Process Rationale for Process Description

Haber process Despite the negative associations of the process in the events of
World War II, Haber process is essentially considered to be one of the most
significant invention of the past 200 years. It allows for the continuous production of
crops to support an ever-increasing world population. Haber process solved the
problem of utilizing nitrogen from air. Since nitrogen from air is unreactive,
conversion into ammonium salts and nitrates has proved to be difficult.

1. Desulfurizer The first step in the manufacturing process is the

pretreatment of natural gas. It is important that all sulfurous compounds be
removed from the natural gas to prevent catalyst poisoning. The coated iron
complex catalyst is the key to the conversion of nitrogen to ammonia.
2. Primary Reformer the heat-exchanger type reformer is a type of energysaving technology in which exhaust heat emitted at the exit of the secondary
reformer is used as a heat source for the heat-absorbing reaction in the
primary reformer.
3. Secondary Reformer phase of manufacturing where the nitrogen needed
is introduced in the process. The secondary reformer allows the primary
reformer to be constructed as small as possible. It also minimize methane slip
since methane is an inert in the ammonia synthesis loop.
4. Shift Converter performance of the shift converter is significant for the
overall efficiency of the ammonia plant. Unconverted carbon monoxide will
consume hydrogen and form methane in the methanator, reducing the
feedstock efficiency and increasing the inert content in the synthesis loop.
5. Carbon Dioxide Removal This is done through water gas shift reaction.
The phase is necessary to avoid poisoning of the catalyst, specifically to
prevent the oxidation of the iron catalyst.
6. Methanation this step aids in the purification of the hydrogen gas
needed for ammonia synthesis as the COx produced in the overall steam
reforming process need to be separated from the hydrogen gas. For this
reason, it also prevents catalyst poisoning.
7. Carbon Dioxide Stripper recovered carbon dioxide from UCARSOL can be
made useful in the production of urea, another synthesis product from
ammonia.