Successful Project Completion at Kocaeli Facility
thyssenkrupp Uhde, in collaboration with Johnson Matthey, has successfully completed a major modernization project at İGSAŞ’s ammonia plant in Kocaeli, Türkiye. The project involved the replacement of the ammonia converter cartridge and catalyst system, marking a significant upgrade to the plant’s synthesis loop performance.
Moreover, the revamp was executed smoothly under carefully planned conditions, ensuring minimal disruption to ongoing operations and a swift return to full production capacity.
Advanced Technology Upgrade Improves Plant Performance
The modernization focused on replacing a 36-year-old converter cartridge with a newly engineered uhde® design. In addition, a high-performance catalyst system was installed to enhance efficiency and reliability.
As a result, the upgraded system now delivers improved operational stability, reduced pressure drop, and enhanced energy efficiency. Furthermore, the plant benefits from restored nameplate capacity and optimized synthesis loop performance.
Significant Gains in Capacity and Energy Efficiency
The revamp has delivered measurable performance improvements. Specifically, a recent performance test confirmed a 13% increase in production output, fully restoring the original ammonia capacity of 1,200 metric tons per day.
In addition, the plant now operates at a 7% lower synthesis loop pressure, which significantly reduces energy consumption. Consequently, the overall efficiency of the facility has improved, along with long-term reliability of operations.
Smooth Execution Through Strong Collaboration
The success of the project was made possible through close coordination between thyssenkrupp Uhde, Johnson Matthey, and İGSAŞ technical teams. Catalyst loading was carried out efficiently using advanced dense-loading technology, followed by systematic commissioning and start-up activities.
As per thyssenkrupp Uhde’s official news release, “the installation proceeded smoothly under the supervision of Uhde specialists, ensuring a swift and reliable return to full operation.”
Moreover, full supervision was provided throughout critical phases such as converter opening, catalyst unloading, assembly, and performance testing, ensuring high execution quality and operational safety.
Long-Term Reliability and Sustainability Benefits
Importantly, the upgrade replaces equipment that had been in operation for over three decades, demonstrating the durability of the original design. Meanwhile, the new system enhances long-term plant reliability and reduces overall energy consumption.
In addition, the combination of Uhde’s converter technology and Johnson Matthey’s catalyst supports future flexibility, including potential capacity expansion and greener ammonia production pathways.
Conclusion
Overall, the successful revamp of İGSAŞ’s ammonia converter marks a significant step toward higher efficiency, lower energy use, and improved reliability. Consequently, the project strengthens long-term operational performance while supporting more sustainable fertilizer production at the facility.
