chemieanlagen aus dem baukasten das pre-configured plant

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 &


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


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


Agenda







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


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


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


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.


Portfolio

• Ammonia & urea

• Hydrogen & nitrates

• Phosphate fertilizers

• Granulation technologies (UFT)

• Coal gasification

• Services

Fertilizer industry


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


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


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


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


… 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…


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


• 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


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


Agenda







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


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


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


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


© 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


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


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



Agenda







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


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


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)


Sales

Component System

Commission (CSC)

Component System

Manager

PCPC-Manager

Construction

Process

Procurement

and more…

Engineering Disciplines


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


Quality KPIStandardization

KPITime KPI Budget KPI

Change KPI

10 10 20

Dashboard allows easy tracking over time

Exemplary selection


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


Basis for implementation and work in projects is established


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


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


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.


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


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


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


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


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


Agenda







• 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


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


Pre-configured plant concept

WINNING PRODUCTS

…MAKE WINNING COMPANIES

Thank you for your attention