Thyssenkrupp Uhde, Johnson Matthey to Increase Ammonia Capacity at Koch Unit

Plant Engineering Thyssenkrupp Uhde, Johnson Matthey to Increase Ammonia Capacity at Koch Unit

2023-06-20 Source: Press release thyssenkrupp Uhde 1 min Reading Time

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Koch Fertilizer has decided to revamp its Fort Dodge facility in the USA in order to increase its ammonia production capacity by 85,000 tons per year. Thyssenkrupp Uhde and Johnson Matthey have been selected by the company to achieve this goal.

Koch Fertilizer’s facility in Fort Dodge, Iowa, USA. (Source: thyssenkrupp Uhde) — Koch Fertilizer’s facility in Fort Dodge, Iowa, USA.
(Source: thyssenkrupp Uhde)

Essen/Germany – 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-dollar 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.

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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.

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