ThyssenKrupp Industrial Solutions
Engineering Excellence3
Accelerated start-up of magnesia plants
Heiko Goseling – MagMin Conference, 3rd June 2014
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 2 ThyssenKrupp Industrial Solutions
Business Areas
ThyssenKrupp – Business Areas Key indicators – fiscal year 2012/2013*
Industrial Solutions**
Components Technology
Materials Services
Steel Americas
Elevator Technology
Sales (€ mill) 5,712
EBIT** (€ mill) 244
Employees 27,737
Sales (€ mill) 6,155
EBIT** (€ mill) 675
Employees 49,112
Sales (€ mill) 5,641
EBIT** (€ mill) 640
Employees 18,841
Sales (€ mill) 11,700
EBIT** (€ mill) 236
Employees 26,978
Steel Europe
Sales (€ mill) 9,620
EBIT** (€ mill) 143
Employees 26,961
Sales (€ mill) 1,867
EBIT** (€ mill) -495
Employees 4,112
*) Continuing operations (after reclassification of Steel Americas) before consolidation **) Adjusted before consolidation
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 3 ThyssenKrupp Industrial Solutions
ThyssenKrupp Industrial Solutions The new dimension in Plant Engineering
Assembly Systems
Car Body Technology+F
Lightweight Solutions
Forming Dies
Testing Solutions
Business Area ThyssenKrupp Industrial Solutions
System Engineering Marine Systems Resource Technologies Process Technologies
Mining
Cement
Service
Fertilizers
Base Chemicals
Contracting
Submarines
Surface Vessels
Services
TKMS AB
Business Unit
Operating Unit
Engineering Excellence3
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 4 ThyssenKrupp Industrial Solutions
Technical Excellence 70% of all employees are engineers or have a technical degree
Know-how Exchange Knowledge transfer via a close-knit global network
Engineering Procurement Construction (EPC) The right partner for your turnkey projects
Employees worldwide 2011/12
~25% Technicians
~45% Engineers
~30% Others
Construction (C) Procurement (P) Engineering (E)
Engineering Procurement & integration
Service Provider
Engineering Powerhouse
Construction Construction
Contractors Management
Titel Datum Name des Sprechers 5
ThyssenKrupp Industrial Solutions
Regional cluster organization We are present wherever our customers need us
Americas II
Europe/CIS I
Sub-Saharan Africa VI
India III Asia-Pacific IV
Calgary
Johannesburg
Doha
Mumbai
Singapore
Moscow
ME/NA V
TKIS Headquarters
Regional Headquarters Locations
TKIS Headquarters
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 6 ThyssenKrupp Industrial Solutions
ThyssenKrupp Industrial Solutions Business Unit Resource Technologies at a glance
Mining
Open Pit Mining Bucket wheel excavator systems Belt conveyor systems In-pit crushing systems Materials Handling Stockyard & port handling systems for bulk materials Cable cranes Drive units and gearboxes
Cement
Raw material preparation
Clinker production
Cement manufacturing
Factory automation
Service
Service centers Spare parts management Maintenance and repair Upgrading Plant optimization Operation & Maintenance Consulting Training Life-cycle services
Mineral Processing
Crushing & grinding
Services
Pyroprocessing
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 7 ThyssenKrupp Industrial Solutions
• Introduction of the first RCE pressurized shaft kiln in the late 70’s
• Major role in thermal processing of refractory raw materials
• Since 2009, business centered in Germany with the RCE members still involved and active
• POLSINT and MULTIPOL best available pyroprocessing technologies for the refractory industry
• More than 60 installations worldwide
Resource Technologies High Temperature Technologies
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 8 ThyssenKrupp Industrial Solutions
References High Temperature Technologies
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 9 ThyssenKrupp Industrial Solutions
“The fast-track way to a positive cash flow”
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 10 ThyssenKrupp Industrial Solutions
Plant amortization
0
5
10
15
20
1 2 3 4 5 6 7 8 9 10
Mon
etar
y un
its
Time
Investment
Return
Return(start-up 1 year earlier)
One-dimensional view!
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 11 ThyssenKrupp Industrial Solutions
“Tailor-made plant”
© Kölner Maßkleidungsmanufaktur UG
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 12 ThyssenKrupp Industrial Solutions
Generation of costs
0
2
4
6
1 2 3 4 5 6 7 8 9 10
Mon
etar
y un
its
Time
Potentialof cost controlInvestment costs(cumulative)Additional costs(commissioning, ...)Loss of production
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 13 ThyssenKrupp Industrial Solutions
Amortization
-4
-2
0
2
4
6
6 7 8 9 10 12 14 16 18 20
Mon
etar
y uni
ts
Investment costs(cumulative)
Additional costs(commissioning, ...)
Loss of production
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 14 ThyssenKrupp Industrial Solutions
Coordination problems – example: heat exchanger
© Güntner GmbH & Co. KG
© Anlagenbau Böhmer GmbH
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 15 ThyssenKrupp Industrial Solutions
• Inquiry and calculation based on tonnage • Complexity often unkown to installation
company
• May result in cost explosion and delay
Coordination problems – phase of construction
Construction of a MULTIPOL
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 16 ThyssenKrupp Industrial Solutions
Reliable partner – Krupp Canada
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 17 ThyssenKrupp Industrial Solutions
Project network
Client
Consultant
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 18 ThyssenKrupp Industrial Solutions
Coordination problems – health and safety standards
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 19 ThyssenKrupp Industrial Solutions
Coordination problems – health and safety standards
machinery
instructions
EC declaration of conformity
CE-marking
partly completed machinery
assembly instructions
declaration of incorporation
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 20 ThyssenKrupp Industrial Solutions
• Professional project planning
• Engineering expertise
• Well balanced division of scope of work (TK Industrial Solutions / local)
• Reliable partner and contractors
• Experienced suppliers
• Optimized plant construction
• Cost-efficient plant start-up
Conclusion
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 21 ThyssenKrupp Industrial Solutions
ThyssenKrupp Industrial Solutions Pyroprocessing @ MagMin2014
Walter Egger Consultant Tel: +43(0)664.3377225 [email protected]
Heinz Tölke Section Manager Tel: +49(0)2525.99-2799 [email protected]
Dr. Christoph Beyer Vice President Tel: +49(0)2525.99-2954 [email protected]
Dagobert Schwarz Senior Project Manager Tel: +49(0)2525.99-2280 [email protected]
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 22 ThyssenKrupp Industrial Solutions
Thank you for your attention.
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 23 ThyssenKrupp Industrial Solutions
Back-Up
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 24 ThyssenKrupp Industrial Solutions
Introduction
Heiko Goseling
ThyssenKrupp Industrial Solutions AG Resource Technologies High Temperature Technologies Section Manager Design Engineering Tel: +49(0)2525 99 - 3449 Mail: [email protected]
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 25 ThyssenKrupp Industrial Solutions
Coordination problems – example: temperature measurement
Control system integration
© Siemens AG
Spare parts availability
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 26 ThyssenKrupp Industrial Solutions
“Plant to Money” - Amortization
-4
-2
0
2
4
6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Mon
etar
y uni
ts
Potential of cost control Investment costs(cumulative)
Additional costs(commissioning, ...)
Loss of production
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 27 ThyssenKrupp Industrial Solutions
ThyssenKrupp Industrial Solutions Process Technologies at a glance
Fertilizers
Ammonia/Urea
Hydrogen/Nitrates
Technical services
Contracting
Polymers
Oil & Gas
Engineering services
Implementation
Global project management, engineering, procurement, site management, and IT
Base chemicals
Electrolysis
Coke plant technologies
Gasification technologies
Technical services
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 28 ThyssenKrupp Industrial Solutions
Resource Technologies More than 3,000 built plants and components around the globe
>200 >320
>2,500 >200
Bucket wheel excavators Mobile and semi-mobile crushing plants
Spreaders/Belt wagons/ Tripper cars
Cement kiln lines
>550 >250
> 900
POLYSIUS QUADROPOL Roller mill
>350 Roller mills
Cable cranes >1,200 with POLYSIUS POLSCAN
Port handling systems Stockyard handling systems Wagon tipplers
Crushers Screens Kiln geometry measurement
>1,300
>10,000
>600
Engineering Excellence3 – Accelerated start-up of magnesia plants June 3, 2014 Heiko Goseling 29 ThyssenKrupp Industrial Solutions
130 plants
115 plants 375 plants
100 plants 500 plants 150 plants
Fertilizers Refineries Nitric acid Aromatics 185 plants 380 plants 75 plants
Polyester, Polyamides 400 plants
Electrolysis 150 plants
Process Technologies More than 2,000 built plants around the globe
Organic chemicals , Petrochemicals Hydrogen, Ammonia, Methanol Plastics, Synthetic fibers
Coke plants Gasification Industrial plants
120 plants