[ Fertiliser Production ] and long-term soil health, inorganic fertilisers still account for more than 90 % of global production due to their scalability and effectiveness. Despite their agronomic benefits, fertilisers have a significant environmental impact. Manufacturing processes emit SO x, NO x, and particulates, while field application can lead to nitrate leaching, eutrophication, soil acidification, biodiversity loss, and greenhouse gas emissions- particularly nitrous oxide and ammonia. Improving nutrient-use efficiency and reducing losses remain critical challenges for the industry.
[ Fertiliser Production ] and long-term soil health, inorganic fertilisers still account for more than 90 % of global production due to their scalability and effectiveness. Despite their agronomic benefits, fertilisers have a significant environmental impact. Manufacturing processes emit SO x, NO x, and particulates, while field application can lead to nitrate leaching, eutrophication, soil acidification, biodiversity loss, and greenhouse gas emissions- particularly nitrous oxide and ammonia. Improving nutrient-use efficiency and reducing losses remain critical challenges for the industry.
Equipment challenges: corrosion and erosion Fertiliser plants operate under exceptionally aggressive conditions due to the combined effects of highly corrosive chemicals, elevated temperatures and pressures, and abrasive process media. These factors accelerate material degradation, leading to frequent equipment failures, increased maintenance requirements, and higher operating costs. Corrosion is the dominant challenge, arising from continuous exposure to sulphuric, nitric, and phosphoric acids, as well as salts and reactive intermediates such as ammonium carbamate. Progressive metal loss reduces wall thickness and mechanical strength, increasing the risk of structural failure.
Typical stainless steel grades used in fertiliser plants Equipment / application area
Ammonia storage tanks & pipelines
Urea reactors, strippers & condensers
Nitric acid production units
Heat exchangers & high-pressure vessels
Pumps, valves, and general process piping
304L, 316L
Stress corrosion cracking can occur in ammonia storage tanks and process equipment, particularly in the presence of chlorides from cooling water ingress or insulation deposits. Erosion – corrosion caused by highvelocity fluids or solid-laden slurries damages pump impellers, pipelines, and valve internals.
High-temperature processes High-temperature processes such as ammonia synthesis and urea production further exacerbate degradation. Primary reformers operate at temperatures approaching 850 ° C, where mechanisms including hydrogen attack, carburisation, metal dusting, and creep can significantly shorten equipment life. In urea plants, the synthesis and first recycle sections
Common stainless steel grades used
316L Urea Grade( low ferrite, high nitrogen), Duplex steels( e. g., 2205, 2507)
Grades with high chromium and molybdenum content( e. g., 317L, 904L, Duplex)
316L, 310S( for high temperatures), 321 / 347( stabilised for high temp)
Various austenitic and duplex grades depending on the specific fluid and conditions are especially vulnerable due to hot, concentrated ammonium carbamate. Critical components at risk include reactor liners, high-pressure piping, pumps, decomposers, strippers, and condensers. Localised condensation corrosion frequently develops at structural“ heat sinks” such as supports, lifting trunnions, and thermowells, where corrosive vapours condense into liquid phases. Corrosive gases may also migrate into control rooms, leading to failures in sensitive electronic and electrical components. The use of conventional materials, such as carbon steel or inadequately specified stainless steels, in these environments often results in premature failure unless supported by appropriate coatings, inhibitors, and design measures. In addition, specialised maintenance activities-
The Riga Fertiliser Terminal in Latvia has the capacity to handle two million tons of product annually. Photo: Dreamstime.