Our Market is the World

Transcription

1 Our Market is the World

2 Our Market is the World Managing Director Dr.-Ing. Hans-Jürgen Schrag It was a long way from Meerane to Nanjing but we enjoyed every step of the way. When Franz Louis Oschatz worked on the first steel sheet in his workshop in Saxony in 1849 and my father founded the company anew under this name in 1948, neither of the two would have thought that in 2006 a huge manufacturing plant would start production in China under the Oschatz name. Today, Oschatz is a globally operating plant constructor with approximately 800 employees as well as subsidiaries, representatives, and branches all around the globe. Despite our global thinking and acting, our commitment and close contact to the customer have remained just as they were during the founding years. We follow a clear concept: With our know-how, products, and services, we realize the maximum possible productivity and cost effectiveness for our customers. Today, Oschatz is building plants that function reliably even after many years of rigorous continuous operation and just as important can be upgraded with new technologies. On the following pages, we would like to further introduce our company to you. And if you would like to know more, just visit us on the Internet at F.L. Oschatz is founded in Meerane, Germany The company manufactures tanks for breweries and malthouses Delivery of the thousandth boiler and pressure tank Oschatz manufactures boilers with outputs of 220 t/h and 150 bar The first steam boiler is being built. 2

3 Our market is the world Innovative + Reliable Waste Heat Systems for Non-Ferrous Metallurgy For decades, Oschatz waste heat boiler systems have been used throughout the world in all processes of extraction of non-ferrous metals such as copper, zinc, or lead. Our engineers develop customized solutions for each individual customer's plants and processes, according to their particular requirements and needs. The goal: Maximization of productivity and profitability. Not only the hot, sticky, and dust-laden process gas but also the different processes in non-ferrous metallurgy represent a challenge for our gas cooling and heat recovery boiler technology. But thanks to state-of-the-art manufacturing methods for gas cooling surfaces in combination with innovative cleaning systems for heat transfer surfaces, the manufacture of safe and reliable process gas cooling systems is made possible. Due to our customized solutions, these systems provide our customers with the option to increase the capacity if required, even after decade-long operation. All Oschatz systems are manufactured with state-of-the-art technology so that, even after many thousands of hours of operation, they keep functioning optimally and with high reliability. With our diversified product range, we address all the needs of the non-ferrous metallurgy industry worldwide. Among other things, we deliver tailored solutions for the following processes: Flash smelting ISASMELT Ausmelt Fluidized bed roasting Cyclone smelting/gasification Transport of a pre-assembled flash smelter waste heat boiler to the installation site in South Australia 1933 The first La Mont boiler is produced Dr.-Ing. Hans Schrag joins the company as engineering manager Delivery of the first La Mont boiler for a nitric acid plant After the plant's destruction during the war, the victorious powers expropriate the company after the end of the war Dr.-Ing. Hans Schrag establishes a company in Mannheim for the construction of boilers and plants. In consultation with the heirs, he adopts the name Oschatz for marketing strategy reasons. 3

4 Cost-Effective + Environmentally Friendly Cooling Systems for Iron and Steel Metallurgy Part of a waste gas cooling plant for the Hismelt process To ease the burden on the environment and to utilize the heat energy in waste gas, Oschatz has developed systems for the cooling of hot, highly dustladen, and CO-containing waste gases from production plants. As is customary with our plants, each concept is based on the customer's individual wishes and requirements. Only in this way do our systems achieve the highest possible operational safety and profitability, which is something that is expected throughout the world of Made by Oschatz plants. For our customers internationally operating steel producers and power companies we develop, produce, and install waste heat boilers downstream sinter belts and sinter coolers as well as in coking plants and coke dry cooling plants. For oxygen steel plants, we supply complete converter waste gas cooling systems, also called cooling stacks. In recent years, Oschatz has specialized in the modification of older steelwork facilities by rebuilding the bottom part of the coolingstack for optimal CO-gas collection capability so that these facilities comply with the new environmental regulations. At the same time, additional energy recovery is achieved because, unlike with earlier systems, the purified CO-containing gas is not flared off, but instead, a continuous release of fuel gas can take place by means of a downstream gas holder The company relocates its headquarters to Essen Commissioning of Oschatz's first La Mont boiler downstream a copper converter Construction of the first waste gas cooling stack downstream a steelworks converter Production of waste heat boilers downstream pyrite fluidized bed roasters featuring the first mechanical cleaning system powered by pneumatic cylinders Oschatz builds the first waste heat boiler worldwide downstream sulfur combustion with cylindrical tube-totube welded boiler wall. 4

5 Our market is the world Cost-Effective + Clean Waste Management Plants for Environmental Technology The ever increasing requirements set by the legislation necessitate innovative and complex technical solutions in the field of environmental technologies. Despite these difficult general conditions, Oschatz, together with its customers, succeeds time after time in developing and building plants for an environmentally sensible thermal utilization of biomasses, alternative fuels, and residues. The use of state-of-the-art energy conversion technologies ensures that these requirements are met. We provide complete turnkey systems. For example, this includes the thermal utilization of alternative fuels, residues from the paper industry, as well as sludge and waste wood which, irrespective of the level of calorific value, are burned in water- or aircooled grate firing systems. The high temperature cyclone gasifier is a special type in which sewage sludge, lacquer sludge, plastics, recycling residues, and used tires can be disposed of. Oschatz has also developed systems for the utilization of biomasses from agriculture, forestry, as well as industrial processing in order to produce thermally usable energy. Energy conversion takes place in specially designed combustion systems to achieve an optimal combustion for renewable fuels such as straw, corn, wood, as well as olives pits, pomace residues, and rice husks. Oschatz provides systems for the utilization of solid raw materials as complete and component solutions Oschatz is the first company worldwide to produce a waste heat boiler with a gauze diameter of 4,100 mm for a nitric acid plant Commissioning of the first turnkey thermal waste management plant (combustion chamber with waste heat boiler and heat exchangers) in an acrylic acid factory Dr.-Ing. Hans-Jürgen Schrag, the son of the company's founder, assumes the responsibility for the family business as the Managing Director Oschatz takes over Reining Heisskühlung, based in Mülheim an der Ruhr. The Oschatz Group is born. 5

6 Safe + Turnkey Ready Heat Utilization for the Chemical Industry This waste management plant for poly-thf in China was built by Oschatz. In the past years, Oschatz has built eight turnkey plants worldwide for the disposal of liquid and gaseous residues, among others for acrylic acid plants, butanediol plants, and tetrahydrofuran plants. Thanks to this experience, we rank among the world's specialists when it comes to utilizing heat or disposing of gaseous or liquid products generated in the chemical industry's multifaceted production flows. The following are typical examples of chemical plants in which Oschatz process gas coolers and waste heat steam boilers are installed: Nitric acid plants Caprolactam or hydroxylamine plants Sulfuric acid plants as well as all processes in which hot gases, with or without dust, are used for energy through steam generation. By now, Oschatz has built more than 100 waste heat systems worldwide for the cooling of process gases in nitric acid plants and caprolactam plants An engineering firm is opened in Budweis, Czech Republic: Oschatz Bohemia Complete energy supply for a paper factory is made possible through thermal utilization of residues and a combined cycle power station In Denmark, Oschatz takes over IF Energy - grate firing and dust removal systems. Today, the company is called Danish Energy Systems A/S and is based in Birkeroed near Copenhagen Oschatz's representative office in Nanjing, China, is opened. 6

7 Our market is the world Competent + Fast Perfect Service 24/7 Even the best product can have a failure at some point in time; parts have to be repaired or replaced. In these cases, our customers can rely on Oschatz's service. We pull out all the stops to keep downtime at the plant to a minimum. Through the fast availability of replacement parts, installed directly on site by our specialists if required, we ensure that the plant can resume production as quickly as possible. Our service provides: The fastest possible availability of your facilities in the case of failure or repair Highly qualified repair personnel with plant-specific know-how Emergency services 24/7 We also provide consulting: Optimization of operating costs Improved technical and personnelrelated planning of resources and costs Planning of environmental protection measures Conversion of furnaces Performance-enhancing adjustment of steam parameters 1996 Inauguration of the new manufacturing plant in Istanbul, Turkey Trial operations begin at the new manufacturing plant in Nanjing, China Oschatz Swiss AG is founded Production begins at the plant in Nanjing. In Donezk, Ukraine, Oschatz-Küttner is founded. 7

8 At Home throughout the World Here, you will find information on our branches and representatives all around the world Australia Floreat Park Representative Massee Consulting Pty. Ltd. Peter Massee 18, Clanmel Road Floreat Park, Western Australia 6014 Phone Fax peter@masseeco.com.au Benelux Hattemerbroek Representative Markhoven Engineering B.V. W.M.J. Visser Zuiderzeestraatweg AV Hattemerbroek Netherlands Phone Fax pimvisser@markhoven-engineering.com China Nanjing Branch Oschatz Energy and Environment (Nanjing) Co., Ltd. Office: , World Trade Center Nanjing 2, Hanzhong Road Nanjing, China Phone Fax Manufacture: 1, Shu Gang Road Qi Xia District Nanjing, China Phone Fax Shanghai Branch Oschatz Shanghai Contracting & Trading Co., Ltd. Rm. 1102, Kaixing Masion, No. 35 Rijing Road Wai Gao Qiao. Free Trade Zone, Pudong Shanghai China Denmark Birkeroed Branch Danish Energy Systems A/S Topstykket 16 DK-3460 Birkeroed Denmark Phone Fax des@des-dk.com Great Britain Karlsruhe Representative ROPA Stahl GmbH Steve Parton Am Rueppurrer Schloß Karlsruhe Germany Phone Fax steveparton@ropa-stahl.com Italy Milan Representative Ravizza & C. Srl. Massimo Ravizza Via Fabio Filizi, 25/A Milan Italy Phone Fax m.ravizza@ravizza.it Austria Linz Representative REICO GmbH Industrieanlagenbau Elmer Reischl Negrelliweg 10/ Linz Austria Phone Fax elmer.reischl@aon.at Spain/Portugal Madrid Representative Selke Consulting Angel Selke Avenida del Doctor Arce, Madrid Spain Phone Fax selkeconsulting@tiscali.es Taiwan Taipei Representative DKSH Taiwan Ltd. Danny Wang (Department Manager) Infrastructure Energy & Environment 10F, No. 22, Lane 407, Ti-Ding Blvd. Section 2, NeiHu Technology Park Taipei 114 Taiwan Phone Fax Danny.wang@dksh.com Czech Republic Ceske Budejovice Branch Oschatz Bohemia s.r.o. U tri lvu Ceske Budejovice Czech Republic Phone Fax info@oschatz.cz Turkey Gebze-Kocaeli Branch Oschatz A.S. Enerji ve Cevre Koruma Tesisleri Sanayi ve Ticaret A.S. Cumhuriyet Mah. Turgut Özal Cad. 13. Sokak No.: 16 PK: Sekerpinar/Gebze - Kocaeli Turkey info@oschatz.com.tr Ukraine TOV Oschatz & Küttner Ukraine Pr. B. Chmelnizkogo 71a Donetsk Ukraine Phone Fax j.bagh@oschatz-kuettner.com.ua Germany Essen Headquarters Oschatz GmbH Westendhof Essen Phone +49 (0) Fax +49 (0) info@oschatz.com Mülheim/Ruhr Branch REINING-Heißkühlung GmbH & Co. KG Dessauerstr. 60 D Mülheim/Ruhr Germany Phone +49 (0) Fax +49 (0) Concept development, text, and design: commedia, Essen Photos: Oschatz, Matthias Duschner (p. 5 top), printing: grafistar

9 Chemical Technology Plant construction and waste heat systems for the chemical industry

10 Our market is the world Oschatz cutting-edge technology and experience Oschatz is an innovative company operating globally in the areas of plant construction, energy recovery and environmental technology. With over 160 years of experience Oschatz is today a leader in the product areas of chemical technology, non-ferrous metallurgy, iron and steel metallurgy, environmental and power plant technology. Our customers particularly appreciate our first rate global service which goes far beyond installation and start-up. Problem solvers for the chemical industry Oschatz produces turnkey residue combustion systems for the chemical industry and core components for sulphuric acid, nitric acid, caprolactam and hydroxylamine systems. For this work the company and its staff have developed a particular expertise thanks to decades of experience in the areas of residue combustion, heat transfer, water circulation, cleaning of heating surfaces, corrosion and erosion processes and damage point analyses. Depending on where they will be eventually used, systems and components are produced in either of the two very modern production plants in Istanbul/Turkey or Nanjing/China observing, of course, all the international quality standards such as ISO 9001, ASME approval, EU pressure vessel regulations, etc. The much appreciated qualities of all Oschatz products are: excellent cost effectiveness, great ease of maintenance and excellent accessibility of individual components. Made by Oschatz: The largest completely prefabricated water tube boiler in the world for a sulphuric acid plant in New Caledonia 2

11 Chemical Technology Using heat Waste heat recovery systems for the chemical industry For many years the Oschatz chemical technology division has been a partner for companies operating in the chemical industry needing systems to reclaim waste heat from complex production processes for the purposes of energy recovery. Here are some examples of typical chemical processes where Oschatz process gas coolers and waste heat boilers have been installed in chemical plants all over the world: Nitric acid, caprolactam and hydroxylamine plants Here the ammonia is burned catalytically with air or oxygen. Turnkey thermal disposal plants Here solid, liquid and gas residues are burned. Turnkey plant for the thermal use of gases Here low to high calorific value gases are burned. Every plant is unique Although Oschatz uses the most modern and cost-effective production processes in planning and constructing plants, customers requirements and wishes are always observed. These are the central issues in the design of each individual system: How high is the temperature of the hot gases and are they under pressure? What do the gases contain? What is the level of dust content? Do the gases contain dusts with different compositions and different properties? Are the gases and dusts corrosive? Do the dusts have erosive properties? Thermal disposal plants for gaseous and liquid residues in Antwerp 3

12 Steam produced from waste heat Process gas cooler for nitric acid and caprolactam plants Oschatz has now built over 200 waste heat systems for cooling processing gases in nitric acid and caprolactam plants throughout the world. The process As soon as the gas enters the processing gas cooler it is distributed in the burner head. Here the ammonia contained in the gas is oxidised on a catalyst gauze using air or oxygen. The nitric oxide gas thus produced has a temperature of 850 to 950 C. It is then cooled to a temperature of 500 to 180 C, depending on the process requirements, on heat transfer surfaces located beneath the platinum gauze. The energy thus produced is used in the factory to produce steam. The cooler The process gas coolers developed by Oschatz consist of the following components: the burner head with ignition system and internals for optimum distribution of the in-flowing ammonia gas gauze-clamping device to support and retain the catalyst gauze the spiral heating surfaces to cool the gases to the required temperature. The heating surfaces consist of pre-evaporator, superheater, main evaporator and if required economiser the cylindrical gas pressure vessel in which the heating surface is mounted. Here a gas-tight welded tube wall protects the vessel from the high gas temperatures. Checking for leaks In spite of the greatest care taken with design and manufacture leaks can occur in the spiral heating surfaces after years of use in unusual exceptional cases. With the leakage testing system developed by Oschatz the defective tube in a pressure vessel can be identified easily and reliably. Six metre diameter At Oschatz we are very well acquainted with all types of gauze clamping systems and can build process gas coolers up to a gas volume of 230,000 Nm 3 /h and a gas pressure of 12 bar. One of the largest process gas coolers in the world with a vessel diameter of six metres was built and put into operation for UHDE in Before installation: heating elements for NH 3 boiler Oschatz Know-how Fully installed: NH 3 boiler with spiral tube heating surfaces 4

13 Chemical Technology Individual and turnkey Thermal disposal and heat recovery Disposal of fluid and gaseous residues In the last 15 years Oschatz has built eight plants for the disposal of liquid and gaseous residues throughout the world. These were mainly disposal systems for acrylic acid, butanediol, and THF. The plants which were designed by Oschatz in close collaboration with the customers and delivered ready for operation according to the individual requirement profile consist of: a brick-lined combustion chamber for burning residues the burner system developed individually for the process to guarantee compliance with the required emission levels the waste heat boiler consisting of superheater, evaporator, economiser, heating surface cleaning system and air and gas pre-heaters process control system for the highest level of plant safety and availability. Safe, cost effective, durable The thermal disposal plants manufactured by Oschatz immediately provide the customer with two benefits: they guarantee that the residues produced are disposed of safely and they simultaneously function as power plants providing the chemical plant with steam. All Oschatz systems are designed and built for large volumes, long operating periods and constant availability. Up to now systems have been built with a gas disposal volume of up to 390,000 Nm 3 /h and steam production capacity of 200 tonnes per hour. Utilisation of gases containing carbon monoxide Oschatz has developed a custom-built waste heat system for metallurgical production units to produce steam in this type of plant by burning gases containing carbon monoxide. The gases containing carbon monoxide, which are produced in these processes, are thus burned with proper provision for the extremely high load fluctuations which occur. In order to even out these fluctuations natural gas is added as required. In this way it is always possible to produce the desired amount of steam. One of eight waste heat disposal systems which Oschatz has built ready for operation. This unit is located in China. Cross section of a waste heat disposal system for gaseous and liquid residues with additional combustion chamber. This plant in Australia is setting the trend for the process of burning additional natural gas in the disposal of gases containing carbon monoxide. 5

14 Rapid drop in temperature Waste heat boilers and heat exchangers for sulphuric acid plants In order to make sulphuric acid from the element sulphur, catalytic exothermic processes are used. These require special cooling sections. Oschatz uses water tube boilers to cool down the gases containing sulphur dioxide which are produced in the combustion chamber. Several heat exchangers precisely geared to the process requirements for the catalytic converter cool the gases down to the required temperatures. Over the years Oschatz has built numerous waste heat boilers which are now in use all over the world. They are very flexible in application and are ideal for: hyper- and hypostoichiometric combustion for gas-side overpressure for a wide range of steam pressures and temperatures Installation of a sulphur combustion unit with a downstream Oschatz waste heat system Oschatz Know-how Constant temperatures One of the biggest challenges in this process is maintaining a constant gas exit temperature from the waste heat boiler independently of the load. Oschatz has found a solution by which this constant temperature is maintained by internal or external gas- or steamside bypasses which can be regulated. Transporting an Oschatz water tube boiler to the port of Nanjing 6

15 Chemical Technology One of the largest one-piece, water tube boilers waiting at the port of Nanjing for shipment to Saudi Arabia Innovations Made by Oschatz Over the years Oschatz has accumulated a great deal of expertise in the design and construction of waste heat boilers and has incorporated innovations in its production processes which have proved themselves in daily use to the greatest extent for many years: provision for vertical and horizontal thermal expansion avoiding the use of compensators as far as possible boiler walls are produced to be gas-tight the heating surfaces can be cleaned easily and using simple maintenance procedures during shutdown periods heating surfaces can be exchanged in segments, thus reducing shutdown periods all systems are designed right from the planning stage for operation with minimum maintenance. Oschatz Know-how Design, text and layout: commedia, Essen Photos: Oschatz Printing: grafistar 7

16 Oschatz GmbH Westendhof Essen Tel Fax Production plant in Istanbul, Turkey Oschatz has been manufacturing boilers and waste heat systems, i.e. heat recovery, at its plant in Istanbul since 1997, for customers located all around the world. The production shops of the Gebze-Kocaeli plant, located on a 21,000 m 2 (226,000 ft 2 ) site on the immediate outskirts of the Turkish metropolis, offer 5,000 m 2 of floor space plenty of room in which to manufacture vessels with a maximum diameter of 6.5 metres to ASME, TRD/AD and ISO 9001 standards and in compliance with the EU s Pressure Equipment Directive. In an initial expansion phase scheduled to be completed in 2010, production is being relocated and expanded. 50 kilometres from our present location, we are constructing four new factory buildings with a production area of 10,000 m 2 (108,000 ft 2 ) on a 60,000 m 2 (646,000 ft 2 ) site located immediately next to the sea. Production plant in Nanjing, China To be able to supply the markets in Asia, Australia and Oceania faster and more cost-effectively, Oschatz has built a second production plant in Nanjing, China. Production at the plant began in October A second expansion phase at this plant was completed only three years later in the summer of In seven shops with a total floor space of 15,000 m 2 (161,000 ft 2 ), located on a 50,000 m 2 (538,000 ft 2 ) site with good connections to the port of Changjiang, Oschatz now manufactures waste heat boilers and cooling stacks in accordance with the Chinese GB, ASME, TRD/AD and ISO 9001 standards. Some 650 people are now employed here under European management in production, design, finance and procurement.