thyssenkrupp Uhde completes İGSAŞ ammonia converter cartridge and catalyst replacement
- Original nameplate capacity of 1,200 mtpd fully restored with a 13% production increase.
- Synthesis loop pressure reduced by 7%, delivering a meaningful reduction in specific energy consumption.
- Converter pressure drop cut by 70%, improving efficiency and long-term reliability.
- 36-year-old converter cartridge replaced; job executed with uhde® dense-loading and Johnson Matthey KATALCO™ 74‑1 catalyst under thyssenkrupp Uhde supervision.
Project results
The modernization restored the ammonia plant to its 1,200 mtpd nameplate capacity and produced a 13% increase in output during performance testing. The plant now operates at a 7% lower synthesis loop pressure, which reduces overall specific energy consumption, and the revamped converter shows a 70% lower pressure drop, improving efficiency and reliability.
Execution and technology
thyssenkrupp Uhde led field activities including converter opening, catalyst unloading, assembly, catalyst filling and activation, start-up and performance testing. Catalyst loading used uhde® dense-loading technology and was followed by a coordinated catalyst reduction and commissioning sequence with Johnson Matthey. The upgrade replaced a converter cartridge that had been in service for 36 years.
Collaboration and next steps
The project was delivered in close cooperation with İGSAŞ and Johnson Matthey, with smooth installation supervised by thyssenkrupp Uhde specialists. The new uhde® cartridge combined with Johnson Matthey’s KATALCO™ 74‑1 catalyst is positioned to support operational stability and further optimization, and thyssenkrupp Uhde is executing additional revamps using the same approach.
Source: thyssenkrupp
