Decarbonisation Technology May 2026 Issue

feed temperature before synthesis.

HP purge

Dryers

Steam system The redesigned steam system is thermally balanced to minimise external steam import. MP superheated steam is generated within the synloop and used to drive one of the new syngas compressors. The ammonia refrigeration compressor turbine is

NH chillers

Syngas compressor

Ammonia

Ammonia compressor

Converter

Syngas compressor-A

MP superheated steam

Syngas compressor-B

To HP steam drum

1. Steam superheater pkg includes an integrated BFW preheater, steam generator and steam superheater.

Existing- removed Modied New

Steam superheater Pkg

Nitrogen Hydrogen

Feed purication

BFW

Figure 3 Case 1: New synloop configuration

compressor drivers. This involved replacing the existing HP boiler feedwater exchanger with a new MP steam generator coupled with a superheater. New plant configuration In the revamped configuration, the majority of the front-end equipment from the legacy ammonia plant is decommissioned. However, several components – including the existing desulphurisers, methanation vessels, and selected heat exchangers – were successfully repurposed within the new feed purification unit designed for blended hydrogen and nitrogen streams. Major modifications to the synloop, illustrated in Figure 3 , include: • Reconfiguration of the syngas compression system with two new 50% capacity compressors – one steam-driven and the other motor-driven – for operational flexibility. • Improved turndown performance. • Installation of a MP steam generator and superheater by replacing the HP boiler feedwater (BFW) exchanger within the synloop. • Addition of a new feed preheater in the purification section, utilising steam to optimise ammonia production is reinforced by a convergence of regulatory, financial, and infrastructure developments across Europe ” “ The economic rationale for complete conversion to clean

also powered by MP steam, ensuring efficient energy utilisation across the cycle. A minimal amount of steam is imported for a heat- integrated feed purification section. Specific energy consumption The specific energy consumption for clean ammonia production is estimated to be approximately 16% lower than that of the existing plant (on a higher heating value basis). This figure accounts for the energy content of the hydrogen feed, power required for nitrogen production, steam import/export credits, and auxiliary power consumption (such as pumps). Carbon emissions Scope 1 carbon emissions for the clean ammonia configuration are projected to be less than 0.2% of those from the existing plant. For reference, the current facility emits approximately 1.8 metric tons of CO₂ per metric ton of ammonia produced. This dramatic reduction underscores the decarbonisation potential of complete hydrogen substitution and process electrification. Economic justification The economic rationale for complete conversion to clean ammonia production is reinforced by a convergence of regulatory, financial, and infrastructure developments across Europe. Stringent environmental policies, notably the tightening of the EU ETS and the phased implementation of CBAM, are driving up