Plant-wide modeling and techno-economic optimization of a low-pressure microwave-assisted ammonia synthesis process with adsorption separation

Ammonia production has traditionally been done by using the Haber-Bosch process, that operates at extremely high pressure (200-300 bar), has a large carbon footprint, and requires significant energy. For ammonia to be used as a hydrogen carrier, it is desired that it is produced by using modular technologies under benign conditions, yet the economics remain commercially viable. This paper investigates a novel technology for ammonia synthesis by using a microwave-assisted low-pressure reactor. Microwave reactors are compact and can be readily modularized and started/shutdown thus making them ideal to be integrated with the electric grid or with regional/local renewable-based electric generation facilities. For separation of unreacted reactants from the product ammonia, if the traditional condensation separation technology used in the high-pressure Haber-Bosch process is used, then the separation process needs to be operated under cryogenic condition thus adversely affecting the economics. A solid sorbent based separation technology is investigated in this paper. A kinetic model for the microwave-catalytic synthesis process is used. An isotherm model is developed for MgCl2-Si adsorbent and used for modeling the dynamic adsorption-desorption cycle. A plant-wide model with heat and mass integration is developed. An economic model is developed and used for economic optimization by using an equation-oriented approach. Since the adsorption-desorption process is dynamic, for techno-economic optimization, a reduced order model for the key performance measures of the adsorption-desorption process as a function of its input and decision variable is developed under cyclic steady-state conditions. For the optimized MW-assisted process, the levelized cost of ammonia is $772/mt as opposed to $808/mt for the conventional Haber-Bosch process for a hydrogen price of $2.07/kg. The MW-assisted process is found to be economically viable in the US market if the hydrogen price is below $4/kg.