Ammonia production by Haldor Topsoe process

Naphtha obtained from the distillation of petroleum crude is used as the source of
hydrogen which acts as the reactant for the production of ammonia. One mole of
Ammonia requires one mole of nitrogen and three moles of hydrogen as per
stoichiometry equation. Natural gas is the better option for hydrogen source and
advantages over the naphtha process as most of the unit operations are reduced getting
down the installation and production cost.

Many variations of the Haber’s process are now being used for the manufacture of
synthetic ammonia some varying to such an extent that they are identified by a name
often that of the group of men developing them. Important among these are the
modified Haber Bosch, Haldor Topsoe, Claude, Casale, Fauser and Mount Cenis
processes.

All of them are fundamentally the same in that nitrogen is fixed with hydrogen as
ammonia in the presence of a catalyst but have variations in the construction of
equipment their arrangement, the composition of catalyst and temperature and
pressure used but an ideal process flow sheet becomes the platform for improvement in
the process. A simple block diagram shows the Haber’s process -:
1. Naphtha gas supply: Naphtha is used as feedstock and fuel for Ammonia plant and is
supplied at the offsite Gas Metering station at a pressure of 44 kg/cm2 . After metering
at offsite, the naphtha gas for process feed is directly received at Ammonia plant battery
limit at 40 kg/cm2 and 40℃. Fuel gas is used for burners of feedstock preheater,
primary Reformer, Auxiliary superheater and start-up heater in Ammonia plant-Feed gas
goes to the Desulphurization unit for sulphur removal, if any and subsequently
processed to produce synthesis gas for Ammonia production.
2. Desulphurization: Raw naphtha contains high sulphur which harms the catalyst in
the reforming reactor and even consumes hydrogen by undesired side reactions. A
packed bed reactor is utilized for the removal of sulphur. Zinc oxide based bed absorbs
the sulphur.

3. Primary reformer: Naphtha contains carbon and hydrogen compounds to separate

hydrogen all the carbon is converted to carbon dioxide and hydrogen by means of steam
at high temperature with the presences of the nickel based catalyst.
4. Secondary reformer: Nitrogen required for the synthesis reaction is obtained from
the air so, the carbon dioxide and hydrogen stream is mixed with the air.
5. Shift conversion: Carbon monoxide which is formed in the previous process is
converted to carbon dioxide by using steam which results in shift reaction producing
hydrogen. High and low shift reactors are arranged for this conversion process.
6. 𝐂𝐎𝟐 removal: All the carbon dioxide produced is removed by the absorption process.
Absorption and stripping towers recover the most of the gas which is used in the urea
production.
7. Methanation: The traces of carbon dioxide and carbon monoxide are converted to
methane by means of hydrogen on the catalyst like nickel in methanation reactor. Heat
is produced due to the exothermic reaction.
8. Ammonia synthesis reactor: Iron acts as the catalyst at temperature 400℃ and
pressure 142 kg/𝑐𝑚2 the reaction proceeds for the formation of ammonia.
9. Chilling system: A compression absorption refrigeration system is used for
liquefaction of ammonia. At 1 atm the boiling point of ammonia is -33℃.

The advantages of this process are:

1. Greater compactness, simplicity in case of converter design since under high-

pressure gases have a smaller volume.
2. Elimination of expensive heat exchanger required in processes operated at low
pressure.
3. Removal of ammonia with water cooling alone.

The disadvantages of this process are:

1. Shorter life of converters.

2. High apparatus upkeep in the high-pressure operation.
3. Efficiency loss in approximately 20% of making up gas, which is unconverted.
In comparison, Haldor Topsoe process operates at the pressures lower than Claude
process and against the disadvantage of using a heat exchanger for heat recovery and
less compactness in converter design. Recovery of 20% of unconverted gas and recycling
it to increase the efficiency and conversion of the complete process and the large and
massive compressors which are used in Claude process are required to maintaining 900
atm which cost millions of dollars are avoided in Haldor Topsoe and is thus more
economical and good especially for large capacity process. Also, the life of the converter
is very long and ammonia is removed by water-cooling and by knock out the drum.

A Table of Process Design Modifications in Ammonia Production:

Ever-evolving technologies are been adopted by the modern industries to improve the
conversion rate with efficiency and less energy consumption for complete process,
some of the competitive designed techniques are given and much more are to be
introduced.
 Process Pressure (atm) Temperature (℃) Conversion (%)
Mont Cenis 120 400 8-20
Stami Carbon 310 500 10-30
Fauster-Montecatini 220-230 500 10-30
Casale 500-700 500 15-25
Clued 330-630 540-590 15-25
Haber Bosch 330 500-550 10-30
Nitrogen Eng. Corp. 200-300 500-550 10-30
Lummus 270-330 500-510 10-25
Kellogg 300-350 500-510 10-30
Du Pont 900-1000 500-600 40-80