Kermanshah Petrochemical, relying on research and innovation, broke an eight-year production record
Kermanshah Petrochemical Company, taking an innovative approach and leveraging its research and development (R&D) capabilities, achieved an outstanding 103.2% of nameplate production capacity in Mordad 1404 (July–August 2025). This feat is unprecedented over the past eight years, particularly in the hot weather, challenging month of Mordad.
This achievement is the result of informed, bold management and the coordinated efforts of all operational and support staff—where research and innovation were not merely slogans but the basis for decision-making and action.
A series of transformative measures paved the way for increased production capacity: establishing and strengthening an innovation center, smart use of artificial intelligence capabilities, optimizing processes in the ammonia and urea units, and improving utility performance.
Alongside this short-term success, Kermanshah Petrochemical’s R&D unit is pursuing several strategic projects:
- Revamping and rehabilitation of the urea and ammonia production units to improve energy efficiency, reduce CO₂ emissions, and raise production capacity by up to 25%.
- A slow‑release nano‑urea fertilizer project, designed in three phases, currently in pilot and field evaluation stages to become a high value‑added knowledge‑based product.
- A carbon management (Net Zero Emission) project including preparing a carbon source inventory and developing greenhouse gas reduction plans in line with national policies and sustainable development goals.
- Hydrogen recovery from the ammonia unit’s purge gas, which will reduce feed gas consumption by 9%, increase ammonia unit capacity by 10%, and improve operational flexibility.
Setting this record demonstrates the strategic, multifaceted role of the R&D unit in overcoming constraints, enhancing technical capability, and turning industry challenges into growth opportunities. Kermanshah Petrochemical has now proven that with targeted investment in research and innovation, it is possible—even under the toughest conditions—to reach new heights of production and efficiency and advance toward sustainable development.
Kermanshah Petrochemical Breaks Records Amid Constraints; Leads Iran’s Urea Producers
Facing the combined pressures of economic sanctions, logistical limitations, and instability from regional tensions, Kermanshah Petrochemical—through strategic management and the dedication of its staff—not only avoided a production decline but surpassed 103% of its nameplate capacity in Mordad and set historic sales and export records. This performance cements its position as a leading player in Iran’s urea industry, and with expanded exports and improvement projects it aims to further strengthen that standing.
According to the official performance report for Mordad 1404, Kermanshah’s urea production reached 63,962 tonnes, achieving 103.2% of its monthly nameplate capacity—a 4.7% increase compared with Mordad of the previous year. Ammonia production also exceeded the monthly target, reaching 36,727 tonnes (103.9% of plan).
These figures represent the highest monthly urea production in the past two years and were achieved by identifying and removing process bottlenecks and optimizing equipment under constrained resource conditions. Data from the Petrochemical Employers’ Association show that the average realization of nameplate capacity for urea production among the country’s four major companies in Mordad ranged from 87% to 96%, while Kermanshah, at 103.2%, outperformed the industry average by a meaningful margin and was the only producer to exceed 100%.
“Realization of nameplate capacity” Top national ranking in two timeframes:
* In the cumulative period (Farvardin–Mordad 1404): Kermanshah covered 100% of its nameplate capacity.
* Only Khorasan and Shiraz approached this figure, but Kermanshah showed greater consistency. * In the monthly period (Mordad 1404): Kermanshah reached 114% of nameplate capacity—i.e., operated 14% above its design limit. Operating beyond design capacity is an important indicator of productivity and production management. Kermanshah’s sales in Mordad amounted to 75,766 tonnes of urea, 53% above the monthly plan; of this total, more than 69,000 tonnes were exported. This export volume is an unprecedented four-year record and was achieved despite reduced industry export pace caused by maritime transport restrictions, rising insurance costs, and the complexities of financial transactions arising from sanctions.
In the first five months of the year, 78% of Kermanshah’s sales were exports and 22% were domestic; this balance has created greater market diversity and reduced the risks of currency fluctuations and export restrictions. “A smarter balance compared with competitors”: – Over the five-month period: 78% exports and 22% domestic sales – indicating a thoughtful, well-balanced approach across the company. – This balance provides market diversification and lowers the risk from exchange-rate volatility and export limitations.
Urea sales revenue in Mordad reached 18,914 billion rials, a 127% increase compared with the same month last year.
Zahir Heidari-Nejad, referring to this unprecedented achievement, said: these records are not just numbers and percentages; they tell a story of solidarity, planning, and perseverance amid numerous challenges. Sanctions and crises, when met with scientific thinking and collective will, can become a springboard for a leap forward.
By maintaining its full annual nameplate capacity, temporarily exceeding design limits in Mordad, and intelligently balancing domestic and export markets, Kermanshah Petrochemical has presented a model of sustainable and flexible operation in Iran’s urea industry, and intends to solidify and enhance this position in the coming years through new market development and optimization projects.
