UAE ammonia plant retrofit enhances hydrogen recovery, boosts efficiency and reduces emissions

On September 30, 2025, thyssenkrupp Uhde—well-known German experts in engineering, procurement, and construction (EPC)—unveiled a cutting-edge Hydrogen Recovery Unit (HRU) at Fertiglobe’s ammonia plant located in Ruwais, Abu Dhabi. This retrofit marks a pretty significant leap forward in how efficiently and sustainably ammonia is made, aligning nicely with the UAE’s broader push toward industrial decarbonization.

What’s really interesting about the HRU is how it boosts ammonia production—by recovering hydrogen from purge gas streams. I mean, this is a pretty clever move because normally, in ammonia synthesis, a lot of unreacted hydrogen gets lost through purge gas, which either gets burned off or used inefficiently as fuel. By capturing and recycling this hydrogen back into the process, Fertiglobe has managed to bump up production by about 6%, now reaching roughly 2,120 metric tons daily. And, honestly, it’s not just about more ammonia—this improvement also cuts down CO₂ emissions per ton of ammonia made. Pretty neat, right?

Financially speaking, the project looks just as promising. Fertiglobe estimates an internal rate of return (IRR) over 25%, with the investment paying off within about four years. That’s quite attractive, especially considering the volatile natural gas prices and the increasing regulatory pressure to lower industrial emissions. Plus, the entire upgrade was completed without any unexpected downtime, which really highlights excellent project management and safety practices—something that’s not always easy to pull off during complex retrofits.

The plant itself sits within the sprawling Ruwais industrial complex, a major hub for petrochemicals with over 34,000 workers. The retrofit’s importance is underscored by UAE’s commitment to greener energy pathways, especially for heavy industries. Fertiglobe’s CEO, Ahmed El-Hoshy, emphasizes that their goal isn’t just ramping up production but also significantly lowering carbon emissions. The project leverages plentiful local natural gas resources and incorporates sustainable tech to meet rising global demand for cleaner supply chains—especially from Europe and Asia, where low-carbon products often command a premium.

From a technical perspective, the HRU make use of advanced membrane technology, installed in skid-mounted units that operate in parallel. These semi-permeable membranes selectively pull out hydrogen from the purge gas, then pressurize it to conditions suitable for synthesis and feed it back into the ammonia reactor. Essentially, this setup ensures every bit of hydrogen gets reused—maximizing feedstock efficiency. And the modular design means the plant can keep running smoothly without shutdowns during installation or maintenance, thanks to precise digital planning using 3D laser scanning, digital twin simulations, and strict safety protocols—every step carefully managed.

This new HRU isn’t appearing in a vacuum either. It builds upon Fertiglobe’s existing decarbonization efforts, which include partnerships with ADNOC and other entities to capture and store carbon emissions. For example, AFP News points out that ADNOC and Fertiglobe have worked together to develop the UAE’s first blue ammonia, utilizing carbon capture and storage (CCS) at the Al Reyadah facility. The Ruwais HRU fits into this broader low-carbon ecosystem by addressing hydrogen losses—those inefficiencies that were often overlooked but are actually significant sources of emissions.

On a global scale, this aligns well with industry trends pushing ammonia producers to clean up their act. Initiatives like the European Green Deal and emission caps imposed by large agricultural buyers in the US and Asia are increasingly pushing companies to adopt technologies like hydrogen recovery. Industry experts are seeing this retrofit as a kind of blueprint that other ammonia hubs—say, in Qatar, Louisiana, or Western Australia—might emulate, seeking similar gains in capacity and reductions in emissions through fairly cost-effective upgrades.

Looking ahead, Fertiglobe and thyssenkrupp Uhde are exploring pilot projects that combine green hydrogen—produced using electrolysis powered by the UAE’s expanding solar and wind energy—with recovered hydrogen streams. The idea is that blending electrolytic hydrogen with recovered hydrogen could make the overall carbon footprint of ammonia production nearly zero one day. It’s pretty exciting to think about, right? A sort of transition toward genuinely zero-emission hydrogen and ammonia by the middle of the decade.

All in all, this milestone proves that industrial decarbonization doesn’t have to be postponed or come with sky-high costs. Retrofitting existing plants with advanced hydrogen recovery tech offers a way to cut emissions immediately while also boosting process efficiency. And as more plants jump on board, the vision of sustainable ammonia and a cleaner energy future becomes more and more achievable.

thyssenkrupp Uhde, under the leadership of CEO Nadja Håkansson, brings over a century of expertise in chemical plant engineering and green technology. Fertiglobe, led by CEO Ahmed El-Hoshy, continues to push forward with its Manufacturing Improvement Plan (MIP), scaling low-carbon ammonia output from its roots in the UAE’s oil and gas sector into global markets. Together, they’re setting a really impressive standard for innovation, efficiency, and sustainability—both regionally and worldwide.

Source: Noah Wire Services