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References: Plant Services
Chemical Industry
Significant OEE improvement of a chemical complex for fertilizer production
Significant OEE improvement of a chemical complex for fertilizer production
Project description
Grasim Industries is the flagship company in the Aditya Birla Group, India’s leading Caustic Soda manufacturer. The company invested in the thyssenkrupp group’s Bipolar Membrane Cell technology way back in 1992 for conversion of their then 260 tpd Mercury Cell Caustic Soda plant, and followed it up with no fewer than 6 contracts for replacement of cell element with new generation cell elements that provide considerable savings in terms of power consumption while improving product yield and reducing emissions.
Results
Location: Nagda, India
Plant type: Membrane Cell Caustic Soda Complex
Service type: Revamps - Capacity Expansions, Technology upgrades
27 years and counting for record-breaking Indian Caustic Soda complex using tk group Membrane Cell technology
27 years and counting for record-breaking Indian Caustic Soda complex using tk group Membrane Cell technology
Project description
In 1992, then amongst India’s leading Caustic Soda manufacture operating out of Vadodara and Dahej in Gujarat India, embarked on a path-breaking decision to invest in the thyssenkrupp group’s Membrane Cell technology for their 200 tpd Mercury Cell plant. It was a decision that put the company on the Caustic Soda map of the country as the first company to adopt path-breaking technology to eliminate mercury wastes, and catapulted them into the position of India’s leading Caustic Soda manufacturer.
Since then, the company has invested many times over in terms of new generation cell elements in no fewer than 9 contracts, spanning 27 years. The plant, still operational and working at peak efficiency, now utilizes the new generation V and VI cell elements and remains a testimony of the tk group’s technological and sustainable solutions for a customer committed to working with the very best the industry can offer.
Results
Customer: Gujarat Alkalies & Chemical Limited (GACL)
Location: Dahej, Gujarat, India
Plant type: Membrane Cell Caustic Soda Complex
Service type: Revamps - Capacity Expansions, Technology upgrades
Engineering consulting for PTT Global Chemical
Engineering consulting for PTT Global Chemical
Contract October, 2014 until present
Responsibilities
Main Areas
Results
Customer: PTT Global Chemical Public Co., Ltd.
Location: Map Ta Phut, Rayong, Thailand
Plant type: Refinery and Petro chemical
Service type: Engineering Consultancy - Team Services
MISR Chemical Industries - operations training
MISR Chemical Industries - operations training
Project description
Electrolysis plant
Training of operating personnel at Uhde's Petrochemical Training Center in Egypt
Customer: MISR Chemical Industries
Location: Alexandria, Egypt
Abu Qir Fertilizer Co. - revamp of field & control instrumentation
Abu Qir Fertilizer Co. - revamp of field & control instrumentation
Project description
Ammonia and urea plant
Revamp of complete field and control room instrumentation
Customer: Abu Qir Fertilizer Co.
Location: Alexandria, Egypt
Modernized new S-PVC plant in chemical complex
Modernized new S-PVC plant in chemical complex
Project description
Karpatnaftochim Ltd. contracted thyssenkrupp Industrial Solutions to modernize the chemical complex with a new S-PVC plant.
The new plant consists of the core unit with 4 reactors a 150 m³ each and 2 degassing and drying lines as well as auxiliary units such as bagging, palletizing, waste water treatment, demin. water generation, and others.
Results
The new plant produces K-values?from 57 to 70 for rigid and flexible ?grades.
At the site a complete process chain?from caustic/chlorine via EDC/VCM to?PVC production is established by ?thyssenkrupp Industrial Solutions.
Customer: Karpatnaftochim Ltd.
Location: Kalush, Ukraine
Plant type: S-PVC
Service type: EP contract & technical supervision service
Capacity increase of oxichlorination unit
Capacity increase of oxichlorination unit
Project description
BorsodChem Zrt. contracted thyssenkrupp Industrial Solutions to increase capacity of existing oxichlorination unit by
Results
After the positive result of the feasibility study ?BorsodChem decided to revamp existing?oxichlorination unit with modified reactor ?cooling system.
Customer: BorsodChem Zrt
Location: Kazincbarcika, Hungary
Plant type: Plant for EDC production
Service type: Revamps, Basic engineering
Modernization of existing EDC/VCM/PVC chemical complex
Modernization of existing EDC/VCM/PVC chemical complex
Project description
Sayanskimplast contracted thyssenkrupp Industrial Solutions to modernize existing VCM plant by installation of a new cracking unit.
Heat recovery has been implemented by installation of an external EDC evaporator. The old quench column was replaced by a new hot quench column for separation of tars and coke from cracking products.
Results
Customer: JSC Sayanskimplast
Location: Sayansk, Russia
Plant type: Plant for EDC/VCM production
Service type: Revamps, EPC contract
Responsibilities
Main Areas
MPPU and infrastructure project
Results
Customer: Styrolution (Thailand) Co., Ltd.
Location: Map Ta Phut, Rayong, Thailand
Plant type: Chemical plant
Service type: FEED & Basic design
Cement
Re-use and refurbishment of existing components allow a successful and efficient project execution
Re-use and refurbishment of existing components allow a successful and efficient project execution
Project description
Ashaka Cement contracted thyssenkrupp Industrial Solutions to modernize a feed conveyor and spillage.
Parts of the old apron conveyor and spillage conveyor were removed and replaced with the new machine components. It was possible to retain the existing drives, the main and longitudinal beams.
Results
Cementa AB - turnkey project for cement mill
Cementa AB - turnkey project for cement mill
Manufacturing and assembly of mill shell section for Cement mill 2, replacement of the bearings and sealing systems (inlet and outlet) as a turnkey project.
Customer: Cementa AB
Location: Slite, Schweden
Re-use and refurbishment of existing components allow a successful and efficient project execution
Re-use and refurbishment of existing components allow a successful and efficient project execution
Project description
Cementos del Norte contracted thyssenkrupp Industrial Solutions to modernize a apron feed conveyor.
Parts of the old apron feed conveyor were removed and replaced with the new machine components. It was possible to retain the existing drives, the main and longitudinal beams, and the drive and return shafts. The existing drive shaft was re-machined while all other components were delivered as new items.
Results
Reduction of power consumption by 10 %
Cost savings through maintenance optimization by 20 %
Customer: Cementos del Norte
Location: Honduras
Plant type: Crushing plant for cement production
Service type: Plant modernization
Mixture of reused and new components allows a cost efficient and fast project execution
Mixture of reused and new components allows a cost efficient and fast project execution
Project description
Cemex contracted thyssenkrupp Industrial Solutions to exchange a
cement mill. A special challenge, the exchange had to be completed on turn key basis.
Parts of the cement mill were removed and replaced. It was possible to retain the motors, bearings and gear rim, pinions.
Customer: Cemex (today: Lafarge/Holcim)
Location: Beckum, Germany
Plant type: Cement grinding plant
Service type: Plant modernization
Upgrade of separator increases output and saves investment costs
Upgrade of separator increases output and saves investment costs
Project description
Ciplan contracted thyssenkrupp Industrial Solutions to increase the performance of their separator. The time frame for the modification is usually between 5 and 12 days depending on the size and circumstances on-site.
Results
Customer: Ciplan-Cimento Planalto S.A.
Location: Brasilia, Brazil
Plant type: Cement grinding plant
Service type Plant modernization & performance increase
Integrated Asset Management for gyratory crusher
Integrated Asset Management for gyratory crusher
Project description
Integrated Asset Management with permanent thyssenlrupp team on site. Open book, performance based contract for 18 months (directly after commissioning thyssenkrupp equipment).
Equipment responsibility for gyratory crusher (KB 63 - 89), including discharge conveyor and overland conveyor (2.86km).
Tasks: Predictive, preventive and corrective maintenance including maintenance engineering and planning.
(Completion August 2013)
Customer: Codelco División Ministro Hales
Location: Copper Mine - Calama, Chile
Replacement of new efficient components into existing structures increase plant efficiency and save costs
Replacement of new efficient components into existing structures increase plant efficiency and save costs
Project description
HeidelbergCement contracted thyssenkrupp Industrial Solutions to exchange a powder cooler Ø 2,5m x 6,5m. As special challenge, the exchange had to be completed in 15 working days on turn key basis.
Parts of the old powder cooler were removed and replaced with the new bigger machine. It was possible to retain the substructure and water system.
Results
Customer: HeidelbergCement
Location: Schelklingen, Germany
Plant type: Cement grinding plant
Service type: Plant modernization & performance increasing
HeidelbergCement AG - turnkey project for kiln roller station
HeidelbergCement AG - turnkey project for kiln roller station
Project description
Cement plant
Manufacturing and assembly of kiln roller station II (turnkey project) with a splined kiln tyre. Manufacturing and assembly of kiln roller station III with slipping tyre was already done in 2008.
Customer: HeidelbergCement AG
Location: Schelklingen, Germany
Replacement of components with tailor-made concepts save costs
Replacement of components with tailor-made concepts save costs
Project description
Huasheng contracted thyssenkrupp Industrial Solutions to modernize two kiln clinker coolers.
thyssenkrupp Industrial Solutions delivered the modular cooler concept POLYTRACK.
Results
Customer: Huasheng
Location: China
Plant type: Plant for cement production
Service type: Plant modernization
JIMAH Power Plant - repair after fire damage
JIMAH Power Plant - repair after fire damage
Project description
Repair after fire damage. Fabrication and erection of main elements of the carrying steel structures under-carriage and upper-carriage plus parts of the tripper-car. Renovation of machine parts and parts of conveyor system.
Customer: JIMAH Power Plant
Location: Mukim Jimah, Malaysia
Equipment: Stacker Reclaimer SR - 2
Project description
Delivery and assembly of mill slide ring as well as extension of grinding track of department 2.
Customer: Märker Zement GmbH
Location: Lauffen am Neckar, Germany
Mixture of refurbished and new components allows a cost efficient project execution
Mixture of refurbished and new components allows a cost efficient project execution
Project description
National Cement contracted thyssenkrupp Industrial Solutions to revamp their crushing plant. As a special challenge, thyssenkrupp had to retrofit a crusher from a third party.
Parts of the crusher were reengineered, removed and replaced with new machine components. It was possible to retain the existing drives and crusher housing.
Results
Customer: National Cement Company
Location: Cairo, Egypt
Plant type: Crushing plant for cement production
Service type: Plant modernization & expansion
Rotary kiln with graphite block seal- effective sealing, designed for easy mounting
Rotary kiln with graphite block seal- effective sealing, designed for easy mounting
Project description
The client PHOENIX decided to install our new designed kiln outlet sealing system with graphite blocks.
A special challenge was the short delivery time for creating the technical drawings and manufacturing. And of course the installation for this unknown prototype during 10 days.
Results
Customer: PHOENIX Zementwerke
Location: Beckum, Germany
Plant type: Plant for cement production
Service type: Spare parts
Installation of new components into existing structures saves costs for our customers
Installation of new components into existing structures saves costs for our customers
Project description
P.T. Semen Tonasa contracted thyssenkrupp Industrial Solutions to deliver a rollsizer and integrates it into the process. As special challenge, the existing concrete structure, feed and discharge conveyor had to be re-used.
Results
Customer: P.T. Semen Tonasa
Location: Indonesia
Plant type: Plant for cement production
Service type: Plant modernization & optimization
Project description
Comprehensive renovation of kiln plant with planetary cooler and upgrading to state-of-the-art technology within planned budget and timeline.
Customer: Rohrdorfer Zement, Portland cement plant
Location: Rohrdorf, Germany
Replacement of components with cost saving thought-out assembly concepts
Replacement of components with cost saving thought-out assembly concepts
Project description
SCHWENK Zement KG contracted thyssenkrupp Industrial Solutions to modernize their kiln cooler. thyssenkrupp delivered the modular cooler concept POLYTRACK. To reduce the plant downtime, the cooler was preassembled beside the existing cooler. After the disassembly of the old cooler the complete POLTRACK was moved on rails into his final position.
Results
Location: Germany
Plant type: Plant for cement production
Service type: Plant modernization
Schwenk Zement KG - modernization of feed apron conveyor
Schwenk Zement KG - modernization of feed apron conveyor
Project description
SCHWENK Zement KG contracted thyssenkrupp Industrial Solutions to modernize a feed apron conveyor. As special challenge, the conversion had to be completed in 20 working days during the coldest weeks of the year (- 20 °C and freezing rain).
Parts of the old apron conveyor were removed and replaced with the new machine components. It was possible to retain the existing drives, the main and longitudinal beams and the drive and return shafts. The existing drive shaft was re-machined while all other components were delivered as new items. ??
Results
Customer: SCHWENK Zement KG
Location: Karlstadt, Germany
Plant type: Crushing plant for cement production
Service type: Plant modernization
Training of international customers in Germany and on site
Training of international customers in Germany and on site
Project description
Practical exercises and theoretical lectures of operating and maintenance staff and in 15 different training units.
Location: Beckum, Germany & on site
Replacement of new efficient components into existing structures increases plant efficiency and saves investment costs
Replacement of new efficient components into existing structures increases plant efficiency and saves investment costs
Project description
Yanbu Cement contracted thyssenkrupp Industrial Solutions (tkIS) to deliver a wobbler. As special challenge, tkIS has to contracted this machine on EPC basis including using of the existing substructure.
Results
Customer: Yanbu Cement
Location: Yanbu, Kingdom of Saudi Arabia
Plant type: Plant for cement production
Service type: Plant modernization & optimization
Re-use and refurbishment of existing components allow a successful and efficient project execution
Re-use and refurbishment of existing components allow a successful and efficient project execution
Project description
Vissai Cement contracted thyssenkrupp Industrial Solutions to deliver our new custom made POLFLAME kiln burner.
A special challenge was the implementation into the existing structure.
Customer: Vissai Cement Company
Location: Ninh Binh, Vietnam
Plant type: Plant for cement production
Service type: Plant modernization
Installation of new components into existing structures save invest costs and increase the performance of the complete unit
Installation of new components into existing structures save invest costs and increase the performance of the complete unit
Project description
Zementwerk Hatschek contracted thyssenkrupp Industrial Solutions to install a new separator. The time frame for the modification is usually between 10 -12 days depending on the size and circumstances on site.
Results
Customer: Zementwerk Hatschek
Location: Gmunden, Austria
Plant type: Cement grinding plant
Service type: Plant modernization & performance increase
Mining
Re-use and refurbishment of existing components allow a successful and efficient project execution
Re-use and refurbishment of existing components allow a successful and efficient project execution
Project description
Project consists of replacing the existing Car Dumper Barrel. Existing equipment is from a known competitor which is reaching end of structural lifecycle. New parts must be geometrically suitable to the existing basement. Drive components and electrical infrastructure must be reused. Main mission involves optimize the production by increasing the equipment availability for operation and increasing expected life period.
Results
Enhanced lignite productivity attained through reliable bucket wheel excavators (BWE) & conveyors system
Enhanced lignite productivity attained through reliable bucket wheel excavators (BWE) & conveyors system
Project description
Performance based maintenance contract involves all maintenance aspects of Bucket Wheel Excavators (BWE) – 2 Nos & Conveyors
– 2 System round the clock with predefined operating consumables and spares.
Results
Location: Neyveli, India
Plant type: Open Cast Lignite Mines/
Bucket Wheel Excavators & Conveyors
Service type: Asset Management – Maintenance contract
Increasing lifetime and maintainability through spare parts availability
Increasing lifetime and maintainability through spare parts availability
Project description
Compañía Minera Doña Inés de Collahuasi contracted thyssenkrupp Industrial Solutions to revamp the current ship loading system. Modernization includes: overhaul of driving and rolling system of Portal Reclaimer and a complete refurbishment of VDF’s and control system of Shiploader and Portal Reclaimer.
Results
Restore the Portal Reclaimer to its original operational condition and extend the lifetime
Increase system availability by establishing
redundancy in communications
Migrate the obsolete VDF system
to technology with available spare parts
Contract duration: 8 months
Location: Iquique, Puerto Collahuasi, Chile
Plant type: Copper concentrate storage and ship loading system
Service type: Revamp & modernization
AOS aluminiumoxid - repair of bucket wheel excavator after collision
AOS aluminiumoxid - repair of bucket wheel excavator after collision
Project description
Collision of the ballast box with the stockpile, thus resulting in collapse. Disassembly, salvaging and assessment of the damaged device; refurbishment or re-procurement in line with the state of the art; delivery and commissioning of the replacement device.
Customer: AOS aluminiumoxid
Location: Stade, Germany
KPC - modification of shiploader
KPC - modification of shiploader
Project description
Modification of the shiploader North and South. Fabrication and erection of main elements of the carrying steel structures for the upper-carriage. Renovation of machine parts and parts of conveyor system.
Location: Kalimantan (Borneo), Indonesia
Customer: KPC
EPS (Elektropriwreda Srize) - 10 gearboxes of different types
EPS (Elektropriwreda Srize) - 10 gearboxes of different types
thyssenkrupp Industrial Solutions was supplying various gear-unit types within the framework of a new-build order for a bucket wheel excavator.
From belt gear units to a swivel gear weighing 15 tonnes. In relation to this, every high standard with regard to date specifications, costs and customer satisfaction was implemented.
Customer: EPS (Elektropriwreda Srize)
Location: Serbia
RWE Power - Modification of winch drive braking system
RWE Power - Modification of winch drive braking system
Project description
RWE Power AG contracted thyssenkrupp Industrial Solutions to revamp a bucket wheel excavator. As special challenge, the modification of winch drive braking system had to be completed.
Parts of the old braking system were removed and replaced with the new designed machine components. It was possible to retain the existing drives. Existing brakes from customers stockyard were implemented, all other components were delivered as new items.
Results
Customer: RWE Power AG
Location: Hambach, Germany
Plant type: Bucket wheel excavator
Service type: Modernization
Coke & Steel
Minimized production loss by refurbishment at operating plant
Minimized production loss by refurbishment at operating plant
Project description
ArcelorMittal Gent contracted thyssenkrupp to undertake the refurbishment of their existing coke plant to prolong the lifetime of their battery. The contract scope was the refractory repair including the partial engineering of the mechanical and refractory parts.
An important part of the contract was the handling and removal of asbestos in cooperation with the client and the official governmental agencies.
Redesign of oven doors and full refurbishment.
Results
Location: Gent, Belgium
Plant type: Coke plant
Service type: Revamps battery refurbishment
More than 20 years of customer relationship
More than 20 years of customer relationship
Project description
thyssenkrupp Uhde Engineering Services is contracted by ArcelorMittal Bottrop to perform maintenance on their battery on a year-to-year basis for more than 20 years. All necessary maintenance on refractory material is carried out including additional major projects and repairs where needed.
Results
Customer: ArcelorMittal Bottrop/Prosper
Location: Bottrop, Germany
Plant type: Coke Plant
Service type: Maintenance
Refurbishment of refractory parts
Refurbishment of refractory parts
Project description
Eregli Demir ve Celik contracted thyssenkrupp Uhde Engineering Services to perform refurbishment of the refractory parts with special attention taken to the engineering and redesign of the end flues.
The scope consisted of the demolition of the existing and rebuild of the end flues in parallel with involvement of the client for asbestos removal performed according to the instruction of thyssenkrupp.
Results
Customer: Eregli Demir ve Celik
Location: Eregli, Turkey
Plant type: Coke plant, Koppers-Becker
Service type: Revamps
Fastest repair in North America for battery refurbishment
Fastest repair in North America for battery refurbishment
Project description
thyssenkrupp Uhde Engineering Services (tkUES) was contracted by Essar Steel Algoma for the refurbishment of nine through-walls. During the initial execution, tkUES was further contracted to refurbish additional three walls during the execution period. tkUES performed this additional work before the original expiry deadline.
Results
Customer: Essar Steel Algoma
Location: Sault Ste Marie, Canada
Plant type: Coke plant
Service type: Revamps
Repairing of Moneypoint Power Station after fire
Repairing of Moneypoint Power Station after fire
Stacker / Reclaimer 1
Project description
Repair after fire damage. Fabrication and erection of the bucket-wheelboom endpart including pivot point. Change of the main roller bearing. Reinforcement of the under-carriage due corrosion damage. Renovation of machine -parts and parts of conveyor system.
Fertilizer
BASF - Advanced process control for ammonia plant
BASF - Advanced process control for ammonia plant
BASF
Antwerp, Belgium (Completion 2001)
Ammonia plant
Advanced Process Control (APC)
Return on investment for APC < 1 year
Egyptian Fertilizer Co. - maintenance engineering, planning & execution
Egyptian Fertilizer Co. - maintenance engineering, planning & execution
Project description
Review of maintenance engineering, planning and execution
Comprehensive Report including detailed plans for implementation of optimisation
Location: Ain Sukhna, Egypt
Qatar Fertiliser Company - new supply station & revamp
Qatar Fertiliser Company - new supply station & revamp
Project description
New high-voltage supply station for fertilizer plants 1 and 2. Plant 3 was revamped to increase capacity up to 36%
Customer: Qatar Fertiliser Company
Location: Mesaieed, Qatar
Refinery
Capacity increase of LDPE autoclave plant
Capacity increase of LDPE autoclave plant
Project description
SCG THAI Polyethylene Co. Ltd contracted thyssenkrupp Industrial Solutions to revamp existing LDPE autoclave reactor by adding tubular tail reactor.
Furthermore the secondary compressor has been replaced by a larger machine and a new high pressure separator was implemented. ?As special challenge, the major site activities had to be completed during 80 days plant shutdown.
Capacity old/new 100 kta/152 kta
Start-up 1996
Start-up revamp 2017
Results
Capacity increase of 52 % by adding ?a tubular tail reactor to an existing?LDPE autoclave reactor
Location: Map Ta Phut, Thailand
Plant type: LDPE (Autoclave)
Service type: Revamps, EPC contract
Binh Son Refining and Petrochemical - training for O&M personnel
Binh Son Refining and Petrochemical - training for O&M personnel
Project description
Training for the entire O&M personnel of a newly built refinery in Vietnam. The training was executed in a dedicated training facility in Vietnam as well as at a similar refinery.
Customer: Binh Son Refining and Petrochemical Co. Ltd.
Location: Dung Quat, Vietnam
Project description
Coordination, assessment and theoretical and practical training of some 400 trainees as operating personnel for a Petrovietnam refinery in Dung Quat, Vietnam
Additional assistance in commissioning the plant
Customer: Petroconsult
Location: Dung Quat, Vietnam
Oil & Gas
Mellitah Oil & Gas - Full service maintenance
Mellitah Oil & Gas - Full service maintenance
Project description
Full Service Maintenance contract as a direct follow-up to the commissioning phase. The scope of work included the setup of the camp and the workshops.
Customer: Mellitah Oil & Gas
Location: Libya
Mellitah Oil & Gas - maintenance training
Mellitah Oil & Gas - maintenance training
Project description
Wafa Oil & Gas Field
Maintenance training for customer’s engineers from various disciplines in a training facility in Germany as well as on-the-job training in Libya.
Customer: Mellitah Oil & Gas
Location: Libya