Name of Fertilizer
Address Contact No
Company
Coromandel House,
Coromandel Sardar Patel Road, Tel: +91 40 27842034 Fax: 91 40 27844117 Website :
International Ltd. Secunderabad 500 003, www.coromandel.biz/
Telangana, India.
Priyadarshini Building,
Rashtriya Chemicals Tel:- 022-2552 2000/022-2552 2040 Website :
Eastern Express Highway
& Fertilizers Ltd. www.rcfltd.com
Sion, Mumbai-400 022
SPIC House
Southern
88 Mount Road Guindy Tel+91.44.22350245 E-mail spiccorp@spic.co.in
Petrochemicals Ind.
Chennai 600032 Website : www.spic.co.in
Ltd
India
Because of its many uses, ammonia is one of the most highly produced inorganic chemicals.
There are numerous large-scale ammonia production plants worldwide, producing a total of
131 million tonnes of nitrogen (equivalent to 159 million tonnes of ammonia) in 2010.[1] China
produced 32.1% of the worldwide production, followed by India with 8.9%, Russia with 7.9%,
and the United States with 6.3%. 80% or more of the ammonia produced is used for fertilizing
agricultural crops. Ammonia is also used for the production of plastics, fibers, explosives, nitric
acid (via the Ostwald process) and intermediates for dyes and pharmaceuticals.
Contents
1 History
2 Modern ammonia-producing plants
3 Sustainable ammonia production
4 See also
5 References
6 External links
History
Before the start of World War I, most ammonia was obtained by the dry distillation of
nitrogenous vegetable and animal products; by the reduction of nitrous acid and nitrites with
hydrogen; and also by the decomposition of ammonium salts by alkaline hydroxides or by
quicklime, the salt most generally used being the chloride (sal-ammoniac).
Today, most ammonia is produced on a large scale by the Haber process with capacities of up to
3,300 metric tons per day. 1) Ammonia is manufactured on a large scale by Haber's process. 2)
In this process,N2 and H2 gases are allowed to react at high pressure of 200 bar (a).
A typical modern ammonia-producing plant first converts natural gas (i.e., methane) or LPG
(liquefied petroleum gases such as propane and butane) or petroleum naphtha into gaseous
hydrogen. The method for producing hydrogen from hydrocarbons is referred to as "Steam
Reforming".[2] The hydrogen is then combined with nitrogen to produce ammonia via the Haber-
Bosch process.
Starting with a natural gas feedstock, the processes used in producing the hydrogen are:
The first step in the process is to remove sulfur compounds from the feedstock because
sulfur deactivates the catalysts used in subsequent steps. Sulfur removal requires catalytic
hydrogenation to convert sulfur compounds in the feedstocks to gaseous hydrogen
sulfide:
H2 + RSH → RH + H2S(gas)
The gaseous hydrogen sulfide is then adsorbed and removed by passing it through beds of
zinc oxide where it is converted to solid zinc sulfide:
Catalytic steam reforming of the sulfur-free feedstock is then used to form hydrogen plus
carbon monoxide:
The next step then uses catalytic shift conversion to convert the carbon monoxide to
carbon dioxide and more hydrogen:
CO + H2O → CO2 + H2
The carbon dioxide is then removed either by absorption in aqueous ethanolamine
solutions or by adsorption in pressure swing adsorbers (PSA) using proprietary solid
adsorption media.
The final step in producing the hydrogen is to use catalytic methanation to remove any
small residual amounts of carbon monoxide or carbon dioxide from the hydrogen:
To produce the desired end-product ammonia, the hydrogen is then catalytically reacted with
nitrogen (derived from process air) to form anhydrous liquid ammonia. This step is known as the
ammonia synthesis loop (also referred to as the Haber-Bosch process):
3H2 + N2 → 2NH3
Due to the nature of the (typically multi-promoted magnetite) catalyst used in the ammonia
synthesis reaction, only very low levels of oxygen-containing (especially CO, CO2 and H2O)
compounds can be tolerated in the synthesis (hydrogen and nitrogen mixture) gas. Relatively
pure nitrogen can be obtained by Air separation, but additional oxygen removal may be required.
Because of relatively low single pass conversion rates (typically less than 20%), a large recycle
stream is required. This can lead to the accumulation of inerts in the loop gas.
The steam reforming, shift conversion, carbon dioxide removal and methanation steps each
operate at absolute pressures of about 25 to 35 bar, and the ammonia synthesis loop operates at
absolute pressures ranging from 60 to 180 bar depending upon which proprietary design is used.
There are many engineering and construction companies that offer proprietary designs for
ammonia synthesis plants. Haldor Topsoe of Denmark, Uhde GmbH of Germany, Ammonia
Casale of Switzerland and Kellogg Brown & Root of the United States are among the most
experienced companies in that field.
Ammonia production depends on plentiful supplies of energy, predominantly natural gas. Due to
ammonia's critical role in intensive agriculture and other processes, sustainable production is
desirable. This is possible by using renewable energy to generate hydrogen by electrolysis of
water. This would be straightforward in a hydrogen economy by diverting some hydrogen
production from fuel to feedstock use. For example, in 2002, Iceland produced 2,000 tons of
hydrogen gas by electrolysis, using excess electricity production from its hydroelectric plants,
primarily for the production of ammonia for fertilizer.[3] The Vemork hydroelectric plant in
Norway used its surplus electricity output to generate renewable ammonia from 1911 to 1971.[4]
In practice, natural gas will remain the major source of hydrogen for ammonia production as
long as it is cheapest.
As an alternative to the relatively inefficient electrolysis, hydrogen can be generated from
organic wastes (such as biomass or food-industry waste), using catalytic (thermal) reforming.
This releases hydrogen from carbonaceous substances at only 10-20% of energy used by
electrolysis and may lead to hydrogen being produced from municipal wastes at below zero cost
(allowing for the tipping fees and efficient catalytic reforming, such as cold-plasma). Catalytic
reforming is possible in small, distributed (even mobile) plants, to take advantage of stranded
biomass/biowastes or natural gas deposits. Conversion of such wastes into ammonia solves the
problem of hydrogen storage, as hydrogen can be released economically from ammonia on-
demand, without the need for high-pressure or cryogenic storage.
It is also easier to store ammonia on-board of vehicles than to store hydrogen, as ammonia is less
flammable than gasoline or LPG.
Waste water is often high in ammonia. Because discharging ammonia laden water into the
environment can cause problems, nitrification is often necessary to remove the ammonia. This
may be a potentially sustainable source of ammonia in the future because of its abundance and
the need to remove it from the water anyway.