Ammonia Reactor System Design and Optimization Study for High Efficiency

This material discusses the design and optimization of an ammonia synthesis reactor system for maximizing conversion efficiency while minimizing CAPEX costs. Various factors such as managing heat effects, reaction runaway prevention, and cooling profiles are explored. Recommendations include using a fired heater and a single jacketed reactor with high pressure steam generation. The analysis involves Aspen simulation with FNH3 maximization and considerations for material construction. The memo includes reactor feed and exit temperatures, ammonia flow rates, and total bare module costs. The goal is to achieve the highest NH3 yield efficiently.

• Ammonia synthesis
• Reactor design
• Optimization
• CAPEX costs
• Heat management

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1. HW 3 Debriefing Terry A. Ring Chemical Engineering University of Utah Aspen File : Ammonia Synthesis Reactor Design-4.apwz MathCadfile: HW 3 Ammonia Reactor

2. Managing Heat Effects Reaction Run Away Exothermic Reaction Dies Endothermic Preventing Explosions Preventing Stalling Most Conversion with least CAPEX Cost

3. Ground Work for Reactor 0.5 N2 + 1.5 H2 NH3 Conversion Rate=0.001, 0.01, 0.1, 1 Temperature (K)

4. Ground Work for Reactor 0.5 N2 + 1.5 H2 NH3 Conversion Cooling Rate=0.001, 0.01, 0.1, 1 Temperature (K)

5. Ground Work for Reactor 0.5 N2 + 1.5 H2 NH3 Conversion Mixing Rate=0.001, 0.01, 0.1, 1 Temperature (K)

6. Ground Work for Reactor Cooling Profile Conversion Feed Temperature Temperature (K)

7. Aspen Simulation with FNH3 Maximization Optimized Thermo Fluid T & P Optimized Feed Temp for B8 and B3 Optimized Split to get highest FNH3

8. Memo Questions Description of the reactor system you think is best for this application. Fired Heater then a single reactor with a jacket generating high pressure steam Material of Construction for any or all Reactors, heat exchangers and Fired Heaters Carbon Steel Reactor, Stainless Steel Fired Heater Reactor Feed Temperatures and Reactor Exit Temperatures 507C Feed T, 301C Exit T Ammonia Flow in kmol/hr leaving your reactor system. This is related to the single pass conversion, more ammonia flow = higher conversion. 13536.96 kmol/hr (XN2=50.5%) This is also the case for the 3 reactor + interstage cooler simulation Total Bare Module Cost (CBM) for your reactor system including fired heater(s), S&T heat exchangers (if any), reactors and catalyst. $ 55,897,463 for the one jacketed reactor generating steam Please submit your Excel files and your Aspen Files into Canvas.

9. CAPEX Only One Reactor

10. Flow Sheet Improvements Steam Product Feed Fired Heater RX Steam Feed Fired Heater RX HX HX Product