Category: Innovation

M. Østberg and M. Rautenbach of Haldor Topsoe describe ReShift ™ technology, a new high temperature CO 2 reforming process, where preheated CO 2 is added directly downstream of a main reformer and then equilibrated in an adiabatic reactor. This new technology makes use of the high temperature of the reformer effluent to circumvent carbon formation, while at the same time maintaining an overall minimum steam to hydrocarbon carbon ratio, depending on process specific conditions. An increase in the amount of CO 2 added to the process will result in an increased fraction of CO in the produced synthesis gas. Synthesis gas with H 2 /CO ratios in the range 0.5-3 can be produced. These CO-rich gases are typically utilised in the production of functional chemicals and synthetic fuels.

Temperature monitoring and measurement of the Claus thermal reactor in sulphur recovery units is one of the most challenging applications in the oil and gas industry. Recently, market interest in unpurged thermocouples has increased with the introduction of new unpurged thermocouple designs utilising alternative thermowell materials such as monocrystalline sapphire.

N. Clark, B. Avancini and V. Sturm of Clark Solutions discuss a novel technology, SAFEHX® , providing a new approach to the cooling of strong sulphuric acid. Prototype results are shown and indicate a safe and stable cost-effective technology. SAFEHX® can be extended to every heat exchanger system where corrosion, mixture risks, fouling, process liquid loss (or contamination) and temperature control are key concerns.

Prayon’s Hadrien Leruth and Marc Sonveaux highlight the latest phosphate production developments at the company – and share their experience of how innovative ideas are validated, industrialised and turned into commercially-viable technologies.

Recent innovations in fertilizer granulation include thyssenkrupp’s new process for premium ammonium sulphate production. Eirich has launched new equipment for NPK granulation, while Rhewum is also offering new screening technology.

By harnessing the power of real-time data and exploiting the opportunities provided by digital solutions plant owners can achieve greater plant efficiency and reliability. In this article Stamicarbon shows the benefits of the Stami Digital Plant Optimiser for urea plants, OnPoint Digital Solutions provides a case study on optimising primary reformer heater operations using Smart Combustion™ , TOYO provides an update on its digital transformation service DX-PLANT® and thyssenkrupp Industrial Solutions provides examples of how digital solutions can be used to improve plant operation.

As the world focuses on clean fuels for the 21st century, there is an emerging opportunity to use ammonia as a source of hydrogen. Hydrogen fuel cells are expected to play a significant role as part of a clean energy portfolio. T2M Global and its development partner, SAFCell, are collaborating to develop a modular system to produce hydrogen from ammonia using a novel solid state separation system that does not require pressure or solvents. P. Patel of T2M Global, C. Chisholm of SAFCell and V. Pattabathula of Incitec Pivot explain the challenges, the opportunities and the current status of this new technology.

Evaporation and crystallisation are widely used throughout the fertilizer industry. Major applications and the types of equipment used are reviewed by Laurent Palierne and Norbert Strieder of GEA Group.

We highlight recent innovations in sulphuric acid plant design and construction. NORAM and CPPE are offering a new hybrid sulphuric acid process. KVT, meanwhile, has upgraded its wet sulphuric acid technology to reduce capex, opex and emissions. Improved methods of construction and new materials from Koch Knight are also helping to optimise acid tower design

Applied Analytics discusses potential improvements made possible with data and analytical measurements fed into improved mathematical models to produce a more proactive approach to control and better performance of sulphur recovery units, AMETEK Process Instruments explains the benefits of feed forward control, SICK reports on reliable continuous emission monitoring systems and WIKA introduces a new purge-free system to measure refractory temperature in the Claus reaction furnace.