Section: Features

Venkat Pattabathula reports on the American Institute of Chemical Engineers’ (AIChE) Safety in Ammonia Plants and Related Facilities Symposium, held from September 7–11th 2025, in Atlanta, Georgia, USA.

Joel Cantrell of Bryan Research & Engineering and Clay Jones of INEOS GAS/SPEC re-evaluate the historical practice of intentionally adding strong base such as caustic (NaOH) to amine with the purpose of improving performance and reducing corrosion by “neutralising” heat stable amine salts (HSAS) which have accumulated in the amine.

Platinum-promoted honeycomb catalyst bricks offer function as total oxidation catalysts that convert all oxidisable species under appropriate temperature and oxygen conditions. P&P Industries presents a case for a H2S-rich gas stream – relevant to the fibre industry, Claus offgas treatment, and other chemical sectors.

A full sulphur pit turnaround and rehabilitation is typically a once in a lifetime experience for refinery personnel. Specialists in sulphur pit turnarounds, Gavin Palmer of Brindley Engineering, Tom Kline and Bob Hall of Structural Technologies have compiled a database based on multiple sulphur pit turnarounds to identify typical deficiencies in mechanical systems, along with improvements to enhance operability, restore functionality and meet all codes/standards and best practices.

Continuous monitoring of sulphur recovery units (SRUs) has proven to be an excellent tool for energy optimisation and emissions reduction, yielding financial incentives in the form of CO2 credits and sustainability. Even in markets with limited CO2 credits, significant economic benefits can still be realised through reduction in utility consumption, as demonstrated by a recent collaboration between Worley Comprimo and PRefChem in Malaysia.

MHI has successfully completed the Ghorasal Polash Urea Fertilizer Project in Bangladesh - the country’s largest fertilizer complex. Key features of the project include: the KM CDR Process™ that captures CO2 , cuts emissions and boosts urea output; an energyefficient granulation unit using a bulk flow cooler to reduce power demand; and reinforced digital safety management.

Advances in cooling technology are providing fertilizer facilities with new options when it comes to upgrading outdated equipment and improving environmental sustainability of their existing operations. Igor Makarenko of Solex Thermal Science explores cooling strategies to improve operational efficiencies while also reducing their energy consumption, greenhouse gas emissions and overall carbon footprint.

Globally, operational renewable ammonia projects have exceeded one gigawatt (GW) of installed electrolyser capacity for the first time. Kevin Rouwenhorst of the Ammonia Energy Association (AEA) provides an overview of well-advanced projects and the associated technology options for ammonia synthesis.

Air Liquide is developing a new ammonia cracking technology based on its proven steam methane reforming (including SMRX™ ) technology, which introduces a heat exchange concept to cut energy use, lower environmental impact, and potentially eliminate steam export. Leveraging extensive SMR design expertise, a robust R&D programme, and an industrialscale NH3 cracking pilot plant, it aims to rapidly mature all technology blocks and deliver safe, reliable, and customisable lowcarbon hydrogen solutions to meet growing demand.

Ammonia is poised to grow beyond fertilizers into energy transition roles, with lowcarbon pathways via blue ammonia and green ammonia, supported by existing logistics and market structures. To support this transition, Stamicarbon is expanding its NX STAMI™ ammonia technologies – with a mediumpressure design for large, CCUSintegrated plants and a highpressure design for small/ medium renewable projects – demonstrating efficiency, reliability, and cost advantages.