Technology Services Lifecycle solutions for your plant

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Technology Services

Lifecycle solutions for your plant

Our new name is

ThyssenK

rupp Industrial

Solutions

www

.thyssenkrupp-indust

rial-so

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Content

Scope of services 4

Added value 6

Fields of activity 8

Expertise – more than 2000 plants worldwide 10

Case studies 12

Quality management 20

Competences 22

thySSenKrUPP UhDe

one gloBal netWorK.

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Company proﬁ le

With its highly specialised workforce of more than 5,600 employees and its international network of local organisations, ThyssenKrupp Uhde, a Dortmund-based engineering contractor, has to date successfully completed over 2,000 projects throughout the world. ThyssenKrupp Uhde’s international reputation has been built on the successful application of its philosophy engineering with ideas to yield cost-eff ective high-tech solutions for its customers. The ever-increasing demands placed upon process and application techno-logy in the fi elds of chemical processing, energy and environmental protection are met through a combination of specialist know-how, Company proﬁ le

With its highly specialised workforce of more than 5,600 employees and its international network of local organisations, ThyssenKrupp Uhde, a Dortmund-based engineering contractor, has to date successfully completed over 2,000 projects throughout the world. ThyssenKrupp Uhde’s international reputation has been built on the successful application of its philosophy

yield cost-eff ective high-tech solutions for its customers. The ever-increasing demands placed upon process and application techno-logy in the fi elds of chemical processing, energy and environmental protection are met through a combination of specialist know-how,

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Scope of services

The modular services concept, which consists of basic, system, performance and consulting services, presents a range of options for increasing effi ciency, conserving resources and reducing emissions. The concept enables operators to identify any potential for optimising their existing plants, and provides a framework for implementing improvements within the fi xed budget and timeframe.

The innovative building block system of optimised components off ers the following advantages:

• Flexible approach to troubleshooting • Technical and commercial calculability • Everything from a single source • Verifi ably proven in reference plants,

with room for further optimisation

revamp of hydrocracker blown-down system

moDUlar

SerViCeS

ConCePt

Maintaining values

Services and high-tech solutions for the entire life cycle of your industrial plant

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• Maintenance and repair

• Maintenance planning and management • Shutdown, turnaround

• Supply of spares and wears

• Root cause analysis and troubleshooting • Inspection

• Condition monitoring

• Replacement of systems, components

• Process optimisation

• Energy effi ciency improvement • Capacity increase • Lifecycle extension • Feasibility studies • Reliability-centered maintenance (RCM) • Technical consulting • Training

BaSiC

SerViCeS

SyStem

SerViCeS

PerFormanCe

SerViCeS

ConSUlting

SerViCeS

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ThyssenKrupp Uhde serves all phases in the life cycle of an industrial plant and for this purpose develops tailored concepts for revamps and production increases, maintenance and repair, compliance with environmental stan-dards and enhancing the cost-eff ec-tiveness and productivity of industrial facilities throughout the world. These concepts are implemented reliably, effi ciently and ﬂ exibly to satisfy the requirements of our customers who wish to equip their facilities to meet the challenges of today’s competitive climate.

As a supplier of state-of-the-art, commercially optimised services, ThyssenKrupp Uhde is your ideal partner if you are looking to gain the decisive edge over your competitors.

Added value

reVamPS,

UPgraDeS &

moDerniSationS

• Process improvement • Improved quality • Increased availability

• Improved safety and reliability • Cost effi ciency

• Increased capacity

It is hoped that valuable shorter-chain products will increase the sales opportunities and profi t of a Petrogal refi nery. The revamp of two reactors will also play a signifi cant part in this. at the same time, the emergency shutdown system is being improved, thus enhancing plant safety.

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oPeration &

maintenanCe

• Customised maintenance services • Minimised downtimes

• Highly qualifi ed staff • Backbone of maintenance

managament (CMMS)

• High availability of right spare parts

enVironmental

ProteCtion

• Environmental improvements • Health, safety & sustainability • Emissions reduction

• Energy savings

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Fields of activity

ThyssenKrupp Uhde is constantly improving and expanding its process portfolio with the aim of providing its customers with even more cost-effective and, at the same time, safe, environment-friendly plants. Proprietary developments, cooperation with external partners and the acquisition of technologies all play a key role in achieving this aim. We thus guarantee at all times up-to-date, technically optimum solutions for our custo-mers, combined with comprehensive, state-of-the-art services for the entire industrial plant construction business in the following fields: Technology and Contracting.

FertiliSer

Ammonia & Urea

Nitrates

Upstream & downstream

oil & gas

ContraCting

Professional overall management with short project exe-cution periods and minimal downtimes

Refining technologies

Steel mill technologies

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Market leading modular technologies

In the production of chlorine and caustic soda solution, ThyssenKrupp Uhde‘s energy-efficient and environment-friendly “single-element” membrane technology is second to none.

BaSe ChemiCalS

Hydrogen

Electrolysis

Coke plant technologies

Gas technologies

PolymerS

Organic chemicals

& polymers

Polyester, polyamide

& polylactic acid

High-pressure technologies

Biotechnologies

teChnologieS

not only for plants built by us

hP6008 is Uhde high Pressure‘s biggest co-monomer pump (vinyl acetate pump). it operates at a maximum pressure of 325 bar and can pump a maximum 5,400 litres an hour.

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Expertise – more than 2000 plants worldwide

185 plants

53 plants

We are your partner

not only for greenfi eld projects but also for

tailor-made revamps, modernisations and

optimisations for the entire life cycle of

your plant

High-tech engineering

Effi cient coordination and eff ective interfaces

In the international plant construction industry, it is essential for companies to provide fi rst-class processes which guarantee industrial plant operators an optimum in quality and operational economy.

Not only does ThyssenKrupp Uhde meet these demands, we have also geared our strategy towards further growth in inter-national markets and towards adopting innovative new processes to boost our existing technology portfolio.

ThyssenKrupp Uhde‘s particular strength is its ability to off er complete production chains incorporating its wealth of expe-rience in process-related areas.

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89 plants

789 plants

898 plants

212 plants

Ammonia & Urea

Nitrates

Hydrogen

Electrolysis

Coke plant technologies

Gas technologies

Organic chemicals & polymers

Polyester, polyamide & polylactic acid

High-pressure technologies

Biotechnologies

Upstream & downstream oil & gas

Refining technologies

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Case studies

Contracting

Oil & Gas

General Maintenance Service Contract for Oil & Gas Separation Plant

Client

Mellitah Oil & Gas B.V. location North Africa Capacity Gas: 12.7 MMscm/d Oil: 60,000 bopd Project description

• Establishment of complete maintenance organisation

• Engineering and planning

• Computerised maintenance management system (CMMS)

• Modifi cations and optimisation • Performance incentives

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Fluidised-Bed Lignite Drying Technology

Up-Front Pre-Engineering for Lignite Drying

and Milling

Client

RWE Power AG (licensor) location

Hürth-Knapsack, Germany Capacity

Raw coal: 2 x 420 t/h (max.) Dry coal: 2 x 110 t/h (max.)

Project description

• Process description for entire unit • Specifi cations for main equipment • Layout engineering

• Process ﬂ ow diagrams • Equipment lists

• Fire and explosion protection concept • Investment costs

Steel Mill Technologies

Mobile “High-Performance” Dedusting System for

Bulk Cargo Unloading

Client

ThyssenKrupp Steel Europe location

Duisburg/Hamborn, Germany

Capacity

18,000 MT/d raw material for blast furnaces

Extremely effi cient dust collection system with very low energy consumption:

• Dust collection system optimised in laboratory-scale tests

• Dust suction hoods with a dust collection effi ciency of between 91 and 97 %

• Approx. 50 % less energy consumption than conventional systems

• Reduction of approx. 27 % in capital investment as well as maintenance and repair costs • Dust levels below statutory thresholds

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Case studies

Technology: Fertiliser

ammonia & Urea

Performance Improvement of Ammonia Plant

by means of ThyssenKrupp Uhde Dual-Pressure Process

Client Duslo a.s. location Sala, Slovakia Capacity 1,300 mtpd ammonia Project description

Revamp/capacity increase of 1973 vintage ammonia plant: • 30 % capacity increase to 1,300 t/d

• 5 % reduction in energy consumption • Patented “Uhde Dual-Pressure Process” • No need for long shutdown

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ammonia & Urea

Capacity Increase of Two Parallel Urea Plants with MP Add-On Technology

Client

Egyptian Fertilizer Co. / Cementech Ltd. location Ain Sukhna, Egypt Capacity 2 x 2,250 t/d urea

Revamp/capacity increase of two urea plants in parallel: • Engineering and procurement

• Capacity increase of approx. 18 % to 2 x 2,250 t/d • Implementation of Stamicarbon “MP add-on technology”

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Case studies

Technology: Base Chemicals

Electrolysis

Full Service for Element Upgrade of a BM2.7v3 Electrolyser

Client Vinnolit Knapsack location Hürth, Germany Capacity 32,000 t/y NaOH Project description

Full service for the revamp of a complete BM2.7v3 electrolyser: • Disassembly of the single elements

• Revamp of 165 anodes through the introduction of new C profi les by laser-welding

• Recoating of cathodes • Delivery of spare parts • Transport and logistics

• Assembly of 165 revamped elements “BM2.7v3 – upgrade” • Loading of electrolyser racks with revamped elements

incl. pressure testing

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Coke Plant Technologies

Revamp of Pushing Emissions Control (PEC) Duct at Prosper Coke

Oven Plant during Ongoing Oven Operation

Client

RAG Aktiengesellschaft location

Prosper coke plant, Bottrop, Germany Capacity

2 m t coke per year

Replacement of full length (approximately 400 metres) of DN 2100 PEC duct, in operation since 1985.

• Re-engineering, fabrication, supply and installation of new PEC duct incl. manholes and pipe saddles

• Supply and installation of a new cover strip, ﬂ ange width 1000 mm • Refurbishment of concrete support heads (support points of suction line)

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Case studies

Technology: Polymers

Polyester (PET)

Two-Fold Capacity Increase at a Polyester Production Plant

Client

Indorama Polyester Industries PCL location

Thailand Capacity 270 t/d

Increase in the capacity of a polyester plant commissioned by Uhde Inventa-Fischer in 1990 from 120 to 270 tonnes per day with no loss in product quality.

• Calculation, design and engineering of all core components for the entire process chain (raw materials and additives consumption, reactors, columns, product lines, granulation unit, utilities, HTM [heat transfer medium] and control system)

• Supply of performance and quality-critical components, especially proprietary equipment

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Organic Chemicals & Polymers

LDPE – Plant Revamp

Client SCG Chemicals location Map Ta Put/Thailand Capacity 100 kt/a Project description Target:

• Shift production from fi lm to coating grade • LP steam production

• Increased plant reliability Scope:

Engineering, procurement, construction and commissioning supervision for

• Product cooler modifi cation • Recycle gas cooler modifi cation • New steam generation unit

Organic Chemicals & Polymers

EDC/VCM – Plant Revamp

Client

Petroquímica de Venzuela location

Ana María Campos, Venezuela Capacity

130 kt/a

Revamp and expansion measures including integration of a new state-of-the-art “EDC cracker”, achieving a capacity increase of 20 %.

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Quality management

General maintenance

services for desert

plant, MENA

ThyssenKrupp Uhde‘s aim is to design and construct chemical and industrial plants which boast the highest possible degree of reliability, safety and environmental compa-tibility to ensure the complete satisfaction of our customers and all those involved in the project.

The application of our quality management system has been certifi ed to DIN/EN ISO 9001 standards by an independent institution at regular intervals since 1993. This QM system is used to ensure that we meet our customers´ requirements for a high-quality “product”. As far as quality management within the fi eld of plant construction is concerned, “product” means all documents, equipment and services involved in the construction of the fi nished plant. The QM documentation defi nes the procedures to be followed by each individual employee involved in bid preparation and contract execution.

These standard engineering procedures are all components of the system we call Uhde Total Engineering (UTE). UTE contains a detailed description of procedures in which all key activities, i.e. preparation of the bid, contract management, engineering, pro-curement, erection and commissioning, are defi ned and portrayed in a logical sequence. All employees throughout the world are kept abreast of the constant improvements to the quality instructions via an internal network. It pays to invest in quality!

modernisation of the electrical equipment and instrumentation at the Abu Qir I and II fertiliser complexes

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An experienced team

of experts guaranteeing

optimum quality

standards

Intelligent technologies from thyssenKrupp Uhde and Bayer improve energy eﬃ ciency

Commissioning of fi rst industrial-scale plant for climate-friendly chlorine production