The majority of global Hydrogen Consumption is for Ammonia (NH₃) Production, commonly using the Haber-Bosch process. Green Ammonia is produced through an integrated Process comprising the following Technology Components:
 
⚡ 𝗘𝗹𝗲𝗰𝘁𝗿𝗼𝗹𝘆𝘀𝗶𝘀 – Splits Water into Hydrogen (H₂) and Oxygen (O₂).
💧 𝗗𝗲𝗵𝘆𝗱𝗿𝗮𝘁𝗶𝗼𝗻 – Removes Water that is a Poison to the Reactor Catalyst.
🌬️ 𝗔𝗶𝗿 𝗦𝗲𝗽𝗮𝗿𝗮𝘁𝗶𝗼𝗻 𝗨𝗻𝗶𝘁 (𝗔𝗦𝗨) – Separates Nitrogen (N₂) from Air via Distillation or Adsorption.
➡️ 𝗖𝗼𝗺𝗽𝗿𝗲𝘀𝘀𝗼𝗿𝘀 – Attain high pressures (~150 bar) to favor NH₃ production as the Haber-Bosch Reaction has 4 mols of Gas as Reactants and 2 mols as Products.
⚗️ 𝗔𝗺𝗺𝗼𝗻𝗶𝗮 𝗥𝗲𝗮𝗰𝘁𝗼𝗿 – Uses an Iron Oxide Catalyst to produce NH₃. A feed stoichiometric H₂:N₂ ratio of 3 is ideal.
❄️ 𝗥𝗲𝗳𝗿𝗶𝗴𝗲𝗿𝗮𝘁𝗶𝗼𝗻 – Condenses NH₃ to separate it from unreacted Gases.
♻️ 𝗥𝗲𝗰𝘆𝗰𝗹𝗲 – Unreacted Gases are sent back to the Reactor to improve overall conversion from ~15% per-pass to 95%⁺. A Purge Line might be needed to assist with imbalances in the N₂ and H₂ feed.
 
It is important to simulate the Ammonia Reactor to optimize its operating temperature and layout.
This is because if the temperature is:
🔥 𝗧𝗼𝗼 𝗛𝗶𝗴𝗵 – The equilibrium would become unfavorable for NH₃ Production as the Reaction is exothermic. This results in excessive Recycle flow rates required.
🧊 𝗧𝗼𝗼 𝗟𝗼𝘄 – The rate of Reaction will slow to a stop, as the Reaction has a high activation energy requirement.
Thus, optimizing the number and volume of Catalyst Beds and the methods of Interstage Cooling (via Heat Exchanger or Quench) is key to maximizing NH₃ Production.

Source: Joaquim Tsu, Bryan Research & Engineering, LLC, 28 Feb 2023, Green Ammonia Process Simulation, Linkedin