Every year, the fertiliser industry produces and trades millions of plant nutrients, contributing significantly to the global economy through investment, sales, and employment. It also plays a crucial role in increasing agricultural productivity. According to Precedence Research, the global fertiliser industry is expected to reach $276.92 billion by 2034, driven by rising agricultural production needs.
Despite its growth, the industry has a significant environmental impact, contributing approximately 7 per cent of global greenhouse gas emissions. Fertiliser manufacturing alone accounts for 2-3 per cent of emissions due to energy-intensive processes, and it consumes 10 per cent of the world’s industrial energy, largely sourced from fossil fuels. Traditional manufacturing processes also face challenges in quality control and sustainability. This calls for the integration of sophisticated technologies such as artificial intelligence (AI) to drive efficiency, reduce emissions, and build a greener future.
AI transforming fertiliser manufacturing
1. Process optimisation
AI plays a crucial role in optimising fertiliser production by enhancing process efficiency and reducing downtime.
● Predictive maintenance: AI analyses sensor data to anticipate equipment failures, reducing unplanned downtimes and maintenance costs.
● Real-time process control: AI-powered systems adjust production parameters such as temperature and pressure in real time, optimising chemical reactions for fertiliser production and improving resource efficiency.
2. Research & development (R&D)
The discovery and development of new fertilisers and chemical compounds have been revolutionised by AI.
● Material Discovery: AI accelerates the discovery of new chemical compounds and fertilisers by simulating molecular interactions. This reduces the time and cost of R&D.
● Formulation Optimisation: AI helps create more effective and tailored fertiliser blends based on specific soil and crop requirements, enhancing nutrient efficiency and minimising environmental impact.
Novel technologies boosting fertiliser production
Beyond AI, several innovative technologies are reshaping fertiliser manufacturing to improve sustainability and efficiency:
Solar energy integration
Many fertiliser producers are incorporating solar panels to reduce reliance on fossil fuels, promoting the use of renewable energy in manufacturing.
Carbon capture utilisation (CCU)
● Captured CO₂ is combined with ammonia to produce ammonium bicarbonate, a commercial fertiliser.
● Compressed and liquefied CO₂ reacts with ammonia to enhance urea production efficiency while reducing carbon emissions.
Green hydrogen in ammonia synthesis
Replacing natural gas with renewable energy sources for green hydrogen production significantly reduces ammonia emissions, aligning with global decarbonisation efforts.
Other innovations in fertiliser manufacturing
● AI-powered electrochemical nitrogen fixation enables low-energy ammonia generation.
● Bio-based fertilisers and digital farming technologies enhance soil health and crop productivity.
3. Quality control & safety
AI ensures product quality and enhances safety measures in fertiliser production:
● Automated Quality Inspection: AI-powered image recognition detects defects in fertiliser products, ensuring higher quality standards.
● Energy Efficiency: AI-powered monitoring systems adjust energy consumption in real time, optimising energy use and lowering production costs.
4. Smart farming solutions
AI is also revolutionising the use of fertilisers in agriculture by ensuring precision and efficiency:
● Precision agriculture: AI integrates with IoT sensors to provide real-time soil analysis, ensuring optimal fertiliser use.
● Automated dosing: AI determines the precise amount of fertiliser needed for different crops, preventing overuse and minimising nutrient runoff.
AI in India’s fertiliser industry
India’s fertiliser industry is undergoing a significant transformation, driven by AI and sustainable technologies. According to Custom Market Insights, the Indian fertiliser market is expected to reach $70.2 billion by 2032. Key trends shaping the future include:
● Adoption of green ammonia and bio-fertilisers to reduce emissions.
● Development of waste-to-energy models to utilise industrial and agricultural waste for electricity generation.
● AI-powered carbon capture, bio-fertilisers, and green hydrogen technologies are being explored in collaboration with global research institute.
AI’s role in India’s green hydrogen transition
Leading Indian firms have already taken steps to set up some of the world’s largest green hydrogen and green ammonia facilities. These projects use electrolysis powered by solar and wind energy to produce ammonia, reducing reliance on fossil fuels.
Collaboration between AI developers and fertiliser producers
The role of AI developers, EPC/EPCM firms, and fertiliser manufacturers is crucial for the industry’s transformation:
● AI developers: Use data analytics, machine learning, and automation to optimise energy use, prevent equipment breakdowns, and enhance production efficiency.
● EPC/EPCM firms: Facilitate seamless integration of AI technologies in manufacturing, supporting the deployment of green ammonia infrastructure, carbon capture utilisation (CCU), and renewable energy solutions.
● Fertiliser manufacturers: Play a key role in demanding and adopting AI-driven solutions, such as electrochemical nitrogen fixation and bio-based fertilisers.
Strategic partnerships with government agencies and research institutions further support innovation, enabling manufacturers to transition to low-emission production methods and circular economy models.
Conclusion
Sustainable practices and AI-driven innovations are essential for reducing emissions and optimising fertiliser manufacturing. Embracing AI-powered process optimisation, predictive maintenance, demand forecasting, and smart farming solutions will enhance efficiency, sustainability, and competitiveness in the global market. Through collaboration, innovation, and regulatory support, India and the world can significantly reduce the fertiliser sector’s environmental footprint and accelerate the transition towards a greener future.
The author is CEO, Simon India Limited
