Ammonia Production plant: Recycle load optimization and effect on process energy consumption and product through-put

Commercial scale NH3 production began in the 20th century, peaking at 131,000,000 metric tons in 2010. The running challenge pertains to optimizing raw material use, energy consumption and environmental pollution as well as. Current industrial ammonia production processes have a 25% [3] feed conversion. The first challenge in this project is minimizing raw material wastage by finding optimal recycle load. Being a very energy intensive process the second challenge is energy efficiency. This study therefore aims at finding an optimal operating mode that looks at using recycle stream to model, simulate and study general plant performance. Operating variables are carefully monitored using Icon simulation software and the results obtained are further analyzed to reach the most economical and energy-efficient operation. By comparing current ammonia production technologies with this process model and simulation, a conclusion is drawn with regard to energy saving potentials and optimal raw material utilization in ammonia production. Included are an outline of the methodology to reach the objectives, the process model and simulation, data, discussion, conclusions and recommendations.