Exergy consumption of ammonia production plants depends strongly on the ammonia synthesis loop design. Due to the thermodynamically limited low degree of conversion of hydrogen-nitrogen mixture to ammonia, industrial ammonia synthesis is implemented as recycle process (so-called "ammonia synthesis loop"). Significant quantities of reactants are recycled back to reactor, after the removal of ammonia at low temperatures. Modern ammonia synthesis plants use well-developed heat- and cold recovery to improve the reaction heat utilisation and to reduce the refrigeration costs. In this work, the exergy method is applied to estimate the effect of the most important process parameters on the exergy efficiency of industrial ammonia synthesis. A specific approach, including suitable definitions of the system boundaries and process parameters, is proposed. Exergy efficiency indexes are discussed in order to make the results applicable to ammonia synthesis loops of various designs. The dependence of the exergy losses on properly selected independent process parameters is studied. Some results from detailed exergy analysis of the most commonly used ammonia synthesis loop design configurations at a wide range of selected parameters values are shown. (C) 2004 Elsevier Ltd. All rights reserved.