New measures for energy savings and consumption reduction in ammonia synthesis using pressurized gas

Any technological upgrades or parameter adjustments are aimed at optimizing existing processes; unless it involves a complete overhaul, such as changing from atmospheric pressure gasification to pressurized gasification, from desulfurization and denitration processes to low-temperature methanol washing or liquid nitrogen treatment, or from high-pressure ammonia synthesis to low-pressure ammonia synthesis. Therefore, the latest technologies are based on certain existing processes and may not be suitable for use in all types of processes.

There are still some common new technologies. For example, applying new materials to the furnace walls and tubes to enhance heat reflection and absorption can effectively reduce gas consumption; another example is the recovery and reuse of heat energy from decarburization processes

A new material shared by coal-based and gas-based processes in ammonia synthesis towers is ruthenium-based catalysts. . . . Direct connection technology for waste boilers. . . .

Thin-walled furnace tubes, catalyst with low water-to-carbon ratio, oxygen-enriched two-stage conversion, efficient flue gas heat recovery, cryogenic purification of syngas, inter-stage heat transfer synthesis tower, low-pressure synthesis

The reduction technology for low-pressure ammonia synthesis catalysts is the most effective measure for saving energy and reducing consumption.

Introduction to the reduction technology of low-pressure ammonia synthesis catalysts. The reduction of ammonia synthesis catalysts is an important step in the production of ammonia, and the pressure used in this reduction process is a key factor that determines the service life and activity of the catalysts, as well as the specific consumption of ammonia and the production capacity of the ammonia synthesis plant. Under normal circumstances, the reduction pressure values for synthetic catalysts recommended by catalyst manufacturers and those used by various ammonia synthesis plants are around 5 MPa. Through relevant calculations and coordination with the on-site equipment, this value can be reduced by half; as a result, the residence time of water vapor in the synthetic ammonia catalyst reduction gas within the synthesis tower is also reduced by half. In other words, the probability of the synthetic ammonia catalyst being damaged by water vapor in the reduction gas is diminished by half. The activity of the synthetic ammonia catalyst after final reduction is significantly increased. This is particularly evident in iron-based ammonia synthesis catalysts, as such catalysts result in a low temperature of the effluent water and a fast rate of water output during the main operation phase; if this water vapor cannot be removed from the tower in a timely manner, the ammonia synthesis catalyst will suffer severe contamination. These are also important reasons why many synthetic ammonia catalysts fail to demonstrate their advantages in actual production. Although catalyst manufacturers currently widely use pre-reduced catalysts to replace in-situ reduction, due to objective constraints, the use of pre-reduced catalysts can only shorten the heating and reduction time required for the catalysts; it cannot change the fact that these catalysts retain low activity after reduction, failing to achieve the desired results. This is also why the reduction of ammonia synthesis catalysts under low pressure is not merely a modification of a reduction parameter, but rather becomes an important aspect of the technology involved in ammonia production. Moreover, this pressure indicator cannot be reduced simply by wishing to do so, as it is subject to various constraints. Low-pressure ammonia synthesis reduction technology can not only be applied in chemical engineering

With the support of basic data, the appropriate pressure for reducing ammonia synthesis catalysts can be determined based on the capacity of the on-site ammonia synthesis plant, along with specific control measures. If implemented, this technology will undoubtedly demonstrate its extraordinary unique appeal and significant economic benefits. It will also provide a fair assessment of some low-temperature brand synthetic ammonia catalysts, revealing their true advantages