Plant Efficiency Thyssenkrupp Uhde, Johnson Matthey Complete Modernization of Ammonia Converter

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In Turkey, igsaş’ ammonia converter has been modernized by Thyssenkrupp Uhde and Johnson Matthey. The result: a significant production increase of 13 % and operates with a 70 % lower pressure drop.

Dortmund/Germany – Thyssenkrupp Uhde, in close cooperation with Johnson Matthey, has successfully completed the modernization of the ammonia converter for igsaş – İstanbul Gübre Sanayii – at its Kocaeli production site. A recent performance test confirmed a significant production increase of 13 %, fully restoring the original nameplate capacity of 1,200 mtpd of ammonia, while operating at a 7 % lower synthesis loop pressure. This results in a meaningful reduction in overall specific energy consumption. In addition, the revamped converter now operates with a 70 % lower pressure drop, further improving efficiency and long-term reliability of the whole plant.

Thanks to careful planning and close collaboration with igsaş, the installation proceeded smoothly under the supervision of Thyssenkrupp Uhde specialists. Catalyst loading was executed rapidly using uhde dense-loading technology together with the igsaş team, followed by a coordinated catalyst reduction and commissioning sequence together with Johnson Matthey. These steps ensured a swift and reliable return to full operation. The upgrade replaces a converter cartridge that had been in operation for an exceptional 36 years – well beyond the industry norm. This longevity reflects the robust engineering and manufacturing quality of Thyssenkrupp Uhde’s ammonia converter technology and igsaş’ continued excellence in operation and maintenance.

Nadja Håkansson, Member of the Executive Board / COO of Thyssenkrupp Decarbon Technologies & CEO of Thyssenkrupp Uhde: “The successful completion of this project demonstrates the strength of our collaboration with igsaş and Johnson Matthey, and the outstanding capabilities of our uhde ammonia technology. With this upgrade, igsaş benefits from significantly improved energy efficiency and reliability, while gaining future flexibility for capacity increase or green ammonia production. We are proud to support our customers in advancing sustainable and high-performing fertilizer production.”

İlkay Ünal, General Manager igsaş: “With the successful completion of this modernization, igsaş has achieved an important milestone in strengthening the reliability, efficiency and long-term sustainability of its production facilities. This project also reflects the strong technical collaboration between igsaş and Uhde teams throughout the execution phase.”

The combination of the new uhde converter cartridge with Johnson Matthey’s high-performance Katalco 74‑1 catalyst forms a strong technological platform for the future, ensuring both operational stability and the potential for further optimization. Thyssenkrupp Uhde’s scope included full supervision of all field activities – from converter opening and catalyst unloading to assembly, catalyst filling and activation, start-up, and performance testing. Beyond the completed igsaş project, Thyssenkrupp Uhde is already executing further revamps with the same approach.

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