- uhde® dual pressure process installed
- High-performance catalyst by Johnson Matthey
Working in collaboration, thyssenkrupp Uhde and Johnson Matthey have delivered a product solution to increase the ammonia capacity at Koch Fertilizer’s Fort Dodge, Iowa (USA) facility. During the revamp of the existing ammonia plant, the team integrated the uhde® dual-pressure process, which was installed upstream of the existing ammonia synthesis loop.
Koch Fertilizer, a leading fertilizer manufacturer and distributor, performed a $140 million revamp at its Fort Dodge facility to further improve reliability, environmental and safety performance. The investment is expected to increase ammonia production capacity by 85,000 tons per year.
To help achieve the additional capacity, process experts from thyssenkrupp Uhde developed a new cartridge insert for the existing pressure shell based on latest design principles. Thanks to thorough scheduling, most of the installation work was done while the existing plant was running. Commissioning of the new uhde® ammonia converter was smooth with Johnson Matthey on-site support and did not impact plant start-up time.
A key challenge was the very low ammonia synthesis operating pressure of only 960 psig/66 barg, which could be solved by combining Johnson Matthey’s high-performance catalyst KATALCOTM 74-1 with an adapted process design from thyssenkrupp Uhde. This joint solution enabled the increased ammonia synthesis capacity. The same combination of the highly efficient uhde® dual pressure process for ammonia production and KATALCOTM 74-1 catalyst from Johnson Matthey is already used in all the world’s largest ammonia plants operating with capacities of more than 1 million tons of ammonia per year.
Thore Lohmann, Executive Director Fertilizer & Methanol at thyssenkrupp Uhde: “We have worked hand in hand with our customers and our partners at Johnson Matthey to make this happen. With our engineering and plant building expertise, we have ensured a smooth integration of the uhde® dual pressure process. The same approach can be applied in many other plants as well.”
Leading technologies for ammonia all along the value chain
thyssenkrupp Uhde has over 100 years of experience in the engineering and construction of chemical plants, having executed more than 2,500 projects in total. Among the 130 ammonia plants built are some of the largest plants worldwide. These have frequently set new industry standards, for example by applying the uhde® dual pressure technology. Besides the fertilizer business, thyssenkrupp Uhde also offers clean ammonia technologies and ammonia storage solutions, which are key for the transition towards clean energy and the use of ammonia as an energy and hydrogen carrier.
About Koch Fertilizer
Koch Fertilizer, LLC and its affiliates own or have interests in nitrogen fertilizer plants in the United States, Canada, and Trinidad and Tobago as well as a phosphate fertilizer plant in Morocco. The companies cover global demand through state-of-the-art terminals in the U.S., Canada, Mexico, Brazil and Australia. Koch Fertilizer, LLC and its affiliates have the capability to market and distribute approximately 12 million tons of fertilizer products annually. Koch Fertilizer, LLC is a subsidiary of Koch Ag & Energy Solutions, LLC.
About Johnson Matthey
Johnson Matthey is a global leader in sustainable technologies, catalysing the net zero transition. With over 200 years of sustained commitment to innovation and technological breakthroughs, we improve the performance, function and safety of our customers’ products. Our science has a global impact in areas such as low emission transport, energy, chemical processing and making the most efficient use of the planet’s natural resources. Today, about 13,000 Johnson Matthey professionals collaborate with our network of customers and partners to make a real difference to the world around us.
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 producing base chemicals, fertilizers and polymers as well as complete value-chains for green hydrogen and sustainable chemicals.
Read the most up to date Fuel Cell and Hydrogen Industry news at FuelCellsWorks
