chemieanlagen aus dem baukasten das pre-configured plant
TRANSCRIPT
October 25th, 2018 | Dr. Tarek El Hawary
Head of Product DevelopmentAmmonia & Urea DivisionBusiness Unit Fertilizerthyssenkrupp Industrial Solutions AG
Chemieanlagen aus dem Baukasten
Das Pre-Configured Plant Concept von thyssenkrupp Industrial Solutions
2thyssenkrupp Industrial Solutions
Agenda
• Introduction to thyssenkrupp Industrial Solutions
• Chemical plant engineering and construction business
• Architechture of pre-configured plant concept (PCPC)
• Journey to introduce pre-configured plant concept in the organization
• Summary / Outlook / Lessons Learned
3thyssenkrupp Industrial Solutions3
We are a global corporation with
presence in 79 countries with >2,000 sites
~ €42.97 bn sales and 158,739 employees &
4thyssenkrupp Industrial Solutions
Components Technology
Elevator Technology
Industrial Solutions
Materials Services
Steel Europe
Steel Americas4
Sales1
7,571 7,674 5,522 13,665 8,915 1,848EBIT2
377 922 111 312 547 186Employees³
32,904 52,660 21,777 19,861 27,646 0
Pre-configured plant conceptthyssenkrupp Business Areas: Key indicators – fiscal year 2016/2017 [€ mn]
1. Before consolidation | 2. Before consolidation/Corporate | 3. Sept. 30 | 4. discontinued operation
thyssenkrupp AG Sales: 42,971 | EBIT adj.: 1,910 | Employees: 158,739
5thyssenkrupp Industrial Solutions
Pre-configured plant conceptIndustries we serve
of our employees are engineers and technicians
machines and systems in use worldwide
chemical installations constructed worldwide
>17,600
Almost 70%
More than
Over 2,500
years of engineering excellence
200
6thyssenkrupp Industrial Solutions
Agenda
• Introduction to thyssenkrupp Industrial Solutions
• Chemical plant engineering and construction business
• Architechture of pre-configured plant concept (PCPC)
• Journey to introduce pre-configured plant concept in the organization
• Summary / Outlook / Lessons Learned
7thyssenkrupp Industrial Solutions
Pre-configured plant conceptthyssenkrupp Industrial Solutions - Business Units
Cement Technologies
Industrial Specialties
Fertilizer & SyngasTechnologies
Service
Electrolysis & Polymers Technologies
Marine SystemsSystem EngineeringMining Technologies
Network of Excellence
8thyssenkrupp Industrial Solutions
Leading technologies & engineering skills
Employeeswordwide
~25%Technicians
~45% Engineers
~30% Others
Global network & efficiency Local know-how & presence
Construction (C)Engineering (E) Procurement (P) Services (S)
Reliability & customer proximity
Pre-configured plant conceptJoint EPC-S business model with aspiration to grow
9thyssenkrupp Industrial Solutions
Pre-configured plant conceptWe are present wherever our customers need us – Regional cluster organization and workforces*
* as of May 12, 2017
RC North America1188
RC CIS451
RC Maghreb635
RC MEA564
RC APAC1452
Europe11852
RC South America486
India2974
10thyssenkrupp Industrial Solutions
Fertilizer industry
90 yearsexperience in the
construction of fertilizer plants
We offer
• All relevant technologies for the productionof fertilizers
• Outstanding management expertise for large-scale projects
• Modern global purchasing strategies
This enables us to supply you with optimum solutions offering maximum cost efficiency around the globe – reliable, sustainable and eco-friendly.
11thyssenkrupp Industrial Solutions
Portfolio
• Ammonia & urea
• Hydrogen & nitrates
• Phosphate fertilizers
• Granulation technologies (UFT)
• Coal gasification
• Services
Fertilizer industry
12thyssenkrupp Industrial Solutions
Pre-configured plant conceptIndustrial Solutions – Outstanding technology portfolio
Uhde / tkIS technology Core licences important intermediate stage
Ethylene dichlorideChlorineCaustic soda sol.
PVC
Polyurethane
Lube oil,waxes
Chlor-alkalielectrolysis
Coking plant
Ethylene
Bioethanol
CokeGasification/power plant
XyleneTolueneBenzene
Oil refinery
Propanedehydrogen.Crude oil
Coal
Salt
Renewableresources
Propylene oxide
Terephthalic acid
Caprolactam
Fischer-Tropsch synthesis
Lactic acid Polylactic acidSugar
Refining/fermentation
Steamcracker
Hydrogen
Propylene
Gasoline, diesel
PolyethylenePolypropylene
Polyester
Polyamide
Vinyl chloride
Plastics
Electric power
Steel
Fuels
Lubricants, waxes
Fuels
BioplasticsFine chemicals
Methanol
Hydrogen
Nitric acid
Urea
Ammonium nitrate
Ammonia
Natural gas/Shale gas
Formaldehyde
Methanol to Gasoline
Urea/Formaldehyde
Granulation
EnviNOx®
GranulationSteam reforming
Autothermalreforming
Feedstocks Intermediates
Adhesives, synthetic resins
Fertilizers
End products
Sulphuric acid
PhosphateSulphur
Phosphate beneficiation Sulphuric acid
Phosphoric acid DAP, MAP, DCP Granulation
Ethylene oxide Ethylene glycol
Oleo-Chem.Verfahren
Succinic acid
Specialty chemicals
10
13thyssenkrupp Industrial Solutions
Synthesis Gas Generation
Ammonia Plant
SulphuricAcid Plant
PhosphoricAcid Plant
Benefication
Gypsum
Urea Plant
AN PlantNitrid Acid Plant
AS GranulationAS Plant
NP(K)Granulation
(c) DAP/MAPGranulation
Urea Granulation
Melamine Plant
UFC Plant
AS
NP(K)
DAP/MAP
AN
UAN
Granules
Mela-mine
UFC
CANAS Solution
AN/CAN Granulation
UAN Plant
Potassium
ROM Phosphate Rock
Sulphur
Limestone
Energy(natural gas, naphtha coal,Biomass, hydrogen)
thyssenkrupp processes External processes
Feedstocks
Products
Nit
roge
n F
erti
lizer
Ph
osp
hat
e u
nd
Co
mp
ou
nd
Fer
tiliz
er
Prayon Incro
Incro
Stamicarbon
Eurotecnica
Pre-configured plant conceptIndustrial Solutions – Fertilizer portfolio
Urea Prilling Prills
Urea ES Granulation
Urea-ES
Sulphur Dispersing
14thyssenkrupp Industrial Solutions
Pre-configured plant conceptOur Portfolio
uhde® Ammonia Process50mtpd to 4.700mtpd
down to 6.5Gcal/ton [27GJ/ton]
A10-Series A20-Series A30-Series
A01-Series A04-Series
Stamicarbon LAUNCH Melt™300mtpd to 5.500mtpd
Ultra Flash
Pool Condenser
Pool Reactor
tk Fertilizer Technologyup to 5.500mtpd
Urea-ES
Fluid BedGranulation
Stamicarbon Prillingup to 4.000mtpd
DEF / UL50
15thyssenkrupp Industrial Solutions
1925: First ammonia pilot plant
1928: First commercial ammonia plant commissioned (4x25 mt/day reactors, 100 bar)
1954: First steam reforming plant
1970: Single train 880 mt/day with turbo-compressor, HP steam generation
in front end and ammonia synthesis
1971: 1400 mt/day, 225 bar pressure
1991: 1800 mt/day, two synthesis reactors, two waste heat boilers
2001: Dual pressure process presented
2004: 2000 mt/day, 210 bar pressure put into operation
2006: First dual pressure plant with 3300 mt/day put into operation
2011: Second dual pressure plant with 3300 mt/day put into operation
2016: Third/Forth dual pressure plant with 3300 mt/day put into operation
Pre-configured plant conceptIndustrial Solutions – Milestones in Ammonia Technology
16thyssenkrupp Industrial Solutions
… specialized fertilizer producers
… oftentimes special purpose companies
… in some cases part of the leading chemical companies
… owned by the state or
… owned by individual private investors or
… stock exchange listed or
… owned by cooperatives
Our customers are…
17thyssenkrupp Industrial Solutions
Sales
1 piece per yearper product
Pre-configured plant conceptMarket environment
4 years time ofproduction
Costs
50-2,000 million € per product (B2B)
Output of plant
4000 tonnes per day
Innovation cycle
10 years
Added value
10% Bid project time
6 months
18thyssenkrupp Industrial Solutions
• No Over-specification
• All optimizations incorporated
• Low configuration complexity
Solutions from executed projects are the basis for the next project
Plant configuration with pre-defined concepts
New Project (Example)
Module 2:
Module 1:
Concepts:
Concepts:
Module 3:
Ammonia Conditioning unit
Process water conditioning unit
Cooling water unit
Pre-configured plant conceptExecution concept – past and future
auth
ori
ties
Plant A
Plant B
Plant C
+
clie
nt
envi
ron
men
t
auth
ori
ties
clie
nt
envi
ron
men
t
auth
ori
ties
clie
nt
envi
ron
men
t − • Complete data set not available
Future SituationCurrent Situation
19thyssenkrupp Industrial Solutions
Pre-configured plant conceptProject target is to define a plant modular system which will be used as the basis for future plant proposal and execution
Plant 1Plant 2
Modular, pre-configured plant system
Plant 3
Specificelements
Sharedelements
Interfaces, Technologies, Processes, Solutions, Modules, Components
From individual / copied plants… …to a Pre-Configured Plant Concept (PCPC)
Nitrogenmüvek
CUF
20thyssenkrupp Industrial Solutions
Agenda
• Introduction to thyssenkrupp Industrial Solutions
• Chemical plant engineering and construction business
• Architechture of pre-configured plant concept (PCPC)
• Journey to introduce pre-configured plant concept in the organization
• Summary / Outlook / Lessons Learned
21thyssenkrupp Industrial Solutions
Pre-configured plant conceptIdentification of modules is based on the proven METUS® Methodology, applying the 18 core elements for optimization and implementation of Winning Products
Functionalstructure
Concepts &technologies
Product structure
Organization & processes
Production
Road-mapping
Variantdrivers
Interfaces
Standardi-zation & variance
Modulari-zation
Supplychain
Require-ments
Intellectualproperty
KPIs
Product portfolio
Modular system
INNOVATION
PRODUCT-ARCHITECTURE
PROCESSES &ORGANIZATION
PRODUCT MANAGEMENT
Winning Products
Market &customers
Cost & effectevaluation
10
09
11
08
12
07
13
06
14
01
05
15
04
16
03
17
02
18
22thyssenkrupp Industrial Solutions
Pre-configured plant conceptConcept of handling different technologies with overlap and governance
Nitric Acidspecific
modules
Ammoniaspecificmodules
Ammo-niumNitrates specificmodules
Hydrogen specificmodules
Cross technology modules
GovernanceProvide ruleset andtools to efficiently
reuse pre-configuredmodules
Urea specificmodules
Collect data for Ammonium Nitrates specific modules to
introduce METUS-model
Provide documentsfor Ammonia-specific
modules
Optimize Nitric Acidplant to improve
PCPC
Provide documents for moduleswhich can be reused across
several technologies1
2
4
3
5
23thyssenkrupp Industrial Solutions
Market view
…
…
…
…
<78
890
>55°
%
t
C
Civil
Groundwater depth
Substation location
>=1m
VIP_FM
%
%Product specification
Acid concentration
Plant capacity
Acid temperature
<62
500
>55°
%
t
C
Discipline view
Instrumentation
Rotating
…
NA plant
Plant
Disciplines
…
….
Functional view
Condition feedstock
…
Oxidize NH3 to NOx Produce NA
Function 2
Function 1
KPIs
KPIs
…
….
RH Cabin stepAmmonia booster
pump
…
RH Cabin stepRH Cabin step
RH Cabin stepRH Cabin stepAbsorption tower
Measuring devices
Components
E € P € C €
Component/modular
view
Modulesh
€
Plant
NA plant
NOx subcooling
…
Air intake
…
…
…
….
….
Pre-configured plant conceptDifferent perspectives to modules – example: Nitric Acid plant
24thyssenkrupp Industrial Solutions
Pre-configured plant conceptPCPC concept of nitric acid with re-use potential across technologies
Cross technology
Module 18
Cross technology
Module 19
Cross technology
Module 11
Cross technology
Module 7
Cross technology
Module 5
NA
Module 3
Cross technology
Module 3
NA
Module 7
NA
Module 6
.
NA
Module 5
Cross technology
Module 4
NA
Module 2
NA
Module 4
Cross technology
Module 6
NA
Module 1
NA
Module 9
Cross technology
Module 2
Cross technology
Module 12
Cross technology
Module 14
Cross technology
Module 15
Cross technology
Module 16
Cross technology
Module 1
Cross technology
Module 17
Cross technology
Module 13
Cross technology
Module 10
NA
Module 8
NA
Module 10
Cross technology
Module 9
Cross technology
Module 8E
P
C
25thyssenkrupp Industrial Solutions
© Copyright ID-Consult GmbH 25
VD 1
VD 2
VD 3
Differing customer requirements…
…are transformed into a modular system
BACustomer
V
S
V
Variant D.
Product function
Sub-function
ComponentV
V
Module
V
ProductProduct
SV
Values
S
V
S
V
Supplier
1
4
65
Equipment
Variant Drivers
Concepts &Technologies
2
Variant Values
Design Parameter
Module7
3
Functions0%
25%
50%
75%
100%Variant Drivers
Variant Values
Functions
Concepts &technologies
DesignParameter
Components
Modules
Degree of harmonization (examples)
low
medium
high
1
2
3
45
6
7
Degree of harmonization
Module A Module B Module C3 modules (examples)
low medium high
Pre-configured plant conceptDifferent degrees of harmonization can be achieved by using specific levers for complexity reduction
26thyssenkrupp Industrial Solutions
Pre-configured plant conceptA company-specific optimum has to be found by degree of harmonization between technologies
Cost
Degree ofharmonization
Optimum
We can’t do without harmonization, but a maximum degree of harmonization is also
not a cure-all
• Modularization is a key lever to handle efforts across department and needs harmonization in between
• Synergies of different technologies become obvious
• Increased customer loyalty because of consistently designed plants with market-oriented differentiation
Comments and conclusion
• Parallel processing of process steps
• Reduced part diversity• Reduced effort for
testing the overall system
• Increase of quality• …
• More interfaces (costs)• More single parts• Increased one-
time expenses• Increased assembly
effort• More installation space• …
Identification of the company-specific optimum
as a combination of the requirements of all
stakeholders
Goal
27thyssenkrupp Industrial Solutions
Pre-configured plant conceptSummary of METUS figures: Nitric Acid was PCPC frontrunner – Ammonia and further technologies followed
Variant drivers
Variant values
Functional
Modules
Components
1st PCPCNA only
All PCPC technologies
482
815
122
141100
90 14
1,282
AN Cross-Tech.O&U NAH2 NH3
197
288
3938
40
439
331
20
65
20
38
23
9
161
2
13
29
275 838
248
924
428
179
55
2,672
Harmonization between technologies
• Methodology developed with manageable product, role out to more complex main product
• Compared to NA, NH3 and other technologies use much more crucial elements of plant model
• Synergies clearly visible in Cross-Technology elements
Comments and conclusion
28thyssenkrupp Industrial Solutions
Agenda
• Introduction to thyssenkrupp Industrial Solutions
• Chemical plant engineering and construction business
• Architechture of pre-configured plant concept (PCPC)
• Journey to introduce pre-configured plant concept in the organization
• Summary / Outlook / Lessons Learned
29thyssenkrupp Industrial Solutions
Pre-configured plant conceptJourney to introduce pre-configured plant concept into the organization
Proposal A
De-Specification /De-Customizing
Custo-mizing
Contract B
time
R&D ProjectsContinuousupdate
Continuousimporove-ments
De-Specification /De-Customizing
Nitric Acid
Am
mo
nia
Lessons Learned
New inputsContinuousupdate
Custo-mizing
Hyd
roge
n
Am
mo
niu
m
Nit
rate
s
Procurement IntelligenceSales Intelligence
Ure
a
Cross-Technology
30thyssenkrupp Industrial Solutions
Pre-configured plant conceptGovernance workstream drives tasks on several action areas to support pre-configured plant concept along its lifecycle
Act
ion
are
as o
f P
CP
C
Define target portfolio
Develop pre-conf. plant
Implement pre-conf. plant
Apply pre-conf. plant
Optimize pre-conf. plant
Extend pre-conf. plant
PCPC Manage-ment process
Introduce PCPC committee
PCPC committee working
Introduce KPIs for PCPC
KPIs to control PCPC maturity & efficiency
Qualification of PCPC developers
Communication to stakeholders
Develop time independent cost relevant quantities
Combine developed quantities with daily price figures
Cost Estimation Database
People
KPIs
Processes & Organization
Each task is broken down into steps to comprehensively manage PCPC
Tool interface between METUS and COMOS
Bid preparation supportTools
Examples for tasks within Governance workstream
31thyssenkrupp Industrial Solutions
Pre-configured plant conceptProcesses & Organization: PCPC-Committee to systematically manage modular system across Technologies
PCPC-Committee
Decision board to
assure profitability
and attractiveness
of PCPC for
projects
Optimize modules
integrating the
view of market
and technology
Challenges:
• Committee has to be built across functions and across Technologies
• Existing organizational structures have to be incorporated
• Existing processes have to be adapted
• Rhythm of PCPC-Committee meetings and decision-making power have to be clearly defined and aligned
Case study between different technologies showed
ability to reach consensus for PCPC changes
• Participating functions defined
• Decision to be taken on variant drivers and values to be used to fit market needs
• Concepts to be used to provide best available technology
• PCPC-Committee formalizes the discussions (which were lead between developing PCPC teams during project phase)
Comments and conclusion
Sales
Component System
Commission (CSC)
Component System
Manager
PCPC-Manager
Construction
Process
Procurement
and more…
Engineering Disciplines
32thyssenkrupp Industrial Solutions
Pre-configured plant conceptKPIs: Measuring PCPC efficiency and continuous improvement is defined, validated an integrated in KPI-Dashboard
PCPC maturity
Bid support
Origin KPIRequest KPICross-technology
KPI Documents KPI
• Existing key performance indicators (KPIs) serve as base, are reused and further developed
• A new set of key performance indicators (KPIs) is defined, validated and agreed with stakeholders
• Detailed description of meaning, goal of metric and calculation is available
Comments and conclusion
Quality KPIStandardization
KPITime KPI Budget KPI
Change KPI
10 10 20
Dashboard allows easy tracking over time
Exemplary selection
33thyssenkrupp Industrial Solutions
Pre-configured plant conceptPeople: The “see it, do it, teach it” approach supports sustainable knowledge transfer and creating value for tkIS
33
METUS BASIC / ADVANCED USER
Experience: Understands the concepts of product architecture design and
modularization.
Support: Heavy facilitation and Ad-hoc queries
METUS ARCHITECT
Experience: Can apply the learned concepts to own workshops and
projects.
Support: Ad-hoc remote support and hands-on on-site support
METUS MANAGER / MASTER
Experience: Can teach and multiply the learned concepts within tkIS
Support: Train-the-trainer and Ad-hoc critique of workshop outputs and
project guidance
“SEE IT”
ID-Consult leads activities, showing
how to apply the tool and methods
“DO IT”
tkIS leads the activity, using tools and
methods with ID-Consult’s support
“TEACH IT”
tkIS resources consolidate their
knowledge through training others
internal capability of tkIS growsIDCs support to build tkIS capability reduces
On the job coaching
Formal training
Real-time feedback
Businessgames
Train-the-Trainer
time
knowledgedepth
• First get in touch by “see it” transfers both theoretical and practical knowledge
• Basic knowledge is broadened by “do it” by means of methodical guidance of ID-Consult
• tkIS gradually takes over control of knowledge transfer to manage and train newly introduced features
Comments and conclusion
Basis for implementation and work in projects is established
34thyssenkrupp Industrial Solutions
Pre-configured plant conceptTools: Customizing METUS allows full adaption to tkIS’ PCPC modular system
• 1st step: add formulas to aggregate data and automatize workflows in a rudimental way
• 2nd step: add scripts to partly automatize workflows
• 3rd step: use pre-defined METUS apps to fully automatize workflows
Comments and conclusion
METUS supports by easy data aggregation, pre-defined
calculations to semi- or fully automatic routines
1st: Formulas 2nd: Scripts
Programming language is “groovy”
3rd: METUS Apps
35thyssenkrupp Industrial Solutions
Define plant specification
Validate module variants
Identify corresp. PFDs
Combine PFDs into new plant
Fine-tune & customize plant
Generate requ.‘d documents
Market Expertise
Opport. Managmt.
Feasibility & Concept
Basic design
Detail design
Con-struction
Commis-sioning
Service
Pre-configured plant conceptTools: Certain bid preparation activities will be executed in METUS, others in COMOS
Bid Managmt.
Comments and conclusion
Data & Tools to apply for PCPC are defined, verified by use
cases and adapted
• First idea of data exchange between METUS & COMOS & METUS by simple use case
• Requirements from PCPC use cases towards interfaces and data exchange are derived
36thyssenkrupp Industrial Solutions
Pre-configured plant conceptTools: Developing a PCPC Configuration Tool enables user-friendly pre-configuration adapted to tkIS’ needs
• Configurator core features:
− Creation of new plant
− Edit of existing plant
− Run of Variants Management App (METUS)
• Automatic Bill of Material generation
• Automatic export for Comos
• Offline capabilities
• Extension for plant complexes
Comments and conclusion
Secure handling ofpre-configuration data
on internal METUS server
Intranet
Server
(running METUS)
Configurator
(WEB UI)
VPN
Configurator
(WEB UI)
Configurator
(WEB UI)
Configurator
(WEB UI)
Configuration Devices:
• Desktop
• Tablet
• Mobile
Prerequisite for introducing a configurator is a clean ruleset concerning the
product which is provided by METUS
37thyssenkrupp Industrial Solutions
Pre-configured plant conceptCost: Module-based cost model expanded common cost calculation
• Incorporation of cost data regarding different…:
− Types of cost
− Origins
− Calculation measures
− Cost centers
− and more
• Ensure cost data actuality and exchange mechanisms
Comments and conclusion
Adapted cost model for PCPC available
components sub modules modules product
Technical basis for
Cost input
PCPC Model Kit contains only time
independent technical information as a basis for downstream cost
factoring
exemplary cost allocation
Construction
Procurement
Engineering
Non-conformity
Others
38thyssenkrupp Industrial Solutions
Agenda
• Introduction to thyssenkrupp Industrial Solutions
• Chemical plant engineering and construction business
• Architechture of pre-configured plant concept (PCPC)
• Journey to introduce pre-configured plant concept in the organization
• Summary / Outlook / Lessons Learned
39thyssenkrupp Industrial Solutions
• Chemical plant engineering starts with modularized approaches
• thyssenkrupp introduced a holistic method as a frontrunner
• Synergies can be found by definition of cross technology modules
• Different levels of harmonization are reasonable
Pre-configured plant conceptSummary / Outlook
Summary
PCPC @ tkIS
tkIS clientsupplier
DriveProgress
ApplyPCPC
LeverageBenefits
• Continue the journey to complete the implementation of PCPC @ thyssenkrupp
• Gain all synergies from procurement and sales
• Identify right proposals / projects for application of PCPC
Outlook
PCPC Publications in „Process“ 01/2018 and
„im+io“ 03/2018
40thyssenkrupp Industrial Solutions
Pre-configured plant conceptLessons Learned
Start small –get bigger • Start with small product and role out to main product
• Establish METUS Forum andexecute project in task force office organization
• Pyramidal star-user profile for methodology and software
• Alternate steering committee format by formalppt-presentation vs. stand-up meeting in METUS Forum
• Stakeholder involvement by casual pizza talks
• Achieve ownership of governance / cross function
• Get every stakeholder on board with supportby upper management
Ensureknowledge
transfer
Communicateoften &
in different forms
Getmanagement
buy-in
41thyssenkrupp Industrial Solutions
Pre-configured plant concept
WINNING PRODUCTS
…MAKE WINNING COMPANIES
Thank you for your attention