Digitalization cooperation: MAN Energy Solutions and thyssenkrupp to work on autonomous operation of turbomachinery

• MAN Energy Solutions and the thyssenkrupp business unit Uhde to use AI to conserve resources and boost efficiency

• Autonomous operation of compressor trains for nitric acid plants and other applications

MAN Energy Solutions and the thyssenkrupp business unit Uhde are looking to drive forward the development, testing and marketing of autonomous turbomachinery systems operation for the nitric acid production industry and have signed a cooperation agreement to this effect. The two major German companies will use artificial intelligence (AI) to aid decision-making in nitric acid plant operation. It will involve taking real-time account of data such as product price, yield, efficiency, emissions, energy costs, process stability, and forecast maintenance requirements.

"Combining human expertise with artificial intelligence is a milestone for the process industry. Autonomous operation of turbomachinery offers advantages in efficiency, machine availability and health, as well as emissions reductions. AI algorithms ensure that machines and plants run reliably and at the optimum operating point at all times. This leads to fewer failures, greater efficiency and lower operating costs. In the final development stage, human intervention is only necessary for maintenance – which in turn leads to lower travel costs and reduced emissions. The development of autonomy thus combines the two strategic targets of digitalization and decarbonization," explained Dr. Uwe Lauber, CEO of MAN Energy Solutions. "MAN Energy Solutions already holds a leading market position when it comes to the unmanned operation of complex compressor trains. Through our cooperation with thyssenkrupp, we hope to further consolidate our lead."

Dr. Sami Pelkonen, CEO of the business unit Uhde said, "As one of the leading suppliers of nitric acid plants, our cooperation with MAN Energy Solutions will soon open up a whole new world of possibilities for operating the plants in a way that is both intelligent and resource-friendly. Our technology and digitalization competences will be a perfect match in achieving this."

Within the framework of this cooperation, the AI algorithms and advanced automation systems developed by thyssenkrupp Uhde and MAN Energy Solutions, as well as a digital controller for MAN turbomachinery systems, will be further developed, tested and interconnected to form a joint digital technology solution that is market-ready.

"In the 2020 pandemic year, MAN Energy Solutions was able to remotely commission complex compressor trains using digital technologies based on MAN CEON. The company has also already successfully demonstrated the continuous unmanned operation of its turbomachinery systems with its subsea compressor systems in the Norwegian Sea," added Jörg Massopust, Head of Digital Sales & Alliances at MAN Energy Solutions. "Together with thyssenkrupp, we now want to take the next step and enable the development from unmanned to autonomous operation. We later plan to apply the experience gained together in the nitric acid industry to other segments."

Thore Lohmann, Head of Operating Unit Fertilizer and Methanol at thyssenkrupp Uhde, concluded, "Digitalization is a topic that is becoming increasingly important. Our focus here is on the use of artificial intelligence to improve product characteristics, consumption figures and maintenance intervals, as well as increased automation. That's why our cooperation with MAN Energy Solutions fits perfectly with our strategy."

About thyssenkrupp’s Business Unit Uhde:

thyssenkrupp’s Uhde business unit combines unique technological expertise and decades of global experience in the engineering, procurement, construction and service of chemical plants. We develop innovative processes and products for a more sustainable future and thus contribute to the long-term success of our customers in almost all areas of the chemical industry. Our portfolio includes leading technologies for the production of basic chemicals, fertilizers and polymers as well as complete value-chains for green hydrogen and sustainable chemicals.

Contact:
thyssenkrupp, Business Unit Uhde
Christian Dill
Communications Manager 

– Digitized screen with intelligent control system

– Increased efficiency, reduced weight and height

– Innovative solution for secondary and tertiary screening

goovi® is the name of a newly developed multi vibrating screen from thyssenkrupp Industrial Solutions. The name says it all: goovi® ensures good vibrations in secondary and tertiary screening in the gravel and crushed stone, mining, mineral processing and recycling industries. A new patented drive technology in combination with an innovative control system provides a significant increase in operational flexibility, product quality and performance, coupled with greatly reduced weight and height.

Achim Schönfelder, Head of Product Line Screens and Feeders at thyssenkrupp Mining Technologies: “With the goovi®, all vibration modes (circular, linear and elliptical) can be realized in one machine, allowing flexible adaptation to changing job requirements and material properties. In addition, the low height of the goovi® facilitates simple installation in existing plants.”

Revolutionary drive system

The goovi® is driven at four different points, one on each side front and back, resulting in an optimum stress distribution in the side walls. It also uses fewer rotating parts than conventional screens, which translates into significantly lower weight and height as well as reduced maintenance and wear. Two or three standard unbalance motors are installed at each drive point, so each goovi® is driven by a total of 8 or 12 motors, depending on size, which are synchronized via a patented PLC supplied with the machine.

Intelligent control and flexible operation

With the patented control system, speed and flow direction can be steplessly adjusted so that all important operating parameters can be optimally adapted to the requirements of production at any time. In addition, with the goovi® it is possible to react flexibly to changes in material properties (e.g. moisture) during operation and optimize the processing of difficult-to-screen materials.

Different product qualities can be saved in recipes and retrieved as required at the touch of a button via the touchscreen supplied. The goovi® can also be integrated into control loops for product optimization. There is a preset cleaning function for the removal of clogged particles. The goovi® is fully digitized and can be integrated into a higher-level control system, paving the way for Industry 4.0 in processing plants.

Peter Berlitz, Product Manager Screens at thyssenkupp Mining Technologies: “To optimize costs and delivery times, thyssenkrupp has developed a range of standard machines. The single-deck and double-deck versions are available in six different widths and four different lengths with a maximum screening area of 26 m². However, due to the straightforward modular design, custom solutions tailored to a particular application can also be supplied.”

• 20 MW green hydrogen installation to kick-off the decarbonization of the world’s largest ammonia production facility

• CF Industries will start production of 20,000 tons per year of green ammonia by 2023

thyssenkrupp has entered into an engineering and supply contract with CF Industries to deliver a green hydrogen plant for the production of green ammonia at the Donaldsonville manufacturing complex in Louisiana. Under this contract thyssenkrupp will engineer and deliver a 20 MW hydrogen production unit based on their alkaline water electrolysis as well as all necessary utilities.

The plant will utilize renewable energy from the grid to produce green hydrogen which then will be converted to 20,000 tons per year of green ammonia in CF Industries existing ammonia plants at the Donaldsonville, LA site. Green ammonia can be used as a highly efficient storage and transport medium for renewable energy and also directly as a clean fuel, e.g. in maritime transportation. Engineering and procurement activities have been initiated; the start of production is scheduled for 2023.

Strong project footprint and organizational set-up in North America

With six ammonia plants and several fertilizer plants, the CF Industries’ site in Donaldsonville is the largest ammonia manufacturing complex worldwide. The largest ammonia plant at this site has also been delivered by thyssenkrupp and is based on the proven uhde® ammonia process. “Following the recent delivery of two world-scale ammonia and fertilizer plants to CF Industries we are honored to have now been selected by our long-term customer to contribute to the decarbonization of their operations and to support them in their mission to provide clean energy to feed and fuel the world sustainably”, says Dennis Lippmann, President Chemical & Process Technologies, thyssenkrupp Industrial Solutions USA.

As a globally renowned EPC specialist for electrochemical plants, thyssenkrupp is a leading supplier of electrolysis equipment, solutions and services – also with a strong footprint in North America. With a total capacity of over >1.4 GW realized in electrochemical projects over the last 30 years (which equates to >290,000 Nm3/h of hydrogen as byproduct), North America is one of the company's key regions. Dr. Christoph Noeres, Head of Green Hydrogen at thyssenkrupp Uhde Chlorine Engineers, adds: “This second water electrolysis success after the recent announcement of an installation in Canada shows the region’s leading role in making the green hydrogen economy a real deal. With our well-established local set-up, we are best prepared to serve the American market which is also key to delivering service solutions throughout the entire plant life-cycle.”

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About us:

thyssenkrupp Industrial Solutions is a leading partner for the engineering, construction and service of industrial plants and systems. Based on more than 200 years of experience we supply tailored, turnkey plants and components for customers in the chemical, fertilizer, cement, mining and steel industries. thyssenkrupp Uhde Chlorine Engineers, a joint venture between thyssenkrupp Industrial Solutions AG and Industrie De Nora, offers world-leading technologies for high-efficiency electrolysis plants. The company has already successfully installed more than 600 projects and electrochemical plants worldwide, with a total capacity of over 10 gigawatts. With its water electrolysis technology for the production of green hydrogen, the associated product division Green Hydrogen offers an innovative solution for industrial-scale applications. Together with thyssenkrupp’s Chemical and Process Technologies business unit, thyssenkrupp covers the entire value chain for green chemicals, from hydrogen to ammonia, methanol and synthetic natural gas – a major step towards a climate-neutral industry.