Modeling and performance improvement of an industrial ammonia synthesis reactor

Ammonia production from synthesis gas is one of the most important processes in the petrochemical industry. A heterogeneous model is used to improve the efficiency of an industrial ammonia synthesis reactor including three adiabatic catalyst beds. In this model, the effectiveness factor was determin...

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Autores principales:	Ahmad Shamiri, Nia Aliabadi
Formato:	article
Lenguaje:	EN
Publicado:	Elsevier 2021
Materias:	Modeling Optimization Reliability Fixed bed reactor Ammonia synthesis Chemical engineering TP155-156
Acceso en línea:	https://doaj.org/article/d14b0274a479408ba6afa00273a4db08
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spelling	oai:doaj.org-article:d14b0274a479408ba6afa00273a4db082021-11-18T04:53:12ZModeling and performance improvement of an industrial ammonia synthesis reactor2666-821110.1016/j.ceja.2021.100177https://doaj.org/article/d14b0274a479408ba6afa00273a4db082021-11-01T00:00:00Zhttp://www.sciencedirect.com/science/article/pii/S2666821121000922https://doaj.org/toc/2666-8211Ammonia production from synthesis gas is one of the most important processes in the petrochemical industry. A heterogeneous model is used to improve the efficiency of an industrial ammonia synthesis reactor including three adiabatic catalyst beds. In this model, the effectiveness factor was determined by considering the diffusion reaction equation. Reasonable agreement was achieved between simulated results and industrial data in terms of reactor component mole fraction and temperature. This mathematical model was modified to use for improving the ammonia converter performance and predict the effectiveness factors, nitrogen fractional conversion, temperature, and hydrogen and ammonia mole fraction profiles. The competency of the modified model has been investigated for industrial application by manipulating the reactor operation conditions and observing their effects on reactor output and results revealed the reliability of the developed model.The model is employed to obtain the optimum temperature profiles of each catalyst bed in the reactor based on equilibrium curve of ammonia synthesis reaction. Operating condition of the reactor was changed to achieve the optimum temperature profile according to model results by manipulating the reactor quench valves. After implementing changes in the reactor, the reactor performance and efficiency has improved with increasing ammonia conversion from 15.26% to 15.45% that increases ammonia production by 3t/d and energy saving by 1.66 Gj/h. The differential temperature of the first catalyst bed significantly increased by 6 °C and overall differential temperature through ammonia converter is increased by around 4 °C. This increases steam production by 2 t/h through loop boiler.Ahmad ShamiriNia AliabadiElsevierarticleModelingOptimizationReliabilityFixed bed reactorAmmonia synthesisChemical engineeringTP155-156ENChemical Engineering Journal Advances, Vol 8, Iss , Pp 100177- (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	Modeling Optimization Reliability Fixed bed reactor Ammonia synthesis Chemical engineering TP155-156
spellingShingle	Modeling Optimization Reliability Fixed bed reactor Ammonia synthesis Chemical engineering TP155-156 Ahmad Shamiri Nia Aliabadi Modeling and performance improvement of an industrial ammonia synthesis reactor
description	Ammonia production from synthesis gas is one of the most important processes in the petrochemical industry. A heterogeneous model is used to improve the efficiency of an industrial ammonia synthesis reactor including three adiabatic catalyst beds. In this model, the effectiveness factor was determined by considering the diffusion reaction equation. Reasonable agreement was achieved between simulated results and industrial data in terms of reactor component mole fraction and temperature. This mathematical model was modified to use for improving the ammonia converter performance and predict the effectiveness factors, nitrogen fractional conversion, temperature, and hydrogen and ammonia mole fraction profiles. The competency of the modified model has been investigated for industrial application by manipulating the reactor operation conditions and observing their effects on reactor output and results revealed the reliability of the developed model.The model is employed to obtain the optimum temperature profiles of each catalyst bed in the reactor based on equilibrium curve of ammonia synthesis reaction. Operating condition of the reactor was changed to achieve the optimum temperature profile according to model results by manipulating the reactor quench valves. After implementing changes in the reactor, the reactor performance and efficiency has improved with increasing ammonia conversion from 15.26% to 15.45% that increases ammonia production by 3t/d and energy saving by 1.66 Gj/h. The differential temperature of the first catalyst bed significantly increased by 6 °C and overall differential temperature through ammonia converter is increased by around 4 °C. This increases steam production by 2 t/h through loop boiler.
format	article
author	Ahmad Shamiri Nia Aliabadi
author_facet	Ahmad Shamiri Nia Aliabadi
author_sort	Ahmad Shamiri
title	Modeling and performance improvement of an industrial ammonia synthesis reactor
title_short	Modeling and performance improvement of an industrial ammonia synthesis reactor
title_full	Modeling and performance improvement of an industrial ammonia synthesis reactor
title_fullStr	Modeling and performance improvement of an industrial ammonia synthesis reactor
title_full_unstemmed	Modeling and performance improvement of an industrial ammonia synthesis reactor
title_sort	modeling and performance improvement of an industrial ammonia synthesis reactor
publisher	Elsevier
publishDate	2021
url	https://doaj.org/article/d14b0274a479408ba6afa00273a4db08
work_keys_str_mv	AT ahmadshamiri modelingandperformanceimprovementofanindustrialammoniasynthesisreactor AT niaaliabadi modelingandperformanceimprovementofanindustrialammoniasynthesisreactor
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Modeling and performance improvement of an industrial ammonia synthesis reactor

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