AMMONIA (NH₃): PROPERTIES, PRODUCTION PROCESSES, AND ENVIRONMENTAL IMPACT

Ammonia (NH₃) is a fundamental chemical with a wide array of applications across multiple industries. Its primary use is in the production of nitrogen-based fertilizers, which account for approximately 80-85% of global ammonia production. This industry is pivotal, with the global market for nitrogen fertilizers valued at over $70 billion, closely tied to worldwide agriculture and food production.

However, ammonia's applications extend beyond agriculture, playing vital roles in chemical manufacturing, refrigeration, and, more recently, as a potential hydrogen carrier in clean energy transitions.

PRODUCTION PROCESSES OF AMMONIA

1. HABER-BOSCH PROCESS

The Haber-Bosch process is the predominant method for producing ammonia, responsible for nearly all global ammonia production, totalling around 180 million tons annually. This process synthesizes ammonia by combining nitrogen (N₂) from the air with hydrogen (H₂) under high pressure (150-250 bar) and temperature (400-500°C) in the presence of an iron catalyst.

• Hydrogen Source: The hydrogen required is typically obtained from natural gas (methane) through steam methane reforming (SMR). SMR is an energy-intensive process that emits approximately 1.9 tonnes of CO₂ for every ton of ammonia produced.

• Energy Efficiency: The Haber-Bosch process is energy-intensive, with the energy input being about 28-35 GJ (9,722 kWh) per ton of ammonia produced, primarily derived from fossil fuels. 1,000 kg of ammonia contains approximately 176.5 kg of hydrogen. Producing grey hydrogen via steam methane reforming (SMR) typically requires about 8-12 kWh per kg of H₂.

• CO₂ Emissions: Traditional ammonia production emits roughly 400-500 million tons of CO₂ annually, accounting for about 1-2% of total global CO₂ emissions. The process emits approximately 9-10 kg of CO₂ per kg of H₂.

2. GREEN AMMONIA PRODUCTION

Green ammonia is an emerging alternative that addresses the environmental concerns of traditional production methods. Green ammonia is produced using hydrogen derived from water electrolysis powered by renewable energy sources such as wind, solar, or hydroelectric power.

• Hydrogen Source: The hydrogen is produced via electrolysis, a process where water (H₂O) is split into hydrogen and oxygen using electricity from renewable sources. This method is carbon-free if the electricity used is entirely renewable.

• Energy Efficiency: Although more sustainable, the energy required for electrolysis is higher, ranging from 50-55 kWh per kilogram of hydrogen produced when current electrolyser technology is used. However, this is offset by the absence of CO₂ emissions during hydrogen production.

• CO₂ Emissions: Green ammonia production is essentially carbon-neutral, emitting zero CO₂ if powered by renewable energy, making it a critical technology in reducing the carbon footprint of ammonia production.

KEY COMPARISONS BETWEEN AMMONIA AND GREEN AMMONIA

• Hydrogen Source: Traditional ammonia relies on hydrogen from natural gas, producing significant CO₂ emissions. In contrast, green ammonia uses hydrogen from renewable energy sources, leading to zero CO₂ emissions.

• Environmental Impact: Traditional ammonia production is a major contributor to global CO₂ emissions, while green ammonia represents a sustainable solution with a drastically reduced environmental impact.

• Energy Source: Traditional ammonia production relies heavily on fossil fuels, while green ammonia leverages renewable energy, aligning with global sustainability efforts.

GREY V GREEN HYDROGEN AMMONIA – CONSUMPTION & EMISSIONS

Energy Requirements

To determine the energy used in producing 1,000 kg of ammonia (NH₃) when green hydrogen is used instead of grey hydrogen, we calculate the consumption in the following way.

Step 1: Hydrogen Requirement for Ammonia Production

• Ammonia (NH₃) has a molecular weight of 17 g/mol.

• Of this, hydrogen contributes 3 g, which is 17.65% by weight.

For 1,000 kg of ammonia:

Hydrogen required = 1,000 kg × 0.1765 = 176.5 kg of H₂

Step 2: Energy Required to Produce Green Hydrogen (HFI)

Producing green hydrogen via electrolysis typically requires about 50-55 kWh per kg of H₂. The HFI hydrogen production system requires significantly less energy at approximately 40 kWh/kg, and this is what we will use for this calculation.

Energy for 176.5 kg of H₂= 176.5 kg × 40 kWh/kg = 7,060 kWh

Step 3: Grey Hydrogen Energy Consumption (Baseline)

Producing grey hydrogen via steam methane reforming (SMR) typically requires about 8-12 kWh per kg of H₂.

Energy for 176.5 kg of H₂ = 176.5 kg × 12 kWh/kg = 2,118 kWh

Step 4: Difference Between Green (HFI) and Grey Hydrogen

The additional energy required when using green hydrogen instead of grey hydrogen:

ΔEnergy = 7,060 kWh – 2,118 kWh = 4,942 kWh

When using green hydrogen instead of grey hydrogen, producing 1,000 kg of ammoniarequires approximately 4,942 kWh more energy.

CO₂ EMISSIONS

Emissions for Grey Hydrogen Based Ammonia

Grey hydrogen is typically produced via steam methane reforming (SMR). The process emits approximately 9-10 kg of CO₂ per kg of H₂.

Using an average of 9.5 kg of CO₂ per kg of H₂:

= 176.5 kg of H₂ × 9.5 kg CO₂/kg H₂

CO₂ emissions = 1,676 kg of CO₂

CO₂ Emissions for Green Hydrogen

Green hydrogen is produced using renewable energy (via electrolysis). It is carbon-free, so:

CO₂ emissions from green H₂ production = 0 kg CO₂.

Additional CO₂ Emissions in Ammonia Production

The production of ammonia involves additional steps, but the CO₂ emissions difference primarily arises from the hydrogen source.

Assuming no significant differences in downstream emissions:

CO₂ emissions difference = 1,676 kg CO₂

The difference in CO₂ emissions between green ammonia and grey ammonia for 1,000 kg of ammonia is approximately 1,676 kg of CO₂, with green ammonia being the carbon-free option.

So, while considerably more energy is required to produce ammonia cleanly the reduction in emissions is very significant. You pay your money, and you make your choice.

AMMONIA AS A HYDROGEN CARRIER

Ammonia is increasingly recognised as an efficient hydrogen carrier due to its high hydrogen content (17.8% by weight). It can be liquefied at relatively low pressures (8-10 bar), making it easier and more cost-effective to store and transport compared to liquid hydrogen, which requires cryogenic temperatures.

• Pros:
• Storage Efficiency: Ammonia's high hydrogen content allows for more hydrogen to be stored in a given volume.

• Infrastructure Utilisation: Existing ammonia production and distribution infrastructure can be repurposed for hydrogen, reducing the need for new investments.

• Cons:
• Toxicity and Safety: Ammonia is highly toxic and corrosive, necessitating stringent safety measures during storage and transportation, increasing costs.

• Energy-Intensive Cracking: The process of releasing hydrogen from ammonia (cracking) requires significant energy input, reducing the overall energy efficiency.

• NOx Emissions: The combustion or cracking of ammonia can produce nitrogen oxides (NOx), which are harmful pollutants that contribute to smog and acid rain.

HYDROGEN EXTRACTION FROM AMMONIA

The extraction of hydrogen from ammonia is a critical step in using ammonia as a hydrogen carrier. Here are the main methods:

THERMAL CRACKING (DECOMPOSITION)

• Process: Ammonia is thermally decomposed at high temperatures (850-900°C) to produce hydrogen and nitrogen.

• Efficiency: The energy input is about 30-40% of the energy content of the hydrogen produced.

• CO₂ Emissions: Although no direct CO₂ emissions are produced, the energy required may involve fossil fuels, indirectly contributing to emissions.

CATALYTIC CRACKING

• Process: This method uses a catalyst to lower the decomposition temperature to 500-700°C, increasing efficiency.

• Efficiency: The energy requirement is lower, about 15-20% of the hydrogen's energy content.

• CO₂ Emissions: Like thermal cracking, emissions depend on the energy source used.

ELECTROCHEMICAL AMMONIA SPLITTING

• Process: An electrochemical cell splits ammonia into hydrogen and nitrogen at lower temperatures, potentially using renewable energy.

• Advantages: This method can integrate with renewable energy sources, reducing carbon emissions.

• Challenges: The need for specialized materials resistant to ammonia's corrosive nature.

PLASMA-ASSISTED AND PHOTOCATALYTIC DECOMPOSITION

• Emerging Technologies: These advanced methods use plasma or light energy to decompose ammonia at lower temperatures, potentially reducing energy consumption.

• CO₂ Emissions: If powered by renewable energy, these methods could be carbon-neutral, though they are still in the research phase and not commercially viable.

Ammonia is a vital chemical with significant industrial applications, but its traditional production methods are a major source of CO₂ emissions. Green ammonia and advanced hydrogen extraction technologies offer promising pathways to reduce the environmental impact of ammonia production. However, challenges remain, particularly in terms of energy efficiency, safety, and cost. Ongoing research and development are crucial to overcoming these challenges and realizing the full potential of ammonia as a sustainable hydrogen carrier.