ThyssenKrupp Uhde restores Turkey’s IGSAS ammonia plant to 1,200t/day with 13% output boost

ThyssenKrupp Uhde, working with Johnson Matthey, has completed a major modernization of the ammonia converter at IGSAS’s fertilizer complex in Kocaeli, Turkey, restoring the plant to its original nameplate capacity of 1,200 metric tonnes of ammonia per day.

A performance test following the upgrade confirmed a 13% increase in production. The revamped converter now operates at 7% lower synthesis loop pressure, reducing overall specific energy consumption, and at 70% lower pressure drop across the unit — improving both efficiency and long-term plant reliability.

The project replaced an ammonia converter cartridge that had been in continuous service for 36 years, well beyond the typical industry lifespan. ThyssenKrupp Uhde’s scope covered the full field execution sequence, from converter opening and catalyst unloading through assembly, catalyst loading using Uhde dense-loading technology, commissioning, and performance testing. Johnson Matthey supplied its KATALCO 74-1 catalyst.

IGSAS General Manager Ilkay Ünal said the upgrade marks an important milestone in strengthening the reliability, efficiency and long-term sustainability of the company’s production facilities. ThyssenKrupp Uhde COO Nadja Håkansson noted the plant now has flexibility for future capacity increases and potential transition toward green ammonia production.

IGSAS, part of Yıldızlar Yatırım Holding, is one of Turkey’s largest fertilizer producers and suppliers to the Turkish agricultural and industrial sectors. ThyssenKrupp Uhde said it is already executing additional converter revamps with the same approach at other sites.

Source: Hydrocarbon Processing