Process Modeling and Simulation of Ammonia Production from Natural Gas: Control and Response Analysis

Abdulhalim Abubakar; Mahlon Kida Marvin; Sijan Devkota; Ahmad Royani; Ahmet Ozan Gezerman; Cemre Avsar; Ehime Irene Itamah; Issam Ferhoune

doi:10.56556/jtie.v2i1.417

Authors

Abdulhalim Abubakar Modibbo Adama University https://orcid.org/0000-0002-1304-3515
Mahlon Kida Marvin Department of Chemical Engineering, Faculty of Engineering, University of Maiduguri, Borno State, Nigeria
Sijan Devkota Department of Chemcal Engineering, Chungbuk National University, Cheongju, Chungbuk 28644, South Korea
Ahmad Royani Research Center for Metallurgy, National Research and Innovation Agency, Tangerang Selatan 15314, Indonesia https://orcid.org/0000-0003-1004-3293
Ahmet Ozan Gezerman Toros Agri-Industry, Research and Development Center, Mersin, Turkey
Cemre Avsar Toros Agri-Industry, Research and Development Center, Mersin, Turkey
Ehime Irene Itamah Department of Electrical and Electronics Engineering, Faculty of Engineering, Federal Polytechnic Daura, P.M.B 1049, Daura, Katsina State, Nigeria
Issam Ferhoune Department of Process Engineering, Faculty of Science and Applied Sciences, University of Oum El Bouaghi, ‘Larbi Ben M’hidi’, Algeria https://orcid.org/0000-0002-2932-3626

DOI:

https://doi.org/10.56556/jtie.v2i1.417

Keywords:

Ammonia Plant, Aspen Plus Simulation, Process Control, Natural gas, Sensitivity Analysis, Modeling and Simulation, Plant layout

Abstract

Optimal production of ammonia (NH₃) using natural gas is necessary in order to make it available for wide range of applications including the manufacture of fertilizers, fuel for transportation and during synthesis of some chemicals. Achieving this would require strategic implementation of a control scheme to simulated ammonia production, capable of ensuring adequate realization of production targets. The work involves ASPEN Plus modeling, simulation, sensitivity analysis and control of NH₃ production process. Steam/carbon ratio, conversion of CH₄, removal of carbon dioxide (CO₂) and carbon monoxide (CO), hydrogen/nitrogen ratio and heat exchanger and separator temperatures were identified as requiring control in units any of these specifically impacts. As a result, approximately 176 tons of NH₃ was realized daily based on the simulation results and can be scaled-up using a calculated factor equivalent to 1.1375 to 200 tons/day capacity, in this design. Sensitivity analysis resulting in control of certain unit parameters is effective in ensuring process safety, maximum yield of important end-products and reduction in the cost of operation