Ammonia cracking

Ammonia cracking – Closing the energy value chain

Hydrogen is a cornerstone of the global energy transition, but its efficient storage and transport remain significant challenges. Ammonia (NH3), a globally traded commodity with established infrastructure, presents a powerful solution as a hydrogen carrier. thyssenkrupp Uhde's advanced ammonia cracking technology unlocks this potential, enabling the efficient release of hydrogen from ammonia at the point of use, paving the way for a sustainable hydrogen economy.

thyssenkrupp Uhde ammonia cracking plant scene

Hydrogen has many advantages but there is also a disadvantage: While there is great demand in the Northern hemisphere, the most cost-effective production of green hydrogen takes place in the Southern hemisphere. Clean hydrogen is produced by splitting water with green electricity in places where the sun and the wind provide plenty of renewable energy. Liquid hydrogen then could be delivered by ship to places that urgently need it as the distance is too long for pipelines. However, this method is complex and expensive.

The solution: The hydrogen is converted into ammonia (NH3) together with nitrogen, which is simply extracted from ambient air. With ammonia as a carrier, hydrogen can be transported in a much simpler, more affordable and energy-efficient way via ships. The necessary infrastructure is already in place and well-proven.

Upon arrival at its destination, the ammonia is either burned directly for energy generation or the ammonia is decomposed again into nitrogen, which can simply be released into the atmosphere, and into hydrogen, which is so important for energy transition. The solution for this is called: Ammonia Cracking.

thyssenkrupp is currently the only group of companies worldwide able to provide the entire hydrogen value chain – from water electrolysis to ammonia production and storage to ammonia cracking.

Hydrogen value chain – from water electrolysis to ammonia production and storage to ammonia cracking. — Ammonia usage for energy transport, utilization as an energy carrier or re-conversion to hydrogen

The thyssenkrupp Uhde ammonia cracking process: Highest efficiency & conversion rates

Leveraging over a century of experience in designing and building more than 130 ammonia plants worldwide, thyssenkrupp Uhde is developing an innovative, world-leading ammonia cracking process.

Within the ammonia cracking process, ammonia is cracked into valuable hydrogen. Our ammonia cracking technology is built on a foundation of designs and innovative features that ensure high efficiency and environmental sustainability. The core of our technology is based on the proven Steam Methane Reforming (SMR) process.

Key technology features of the uhde^®ammonia cracking process

Proven SMR-based technology: The core reaction is the decomposition of ammonia over a catalyst in tubular reactors, ensuring reliability and efficiency.
Zero carbon intensity: In our uhde^® ammonia cracking process, ammonia and offgas are used as a burner fuel, resulting in zero carbon intensity.
Advanced Emission Control: NOx and N₂O, which are formed during the combustion of ammonia containing gas will be eliminated with thyssenkrupp Uhde's own DeNOx- and EnviNOx® technology. This cutting-edge technology meets the highest environmental standards, has a long reference list and is a unique selling point. The EnviNOx^® technology is defined as Best Available Technology (BAT) by the European Union.
Low turndown ratios can be reached.
Superior energy efficiency: The uhde^® ammonia cracking process is designed for the highest energy efficiency.
Proven components: Utilizes reliable equipment adapted from decades of industrial ammonia and hydrogen plant experience.

Process Overview

Our process is designed for efficiency, reliability, and large-scale hydrogen production:

Feed Preparation & Preheating: Ammonia feedstock is vaporized and preheated
Catalytic Cracking: The gaseous ammonia is routed through a pre-cracker followed by our proprietary ammonia cracker, filled with highly efficient catalysts. The ammonia is decomposed into hydrogen (H₂) and nitrogen (N₂).
Energy Recovery: The hot product gas stream is cooled down. Our process design features optimized energy integration, maximizing thermal efficiency.
Hydrogen Purification: Depending on the required hydrogen purity, a downstream pressure swing adsorption (PSA) unit is employed to separate the hydrogen from the nitrogen, delivering high-purity hydrogen suitable for various applications, including fuel cells.

Ammonia cracking process flow by thyssenkrupp Uhde

Advantages of the uhde^® ammonia cracking process

Choosing thyssenkrupp Uhde for your ammonia cracking provides significant benefits:

Profound expertise

Our in-house experts cover all technical aspects, delivering comprehensive and reliable solutions. Our extensive engineering expertise minimizes risks through deep system knowledge and a thorough understanding of the entire process – not just the catalyst.

Proprietary uhde® cracker design

The ammonia cracker is based on thyssenkrupp Uhde’s proven steam methane reformer design and proprietary engineering, ensuring exceptional performance and reliability.

"Best Available Technology" for emissions control

Equipped with the EnviNOx^® flue gas cleaning system – recognized as Best Available Technology for NO_x and N₂O reduction – ensuring compliance with the strictest environmental standards.

Unmatched energy efficiency

Engineered for optimal energy efficiency, significantly reducing both operational costs and environmental impact.

Superior catalyst performance

Demonstration plant results will validate top-performing, best-available catalysts – giving clients a clear competitive advantage.

Operational flexibility

The demonstration plant is designed to confirm maximum flexibility in burner and catalyst configurations, enabling adaptable operation.

Zero carbon intensity

When firing ammonia, the plant operates with net-zero carbon intensity, supporting a truly climate-neutral production process.

Applications of hydrogen from cracked ammonia

The hydrogen produced via uhde^® ammonia cracking is suitable for a wide range of applications:

Your partner for large-scale ammonia cracking

Image of a state-of-the-art ammonia plant, highlighting our cutting-edge technology and expertise developed since 1928

thyssenkrupp Uhde is one of the leading technology providers in the field of ammonia with its proven uhde^® ammonia process. We are your partner throughout the entire project lifecycle, from conceptual design and feasibility studies to engineering, procurement, construction, and service. As a world market leader in ammonia plants, we have built more than 3,000 chemical plants worldwide and draw on over 100 years of experience. We have a long track record of building ammonia plants. Among the 130 ammonia plants built are some of the largest plants worldwide, frequently setting new industry standards such as the uhde^® dual pressure technology. We are constantly improving our designs and technologies, and working towards improved energy efficiencies and higher capacities.

Discover our extensive expertise

We have built many of the world’s largest steam reformers for ammonia, methanol, hydrogen and propane dehydrogenation plants.

World map displaying the global distribution of 24 hydrogen plants by thyssenkrupp Uhde

Ammonia cracking is the 'missing piece of the puzzle' needed for the large-scale trade of clean hydrogen and thus an essential step towards enabling the green transformation.
Dr. Christian Renk
Head of Technology, Innovation & Sustainability - Fertilizer

On-demand video: Closing the green value chain with uhde^® ammonia cracking

Dr. Christian Renk at the Uhde Innovate 2024 in Essen, Germany

Ammonia Cracking is rapidly becoming a crucial topic in the energy sector. At the Uhde Innovate 2024 in Essen, Germany, Dr. Christian Renk presented an insightful session on our way to a hydrogen society and integrating Ammonia Cracking to close the green value chain.

In this 20-minute deep dive, Dr. Renk delves into:

The critical need for Ammonia Cracking in renewable energy transitions
Energy losses in hydrogen transport via ammonia & cracking
Produced hydrogen vs. imported hydrogen via ammonia
The uhde^® Ammonia Cracking process flow
A closer look at the uhde Ammonia Cracking demo plant

Join us to gain a deeper understanding of hydrogen production from ammonia and see how our innovative ammonia cracker technology is shaping a sustainable energy future.
Don't miss this opportunity to hear from a leading expert in the field.

Watch the exclusive video now

Download our resources

Get detailed insights into the uhde^® ammonia cracking technology.

One pager: uhde® ammonia cracking – enabling the global hydrogen economy

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Clean chemicals brochure by thyssenkrupp Uhde

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Get started with your ammonia cracking project

Ready to unlock the potential of ammonia for sustainable hydrogen production at scale? Discuss your specific project needs with our ammonia cracking specialists.

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FAQs (Frequently Asked Questions) about uhde^® ammonia cracking

What is an ammonia cracking plant and why is it needed?

An ammonia cracking plant is a facility that converts ammonia (NH₃) back into hydrogen (H₂) at the point of use. This technology is essential for enabling the global hydrogen economy.

Ammonia serves as an ideal carrier for hydrogen because it is energy-dense, easy to store and transport, and benefits from an already established global infrastructure. However, to fully realize its potential as a hydrogen carrier, efficient and sustainable cracking technology is needed at the point of use.

uhde^® ammonia cracking provides exactly that – a reliable solution to extract clean hydrogen from ammonia, supporting the transition to a low-carbon energy future.

thyssenkrupp Uhde offers end-to-end project execution – from idea to implementation. Our portfolio includes complete solutions covering process design, technology licensing, engineering, procurement, and construction (EPC), as well as ongoing services and digital operation support.

We provide a single point of responsibility, backed by the full power of a global engineering powerhouse.

Ammonia or NH₃ is a compound of nitrogen and hydrogen and is a fundamental building block in the chemical industry because of its wide range of applications. Ammonia is extensively used in the production of fertilizers, which are essential for modern agriculture. 80% of the annual global production of over 170 million metric tons of ammonia is used in this way.

In the context of hydrogen production from ammonia, ammonia serves as an ideal hydrogen carrier. It can be easily liquefied and transported, making it a practical option for storing and shipping hydrogen over long distances.

Advantages of amnmonia as a hydrogen carrier

Transporting liquid hydrogen over long distances, such as by ship, is often complex and expensive due to the need for maintaining extremely low temperatures. This method becomes impractical for locations far from pipelines. However, converting hydrogen into ammonia offers a more efficient and cost-effective solution.

Here are the advantages of using ammonia as a hydrogen carrier:

Simplified Transportation: Ammonia can be transported more easily and at a lower cost compared to liquid hydrogen. It doesn't require the same extreme cryogenic conditions, making the logistics simpler and more affordable.
Energy Efficiency: Transporting hydrogen in the form of ammonia is more energy-efficient. The energy density of ammonia is much higher compared to hydrogen. To transport the same amount of energy, only two ammonia ships are needed compared to three hydrogen ships.
Readily Available Infrastructure: The infrastructure for ammonia transportation is already well-established and proven. 20 million tons were transported by ship in 2020. This means that existing facilities can be used without the need for significant new investments, facilitating a faster and smoother transition to using ammonia as a hydrogen carrier.

By using ammonia as a carrier, hydrogen can be transported to places that urgently need it in a more economical and efficient manner. This method leverages existing infrastructure and reduces overall costs and energy consumption, making it a practical choice for long-distance hydrogen transport.

The uhde^® ammonia cracking plant can be supplied with two different fuel options - clean ammonia or natural gas - which is mixed with the PSA off gas (Pressure Swing Absorption).

Turndown rates below 60% are possible.

The plant provides pressurised hydrogen at the purity required by the customer. Fuel cell grade (99.97%) or higher is possible.

uhde^® ammonia cracking is designed for large-scale applications, supporting capacities above 5,000 metric tons per day (mtpd) of ammonia – equivalent to over 700 mtpd of clean hydrogen. This scale is made possible by thyssenkrupp Uhde’s proven expertise in large-scale reformer technology.

thyssenkrupp Uhde is partnering with established catalyst suppliers and is currently qualifying and benchmarking several catalysts through final testing in the demo plant. This ensures that customers benefit from the most efficient and reliable catalyst system available.

By mid-2025, thyssenkrupp Uhde considers ammonia cracking technology to be at TRL 6-7. We are taking a realistic approach here, as neither the catalyst nor the ammonia burners have been installed in commercial-scale crackers.

thyssenkrupp Uhde’s EnviNOx^® system will be installed in the flue gas duct reaching outstanding 99,9% NO_x and N₂O separation rate.

Originally developed for nitric acid plants, this technology is recognized as “Best Available Technology” by the European Union and represents a proven success in emissions control.

With over 3,000 plants designed, built and put into successful operation, thyssenkrupp Uhde is one of the leading EPC contractors globally. Our scope of work ranges from new technology developments and advancements through the performance of process design packages, basic engineering, detailed engineering, procurement, fabrication and construction management to plant commissioning and services beyond start-up.

The EPC execution for a commercial-scale uhde^® ammonia cracking plant is expected to take between 32 and 38 months, depending on the project location and specific requirements.

For detailed cost estimates and tailored information about the uhde^® ammonia cracking plant, please reach out to our Sales team via the contact form. We’ll provide you with the data you need to support your business model.

thyssenkrupp Uhde typically offers engineering and mechanical guarantees, as well as process performance guarantees covering key factors such as production capacity (including turndown rates), energy efficiency, plant emissions, and product quality.

Currently, thyssenkrupp Uhde supports clients with feasibility studies, technical information packages, and CAPEX/OPEX estimates.
Starting in 2026, thyssenkrupp Uhde will offer full Project Definition Packages (PDP) and Front-End Engineering Design (FEED) packages for commercial plants, including permitting support.

The demo plant has a capacity of 28 mtpd of ammonia. The cracker will be equipped with commercial size tubes and burners, which will allow a direct step to TRL following a numbering up rather than a scale-up approach.

The tests conducted will demonstrate:

Flexibility in operation (pressure, temperature, throughput)
Flexibility in design (burner and catalyst type, material)
Flexibility in firing (ammonia and hydrogen)
Functionality of the EnviNOx^® system

thyssenkrupp Uhde and Uniper have formed a strategic partnership to develop one of the world’s first large-scale ammonia cracker demonstration plants at Uniper’s Gelsenkirchen-Scholven site. This collaboration combines Uniper’s energy market expertise with thyssenkrupp Uhde’s leading ammonia technology to advance the hydrogen economy, supported by funding from the State of North Rhine-Westphalia. The partnership aims to enable industrial-scale hydrogen production from imported ammonia, strengthening energy security and driving sustainable transformation across multiple industries.

The demo plant is scheduled to go online end 2026, followed by testing campaigns.

Ammonia cracking