International Journal of Industry and Sustainable Development (IJISD), Volume 5, Issue 1, 2024

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PROCESS SIMULATION AND DESIGN OF

GREEN AMMONIA PRODUCTION PLANT FOR
CARBON NEUTRALITY
Islam Shaker 1, Moataz El-Bagoury1*, Salma Yaser 1, Habiba Emad 1, Omar Hamdy 1, Nour
Abouseada 1, Mohamed Bassyouni 1,2, and Dina Aboelela 1
1
Faculty of Energy and Environmental Engineering, the British University in Egypt (BUE), El-Sherouk
City, Cairo 11837, Egypt
2
Department of Chemical Engineering, Faculty of Engineering, Port Said University, Port Said 42526,
Egypt
* Corresponding author: [email protected]

Abstract: This study investigated the viability of green hydrogen as an essential

component in the global energy transition. Despite intensified efforts prompted by the
ongoing global energy crisis, impediments have arisen, notably in the area of green
hydrogen storage techniques. The inherently hazardous nature of hydrogen gas,
resembling an explosion when stored conventionally, presents a significant challenge.
In response, this study proposed an environmentally friendly, carbon-neutral, and
secure storage technique. The focus is on utilizing green hydrogen in the production
of ammonia, serving as both a hydrogen carrier and energy storage medium on an
industrial scale. The versatile application of green ammonia extended beyond storage,
encompassing fertilizer production, refrigeration, and chemical manufacturing, all
aligned with principles of sustainable development, green energy transition, and
achieving net-zero carbon emissions. The comprehensive study involved the plant
design, process flow diagrams, Aspen HYSYS simulation, plant layout, HAZOP
study, and an in-depth economic analysis to evaluate feasibility and profitability. The
Haber-Bosch simulated process encompassed the entire production line, starting from
sustainably sourced hydrogen to the separation unit ensuring a green nitrogen source.
Further optimization was achieved through a heat exchanger network utilizing Aspen
Energy Analyzer. The study yielded a substantial ammonia production rate of 7058
kg/hr with an impressive conversion rate of nearly 85%, minimizing waste through
the recycling of excess hydrogen within the process. The resultant liquid form of
stored ammonia in the refrigeration loop facilitates convenient and safe storage of
hydrogen.

Keywords: Green Hydrogen; Process Design; Green Ammonia; Energy Transition;

CO2 Reduction

1 INTRODUCTION

F or the purpose of limiting climate change and its detrimental consequences,

greenhouse gas (GHG) emissions and global warming must be reduced [1-4].
Several tactics and steps can be taken to accomplish this objective [5-7].
Reducing GHG emissions can be accomplished by switching from fossil fuels to
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renewable energy sources including solar, wind, and hydropower [8-10].

Infrastructure for renewable energy should be funded by governments, companies,
and individuals, who should also encourage its use [11,12]. In addition to increasing
energy efficiency in industrial operations, transportation, and buildings can lower
energy use and related emissions [13-15]. Improved insulation, energy-saving
appliances, and innovative manufacturing processes are some ways to be provided
[16,17]. Encouraging environmentally friendly mobility through promoting the use of
electric automobiles, bicycles, walking, and public transportation can lower emissions
from the transportation sector [18,19]. The production of green hydrogen via
electrolysis and renewable energy sources is crucial for combating the effects of
climate change [20].
There are several main arguments in favor of the necessity of green hydrogen such as
decarbonizing hard-to-electrify sectors. Green hydrogen can be crucial in
decarbonizing industries including heavy industrial, shipping, aviation, and long-
distance transportation that are difficult to directly electrify [16,17]. These fields can
lessen their dependency on fossil fuels and cut their carbon emissions by using green
hydrogen as a clean fuel or feedstock [18,19]. Green hydrogen can also be used for
grid balancing and energy storage, assisting with the balancing of intermittent
renewable energy sources like solar and wind. During times of high production,
excess renewable energy can be electrolyzed to produce hydrogen [20,21].
While green hydrogen has a number of advantages, it also has some drawbacks,
notably in terms of storage. The following are some of the major difficulties with
hydrogen storage [22].
Low energy density as known hydrogen has a lower energy density than fossil fuels,
which means that to store enough energy, a large volume or high-pressure storage is
needed. Because handling and storing hydrogen under high pressure calls for
specialized infrastructure and security measures, this presents logistical and safety
issues.
Storage technologies for example, compressed gas, liquid hydrogen, and solid-state
storage are a few of the ways hydrogen can be kept in storage. Each storing technique
presents unique difficulties. High-pressure tanks, which can be big and expensive, are
necessary for compressed hydrogen. Storage of liquid hydrogen needs cryogenic
temperatures.
Leakage and permeation are common problems, hydrogen possesses small molecules
that easily pass through materials, such as storage tanks and pipes, or leak or permeate
through them. To stop hydrogen loss and keep safety, leaks must be controlled, and
storage systems must be reliable.
Price represents a significant problem making hydrogen storage systems can be
expensive, particularly when taking into account large-scale applications. The total
economics of hydrogen storage and use can be affected by the price of high-pressure
tanks, cryogenic equipment, or new materials for solid-state storage.
construction of infrastructure Investments in hydrogen storage facilities, pipelines,
and transportation infrastructure are necessary to develop a dependable infrastructure
for hydrogen storage. The establishment of such infrastructure is essential for
enabling the widespread adoption of green hydrogen, but it can be challenging due to
the costs involved and the need for cooperation from multiple stakeholders.
Market demand of ammonia is used in fuel cells, agriculture, and chemical production
in addition to energy storage. This broad spectrum of market demand could promote
economies of scale and reduce ammonia production and storage costs.
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It is crucial to keep in mind that the use of ammonia as a hydrogen transporter is still
in its infancy and has its difficulties. The efficiency of ammonia cracking operations
must be increased, costs must be cut, and ammonia production’s impact on the
environment must be addressed. In addition, nitrogen is produced as a byproduct of
the conversion of ammonia back to hydrogen, which could have its own effects on the
ecosystem if released in significant amounts into the atmosphere. Ammonia must be
handled, stored, and used properly to guarantee safety and reduce environmental
impact. Ammonia (NH3) is a real possibility for the delivery and storage of hydrogen.
It can assist in overcoming some of the difficulties related to hydrogen storage and
has certain advantages over direct hydrogen storage [23].
Ammonia has a higher energy density than hydrogen gas, allowing for the storage of
more energy in a given volume. This improves its suitability for long-term storage and
shipping. Alongside its extensive use in the fertilizer business, ammonia has a global
infrastructure for production, storage, and delivery. This infrastructure’s acceptance as
a hydrogen transporter might be sped up by repurposing it for ammonia-based energy
systems. Ammonia is easier to handle and store than hydrogen gas since it is a liquid
at standard ambient temperature and atmospheric pressure. It can be transported using
already-built infrastructure, including pipelines and tankers, and conventional tanks
for storage. As for extracting back green hydrogen back ammonia, A procedure
known as ammonia cracking or decomposition can quickly convert ammonia back to
hydrogen. Ammonia may be split up into hydrogen and nitrogen using a catalyst,
enabling the creation of hydrogen whenever it is required. As for safety concerns,
ammonia has its own safety concerns, although compared to pure hydrogen, it is less
likely to leak and permeate. Ammonia has a distinctive smell and may be detected at
low amounts, making it possible to find leaks and take action to stop them. On the
market level, ammonia has other uses besides energy storage, including fuel cells,
agriculture, and chemical manufacturing. This wide range of market demand may
encourage economies of scale and lower production and storage costs for ammonia. It
is crucial to keep in mind that the use of ammonia as a hydrogen transporter is still in
its infancy and has its difficulties. The efficiency of ammonia cracking operations
must be increased, costs must be cut, and ammonia production's impact on the
environment must be addressed. In addition, nitrogen is produced as a byproduct of
the conversion of ammonia back to hydrogen, which could have its own effects on the
ecosystem if released in significant amounts into the atmosphere. Ammonia must be
handled, stored, and used properly to guarantee safety and minimize the
environmental impact [24].
In this paper, the production of green ammonia will be discussed as a means of
storage for green hydrogen, where green ammonia can be considered a power-to-x
technology. The project consists of a full-on plant design study, where a preliminary
design is made using process simulation and diagram sketching, which is then
converted into a detailed plant design to assess the selected design’s feasibility and
profitability, while considering other plant design steps such as plant layout and
equipment spacing.

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2 METHODOLOGY
After assessing the importance of green ammonia in its role towards the green energy
transition and applications, a methodological plan is made for designing the most
optimum, feasible and recent method to produce green ammonia. Several software
programs were used as means of providing figures and data, including Aspen HYSYS
V10, Aspen Energy Analyzer, Capcost and Microsoft Visio 2013. Table 1 lists the
tools used and their main purposes.

Table 1 Software Programs Used

Program Purpose
Aspen HYSYS V10 Process simulation
Aspen Energy Analyzer Process optimization (heat exchanger network)
Block flow diagrams (BFD) and process flow
Microsoft Visio 2013
diagrams (PFD) sketching
Capcost (Microsoft Excel
Equipment cost analysis.
macro-enabled file)

- Research phase
Literature Review - Determining most recent technologies
- Get required parameters for logical assumptions

- Targeted output
Set Design
- Reactor type
Parameters
- Reaction Kinetics
Preliminary Design

Block Flow Process Flow

Diagrams Diagrams

Process Simulation
(Aspen HYSYS)

Evaluate Detailed Plant Final Report

Optimization Select Best Design
Economics Design Submission

- Feasibility Study - Energy recovery - Most feasible - Hazard and operability

- Profitability Analysis - Heat exchanger network - Most logical study (HAZOP)
- Cash Flow Analysis - Process re-evaluation - Easiest to operate and - Plant Layout
maintain - Equipment Spacing

Detailed Design

Figure 1 Design steps flowchart.

A series of steps were taken for the construction of a detailed plant design, as seen in
figure 1. The plant design methodology is divided into two main design sections:
preliminary and detailed design. The preliminary design stage is the first section of
the plant design study, it first starts with collecting required data and assumption
through research and literature review, which is then used to set the design
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parameters, as in the inputs, outputs, flowrates, reaction kinetics, suggested BFD’s

and PFD’s and the sorts. The parameters are then used to construct a simulation model
of the entire process on Aspen HYSYS V10, the process is then economically
evaluated as well as optimized using Aspen Energy Analyzer, which aided in the
development of a heat exchanger network whose main function is perform energy
recovery and heat integration between heat exchanger systems. The design is then
chosen at its most optimum and feasible form to assess its profitability, and create a
plant layout for the process lines, and modify in the process according to the hazard
and operability (HAZOP) study. Egypt has been chosen as the region to perform the
plant design study. Figure 1 is sketched based on the Coulson’s general steps of plant
design [25].

I. Process Overview
The process of green ammonia is revolved around one main reaction, which is the
Haber-Bosch reaction. The Haber process as shown equation 1, consists of one mole
of nitrogen gas and 3 moles of hydrogen gas react in a dynamic equilibrium to
produce ammonia gas; due to exothermic nature of the reaction (Illustrated by the
negative value ∆H) is favored under relatively low temperature conditions.
Furthermore, high pressure is also favored since there are fewer ammonia molecules
on the right-hand side [26].
(1)

II. Nitrogen Source

As previously mentioned, ammonia is produced by a Haber-Bosch process where the
two main reactants are hydrogen and nitrogen [26]. Obtaining nitrogen can be via
several ways. Nitrogen is a very readily available source in air making up 79% of it;
therefore, air as a source nitrogen is the most viable option. The main issue is the
withdrawal of nitrogen from the air; there are several ways to extract nitrogen from air
other than the use of Air Separation Unit (ASU), like the use of a combustion reaction
to get rid of the oxygen in air leaving the unreacted nitrogen behind [27]. Although it
is considered economically feasible option compared to installing an air separation
unit, the downside of such process is the formation of Carbon monoxide as a
byproduct and additionally the energy needed to burn the hydrocarbon source is also
taken in consideration when calculating the capital cost needed. Nitrogen Purification
technologies can be divided into three main methods [28].
1- Air separation unit (ASU), Cryogenic distillation.
2- Pressure swing adsorption (PSA).
3- Membrane permeation.
All three technologies have a very seminal purity, but they differ in the operating
temperature as well as the energy consumption of each. So, choosing Cryogenic air
distillation was based on a selection criterion, having the lowest energy consumption
and the lowest investment cost on the long term. One might argue that it has the
highest operating temperature but this can be easily fixed with a heat exchanger
network discussed on later sections [29].
Cryogenic distillation works on the basis of separating the elements in air after
extreme cooling in a refrigerating system and high compression. The main application
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of this separation technique is oxygen separation so usually the nitrogen is a by-

product in such application but a main one in ammonia production [30].

III. Green hydrogen Input

Scientists and researchers are working to advance the proton exchange membrane
water electrolyzing (PEMWE) technology, which is now only accessible in a few
developed nations, to manufacture green hydrogen from clean and renewable sources.
The biggest problem with this technology is that it requires pricy metal catalysts and
proton exchange membranes made of perfluorocarbons (PFC), which increase the
expense of production. Because of this, a research team in South Korea has created a
new technique for advanced generation electrolyzes that increases lifespans and
performance while reducing the price. Additionally, the researchers were able to
create an anion exchange membrane fuel cell (AEMFC)-equipped electrolyze, which
is expected to take the place of the currently pricey PEMWE. AEMWE's technique
does not require pricey platinum-group metal (PGM)-free catalysts because it uses
iron instead of titanium for the separation plate of the electrolytic cell [31]. Therefore,
the manufacturing cost is decreased by roughly 3000 times compared to the
manufacturing cost of PEMWE technology when comparing the price of the catalyst
and the separator material in the electro catalyst. However, because of the poor
performance compared to PEMWE technology and the problem with the catalyst
durability and lifetime of fewer than 100 years of continuous operating hour, this
technology has not been used commercially. Additionally, the research team was
successful in creating anion exchange materials based on (polyfluorenyl aryl
piperidinium) (PFAP) (electrolyte membrane and electrode bonding), a membrane
with high conductivity and durability. The material they created has excellent
durability over 1,000 runs and a new record cell performance of 7.68 A/cm2. This
created material performs roughly 1.2 times better than the PEMWE technology,
which has a performance of 6 A/cm2, and about six times better than the performance
of the existing anion exchange materials. Due to its great efficiency and low cost,
AEMWE technology overcomes the limitations of the most recent electrolyze
technology for hydrogen generation. Therefore, it is predicted that this technology
will pave the way for the launch of next-generation electrolyze technology in a short
amount of time and make it a strong competitor commercially [32]. Figure 2
demonstrates a PFD for production of green hydrogen. PFD is sketched based on the
most common method used for green hydrogen synthesis, which is water electrolysis
[33].

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Figure 2 Green hydrogen from water electrolysis PFD.

IV. Green Ammonia Production

In figure 3, green ammonia production requires two inputs, similar to the conventional
ammonia pathway. It requires a hydrogen stream and a nitrogen stream. The nitrogen
stream can be obtained from cryogenic distillation (ASU), while the hydrogen can be
obtained through the process of electrolysis of water which divides the water
molecules into hydrogen and oxygen. This is the main reason that this synthesis
method is called green; it is because the ammonia produced is via green hydrogen.
Collectively, there are three main units. The hydrogen production unit, the nitrogen
extraction unit, and the ammonia synthesis unit. The nitrogen extraction unit will
remain the same while the hydrogen production unit will be assumed in the form of
single hydrogen stream with authentic composition [34-36]. This is due to the absence
of the required electrolyzer in Aspen HYSYS10. The ammonia synthesis process will
consist of mixers, compressors, and heat exchangers in order to reach a mixture of
nitrogen and hydrogen at certain pressure and temperature so that it can activate the
reaction kinetics. The output stream is separated to obtain a stream with as much
product ammonia as possible to be used at room temperature and atmospheric
pressure.

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Figure 3 Green ammonia synthesis BFD.

3 SIMULATION RESULTS
The process flowcharts generated and the results discussed as a PFD (Figure 4)
extracted from HYSYS V10 (Figure 5), a datasheet regarding the stream properties,
the conversion rate, the purity of the product and an energy savings report before and
after optimization and/or heat integration with an economic evaluation of the
equipment purchasing costs. Aspen Energy Analyzer has been used to suggest
possible heat integration between the heat exchangers to reduce amount of heat input
and utilize on the internal heat energy of the streams.

I. Process Flow Diagrams

After looking into each process line, the whole production flow can be assembled into
the following process flow diagrams (PFD’s).

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Figure 4 Green ammonia PFD. Landscape

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II. Aspen HYSYS Simulation

This process flowchart illustrates green ammonia synthesis using aspen HYSY v10 by Haber-
Bosch reaction. First, nitrogen and hydrogen are mixed at 25c and 101.3 kPa, then pass
through a certain number of heat exchangers and compressors for heating up the mixture
temperature and pressure until it reaches 438 °C and 2.533e+004kpa which assists Haber-
Bosch reaction to start in plug flow reactor as shown in figure 6. Before ammonia could be
stored in a tank, the temperature and pressure should be dramatically decreased to around -
35.52 °C and 101.3kpa respectively.

Figure 5 Process flowchart of green ammonia synthesis on Aspen HYSYS V10.

Table 2 shows the values of hydrogen and nitrogen as an input and the final product
(ammonia) as an output regarding their vapor fraction, temperature, pressure, and mass flow
rate. The temperature of inputs is almost the same at 25 °C while the ammonia was kept in at
extremely low temperature of -35.52 to stay in liquid form in the refrigeration loop.

Table 2 Datasheet for input and output streams.

Table 3 shows the detailed and total purchasing equipment cost for utilities needed. Total
purchased equipment cost is 22,556,800 Dollar, bare module cost is 61,487,600 Dollar, base
equipment cost is 10,598,280 Dollar and base bare module cost is 29,079,800 Dollar.
Materials of construction and cost are listed in table 4.

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Table 3 Purchasing equipment cost of utilities.

Figure 6 Heat exchanger network of green ammonia synthesis.

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Table 4 Materials of construction and cost

4 PIPING AND INSTRUMENTATION DIAGRAM

One must note that the P&ID has been single-handedly made on the refrigeration loop which
can be found in both production lines. A P&ID (Piping and Instrumentation Diagram) is a
graphical representation of a process system that shows the interconnection of process
equipment, piping, and instrumentation, along with their associated control and
monitoring devices. P&IDs are important tools for engineers, operators, and maintenance
personnel to understand the configuration and operation of a process system. They are used
for various purposes, including design, construction, operation, maintenance, troubleshooting,
and safety analysis as shown in figure 7.

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Figure 7 P&ID for ammonia refrigeration loop.

5 HAZARD AND OPERABILITY STUDY

The importance of conducting a Hazard and Operability (HAZOP) study cannot be
overstated. This systematic process safety management tool serves as a cornerstone for risk
assessment and mitigation in industries prone to hazardous operations. Through a HAZOP
study, potential hazards and deviations from normal operation are meticulously unearthed,
enabling organizations to take initiative-taking measures to minimize or eliminate these risks.
Such preventive actions not only safeguard against accidents and injuries but also prevent
environmental harm and property damage. Furthermore, HAZOP studies are often a legal
requirement, ensuring compliance with regulatory standards and reducing the likelihood of
legal repercussions. Beyond compliance, these studies offer the opportunity for process
optimization, enhancing operational efficiency and cost-effectiveness.

I. HAZOP Study
The previously stated P&ID shows the refrigeration loop under normal operating conditions.
However, it must be taken into consideration that there is a possibility of a cluster of hazards
that may occur due to human and other interventions or deviations. Therefore, a hazard and
operability study (HAZOP) has been made as database for as many hazards that may cause
deviations and a precaution and monitoring solution to each hazard as listed in tables 5 & 6

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Table 5 HAZOP study on compressor (k-303) Intention- increase pressure of hydrogen and nitrogen
Guide Deviation Cause Consequences Action Recommendation
word
Non return Non return valve.
potential of valve Temperature alarm.
High pressure
pressure and installation Pressure alarm
level at reactor or
Reverse Flow temperature Proper inspection and
heat exchanger or
increase led to Pressure and measuring on
both
explosion hazard temperature pressure and
alarm or sensor temperature level
Possible
Compressor Low Low concentration
hazardous NH3
No/none Flow failure – (small concentration alarm interlocked to
concentration
hole for example) alarm shut-down NH3 flow
changes
Temperature High Temperature
Temperature and sensor sensor
pressure
failure of
increasing Pressure High Pressure
More Flow compressor
Sensor Sensor
control
High reaction Measure reaction rate
rate by liquid level
observation

Table 6 HAZOP study on reactor (R-303) Intention- increase temperature of hydrogen and nitrogen
Guide Deviation Cause Consequences Action Recommendation
word
Reverse Reverse cooling Loss of water Less cooling Install check Install non return valve.
flow control in the valve or non-
opposite direction Possible reaction return valve. Repeatedly measure on
changing rate the reactor function
Continuous
inspection
No No cooling Cooling water Temperature Install high Install high temperature
effect valve break down increases in the temperature alarm.
reactor above target. alarm
Possibility of Continuous inspection
explosion
More More than Loss of control in Temperature Low Low temperature alarm
wanted cooling cooling water decreases temperature Install temperature
valve alarm check valve.
Reaction rate Install Repeatedly observation
increases temperature Install insulation for
check valve alternative heating
Less Less cooling Loss of control in Temperature High high temperature alarm
targeted cooling water decreases temperature Install high temperature
valve alarm check valve.
Reaction rate Repeatedly temperature
increases Install High measuring
temperature Install water jacket for
Possibility of check valve alternative cooling
explosion

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As well Unwanted More pressure in Contamination in the Check Install more control
as product reactor product lead to maintenance valves.
specifications change in its procedures and Repeatedly observation
Loss of pressure specifications schedules. Instruct operators on
control valve Poisoning in the Maintenance of procedures.
reaction the control
Impurities valves
Other Another material Water source May be cooling If less cooling, Temperature alarm high
than besides water contaminated. ineffective and effect TAH will installation
on the reaction. detect. If Water insulating system
detected, isolate
water source.
II. Modified P&ID
As a result of the previously constructed HAZOP study, a modification can be made on the
P&ID in figure 8. This might be a safer alternative to the system which will result in fewer
failure costs.

Figure 8 modified Refrigeration Loop P&ID.

6 GENERAL PLANT CONSIDERATIONS

Designing a plant involves a range of critical considerations to ensure its efficient and safe
operation. First is the choice of site location, which should factor in geological stability,
accessibility to transportation networks and resources, and environmental impact assessments
to minimize harm to local ecosystems and communities. The plant layout is equally vital,
encompassing equipment spacing to allow for maintenance access and potential expansions,
as well as efficient material flow for optimized operations. Safety zones and areas for
emergency response and fire protection must also be designated within the layout. Moreover,
assessing wind direction and weather patterns is crucial when positioning equipment and
emissions stacks to minimize pollutant dispersion and maximize safety, especially in regions
prone to extreme weather conditions. Ensuring safety and security measures, including fire
prevention and suppression systems and access control, is paramount for protecting critical
infrastructure. Thinking ahead, plant designs should incorporate scalability and future
expansion possibilities to accommodate growing energy demands or technological
advancements. Aesthetic considerations should not be overlooked, as the visual impact on the
local community can influence public perception. Finally, operational efficiency should be at
the forefront of planning, with a focus on process integration and maintenance accessibility to
optimize energy efficiency and reduce operational costs. By addressing these multifaceted
considerations, plants can be designed to meet energy needs while minimizing environmental
impacts and ensuring long-term sustainability.
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I. Equipment Spacing
Equipment spacing is necessary to ensure safe operations and minimize failures in case of
accidents. Equipment Spacing has been made once for grey ammonia and green ammonia,
however later the design is continued on the green ammonia since it is more environmentally
friendly as shown in figure 9.

Figure 9 green ammonia equipment spacing

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II. Plant Layout

This section will discuss the overall plant layout with respect to equipment spacing and
administrative area as well as potential areas for expansion. It is important to be aware of the
wind direction and intensity to set up the orientation of the plant as shown in figure 10.
Therefore, it would make sense to analyze the wind atlas or so-called wind rose of Al Ain Al
Sokhna. Although a Windrose for Ain Sokhna cannot be found, a wind rose of nearby gulf of
Suez can be used to estimate the direction of wind in Ain Sokhna [37-40].

Figure 10 plant layout.

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III. Site Location

The following sites have been taken into consideration:
 October industrial zone
 15 May industrial zone
 Abo Rawash industrial zone
 New Al Nubaria
 Tarboul
 Fayoum industrial zone
 Marsa Matrouh
 Al Shlallat Al Aulaqui Valley Industrial Zone Aswan
 Ras Ghareb, Red Sea Governate
The following reasons have been used as a basis for choosing the best area:
 Location, with respect to the marketing area.
 Raw material supply.
 Transport facilities.
 Availability of labor.
 Availability of utilities: water, fuel, power.
 Availability of suitable land.
 Environmental impact, and effluent disposal.
 Local community considerations.
 Climate.
 Political and strategic considerations.
As result, one can assume that the Industrial Zone in Ain Sokna (SIDC Industrial Park) is the
most optimum for green ammonia production plant while 6th October industrial zone is best
for grey ammonia.

7 PROFITABILITY STUDY
Thorough examination of the various financial prospects is essential when conducting a
profitability study to determine an estimate of how much profit the initial investment will
generate. This study assessed the upfront capital costs associated with building and operating
the plant, including the expenses related to green ammonia production technology and
infrastructure as listed in table 6. It would also consider revenue generation potential,
considering factors like electricity generation, potential government incentives for clean
energy, and market demand for ammonia as a clean fuel or chemical feedstock. Additionally,
the study would analyze ongoing operational expenses, maintenance costs, and environmental
benefits such as reduced greenhouse gas emissions. Ultimately, this profitability study aims
to determine if the long-term economic benefits, including potential profitability and positive
environmental impact, justify the investment in a green ammonia plant.

Table 6 Fixed and variable cost

PCE $ 761,545
PPC $ 959,497,437
Fixed Capital Cost $ 376,586,333
Total Investment $ 395,333,933

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Variable Cost:
Raw Materials $ 5,495
Miscellaneous $ 1,976,593
Utilities $ 97,200
Shipping and Packaging not applicable
Sub Section A $ 2,079,285

Fixed cost:
Maintenance $ 19,765,933
Operating labor $646,933
Supervision $ 599٬943
Plant Overhead $ 393,533
Laboratory costs $ 5,495,643
Capital charge $ 38,359,333
Insurance $ 38,359,333
Local taxes $ 759,584,333
Royalties not applicable
Sub Section B $ 71,566,653
Direct Costs (A +B) $ 73,645,935

Sub Section C

Sales expense $ 58,456,733

General overheads not applicable
Research and Development not applicable
Sub Section C $ 18,416,700

Profitability

Annual Production costs (A + B + C) $ 92,362,635 / year

Production Cost $ 3.62 / kg
Profit per kg $ 4.53 / kg
Total annual production 25,409,000 kg
Net Profit $ 23,122,190

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8. ENVIRONMENTAL IMPACT ASSESSMENT

Environmental Impact Assessment (EIA) is essential study that uses various data and
prediction to insure sustainability in any project. Assessing the environmental impact
especially in green projects is a necessary to build a common ground for competition with
other alternatives in a growing sustainable green economy offering a plethora of alternatives
and options. Due to ammonia being one of the most produced chemicals worldwide with
already established facilities, [41-43] assessing the direct impacts like the resources
consumption from water, energy and materials is already acknowledged. Although the
process is green, analyzing the potential of any indirect pollutants and greenhouse gases
(GHG) [44-46]. Some of the indirect emissions include the source of energy used in
producing the hydrogen. Solar and wind power used can have unintended greenhouse gas
emissions from the land use change that could have been utilized for other non-emitting
practices [47-49]. Furthermore the emissions of maintenance and manufacturing of the
systems including the end of life consideration and decommissioning of all the technology
and the ammonia plant in general [50-52]. [3].Hydrogen storage technologies is considered a
gap hindering the progress of the green energy, the scaling up from pilot to industrial scale
has a lot of factors to take in consideration; one of those is having a way to store the larger
potential of hydrogen in an effective way as shown in figure 11.
Storing hydrogen using established methods like compressed gas or liquid hydrogen presents
a number of limitations. Safety risks, high costs, and logistical hurdles associated with
transportation can hamper their widespread adoption. However, emerging options like the
liquid organic hydrogen carrier (LOHC) offer a glimmer of hope by addressing these critical
concerns. Unlike conventional methods, LOHCs promise safe, cost-effective storage of large
quantities of hydrogen for extended periods. This not only enhances safety but also simplifies
long-distance transport, making LOHCs a potentially transformative solution for hydrogen
utilization. It's important to note that LOHCs aren't the only contenders in the race for

Figure 11 Classification of Hydrogen Storage Techniques

efficient hydrogen storage. Research explores various chemical hydrides like ammonia,
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methanol, and formic acid, each showcasing exciting potential. This diverse landscape of
innovative approaches underscores the commitment to developing robust and practical
solutions for harnessing the clean energy potential of hydrogen. So, while traditional methods
face practical limitations, the emergence of LOHCs and other chemical hydrides paints a
promising picture for the future of hydrogen storage and utilization. Technological
advancements in this field hold significant promise for unlocking the true potential of
hydrogen as a clean and sustainable energy carrier.

9. CONCLUSION
In summary, this research highlights the pivotal role of green hydrogen and green ammonia
in advancing the global transition toward cleaner and more sustainable energy sources. By
utilizing green ammonia as an efficient carrier for green hydrogen, coupled with meticulous
process modeling and simulation, this study offers a promising pathway toward an
environmentally friendly and energy-efficient future. As mentioned in the publication of The
International Renewable Energy Agency (IRENA), one of the key points of the cost reduction
strategy other than governmental support towards the renewable technology projects and
finding cheaper alternatives materials used is increasing the size of the facility; the small
scale facilities are considered a hindrance in relation to the amount of hydrogen produced.
Taking a closer look in the overall process, ammonia synthesis compared to the hydrogen
production itself is far less cheap regarding the capital needed for the process. As for global
investments, an estimate of USD 2.8 trillion is invested in energy projects with USD 1.7
trillion of them is invested in clean energy projects of all sorts in the year 2023. It was
recorded in 2022 according to the International Renewable Energy Agency (IRENA),
hydrogen investments were tripled compared to 2021, with a very small portion going into
energy storage technologies making the storage technologies economically challenging
alongside the technical challenges of hydrogen storage methods. Therefore, storage must be
commercialized, in order to achieve higher sustainability. Although the previous process
flowcharts are a modified version from the literature, it can be assumed that there is always
room for improvement. In addition, the use of fired heaters and high cooling systems instead
of a series of heat exchangers could be more spacious but the purchasing cost difference
between both options should be considered. The compressors used are prescribed with Aspen
HYSYS default efficiency, one might consider finding ways to increase it. Another factor
that must be considered is to recycle in order to avoid waste streams as much as possible and
increase cost effectiveness. This was not possible to implement in the process simulation due
to the program’s maximum number of iterations. Some researches discussed the use of
absorbing solvents for ammonia extraction. Moreover, to get a more accurate economic
comparison, a cash flow analysis could be made to calculate the return on capital over time.
In conclusion, green ammonia production has been discussed to convert it to store green
hydrogen as well as reduce the carbon dioxide emissions, this is to contribute to the 2030
vision, especially goal 7 in providing clean and affordable fuel, while avoiding the distortion
in the stability of the ammonia market and its applications on day-to-day basis. The goal can
be achieved through the proposed project of green ammonia production for hydrogen storage,
where the commercialization of the project on a larger scale can help in making the dream of
clean fuel affordable to all a reality in the near future.

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