Making ammonia

Summary

The script details the global production of ammonia, approximately 140 million tons annually, highlighting its diverse applications in explosives, medicines, and fertilizers. The manufacturing process involves reacting natural gas, primarily methane, with steam to produce hydrogen, followed by secondary reactions with air to form ammonia. The process includes desulfurization, carbon dioxide removal for alternative uses, and the use of catalysts under high pressure and temperature. Ammonia is either stored or directly utilized by nearby chemical plants, emphasizing the interconnectedness of industrial operations.

Takeaways

• 🌍 Global Ammonia Production: About 140 million tons of ammonia is produced worldwide each year.
• 💥 Uses of Ammonia: It is utilized in the manufacturing of explosives, die making, medicine preparation, and fertilizer production.
• 🔁 Production Process: Ammonia is made by reacting natural gas, primarily methane, with steam to form hydrogen, followed by further reactions with air.
• 🌐 Gas Stream Treatment: Carbon dioxide is removed from the gas stream by dissolving it in alkali, and the remaining hydrogen and nitrogen are combined to produce ammonia.
• ♻️ Recycling Uncombined Gases: Uncombined gases are recycled back to the converter for further processing.
• 📍 Plant Location: The plant is situated near other chemical plants for convenient use of the produced ammonia.
• 🌊 Natural Gas Source: Natural gas, which is about 90% methane, is sourced from the North Sea and fed to the plant through a pipeline.
• 💨 Raw Materials: The main raw materials for ammonia production are water, air, and natural gas, with air being filtered and compressed.
• 🚫 Desulfurization: Natural gas contains sulfur compounds that are removed to prevent catalyst poisoning in the desulfurizer.
• 🔥 Reformer Reaction: Methane and steam react in the presence of a nickel-based catalyst to produce carbon monoxide and hydrogen, with further reactions forming carbon dioxide and more hydrogen.
• 🔬 Secondary Reformer: Heated air is added to convert any remaining methane into carbon dioxide, which is then removed to prevent catalyst poisoning.
• 🌡️ Converter Conditions: The ammonia converter operates at high pressure and temperature to convert nitrogen and hydrogen into ammonia using an iron-based catalyst.
• 🔄 Gas Stream Recycling: The gas stream containing ammonia, hydrogen, and nitrogen is cooled and compressed, with ammonia condensing out as a liquid and the remaining gases recycled.
• 🚀 Transportation: Ammonia can be transported as a liquid under pressure in tankers or piped directly to nearby plants.

Q & A

How much ammonia is produced worldwide annually?

Approximately 140 million tons of ammonia is produced per year worldwide.

What are some of the main uses of ammonia?

Ammonia is used in the manufacturing of explosives, in the die-making industry, in preparing medicines, and in the production of fertilizers.

What is the primary raw material used to make ammonia?

The primary raw material used to make ammonia is natural gas, which is mainly methane (CH4).

How is hydrogen produced in the ammonia production process?

Hydrogen is produced by reacting natural gas with steam in the primary reformer.

What happens in the secondary reformer during ammonia production?

In the secondary reformer, air is added to the gas stream, and any remaining methane is converted into carbon dioxide.

Why is carbon dioxide removed from the gas stream in ammonia production?

Carbon dioxide is removed because it would poison the catalyst used for the conversion of nitrogen and hydrogen to ammonia.

What is the role of alkali in the ammonia production process?

Alkali is used to dissolve and remove carbon dioxide from the gas stream in the converter.

What is the ratio of nitrogen to hydrogen in the gas stream fed to the ammonia converter?

The ratio of nitrogen to hydrogen in the gas stream fed to the ammonia converter is 3:1.

What is the operating pressure and temperature of the ammonia converter?

The ammonia converter operates at a pressure of 200 atmospheres and a temperature of about 400° C.

How is the produced ammonia separated from the gas stream?

The hot gas stream containing ammonia, hydrogen, and nitrogen is cooled to about -1° C and compressed, causing ammonia to condense out as a liquid.

What happens to the uncombined gases after ammonia production?

The uncombined gases are recycled back to the converter along with a fresh gas mixture.

How is the sulfur content in natural gas treated before it is used in ammonia production?

The sulfur compounds in natural gas are removed in a desulfurizer before the gas is piped to the primary reformer.

What is the final form of ammonia for transportation or use?

Ammonia can be transported in tankers as a liquid under pressure or piped directly to nearby plants for use.

Outlines

00:00

🌿 Ammonia Production Process Overview

This paragraph provides an overview of the global ammonia production, which stands at about 140 million tons annually. Ammonia is pivotal in the manufacturing of explosives, dies, medicines, and fertilizers. The production process begins with the reaction of natural gas, primarily methane, with steam in a primary reformer to generate hydrogen. Subsequently, air is introduced in the secondary reformer, where carbon dioxide is removed by alkali absorption in a converter. The remaining hydrogen and nitrogen are combined to produce ammonia. Uncombined gases are recycled, and the plant's location near other chemical plants facilitates the use of produced ammonia. The script also details the sourcing of raw materials like natural gas from the North Sea, water, and air, and the removal of sulfur compounds before the reforming process. The reforming reaction requires a nickel-based catalyst and produces carbon monoxide and hydrogen, with further reactions forming carbon dioxide and more hydrogen. The carbon dioxide is removed and utilized in other industries, while the hydrogen and nitrogen are fed into an ammonia converter at high pressure and temperature, using an ion-based catalyst to produce ammonia, which is then cooled and compressed into a liquid form for storage or transportation.

Keywords

💡Ammonia

Ammonia is a compound of nitrogen and hydrogen with the formula NH3. It is a key chemical used in the production of fertilizers, explosives, and various industrial chemicals. In the video, it is mentioned that about 140 million tons of ammonia are made per year worldwide, highlighting its importance in various industries.

💡Natural Gas

Natural gas is a fossil fuel consisting primarily of methane (CH4). It is used as a raw material in the production of ammonia, as described in the script where it is reacted with steam to form hydrogen in the primary reformer. The script also mentions that natural gas, which is about 90% methane, is piped from the North Sea to the plant.

💡Steam Reforming

Steam reforming is a process used to produce hydrogen by reacting natural gas with steam. In the context of the video, this process occurs in the primary reformer, where methane reacts with steam to produce carbon monoxide and hydrogen, which are essential for the subsequent production of ammonia.

💡Catalyst

A catalyst is a substance that increases the rate of a chemical reaction without being consumed in the process. In the video, a nickel-based catalyst is used in the reformer to facilitate the reaction between methane and steam. Additionally, an ion-based catalyst is used in the ammonia converter to convert nitrogen and hydrogen into ammonia.

💡Desulfurization

Desulfurization is the process of removing sulfur compounds from natural gas to prevent them from poisoning the catalysts used in the ammonia production process. The script mentions a desulfurizer where sulfur compounds are removed from the natural gas before it is fed to the primary reformer.

💡Secondary Reformer

The secondary reformer is a part of the ammonia production process where air is added to the stream of hydrogen and carbon oxides. This step converts any remaining methane into carbon dioxide, which is then removed to prevent poisoning the catalyst used for ammonia conversion.

💡Carbon Dioxide

Carbon dioxide (CO2) is a byproduct of the steam reforming process. In the video, it is mentioned that CO2 is removed from the gas stream and sold for making fizzy drinks and as a coolant in nuclear power stations, illustrating the multiple uses of byproducts in industry.

💡Alkali

An alkali is a substance that can dissolve carbon dioxide, which is used in the process described in the video to remove CO2 from the gas stream. This is part of the process to purify the gas mixture before it is used in the ammonia converter.

💡Ammonia Converter

The ammonia converter is the equipment where nitrogen and hydrogen are combined under high pressure and temperature to produce ammonia. The script describes the converter operating at 200 atmospheres and about 400° C, using an ion-based catalyst to facilitate the conversion reaction.

💡Recycling Uncombined Gases

In the ammonia production process, uncombined gases are recycled back to the converter to increase the efficiency of the process. The script mentions that the remaining nitrogen and hydrogen after the ammonia condensation are recycled with a fresh gas mixture to the converter.

💡Control Room

The control room is the central location where the operation of the ammonia plant is monitored and controlled. The script refers to the control room as the place where ammonia can be managed for transportation or direct piping to nearby plants, emphasizing the importance of centralized control in industrial processes.

Highlights

140 million tons of ammonia is produced worldwide annually.

Ammonia is used in manufacturing explosives, dies, medicines, and fertilizers.

Ammonia production starts with natural gas, primarily methane, reacting with steam to form hydrogen.

Air is added to the gas stream in the secondary reformer to convert remaining methane into carbon dioxide.

Carbon dioxide is removed by dissolving it in alkali and can be sold for other uses.

Hydrogen and nitrogen from the air are combined to produce ammonia.

Uncombined gases are recycled back to the converter.

The plant is located near other chemical plants for easy ammonia usage.

Natural gas, mainly methane, is sourced from the North Sea and piped to the plant.

Air, water, and natural gas are the raw materials for ammonia production.

Sulfur compounds in natural gas are removed in a desulfurizer before the primary reformer.

A nickel-based catalyst is used in the reformer, heated by natural gas burners.

The reformer reaction produces carbon monoxide and hydrogen.

Carbon dioxide is removed to prevent poisoning the catalyst used for ammonia conversion.

The ammonia converter operates at 200 atmospheres and 400°C to convert nitrogen and hydrogen to ammonia.

An ion-based catalyst is used in the conversion vessel for the reversible reaction.

About 15% of the hydrogen and nitrogen mixture is converted to ammonia.

Ammonia is cooled and compressed, condensing into a liquid for storage or transport.

The control room manages the ammonia production process.

Ammonia can be transported as a liquid under pressure or piped to nearby plants.

Transcripts

about 140 million tons of ammonia is

made per year worldwide it is used in

the manufacturer of explosives for die

making preparing medicines and in the

production of

fertilizer ammonia is made by first

reacting natural gas mainly methane CH4

with steam to form hydrogen in the

primary

reformer in the secondary reformer air

is added to the gas

stream the carbon dioxide is then

removed by dissolving it in

Alkali in the converter the remaining

hydrogen and nitrogen from the air are

combined to produce

ammonia the uncombined gases are

recycled to the

converter ammonia is either stored or

piped directly from the site

this plant is situated close to other

chemical plants where much of the

ammonia is

used this is the primary reformer and

this is the secondary

reformer carbon dioxide is absorbed from

the gas stream in these

towers nitrogen and hydrogen are

combined here in the

converter

natural gas which is about 90% methane

is piped from the North Sea and fed to

the plant through a

pipeline the other raw materials are

water and air air is drawn in from the

atmosphere it is filtered and compressed

here natural gas contains sulfur

compounds which are removed in this

desulfurizer

the sulfur-free gas is piped to the

primary reformer where it reacts with

the steam the reaction requires a

nickel-based catalyst and this is heated

by the natural gas burners in the

reformer the reaction in the reformer

produces

heat methane and steam react to produce

carbon monoxide and

hydrogen some carbon monoxide reacts

further with the steam to form carbon

dioxide and more

hydrogen the stream of hydrogen and

oxides of carbon passes to the secondary

reformer heated air is fed to the stream

of gas and this converts any remaining

methane into carbon

dioxide carbon dioxide would poison the

Catalyst used for conversion to ammonia

the carbon dioxide is removed and sold

for making fizzy drinks and as a coolant

in nuclear power

stations the gas stream with hydrogen

and nitrogen in the ratio 3:1 is fed to

the ammonia

converter the converter operates at a

pressure of 200 atmospheres and a

temperature of about 400° C to convert

nitrogen and hydrogen to

ammonia

the reaction is reversible and uses an

ion-based

Catalyst the conversion vessel contains

beds of this

Catalyst the mixture of hydrogen and

nitrogen in the ratio of 3:1 feeds in at

the

top about 15% of the mixture is

converted to

ammonia the hot gas stream containing

ammonia hydrogen and nitrogen is cooled

to about -1° C and compressed ammonia

condenses out as a

liquid the remaining nitrogen and

hydrogen are recycled back to the

converter with fresh gas mixture this is

the control room of the

plant ammonia can be transported in

tankers as a liquid under

pressure or piped to nearby

plants

for