Safe green ammonia production

Protecting people, environment and assets through reliable measurement

Transitioning to green ammonia and reducing its carbon footprint requires implementing safety procedures and technical solutions to minimize greenhouse gas emissions and gas leakages. A key challenge is over pressurization. Reactors and tanks operate under high pressures, and sudden changes can cause explosions or ruptures. Additionally, ammonia's flammable nature poses a risk of fire or explosion. Leaks expose workers and the environment to hazardous conditions due to ammonia's toxicity.

How to make green ammonia production safer

Process instrumentation plays a crucial role in increasing the safety of green ammonia production by providing reliable data on critical process parameters. Reliable measurement can increase safety by:

Identifying hotspots in the reactor and thus preventing localized overheating by monitoring and controlling multipoint temperature
Preventing overpressurization through monitoring
Detecting impurities in the ammonia stream which can pose safety hazards with TDLAS technology
Monitoring high pressure fluctuations in the ASU
Detecting leaks in the storage of green hydrogen

Applications

Air separation unit (ASU)

Air separation units separate air into its primary components, nitrogen and oxygen, and are crucial in providing industrial gases for chemical manufacturing. The process typically involves cryogenic distillation, which exploits the differences in boiling points of these gases at low temperatures. The ASU provides a source of nitrogen for the ammonia synthesis process. The obtained nitrogen is then combined with the green hydrogen produced through electrolysis in a reactor.

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To increase safety in the production of green ammonia with renewable resources, the measurement of key parameters is crucial. Parameters such as pressure, temperature and level are essential to minimize risk and implementing safety procedures. With Endress+Hauser instrumentation these parameters can be effectively monitored to ensure safety and performance in the ASU.

Monitoring pressure with our Cerabar PMP71B before the compressor ensures optimal intake conditions and protects the compressor from damage due to low or fluctuating pressure.
In each cooling stage, precise temperature measurements ensure efficient liquefaction and are crucial for cycle timing, regeneration and product quality. Our iTHERM TM131 temperature sensor is the right choice for these applications.
During separation the cooled air is cooled to extremely low temperatures (below -184°C). The multipoint thermometer iTHERM TMS02 ensures reliable temperature monitoring for an effective separation of nitrogen, oxygen, and argon.
Ensuring sufficient liquid for vaporization is crucial for stable operations. Our guided radar Levelflex FMP54 reliably monitors the liquid level in the reboiler thus also avoiding damage to the reboiler.

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Green hydrogen: the CO₂-free feed for ammonia production

Traditionally the majority of hydrogen used in ammonia synthesis comes from steam methane reforming (SMR) of natural gas. This process releases significant carbon dioxide emissions ("grey" hydrogen). Green hydrogen, produced through electrolysis of water using renewable energy sources, offers a clean alternative to replace fossil-fuel-derived hydrogen.

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Storing hydrogen presents unique challenges. It takes up a lot of space due to its low energy density, and requires either high pressures or extremely cold temperatures for storage, making it costly. Additionally, hydrogen is flammable and prone to leaks, demanding strict safety measures. Storing large quantities of green hydrogen also means some energy is inevitably lost over time.

Ensuring accurate pressure measurement is essential to prevent overpressures and extend the lifetime of the compressors. Our pressure transmitter Cerabar PMP71B measures accurately and reliably the hydrogen compression.
The temperature affects the efficiency of the compression. Our temperature sensor iTHERM Moduline TM131 can be used to monitor the compressor's efficiency.
Endress+Hauser is a 'ONE-STOP' supplier for your metering skids across the entire hydrogen value chain. To ensure reliable transactions and compliance with standards, our expertise in the field accompanies you throughout the project.

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Ammonia production (Haber-Bosch)

The Haber-Bosch process is a well-established industrial method for the production of ammonia (NH₃). The primary raw materials for the process are nitrogen and hydrogen. The N2 from the air separation unit is combined with the H2 and reacted via the Haber-Bosch process in an ammonia conversion reactor.

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Measurement instrumentation plays a crucial role in ensuring the safe and efficient operation of ammonia production processes. Here are some key aspects of how measurement instrumentation contributes to safe ammonia production:

Oxygen can be a real issue regarding catalyst poisoning. Even trace amounts of oxygen can cause irreversibly damage. With an oxygen analyzer like OXY5500 impurities in the feed gas can be monitored closely.
Multiple thermocouples such as iTHERM MultiSens Flex TMS01 are strategically placed throughout the catalyst bed to detect any abnormal temperature spikes or gradients.
A Raman Rxn5 process analyzer enables quantitative chemical composition measurements, helping you to monitor and control the ammonia concentration in the reactor loop, the catalyst performance and to optimize process.
Too much hydrogen creates a risk of explosion within the process loop. That's why getting the right stoichiometric ratio of hydrogen to nitrogen going into the reactor is essential. Our Coriolis flowmeter Promass F 300 is a fit for this application.
The reactor is a prime focus of overpressure protection due to the exothermic reaction and potential for runaway conditions. The smart pressure transmitter Cerabar PMP71B can help prevent overpressurization in the heart of the Haber-Bosch process.

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