Pioneering with a higher purpose

Transcription

1 Pioneering with a higher purpose

2 CONTENTS 1. About us Maire Tecnimont Our vision Our industries and markets Crops nutrition and fertilizers Air quality improvement through emission reduction Improved quality of life through melamine production Our solution Designing and developing a new urea plant our LAUNCH series Optimizing your plant our ADVANCE series Upgrading an existing plant our EVOLVE series Innovation Licensing References and partnerships with customers Discover it for yourself 27

3 WELCOME Life in the 21st Century is full of exciting challenges. Feeding the world is the one that is closest to our heart. Over the next three decades, the growing global population will generate an increase in food demand that will place increasing pressure on our agricultural resources, which are already feeling the impact of climate change. Creating the right conditions for food security will mean improving agricultural production, increasing crop yields and farming in ever more sustainable ways. It s the motivation behind everything we do. Of equal importance to improving food production are the challenges we face on an environmental level. Maintaining air and soil quality is also very important for future generations. As pioneers with a higher purpose, we believe we can contribute to helping the world to feed itself and improve the quality of life. This brochure will guide you through our company ethos, market-leading licensing expertise and full lifecycle support services. We hope it inspires you to rise to the challenge and play your part in improving yield and food security by teaming up with Stamicarbon. Together we have the power to change lives.

4 1. ABOUT US We are Stamicarbon. The world s leading company in the design and project development of chemical plants, licensing of technologies and supply of high end equipment and services for the petrochemical industry. A company specialized in the fertilizer industry with the pioneering vision to help enable the world to feed itself and improve the quality of life.

5 Launched in 1947, we ve travelled the globe, crossing borders and boundaries to gain the pure knowledge that has helped us excel in our field. It s given us generations of high-quality research. Not to mention an in-depth knowledge of the processes and practices, that prove to be so successful for our customers. In fact, more than 250 urea plants licensed around the world have already used our technology, which is more than half of the installed capacity, to add nutrients to crops, replenish arable land and increase crop yields. But we think more people should be able to benefit from our innovations. It s the reason we continue to work closely with research institutes, suppliers and our licensees. So we can push the boundaries even further, upgrading our technologies and developing new ones to help produce enough food to feed the world. A world of expertise Wherever you are in the world, you can rely on our global network to create the best solution for your business. At the heart of our operation is our head office in Sittard, the Netherlands. We also have representative offices in Beijing (China) and Moscow (Russia). Together with our excellent network of reputable partners in engineering, procurement, construction and equipment supply, we can provide all the technologies, critical equipment, products and services you ll need to get your solution up and running. Pioneering heritage Stamicarbon was established for the sole purpose of obtaining and exploiting inventions and patents and licensing of technologies. We constantly moved with the times, often even setting the standard. This called for an entrepreneurial, pioneering and adaptive mindset to respond to a wide range of economic and technological challenges and developments. We started in 1947 with the licensing of coal processing technologies and over time made the switch to the licensing of several other technologies: mineral fertilizers, urea, caprolactam, melamine, polyethylenes, phenol, EPDM rubber, melamine barrier film and secondary fuel pellets. We always have been pioneers in exploiting our knowledge worldwide. For example we sold our first urea licenses in 1957 in Belgium and South Africa. In the nineteen sixties the Chinese and Russian markets were very difficult to access, and yet we were a frontrunner with the building of a urea plant in China in 1963 and a caprolactam plant in Russia in On the following pages you ll learn more about our innovative solutions and pioneering spirit. We hope it will inspire you to share our knowledge and rise to the challenge. Together we can make a difference. 05

6 2. MAIRE TECNIMONT Stamicarbon is the leading technology provider and licensing company of Maire Tecnimont Group, a top level international player in Engineering & Construction, Technology & Licensing, Energy Business Development & Ventures. The Group is focused on plants for the hydrocarbon processing industries (Oil & Gas, Petrochemicals and Fertilizers), with competences in Power Generation and Infrastructure. Focus on innovation Maire Tecnimont Group cultivates bestin-class expertise and leverages it to gain high level performance. Thanks to its well rooted advanced skills and knowledge in engineering, procurement, construction and project management, Maire Tecnimont Group has gained an unrivalled reputation, and a significant track record, in managing and completing successfully numerous complex lump sum turnkey projects in different contexts worldwide. 30 countries, one company The Group, listed on the Milan Stock Exchange since 2007, is headquartered in Milan, but is present in over 30 countries. It controls 45 operating companies around the world and can count on about 4,300 employees, more than half of whom are located outside of Italy. To find out more about the Group and its activities, visit 06

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8 3. OUR VISION At Stamicarbon we like to lead the way. Without exception, everyone in the company has a reliable and pioneering spirit. We go out of our way to develop and apply new techniques, explore unchartered areas of knowledge and engage in new activities. Because that s when, we can share the most exciting discoveries. We encourage our employees to balance ownership and entrepreneurship as they take on the responsibility for searching for the best solution for your problem. For example, as the global population increases so too does the reliance on the planet s farmland to produce enough food to feed the world. Current predictions by the United Nations estimate that the world s population might reach nine billion by The increasing amount of food that will be needed and the impact that this has on the environment, is a challenge that our employees relish. Our state-of-the-art technologies are designed to provide solutions and to improve the quality of life. Simple, effective and for everyone. 08

9 PIONEERING SPIRIT A passion for sustainable performance Sustainability is the driving force behind our culture of innovation. We combine it with an excellent Safety, Health and Environment (SHE) ethos, a key consideration for sustainable licensing. Our production processes combine unparalleled efficiency with operation simplicity. Designed for a high on-stream time and utilization rate, they meet all product quality standards. Our processes comply with the most stringent environmental requirements, so your plant is safe, efficient, ultra reliable, and will have the least impact on the world as possible. Simply reliable Our track record of plant and equipment lifetime has shown that Stamicarbon stands for reliability: we design safe plants with a minimum of equipment for a long lifespan and we keep our promises and agreements. 09

10 4. OUR INDUSTRIES AND MARKETS As a leading global player in the design, development and licensing of technologies, Stamicarbon applies its expertise and knowledge in several industries and markets: crop nutrition and fertilizers, air quality and emission reduction technologies and technologies for integration of urea and adjacent processes, such as melamine. 10

11 4.1 CROPS NUTRITION AND FERTILIZERS As crops grow they absorb nutrients directly from the soil. To maintain a rich and fertile growing environment, these nutrients need to be returned to the soil to prevent it from being depleted or crop production will stagnate or even cease. So what is the role of fertilizers and how can they help the world to feed itself? Fertilizers are in essence crop food. They contain all the essential nutrients that crops need to grow, to be strong and to resist diseases, in a form that they can easily use. A conservative estimate suggests that at least 30% to 50% of crop yield can be attributed to the input of commercial fertilizer nutrients. Urea fertilizer Since its discovery in 1773, urea has become the most important nitrogen-based fertilizer in the world. Produced from natural gas (ammonia and carbon dioxide), it s a white crystalline organic compound that contains about 46% nitrogen. This is a higher amount than in any other fertilizer. That is why urea is used in the agricultural sector as the most important fertilizer to increase crop yield. Some 190 million tons of urea is produced each year, 80% of which is used to fertilize crops. In fact almost half of all food grown in the world is fertilized by urea, specifically the staple crops like grain, wheat, rice and corn. What s more, around half of the world s population would be undernourished today if food production wasn t fuelled by fertilizers. 11

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13 4.2 AIR QUALITY IMPROVEMENT THROUGH EMISSION REDUCTION 4.3 IMPROVED QUALITY OF LIFE THROUGH MELAMINE PRODUCTION An increase in global welfare has brought environmental constraints to the planet. The rapid growth of industrial nations since the birth of the industrial revolution and an increase in the global use of the diesel engines for transport, have had a very real impact on air quality and the environment in general. In January 2010, in order to improve air quality the U.S. Environmental Protection Agency (EPA) brought in new emissions standards that required medium and heavy duty vehicles to significantly reduce engine emissions, particularly NOx and particulate matter (PM). These emissions are associated with a wide range of health problems including respiratory and cardiovascular diseases and decreased lung functions. Manufacturers developed Selective Catalytic Reduction (SCR) technology to meet these standards. NOx reduction fluids, also known as Diesel Exhaust Fluids (DEF) or AdBlue is sprayed into the exhaust system while the vehicle is running that breaks down NOx gases and converts them in to nitrogen and water. As a result most new diesel trucks, pickups, SUVs, and vans are now fitted with SCR technology and have a DEF tank that must be regularly refilled. Urea is used by almost all industrial manufacturers in the production of melamine. As a finished product, melamine resin is a very durable thermosetting plastic used in wood adhesives, laminates, coating resins and molding compounds. Also available as foam, it can be used as insulation, soundproofing material and in polymeric cleaning products. Because of melamine s high nitrogen content (66%), it is an established ingredient in fire retardant materials. Used in many household applications, melamine helps to improve the quality of our lives. Urea and melamine plants have been designed and licensed by Stamicarbon and built in all regions across the world. Implementing our unique knowledge in both urea and melamine production, we find and implement the most effective solution for any type of coupling between a new or existing urea and melamine plant. Stamicarbon can deliver technology solutions for the production of AdBlue and Diesel Exhaust Fluids (DEF), in an efficient and cost-effective manner. More over we offer solutions for the reduction of emissions in industry. 13

14 5. OUR SOLUTION Stamicarbon s unique solution for an optimal and sustainable business is a full life-cycle philosophy, based on decades of experience in meeting the needs of a diverse range of customers. Stamicarbon has the insight and expertise you need to create a marketable product that will increase production in sustainable ways. There are three proven solutions to suit a wide range of requirements: LAUNCH TM, ADVANCE TM and EVOLVE TM.

15 5.1 DESIGNING AND DEVELOPING A NEW UREA PLANT OUR LAUNCH SERIES Our LAUNCH TM series covers all the knowledge and resources you ll need to build a reliable and profitable new plant, from project initiation, to process design, basic engineering, project management through to plant start-up, all being done on a fast delivery schedule. Project Development Whether you are a government or an investor, you ll need to make a fundamental decision where and what to invest in. Stamicarbon can get involved in the early stages to set up a plant project from scratch. We can help you finding finance possibilities, determining the ROI, locating all relevant parties and arranging relevant permits to successfully start a plant construction project. Feasibility assessment Stamicarbon will support you in making feasibility studies: both from an economical perspective as well as from a technical point of view. Important parameters include: market size, captive use, regional consumption, export possibilities, feedstock access, plant size and the most suitable technology. Technology and Commercial Proposal Stamicarbon has vast experience in developing technology solutions. Based on a feasibility study, we will propose a tailor-made technology solution, best fitting your needs. Process design and basic engineering Based on the technology choice we will supply you with a comprehensive basic engineering package. This will contain all specifications, which will enable your contractor to carry out detailed engineering, procure equipment and materials and construct your plant. Construction guidance During the construction phase, Stamicarbon will take care of the contractor guidance and control. A key part of our project management is that we ensure that the detailed engineering is in line with our process design and basic engineering specifications. Equipment supply and solutions The design of the high-pressure and other high-end equipment is of critical importance in the construction of any plant. Our equipment supply and solution services are supported by our design and engineering expertise and our in-depth knowledge of the fabrication process, resulting in the highest quality equipment with the shortest delivery times. Start-up During the implementation and start up of your plant, we will support you with Hazard and Operability (HAZOP) assistance, plant operator s training and the actual start up of the plant. 15

16 TECHNOLOGY EXCHANGE 5.2 OPTIMIZING YOUR PLANT OUR ADVANCE SERIES Stamicarbon can help you to optimize the performance of your existing plant in all manner of ways. From production improvements, monitoring and detection to tailored staff training and full lifecycle support. With our ADVANCE series you can maintain a competitive edge for the entire operational life of your plant and even extend its longevity resulting in a better return on your investment. Stamicarbon offers a comprehensive portfolio of products and services within its ADVANCE series that ensure the smooth and efficient running of your urea facility in five different areas: Knowledge support and training Plant maintenance and equipment renewal Safety and environmental impact enhancements Product quality improvements Plant output optimization

17 5.3 UPGRADING AN EXISTING PLANT OUR EVOLVE SERIES If you have an existing plant, you may need to adapt to changes in legislation and market conditions. Stamicarbon can help you to stay compliant and competitive with a range of safe, cost-effective and environmentally friendly revamp schemes. Stamicarbon s range of EVOLVE services ensures your plant stays competitive. An EVOLVE project starts with an onsite plant assessment and debottlenecking study, resulting in opportunities for capacity increases or a reduction of plant emissions or energy consumption. We can provide solutions that improve on your existing high-end equipment, maximizing efficiency and minimizing plant downtime. Revamping your plant will help you to take full advantage of the plant s design margins to boost production while minimizing investment in additional resources and infrastructure. 17

18 REVAMP AND REPLACEMENT OF EQUIPMENT

19 6. INNOVATION Constant innovation drives performance in the fertilizer industry. Stamicarbon maintains its market leading position through continuous high-quality innovation in close cooperation with research institutes, suppliers and customers. The benefit of these collaborations has lead to the development of many breakthrough innovations that have resulted in reduced investment and operating costs. Our innovation effort is based on global customer needs and changing environmental, state and government policies and requirements. Two core principles in all our innovation is sustainability and open innovation. Sustainability An example of a recent sustainable innovation is the De-NOx system in Stamicarbon s urea plant design. This eliminates ammonia emissions from the urea melt plant entirely. This renders urea plant operation free of any toxic emissions. Stamicarbon has developed a very cost-effective and environmentally friendly alternative to the ubiquitous fossil fuel-based flaring systems. On top of that, the De-NOx system reduces investment and operating costs for the urea plant owner and the surface area (plant footprint) taken up by urea plants. Open innovation Open innovation is key for advanced technology solutions. Utilizing our extensive network and engaging with people of varied disciplines in diverse companies we have realized several open innovation projects with our customers, suppliers, universities and design institutes. Partnerships with suppliers With an open mind to innovation, we work in close collaboration with some of the world s most highly regarded equipment manufacturers. An example of open innovation with an equipment supplier is the co-development of Safurex, with Sandvik, Sweden, the leading stainless steel producer. Safurex is a corrosionresistant material, which has enabled all the critical areas of a plant to be designed, engineered and built: smaller, lighter and safer, which ultimately leads to more profitability. 19

20 7. LICENSING Licensing commercializes the know-how that has been developed and patented over the years as a result of Research & Development activities and experience of plant operations. This protects the industry s need for access to the most reliable, cost-efficient and environmentally friendly technologies and related services that a licensor and their partners can offer. With more than 65 years of unrivalled expertise in licensing of technologies, we cover every aspect of your project from creating a facility to training staff. We can provide technology licenses for new plants, maintain, optimize and upgrade existing plants or supply and replace equipment to maintain or upscale the output. And for many years already Stamicarbon is the market leader in licensing urea technology for the fertilizer industry. Applying for a license You can apply for a Stamicarbon license, for example to produce urea, based on the natural resources that can be used as feedstock and are present on your location. We can also help you to identify the most viable option for product grade and finishing options depending on specific market demands. So you can produce urea for export or local distribution and ultimately help to establish crops with a higher yield per hectare. 20

21 FERTILIZER PLANT PROJECT AMMONIA NATURAL GAS EXTRACTION NATURAL GAS FERTILIZER PRODUCTION CARBON DIOXIDE UREA FERTILIZER DISTRIBUTION 21

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23 Your business partners The Licensor provides the engineering for the basic process design. This becomes the blueprint for the facility. Based on this the Contractor does the detailed engineering, procurement of equipment and materials and constructs the actual facility. The Equipment Supplier is responsible for the materials and equipment needed. The Plant Owner operates the facility, sources the raw materials and sells the urea. Plant Owner Licensor Equip. Supplier Contractor 23

24 8. REFERENCES AND PARTNERSHIPS WITH CUSTOMERS At Stamicarbon, our pioneering spirit is built on strong partnerships. With more than 250 licensed plants and over 90 debottlenecking projects there is no other company with more experience in the fertilizer industry. We collaborate with our customers for the entire lifecycle of their urea facility, investing in state-of-the-art technology and innovative solutions to maintain and improve plant performance. Below are just a few of our successful partnerships with our customers from the fertilizer industry. Synthesis technology development Our partnership with Karnaphuli Fertilizer Company Limited (KAFCO) in Bangladesh is an example of true economic and social development in action. Due to the close proximity of an international airport, the urea plant couldn t be built with the standard vertical reactor. Stamicarbon designed and developed a new synthesis with a pool condenser, in which a condenser and a reactor are combined in one horizontal vessel. This brought down the overall height of the plant and met the requirements of the government and airport authorities. This also offered other advantages for the customer, like lower investment cost and higher efficiency. Thanks to this technology, KAFCO states; We have a flagship status for the future industrial and economic development of Bangladesh. This invention was to become the basis for all urea plants designed thereafter. 24

25 Finishing technology development Stamicarbon first commercialized its own patented urea granulation finishing technology in For successful commercialization, cooperation with our customers was essential for up-scaling from pilot plant to a commercial capacity. This has been done with two customers in two phases: 1. Grodno Azot, Belarus In 1996 Stamicarbon embarked on a joint venture with urea producer Grodno Azot in Belarus. Originally designed and supplied by a different licensor, their existing granulation plant was functioning well below par. Stamicarbon installed a unit with our proprietary fluid-bed granulation technology. The improved production process with increased capacity was started successfully and is in production since Agrium, Canada In 2002, Agrium decided to implement the Stamicarbon fluid bed granulation technology in their existing urea plant with two granulation lines in Fort Saskatchewan, Canada. The new process shows reliable performance resulting in an excellent product with the world s lowest dust production in the granulator, low spray energy per tonne of urea, lowest formaldehyde content and high bulk density, meaning less storage space and more economical transport. Stamicarbon implemented similar solutions with four Egyptian companies, Egyptian Fertilizer Company, Alexandria Fertilizers Company, Helwan Fertilizers Company and Misr Oil Processing Company- creating the first Stamicarbon proven and reliable world-scale granulation plants. In fact Stamicarbon has now licensed more than 20 granulation plants with capacities of up to 3600 metric tons per day. It s a perfect example of how a strong initial partnership can snowball into major, multiple commercial success stories. 25

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27 9. DISCOVER IT FOR YOURSELF Stamicarbon is the global market leader in the design and development of urea production facilities and has a long and outstanding experience in licensing of several other technologies. Our pioneering spirit has enabled us to boost operational flexibility, improve performance, reduce maintenance and increase the amount of time that facilities are on stream. As part of our pioneering heritage we are constantly looking for partners for technology development and co-creation. So if you have an idea and are looking for a partner to realize it with, think of us then. If you are considering developing a project or building a plant, we would like to invite you to contact us. We can work closely with you to assess your requirements and develop a customized proposal that s tailored to your exact needs. For more information contact your Stamicarbon representative or to communication@stamicarbon.com 27

28 Stamicarbon B.V. Mercator KW Sittard, The Netherlands. P.O. Box AB Geleen, The Netherlands. Tel Fax