Process Simulation, Optimization and Techno-Economic Analysis of Ammonia Production from Natural Gas

Abstract

The increasing global demand for ammonia, primarily used as a key raw material in the production of fertilizers and other chemical compounds, necessitates efficient and costeffective production methods. This thesis aims to address this challenge by conducting a comprehensive study focused on process modelling, optimization, and cost analysis of ammonia production from natural gas. The first phase of the thesis involves process modelling, where a detailed investigation of the Haber-Bosch synthesis process is carried out. Various process parameters, such as temperature, pressure, and flow rates, are analysed using advanced simulation tools. A robust and accurate process flow diagram is developed using Aspen HYSYS, offering valuable insights into the complex kinetics and dynamics of ammonia synthesis. In the optimization phase, pinch analysis is carried out with the help of Aspen Energy Analyzer to enhance the efficiency and sustainability of the ammonia production process. Pinch analysis is used to determine the optimal operating conditions, maximizing ammonia yield while minimizing energy consumption, utilities required and greenhouse gas emissions. The final aspect of this thesis involves conducting a comprehensive cost analysis of ammonia production from natural gas. An economic evaluation is performed, taking into account various factors such as feedstock prices, energy costs, capital investments, and environmental compliance. This is done by activating Aspen Economic Analyzer in the HYSYS simulated model. The objective is to identify potential cost reduction strategies while ensuring the overall economic viability and competitiveness of ammonia production. The findings of this thesis contribute significantly to the field of ammonia production, providing valuable insights into process optimization and cost-efficient production methods. The developed process model and optimization strategies offer a reliable framework for industrial implementation, fostering sustainable ammonia production from natural gas. As the world seeks to address the challenges of population growth and food security, this research contributes to the global endeavour to achieve sustainable and responsible production of essential chemical commodities.