Production of Ammonia on small scale

[ENGMechanical]

Friends, I’m with an idea for an ammonia plant. In this case, a small scale. That is, develop a factory since the beginning of ammonia in reduced scale. So my question is: Has anyone seen any case of ammonia production on a small scale? There is some inconvenience, trap or critical detail that will meet along the way? The equipments I believe that I can develop by myself. Tank’s for all.
EDY

 

[rmw]

How much do you know about ammonia being manufactured on a "large" scale?

And, what is your definition of a "small" scale?

For those operating 2000-2400 tpd ammonia plants, they might consider some of the older 1200 tpd plants 'small' scale.

rmw

 

[ENGMechanical]

I think as small scale about: 200/500 Kg per day. I know some large industries that manufacture about 60.000 tpd or more. If some one know more details about ammonia plants, please. This can be videos, links, books. thanks.

 

[mbt22]

ENGMechanical,

Assuming you know all about ammonia production on a large scale (safety, control, operability, metallurgy, equipment process and mechanical design and so on - in other words more than google and a couple of weeks reading), I'd suggest looking at the literature around process scale up. Most of the problems you'd encounter are effectively the reverse of what most of us try to do when developing a new process.

As a starting point, the obvious issues are:
Heat losses become more significant as equipment gets smaller
The process volume in pipework will be a significant fraction of the overall plant inventory.
Small scale equipment often isn't an exact analogue of the larger commercial equipment, is disproporionately expensive or simply not available.
Heat integration is much more difficult
Different technologies may be better - electrical heating may be better than steam for example.

There are a few companies out there that build this sort of plant for a living. As a wild guess, assuming a team experienced in small scale design, maybe a project cost in the high tens of millions of dollars for something like this.

Regards,

Matt

 

[dogtop]

For what's worth:

http://www.zeton.com/

http://www.epicmodular.com/index.html

HTH

 

[Oppau]

There are numerous things that you need to take into account for this type of project. First read up extensively on the Haber-Bosch process. Once you actually understand how NH3 is made decide what process is most feasible to implement. I have read about some smaller pilot plants that use electrolysis and PSA to get your H2/N2 however these are only viable at prices around $1200/ton. A more conventional primary and secondary steam methane reformer/ water shifts / amine / methanation / synloop might be more suited for your needs.

First I think you need to become more familiar with ammonia production though because when you believe you can make an ammonia converter on your own (that runs at more than 1500# of pressure) you make me believe you aren't aware of the process or problems associated with it.

If you want a good read on how the Haber-Bosch process was invented read The Alchemy of Air. It explains a lot of the challenges encountered when taking a table top setup that produced about half a cup of NH3 an hour to an industrial scale.