Jun 7, 2023 8:00 AM
thyssenkrupp Uhde awarded supply of new uhde® ammonia converter cartridge in-cluding synthesis catalyst by İGSAŞ - İstanbul Gübre Sanayii A.Ş.
Ammonia converter revamp to set new standards in reliability
Reduced energy consumption of ammonia plant
thyssenkrupp Uhde and Johnson Matthey have been commissioned by İGSAŞ - İstanbul Gübre Sanayii A.Ş., Kocaeli (Turkey) to supply a solution to significantly reduce the pressure in the synthesis loop of an ammonia plant while maintaining the nameplate capacity of 1,200 mtpd. The new cartridge will be based on the latest design principles, including a modular design with removable catalyst beds which enable better accessibility during catalyst filling, axial-radial flow beds, lower pressure drop, etc. The cartridge, which will be installed in the existing pressure shell, will bring further benefits in terms of safety as no major welding activities are required during installation.
The currently installed cartridge, based on a reliable design by thyssenkrupp Uhde, has reached an extraordinarily long lifetime of 36 years in operation. Usually, replacements are necessary after two catalyst exchange cycles, approximately after 20 years. However, thanks to the robust design and high quality requirements set by thyssenkrupp Uhde during equipment manufacturing and testing, life times of 30 years and more are feasible.
Kutay Durna, factory manager at İGSAŞ: “With this upgrade of our plant, we are ready for the future. Key decision points for choosing thyssenkrupp Uhde were the proven reliability of their products combined with reducing the energy consumption in our Kocaeli plant.”
Thore Lohmann, Executive Director Fertilizer and Methanol at thyssenkrupp Uhde: “This is further proof that our uhde® ammonia technology can meet the diverse requirements of plant owners around the globe. Our proprietary design of ammonia converter cartridges meets the highest quality standards and, when retrofitted to ammonia converters, it hugely enhances plant performance.”
The improved reliability of the plant and the energy savings will be achieved by combining the new uhde® ammonia converter cartridge with Johnson Matthey’s high-performance catalyst KATALCOTM 74-1. This combination will open up the potential for a further increase in plant capacity in the future, for example for green ammonia production.
The new equipment is under fabrication, and start-up is scheduled for mid-2024. thyssenkrupp Uhde will perform full supervision services during converter opening, catalyst unloading, cartridge disassembly, converter inspection, cartridge assembly, catalyst filling/activation, startup and performance testing at this time.
Besides supplying the new cartridge for İGSAŞ, thyssenkrupp Uhde currently has eight additional uhde® ammonia converter cartridges underway for their current blue ammonia projects.
İGSAŞ with its products transported to each agricultural district of Turkey, joined Yildizlar Yatirim Holding by the way of privatization in 2004 and is one of the largest industrial corporations of Turkey. The plant in Kocaeli, as one of four fertilizer factories in total, produces ammonia and composite fertilizer products.
About thyssenkrupp Uhde:
thyssenkrupp Uhde combines unique technological expertise and decades of global experience in the engineering, procurement, construction and service of chemical plants. We develop innovative processes and products for a more sustainable future and thus contribute to the long-term success of our customers in almost all areas of the chemical industry. Our portfolio includes leading technologies for the production of base chemicals, fertilizers and polymers as well as complete value chains for green hydrogen and sustainable chemicals. www.thyssenkrupp-uhde.com