Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Obstacles Our Experts Have Transformed into Opportunities
The client, managing a 20-year-old ammonia production plant, faced persistent operational issues:
Underperforming Yield
A 6% gap between actual and target yield due to unoptimized reaction conditions.
Excessive Energy Use
Increasing natural gas consumption with no existing heat recovery strategy
Fragmented Data
Key process data was dispersed across spreadsheets and manual logs, limiting visibility
Operational Instability
Frequent process upsets requiring hands-on operator intervention.
Audited the baseline
using site data, control room trends, and first-hand observations.
Reactive Improvements
Prior efforts lacked structure, validation, and long-term sustainability.
Teec’s Expert-Led Solution: Process Performance Enhancement
This transformation was driven by data experts, who led a comprehensive optimization program through a mix of fieldwork, simulation, and digital integration.
What Our Experts Did
using site data, control room trends, and first-hand observations.
of the ammonia process in Aspen HYSYS to safely test new strategies.
in temperature control, reformer loading, and pressure balancing.
with client engineers to validate findings through real-time trials.
directly linking energy savings to production performance.
This wasn’t a theoretical exercise—our experts tailored each recommendation to the plant’s unique constraints and goals.
Execution Approach by Teec’s Experts
- Conducted on-site walkthroughs and control room shadowing to map current workflows.
- Extracted production data and built a digital twin of the process in Aspen HYSYS.
Applied TEEC’s proprietary Loss Matrix to quantify yield and energy inefficiencies.
- Simulated alternative operating conditions under varied load scenarios.
- Fine-tuned reformer setpoints (pressure, flowrates, temperatures) in the digital model.
TEEC engineers validated all simulations in collaboration with client teams before implementation.
- Gradual rollout of optimized setpoints under expert supervision.
- TEEC created a custom Yield Tracker Dashboard to monitor real-time KPIs.
Weekly review sessions facilitated by TEEC helped align plant shifts on the new strategy.
Knowledge Transfer
- Documented updated SOPs for long-term reference.
- Delivered expert-led training to operations staff for ongoing performance sustainment.
Provided 90-day post-project support to ensure stability and performance fine-tuning.
Results & Impact
Sustained Yield Increase over 60-day production cycles
11% drop in natural gas consumption per ton of ammonia
$480K annual energy cost savings based on fuel benchmarks
30% reduction in process variability improving consistency and reducing operator burden
Integrated Value Through Teec’s Data-Driven Solutions
Our data experts ensured performance improvement wasn’t a one-time success:
Through our expert-driven integration of process and data, improvements became embedded—measured, sustained, and continuously refined.
