QAFCO V and VI projects are still the largest, most demanding achievement worldwide in the history of fertilizers. With a total capacity of 7,700 t /day of urea in two trains, it is the largest urea complex in the world: a milestone in the sector.
It was developed on 3 different construction sites: one in the desert, one at an existing coastal plant, and one that serves as an interconnection between the two sites, interspersed with existing infrastructure, underground pipelines and cables, and industrial roads. Geographical constraints posed challenges — such as lack of access to sea water and jetties at the desert site — and there were logistical complexities, limitations from local and environmental regulations, and building restrictions.
Coordination between the plant sites and interface management were key for the proper rollout of the project. The plant has numerous efficiency and integration solutions, making it more reliable and efficient. Here, the zero effluent philosophy is not just a motto but a reality: contaminants are recovered and recycled in the process, and the use of a thermal concentrator and an evaporation pond ensures total compliance with environmental limits in every operational situation.
It also includes various sustainable solutions, like its water supply and recovery and reuse of CO₂. The production of drinking, cooling, and demineralized water for the production of steam is obtained from a flow of seawater discharged from the existing plants through its filtration, pumping and subsequent treatment. This avoids expensive marine work and is not invasive for the environment. CO₂ emissions were reduced by 700 t /day at existing plants by recovering and reusing CO₂ for additional production of urea in the new plants.
4,600 t
daily ammonia production
7,700 t
daily urea production with Snamprogettiᵀᴹ technology
125,000 t
of material and equipment
100,000 m³
of liquid ammonia
8,000 km
of instrument and electrical cables
3
different operating sites
120 mln
construction manhours
5 km
pipe conveyor belt