Modern ammonia plants produce more than 3000 tons per day in one production line. The following diagram shows the set-up of a Haber–Bosch plant:
Depending on its origin, the synthesis gas must first be freed from impurities such as hydrogen sulfide or organic sulphur compounds, which act as a catalyst poison. High concentrations of hydrogen sulfide, which occur in synthesis gas from carbonization coke, are removed in a wet cleaning stage such as the sulfosolvan process, while low concentrations are removed by adsorption on activated carbon. Organosulfur compounds are separated by pressure swing adsorption together with carbon dioxide after CO conversion.
To produce hydrogen by steam reforming, methane reacts with water vapor using a nickel oxide-alumina catalyst in the primary reformer to form carbon monoxide and hydrogen. The energy required for this, the enthalpy ΔH, is 206 kJ/mol.
The methane gas reacts in the primary reformer only partially. To increase the hydrogen yield and keep the content of inert components (i. e. methane) as low as possible, the remaining methane gas is converted in a second step with oxygen to hydrogen and carbon monoxide in the secondary reformer. The secondary reformer is supplied with air as the oxygen source. Also, the required nitrogen for the subsequent ammonia synthesis is added to the gas mixture.
In the third step, the carbon monoxide is oxidized to carbon dioxide, which is called CO conversion or water-gas shift reaction.
Carbon monoxide and carbon dioxide would form carbamates with ammonia, which would clog (as solids) pipelines and apparatus within a short time. In the following process step, the carbon dioxide must therefore be removed from the gas mixture. In contrast to carbon monoxide, carbon dioxide can easily be removed from the gas mixture by gas scrubbing with triethanolamine. The gas mixture then still contains methane and noble gases such as argon, which, however, behave inertly.
The gas mixture is then compressed to operating pressure by turbo compressors. The resulting compression heat is dissipated by heat exchangers; it is used to preheat raw gases.
The actual production of ammonia takes place in the ammonia reactor. The first reactors were bursting under high pressure because the atomic hydrogen in the carbonaceous steel partially recombined into methane and produced cracks in the steel. Bosch, therefore, developed tube reactors consisting of a pressure-bearing steel tube in which a low-carbon iron lining tube was inserted and filled with the catalyst. Hydrogen that diffused through the inner steel pipe escaped to the outside via thin holes in the outer steel jacket, the so-called Bosch holes. A disadvantage of the tubular reactors was the relatively high-pressure loss, which had to be applied again by compression. The development of hydrogen-resistant chromium-molybdenum steels made it possible to construct single-walled pipes.
Modern ammonia reactors are designed as multi-storey reactors with a low-pressure drop, in which the catalysts are distributed as fills over about ten storeys one above the other. The gas mixture flows through them one after the other from top to bottom. Cold gas is injected from the side for cooling. A disadvantage of this reactor type is the incomplete conversion of the cold gas mixture in the last catalyst bed.
Alternatively, the reaction mixture between the catalyst layers is cooled using heat exchangers, whereby the hydrogen-nitrogen mixture is preheated to the reaction temperature. Reactors of this type have three catalyst beds. In addition to good temperature control, this reactor type has the advantage of better conversion of the raw material gases compared to reactors with cold gas injection.
Uhde has developed and is using an ammonia converter with three radial flow catalyst beds and two internal heat exchangers instead of axial flow catalyst beds. This further reduces the pressure drop in the converter.
The reaction product is continuously removed for maximum yield. The gas mixture is cooled to 450 °C in a heat exchanger using water, freshly supplied gases, and other process streams. The ammonia also condenses and is separated in a pressure separator. Unreacted nitrogen and hydrogen are then compressed back to the process by a circulating gas compressor, supplemented with fresh gas, and fed to the reactor. In a subsequent distillation, the product ammonia is purified.