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Chemicals

The chemical industry is a key part of the CIS industrial sector. Mineral fertiliser production remains its largest segment, encompassing nitrogen, phosphate, potash and compound NPK fertilisers. Russia, the region's largest producer, is one of the world's top three mineral fertiliser producers, with annual output of 60–70 million tonnes. It ranks second in potash fertilisers and among the top five in nitrogen and phosphate fertilisers.

For chemical companies, further processing of raw materials, broader ranges of specialised products, stable production processes and efficient use of existing capacity are becoming increasingly important.

The Pieff team helps chemical companies identify and realise this potential by improving production efficiency, eliminating bottlenecks and improving the financial performance of their operations.

Chemicals

Laboratory glassware containing blue liquids.
The challenges
our clients face
Pressure on margins and product portfolios

Volatile prices for fertilisers and chemicals, sanctions and the restructuring of export logistics are putting greater pressure on revenue.

Flexible management of product portfolios, sales channels and pricing is becoming increasingly important.

Developing high-value-added products, including speciality and water-soluble fertilisers, feed phosphates and industrial reagents, is an increasingly important priority.

Constraints on production chain throughput and reliability

Increasing output depends on throughput at key processing stages, the elimination of bottlenecks and stable process operating conditions throughout the production chain.

The reliability of critical equipment and the quality of turnaround maintenance directly affect output and production costs.

Reducing losses, off-specification output and deviations from quality standards requires a systematic approach to process operating conditions, grade changeovers and operational discipline.

Pressure on costs and capital project delivery

Rising prices for natural gas, electricity, raw materials, catalysts and consumables are putting greater pressure on unit costs.

The capital intensity of new production facilities and modernisation projects places greater demands on engineering design, delivery schedules and contractor management.

The complexities of commissioning, import substitution and integrating new process units into existing operations make it harder to achieve target performance.

The complexity of managing production systems

Vertically integrated structures make it harder to coordinate raw material supply, production, logistics and sales.

Companies face shortages of skilled staff, particularly in single-industry towns and smaller communities.

Fragmented IT systems and stringent industrial safety requirements slow decision-making and reduce the benefits of digital initiatives.

How we can help

Operational Efficiency and Production Systems
  • Increasing output and saleable product yield by optimising process operating conditions, reducing losses and eliminating bottlenecks
  • Transforming maintenance and repairs for critical equipment and improve availability
  • Optimising the planning and execution of maintenance turnarounds
  • Reducing unit costs for raw materials, gas, energy and consumables
  • Optimising operational and tactical production planning, taking account of capacity and logistics constraints and contractual obligations
  • Implementing a production system with an emphasis on standardising practices, mentoring and a culture of safety
Capital Project Performance
  • Managing the portfolio of capital projects to expand and upgrade production capacity
  • Optimising engineering solutions, schedules and budgets for construction and modernisation projects
  • Managing project delivery within operating facilities and under stringent industrial safety requirements
  • Preparing for commissioning and for achieving design targets for throughput, quality and specific consumption
Organisational Transformation
  • Developing functional strategies for production, maintenance and repairs, procurement, logistics and sales
  • Developing a strategy for the product portfolio and export logistics
  • Optimising the company's operating model and coordination between processing stages
  • Developing and implement a KPI system covering output, quality, costs, reliability and safety
  • Developing approaches to attracting and retaining staff
Digitalisation
  • Developing a digital transformation roadmap with priorities based on financial benefits
  • Creating a unified digital data environment spanning raw material receipt through to finished product dispatch
  • Improving the sustained adoption of digital solutions by process engineers, operators and engineering teams
Discuss working together
/ Case Studies

Real-world results,

that speak for themselves

View all case studies
Worker beside machinery and metal shavings in a workshop.
from -14% to -33%
Reducing major maintenance shutdown duration by 14–33% in three production units at a mineral fertiliser plant in Russia
Stacks of white bulk bags in an outdoor storage area.
+200$
Identifying $200 million in potential value through a transformation programme for a chemical company’s project management office
Overhead crane lifting a white bulk bag inside an industrial loading hall.
+19%
19% increase in mineral fertiliser output at a Russian plant
Industrial plant with pipework and tall process towers at sunset.
+14%
Programme developed to increase fertiliser output by 14% for a major ammonium nitrate producer in Russia
Rows of large cylindrical mills inside an industrial hall.
+11.4%
11.4% increase in apatite concentrate throughput through improved maintenance performance
Chemical plant with process vessels, towers and pipework.
by 12.9%
Major maintenance shutdown duration reduced by 12.9% at a phosphoric acid operation in Russia
Large circular tank surrounded by pipework and platforms inside an industrial plant.
5%
Potential identified to reduce direct costs by 5% for a major fertiliser producer in Russia
Hard hat, ear defenders, safety glasses and protective gloves on a workbench.
-270 issues
270 fewer safety and quality issues on a construction project for a chemicals group
Chemical plant with large vessels, pipework and chimneys emitting vapour.
from 12% to 19%
Potential identified to increase productivity by 12–19% at a phosphate fertiliser plant
Large cylindrical storage tank beside yellow access stairs.
+$100 million
A $100 million increase in NPV for a fertiliser producer’s mining asset development project in Russia
Rows of white bulk bags beneath industrial handling equipment.
+51%
A 51% increase in mineral fertiliser production at a plant in Russia
Chemical plant with extensive pipework and tall process towers under a blue sky.
+20%
Increasing mineral fertiliser output at a Russian plant by 20%
Large industrial ducts beside platforms and yellow access stairs.
31%
Identified potential to shorten major maintenance shutdowns at sulphuric acid plants for mineral fertiliser production by 31%
Worker beside machinery and metal shavings in a workshop.
from -14% to -33%
Reducing major maintenance shutdown duration by 14–33% in three production units at a mineral fertiliser plant in Russia
Stacks of white bulk bags in an outdoor storage area.
+200$
Identifying $200 million in potential value through a transformation programme for a chemical company’s project management office
Overhead crane lifting a white bulk bag inside an industrial loading hall.
+19%
19% increase in mineral fertiliser output at a Russian plant
Industrial plant with pipework and tall process towers at sunset.
+14%
Programme developed to increase fertiliser output by 14% for a major ammonium nitrate producer in Russia
Rows of large cylindrical mills inside an industrial hall.
+11.4%
11.4% increase in apatite concentrate throughput through improved maintenance performance
Chemical plant with process vessels, towers and pipework.
by 12.9%
Major maintenance shutdown duration reduced by 12.9% at a phosphoric acid operation in Russia
Large circular tank surrounded by pipework and platforms inside an industrial plant.
5%
Potential identified to reduce direct costs by 5% for a major fertiliser producer in Russia
Hard hat, ear defenders, safety glasses and protective gloves on a workbench.
-270 issues
270 fewer safety and quality issues on a construction project for a chemicals group
Chemical plant with large vessels, pipework and chimneys emitting vapour.
from 12% to 19%
Potential identified to increase productivity by 12–19% at a phosphate fertiliser plant
Large cylindrical storage tank beside yellow access stairs.
+$100 million
A $100 million increase in NPV for a fertiliser producer’s mining asset development project in Russia
Rows of white bulk bags beneath industrial handling equipment.
+51%
A 51% increase in mineral fertiliser production at a plant in Russia
Chemical plant with extensive pipework and tall process towers under a blue sky.
+20%
Increasing mineral fertiliser output at a Russian plant by 20%
Large industrial ducts beside platforms and yellow access stairs.
31%
Identified potential to shorten major maintenance shutdowns at sulphuric acid plants for mineral fertiliser production by 31%
View all case studies
/ Insights

Useful articles

View all insights
Two workers in hard hats standing beside yellow pipework at a gas facility.
13 March 2026
The decline in pipeline gas exports has freed up significant volumes of gas within Russia. This raises a question: which industries can process this gas and turn it into high-value-added export products?
Team reviewing an engineering drawing spread across a table.
6 November 2025
When designers fall behind and construction is left waiting, companies face delays and financial losses. We see this frequently on capital projects. In this article, we explain how to turn a chaotic design process into a well-managed system and align it with construction without complex IT platforms.
Road roller compacting freshly laid asphalt.
3 March 2023
On 25 February 2023, the EU adopted its tenth sanctions package, which included restrictions on imports of bitumen and asphalt from Russia. In this article, we examine the main consequences of the sanctions and the prospects for developing bitumen production in Russia.
Two workers in hard hats and high-visibility vests reviewing a document in a workshop.
15 February 2023
More than 70% of programmes to transform the maintenance and repairs function fail to achieve their stated objectives. We have identified 4 key factors in successful maintenance and repairs transformation.
View all insights

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