Batch: FA-20 SECTION: B

FINAL YEAR DESIGN PROJECT-I

PROJECT PROPOSAL

GROUP MEMBERS:

MUHAMMAD ZUBAIR NAEEM (CIIT/FA20-CHE-001/LHR)

HAMZA AASIM (CIIT/FA20-CHE-013/LHR)

ABDUL REHMAN VIRK (CIIT/FA20-CHE-051/LHR)

MISBAH QUTAB (CIIT/FA20-CHE-055/LHR)

SHOAIB MALIK (CIIT/FA20-CHE-092/LHR)

PROJECT SUPERVISOR:
DR. WAJIH-UR-RAHMAN
Ammonia:

Ammonia is a colorless gas with a penetrating pungent-sharp odor in small concentration

that, in heavy concentrations produces a smoothing sensation when inhaled. Ammonia is

water soluble forming a strongly alkaline solution of ammonium hydroxide and the aqueous

solution is called ammonia water, aqua ammonia. Ammonia burns with a green yellowish

flame. Ammonia is an important raw material for fertilizer sector, Nitric acid production and

for production of various pharmaceuticals products.

Objective:
Using lithium pathway to develop a sustainable solution for green ammonia production to

reduce the energy requirement with no hydrogen requirement.

Conventional Production:

Ammonia is produced through two main conventional methods.

i. Haber-Bosch process

ii. Kendall process

Haber-Bosch process:

Haber Bosch process is a conventional method of ammonia production using hydrogen and

nitrogen as reactants. This reaction is carried out at elevated temperature and pressure

around 410°C and pressure around 150 bar in the presence of iron oxide catalyst. Hydrogen

which is a raw material for ammonia synthesis is obtained from natural gas by reforming and

shift conversions. Reforming is highly energy extensive which use fuel natural gas mostly to

provide heat flux to the methane with the help of catalyst present is tubes to produce

hydrogen gas. In a result Carbon monoxide is formed which is converted to Carbon-dioxide

by gasification in secondary reformers and in shift converters. Requirement of fuel is quite

high as industrial flow rate are in tons per hour in order to entertain the processing of natural

gas.
Kellog Ammonia process:

The Kellogg process is along traditional lines, operating with steam/carbon ratio of about 3.3

and stoichiometric amount of process air and low methane slip from the secondary reformer.

The synthesis pressure depends on plant size and is between 140 and 180 bar. Temperatures

of the mixed feed entering the primary reformer and of the process air entering the secondary

reformer is raised to the maximum extent possible with today’s metallurgy. This allows

reformer firing to be reduced and, conversely, the reforming pressure to be increased to some

extent to save compression costs. An important contribution comes from Kellogg’s

proprietary cross-flow horizontal converter, which operates with catalyst of small particle

size, low inlet ammonia concentration, and high conversion. Low-energy carbon removal

systems contribute to the energy optimization. When possibilities to expert steam or power

are limited, part of secondary reformer waste heat is used, in addition to steam generation,

for steam superheating, a feature in common with other modern concepts. Proprietary items

in addition to them horizontal converters are the traditional Kellogg’s reformer, transfer lines

and secondary reformer arrangement, waste-heat boiler, and chiller in the refrigeration

section

Modern Approach for ammonia production:

Green is future. As hydrocarbon reserves are getting lower and lower day by day which will be

an alarming situation for upcoming future. Over a past decades modern approaches,

alternatives and research increased significantly. This project is based on a promising

approach for ammonia production as a novel innovation.

This project revolves around ammonia production using lithium pathway. The reactants which

are required for this process is LiOH and Nitrogen from air. As this project involves no

hydrogen and is a cyclic process reactant LiOH is regenerated which make this process more

efficient than others.

Other conventional projects have low conversion increasing their conversion causes more

work on separation units. One of the benefits for this project is gaseous product ammonia is

obtained with minimum inerts present and require minimum work on separation units with
conversion approximately around 90% and faradic efficiency >70%. The temperature and

pressure requirement for this whole process are temperature <150 and atmospheric pressure

conditions which makes this system more efficient.

LiOH regenerate

-H2O LiOH

Reduced to ions

H2O is removed or de-hydrated Li+, OH-

From solution.

NH3 Li+ ions

N2 reacts with Li+ to produce Li3N

Li3N reacts with H2O to produce NH3
Li3N
Li OH and H2O Solution

REACTOR SEPARATOR

MAKEUP LiOH

AIR FEED HEAT EXCHANGER

LiOH N2 feed
COMPRESSOR SEPARATOR

NH3 VAP
CRYOGENIC SEPRATOR
NH3 CHILLER
H2O REACTOR
H2O

SEPARATOR LiOH + H2O SOLUTION

Figure 1 Process flow diagram of green ammonia production

Economic analysis overview:
Conventional process:

As addressed earlier the conventional Hager bosh process which is a common practice of

industry for ammonia production is used require hydrogen content. Hydrogen is produced

from natural gas through reforming and shift conversion. Fuel is burnt to provide heat for

reformers which require burners and a proper pipeline system for fuel distribution a

continuous supply of electric current to produce spark and proper instrumentation and control

system to control fuel. For natural gas as fuel, it requires desired compression to meet

pressure requirement for fuel system.

Compressor that ultimately require source to rotate its rotor. For other fuel like coal and fuel

oil proper processing is required as carbon can deposit which causes decrease in heat flux

and can compromise the integrity of pipelines. Due to impurities present in fuel results

formation of higher Co2 content, NOx’s and SOx’s in flue gases which make the system

environmental enemy and imposes more environmental restriction. Catalyst is required for

most of the conventional methods.in order to avoid catalyst poising more systems are

introduced which results more energy consumption in overall system. Catalyst replacement

also makes the economic condition inefficient.

Green ammonia process:

Proposed proposal requires no catalyst conditions. Production method is energy intensive

require no elevated Temperature & pressure requirement. Separation units operating cost in

minimum as a very low amount of inerts are present. There is no fuel is requirement No CO2

content is present is this system which increase the lifespan of equipment because of no

corrosion. System spontaneously reacts and is exothermic in nature heat rejected by the

system is utilized to pre-heat other streams.

Conclusion:
In conclusion, the synthesis of green ammonia presents a promising and sustainable
alternative to conventional methods of ammonia production. As the world grapples with the
urgent need to address environmental challenges, such as climate change and resource
depletion, the advantages of green ammonia synthesis become increasingly evident. Green
ammonia production offers a significant reduction in greenhouse gas emissions compared to
the energy-intensive Haber-Bosch process. This reduction in emissions aligns with global
efforts to mitigate climate change, reduce the carbon footprint of industrial processes and
making the system energy efficient.

However, challenges remain in scaling up and commercializing green ammonia production

methods. Additionally, the transition from conventional to green ammonia synthesis will
require investment, policy support, and a commitment from stakeholders across industries
and initial funding for pilot scale plants.