Tock2015 Thermo-Environomic Evaluation of The Ammonia Production
Tock2015 Thermo-Environomic Evaluation of The Ammonia Production
Within the global challenge of sustainable energy supply and greenhouse gas emissions mitigation, carbon capture and storage and the deployment
of renewable resources are considered as promising solutions. In this study the production of ammonia mainly used in the fertilizer industry and that
is responsible for around 2–3 % of the world greenhouse gas emissions is analyzed. Considering natural gas and biomass as a resource and the option
of CO2 capture and storage, different process configurations are systematically compared with regard to energy, economic and environmental
considerations. A consistent thermo-environonomic optimization approach combining flowsheeting, process integration techniques, economic
performance evaluation, life cycle assessment and multi-objective optimization is applied for the conceptual process design and competitiveness
evaluation. It is highlighted that the quality of the process integration is a key factor for improving the performance by valorizing the heat excess
through electricity cogeneration. Including CO2 mitigation in the ammonia production allows to reduce the emissions but leads to a slight efficiency
decrease due to the energy consumption for the CO2 compression. For the natural gas fed process yielding an energy efficiency around 65 %, the
overall life cycle emissions can be reduced to 0.79 kgCO2/kgNH3 with CO2 capture compared to 1.6 kgCO2/kgNH3 without capture. Considering the
biogenic nature of the carbon in the biomass, the emissions drop to 1.79 kgCO2/kgNH3 for the biomass process having an energy efficiency of 50 %.
The economic competitiveness highly depends on the resource price and the introduction of a carbon tax. This study reveals the potential of the
decarbonization of the fertilizer industry.
I
n the chemical industry ammonia is a fundamental compound analyze the production of ammonia from fossil and renewable
required for the production of nitrogen-based fertilizers. resources by assessing the potential of CO2 mitigation with
Approximately 157 Mt of ammonia have been consumed in regard to the energy efficiency, the costs and the environmental
2010.[9] More than 90 % of the world’s ammonia consumption is impacts.
manufactured from nitrogen and hydrogen by the catalytic Haber-
Bosch process.[2] The H2 is essentially produced from natural gas THERMO-ENVIRONOMIC OPTIMIZATION METHODOLOGY
by steam reforming and the N2 from air. The large energy
requirement (28–33 GJ/tNH3) and the high CO2 emissions The systematic methodology that is applied follows the one
(1.6 tCO2/tNH3) for the ammonia production[10] are mainly due proposed by Gassner et al.,[6] Gerber et al.[7] and Tock et al.[18]
to the energy and carbon intensive reforming process. combining flowsheeting, energy integration techniques, life cycle
The depletion of fossil fuels and the increase of greenhouse gas assessment (LCA) and economic performance evaluation in a multi-
emissions contributing to the climate change have raised the need objective optimization framework. The main steps are illustrated in
to limit the carbon emissions and to deploy the usage of renewable Figure 1. First candidate technologies are identified and summar-
resources in energy and carbon intensive processes, ammonia ized in a superstructure. Then thermo-environomic models are
production inclusive. Fossil fuel could be substituted by biofuels developed for each unit operation option based on literature data in
whose life cycle emissions will be affected by the use of fertilizers order to compute the chemical and physical transformations and to
for the energy crops. It is therefore important to study the identify the process heat transfer requirements. The models are
decarbonization of the ammonia production. For the ammonia developed in the flowsheeting software Belsim Vali[4] applying a
production, fuel decarbonization by CO2 capture and storage simultaneous resolution method. Based on the simulation results,
(CCS), and the usage of renewable resources, such as biomass, can the energy-integration model optimizes the heat recovery and the
be considered as promising solutions. Several authors have combined fuel, heat and power production by using the heat
already assessed the performance of the ammonia production cascade constraints and a linear programming model minimizing
from biomass in terms of efficiency and life cycle emis- the operating cost.[12] Applying pinch analysis, the optimal process
sions.[1,3,8,16] Potentials for energy efficiency improvements in integration is computed and the process needs are satisfied by
existing plants have been investigated in Panjeshahi et al.,[15] different hot utilities including waste and process gas combustion,
Rafiqul et al.,[16] and Wang et al.[22] Applying pinch analysis and Rankine cycle, gas turbine and cogeneration, and cold utilities
exergy analysis, power savings of 15 % through optimization of
the refrigeration system were revealed in Panjeshahi et al.[15]
However, no consistent optimization with regard to multiple *Author to whom correspondence may be addressed.
criteria, combining energy integration techniques with life cycle E-mail address: laurence.tock@epfl.ch
assessment (LCA) and economic evaluation have been performed Can. J. Chem. Eng. 93:356–362, 2015
so far to assess the potential benefit of CO2 capture and storage in © 2014 Canadian Society for Chemical Engineering
DOI 10.1002/cjce.22126
ammonia production processes and compare different resources Published online in Wiley Online Library
and technologies in a systematic manner. (wileyonlinelibrary.com).
356 THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING VOLUME 93, FEBRUARY 2015
Table 1. Economic assumptions
_
Dh0NH3 m PROCESS DESCRIPTION
etot ¼ þ E_ Dh0feed m
_þ _þ
feed þ E ð1Þ
NH3 Ammonia is primarily produced from hydrogen and nitrogen.
The major process steps are N2 and H2 generation, methanation,
The specific energy consumption of the ammonia production ammonia synthesis and purification. The process layout is
(E_ ton [GJ/t]) is computed by Equation (2). illustrated in Figure 2 and the key operating conditions are
reported in Table 2. H2 can be produced from several fossil and
_ renewable resources. Here the conventional natural gas reform-
Dh0feed m_þ
feed þ DE
E_ ton ¼ ð2Þ ing process is compared with the emerging biomass (i.e., wood)
m_ NH3 gasification process.
VOLUME 93, FEBRUARY 2015 THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING 357
Table 2. Operating conditions of the process units and feasible range shift reaction, the gas consists mainly of H2 and CO2. The CO2 is first
for optimization removed by chemical absorption with amines (i.e., MEA) or by
physical absorption (i.e., Selexol or Rectisol). The H2 is further purified
Parameter Nominal Range
by pressure swing adsorption (PSA). In the carbon capture config-
Methanation [K] 530 523–873 urations, the CO2 flow is compressed to 11 MPa for transport and long
PMethanation [MPa] 3 2.5–3.5 term storage in geological formations. The H2 production model is
Tcondensation [K] 275 250–330 described in more detail in Tock et al.[17] The heat requirement of the
Pcondensation [MPa] 0.8 0.1–2 endothermic steam methane reforming is satisfied by heat recovery
Pcompression, 1 [MPa] 0.8 0.1–2 and by the combustion of waste process gases and if needed of natural
Pcompression, 2 [MPa] 9 6–16 gas to close the energy balance. With SMR, the H2 production process
Pcompression, 3 ¼ Psynthesis [MPa] 28 15–30
with CO2 capture reaches an energy efficiency around 80 % according
H2/N2 ratio [] 3 1.5–4.5
to the preliminary study made by Tock et al.[17]
Treactants [K] 313 300–373
Purge [%] 10 5–30 H2 from biomass
Split [%] 10 5–20
Tquench [K] 393 350–450
In this configuration, the hydrogen is produced by thermochem-
Tsynthesis [K] 723 550–800 ical gasification of wood. The considered wood has an humidity of
Tflash1 [K] 295 273–500 50x2009;% and the following dry weight composition: 51.1 % C,
Pflash1 [MPa] 28 2–30 43 % O, 5.7 % H and 0.2 % N. The major process steps are wood
Tflash2 [K] 377 300–450 drying, indirectly heated fast internal fluidized bed gasification
Pflash2 [MPa] 10 5–16 (FICFB) with steam oxidant, gas cleaning, gas treatment by
Tflash3 [K] 368 300–450 reforming and water gas shift followed by H2 separation and
Pflash3 [MPa] 6 2–20 purification. The gasification takes place at around 0.1 MPa and
Trecup.1 [K] 400 300–500 1000 K. The gas treatment and purification technologies are the
Precup.1 [MPa] 2 1–10 same as in the natural gas fed process. The high temperature heat
Trecup.2 [K] 264 250–350 required for the gasification and the reforming is satisfied by the
Precup.2 [MPa] 1.5 1–10
combustion of process off gas and if necessary by burning part of
TNH3 [K] 293 283–313
the process syngas. The removed CO2 can optionally be com-
PNH3 [MPa] 1 0.1–1.5
pressed to 11 MPa for subsequent transport and sequestration. In
this case, the captured carbon comes from the biogenic CO2
H2 and N2 Production assimilated in the biomass by photosynthesis and can conse-
quently lead to a low, zero or even negative CO2 balance. This
H2 from natural gas process has been previously modelled and studied in Tock
et al.[17,19] reporting an overall efficiency up to 60 % for the H2
Large scale H2 plants typically use natural gas as a feedstock. The
production process with CO2 capture and when including the life
process steps include desulphurization, steam methane reforming
cycle emissions a global warming potential (GWP) in the order of
SMR (Equation (3)), water gas shift WGS (Equation (4)) and H2
90 kgCO2,eq/GJH2.
purification.
N2 generation
0
CH4 þ H2 Ofi CO þ 3H2 D hr ¼ 206kJ=mol ð3Þ Nitrogen is extracted from air in an air separation unit. The energy
0 consumption and the equipment costs for the N2 generation are
CO þ H2 Ofi CO2 þ H2 D hr ¼ 41kJ=mol ð4Þ estimated on the basis of a pressure swing absorption unit and
included in the performance evaluation. For the power con-
In the reforming step, methane (CH4) is reacted with water (steam to sumption the data are taken from MVS Engineering[14] while the
carbon ration of 2.5–3) to produce H2 and CO. The endothermic costs are estimated on the basis of cost correlations.[20,21]
reforming is typically operated at 1–4 MPa and around 1173 K in the
presence of a Nickel catalyst. The H2 concentration is then increased by Ammonia Synthesis
two shift reaction steps, one operating at high temperature (HTS: 523– Ammonia is typically produced by the catalytic reaction
683 K) and the other at low temperature (LTS: 423–523 K). After the Equation (5) (Fe-catalyst) between H2 and N2 at elevated
358 THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING VOLUME 93, FEBRUARY 2015
temperature (130–230 K) and pressures above 10 MPa.[2] Since this Table 3. Ammonia production performance results
Haber-Bosch reaction has a low conversion efficiency of around
Parameter Natural gas Biomass
20–30 %, the unconverted part of the reactants is recycled and
mixed with fresh gas in the synthesis loop. The produced ammonia Production [t NH3/d] 916 1187
is separated from the non-converted gas by cooling and con- etot [%] 65.6 50.6
densation and is further purified at high pressure. In order to avoid Eton[GJ/tNH3] 28.3 36.6
þ
the accumulation of inerts in the loop that would decrease the E_ consumption [GJe/tNH3] 5.7 9.9
overall conversion, a purge stream is taken out of the cycle after NH3 E_ production [GJe/tNH3] 1.5 0.97
condensation. This purge corresponds to about 10–15 % of the CO2 capture rate [%] 67 74
recycled gas stream. The purge is scrubbed with water to recover CO2 emissions [tCO2/tNH3] 0.43 0
NH3 and is then sent either to a burner or a H2 recovery system. The Total costs [$/tNH3] 650 968
synthesis reaction (Equation (5)) being exothermic, the process
excess heat can be valorized by high pressure steam production for
electricity cogeneration allowing to satisfy part of the compression Since the process temperature can drop below ambient conditions
requirements and in certain cases to export steam or electricity. during the purification step, a refrigeration cycle using ammonia
as refrigerant has been included to satisfy the cooling utility.
0
3H2 þ N 2 fi 2NH3 D hr ¼ 92:2kJ=mol ð5Þ
PROCESS PERFORMANCE COMPARISON
The residues of CO and CO2 in the H2-rich fuel, being poisonous The performance of two different ammonia production process
for the Haber-Bosch reaction catalyst, a methanation step is configurations using natural gas or biomass as a resource and
included before the ammonia synthesis itself. The methanation capturing CO2 are compared. The plant scales correspond to
(Equation (6)) and the reverse WGS (Equation (4)) take place at 255 MWth of natural gas and 380 MWth of biomass respectively.
around 530 K and 3 MPa in a reactor filled with a Ni-catalyst. At the These optimized configurations reported in Table 3 result from
reactor outlet, the carbon oxides concentration is below 5 ppm and sensitivity analyses and multi-objective optimizations of the
the produced water is removed by condensation. operating conditions with regard to the two objectives: energy
efficiency maximization and costs minimization. The configu-
0
CO þ 3H2 fi CH4 þ H2 O D hr ¼ 206kJ=mol ð6Þ rations have been selected in the Pareto optimal set of solutions
and correspond to a capture rate around 70 %.
VOLUME 93, FEBRUARY 2015 THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING 359
Figure 6. Ammonia production performance results: Total cost build-up.
Economic Performance
The difference in terms of productivity results also in a difference
in the ammonia production costs (Figure 6). Even if the specific
360 THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING VOLUME 93, FEBRUARY 2015
A B
C D
Figure 9. Environmental performance of natural gas fed process: Impact 2002 method –4 endpoints: A) Climate change, B) Resources, C) Human health
and D) Ecosystem quality.
production costs of 72$/tNH3 for the ammonia production from show the impact of the fossil natural gas on the resources
biomass due to the economic profit of capturing biogenic CO2. As depletion compared to the renewable biomass resource, and the
the NH3 production from biomass leads to a negative carbon influence on climate change impact. Looking at the four different
balance the introduction of a carbon tax results in an income due to endpoints categories (Figure 9) the different contributions are
the avoided CO2 emissions. clearly revealed for the natural gas fed process. The extraction of
the natural gas and the electricity (UCTE mix) consumed by the
Environmental Impacts process are the major contributions. The biomass fed process has
a larger impact on the ecosystem due to the wood cultivation and
The advantage of using a renewable resource and of capturing
due to the contribution of the rape methyl ether (RME) used in
CO2 is clearly reflected by the environmental performance over
the syngas cleaning step. However, the overall environmental
the whole life cycle, from the resource extraction to the final
impact is beneficial compared to the natural gas fed ammonia
product, reported in Figures 7–9. In the natural gas fed ammonia
production due to the benefit of capturing biogenic CO2 and due
process with 67 % of CO2 capture, the global warming potential
to the lower impact on the fossil fuel depletion. When using
is reduced by 51 % from 1.6 kgCO2/kgNH3 without CO2 capture to
palm biodiesel instead of RME, the ecosystem impact could be
0.79 kgCO2/kgNH3 with CO2 capture and sequestration (Figure 7).
reduced by 35 %.
When biomass is used as a resource, the emitted CO2 which is
These results show that using biomass and capturing CO2 in the
biogenic does not contribute to the GWP and consequently the
ammonia production is a promising alternative for decarbonising
emissions of the ammonia production are only about 20 % of the
the fertilizer industry. However, a sustainable exploitation of the
reference case (0.3 kgCO2/kgNH3). If part of this biogenic CO2 is
biomass has to be ensured.
captured and stored, it will have a negative contribution to the
GWP and consequently will lead to a negative CO2 balance of
1.7 kgCO2/kgNH3. In addition to the climate change impact, the CONCLUSIONS
impact on the resources, ecosystem and human health are Within the objective of reducing the CO2 emissions from the
assessed by the Impact 2002 indicator (Figure 8 single score and fertilizer industry, different ammonia production process config-
Figure 9 endpoints). The results reported in Figure 8 clearly urations have been evaluated here in detail by taking into account
VOLUME 93, FEBRUARY 2015 THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING 361
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LCIA Life cycle impact assessment
[17] L. Tock, F. Maréchal, Int. J. Hydrogen Energy 2012, 37,
LTS Low temperature shift
11785.
MEA Monoethanolamine
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Roman Letters
[21] G. Ulrich, P. Vasudevan, A Guide to Chemical Engineering
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þ
E_ Electricity consumption, kW CRC Press, Boca Raton, USA 2003.
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P Pressure, Mpa
Greek Symbols Manuscript received January 27, 2014; revised manuscript received
D hr
0
Reaction enthalpy, kJ/mol June 30, 2014; accepted for publication July 7, 2014.
Dh0 Lower heating value, kJ/mol
etot Energy Efficiency, %
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362 THE CANADIAN JOURNAL OF CHEMICAL ENGINEERING VOLUME 93, FEBRUARY 2015