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Ammonia synthesis catalyst

Ammonia is one of the most important and widely used petrochemical products and is the second synthetic substance with the chemical formula NH3, which is formed in nature from the decomposition of nitrogenous organic matter. The highest amount of ammonia consumption is in the production of fertilizers (urea, ammonium sulfate, ammonium phosphates). In the ammonia production unit, 8 catalysts are used to prepare the gas for the last reactor, which is responsible for the production of ammonia. The latest reactor is called ammonia synthesis. Smart Catalyst Company, which previously produced sulfuric acid catalysts, is now one of the companies that has taken an important step in the technical knowledge of ammonia synthesis catalyst production and has achieved this important production.

Magnetite-based iron catalysts with enhancers are commonly used. It has two types: structural (such as aluminum oxide, calcium oxide) and electronic (potassium oxide). Because it has a more active and suitable phase for ammonia synthesis. The main purpose of adding enhancers during the reaction is to improve catalytic activity, increase thermal resistance, help improve detoxification currents and increase the service life of catalysts. The activity of magnetite-based iron catalysts increases by only 2 to 3%, which makes the process more difficult. Some production units use non-ferrous catalysts, which is a good alternative to magnetite.

Magnetite type catalyst description
Catalyst Type SmartAM SmartAM-Lord
Particle shape Irregular granules Irregular granules
Appearance Black Black
Delivery Form 60 liter Steel drums 60 liter Steel drums
Particle size, mm 1.5-3, 3-6 ,6-12 1.5-3, 3-6 ,6-12
Surface Area, m2/g – 15
Bulk Density, kg/l 2.6 – 3.0 2.1 – 2.4
Attrition Loss, %

Method: ASTM D-4058

 < 2.5 < 4.0

Chemical Composition (Nominal, wt. %)
Fe, Fe Oxides – 94 ± 2
Fe Oxides 94 ± 2 –
Al2O3, CaO, K2O, SiO2 6 ± 2 8 ± 2

In 1986, studies on iron catalysts with the Wustite precursor concluded that due to the greater activity of this catalyst during reactions and its high regeneration rate, it could be used to synthesize ammonia. Initially, it was produced under the brand name A301, but due to instability in its activities, researchers had to improve its formulation. Wustite iron catalyst is the most active type of molten iron catalyst for ammonia synthesis process. The most important additives of ferrous catalysts include Al2O3, K2O, CaO, etc.

Wustite type catalyst description
Catalyst Type SmartAW SmartAW-Lord
Particle shape Granules Granules
Appearance Black Black
Delivery Form 100 liter Steel drums 100 liter Steel drums
Particle size, mm 1.5-3, 3-6 ,6-12 1.5-3, 3-6 ,6-12
Bulk Density, kg/l 2.8 – 3.2 2.4 – 2.6

Wustite type catalyst Composition (wt %)
Fe, Fe Oxides – 83 Min
Fe Oxides 69 Min –
Al2O3, CaO, K2O, SiO2 6 ± 2 8 ± 2

Catalytic properties of ammonia synthesis

  • High activity
  • Long life
  • Abrasion resistant
  • High mechanical strength
  • Minimal sensitivity to catalytic toxins
Ammonia synthesis catalyst

Use of SMART CATALYST in the production of ammonia synthesis catalyst

  • Production of ammonia synthesis catalysts based on magnetite and wustite on industrial scales
  • Perform all relevant tests and trials
  • Performing reactor tests
  • Accurate determination of the activity of ammonia synthesis catalysts
  • Provide advice to ammonia units in order to select or replace the appropriate catalyst with their working conditions
  • Update old ammonia units by performing corrective methods (catalyst, reactor and synthesis cycle)

Petrochemical Research and Technology Company is the highest reference in the field of testing, development and creation of technical knowledge of various petrochemical catalysts in Iran. Ammonia synthesis catalyst products in Smart Catalyst Company with the cooperation of the expert team of Petrochemical Research and Technology Company will be examined and after confirmation of physical, chemical and reactor specifications will be sent to the relevant petrochemicals. Ammonia synthesis catalyst samples produced by Smart Catalyst Company are produced by numerous reactor tests at temperatures above 2000°C,  and  by determining  their physical  characteristics. Ammonia synthesis catalyst manufactured by Smart Catalyst Company includes 4 types of ammonia catalysts: magnetite, reduced magnetite, and wustite and reduced wustite. In the following, we examine ferrous and non-ferrous catalysts.

Ammonia synthesis catalyst

The first ammonia synthesis catalyst was discovered in 1909 and has been used in various industries for over 100 years. The synthesis of ammonia from nitrogen and hydrogen has several stages, the most difficult of which is the N2 separation step, because there is a lot of energy in this bond. Ammonia synthesis catalyst has a direct effect at this stage. The role of this catalyst is remarkable, which is also called the heart of ammonia units. The synthesis catalyst also has a direct effect on the operating pressure and temperature, the percentage of purity of the consumed gas, the amount of ammonia production and the energy required to produce the synthesis gas. For this reason, its performance leads to the economy of the whole production process.

Catalysts used in ammonia industrial production unit

Increased activity and catalytic reactions at low temperatures increase the conversion rate. As a result, the development of active catalysts at low temperatures is very important. Ammonia units use 8 types of catalysts that can be divided into two different parts.

  • Protective catalyst: includes cobalt hydrogenation catalyst, zinc oxide, methanation and high temperature shift catalyst
  • Economic catalyst: includes primary and secondary reforming catalysts, low temperature shift and ammonia synthesis

Economic catalysts show the percentage of returns and have a direct impact on economic profits in production.

Types of ferrous and non-ferrous catalysts for ammonia synthesis:

Iron-based catalysts include:

  • Cobalt-containing iron catalyst
  • Magnetite-based iron catalyst
  • Wustite-based iron catalyst, which has the highest activity among iron catalysts for ammonia synthesis.

Non-ferrous catalysts include:

  • Ruthenium-based catalysts (graphite carbon)
  • Cobalt-molybdenum nitride catalyst
Converters in the process of ammonia synthesis

Uses of ammonia

More than half of world ammonia production is used to make chemical fertilizers. But ammonia is also used in the following sections.

  • Industrial sectors
  • Ice factories
  • Production of sulfate, ammonium phosphate, nitric acid and urea
  • Nitrogenous compounds
  • Synthetic fibers
  • Nitro paraffin
  • Plastic and fiber
  • Pharmacy to make sulfonamides and B vitamins
  • Paper
  • Mining and metallurgy to extract zinc and nickel
  • Cleaning

Ammonia synthesis companies

The process of ammonia synthesis was performed for the first time in the world by BASF company. Over time, this technology became pervasive. Currently, many companies in the world, such as Kellogg, Haldor Topsoe, Cassale, etc., use this process. The main material in the ammonia unit is natural gas (methane). In our country, Iran, despite the large gas resources, the annual production is estimated at more than 4 million tons. The process of producing ammonia economically depends on the catalyst for ammonia synthesis. In most ammonia production units in Iran, to increase efficiency, the reactor has changed the ammonia synthesis, during which the inlet gas flow changes from axial  to  radial  or  intersection  and  reaches  a conversion rate of 15%. Also, new types of non-ferrous catalysts should be used for this method. The use of non-ferrous catalysts in ammonia synthesis is the main factor in reducing the pressure from 130 to 90 bar.

Companies in the industry around the world use catalysts based on magnetite, Wustite and ruthenium to synthesize ammonia.

Comparison of ferrous and non-ferrous catalysts
Advantages of Wustite Catalyst over Magnetite Catalyst Ruthenium catalyst
  • High activity
  • Activation at low temperatures
  • Speed regenaration
  • Heat resistant
  • Return to the original state in case of poisoning with oxygenated compounds
  • High mechanical strength
  • Reduce energy consumption and construction costs
  • Reduce water and hydrogen consumption
 Advantages:
Optimization of temperature and pressure operating conditions
Increase conversion percentage
Disadvantages:
Carbon base (carbon is methanized in ammonia synthesis operations)
More expensive than ferrous catalysts

FAQ

The process by which ammonia is formed from nitrogen and hydrogen on a catalyst (usually iron) is called the ammonia synthesis process.

In a chemical process called the Haber-Bosch method, magnetite is used as a source of iron in catalysts because it has a high surface area and increases the reaction between nitrogen and hydrogen to form ammonia. This method was first developed by Nobel Prize winners Haber and Bosch, and is most widely used today for large- scale ammonia production.

Catalyst reduction is required to convert hydrogen and nitrogen gases in the ammonia synthesis reactor, a process that takes between 4 and 7 days. To avoid environmental problems, high process costs and energy loss, regenerative catalysts are usually used in the first stage (in some units in all stages), which speeds up the production process. The process of reducing the ammonia synthesis catalyst is possible at the catalyst plant, but this process is expensive and involves several steps of reduction and passivation. In addition, instead of regenerated magnetite layer, wustite catalyst can be used in the first stage, but it needs to be reviewed by the smart catalyst process teams.

Due to the fact that wustite catalyst has a higher efficiency output under the same conditions than magnetite catalyst, as a result, the outlet temperatures of the beds are higher and the need for catalytic bed design and changes in reactor and flow rates and reactor pressure is required. Another method is to place the reactor at a lower operating pressure than the magnetite catalyst, which causes changes in the flow rate according to the condition and type of reactor, resulting in a reduction in pressure that drastically reduces energy costs and Conditions become operational.

Typically, the life of these catalysts is between 15 and 20 years.

Ammonia gas is flammable, so avoid exposing it to petroleum and incendiary materials. Contact with liquid ammonia also causes skin burns. In case of accident, be sure to wash the contact area with soap and water.

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