thyssenkrupp Uhde’s IGSAS ammonia upgrade boosts production, lowers energy consumption, improves reliability, and enables future green ammonia opportunities.
thyssenkrupp Uhde, working in close partnership with Johnson Matthey, has successfully completed a major modernization project at IGSAS – Istanbul Gübre Sanayii A.S.’s ammonia production facility located in Kocaeli, Türkiye. The project involved the replacement of the ammonia converter cartridge and catalyst system, delivering substantial improvements in plant performance, energy efficiency, and long-term operational reliability.
Following the completion of the upgrade, a comprehensive performance assessment confirmed impressive results. The modernized ammonia converter achieved a 13% increase in production output, allowing the facility to regain its original design capacity of 1,200 metric tons of ammonia per day (mtpd). This achievement was particularly significant as the plant reached this production level while operating at a 7% lower synthesis loop pressure compared with previous operating conditions. The lower operating pressure directly contributes to reduced specific energy consumption, supporting more economical and environmentally efficient ammonia production.
Another key advantage of the upgrade is the remarkable 70% reduction in pressure drop across the converter. This improvement enhances the overall performance and stability of the ammonia synthesis loop, reducing operational stress on equipment and improving the long-term reliability of the entire production unit. These enhancements position IGSAS to maintain efficient operations while creating opportunities for future capacity expansion and more sustainable ammonia manufacturing approaches.
The successful execution of the project was made possible through detailed preparation and close cooperation between thyssenkrupp Uhde, Johnson Matthey, and the IGSAS operational team. Installation activities were carefully managed under the supervision of experienced thyssenkrupp Uhde specialists, ensuring the modernization process was completed safely and efficiently. The catalyst loading phase was carried out using thyssenkrupp Uhde’s advanced uhde® dense-loading technology, which enabled rapid and optimized catalyst installation. The subsequent catalyst reduction, commissioning activities, and plant restart were completed in collaboration with Johnson Matthey, ensuring a smooth and reliable return to full-scale ammonia production.
The modernization also marked the replacement of an ammonia converter cartridge that had remained in continuous operation for an extraordinary 36 years, significantly exceeding the typical lifespan expected in the industry. The exceptional durability of the original equipment highlights the robust engineering standards of thyssenkrupp Uhde’s ammonia technology, combined with IGSAS’s strong commitment to effective plant operation, maintenance, and asset management over several decades.
Nadja Håkansson, Member of the Executive Board and Chief Operating Officer of thyssenkrupp Decarbon Technologies as well as CEO of thyssenkrupp Uhde, emphasized that the project demonstrates the strength of the long-standing collaboration among thyssenkrupp Uhde, IGSAS, and Johnson Matthey. She noted that the upgraded facility delivers significant improvements in energy efficiency and reliability while providing flexibility for future production increases and potential transition toward green ammonia production. According to Håkansson, the project reflects thyssenkrupp Uhde’s commitment to helping customers achieve more sustainable and high-performance fertilizer manufacturing.
Ilkay Ünal, General Manager of IGSAS, stated that the successful completion of the modernization represents an important step toward improving the reliability, efficiency, and sustainability of the company’s production assets. He highlighted the strong technical cooperation and effective teamwork between IGSAS and thyssenkrupp Uhde throughout every stage of the project execution.
The upgraded converter combines thyssenkrupp Uhde’s latest uhde® converter cartridge technology with Johnson Matthey’s advanced KATALCO™ 74-1 catalyst, creating a highly efficient technological platform designed for future optimization, enhanced operational stability, and reduced environmental impact. thyssenkrupp Uhde’s responsibilities covered the complete field execution process, including converter opening, catalyst removal, equipment assembly, catalyst loading, activation procedures, start-up operations, and final performance testing.
Building on the success of the IGSAS modernization, thyssenkrupp Uhde is continuing to implement similar ammonia plant revamp projects worldwide, leveraging the same advanced technologies and engineering expertise to improve efficiency, reliability, and sustainability across the fertilizer industry.
