IPCOS offers control based optimization solutions for all processes used in the fertilizer industry ( Ammonia, urea, nitric acid, granulator and steam networks). Control based optimization covers base layer control optimization, Advanced Process Control and Alarm Management.

The most cost effective way to improve fertilizer plant operations

Fertilizer complex

The significance of fertilizers is increasing as the population grows and as more developing countries increase their fertilization rates. Fertilizer production consumes approximately 1.2% of the world’s total energy. We help our customers from the fertilizer industry to boost their production while reducing their specific energy consumption.

Typical benefits generated by IPCOS in the fertilizer industry around the globe:

  • Ammonia
    • Production increase: 0.5% to 2%
    • Specific energy consumption reduction: 0.5% to 2%.
    • Steam Export increase: 1% to 20%.
  • Urea
    • Production increase: 2% to 5%.
    • Specific energy consumption reduction: 1% to 5%.
  • Nitric Acid
    • Production increase: 0.5% to 2%.
    • Specific energy consumption reduction: 0.5% to 2%.
    • Steam Export increase: 1% to 20%.
  • Granulators
    • Production increase: 2% to 6%.
    • D50 variations: reduced by a factor 2 to 10.
  • Steam Networks
    • Less venting.
    • Less let downs.
    • Optimal use of different boilers with different efficiencies.
    • Handsoff operations.

These benefits have been created on plants of Yara (worldwide), BASF, Sabic, Ma’aden, Nutrien, Petronas, OCI Nitrogen, FATIMA, Engro, Igsas, Koch, Fauji, …..

What defines the IPCOS Fertilizer solutions?

  • IPCOS combines in depth knowledge of all fertilizer processes and all aspects of process control. This results in very cost effective solutions with a high ROI.
  • IPCOS not only provides the implementation services but also delivers long term support and maintenance programs to ensure that these optimisation solutions will keep running at their maximum performance for many years.
  • IPCOS has extensive expertise on ammonia, urea, nitric acid, AN, UAN, and granulation (CAN/NPK,…).
  • Steam grids are an important part of fertilizer sites. IPCOS optimizes your steam grid in order to reduce venting, optimize the use of boilers, letdown valves, turbines,….

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