chemicals is also moderate, and the olefinic feedstocks available from the refinery and petrochemical complex are generally sufficient to meet most of this demand. Similarly, the amount of recovered NH₃ may be lower than the overall demand; nonetheless, it is possible to produce additional NH₃ by utilising surplus H₂ and N₂ available within the complex. • Higher solid handling requirements: The integration of petrochemical and fertiliser production will result in increased demand for solid handling, including bag - ging, packaging, and storage. However, solid handling is not unfamiliar to the refinery industry, which routinely manages catalysts, sludge, and products like coke. As a result, the necessary expertise is already in place, facili - tating a smooth and seamless transition in operations and management. • Permitting and regulatory hurdles: The proposed inte - gration may involve complex permitting processes, espe - cially given the cross-sector collaboration between the Indian Ministry of Petroleum and Natural Gas (MoPNG) and the Ministry of Chemicals & Fertilizers (MoCF). These challenges can be effectively managed through proactive regulatory consultations and by establishing a joint pol - icy framework. Addressing potential concerns early in the development process will facilitate smoother approvals and better coordination among stakeholders. • Different locations of refinery and fertiliser complexes: Most of the existing refinery and fertiliser complexes are not situated adjacent to each other, which may limit some benefits of integration. However, the distances between these complexes are generally manageable, allowing for the establishment of suitable piping corridors. This infra - structure can facilitate the sharing of raw materials, utilities, effluents, and other resources, thereby enabling effective integration and maximising potential benefits. Conclusions The proposed refinery-petrochemical-fertiliser integration represents a foundational structural shift essential for long- term viability, environmental performance, and national self-reliance. The proposed integration transforms refiner - ies from fuel-oriented assets into multi-product molecular transformation platforms capable of producing high-value chemicals, polymers, and fertilisers with significantly lower carbon intensity. The incorporation of circular fertiliser production strengthens the system by converting traditionally wasted byproducts like ammonia, hydrogen sulphide, and carbon dioxide into essential agricultural inputs. This transforma - tion supports national fertiliser security, reduces import dependency, and promotes the closing of elemental loops within the industrial ecosystem. Key benefits of an inte - grated and optimised system include: • Reduced carbon footprint through efficient feedstock uses and waste recycling. • Enhanced product flexibility to meet evolving market demands. • Greater economic resilience via diversified and sustaina - ble supply chains.
Ammonia recovery and utilisation potential
Refinery
Crude N
NH₃
Annual
Fertiliser equivalent
capacity, content, generation, recovery,
MMTPA
wt% 0.12
TPD
KTPA
9
40
13
23 KTPA urea OR 50 KTPA DAP 658 KTPA urea OR 1,432 KTPA DAP
258
0.12
1,145
372
Table 3
• Improved compliance with environmental regulations and sustainability commitments. For a typical 9 MMTPA refinery complex, integration of a steam cracker and aromatics complex can achieve ~26% reduction in CO₂ emissions. Further integration of a fer - tiliser complex can increase the reduction to around 31%. Additionally, the proposed integration can lead to approxi - mately a 112% GRM improvement. While there are challenges, such as limited licensing options for speciality chemicals, differing locations and ownership structures of existing refinery and fertiliser plants, and the need for cross-sector collaboration between MoPNG and MoCF, these can be addressed through suita - ble strategic solutions. The integrated approach not only enhances resource efficiency and profitability but also supports CO₂ emission reduction, aligns with India’s sustainability and self-suffi - ciency goals, and paves the way for the industry’s transition to a low-carbon future. References 1 International Energy Agency (IEA). (2022). World Energy Outlook 2022. Paris: IEA Publications. 2 International Energy Agency (IEA). (2023). Oil 2023: Analysis and forecast to 2028 . Paris: IEA Publications. 3 Press Information Bureau (PIB), Government of India. Various releases on fertiliser production and imports (2023-24). Sabrin Khan is a Senior Engineer with Genesis at the Technip Energies India Operating Center. She is a highly analytical, performance-driven chemical engineer from the University of Calcutta, India, with around six years of experience in the downstream refining and petrochemi - cal industry. She is skilled in strategic master planning, refinery mod - ernisation, and refining-petrochemical integration. Khan’s experience includes developing advanced linear programming models, early-stage concept studies, economic analysis, and technical negotiations, with a strong focus on improving efficiency and driving sustainable solutions. Chiranjib Haldar is acting as the Delivery Manager with Genesis at the Technip Energies India Operating Center. He has 25 years of experience in master planning, conceptual study, feasibility study, process modelling and simulation, licensor evaluation, energy effi - ciency improvement using pinch technology, Basic, FEED and detailed engineering of various refining and petrochemical units. A member of Technip Energies Expert network, Haldar holds a bachelor’s degree in chemical engineering from the University of Calcutta, India.
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PTQ Q4 2026
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