A century ago, scientists like Walther Nernst and Fritz Haber reshaped global agriculture by industrializing ammonia production. Their discoveries didn’t just change chemistry—they fed billions of people and redefined modern industry.
History has a way of repeating itself. Today, ammonia is once again at the center of a major transformation. No longer just a fertilizer component, it is emerging as a hydrogen carrier and low-carbon fuel, capable of supporting decarbonization efforts worldwide. With renewable energy enabling the production of green ammonia and carbon capture usage and storage (CCUS) integration enabling blue ammonia, this compound is poised to transform industries beyond agriculture—including power generation and heavy industry. Hydrogen extracted from green or blue ammonia could one day help decarbonize some of the hardest-to-abate sectors, such as steel, cement, and shipping.
However, achieving sustainable ammonia production is no small feat. In modern ammonia plants, engineering uncertainties in determining optimal plant capacity and configuration can lead to inefficiencies. At the same time, inaccurate capital expenditure (CapEx) and operating expenditure (OpEx) estimates can derail projects before reaching the final investment decision (FID). Further, traditional design processes reliant on manual calculations and fragmented data often result in schedule and budget overruns, while electrification and renewable energy integration increase operational complexities and unpredictability.
Addressing these issues requires smarter, more integrated approaches that combine process and power systems seamlessly. This is where smart design and engineering, powered by co-simulation tools, can transform ammonia plant design. By integrating advanced process and electrical simulation technologies into a dynamic digital twin, co-simulation can:
- Reduce project risks, both immediately and later in operation
- Accelerate engineering, procurement, and construction (EPC) schedules
- Enable more sustainable and economically viable production
- Deliver up to 30% reduction* in engineering costs in electrical instrumentation and control (EIC) scope
- Empower stakeholders to overcome complex challenges quickly, precisely, and confidently
How co-simulation transforms ammonia plant design
At its core, co-simulation acts as a dynamic digital twin, creating a unified model of an ammonia plant by integrating advanced process and electrical simulation tools. It enables holistic modeling by analyzing thermodynamics, mass balances, and electrical systems simultaneously with unprecedented detail. The platform also supports integration from a variety of sources via open platform communications unified architecture (OPC-UA).
Integrated workflows break down silos, connecting process and power simulations for real-time adjustments and faster decision-making. By delivering early-stage accuracy, co-simulation allows stakeholders to evaluate diverse scenarios—from plant configurations to renewable energy inputs—before construction begins.
Design smarter, save more
The benefits of co-simulation are tangible and far-reaching. Here’s how it addresses key challenges:
- Reduced design risks: Minimize uncertainties and accelerate the FID process by up to 20%* by enabling precise plant capacity and configuration determination during feasibility studies.
- Improved cost accuracy: Boost investor confidence, minimize financial risks, and enhance the likelihood of securing project approval and advancement by producing accurate CapEx and OpEx estimates via reliable engineering inputs.
- Optimized engineering economics: Streamlined workflows reduce engineering costs by up to 30%,* addressing a significant cost burden. By quantifying these economic benefits, co-simulation ensures that ammonia plants can be designed efficiently and economically, making them better equipped to meet the demands of a transitioning energy market.
- Accelerated timelines and improved EPC schedules: Reduce project complexity by integrating process and power system simulations. This enables plant design evaluation earlier and compresses schedules by up to 15%,* enabling faster commissioning and returns on investment.
These advantages make co-simulation an invaluable tool for ammonia plant projects, whether for traditional industrial applications or emerging energy uses.
Real-world applications and future readiness
Co-simulation’s impact extends beyond the design phase, offering value throughout the entire lifecycle of an ammonia plant. By maintaining a dynamic digital twin, operators can:
- Enhance operational efficiency: Test new setpoints and simulate “what-if” scenarios to optimize performance without disrupting operations.
- Enable operator training and skill development: Use Operator Training Simulators (OTS) to create realistic training environments for teams to practice responses to various plant conditions and improve decision-making in a risk-free setting.
- Predict equipment lifespan: Receive insights into equipment wear and tear and enable proactive maintenance strategies with integrated analysis tools.
- Adapt to regulatory and technological changes: Reconfigure plant systems and estimate profitability without extensive retooling as new regulations emerge or renewable energy technologies evolve.
A standout example of co-simulation’s capabilities is a recent project with Shuimu Mintal. This project represents the first fully integrated green hydrogen project, encompassing a 1.4 GW onshore wind farm with 750 MW of green hydrogen capacity and the world’s first variable ammonia plant.
Smart design and co-simulation for the win
Sustainable, efficient, scalable solutions are critical to accelerating the energy transition. Tools like AVEVA™ Dynamic Simulation and ETAP provide a unified, co-simulation-driven approach that empowers stakeholders to tackle the most pressing challenges in ammonia plant design and engineering.
By optimizing plant capacity during feasibility studies, ensuring accurate cost projections, and compressing project timelines, solutions from Schneider Electric™ lay the groundwork for more intelligent, sustainable ammonia production infrastructure. As the global energy transition accelerates, these tools address today’s engineering challenges and prepare profitable ammonia plants to confidently meet future demands.
The future of ammonia production
The combined capabilities of co-simulation tools can transform ammonia plant design from a high-risk, uncertain process to a more predictable, efficient, and economically viable endeavor for end-users and EPC contractors.
Click here to learn more about how we can help with co-simulation in ammonia plants.
*Based on Schneider Electric’s internal customer data.
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