en.Wedoany.com Reported - thyssenkrupp Uhde, in collaboration with Johnson Matthey, has completed the modernization of the ammonia converter at İGSAŞ's (İstanbul Gübre Sanayii A.Ş.) production site in Kocaeli. Performance test results show a 13% increase in output, restoring the original design capacity of 1,200 metric tons of ammonia per day, while the synthesis loop pressure was reduced by 7%, leading to lower unit energy consumption. Additionally, the converter pressure drop was reduced by 70% after the revamp, improving plant efficiency and long-term reliability.
The installation work was carried out under the supervision of thyssenkrupp Uhde experts, with catalyst loading using the uhde® dense-phase loading technology, completed quickly in coordination with the İGSAŞ team. Subsequently, catalyst reduction and commissioning were coordinated with Johnson Matthey to ensure a rapid return to full-load operation.
This upgrade replaced converter internals that had been in operation for 36 years, far exceeding the typical industry lifespan. This longevity attests to the engineering and manufacturing quality of thyssenkrupp Uhde's ammonia converter technology as well as İGSAŞ's operational and maintenance standards.
Nadja Håkansson, Member of the Executive Board and Chief Operating Officer of thyssenkrupp Decarbonization Technologies and CEO of thyssenkrupp Uhde, stated that the project demonstrates the power of collaboration and technical capability, enabling İGSAŞ to improve energy efficiency and reliability while gaining flexibility for future capacity increases or green ammonia production.
İlkay Ünal, General Manager of İGSAŞ, said that the successful completion of the modernization is an important milestone in strengthening the reliability, efficiency, and long-term sustainability of the company's production facilities, reflecting close technical cooperation between both parties.
The new uhde® converter internals, combined with Johnson Matthey's KATALCO™ 74-1 catalyst, create a technology platform for the future, ensuring operational stability and optimization potential. thyssenkrupp Uhde's scope of work included supervision of the entire process from converter opening to catalyst discharge, assembly, loading, activation, startup, and performance testing. In addition to the İGSAŞ project, the company is already executing more revamp projects using the same approach.
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