thyssenkrupp Uhde, working closely with Johnson Matthey, has completed a major modernization of the ammonia converter at İGSAŞ’s Kocaeli production site, delivering a sharp boost in performance and efficiency.

 

A recent performance test confirmed a 13% increase in production, restoring the plant’s original nameplate capacity of 1,200 mtpd of ammonia, while operating at a 7% lower synthesis loop pressure. The upgrade also cuts overall specific energy consumption, and the revamped converter now runs with a 70% lower pressure drop, significantly improving efficiency and long-term reliability.

 

The project was executed under tight coordination with İGSAŞ and supervised by thyssenkrupp Uhde specialists. Catalyst loading was completed rapidly using uhde dense-loading technology in collaboration with the İGSAŞ team, followed by a carefully sequenced catalyst reduction and commissioning process with Johnson Matthey—enabling a swift return to full operation.

 

At the heart of the upgrade was the replacement of a converter cartridge that had been in service for an exceptional 36 years, far beyond typical industry lifespans. The milestone underscores both the durability of thyssenkrupp Uhde’s ammonia converter design and İGSAŞ’s operational discipline in maintaining long-term plant performance.

 

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 İGSAŞ and Johnson Matthey, and the outstanding capabilities of our uhde ammonia technology. 

 

"With this upgrade, İGSAŞ 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 İGSAŞ: “With the successful completion of this modernization, İGSAŞ 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 İGSAŞ and Uhde teams throughout the execution phase.”

 

The upgraded system pairs the new uhde converter cartridge with Johnson Matthey’s KATALCO™ 74-1 catalyst, creating a high-performance platform designed for stable operation, lower emissions, and future optimization potential.

 

thyssenkrupp Uhde managed the full scope of field operations, including converter opening, catalyst unloading, assembly, filling, activation, start-up, and performance testing. The company says it is already applying the same revamp approach in additional projects worldwide.