Operators Only

Looking to enhance your urea plant's operational resilience and troubleshooting capabilities? Join the workshop where you’ll explore common and challenging case studies using dynamic simulation (OTS) and real-time process monitoring to learn effective strategies for handling upset conditions in the urea plant.

The transition to low-carbon production doesn’t always require starting from scratch. This workshop will explore how smart revamping strategies and advanced technologies can extend the life of existing fertilizer and methanol plants, while significantly reducing emissions. Through real project insights, the workshop will also highlight practical solutions—from blue ammonia and oxidative reforming to hybrid configurations with green hydrogen and CO2 capture, to conventional revamping —showcasing how existing assets can become powerful drivers of industrial decarbonisation.

Join us for an exclusive, interactive technical workshop moderated by UreaKnowHow and designed specifically for nitrogen and syngas operators. This specialised workshop focuses on real-world safety cases and practical risk mitigation strategies within the industry.

Speakers: Yara, Nutrien and Badotherm

• Feedstock Volatility and Cost Projections in a Shifting Industry Landscape
• Global Trade Dynamics under Decarbonisation Policies and Regulatory Pressures
• Demand vs Supply Market Trajectories and Cost vs Price Challenges in Ammonia, Urea, and Nitrates

The presentation will provide a comprehensive outlook on the nitrogen and syngas markets heading into 2026, offering critical insights into the economic and geopolitical factors shaping the industry.

The presentation examines how evolving regulatory frameworks — notably the Environmental Protection Agency (EPA) mandates, the Carbon Border Adjustment Mechanism (CBAM), and new tariffs and sanctions — are reshaping production strategies, international trade flows, and the pace of sustainable innovation in the global nitrogen and syngas industries. The speaker will provide practical insights on compliance challenges, risk-mitigation strategies, and opportunities for differentiation in an increasingly sustainability-driven market.

 Transforming the Nitrogen and Syngas Industry: Economics, Sustainability, and Strategic Resilience

• The Low Carbon Transition - Navigating the global energy security space
• Deglobalisation and Trade Dynamics – Exploring how regional strategies are reshaping global trade and market independence
• Operational Risk and Resilience – Identifying limitations and mitigating risks to safeguard long-term scalable production performance
• Capital and Financing in a Volatile Market – Strategic approaches to funding innovation and capacity growth amid economic uncertainty and geopolitical  tensions
• Regional Market Snapshots – Focused updates on production trends across key regions, highlighting unique market drivers and pressures 
•  

• Economics and feasibility of deploying ammonia as a hydrogen carrier
• Global distribution and outlook for low-emissions ammonia supply
• Policy drivers and key regulatory developments shaping market demand
• Economic competitiveness of green ammonia projects in China

This presentation examines prospects for deploying green ammonia technology in Uzbekistan, a landlocked country at the heart of the Eurasian continent and the oldest nitrogen-fertilizer producer in the Central Asian region. Key technical and system challenges are discussed, notably integration of excess renewable generation and maintaining grid balance given Uzbekistan’s synchronous interconnection with Kazakhstan, Kyrgyzstan, and Tajikistan, and the practical advantages of retrofitting existing ammonia assets with electrolysers to lower capital costs.

Ministry of Economy and Industry Uzbekistan

Hydrogen Power Plant 1 is the first of two large-scale, low-carbon hydrogen plants selected by the UK Government within the HyNet industrial decarbonisation cluster; located at Essar Stanlow in Ellesmere Port. The project now developed under the brand EET Hydrogen will produce blue hydrogen from natural gas with carbon capture to supply industrial businesses across the North West of England, support Net Zero goals, and is planned to deliver an initial 350 MW capacity from 2026/2027, presenting significant investment, and offtake opportunities.

The presentation outlines how modularisation is transforming large-scale ammonia and urea projects and highlights Saipem’s modularisation experience with the EPC project CERES—the first Topsoe Ammonia SynCOR plant in advanced construction and one of the world’s largest ammonia–urea complexes. 

This presentation showcases the turnkey delivery of a state-of-the-art nitric acid production plant in Ostrava, Poland executed as an EPC project by Casale. The project combines a proven, risk-mitigated EPC model with a licensed, best-in-class technology, strong cost-and-schedule control, and an integrated energy solution that lowers operating costs and improves project returns while aligning with ESG and emissions-reduction priorities.

This presentation introduces ATOME’s flagship 145MW Villeta Project, a pioneering green fertilizer plant (online 2028) to produce low-carbon Calcium Ammonium Nitrate (CAN) for Latin America. With secured low-cost hydro power, completed FEED, 100% offtake with Yara International, anchor equity from Hy24’s Clean H2 Infra Fund, and a fixed-price EPC with Casale, Villeta offers subsidy-independent, de-risked returns and a competitive sustainable supply proposition.

The presentation introduces the strategic partnership between thyssenkrupp Uhde and Uniper to industrialise a large-scale ammonia cracker — key enabling technology for global hydrogen trading. Beginning with a world-leading 28 t/day demonstration plant at Gelsenkirchen-Scholven and progressing to a full-scale import terminal in Wilhelmshaven, Germany, the project converts imported ammonia into high-purity hydrogen for energy, steel and chemicals. It represents a scalable, market-ready route to low-cost, globally sourced hydrogen and offers significant engineering and delivery opportunities during scale-up, promising enhanced energy security and a practical pathway to decarbonisation through large-volume hydrogen supply.

TBC

The Kassø e-methanol plant is a landmark—the first commercial e-methanol facility (42,000 MTPA). The presentation details the technical partnership between European Energy and Clariant, where Clariant’s Advanced Catalyst Technologies (ACT) team delivered end-to-end catalyst design, loading and activation using proprietary gas analysis. Operational data demonstrate the robustness and efficiency of the MegaMax™ 900 catalyst and its implications for scaling green methanol.

The presentation outlines Engro Fertilizers’ operating experience with Yokogawa DCS-based automation implemented at the Ammonia-II plant to enhance emergency handling using existing hardware. The initiative successfully reduced manual emergency actions from approximately 100 to just 10, achieving a 90% reduction in operator intervention during total plant trip scenarios. Now in its fifth year of continuous operation, the system has significantly improved safety, reliability, and operational efficiency.

Discover a practical roadmap to commercial blue ammonia. This presentation unveils a rigorous methodology comparing SMR, ATR and POX integrated with CCS, assessing carbon intensity (Scope 1 / Scope 2), material & energy balances, feedstock impacts, and alternative configurations (H2 extraction, pre-combustion capture). The presentation showcases case studies on scalability, operability and HSE risks lead to clear recommendations for tech selection and cost-effective rollout.

This presentation introduces N06699, a high-chromium, high-aluminium, low-iron alloy engineered for high–carbon-activity environments to combat metal dusting; tested in printed and welded forms using PBF-LB/M and field-trialed as seamless tubes in a refinery hydrogen-unit reformer for over 36,000 service hours, the material showed no metal-dusting corrosion, demonstrating robust long-term industrial reliability.

The Hazer® Process, developed by Hazer Group Limited and licensed by KBR, is a scalable methane-pyrolysis route that uses low-cost iron ore catalyst in a fluidized-bed reactor to produce low-emission hydrogen and high-quality synthetic graphite from natural gas or biogas with no direct CO2 emissions; commercial demonstration results, economics and carbon intensity will be presented, along with integration opportunities for ammonia, methanol, steel and other industrial sectors.

The presentation will explore a small-scale urea solution that integrates green ammonia synthesis, urea melt and finishing under a single license to enable low-carbon, localised fertilizer production in infrastructure-limited regions; the design supports flexible CO2 sourcing, redirects ammonia-loop purge gas into the urea section—eliminating a dedicated purge treatment unit—and keeps standardised low-pressure absorbers for easy scaling, while utility synergies reduce Capex/Opex and emissions, making modular, rapid deployment technically and economically attractive for fertilizer plants.

Join this technical briefing on the decade-long partnership between Casale and Xin Lian Xin Group (XLX), which reviews ten technology contracts and spotlights a world-scale ammonia–urea complex pairing N-LOOP™ with the first commercial HYPER-U™. HYPER-U™’s self-stripping Medium-High Pressure (MHP) decomposition stage sharply reduces steam and cooling demand—lowering Opex and water use—and sets a new energy-efficiency benchmark with direct implications for plant layout, utilities integration, and lifecycle costs.

The speaker will present a case study of an in-situ rehabilitation strategy employed for a 5000 MT double-walled ammonia storage tank (Tank AT-911) installed at the Fauji Fertilizer Company Limited, Port Qasim Plant. The tank comprises an inner low-temperature storage vessel encapsulated within a secondary outer containment shell. Originally commissioned in 1998 and designed by CB&I USA, the outer tank began exhibiting pronounced corrosion degradation at its bottom annular and shell courses by 2014, prompting a rigorous integrity assessment and targeted repair campaign.

This presentation previews the development of a compact, scalable Integrated Multi-Stage Reactor (IMSR) for hydrogen via reforming: an initial stage produces H2/CO-rich syngas, a dedicated oxidation section converts CO to CO2 to maximize H2 yield, and a final graphene-based adsorption stage removes CO2 and heavy impurities to deliver high-purity H2; integrated oxidation and combustion zones provide flexible, thermodynamically efficient heat management and optimized energy recovery.

This presentation introduces g-Urea™, a compact, decentralised solution (50–500 MTPD) for green-fertilizer production using Green NH3 and renewable energy—designed to meet regulatory frameworks such as CBAM and RFNBO. The speaker will compare two process routes the scaled-down ACES21™ (lower Opex) and the Advanced Total Recycle Process (lower Capex), present techno-economic evaluations and show CO2-intensity visualisations for integrated green complexes versus conventional plants.

This presentation introduces a focused root-cause study into the high foaming tendency and actual foaming that enabled the rapid, successful commissioning of Indorama Train 2 Ammonia Plant, making it the world’s fastest commissioned KBR Ammonia Plant — from N2 circulation in the Front End to achieving 100% load with purifier stabilisation. Targeted diagnostics and timely interventions eliminated foaming bottlenecks and provided a reproducible, safe pathway to an exceptionally rapid startup.

About 70% of global ammonia is produced from natural-gas reforming, and many plants use the BASF OASE® two-stage CO2 removal. Adding a Low-Low-Pressure (LLP) flash—implemented with an ejector or compressor—and modelled in BASF OASE® connect delivers major gains: case studies show up to 25% lower reboiler duty or a 115% increase in feed-gas capacity, enabling energy savings or debottlenecking for grassroots and revamp projects.

This presentation focuses on a novel hybrid green-ammonia approach—injecting green hydrogen upstream of the LTS converter into an existing SMR plant without revamp or shutdown—implemented for the first time in Indonesia. Successfully piloted at PT Pupuk Kujang’s Ammonia Kujang 1B, the project demonstrated multiple injections, a full-scale co-firing trial, and was supported by comprehensive instrumentation, HAZOPs and cross-company collaboration.

Join this case study from Adani Group’s venture Adani New Industries Limited (ANIL) under Adani Enterprises on commissioning India’s first off-grid 5 MW pressurised alkaline electrolyser (1000 Nm3/hr) integrated with a BESS (Battery Energy Storage System). Running solely on intermittent RE, the fully automated system dynamically ramps to match generation and SoC, solving BESS tripping, reactive-power and synchronization issues with ramp-rate control, advanced EMS algorithms and interlocks. Measured impacts on Specific Energy Consumption (SEC) and LCOH and practical lessons make this directly relevant for engineers planning gigawatt-scale electrolyser projects.

Discover SCT-CPO — a flexible, cost-effective syngas route that can be tuned by pressure, temperature and steam/oxygen ratios. Applied as a front-end for methanol and ammonia synthesis, to boost SAF via Fischer-Tropsch off-gas recycling, and to decarbonise the steel sector, it cuts external green-H2 demand, enables heat recovery and CO2 capture, and improves carbon efficiency. Join us to see practical integration strategies and real-world gains.

Analytical sensors are vital but costly and downtime-prone — what if you could measure emissions accurately without the hardware headaches? Join the presentation to learn how Siemens’ hybrid solution achieves >99% accuracy for key components, EPA compliance, and far lower cost and maintenance than traditional CEMS. Ideal for brownfield and targeted greenfield projects, PEMS delivers rapid deployment, substantial savings and a practical route to smarter emissions monitoring.

The presentation introduces a novel, safer approach to ammonia removal in fertilizer plant exhausts using in-house CO2 fine-bubble technology to boost mass transfer and replace hazardous sulfuric acid. Backed by lab tests under real plant conditions and data-driven scale-up design, this pioneering solution promises improved safety, lower costs and regulatory benefits—presenting a practical alternative to conventional acid scrubbing for full-scale pilots.

Discover WESP (Wet Electrostatic Precipitator) project, developed for Yara, a hybrid wet-electrostatic precipitator that combines optimised ammonia absorption with high-efficiency electrostatic dust removal to control emissions from ammonium nitrate production. Pilots at Sluiskil and Montoir plants exceeded targets; retrofit completed and started November 2024. The system delivers regulatory compliance, lower pressure drop versus scrubbers, and operational continuity.

Join Engro Fertilizers Limited for a technical presentation on Catacarb-rich solution failures at its vintage Engro Base plant in Pakistan. Learn how multidisciplinary investigation, material upgrades from CS to SS, licensor-approved vendors, interim operational philosophy, and benchmarking restored reliability. Speakers will share root-cause analysis, remediation steps, outage lessons, and safety practices inspired by a DuPont Level 4 rating, practical guidance.

Introducing NX eBlue™ — MAIRE’s industrial-ready electrified hydrogen platform and low-carbon, high-efficiency alternative to SMR. It supports multiple feedstocks, achieves 33–45% CO2 reduction with near-100% capture (recoverable for use or storage), can be net-negative on biomethane, uses only one-third the renewable electricity of electrolysis, and is scalable, CCS-compatible and ready for deployment.

Discover how Solex Thermal Science is reimagining Moving Bed Heat Exchangers (MBHEs) for footprint-constrained fertilizer plants. Strategic plate repositioning boosted heat flux by 50–100% in modelling and bench-scale validation, promising major reductions in equipment size, material and cost. Join this presentation to hear the first physical results and learn how a next-generation MBHE can deliver compact, energy-efficient solutions for brownfield retrofits and new builds.

The presentation will compare three solvent-based carbon-capture routes for blue hydrogen—single-stage and two-stage amine versus the novel HPR amine process—using a representative syngas from autothermal reforming. Rate-based simulations, Capex/Opex estimates and sensitivity analyses show the HPR amine process delivers the lowest capture cost in all scenarios, driven by reduced compression power and smaller amine/compression capital. Join us to see which option maximizes ROI and cuts hydrogen cost.

This presentation provides actionable insights into how CO2 impurities affect critical stages of the CCS value chain. It highlights the operational challenges posed by specific contaminants and explains their impact on equipment performance and safety. By deepening the understanding of impurity behaviour, the paper supports all ammonia producers in designing more robust CCS systems and aligning with evolving CO2 quality requirements.

Join us for a real-world case study on piping integrity—piping incidents cause 40% of major plant losses. We examine an elbow creep failure in a 40-year-old high-pressure steam line at Fauji Fertilizer Company caused by a dislodged support and creep. Using Caesar stress analysis and API 579 Creep Level-II assessments the team derived remaining-life estimates and delivered practical Fitness-for-Service recommendations and inspection strategies to avoid recurrence.

The presentation will focus on how micro additions (Mo, W, V, Ti, Zr) alter high-temperature behavior of HPNb. Five centrifugally cast tubes with identical base chemistry were tested at 900–1100°C in tensile and creep-rupture trials. Additions didn’t change macrostructure but controlled carbide size, fragmentation, distribution and dendritic arm spacing, producing distinct mechanical responses and impacting equipment performance in SMR applications under extreme service conditions.

The presentation addresses a critical operational problem experienced by Fauji Fertilizer Company (FFC), where they discovered advanced creep damage in reformer welds. The presentation further details the solution, which FFC arrived at through collaboration with Quest Integrity, which involved testing, advanced analysis and proactive maintenance planning.

Discover how to keep plants running under extreme conditions. This presentation explores Steam Methane Reforming (SMR) — the backbone of Hydrogen/Syngas production for ammonia, methanol, refineries and DRI — and the critical role of reformer/catalyst tubes in carburising/oxidising environments. Learn why advanced alloys matter for creep, oxidation and carburisation resistance, and how Uni Abex’s 50+ years deliver proven reliability and material solutions for fertilizer, refinery and DRI operations.

Uni Abex Alloy Products Limited, A Neterwala Group Company

Cutting waste and boosting methanol yield — learn how CO2 placement changes everything. This presentation compares CO2 injection into the methanol synthesis loop vs upstream of the Steam-Methane-Reformer (SMR) using Aspen Plus simulations. Key takeaways: shifting CO2 upstream slightly reduces syngas volumetric flow to the Make-Up-Gas compressor, produces syngas richer in CO and enhances reactivity — projecting an average methanol yield gain of ~13 kta over the catalyst lifetime. Join us to hear about practical routes to energy optimisation and increased production.

The presentation showcases how Sipchem (Sahara International Petrochemical Company) and IMC cut specific energy use and raised methanol output by over 25% in a 2019 retrofit. Leveraging Johnson Matthey’s front- and back-end designs with heat integration, CO2 utilisation and added flexibility, this presentation details commissioning, post-revamp optimisation, and lessons from a unique parallel-reforming scheme combining SMR + ATR, plus an OTR upstream of an ARC.

Selecting the right post-combustion carbon-capture route is critical—and plant-specific. This talk contrasts mature solvent-based absorption with high-purity, fully electrified cryogenic capture, weighing energy, Capex and Opex trade-offs. We’ll show hybrid optimization opportunities, key KPI selection for different flue gases, and practical guidance to choose the most cost-effective, scalable solution for your decarbonization project.

Cut spare-part lead times from months to weeks—or days—without sacrificing quality. This presentation unveils R&D breakthroughs: key process developments and performance data for WAAM-manufactured UNS S32906 parts, plus practical operational fixes. Discover how advanced additive manufacturing can redefine maintenance strategies and dramatically boost operational resilience in the fertilizer sector. Join us to see tested solutions that keep plants running and downtime shrinking.

Protect your reformer — pigtail reliability under extreme SMR conditions. This presentation examines high-temperature failures in inlet/outlet pigtails, highlighting creep resistance, corrosion mechanisms, and the decisive role of grain-size control. Learn why high-alloy materials, precise grain-size characterisation (per ASTM B 407, ASTM E112, ASTM E1181), and tailored forming/heat-treatment strategies for bent pigtails extend life and enable single-stop replacements to boost plant uptime.

The transition to net zero is driving ammonia plants to adopt revamp solutions that boost capacity, cut emissions, and improve efficiency. This presentation outlines proven decarbonization strategies, focusing on practical, proven technologies that enhance capacity, reduce emissions, and improve operational efficiency, with real examples and strong business case for sustainable ammonia production. 

Convert ammonia plants to clean production—practically and affordably. This presentation unpacks the reengineering needed to shift from conventional SMR to low-carbon routes, featuring a full-scale European case study on process reconfiguration, hydrogen-backbone integration and alignment with EU frameworks (ETS, CBAM). The three U.S. case studies show viable partial-decarbonisation tactics, while blue hydrogen and modular retrofits offer a phased, cost-effective pathway to decarbonise at scale.

Join a deep dive into the Ostwald process, which underpins ~80 Mt/year nitric acid production and drives significant N2O emissions. Learn catalyst design challenges for ammonia oxidation and advanced characterisation needs. Discover Umicore’s Xtranit gauze family — PGM-based solutions engineered for higher conversion, reduced N2O, longer life and plant-specific customisation, plus practical retrofit benefits and operational gains, delivering measurable cost, efficiency and sustainability improvements.

Stricter regulations, rising energy costs and sustainability targets are pushing nitric acid plants to modernise. This presentation outlines practical upgrades—technologies that increase capacity and efficiency, reduce emissions, and extend plant life—helping operators cut costs and meet compliance.

Discover how a novel syngas catalyst is redefining sustainable production. Operating under drier conditions than conventional steam methane reforming, it resists carbon-induced deactivation for prolonged, high-performance runs. Real-world deployments show higher efficiency, lower steam use, and reduced greenhouse gas emissions, with strong CO2 uptake and conversion. Join us to see how innovative catalyst design and integration accelerate oxo-alcohols production and advance the chemical industry toward net-zero through collaborative R&D.

Join to learn how catalyst and process innovations make renewable methanol commercially viable. Unlock methanol’s potential as a low-carbon energy carrier for aviation and shipping. Produced from biomass, waste or CO2 + green hydrogen, it enables Methanol-to-Jet and clean marine fuel aligned with RefuelEU Aviation, FuelEU Maritime and the IMO latest regulations. Tackle costly, intermittent electrolytic hydrogen with smarter system integration—introducing Johnson Matthey’s eMERALD™: a low-risk, high-efficiency, flexible and scalable solution that cuts levelised cost of methanol.

Toyo Engineering presents an integrated solution for ultra-low carbon methanol: the g-Methanol™ process (powered by the efficient MRF-Z™ reactor and digital controls for flexible renewable operation) paired with the heat-pump distillation SUPERHIDIC™. A pilot at NTPC Limited (June 2025) validated scalability; commercial deployment at Maruzen Petrochemical Co., Ltd. proved energy savings. The combined process cuts indirect CO2, lowers Opex, and targets a GFI <14 gCO2/MJ under MEPC83—a ready pathway to scalable green methanol.

The presentation explores how Ru-based catalysts enable reliable, high temperature ammonia cracking for onsite hydrogen release, overcoming transport challenges. High throughput testing and accelerated ageing show that applying the proprietary impregnation and appropriate dopants significantly improve activity, stability and material efficiency. These shaped Ru catalysts maintain performance at industrial conditions, offering a cost effective, scalable pathway to deploy ammonia as a hydrogen carrier and accelerate the global energy transition.

Discover how ammonia cracking can unlock low-carbon hydrogen by using carbon-free trim fuels and overcoming combustion challenges. An advanced NH3-ready burner and control solution jointly developed and validated by John Zink and Johnson Matthey—leveraging PSA tail-gas recovery, heater modelling and CFD combustion studies—enables controlled, flexible ammonia combustion with minimized slip, NOx and N2O, now proven market-ready for large-scale industrial deployment.

Discover how thyssenkrupp Uhde Fertilizer Technology’s formaldehyde-free additive UFT®Add prevents caking—critical as the European automotive sector requires ~1.9M t/year of ultra-low-aldehyde urea. The talk covers a simple add-on plant integration and two industrial case studies: first commercial Fertiglobe production in Egypt using UFT® Fluid Bed Granulation, and production of AGU prills in an industrial prilling tower.

The presentation will showcase how WIKA’s Refractory Detection System (RDS) and TCC Linear Sensor transform monitoring for refractory-lined units with continuous distributed temperature measurement that forms a temporary hot junction to pinpoint hot spots in real time. Deployed in process gas coolers and reactors, the system supports zoned 24/7 surveillance, predictive maintenance, alarm triggering, simplified brownfield/greenfield installation, LoRaWAN connectivity and turnkey deployment by WIKA’s service teams—preventing failures, maximising uptime and safety.

We will explore how Air Liquide’s GasPOx syngas platform and ATR reforming cut LCOH/LCOA for low-carbon hydrogen and ammonia. GasPOx converts difficult off-gases with minimal pretreatment, high CO selectivity and reduced Capex/footprint, enabling high-pressure syngas and zero direct-emission options when coupled with CryocapTM H2, Rectisol or RecticapTM. The talk compares ATR and GasPOx with industrial case studies showcasing global commissioned plants.

Learn how Hynext by T.EN™ — Technip Energies' thermocatalytic ammonia-cracking technology — delivers low-energy, cost-efficient hydrogen. Pilot plant results under industrial conditions demonstrate novel reactor and catalyst performance, tested burners for ammonia and hydrogen, and a self-sustained, low-utility design (no steam) that reduces Capex and LCOH, enabling practical long-distance ammonia transport and on-site low-carbon hydrogen generation.

Understanding the mechanism and condition of nitridation degradation of the carrier material during ammonia cracking is essential to find reliable solution as it is essential to develop the right testing device, together relevant test conditions can be determined and applied on testing allowing a pertinent and accurate evaluation of material performance. This presentation will focus on evaluation of high corrosion resistant centrifugally cast austenitic alloys Cr-Ni-Fe emphasising specifically on the influence of the chromium content on the ammonia nitridation resistance

Discover scalable valorisation of PhosphoGypsum—produced at ~5.4 t per t of Phosphoric Acid, yielding ~225–245 million tonnes annually from IFA members—and the roadmap to 100% reuse by 2037 through international partnerships with the China Petroleum and Chemical Industry Federation. This presentation reviews urea-with-gypsum benefits (improved nitrogen use efficiency, reduced losses, enhanced soil health) and evaluates production technologies—mechanochemical, dissolution–recrystallisation, coating, thermal addition and core-granulation—for sustainable, circular fertilizer solutions.

The presentation will focus on Yara Sluiskil (Netherlands) synloop waste-heat boiler leak in 2023 that contaminated steam to Urea 7 with H2, NH3 and inerts. Conductivity alarms triggered a rapid risk analysis that identified potential ATEX zones; safety measures included nitrogen blanketing, zone isolation, removal of ignition sources and suspended hot work. Discover how inerts impaired the CO2 stripper, caused reactor, LPCC, LP and HP upsets with urea entrainment, the decision to vent polluted steam, and subsequent monitoring, procedural and resilience improvements.

The presentation will feature Air Products large-scale, low-carbon blue hydrogen solution combining POx syngas generation with the compact CPU CO2 purification unit. The design eliminates fired heaters, minimises methane/CO slip and enables >99% CO2 capture without flue-gas decarbonisation. CPU’s prefabrication reduces Capex, plot area and onsite solvents. Proven to accept diverse liquid and off-gas co-feeds, the integrated suite (including PSA) delivers optimised blue H2.

Learn how BD Energy Systems diagnoses and fixes heat-transfer imbalances in down-fired SMR furnaces that limit capacity, cause premature tube failures and reduce efficiency. Drawing on extensive design and revamp experience, BDE presents root-cause design features, retrofit upgrades and field case studies that restore temperature uniformity, extend catalyst tube life and recover lost hydrogen output—practical guidance for keeping natural-gas hydrogen plants reliable through energy transition.

BD Energy Systems, LLC

This presentation explains how to de-risk ammonia cracking and enable industrial-scale hydrogen reconversion with MACH2™. It details validation of critical components, rigorous performance and safety testing, and scale-up strategies that bridge the gap between proven small-scale systems and the demands of large-scale operations. The presentation will showcase evidence of reliability, efficiency and readiness positioning MACH2™ for commercial deployment within the hydrogen ammonia value chain and rapid global adoption today.

Discover practical revamp strategies to cut energy use, Opex and carbon footprint in energy-intensive fertilizer (urea) plants. Building on decades of project experience, Saipem presents tailored, cost-effective solutions that tackle bottlenecks, respect site-specific constraints, and minimise downtime to restore production quickly. Case-based schemes leverage licensor and EPC expertise to improve efficiency without capacity changes, ideal for operators facing high energy costs or stricter environmental limits.

This presentation demonstrates practical approaches to reformer optimisation in syngas and ammonia production, leveraging advanced analytics, machine learning, and hybrid process models. Key case studies show how adjusting firing, temperature profiles, steam-to-carbon ratios, and feed distribution can improve energy efficiency and reduce operational losses. Insights into operator integration, data requirements, and incremental improvements highlight how dynamic, data-driven optimisation enhances plant performance, lowers emissions, and extends asset life.

Join Air Liquide to learn how its industrial-scale pilot in the port of Antwerp, Belgium validated ammonia-to-hydrogen equipment, proving scalability, safety and energy efficiency. The talk presents R&D results, supplier collaborations, emissions compliance and pathway to a commercial cracking process, demonstrating tangible performance gains and readiness for economically viable, large-scale low-carbon hydrogen deployment across global energy markets today.

Join the presentation to explore readiness of SYNSPIRE® ARC catalysts and SYNSPIRE® ARCsim simulation for industrial ammonia cracking. Pilot deployments demonstrate high efficiency across temperature ranges, reduced Capex/Opex and critical operational learnings from startup and activation. With global projects scaling to meet RePowerEU and market needs in East Asia and Western and Central Europe, BASF’s tailored catalyst portfolio accelerates reliable green-hydrogen supply via ammonia reforming and deployment.

The presentation explores how Johnson Matthey’s novel ADEPTTM ammonia cracking process technology with ammonia firing can serve as an enabler for projects and can be differentiated from conventional SMR based ammonia cracking technologies offering a clean energy feedstock with the lower carbon intensity. 

The presentation will focus on how Engro Fertilizers Daharki, Pakistan’s largest urea complex, successfully modernised its single-train ammonia-urea plant during the 2024 turnaround. By installing state-of-the-art Super Cup Trays in the urea reactor, Engro achieved a 0.6% energy index reduction—surpassing projections—cutting steam use by 50 kg/ton and boosting capacity. This case study highlights engineering innovation driving operational excellence, sustainability, and global competitiveness in fertilizer production.

This presentation explores the critical replacement of equipment in the urea plant heater recirculation section following severe tube blockages that impaired cleaning and reduced efficiency. A detailed Root Cause Analysis identified the blockage mechanisms, leading to the development of an improved perforated plate design replacing fixed plugs. The presentation details the design rationale, implementation challenges, and performance improvements achieved, offering practical insights for plant optimisation and reliability enhancement.

This case study demonstrates practical problem-solving in severe operating conditions, including the transition from globe to angle valves to prevent cavitation damage and restore full plant capacity. Discover how Hazop analysis identified critical safety risks in urea plant startup procedures, leading to innovative solutions that eliminated backflow hazards. Learn about the implementation of high-pressure ammonia pump circulation systems with kickback valves, and the crucial lessons learned when initial valve selection caused capacity limitations.

Steam Reforming drives syngas production for hydrogen, methanol, and ammonia, relying on Ni-based catalysts for efficient conversion. This presentation highlights Johnson Matthey’s portfolio, including the advanced KATALCO™ 54-9Q catalyst, designed for optimised performance, durability, and reliability. Case studies show how these catalysts help operators meet production targets while mitigating risks from supply constraints in an increasingly competitive nickel market, ensuring sustainable, high-performing syngas operations.

This presentation introduces Magshift, UNICAT’s advanced textured sphere catalyst for the water-gas shift (WGS) reaction. Engineered via proprietary gel-cast technology, Magshift offers enhanced mechanical integrity, hydrothermal stability, optimised surface area, and reduced pressure drop in the reactor. Its extensive pore network improves reactant access, heat dissipation, and limits copper sintering, extending catalyst lifetime. Building on the award-winning Magcat, Magshift solves traditional WGS limitations, delivering higher efficiency and reliable performance.

This presentation showcases advanced bench-scale testing of commercial catalysts under industrially relevant conditions using hte’s 4-fold parallel reactor system. By integrating high-resolution temperature profiling, the study reveals spatial thermal gradients, hot and cold spots, and reaction-zone dynamics, providing unprecedented insights into catalyst performance, CH4 suppression, and time-on-stream stability. These findings enable optimised reactor design and improved industrial syngas-from-CO2 processes.

The presentation focuses on groundbreaking insights into the structural evolution and functional mechanisms of complex, multi-promoted iron-based catalysts used in industrial ammonia synthesis plants. It highlights the Clariant's Wustite-based AmoMax 10 Plus catalyst and its proven performance in large-scale ammonia plants. Real-world plant data demonstrate consistent high performance over four years, showing how optimised promoter synergies, controlled reduction, and tailored porosity translate fundamental insights into reliable, efficient industrial ammonia production.