Instrumentation for safe and efficient ammonia cracking
Get real-time data to minimize risks and increase productivity
Introduction
Process instrumentation for ammonia cracking
Ammonia cracking is a process for converting ammonia back to hydrogen at scale. A key element of the ammonia cracking process is the ammonia cracker, which is a catalytic cracking furnace in which the ammonia synthesis reaction is reversed at elevated temperatures. The resulting cracked gas consists mainly of hydrogen and nitrogen. After a subsequent separation step, purified hydrogen is obtained. Process instrumentation is vital for ensuring safety and efficiency by providing accurate, real-time data on critical parameters such as temperature, pressure, flow and gas quality.
Prevent thermal stress
High temperatures can lead to equipment failure, compromising safety and efficiency. Choosing the right instrumentation and implementing regular inspection and maintenance is crucial to mitigate these risks.
High pressures can lead to sensor diaphragm fatigue, seal failures and potential leaks, jeopardizing process safety and reliability. Selecting pressure transmitters with appropriate pressure ranges, robust diaphragm materials and high-temperature seals is crucial.
By carefully monitoring feedstock quality, implementing preventative measures and planning for maintenance, you can minimize catalyst contamination and ensure efficient and reliable operation of the ammonia cracking process.
Multi-point temperature measurement for enhanced yield
Maintaining the reactor temperature within the optimal range (700-800°C) is essential for maximizing ammonia conversion and hydrogen yield. Temperature profiles along the catalyst bed can indicate catalyst deactivation zones or hotspots, which can lead to reduced efficiency or equipment damage. iTHERM TMS02 helps overcome these challenges by:
Facilitating inspection and maintenance by means of the diagnostic chamber.
Enhancing safety through a secondary process barrier.
Monitoring pressure in the diagnostic chamber allows for predictive maintenance.
Direct contact TC/RTD temperature profiling solution with 3D-bendable sensors with diagnostic chamber for oil, gas and petrochemical applications
Pressure
Robust pressure transmitter for highest reliability
Maintaining the reactor pressure within safe and optimal operating limits is essential to prevent equipment damage and ensure stable process conditions. Sudden pressure drops in specific sections of the process can indicate leaks, which can be hazardous due to the flammable nature of hydrogen and the toxicity of ammonia. Cerabar PMP71B pressure transmitter offers several benefits:
Long-term durability of diaphragm seals thanks to materials such as gold, tantalum and monel.
Higher reliability thanks to high temperature resistance.
Enhanced safety due to wireless access and control of the device in the process area.
Accurate gas analyzers for reliable catalyst operation
High-purity ammonia is crucial for optimal catalyst performance. Contaminants like sulfur compounds, carbon oxides and water vapor can poison the catalyst, reducing its activity and lifespan. TDLAS technology provides:
Integrated diagnostic and verification with Heartbeat Technology.
Trace concentration measurement of H2O, H2S and CO2.
Real-time measurement enables fast decision-making.
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