Safe and fast ammonia synthesis catalyst reduction
ActiSafE: Innovative method to measure water and ammonia
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
![Clariant Image ActiSafE Icons 1 570x363 20201217](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Clariant-Image-ActiSafE-Icons-1-570x363-20201217.jpg)
![Clariant Image ActiSafE Text 1 570x363 20201217](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Clariant-Image-ActiSafE-Text-1-570x363-20201217.jpg)
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.
![Clariant Image ActiSafE Icons 2 570x363 20201217](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Clariant-Image-ActiSafE-Icons-2-570x363-20201217.jpg)
![Clariant Image ActiSafE Text 2 570x363 20201217](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Clariant-Image-ActiSafE-Text-2-570x363-20201217.jpg)
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.
![Clariant Image ActiSafE Icons 3 570x363 20201217](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Clariant-Image-ActiSafE-Icons-3-570x363-20201217.jpg)
![Clariant Image ActiSafE Text 3 570x363 20201217](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Clariant-Image-ActiSafE-Text-3-570x363-20201217.jpg)
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
![Clariant Continous real-time measurements 16122020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Continous-real-time-measurements-20201216.png)
CONTINOUS REAL-TIME MEASUREMENTS
of water and ammonia
![Clariant Quick reaction time 16122020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Quick-reaction-time-20201216.png)
QUICK REACTION TIME
![Clariant Higher activity 16122020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Higher-activity-20201216.png)
ENSURING HIGHEST POSSIBLE CATALYST ACTIVITY
and optimized operation conditions
![Clariant Easy installation and use 16122020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Easy-installation-and-use-20201216.png)
DCS SYSTEM
CONNECTIVITY
![Clariant Faster and safer reduction 16122020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Faster-and-safer-reduction-20201216.png)
FASTER AND SAFER
REDUCTION
Economic benefits
![Clariant Faster and safer reduction 16122020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Faster-and-safer-reduction-20201216.png)
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*.
![Clariant Higher activity 16122020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Higher-activity-20201216.png)
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)
![Clariant Image ActiSafE_Text_und Icon_4_1153x165 10022021](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Clariant-Image-ActiSafE_Text_und-Icon_4_1153x165-10022021.png)
*for a typical 2,000 MTPD Ammonia plant (assuming an ammonia price of 350 USD/MT)
How ActiSafE works
![Clariant Image ActiSafE Analizer 570x363 20201217](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Clariant-Image-ActiSafE-Analizer-570x363-20201217.jpg)
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.
![Clariant Image Infrared Light 16-9 Icon 2020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Image-Infrared-Light-16-9-Icon-2020.png)
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.
![Clariant Image Sample Line 16-9 Icon 2020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Image-Sample-Line-16-9-Icon-2020.png)
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.
![Clariant Image Big Like 16-9 Icon 2020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Image-Big-Like-16-9-Icon-2020.png)
ActiSafE equipment consists of a single benchtop device, ensuring easys installation and use.
![Clariant Image Real Time Data 16-9 Icon 2020](/-/media/Images/Business-Units/Catalysts/Syngas-Ammonia-Methanol-Hydrogen/ActiSafE/Icons-ActiSafE/Clariant-Image-Real-Time-Data-16-9-Icon-2020.png)
For optimum utilization, the device can be connected to the DCS via the analog interface, providing real time data in the control room.