Optimal Design of Ammonia Synthesis Reactor for a Process Industry

Ammonia synthesis is a crucial section of ammonia and urea plant. Many industries are facing a challenge of efficient ammonia production every day. In this study, steady state one dimensional pseudo-homogeneous models of an axial flow industrial catalytic packed bed ammonia converter have been developed. The converter is a vertical two catalytic bed reactor with varying volumes of catalysts. Required industrial data for the design were collected from a real fertilizer industry in Bangladesh (RFIB) and the Halder Topsoe process was followed. Differential equations of the the developed mathematical model was solved using Runge-Kutta-Fehlberg (RKF45) method by Polymath solver software. For a 23.8% single-pass conversion total 22.5 (15+7.5) m catalyst bed required. Pressure vessel wall and head thickness were found…