化肥行业：能源效率和脱碳（EE&D）机会（英）2025

ENERGY EFFICIENCY ANDDECARBONIZATION (EE&D)OPPORTUNITIES CFertilizer Sector — Energy Efficiencyand Decarbonization Opportunities Pakistan’s fertilizer sector makes a significant contribution to the country’s economy, accounting forapproximately 4.4 percent of large-scale manufacturing output and 1 percent of the gross domesticproduct (GDP). As part of the large-scale manufacturing sector, the fertilizer industry is driven primarily byagriculture, particularly crops. The sector’s reliance on natural gas makes it vulnerable to supply disruptionsand price volatility. Consequently, government policies on gas allocation, subsidies, and environmentalregulations play a crucial role in shaping the industry’s performance. The production of ammonia, anintermediate product in the manufacture of fertilizer, is a particularly energy intensive value-chain process;natural gas accounts for 70 percent of the total energy consumption in ammonia manufacture with coal,oil, and electricity used in lesser quantities.iOverall, more than 9 percent of gas supplied to the industrialsector in Pakistan is utilized by fertilizer industries.iiProduction of urea makes up nearly 70 percent ofthe fertilizer sector’s output while the rest consists of products such as di-ammonium phosphate (DAP),calcium ammonium nitrate, nitro phosphate (NP), and various mixes of nitrogen, phosphorous, andpotassium (NPK).iiiAccording to the country’s latest greenhouse gas (GHG) inventory, emissions fromfertilizer production amounts to 7 percent of overall national industrial emissions.ivCarbon dioxide (CO2)from ammonia production is the main source of direct GHG emissions from the sector however, fertilizerplants capture most of the CO2for reuse in the manufacture of urea.vThis note describes decarbonizationinterventions to improve energy efficiency and reduce emissions in the fertilizer sector while increasingindustrial competitiveness and providing wider economic and environmental benefits. The current state of energy efficiency and decarbonizationin pakistan’s fertilizer sector Fertilizer manufacture is amongst the most developed industries in the country and most plantscomply with relatively high efficiency standards; Process emissions are abated through captureof CO2from ammonia production and reuse for urea manufacture. Waste heat recovery (WHR)systems and advanced process controls (APC) are also deployed widely across the sector andmany companies have implemented other digitalization and balancing, modernization, andreplacement (BMR) initiatives. The BMR initiatives are driven by gas price-related incentives in thenational fertilizer policy. The energy intensity of ammonia production plants in Pakistan is around38.6 gigajoule (GJ)/tonne (t),1which is lower than the global average of around 41 GJ/t on a netbasis.viThe adoption of best available technologies could improve energy performance levels to 28GJ/t for natural gas-based production and 36 GJ/t for coal-based production.vii Existing & emerging opportunities for improving EE&D There are multiple technology options available to the fertilizer industry for improving energyefficiency and decarbonizing production processes. For instance, energy efficiency can beimproved by installing waste heat recovery systems and control drives on motor driven systems,co-generation and replacing inefficient motors and boilers with more efficient alternatives. Othersector-specific decarbonization options include switching from conventional fuels to biomass andbiofuels (for heat and power generation), green hydrogen (for heat power and green ammoniaproduction), electrification (electric boilers), carbon capture and sequestration (to capture processand energy emissions), process improvement (methane pyrolysis), circularity (production of organicwaste fertilizer), and adopting innovative technologies (WHR on compressors and Organic RankineCycle ORC) in fertilizer production). Although the fertilizer sector is relatively energy efficient, there is still substantial scope forimprovement. For instance, process improvements have the potential to reduce gas consumptionin the sector by 2 percent through 2030. See annex 1 for details on costs and savings and seeannex 2 for the summaries of the analysis of five recommended existing and emerging technologiesfor the fertilizer subsector. Table 1 summarizes existing and emerging energy efficiency anddecarbonization technologies that could benefit Pakistan’s fertilizer subsector. Emerging technologies Existing technologies Retrofitting gas turbines for higher efficiency Cryogenic carbon capture (ccc) This technology can capture less concentrated CO2from energy emissions, which cannot be capturedby the current chemical absorption technologyused in Pakistan’s fertilizer industry. CCC utilizeslow-grade waste heat from the ammonia plant towork absorption refrigeration cycles, making itsuitable for ammonia production. The technologyhas a technology readiness level (TRL) of 7