200 kg/day Catalytic Membrane Reactor Demonstration Plant for Sustainable Ammonia Production Using Produced Water as Feedstock
Solution Developer
McAlpha Inc.
Project Description
The purpose of this test program is to optimize the catalyst performance at 200 kg/day ammonia production to achieve a minimum performance threshold of 95% conversion rate of Nitrogen and Hydrogen conversion into ammonia. The project will assess the interactions of the components catalyst support, membrane separation, selectivity, and heat integration, and as well confirm 60 - 70% energy savings.
1. Basic Concept:
Catalysis: The process uses a catalyst to facilitate the chemical reaction between nitrogen (N₂) and hydrogen (H₂) to form ammonia (NH₃).
Membrane Separation: A selective membrane allows the continuous removal of ammonia from the reaction mixture, preventing equilibrium limitations and increasing the overall conversion efficiency.
2. Feedstock Preparation:
Hydrogen Production: Hydrogen will be generated through both electrolysis and steam methane reforming processes to compare the energy required and economics of both processes and to establish the pathway for green and blue ammonia using CMR.
Nitrogen Supply: Nitrogen is typically sourced from the air using air separation units.
3. Reaction Process:
Catalytic Reaction: In the CMR, nitrogen and hydrogen gases are introduced into the reactor containing a suitable catalyst. The catalyst facilitates the reaction: N2+3H2→2NH3
Operating Conditions: The reaction occurs at lower temperatures (250-350°C) and pressures (1-50 bar) compared to the traditional Haber-Bosch process (600-800°C and 200-400 bar).
4. Membrane Function:
Selective Permeation: The membrane selectively allows ammonia molecules to pass through while retaining unreacted nitrogen and hydrogen gases.
Continuous Removal: As ammonia is formed, it diffuses through the membrane and is continuously removed from the reaction zone. This shifts the reaction equilibrium towards the production of more ammonia, enhancing the conversion rate.
5. Ammonia Collection:
Condensation and Storage: The permeated ammonia is collected on the permeate side of the membrane and then condensed into liquid ammonia for storage and further use.
Support Requested
Funding and technical collaboration for demonstration and piloting.