Production

Production of AB “Achema” consists of over 40 different products. The main raw-material used in the production of ammonia and fertilizers is natural gas. The production of other products includes 75 chemical substances and 18 auxiliary chemical substances not included in the composition of production.

AB “Achema” is continuously developing and modernizing its production technology; all technological processes in the Company are controlled by computer systems. Product formulas are also improved by applying humans and environment friendly substances. The Company is engaged in the continuous development of new high quality products for the present day demanding market.

The main activity of AB “Achema” is the production of nitrogen fertilizers (urea, ammonium nitrate, liquid nitrogen fertilizers – UAN, calcium ammonium nitrate – CAN, nitrogen fertilizers with sulphur) and other chemical products (ammonia, nitric acid, “AdBlue”, formalin, urea formaldehyde resins, etc.).

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Cechų gamybos pajėgumai

Capacities_2021 EN

Nitric acid is a product mostly used as a composite part of other products. The subject matter of the production process consists of catalytic oxidation of gaseous ammonia with oxygen to produce nitrogen monoxide which in the course of further process turns to nitrogen dioxide after binding with oxygen. The final product is obtained after cooling the obtained nitrogen oxides and absorbing them with chemically treated water. Capacity – 1.650 thousand tons per year.

Liquid nitrogen fertilizers (UAN) means liquid fertilizers produced in certain proportion by mixing urea and ammonium nitrate solutions (melts) and diluting them with chemically treated water. The obtained mix is cooled. Capacity – 1.336 thousand tons per year.

Ammonia is the most important raw-material for the production of fertilizers. It is obtained from natural gas and air. Some of gas is incinerated to obtain heat and chemical reactions, the other share is purified and turned into liquid and gaseous ammonia via multi-level conversion. Capacity – 1.117 thousand tons per year.

Urea – granular, bulk fertilizers produced of liquid ammonia and carbon dioxide. Urea is also used as an ingredient in the production of other products. Capacity – 785 thousand tons per year.

Ammonium nitrate (AN) refers to granular bulk fertilizers received by neutralizing nitrogen acid with gaseous ammonia and by adding magnesium nitrate as a stabilizing additive to improve physical properties of the product. Capacity – 651 thousand tons per year.

Calcium ammonium nitrate (CAN) is a granular bulk fertilizer. CAN is produced by grinding dolomite and mixing with ammonia nitrate solution. The mix is granulated, dried, sieved, cooled, and conditioned. Capacity – 540 thousand tons per year.

“AdBlue” is a liquid additive used in the fuel of diesel engines the production of which is based on the dilution of urea solution with salt-free water. Capacity – 160 thousand tons per year.

Urea formaldehyde resins (UFR) and urea melamine formaldehyde resins (UMFR) are produced of formalin, melamine, and urea in two stages. At the first stage, the resins are obtained by polycondensation reaction method, whereas during the second stage, their concentration is increased by using vacuum evaporation. Capacity – 125 thousand tons per year.

Formalin is produced of a mix of air, water and methanol in contact apparatus where formaldehyde is produced under high temperature and catalyzers. It is later absorbed with water and results in the formation of formalin. This product is also used as an ingredient in the production of other products. Capacity – 100 thousand tons per year.

Basic aluminum sulphate solution – used as a coagulant in natural waters for industrial and human consumption, clarification, wastewater treatment, paper industry. The BAST-M modification uses a Fe2O3 additive that accelerates the above mentioned processes.

Investments

2003

Launch of 117 thousand tons per year urea production unit No.3.
Launch of 120 thousand tons per year nitric acid production unit UKL No.7.
Launch of 450 thousand tons per year calcium ammonium nitrate (CAN) production.
Launch of 330 thousand tons per year nitric acid production unit GP.
Launch of 450 thousand tons per year calcium ammonium nitrate (CAN) production.
Launch of the first 21 MW cogeneration power plant.

2006

Launch of 120 thousand tons per year nitric acid production unit UKL No.8.
UAN plant capacity expansion to 1,336 thousand tons per year.
Isothermal nitrogen storage facility was put into operation. Later that year in November, was launched a new ammonia production unit with projected capacity up to 1,500 t/day.

2007

Urea-formaldehyde resins capacity expansion to 75 thousand tons per year.
Liquid carbon dioxide production capacity was increased by 100 t/day.

2008

Start of AdBlue production.
Launch of new 130 thousand tons per year methanol plant.
Considering the market demand for low-emission formaldehyde-based resins production of melamine urea formaldehyde resins was started in 2008.
Launch nitric acid production unit UKL No.9.

2009

Launch of gas mixtures production unit.

2011

Together with foreign partners Achema implements two Joint Implementation projects, the mechanisms provided by United Nations Framework Convention on Climate Change
Launch of a new urea production unit No.4 with project capacity of 1,000 t/day. The rest of urea units have a joint capacity of 1,300 t/day.
Achema further developes its energy sector. Company commissioned a new 47 MW gas-fired cogeneration power plant No.2. Together with similar 21 MW plant No.1 operating from 2004, both plants can entirely supply the company with power and steam.

2012

Under the EU Structural Fund Programme Achema started developing a new investment project "Implementation of New Liquid and Gaseous Product Manufacturing Technologies in Achema".
Achema develops power distribution network modernisation project co-funded by EU Structural Funds to maintain power system security. Modernization is planned to be finished by the second half of 2015.

2013

Achema completed two Joint Implementation projects, aimed to mitigate nitric acid plant greenhouse gas (nitric oxide) emissions by more than 85%.
Achema started the second Grande Paroisse type nitric acid production unit project. By 2015, the project will increase annual nitric acid production by 240 thousand tonnes.
Auxiliary steam boiler burners in ammonia plant No. 2 were changed to optimize steam production. The project was partially funded by the EU Structural Funds.
Start of ammonia plant No. 2 reconstruction. The project is also aimed to reduce energy resource consumption.

2014

AdBlue production and warehouse extension was completed.

2015

In April the modernization of the power distribution network was completed co financed by EU Structural Funds.
In September modern air separation unit started up, in which a gaseous pure nitrogen, gaseous technical oxygen, liquid argon, nitrogen and oxygen are produced.
In November a new Grand Paroisse design of nitric acid unit started up. It will increase the annual nitric acid production capacity by 240 thousand tons per year and will enable the company to reduce energy costs.
In order to further reduce natural gas consumption in the production of ammonia, ammonia plant No. 1 process condensate scheme reconstruction was implemented and designing of further plant modernization began.
ammonia plant No.2 modernization in progress, the project is scheduled to be finished in 2016.

2016

Achema started production of new product „LITFERT StabillioN“. It is slow release urea fertilizer with urease inhibitor NBPT additive.
1st stage of ammonia plant No. 2 modernization finished which decreases natural gas consumption for ammonia production.
Continuing ammonia plant No. 1 modernization – synthesis column internals revamp which decreases natural gas consumption for ammonia production.
Achema started design activities for new formalin unit. Implementation of the project is foreseen in 2017.

2018

In November was successfully launched new 100.000 tons/year formalin production unit.

2021

Urea-formaldehyde resins capacity expanded to 125 thousand tons per year.

Logistics

Chain of handling and logistics is one of the core advantages of Achema, and its gateway to global markets; secure, reliable and effective transport is an essential fertilizer trade component.

Achema exports major part of its production by rail, mostly to the ice-free Klaipeda seaport located 290 km west of the Company headquarters in Jonava. At the port products are loaded to cargo vessels and shipped to destination ports. An important role in this process is played by associated companies of Achema Group:

  • Klasco, Klaipeda State Seaport:
    • Loading services: dry cargo vessels and tankers up to 60 – 65 thousand tonnes;
    • Maximum berth depth up to 13 metres;
    • Liquid fertilizer storage capacity of 87 thousand tonnes;
    • Bulk fertilizer storage capacity of 220 thousand tonnes;
    • Packed fertilizer storage capacity of 15 thousand tonnes;
  • Agro Baltic terminal, Lubeck, Germany: 30 thousand tonnes of liquid fertilizer storage capacity, annual liquid fertilizer reloading capacity of 150 thousand tonnes;
  • Fertigent terminal, Gent, Belgium: 30 thousand tonnes of liquid fertilizer capacity; Convenient geographical location of Gent enables Achema products to reach North-eastern France and North-western Germany;
  • Transachema: rail transport and expedition services (semi-wagons, hopers, tanks);
  • Trasachema branch Euroga: cargo transport; cargo loading/reloading, storage; customs intermediary services; ship agency services;
  • Achempak: polypropylene big-bags for fertilizer and other product packing, transport and storage;
  • Krovinių terminalas: oil, chemical product and liquid fertilizer storage and loading services for panamax-type vessels; annual reloading capacity up to 2 million tonnes.