Safe and fast ammonia synthesis catalyst reduction
Innovative method to measure water and ammonia

ActiSafE

Clariant has developed a safe, efficient and accurate method for measuring water vapor formation and ammonia concentration during ammonia synthesis catalyst activation.

ActiSafETM, the latest innovative technology provides advantages, such as continuous real-time measurements.

The real-time data allows plant operators to respond quickly to changes in water vapor formation and to optimize the reduction procedure. This not only saves time and avoids catalyst poisoning but also extends the lifespan of the catalyst leading to increased ammonia production.

AMMONIA CATALYST REDUCTION

 

Ammonia synthesis catalyst is delivered as iron oxide and the activation of the catalyst is performed by reduction of iron oxide to elementary iron with resultant production of water.

 

The amount of water vapor formed during the reduction has a direct impact on the catalyst activity unless controlled carefully.

Water is a natural poison for the synthesis catalyst.

 

The reduction does not produce nor consume heat in any noticeable amount; however, heat must be supplied to reach catalyst temperatures at which the catalyst is reduced.

MAIN BENEFITS

CONTINOUS REAL-TIME MEASUREMENTS

of water and ammonia

 

QUICK REACTION TIME

 

ENSURING HIGHEST POSSIBLE CATALYST ACTIVITY

and optimized operation conditions

 

DCS SYSTEM
CONNECTIVITY

 

FASTER AND SAFER
REDUCTION

 

ECONOMIC BENEFITS

FAST REDUCTION

Ensuring a fast reduction speed, hence a minimum one day production gain can be guaranteed.

One day additional ammonia production gain can generate a value of about 700,000 USD*.

HIGH CATALYST ACTIVITY

Ensuring a higher catalyst activity, hence higher rates of conversion than any other catalyst in its class, allowing

- capacity increase
(higher ammonia yield)

or

- lowering operating pressure
(energy savings of >5,000 kcal/MT)

*for a typical 2,000 MTPD Ammonia plant (assuming an ammonia price of 350 USD/MT)

HOW ACTISAFE WORKS

THE EVOLUTION OF MEASURING WATER AND AMMONIA

ActiSafE Non-Dispersive-Infrared-Technology (NDIR) can monitor in real-time and simultaneously water vapor formation and Ammonia concentration. 

The speed of reduction can be controlled and optimized to obtain higher catalyst activity, faster activation time, shorter time to production and thereby better plant profitability.

ActiSafE represents the latest technology for simultaneously measuring water vapor and ammonia formation during ammonia synthesis catalyst reduction by utilizing an NDIR (non-dispersive infrared) method.

ActiSafE only needs to be supplied with electricity and connected to the sample line of the converter. It is important that care should be taken to avoid undesired condensation in the sample line.

ActiSafE equipment consists of a single benchtop device, ensuring easys installation and use.

For optimum utilization, the device can be connected to the DCS via the analog interface, providing real time data in the control room.

  • Ammonia Catalysts

    Ammonia catalysts must enable more efficient ammonia synthesis today than ever before. With a growing demand on ammonia for the production of chemical fertilizers, and increasing volatility of feedstock prices and energy resources, ammonia producers need reliable solutions to succeed in this highly competitive market. Clariant’s ammonia catalysts are proven to increase efficiency and productivity while minimizing costs. They offer superior performance to maximize ammonia yields, and allow sustainable management of resources to reduce energy consumption in ammonia production. We offer a complete range of ammonia process catalysts, and support you with comprehensive technical services from plant design or upgrades to ensuring optimal catalyst performance. Clariant collaborates with renowned technology partners, such as KBR and Casale, to provide you with the ideal solution based on your specific requirements. more

  • AmoMax-Casale

    AmoMax®-Casale is a new ammonia synthesis catalyst jointly developed by Casale and Clariant particularly for use in Casale ammonia converters. AmoMax-Casale is a customized evolution of the well-known, wustite-based catalyst, AmoMax® 10. While retaining the same superior resistance to aging, poisoning, and mechanical strength, AmoMax-Casale is significantly more active. With an optimized promoter package, AmoMax-Casale provides a larger active surface area and improved diffusion properties, resulting in a 30 % higher efficiency index compared to the wustite-based reference. This allows to reduce the loop recycle rate and the loop pressure and/or to increase the ammonia production. By optimizing the plant’s overall efficiency, the customers can generate higher profitability by either benefiting from energy savings and reducing the CO2 footprint or monetizing its increased ammonia production. more

  • AmoMax 10

    AmoMax® 10 is a wustite-based ammonia synthesis catalysts with a unique promoter system that provides much higher activity and stability than magnetite-based catalysts. This improves conversion at low operating temperatures and at more thermodynamically favorable conditions, thus raising ammonia yields. Due to reduced loop recycles and loop pressure, it also saves energy and reduces CO2 emissions. more

  • AmoMax 10 Plus

    AmoMax® 10 Plus is Clariant's latest generation of wustite-based ammonia synthesis catalysts. The catalyst is based on the proven ammonia synthesis catalysts AmoMax 10 but with an improved promoter set. The optimization of concentration and ratio of the promoter system leads to a higher activity, higher stability and a faster startup of AmoMax 10 Plus. The higher activity allows an operation with a higher per pass conversion and lower loop pressure, which can be utilized for a higher ammonia production and/or for energy savings. The higher stability and water resistance increases the catalyst lifetime and enables a faster catalyst reduction. more

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