a major refinery in Northeastern Brazil. The tubes had experienced different operating histories, particularly regarding tube metal temperature (TMT) during the final 1.5 years of service, with some tubes exposed to higher temperatures showing signs of deformation. Mechanical, microstructural, and creep tests were conducted to assess the damage in the tubes. By comparing the degradation of these tubes to that of new materials, as well as using theoretical calculations based on creep and oxidation properties, the remaining service life of the equipment was estimated. The correlation between theoretical data and actual operating conditions provided reliable insights into the remaining life of the tubes, offering valuable information for decision-making regarding asset reliability and safety.

Phosphate hideout is a universal phenomenon that occurs in all boiler systems that use phosphate as a corrosion inhibitor. It occurs when there changes in heat flux on the boiler system, producing low or high phosphate in the boiler blow down samples. Incorrect action to phosphate hideout can result in tube wall thinning or blocked tubes from deposits, which normally produce tube ruptures.

This presentation will share our experience with phosphate hideout, how we reacted to it and how we have grown from understanding it. The submission will share examples of boiler failures because of poor response to phosphate hideout that resulted in several tube ruptures. Our journey learning what phosphate hideout is the hard way, and what the best chemistry control is for our high pressure and medium pressure boiler systems.

It is critical to understand how to identify phosphate hideout and even more so how to react when encountering it to maintain optimal boiler health. Failure to do so can lead to unplanned outages and the loss of millions in production time.

To remain competitive in the industrial marketplace, ammonia producers constantly evaluate projects that offer potential savings in operating costs, improved plant reliability, and increased production efficiency, while also promoting sustainable operation. Given the many impacts that the cooling water treatment can have on ammonia plant economics, plant engineers are often asked to review and optimize their existing cooling water treatment programs. This paper provides a case study that describes how changing the cooling water treatment program from a traditional phosphate-based chemistry to a customized non-phosphorus program resulted in significant cost savings and improved reliability at the Koch Fertilizer Ft. Dodge plant in Iowa. The new cooling water program allowed the plant to take the existing cold lime softener out of service with no significant impact on plant water use or discharge rates, while maintaining system cleanliness. This provided operational and maintenance cost savings, eliminated the tasks related to testing and operating the unit,  and removed health hazards associated with lime feed and other chemicals. The new program also resulted in several additional benefits that included reduced discharge of phosphorus to the environment, elimination of lime sludge management and reduction of solids carryover into the cooling water from the cold lime softener.

Plugging a U-tube in a Pool Condenser by welding  is a costly and critical repair job and for this reason Stamicarbon developed a special mechanical plug made out of Safurex®. With respect to the safe use of mechanical plugs in urea service, any crevice between plug and tube wall should be avoided, especially X2CrNiMo25-22-2 or X2CrNiMo18-14-3 tubes, since these austenitic materials are prone for crevice corrosion in ammonium-carbamate. In cooperation with Curtiss-Wright a special crevice free mechanical plug was developed. Accelerated corrosion tests in an autoclave confirmed the reliability of this design in combination with these austenitic materials.

The first Safurex® mechanical plugs are installed in an aging Pool Condenser in operation since 1994 in a Stamicarbon urea plant. The integrity and reliability of the X2CrNiMo25-22-2 U-bundle is compromised due to mechanical damages at the baffles; i.e. so-called baffle hammering. To extend the lifetime of the vessel around 40 U-tubes needed to be plugged.

The paper describes the successful installation of over 80 mechanical plugs in said Pool Condenser as well as the successful accelerated corrosion tests conducted in the autoclave.

The Safurex® plugs can be installed reliably not only in Safurex® but also in austenitic heat exchanger tubes such as X2CrNiMo25-2-2 or X2CrNiMo18-14-3. The Stamicarbon Safurex® mechanical plugs are now available for plugging high pressure  urea equipment, not only Pool Condensers but also other heat exchangers such a HP Stripper. HP carbamate Condenser or HP Scrubber.

Hydrogen has been traditionally used in large scale refinery applications, most commonly for  Hydrogenation operation, where adding a Hydrogen molecule to Hydrocarbon can help simplify  the molecular structure of the hydrocarbon, making it easy to process and use for variety of  consumer applications - from gasoline to specialty chemicals. The other common use of  Hydrogen is in Haber-Bosch process to make ammonia, that has critical application in the  agriculture sector.

Hydrogen is now getting more and more recognition every day as the energy carrier of the  future, expanding its potential use cases - as a direct fuel in transportation sector, or as a key  raw material for sustainable aviation fuels or SAF.

The most common pathway for making Hydrogen is via reforming of Natural Gas, by combining  it with Steam and Air, to make Hydrogen and tail gas, which is is mixture of carbon oxides,  unused methane, and other off gases. Typically, Carbon Dioxide (CO2) is produced as a  biproduct to be vented. The carbon intensity of this pathway is very high, and the Hydrogen  produced is termed as Grey Hydrogen. Conceptually, this CO2 can be captured and utilized or  sequestered. The carbon intensity is lower, and the Hydrogen is termed as Blue Hydrogen.  Another pathway that does not involve use of Natural Gas is through Electrolysis, that involves  splitting of Water molecule into Hydrogen and Oxygen by using electricity. If the electricity is  sourced through renewable sources, such as Solar or Wind, the carbon intensity of Hydrogen  made is very low, and is termed as Green Hydrogen.

Grey, Blue or Green, the Hydrogen produced is a very light molecule, which typically requires  significant compression for packaging cost effectively to be transported as compressed gas - over the road or through extensive Hydrogen pipelines. Compressors involve high frequency  moving parts, on both the gas side and on the electrical side, that are prone to failures.  Compressors, along with other auxiliary equipment requires optimal heat removal through heat  exchangers, for efficient operations. Heat exchangers require acceptable water quality to  perform effectively. Pipelines require extensive maintenance and testing to be compliant with  department of transportation (DOT) standards and avoid accidents and leaks. The Hydrogen  product itself has very high purity requirements (>99.999+ %), which is achieved by use of  Catalysts and Adsorbents at various stages of gas processing in traditional reformer plants, or  by using dryers and gas separation equipment of removing oxygen in case of Electrolyzer  throughput. Catalysts and adsorbents have a finite useful life due to being subject to impurities  and extreme temperature/pressure conditions. Loss of catalyst activity can result in lower  throughput and/or off-spec product quality. Malfunction of any of the equipment described  earlier can result in outages and downtime for Hydrogen plants.

Downtime can be very costly for Hydrogen producers because loss of Hydrogen supply to  refineries, for example, can result in multiple day outage to Hydrogenation units. Operational  uptime is critical to avoid liquidated damages to Hydrogen producers. A data driven strategy to  manage planned and unplanned maintenance is described in the technical publication, which  can result in higher plant availability and profitability, resulting in win-win offtake agreements  to all parties involved in Hydrogen economy.

Low Temperature Shift (LTS) catalysts are utilised in ammonia and hydrogen plants, maximising the amount of hydrogen produced whilst minimising the gas purge within ammonia synthesis loops. Modern LTS catalysts are designed to combine high activity and poison resistance with excellent selectivity to give low methanol by-product formation, allowing more efficient use of feedstocks in ammonia and hydrogen production.

LTS catalysts are typically a combination of copper and zinc oxides supported upon an alumina carrier. Due to the pyrophoric nature and instability of reduced and passivated copper, low temperature shift catalysts are typically supplied to customers in an oxidized state, and therefore must be reduced before putting into service. Copper catalyst display structural sensitivity, with the size and morphology of the copper crystallites playing an important role on the catalytic performance. Poorly managed reduction processes can lead to thermal sintering which can negatively impact the catalyst performance. Ensuring the reduction process is carried out correctly is crucial to maximizing catalyst stability, activity and life. This requires careful monitoring and comprehensive understanding of the parameters that affect this process. LTS catalysts are only reduced infrequently; any unfamiliarity with rarely used equipment, reduction process parameters or any error during the delicate operation of reduction can cause a potential damage to the catalyst.

This presentation describes the theory behind low temperature shift catalyst reduction followed by learning incidents and case studies along with discussion on Hazard Analysis and suggested best practices for this operation.

Many outages fail to learn form the past and continue to repeat history resulting in poor execution and failure to meet schedule and budgets. In order to be successful in capturing the lessons learned, you need to start with the end in minds and prepare ahead to obtain those lost opportunities that continue to hold back on improvements. this presentation will focus on:

• Implementing a sustainable process to capture Lessons Learned during a Turnaround and how to take advantage in a timely manner
• Conducting a post-project review and analysis to identify and categorizes findings so that it improves planning for future turnarounds
• Developing a culture of continuous improvement by dedicating time after a turnaround with stakeholders to capture important takeaways while they’re fresh on everyone’s mind
• Initiate preparation for your next event and proactively taking advantage of the knowledge gathered

KPI would like to share the experience and the challenges associated with conversion of existing Ammonia plants from Gray to clean/green. It is based on our detailed study work done for two large Ammonia plants followed by a detailed process design package for one of the plants.

It will present as a Case study covering the following key items.

• Background
• Feed Purification 
• Main Compressor & drivers
• Changes in Synloop equipment including converter
• New ARU/HRU requirement 
• Re-balancing Steam System 
• Turn down considerations
• Take aways

Plant efficiency is dependent on various factors, including technology, design, maintenance, and operational efficiency. The latter is heavily influenced by the competence and experience of plant operators as human error is one of the most important causes of loss of efficiency and of plant accidents. High turnover rates in the industry make it crucial to prioritize operator training and certification to ensure competent and experienced staff that can keep plant operation efficient and safe.

Operator training usually relies on theoretical and on-the-job training. While theoretical training is essential, practical training in a live plant environment is risky and impractical. As an example, it is not feasible to conduct training exercises that involve the startup of a plant solely for training purposes. High fidelity OTS provide a good means for risk-free practical training in both common procedures (start-up, shutdown, load change…) as well as in seldom occurring situations (leaks, sensor malfunction…). Nonetheless, OTS-based training of operators requires planning the training, monitoring performance, and scoring/certifying operators. For this purpose highly experienced plant operators who are usually not available must be involved.

These challenges would be solved by an integrated solution that combines autonomous training, examination and certification of plant operators both in theoretical content and in practical plant operation situations. This presentation will focus on one such a solution, the eCertifier, and will describe its architecture, present use cases and demonstrate the effectiveness and efficiency of this autonomous training and certification system in improving operator competence and plant efficiency in the chemical industry.

Virtual assembly is challenging historical maintenance paradigms by reducing downtime durations up to 75%, while improving quality and safety. Turbomachinery can be virtually assembled to identify and address assembly issues prior to physical assembly and eliminates traditional, manual, and iterative techniques. Internal clearances and component positioning can be optimized virtually, enabling the precise physical assembly of spare components. Virtual assembly allows us to reimagine the execution sequence for overhauling turbomachinery, enabling the rotor, bearings, and seals to be worked in parallel to the compressor casing, diaphragms, and other stationary components. Virtual assembly enables an innovative, modular approach to maintenance.  

There is a significant amount of detailed planning that is needed to optimize the execution sequence for turbomachinery overhauls, especially when there are multiple equipment bodies needing to be worked in parallel. Maintenance digital twins enable a realistic simulation down to a very granular level. These digital twins can highlight special tooling, rigging plans for complex lifts, and technical hold points for taking critical measurements. These detailed simulations can be leveraged for training engineers, technicians, and supervision prior to a downtime to ensure everyone fully understands the equipment layout, pieces and parts within the machine, and methods for overhauling the equipment. Digital twins can also be used for training new employees that may not have an opportunity to see the equipment open for many years and for knowledge retention of more experienced employees, capturing and incorporating their vast experience collected throughout their careers.

The steam methane reforming (SMR) industry is undergoing significant advancements with the introduction of UNICAT Catalyst Technologies’ Magcat catalyst. This innovative solution has demonstrated notable improvements in commercial unit performance.

Operational data indicate that Magcat catalyst achieves lower reformer tube wall temperatures, enhancing operational safety by reducing the risk of tube failure and extending the lifespan of the reformer tubes. This temperature reduction is crucial for maintaining the structural integrity of the reformer under prolonged high-temperature conditions.

Additionally, Magcat catalyst reduces fuel requirements, leading to lower emissions and contributing to more environmentally sustainable operations. The reduction in fuel consumption not only decreases the carbon footprint of the SMR process but also results in cost savings.

Optimization of hydrogen production is another significant benefit observed with Magcat catalyst. The catalyst’s advanced design and material properties facilitate more efficient methane conversion, resulting in higher hydrogen yields. This optimization is essential for meeting the growing demand for hydrogen in various industrial applications, including refining, ammonia production, and emerging hydrogen economy sectors.

This presentation will provide detailed commercial performance data, highlighting the operational benefits and economic advantages of Magcat catalyst. It will offer valuable insights for producers and licensors involved in SMR projects, showcasing how Magcat catalyst can enhance process safety, efficiency, and sustainability.

Cooling water is an essential component to the ammonia manufacturing process. Without it, parts of the process, such as steam turbine condensers, synthesis gas compressor, refrigeration gas compressor, etc, will not be able to remove enough heat to function properly. Although water is great at absorbing and transferring heat, it needs to be treated properly to ensure it is working and not interfering with the system.

Corrosion - Uncontrolled corrosion actively damages the pipes and heat exchangers in ammonia production system and shortens their lifespan of the equipment. They can lead to process streams leaking into the cooling water, expensive repairs, and possible shutting down a plant.

• Topics would include:
  • How does corrosion work and what are the different types of corrosion
  • What are the common industry practices for treating corrosion
  • How to monitor to ensure your system is being protected

Scale/Fouling – Scale formation and fouling will insulate your system and reduce the amount of heat that is being removed in the cooling water. This will directly translate to the production capabilities of the plant. It can lead to decreased production,

• Topics would include:
  • Common types of scale formation
  • Most common places for scale to occur
  • Industry practices for minimizing scale formation in ammonia plants

Microbiological Growth – Microbial growth in water systems provide greater insulation than scale, while leading to under-deposit corrosion and exacerbating fouling and scaling. Ammonia plants can be specifically vulnerable due to ammonia contamination via process leaks.

• Topics would include:
  • How does microbial growth occur in your systems
  • How does it impact the plant systems and heat transfer efficiency
  • Changes you can make and common strategies to help minimize the impact of microbial growth

Overview

Urea CO2 Stripping Plants Troubleshooting Workshop is meant for plant personnel and process engineers working in urea plants. This workshop will provide valuable insights into common malfunctions and inefficiencies affecting the synthesis section of a CO2 stripping urea plant and how to use digital tools to assist detection, diagnostics, and determining corrective actions.

Workshop Objectives  

This workshop is designed to provide a general description of the synthesis section of urea plants, main challenges involved in its operation and strategies to troubleshoot. The attendants will be able to acquire a sound understanding of a CO2 stripping plant synthesis section that will be applicable on their day-to-day operations. The workshop will also provide an introduction on the digital solutions used for the realistic demonstration of troubleshooting scenarios, and will cover how this tools can support efficient and safe plant operation.

Who Should Attend?

Plant Management, Engineering, Operations, Reliability, Maintenance and Health, Safety & Environmental in Urea plants. Digitalization in the process industry.

Workshop Contents

• Urea CO2 Stripping Plants
  • Process Description
  • Synthesis Section
• Introduction to Digital Solutions
  • Operator Training Simulator
  • Process Monitor
• Demo: Operation of a CO2 Stripping Plant - complexity, diagnostics, troubleshooting
• Q&A