Fertilizer production, especially ammonia and urea plants, is one of the few industrial processes that generates nearly pure CO₂ as a byproduct. With Artificial Intelligence, these streams can be captured, optimized, and monetized – transforming a waste gas into a resource for fuels, chemicals, and building materials.
🎯 How AI Can Make This Product or Solution Much Better
⚙ Optimizing Capture from High-Purity Streams
AI fine-tunes compression, dehydration, and liquefaction to minimize energy consumption while maintaining 99.9% CO₂ purity for food, industrial, or storage uses.
🔄 Dynamic Process Integration
Machine learning links CO₂ capture to urea synthesis loops, dynamically deciding whether CO₂ is used internally or sold externally based on market prices and storage availability.
🛠 Predictive Maintenance of Capture Equipment
AI detects early wear or anomalies in compressors, heat exchangers, and dehydration units, cutting unplanned downtime by up to 20%.
Our specialty focus areas include
Net Zero by Narsi
Insights and interactions on climate action by Narasimhan Santhanam, Director - EAI
View full playlist📏 Emission Monitoring & Compliance
AI-enabled monitoring tracks every tonne of CO₂ captured, enabling both regulatory compliance and verified carbon credit generation.
♻ Optimization for Carbon Utilization
AI connects fertilizer CO₂ streams to methanol, e-fuel, or concrete producers, optimizing supply, dispatch, and pricing in real time.
🛠️ How AI Overcomes Key Challenges
| Challenge | AI Solution |
|---|---|
| Integrating CCS into legacy plant layouts | Digital twins simulate low-cost, low-downtime retrofits |
| Balancing internal vs. external CO₂ use | AI dynamically allocates CO₂ for maximum economic and environmental benefit |
| Energy cost of compression | AI integrates waste heat recovery and load optimization |
| Volatile CO₂ utilization markets | AI forecasts demand and adjusts capture–dispatch strategy |
🤖 Main AI Tools and Concepts Used
- Digital twins for ammonia–urea–CO₂ integration
- Predictive maintenance for CO₂ handling systems
- Optimization algorithms for capture + utilization logistics
- AI-enabled carbon accounting platforms
- Machine learning for process energy minimization
📊 Case Studies
- Yara International (Norway) – AI-managed CO₂ capture in urea loop, selling surplus into food-grade markets.
🚀 Relevant Startups & Providers
| Company | Focus |
|---|---|
| Carbon Clean (UK) | Modular, AI-optimized capture for high-purity CO₂ streams |
| LanzaTech (USA) | AI-driven CO₂-to-ethanol integration for fertilizer plants |
| Aker Carbon Capture (NO) | Modular CCS units for ammonia plant retrofits |
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