Urea revamp activities are performed to achieve improvements of the urea plant. Besides the typical capacity increase there are many options to reduce operation costs, increase plant availability or reduce environmental impact. In this article Marc Wieschalla of thyssenkrupp Uhde GmbH provides an overview of some of the options from an EPC contractor point of view.
One challenge of a green revamp by stepwise injection of green hydrogen into existing ammonia/urea complexes is to cover the nitrogen demand for the ammonia synthesis while stepwise reducing the front-end load, usually by applying a cost-intensive air separation unit (ASU). thyssenkrupp Uhde GmbH has developed an advantageous concept whereby, instead of an ASU, the nitrogen gap is closed by the introduction of pretreated reformer flue gas back into the ammonia process, with the side effect to also enhance CO2 production.
One of the key challenges of producing RFNBO (renewable fuels of non-biological origin) compliant ammonia is managing the intermittency associated with renewable energy sources for hydrogen production. Furthermore, the additional costs associated with managing this intermittency can be significant. In this article, Dr Solomos Georgiou of AFRY Management Consulting explores those additional costs as well as potential ways to achieve cost savings and make RFNBO-compliant ammonia production competitive against conventional ‘grey’ ammonia.
Revamping aging urea plants with the latest urea technology brings many benefits. Not only can greenhouse gas emissions be reduced, but the overall performance and sustainability of these facilities can also be optimised. Hiroo Kunii of Toyo Engineering Corporation discusses TOYO’s approach to urea plant revamping.
OCP’s recent award of a contract to Worley Chemetics for three new greenfield sulphuric acid plants has confirmed the phosphate giant’s plans for its new Mzinda Phosphate Hub in Morocco, one of the largest investments in new phosphate capacity anywhere in the world over the next few years. It is part of a number of new investments under way in Morocco as OCP continues to expand its already considerable phosphate facilities. Three new fertilizer lines came onstream at Jorf Lasfar in 2023 and 2024, each with a capacity of 1 million t/a of diammonium phosphate (DAP). The Mzinda mega-project will add another 4 million t/a of triple superphosphate (TSP) capacity by around 2028-29, and will relieve some of the issues that OCP has in importing ammonia for DAP production, as TSP only requires phosphate rock and phosphoric acid. There is also an additional 1 million t/a of TSP capacity under construction at Jorf Lasfar, which is expected to be completed next year, and OCP also announced last year that it would build an integrated purified phosphoric acid (PPA) plant at Jorf Lasfar. The first phase of the project consists of 200,000 t/a of P2 O5 pretreated phosphoric acid capacity, 100,000 t/a (P2 O5 ) of PPA capacity, and 100,000 t/a of technical MAP (tMAP) capacity. The site will also be home to downstream production of phosphate salts and lithium iron phosphate (LFP) capacities. The initial plants will be delivered starting in mid-2026, carrying through into 2029, constructed in conjunction with JESA, a joint venture between OCP and Worley.
With a large number of green ammonia projects under development, financing remains the greatest hurdle to getting ventures off the ground.
Stamicarbon, in collaboration with KT Tech, has developed a cryogenic energy storage system, named GALCES , for green ammonia plants that addresses the intermittency challenges of renewable energy supply. The technology not only supports the sustainability goals of the ammonia production industry but also contributes to broader energy market stability and efficiency.
Emerging evidence suggests that by-products used as fertilizers, particularly ammonium sulphate, may emerge as winners from the EU’s implementation of the carbon border adjustment mechanism (CBAM). In this article, Franck Boher of Upgraid investigates whether by-products can help reshape sustainable fertilizer production in Europe.
In a major milestone, Yara officially opened its renewable hydrogen plant at Herøya Industrial Park, Porsgrunn, Norway, in June.
Ronald Clemens , ICL’s Marketing & Portfolio Manager CRF, talks to Fertilizer International about the role of controlled-release fertilizers in sustainable agriculture.