Work

Enhancing ammonia reactor efficiency: Numerical modeling and optimization with internal cooling exchanger

Year: 2025

Type: article

Abstract: A comprehensive thermodynamic analysis and multi-bed reactor modeling have been conducted for ammonia synthesis at the Shiraz Petrochemical Complex, integrating internal intermediate heat exchangers to enhance energy efficiency. The reactor was modeled using both one-dimensional (radial) and two-dimensional (coupled radial–axial) approaches. Numerical solutions were obtained via MATLAB and COMSOL Multiphysics by solving mass, energy, and momentum conservation equations. The model was validated against industrial data, demonstrating strong agreement. To enhance reactor performance, a Differential Evolution (DE) optimization algorithm was implemented. Optimal operating conditions were determined as an inlet temperature of 943.6 K, pressure of 99.17 bar, and feed flow rate of 292,437 kg/h. Under these conditions, the ammonia molar fraction reached 0.21 representing a 16.2% increase compared to current plant operation. These findings highlight the effectiveness of integrated modeling and optimization strategies for intensifying ammonia synthesis in industrial-scale reactors.

Source: Chemical Engineering and Processing - Process Intensification

DOI: 10.1016/j.cep.2025.110498

Authors: M.R. Ghorbanie, Z. Arab aboosadi, E. Dehghanfard

Institution: Islamic Azad University, Marvdasht

Language: English

Topic: Ammonia Synthesis and Nitrogen Reduction

Subfield: Catalysis

Field: Chemical Engineering

Domain: Physical Sciences

SDGs: Affordable and clean energy, Industry, innovation and infrastructure

Open Access status: hybrid

Estimated APC paid: $3,910