Process and apparatus for decomposing ammonia

Abstract

To provide a process and apparatus for decomposing ammonia.SOLUTION: The present invention relates to a process and apparatus for decomposing ammonia gas at super-atmospheric pressure in catalyst-filled reactor tubes in a furnace. Each of the tubes has an upstream layer of a first catalyst and a downstream layer of a second catalyst, the first catalyst being more active than the second catalyst. Having the more active catalyst on the upstream reduces the temperature of the outer walls of the tubes in the region of the burner flames and the temperature of the inner walls of the tubes in the region with the highest mole fraction of ammonia. Nitriding of the metal of the tubes in this region is thereby reduced.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention is in the field of decomposing ammonia to produce hydrogen gas, and preferred embodiments specifically relate to a process and apparatus for producing hydrogen gas from liquid ammonia. [Background technology]

[0002] The global interest in renewable energy, and the use of this renewable energy to generate "green" hydrogen, has fueled interest in converting "green" hydrogen to "green" ammonia, as ammonia is easier to transport over distances of hundreds or thousands of miles. In particular, while the transportation of liquid hydrogen is not currently commercially possible, the transportation of ammonia in the liquid state is currently practiced.

[0003] For use in commercial fuel cells, ammonia must be converted reactively to hydrogen.

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[0004] The process is known as decomposition (or sometimes "dissociation") and is usually carried out over a catalyst. The gas produced (or "cracked gas") is a mixture of hydrogen (H) and nitrogen (N) gases, but because the decomposition reaction is an equilibrium reaction, some residual ammonia is also present. The amount of ammonia in the cracked gas, generally referred to as "ammonia slip," can be varied by changing the temperature; ammonia is heated at a higher temperature to promote conversion, thereby reducing ammonia slip.

[0005] In most current cracker applications, the mixture of hydrogen and nitrogen is utilized as is. However, since ammonia can be harmful to fuel cells, this stream can be used directly in fuel cells with suitable removal of the ammonia, such as by washing with water. However, when hydrogen is used in vehicle fueling, the nitrogen present presents a penalty to the process. Fuel to vehicle fueling systems is compressed to significant pressures of up to 900 bar. This means that nitrogen, which is merely a diluent in the process, is also compressed, requiring power, storage, increasing anode gas purge requirements, and reducing efficiency. Therefore, when hydrogen is used in vehicle fueling, it is beneficial to separate the hydrogen and nitrogen.

[0006] There are many examples of ammonia decomposition processes in the art, such as GB977830A, JP5330802A, CN111957270A, US2020 / 0398240A, and KR2022 / 0085469A.

[0007] Additionally, GB1142941A discloses a process for producing a fuel gas interchangeable with city gas. Ammonia is decomposed to form a mixture of hydrogen and nitrogen, which is then enriched by adding a gas with a higher heating value than the mixture, such as methane, propane, or butane, or a mixture thereof. Liquid ammonia is pumped as a cryogenic liquid and vaporized by a closed hot water circuit. The vaporized ammonia gas is superheated by heat exchange with flue gas from the furnace and then decomposed on a suitable catalyst in the tubes of a direct-fired tubular furnace. The decomposed gas is scrubbed with water to recover residual ammonia and ultimately recycled from the ammonia feed to the catalyst-filled tubes of the furnace. The purified decomposed gas is enriched with propane and / or butane to produce a city gas product.

[0008] GB1142941A discloses that the decomposition of ammonia in a direct-fired tubular furnace in the presence of a suitable catalyst is preferred. However, the reference also discloses that other decomposition processes can alternatively be used instead. In this context, GB1142941 mentions heating the ammonia to a suitable temperature and then passing the ammonia through an unheated bed of an ammonia decomposition catalyst to decompose a portion of the ammonia into hydrogen and nitrogen, cooling the gas during the process. Unconverted ammonia can be recovered as described above. Alternatively, the gas mixture can be reheated and passed through a second bed of catalyst to further reduce the ammonia content, and this can be repeated as many times as desired.

[0009] GB 1353751A discloses a process in which ammonia at a pressure between 20 and 300 atm is decomposed in two stages in a heated reactor tube. In the first stage, gas at a temperature between 450 and 800°C is passed through a layer of nickel, iron, or cobalt-containing catalyst produced by co-precipitation with aluminum oxide and magnesium oxide or magnesium-aluminum spinel supports. Alternatively, the first-stage catalyst can consist of either an iron-impregnated ceramic material or iron impregnated on a preformed support composed of magnesium oxide and aluminum oxide and promoted with potassium oxide. After the first stage, the gas then passes through a layer of doubly or triply promoted iron catalyst at a temperature between 450 and 600°C, forming the second stage.

[0010] WO 2022 / 189560A discloses an ammonia decomposition process involving a combustion reactor with tubes filled with an iron catalyst. Liquid ammonia is withdrawn from storage, pumped, preheated, and evaporated to form ammonia gas, which is heated by heat exchange with the decomposed gas. The heated ammonia gas is further heated by heat exchange with flue gas in the convection section of the combustion reactor and then fed to two adiabatic reactors in series (with interstage heating for the flue gas) where it is partially decomposed. The partially decomposed gas is then heated by heat exchange with flue gas in the convection section before being fed to the catalyst-filled tubes of the combustion reactor to decompose the remaining ammonia.

[0011] US11287089A discloses a hydrogen fueling system in which ammonia is decomposed on-site into hydrogen and nitrogen in an ammonia cracker operating at pressures ranging from 5 bar to 40 bar, and the hydrogen is compressed to a pressure of at least 30 MPa (300 bar) and stored ready for distribution to vehicles. When dispensed, the compressed gas from the storage is cooled to a temperature ranging from -40°C to 5°C by heat exchange with a heat exchange fluid, such as D-limonene, FP40, or a water / glycol mixture, circulating around a closed loop. The heat exchange fluid is cooled by heat exchange with the ammonia feed to the cracker and may be further cooled in a conventional cooling system. If the ammonia feed is liquid, at least a portion of the duty required to vaporize the liquid ammonia is provided by the heat exchange fluid. Vaporization of the liquid ammonia is often effected at standard or subatmospheric pressure. US11287089A illustrates a system that produces 7.5 tons of hydrogen gas per day.

[0012] However, in general, there remains a need for improved processes for the production of hydrogen from ammonia, particularly processes that are more efficient in terms of energy consumption and / or have higher levels of hydrogen recovery and / or processes that reduce or eliminate the need to burn fossil fuels. Summary of the Invention

[0013] According to a first aspect of the present invention, there is provided a process for decomposing ammonia, the process comprising: providing heated ammonia gas at superatmospheric pressure; combusting a fuel with an oxidant gas in a furnace to heat reactor tubes containing catalysts, each tube containing an upstream layer of a first catalyst and a downstream layer of a second catalyst, and producing a flue gas; and supplying the heated ammonia gas, or partially decomposed ammonia gas derived therefrom, to the reactor tubes containing catalysts to cause decomposition of the ammonia and produce a cracked gas comprising hydrogen gas, nitrogen gas, and residual ammonia gas, wherein the first catalyst is more active for decomposing ammonia than the second catalyst.

[0014] The use of layers of different catalysts with different activities in the reactor tubes of an ammonia cracker is not new. In known processes, more active catalysts are conventionally used in layers of the reactor tube downstream of an upstream layer of less active catalyst, typically in the final section of the catalyst bed at the outlet of the tube, to ensure a closer approach to equilibrium.

[0015] However, the inventors have discovered that using a more active catalyst in the upstream layer of the reactor tube, typically the first section of the catalyst bed at the inlet of the tube, is beneficial as it reduces nitridation of the reactor tube metal.

[0016] Metal nitriding is a recognized problem in ammonia crackers. The amount of nitriding depends on the partial pressures of ammonia, nitrogen, and hydrogen, as well as the process temperature. Nitridation is most severe at higher temperatures and higher partial pressures of ammonia and nitrogen, with ammonia being a greater risk at typical ammonia decomposition temperatures (nitriding due to nitrogen is unlikely until temperatures become excessively high for ammonia decomposition, e.g., above 1000°C). The exact extent to which materials of construction form nitrides is currently unknown. However, there is data indicating that below 650°C, the degree of nitriding should be acceptable, depending on the materials of construction selected. Operating an ammonia cracker at higher pressures, e.g., 10-50 bar, can lead to more severe failures when the partial pressures of ammonia and nitrogen increase and nitriding leads to brittle fracture of the reactor vessel or tubes.

[0017] This problem is of particular concern in calcination reactors where the temperatures surrounding the reactor tubes holding the process side catalyst can exceed 650°C.

[0018] In the upper combustion reactor, the burner is positioned at the top, with the burner flame extending down a portion of the length of the reactor tube. The ammonia feed is fed to the top of the tube and flows downward, i.e., co-current with the flue gas, to the bottom of the tube. Because the top of the tube is closest to the burner flame, this region of the tube has the highest heat flux. The top of the tube is also found to be where the partial pressure of ammonia on the process side is highest. Therefore, this region of the tube has the greatest potential for nitriding and is therefore of greatest concern.

[0019] Placing a more active catalyst in the first section of the catalyst bed of the reactor tube draws more heat from the metal of the tube, resulting in a strong endotherm that is absorbed into the cracking process itself, thereby reducing the temperature of the inner wall of the tube and allowing the inner wall temperature to be kept below a predefined limit of, for example, 700°C (or 660°C to allow for a margin). Reducing the inner wall temperature in this way reduces nitriding of the metal wall of the tube.

[0020] According to a second aspect of the present invention, there is provided a furnace, typically an upper calciner, for decomposing heated ammonia gas at superatmospheric pressure, comprising: a radiant section comprising at least one inlet for fuel and oxidant gas in fluid flow communication with at least one burner; an ammonia feed inlet; catalyst-containing reactor tubes having an upstream end in fluid flow communication with the ammonia feed inlet and a downstream end in fluid flow communication with an outlet for cracked gas, each tube comprising an upstream layer of a first catalyst and a downstream layer of a second catalyst; and a convection section in fluid flow communication with the radiant section and comprising an outlet for flue gas, wherein the first catalyst is more active for decomposing ammonia than the second catalyst.

[0021] The catalyst bed in each reactor tube typically contains two or three catalyst layers (or sections). Beds with more than two catalyst layers may also be suitable for certain applications.

[0022] The upstream layer will typically be the first layer of the catalyst bed in each reactor tube and will include, e.g., contain, or consist of, the first catalyst. The upstream layer has a length that may be at least 20%, or at least 25%, or at least 30%, or at least 35% of the length of the entire catalyst bed. Typically, the length of the upstream layer is no more than 50% of the length of the catalyst bed. In many cases, the upstream layer extends beyond the end of the burner flame.

[0023] The downstream layer is typically the second layer of the catalyst bed and will comprise, e.g., contain, or consist of, a second catalyst. There may be an intervening layer between the upstream and downstream layers, but this is usually not the case. If there are only two layers in the catalyst bed, the length of the downstream layer constitutes the remainder of the bed. However, in some embodiments, there may be a third catalyst layer downstream of the second catalyst layer. The length of the third catalyst layer will typically not exceed 10% of the total bed length. Thus, if there are three layers in the catalyst bed, the downstream layer again constitutes the remainder of the bed.

[0024] If present, a layer of third catalyst allows for a closer approach to equilibrium, since the third catalyst is ideally more active than the second catalyst.

[0025] The furnace of the second aspect of the invention is particularly suitable for carrying out the process of the first aspect of the invention.

[0026] According to a third aspect of the present invention there is provided an apparatus for decomposing heated ammonia gas at superatmospheric pressure comprising: a source of liquid ammonia; a pump in fluid flow communication with the source of liquid ammonia for pumping the liquid ammonia; and a furnace as defined in the second aspect, wherein an ammonia supply inlet of the furnace is in fluid flow communication with the pump, the apparatus further comprising at least one heat exchanger arranged to preheat the liquid ammonia upstream of the pump; and at least one heat exchanger arranged to vaporize the pumped liquid ammonia and heat the ammonia gas by heat exchange with flue gas and / or cracked gas located between the pump and the ammonia supply inlet of the furnace.

[0027] The apparatus of the third aspect of the invention is particularly suitable for carrying out the process of the first aspect of the invention. [Brief explanation of the drawings]

[0028] [Figure 1] 1 is a simplified flowsheet of an ammonia decomposition process in which the present invention may be used. [Figure 2] 1 is a graph depicting how various temperatures and ammonia mole fractions vary as a function of cracker length for a comparative example using a nickel-based catalyst as the sole catalyst. [Figure 3] 1 is a graph depicting how various temperatures and ammonia mole fractions vary as a function of cracker length for one embodiment of the invention using an upstream layer of ruthenium-based catalyst and a downstream layer of nickel-based catalyst. DETAILED DESCRIPTION OF THE INVENTION

[0029] Unless otherwise specified, amounts of ingredients given in parts per million (or ppm) are calculated by weight. Additionally, all percentages are calculated by moles unless otherwise specified. Furthermore, any references to pressure are references to absolute pressure unless otherwise specified.

[0030] In the context of the present invention, the activity of a catalyst is understood to refer to the rate of conversion of ammonia at a given partial pressure for a given amount of catalyst over a given period of time at a particular temperature and overall pressure. The units used to define the activity of a heterogeneous catalyst are per gram (or mole g) of catalyst (including substrate, if present) per second. -1 s -1 ) is the moles of ammonia converted

[0031] The phrase "in fluid flow communication" will be understood to mean that piping or other suitable conduit is used to transport a fluid from one designated location to another. During its passage between two locations, the fluid may flow through one or more other units (e.g., catalytic reactors) that may be designed and / or arranged to change the physical conditions of the fluid, such as its temperature (e.g., heat exchangers) and / or pressure (e.g., compressors or pumps), or its composition through reaction of components within the fluid. The phrase "in direct fluid flow communication" will be understood to mean that the fluid flows directly from one location to the other, i.e., does not flow through another such unit during its passage, and therefore there is essentially no change in the composition or physical condition of the fluid.

[0032] The term "superatmospheric pressure" will be understood to mean a pressure significantly higher than atmospheric pressure, such as a pressure of at least 5 bar, for example a pressure of at least 10 bar, or a pressure of at least 20 bar or at least 30 bar. Typically, the pressure is not more than 60 bar.

[0033] The term "upstream" will be understood to mean the direction opposite to the flow of fluid during normal operation, and the term "downstream" will be interpreted accordingly.

[0034] A typical composition of the ammonia feed is shown in Table 1. Table 1 [Table 1]

[0035] Oil may be present in ammonia in local storage tanks, at the production site, or any other storage tanks in between due to the boil-off gas compressor used for ammonia storage. The presence of oil is problematic because it poses the risk of blockage and / or contamination. This can lead to poor performance of heat exchangers or reduced catalytic activity in reactors. Therefore, if present, the oil may need to be removed in some way. In this regard, oil can be removed by passing the liquid ammonia through a bed of activated carbon. However, in a preferred embodiment, the catalyst used in the adiabatic reaction unit cracks the oil into short-chain hydrocarbons, which can react with any water present to form carbon monoxide, hydrogen, and methane.

[0036] Inert gases are not expected to be a problem other than potentially becoming product hydrogen. In this regard, helium may be present in ammonia derived from natural gas, but ammonia derived from renewable hydrogen does not contain helium.

[0037] Liquid ammonia is typically withdrawn from storage and pumped from the storage pressure (e.g., about 1 bar) to a pressure in the range of about 5 bar to about 60 bar, for example, about 10 bar to about 50 bar, such as about 10 bar to about 30 bar, or about 40 bar to about 50 bar. The temperature of the liquid ammonia is increased slightly from the storage temperature (e.g., about -34°C) to about -32°C.

[0038] The pumped (superatmospheric) liquid ammonia is then typically preheated to its boiling point, ideally by suitable heat integration within the process. Preferably, part of the preheating is achieved using a heat transfer circuit in which heat from, for example, intercooling and post-cooling of the PSA off-gas compressor is recovered, optionally along with heat from the cracked gas and / or flue gas, using a heat transfer fluid such as an aqueous solution of glycol, e.g., an aqueous solution containing about 50% to about 60% by weight of glycol, such as ethylene glycol or propylene glycol, and used to preheat the liquid ammonia. If such integration is not possible, such as when the compressor is not running, heat from an external source, such as an electric heater, may be required to preheat the ammonia.

[0039] The preheated liquid ammonia is then vaporized and the ammonia gas is further heated before being fed to the catalyst-containing reactor tube or adiabatic reactor unit. In this regard, the ammonia gas is typically superheated, i.e., heated to a temperature above its boiling point, above 350°C, to ensure a useful reaction rate in the catalyst-containing reactor tube or adiabatic reactor unit.

[0040] The duty for heating and vaporizing the preheated liquid ammonia can be provided by cracked gas, flue gas, or a combination of both cracked gas and flue gas. In a preferred embodiment, the cracked gas is used to heat and vaporize the preheated liquid ammonia by heat exchange, and the ammonia gas is then further heated by heat exchange with the flue gas.

[0041] The heated ammonia gas can be fed directly to the reactor tube containing the catalyst, i.e., without first partially decomposing a portion of the ammonia.

[0042] The reactor tubes of the furnace are packed with at least two different ammonia decomposition catalysts having different activities, with the first (more active) catalyst positioned upstream of the second (less active) catalyst. In some embodiments, the beds in each reactor tube have only two layers: an upstream layer of the first catalyst and a downstream layer of the second catalyst. However, in other embodiments, the beds may have a third layer of catalyst downstream of the second catalyst, where the third catalyst may be more active than the second catalyst and may allow for shorter tubes. The catalytically active metals of the first and third catalysts may be different, but in preferred embodiments, the metals are the same, e.g., ruthenium.

[0043] The activity of the first (or third) catalyst is typically at least 50% greater than the activity of the second catalyst. However, the difference in relative activity is often substantially greater than 50%. In this regard, the activity of the first (or third) catalyst is often at least two-fold (i.e., double), or at least three-fold, or at least four-fold, or at least five-fold greater than the activity of the second catalyst. In some embodiments, the activity of the first (or third) catalyst is at least 10-fold (i.e., an order of magnitude), or at least 15-fold greater than the activity of the second catalyst.

[0044] Many metals are known in the art to catalyze the decomposition of ammonia. These metals include transition metals from Group 6 of the periodic table, such as chromium (Cr) and molybdenum (Mo); Group 8, such as iron (Fe), ruthenium (Ru), and osmium (Os); Group 9, such as cobalt (Co), rhodium (Rh), and iridium (Ir); Group 10, such as nickel (Ni), palladium (Pd), and platinum (Pt); and Group 11, such as copper (Cu), silver (Ag), and gold (Au). Metalloids such as tellurium (Te) can also be used.

[0045] The activity of some of these metals as catalysts for ammonia decomposition has been reported by Masel et al. (Catalyst Letters, vol. 96, Nos. 3-4, July 2004) to vary in the following order: Ru>Ni>Rh>Co>Ir>Fe>>Pt>Cr>Pd>Cu>>Te The metals can be unsupported, but are often supported on a suitable support (or substrate), typically a metallic support such as silica (SiO), alumina (AlO), zirconia (ZrO), or a mixed metal oxide support such as spinel (MgAlO) or perovskite (CaTiO).

[0046] As will be appreciated by those skilled in the art, the activity of a supported metal catalyst typically depends in part on the loading of the catalytically active metal on the support. In this regard, metal loading will vary according to specific requirements, but is typically within the range of about 0.1 wt. % to about 70 wt. %. For more active metals, such as ruthenium, the loading may be toward the lower end of the range, e.g., about 0.1 wt. % to about 10 wt. %, or about 0.2 wt. % to about 5 wt. %. For less active metals, such as nickel, the loading may be toward the higher end of the range, e.g., about 20 wt. % to about 65 wt. %.

[0047] Supported metal catalysts may be unpromoted or may be promoted with at least one other metal, for example, one or more Group 1 metals, such as lithium (Li), sodium (Na), and potassium (K); Group 2 metals, such as magnesium (Mg) and calcium (Ca), or Group 13 metals, such as aluminum (Al), to improve activity, as is known in the art.

[0048] Any conventional catalyst known for ammonia decomposition can be used in the present invention. Suitable catalysts are disclosed in US2015 / 0217278A, Masel et al. (supra), Lamb et al. (Int. J. Hydrogen Energy, 44 (2019) pp3726-3736) and Boisen et al. (J. Catalysis 230 (2005) pp309-312).

[0049] Bimetallic catalysts, or catalysts containing two catalytically active metals, are also suitable for use with the present invention. Examples include composite metals or metal alloys or metal nanoclusters supported on perovskites, composite oxides or nitrides, or mixed oxides or mixed nitrides disclosed in US 2021 / 0001311 A, such as CoNi-MgSrCeO4 and 1 wt. % K-CoNi-MgSrCeO4.

[0050] The catalyst of the present invention typically comprises, e.g., contains, or consists of, for example, a metal-based catalyst. The catalytically active metal is typically selected from the transition metals of the periodic table. Suitable transition metal-based catalysts typically have activity at temperatures in the range of 475°C to 600°C suitable for achieving a reaction rate of at least 0.2 times, or at least 0.5 times, or at least equal to, or at least 2 times, or at least 5 times the rate calculated according to Equation 9 proposed by Lamb et al., i.e., r=8.73exp[-76710 / RT].(P NH3 ) 0.28 .(P H2 ) -0.42 .(1-β 2 ) During the ceremony: "r" is the reaction rate (or "activity") of the catalyst; "RT" is the ideal gas constant "R" (8.314 Jmol -1 K -1 ) multiplied by the temperature in Kelvin, "T", P NH3 is the partial pressure of ammonia, P H2 is the partial pressure of hydrogen, β is defined in the research paper as follows (see equation 5 proposed by Lamb et al.):

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[0051] The inventors have recognized that Equation 9 of Lamb et al. can be extrapolated to temperatures outside of the 475°C-600°C range, for example, within the range of 450°C-700°C.

[0052] Transition metals that may be particularly suitable for use as the main catalytically active metal of the catalyst in the catalyst bed of the reactor tubes are selected from chromium, manganese, iron, cobalt, nickel, ruthenium, and copper, e.g., iron, cobalt, nickel, and ruthenium.

[0053] The catalytically active metal of the first (more active) catalyst is preferably ruthenium, and the catalytically active metal of the second (less active) catalyst is typically nickel.

[0054] In preferred embodiments, the first catalyst in the upstream layer is a ruthenium-based catalyst and the second catalyst in the downstream layer is a nickel-based catalyst. If a third catalyst is present in these embodiments, that catalyst is preferably a ruthenium-based catalyst, but the catalyst may be a different ruthenium-based catalyst from the first catalyst, for example, the catalysts have different supports and / or catalyst loadings, and / or, if both are promoted, are then promoted with different metals.

[0055] Thus, the term "ruthenium-based catalyst" refers to a catalyst that contains ruthenium as the only (or at least predominant) catalytically active metal, i.e., the metal for catalyzing the decomposition reaction. Ruthenium may be the only metal in the catalyst, or alternatively, one or more other metals may be present, for example, in a material that supports ruthenium. The terms "nickel-based catalyst" and "iron-based catalyst" are intended to be interpreted accordingly.

[0056] Suitable ruthenium- and nickel-based catalysts may be supported, for example, on alumina (as disclosed in Lamb et al. or Masel et al.) or spinel (as disclosed in Boisen et al.), and may optionally be promoted with a Group 1 or 2 metal.

[0057] As mentioned above, water is often present in ammonia as a contaminant. Water can be removed from the ammonia, in which case a water-intolerant catalyst, such as an iron-based catalyst, can be used in the reactor tubes. However, water is not removed in preferred embodiments to save capital and operating costs and reduce energy consumption. In these embodiments, a catalyst that cannot tolerate water, such as an iron-based catalyst, is not used. Instead, the catalyst in the reactor tubes can tolerate up to 1 mol% water in the ammonia feed. Such catalysts include nickel-based and ruthenium-based catalysts.

[0058] In preferred embodiments, a ruthenium-based catalyst is used in the first layer within each tube, allowing for a faster reaction rate to keep the metal temperature within the 660°C design limit. In these embodiments, the second layer of the tube contains a lower-cost, but less active, nickel-based catalyst. The catalyst is layered in this manner in preferred embodiments, using the endothermic heat of reaction within the tube to keep the tube metal cool in areas where combustion is most intense on the outside of the tube. Because ruthenium is more catalytically active, it generates a strong endothermic heat that cools the inner tube walls in areas of high ammonia concentration on the process side, protecting the tubes from excessive nitriding caused by high ammonia concentrations and high temperatures.

[0059] The combustion process within the furnace is preferably at least partially internally fueled, i.e., at least a portion of the fuel is either ammonia or off-gas generated during hydrogen recovery from the cracked gas, or a mixture of the two. However, trim fuels such as C1-C3 hydrocarbons or natural gas may be used if desired, although the use of hydrocarbon trim fuels would increase the carbon intensity of the process. However, it is generally desirable to minimize or even eliminate the use of such trim fuels to reduce the carbon intensity of the process.

[0060] The oxidant gas is typically air, but can be an oxygen-enriched gas or pure oxygen if desired.

[0061] The feed to the catalyst-filled reactor tube of the furnace can be at a temperature of up to about 800°C if the reactor wall material can withstand the higher temperatures. For lower temperature cycles, the feed is typically at a temperature in the range of about 400°C to about 600°C, or about 450°C to about 550°C, e.g., about 500°C. For higher temperature cycles, the feed can be at a temperature in the range of about 500°C to about 800°C, or about 600°C to about 700°C, e.g., about 650°C.

[0062] The decomposition temperature and pressure typically dictate that the ammonia slip in the reactor tube be no more than 3 mole percent, for example, from about 0.5 mole percent to about 1.5 mole percent.

[0063] In some embodiments, the heated ammonia gas is partially decomposed in an adiabatic reaction unit comprising at least one catalyst bed to produce partially decomposed ammonia gas for feeding into catalyst-packed reactor tubes.

[0064] The mole fraction of ammonia in the gas passing through the adiabatic reaction unit is typically reduced by at least 20%, e.g., at least 25%, or at least 30%, or even at least 35%, e.g., about 40%, and in some cases up to about 50%. Stated differently, the mole fraction of ammonia can be reduced from 1 (or nearly 1) in the heated ammonia gas to an amount in the range of about 0.5 to about 0.8, or to an amount in the range of about 0.5 to about 0.7, or to an amount in the range of about 0.55 to about 0.65, e.g., about 0.6, in the partially decomposed ammonia gas.

[0065] An adiabatic reaction unit may be incorporated into the process design to improve overall efficiency, specifically by using heat available in the flue gas to provide heat for the adiabatic cracking process within the unit. In this regard, the temperature around the adiabatic reaction unit is typically optimized to maximize heat recovery from the flue gas while avoiding temperatures above about 660°C due to material concerns.

[0066] The primary design parameter for an adiabatic reaction unit is the inlet temperature. Higher inlet temperatures allow for greater conversion within the unit because the ammonia decomposition reaction is endothermic. However, higher temperatures place greater demands on the materials of construction and catalyst. Inlet temperatures are typically in the range of about 350°C to about 800°C, and for lower temperature cycles, they can be in the range of about 400°C to about 600°C, or about 400°C to about 450°C. For higher temperature cycles, the inlet temperature can be in the range of about 500°C to about 700°C, or about 550°C to about 650°C.

[0067] Due to the high temperatures and ammonia concentrations, cracking reactor vessels, such as reactor tubes in adiabatic reactors and furnaces, typically must be constructed from materials that are resistant to ammonia and / or nitriding. Suitable materials include nickel-based alloys containing at least 40% or at least 50% nickel by weight. Such alloys typically have up to 90% or up to 80% nickel by weight. The alloys typically contain one or more other metals selected from chromium, cobalt, molybdenum, and iron.

[0068] Specific examples of suitable nickel-based alloys include UNS N06600, N06625, N06601, N06617, N06025, N06230, N07214, N08811. In some embodiments, austenitic nickel-chromium based superalloys such as Inconel may be used.

[0069] The Unified Numbering System (UNS) is an alloy designation system widely accepted in North America. Each UNS number is associated with a specific metal or alloy and defines its specific chemical composition, or in some cases, specific mechanical or physical properties.

[0070] Other suitable materials include cobalt-based alloys such as UNS R30188. In addition, high-temperature alloys with low resistance to ammonia nitriding, such as UNS N08811, or cast alloys such as HPNb, HP Micro-Alloyed, MA-1 (MetalTek International, USA), may be suitable, especially when the surface is modified or coated with a corrosion-resistant layer such as aluminiding, aluminiding followed by pre-oxidation, or a ceramic coating. Nitriding-resistant alloys can also be used with surface modifications or coatings for improved performance.

[0071] The adiabatic reaction unit comprises one or more adiabatic reactors, the or each reactor comprising a catalyst bed, and the or each adiabatic reactor may be made from one or more of the ammonia-resistant and / or ammonia-nitriding-resistant materials listed above.

[0072] In a preferred embodiment, the adiabatic reaction unit comprises two or more adiabatic reactors, for example, two, three, four, five, or six reactors, with interstage heating as needed. The reactors may be arranged in series or parallel, or a combination of series and parallel, depending on the process requirements. However, in a preferred embodiment, the adiabatic reaction unit preferably has two such reactors arranged in series with intermediate interstage heating of partially decomposed ammonia gas by heat exchange against the cracked gas or flue gas.

[0073] Each adiabatic reactor has a bed containing at least one catalyst suitable for decomposing ammonia. Any conventional ammonia decomposition catalyst can be used in the or each adiabatic reactor bed. Suitable catalysts are discussed above in the context of the reactor tube catalysts.

[0074] In embodiments in which water is removed from ammonia prior to decomposition, a non-water-tolerant catalyst, such as an iron-based catalyst, may be used in the adiabatic reactor. However, water is not removed in preferred embodiments to save capital and operating costs and reduce energy consumption. In these embodiments, the catalyst bed of the adiabatic reaction unit does not contain an iron-based catalyst; instead, the use of a water-tolerant catalyst, i.e., a metal-based catalyst that can tolerate the presence of up to 1 mol% water, is preferred. In this regard, either a nickel-based catalyst or a ruthenium-based catalyst, or a combination of a nickel-based catalyst and a ruthenium-based catalyst, may be used in the bed of the adiabatic reactor unit.

[0075] As noted above, ruthenium-based catalysts tend to be more active than nickel-based catalysts, but are more expensive. Therefore, further optimization is possible through catalyst selection and, if more than one catalyst is used, through the ordering of catalyst layers within the bed of the adiabatic reaction unit.

[0076] In some preferred embodiments having two adiabatic reactors in series, the catalyst bed of the first reactor comprises, e.g., includes or consists of a single layer of a first catalyst, e.g., a ruthenium-based catalyst, and the catalyst bed of the second reactor comprises, e.g., includes or consists of an upstream layer of a second catalyst, e.g., a nickel-based catalyst, that is typically less active than the first catalyst, and a downstream layer of a third catalyst, e.g., a ruthenium-based catalyst, that is typically more active than the second catalyst.

[0077] In these embodiments, the first and third catalysts can be the same. Alternatively, the first and third catalysts can be different, for example, comprising different catalytically active metals, or the same catalytically active metals on different supports, or the same catalytically active metals on the same support at different loadings.

[0078] In an embodiment having two adiabatic reactors in series, the catalyst bed of the first reactor comprises, e.g., includes or consists of a single layer of a first catalyst, e.g., a nickel-based catalyst, and the catalyst bed of the second reactor comprises, e.g., includes or consists of an upstream layer of a second catalyst, e.g., a nickel-based catalyst, that has similar activity to the first catalyst, and a downstream layer of a third catalyst, e.g., a ruthenium-based catalyst, that is typically more active than the first and second catalysts.

[0079] In these embodiments, the first and second catalysts can be the same. Alternatively, the first and second catalysts can be different, for example, comprising different catalytically active metals, or the same catalytically active metals on different supports, or the same catalytically active metals on the same support at different loadings.

[0080] In both sets of preferred embodiments, the volume of the upstream layer of the second catalyst in the bed of the second reactor can be about 40% to about 90%, e.g., about 50% to about 70% or about 60%, of the total volume of the bed. If no additional layer of catalyst is present, the volume of the downstream layer of the third catalyst in the bed of the second reactor can be about 10% to about 60%, e.g., about 30% to about 50%, or about 40%, of the total volume of the bed.

[0081] The inventors have recognized that ruthenium-based catalysts are not only sufficiently tolerant of water, but also capable of cracking hydrocarbon oils into shorter hydrocarbons such as methane, along with carbon monoxide and hydrogen. Thus, the use of these catalysts in an adiabatic reaction unit can eliminate the need for an upstream dedicated unit for removing oil from liquid ammonia.

[0082] Also, at higher temperatures, catalyst sintering is known to reduce catalyst activity and life. In this regard, those skilled in the art will recognize that improved conversion must be balanced against higher vessel costs and shorter catalyst life.

[0083] Heat from the cracked gas and flue gas is typically used to heat the feed streams to the adiabatic reaction unit and furnace, thereby reducing the overall energy consumed by the process. In this regard, the temperature of the cracked gas depends on the cycle being operated.

[0084] At lower temperature cycles, the temperature of the cracked gas may be up to about 700°C, e.g., typically about 550°C to about 700°C, or about 600°C to about 650°C. The temperature of the flue gas may be up to about 750°C at its highest point. However, due to heat leaks, the temperature drops, typically to about 600°C to about 700°C, at which point the heat can be effectively utilized.

[0085] At higher temperature cycles, the temperature of the cracked gas may be up to about 750°C, e.g., typically about 650°C to about 750°C, or about 675°C to about 725°C. The temperature of the flue gas may be up to about 840°C at its highest point. However, due to heat leaks, the temperature drops, typically to about 700°C to about 800°C, at which point the heat can be effectively utilized.

[0086] When an adiabatic reactor unit is used to partially decompose heated ammonia gas and the partially decomposed gas is heated to the feed temperature of the catalyst-filled reactor tubes of the furnace, at least a portion of the duty required to heat the partially decomposed gas is provided by heat exchange with the decomposed gas. In preferred embodiments, the decomposed gas is not used elsewhere to heat another process fluid prior to heating the partially decomposed gas. Some of this heating duty could be provided in other ways, for example, by heat exchange with flue gas. However, all of this heating duty is preferably provided by the decomposed gas.

[0087] In a preferred embodiment, the composition of the ammonia typically remains at least substantially unchanged from the liquid ammonia in storage to the heated ammonia gas being fed to the adiabatic reaction unit. Oil present in the liquid ammonia may be removed at some point prior to partial decomposition of the ammonia, although if a ruthenium-based catalyst is used, oil removal is not necessary. However, water is typically not removed, so any water present in the liquid ammonia will also be present in the heated ammonia gas.

[0088] When the partially cracked gas is heated by heat exchange with the cracked gas, the temperature of the cracked gas is reduced. The cooled cracked gas is then typically further cooled by providing at least a portion of the heating duty required to generate heated ammonia gas from liquid ammonia. After cooling, hydrogen can be recovered as a product from the cracked gas. Recovery can be achieved in a pressure swing adsorption (PSA) process, by using one or more selectively permeable membranes, or by a combination of PSA and membrane separation. In a preferred embodiment, hydrogen recovery is achieved by a PSA process alone, i.e., without the use of membrane separation.

[0089] In embodiments using a PSA process, off-gas is generated that includes nitrogen gas, residual ammonia, and residual hydrogen. This off-gas can be preheated and used as fuel for combustion in a furnace. Alternatively, a portion of the off-gas can be used as fuel, while another portion can be compressed and returned to the PSA process for improved hydrogen recovery.

[0090] Aspects of the present invention include the following. #1. A process for decomposing ammonia, providing heated ammonia gas at superatmospheric pressure; combusting a fuel with an oxidant gas in a furnace to heat reactor tubes containing catalyst, each tube containing an upstream layer of a first catalyst and a downstream layer of a second catalyst, and to produce flue gas; feeding the heated ammonia gas, or partially decomposed ammonia gas derived therefrom, into a reactor tube containing a catalyst to cause decomposition of the ammonia and produce a decomposed gas comprising hydrogen gas, nitrogen gas, and residual ammonia gas; A process wherein the first catalyst is more active for decomposing ammonia than the second catalyst. #2. The process of #1, wherein the first catalyst is a ruthenium-based catalyst. #3. The process of #1 or #2, wherein the second catalyst is a nickel-based catalyst. #4. The process of any of #1-3, wherein the catalyst-containing reactor tube includes a layer of a third catalyst downstream of the layer of the second catalyst, the third catalyst being more active for decomposing ammonia than the second catalyst. #5. The process of #4, wherein the third catalyst contains the same catalytically active metal as the first catalyst. #6. The process of #4 or #5, wherein the third catalyst is a ruthenium-based catalyst. #7. Pumping liquid ammonia containing at least 0.1 mole percent water to produce pumped liquid ammonia; preheating the pumped liquid ammonia to produce preheated liquid ammonia; vaporizing the preheated liquid ammonia to produce ammonia gas; heating the ammonia gas to produce heated ammonia gas at superatmospheric pressure; A process according to any one of #1 to #6, wherein water from liquid ammonia is present in the heated ammonia gas. #8. The process of #7, wherein at least a portion, preferably more than half, e.g., greater than 50%, optionally up to 80%, of the heating duty required to provide heated ammonia gas is provided by heat exchange with the decomposed gas. #9. The process of #7 or #8, wherein water is present in the heated ammonia gas in an amount of 1 mol % or less. #10. A process according to any of #1 to #9, wherein the catalyst-containing reactor tube does not contain an iron-based catalyst. #11. The process of any of #1-#10, comprising partially decomposing heated ammonia gas in an adiabatic reaction unit containing at least one catalyst bed to produce partially decomposed ammonia gas for feeding to a catalyst-packed reactor tube. #12. The process described in #11, wherein the catalyst bed of the adiabatic reaction unit contains at least one catalyst selected from a nickel-based catalyst and a ruthenium-based catalyst. #13. The process described in #11 or #12, wherein the catalyst bed of the adiabatic reaction unit does not contain an iron-based catalyst. #14.A furnace for decomposing heated ammonia gas, a radiant section comprising at least one inlet for fuel and oxidant gas in fluid flow communication with at least one burner, an ammonia supply inlet, and catalyst-containing reactor tubes having an upstream end in fluid flow communication with the ammonia supply inlet and a downstream end in fluid flow communication with an outlet for cracked gases, each tube comprising an upstream layer of a first catalyst and a downstream layer of a second catalyst; a convection section in fluid flow communication with the radiant section and including an outlet for the flue gas; A furnace, wherein the first catalyst is more active for decomposing ammonia than the second catalyst. #15. The furnace according to #14, wherein the first catalyst is a ruthenium-based catalyst. #16. A furnace according to #14 or #15, wherein the second catalyst is a nickel-based catalyst. #17. A furnace as described in any of #14 to #16, wherein each catalyst-containing reactor tube includes a layer of a third catalyst downstream of the layer of the second catalyst, and the third catalyst is more active for decomposing ammonia than the second catalyst. #18. The furnace of #17, wherein the third catalyst contains the same catalytically active metal as the first catalyst. #19. A furnace according to #17 or #18, wherein the third catalyst is a ruthenium-based catalyst. #20. A furnace according to any one of #14 to #19, wherein the catalyst-containing reactor tube does not contain an iron-based catalyst. #21.An apparatus for decomposing heated ammonia gas, a source of liquid ammonia; a pump in fluid flow communication with the source of liquid ammonia for pumping the liquid ammonia; a furnace as defined in any of #14-#20, wherein the ammonia feed inlet is in fluid flow communication with the pump; The device, at least one heat exchanger arranged to preheat the liquid ammonia upstream of the pump; and at least one heat exchanger positioned to vaporize the pumped liquid ammonia and heat the ammonia gas by heat exchange with flue gas and / or cracked gas positioned between the pump and the ammonia feed inlet of the furnace. #22. An adiabatic reaction unit for partially decomposing heated ammonia gas at superatmospheric pressure, comprising: an inlet for heated ammonia gas at superatmospheric pressure in fluid communication with a pump; and at least one catalyst bed having an upstream end in fluid communication with the inlet and a downstream end in fluid communication with an outlet for the partially decomposed ammonia gas; #22. The apparatus of #21, wherein the ammonia feed inlet of the furnace is in fluid flow communication with the outlet for partially decomposed ammonia gas of the adiabatic reaction unit.

[0091] The invention will now be described, by way of example only, with reference to the drawings in which:

[0092] In Figure 1, liquid ammonia stream 2 at about -32°C is removed from storage (not shown) and fed to pump P101 where it is pumped at a pressure of about 46 bar to produce pressurized liquid ammonia stream 4, which is preheated by heat exchange in heat exchanger E271 with a heat transfer fluid, in this case typically a glycol solution of about 55% by weight ethylene glycol or propylene glycol in water, to produce preheated liquid ammonia stream 6 at about 55°C. An electric heater may be used to ensure that the temperature of the glycol solution fed to heat exchanger E271 is sufficient to preheat the liquid ammonia to the required temperature.

[0093] The preheated liquid ammonia in stream 6 is further heated by heat exchange in heat exchanger E312 to produce further heated liquid ammonia stream 8. The further heated liquid ammonia in stream 8 is then vaporized by heat exchange in heat exchanger E311 to produce ammonia vapor stream 10. The ammonia vapor in stream 8 is then superheated by heat exchange in heat exchanger E310 to produce ammonia gas stream 12 heated at about 260°C.

[0094] The heated ammonia gas in stream 12 is further heated by heat exchange in heat exchanger E2102 to produce superheated ammonia gas stream 14 at about 420° C. For convenience, heat exchanger E2102 is shown as a single unit; however, in reality there may be two separate exchangers with a selective catalytic reactor (SCR) positioned between them.

[0095] Superheated ammonia gas in stream 14 is fed to first adiabatic reactor vessel C141 at about 420°C and about 43 bar and passed through a bed of ruthenium-based catalyst. A portion of the ammonia gas is decomposed on the catalyst to form intermediate gas stream 16, which contains some decomposed ammonia. The mole fraction of ammonia in the gas passing through first adiabatic reactor vessel C141 is reduced from approximately 1 to about 0.9.

[0096] The intermediate gas is at about 360°C before being heated by heat exchange in heat exchanger E2 103 to produce superheated intermediate gas stream 18, which is then fed to second adiabatic reactor vessel C142 at about 590°C and passed through beds containing an upstream layer of nickel-based catalyst and a downstream layer of ruthenium-based catalyst to produce partially decomposed ammonia gas stream 20. The mole fraction of ammonia in the gas passing through second adiabatic reactor vessel C142 decreases from about 0.9 to about 0.6.

[0097] The catalyst bed in the second adiabatic reactor vessel C142 has two layers, with a layer of nickel-based catalyst on top of a layer of ruthenium-based catalyst, to more efficiently use heat and therefore maximize ammonia conversion. Catalyst volume is also optimized, i.e., by limiting the outlet temperature of the second adiabatic reactor vessel to about 390°C, the volume of the ruthenium-based catalyst is minimized. The inventors have found that this temperature reduction further increases the volume required for the ruthenium-based catalyst.

[0098] The ruthenium-based catalyst is the same in both the first and second adiabatic reactor vessels; however, different ruthenium-based catalysts may be used.

[0099] The partially cracked ammonia in stream 20 is heated by heat exchange in heat exchanger (or "economizer") E305 before being fed as stream 22 at a pressure of approximately 38 bar to the catalyst-filled tubes in the radiant section F201 of the furnace (or reactor). Heating the feed to the tubes increases the amount of cracking that can be done with the heat from the burner by reducing the duty required to heat the partially cracked stream to reaction temperature. Utilizing the cracked stream from the tubes allows for efficient use of this high-temperature stream. The inlet temperature of the direct-fired tubular furnace is limited to approximately 500°C to limit the cracker tube wall temperature.

[0100] Air stream 62 passes through forced draft fan K212 before being preheated by heat exchange in heat exchanger E2141 to produce preheated air stream 64. The preheated air in stream 64 may be mixed with natural gas stream 70 as trim fuel and supplied to the burners (not shown) of furnace F201. Preheating the air in this manner helps reduce fuel requirements.

[0101] The tubes in the furnace's radiant section F201 are packed with two types of ammonia decomposition catalysts in two different layers. A ruthenium-based catalyst is used in the first layer in each tube, allowing for a faster reaction rate to keep the metal temperature within the design limit of about 660°C. The second layer in the tube, downstream of the first layer, contains a lower-cost, but less active, nickel-based catalyst.

[0102] Cracked gas stream 24 exits the radiant section F201 of the direct-fired tubular furnace at approximately 640°C and is then fed to economizer E305 to provide the necessary duty to heat the partially cracked ammonia, thereby reducing the temperature of the cracked gas to approximately 530°C.

[0103] Economizer E305 is illustrated as a shell-and-tube heat exchanger with partially cracked ammonia gas passing through the tubes and cracked gas passing through the shell side, however, this arrangement could be reversed or indeed different types of heat exchangers could be used.

[0104] Cracked gas stream 26 is then fed from economizer E305 to heat exchanger E310 to provide the necessary duty to superheat the ammonia gas, thereby further reducing the temperature of the cracked gas to approximately 389°C.

[0105] Cracked gas stream 28 is then fed from heat exchanger E310 to heat exchanger E311 to provide the necessary duty to vaporize additional heated liquid ammonia, thereby further reducing the temperature of the cracked gas to approximately 109°C.

[0106] Cracked gas stream 30 is then fed from heat exchanger E311 to heat exchanger E312 to provide the necessary duty to further heat the heated pressurized liquid ammonia, thereby further reducing the temperature of the cracked gas again to about 70°C.

[0107] Each of heat exchangers E310, E311, and E312 is illustrated as an individual shell-and-tube heat exchanger with ammonia passing through the tubes and cracked gases passing through the shell side. However, this arrangement can be reversed. Alternatively, the heat exchangers can be combined into a single shell-and-tube heat exchanger, or indeed different types of heat exchangers can be used.

[0108] Cracked gas stream 32 from heat exchanger E312 is then further cooled by heat exchange with a heat transfer fluid in cooler E323 and then fed as stream 34 to PSA system U501 where it is separated into hydrogen gas stream 40, which is removed as product, and PSA off-gas stream 42, which contains nitrogen gas, residual hydrogen gas, and residual ammonia gas. The hydrogen gas in stream 40 may be fed to a hydrogen liquefaction unit (not shown) to produce liquid hydrogen.

[0109] All of the PSA off-gas in stream 42 can be sent directly as fuel (stream 60) for combustion in furnace F201. Alternatively, stream 42 can be split into two portions.

[0110] A first portion of the PSA off-gas in stream 44 is heated by heat exchange in heat exchanger E2112 to produce warmed PSA off-gas stream 60, which is then supplied to the burners in furnace F201 along with an air supply 64 and, optionally, when needed, a natural gas supply 70. A minimal amount of natural gas is used as trim fuel to provide the balance of fuel required in the combustion section.

[0111] The second portion may be sent as stream 46 to multi-stage compression unit K681 for compression. Compression unit K681 has five stages with intercoolers between each stage, with an aftercooler following the last stage. Heat is recovered from the compressed gas in the intercoolers and aftercoolers by heat exchange with a heat transfer fluid. Heat may also be recovered from the lubricating oil or, if a positive displacement compression unit is used, from the compression unit cylinder using a heat transfer fluid.

[0112] For convenience, the intercooler and aftercooler are shown by a single heat exchanger (labeled E6816A-E) that recovers heat from compressed PSA off-gas stream 48 by heat exchange with heat transfer fluid stream 52 to produce cooled compressed PSA off-gas stream 50 and warmed heat transfer fluid stream 54.

[0113] The heat transfer fluid heated in the cooler E323, and the intercoolers and aftercoolers E6816A-E, etc., is then used to provide the duty required to preheat the liquid ammonia by heat exchange in the heat exchanger E271.

[0114] The cooled, compressed PSA off-gas in stream 50 is fed to phase separator C6816 where any condensate is removed as stream 56. The compressed PSA off-gas is then recycled as stream 58 to PSA system U501 for further hydrogen recovery. In this way, hydrogen recovery can be increased from 85% (without recycle) to 95% (with recycle).

[0115] As indicated above, the process can be operated without compression unit K681, resulting in a reduction in hydrogen recovery in PSA unit 501. Reducing hydrogen recovery obviously results in a reduction in hydrogen gas product. However, reduced hydrogen recovery may still be desirable because when more hydrogen is present in the off-gas, the carbon intensity (CI) of the process is reduced, thereby reducing the need for natural gas as a trim fuel and reducing carbon dioxide emissions.

[0116] Flue gas Stream 72, at about 686°C, passes from radiant section F201 to convection section 90 of furnace F201, where it first provides the duty required to heat intermediate gas from Stream 16 in heat exchanger E2103, thereby reducing the temperature of the flue gas used (as Stream 74), and then provides the duty required to further heat heated ammonia gas from Stream 12 in heat exchanger E2102, thereby further reducing the temperature of the flue gas. Thus, the flue gas provides heating duty in a direction countercurrent to the feed gas flow rate to radiant section F201 of the direct-fired tubular furnace.

[0117] The cooled flue gas is then used (as stream 76) to provide the required duty to heat air from stream 62 in heat exchanger E2142, thereby further reducing the temperature of the flue gas. The further cooled flue gas is then used (as stream 78) to provide the required duty to heat PSA off-gas from stream 44 in heat exchanger E2112, thereby further cooling the flue gas.

[0118] The cooled flue gas leaves the convection section 90 of the direct-fired tubular furnace F201 as stream 80 at approximately 121°C, i.e., above the dew point of water, passes through an induced draft fan K211, and then leaves the process as stream 82. All of the useful energy has been extracted from the flue gas at this point, and it can optionally be vented to the atmosphere after further processing if required depending on its composition.

[0119] Oil may be present in liquid ammonia in amounts up to about 5 ppm from boil-off gas compressors (not shown) used in conjunction with ammonia storage tanks (not shown), either where the ammonia is produced, or where the ammonia is decomposed, or indeed anywhere in transit between the two sites. The presence of oil in ammonia can cause difficulties because the ammonia decomposition catalyst may not tolerate the oil. Therefore, it may be desirable to remove the oil before the ammonia is exposed to the catalyst. Oil may be removed by passing the ammonia through a bed of activated carbon.

[0120] If oil is to be removed from the ammonia, then an oil removal unit (not shown) may be located in stream 2 (i.e. in the feed line to pump P101), stream 4 (i.e. between pump P101 and glycol heater E271), stream 6 (i.e. between glycol heater E271 and heat exchanger E312), stream 8 (i.e. between heat exchangers E312 and E311), or stream 10 (i.e. between heat exchangers E311 and E310). [Example]

[0121] Comparative Example The process illustrated in Figure 1 has been simulated by computer (Aspen Plus, ver. 10, Aspen Technology, Inc., Massachusetts, USA) for a plant designed to produce 30 tonnes / day of hydrogen (Stream 40).

[0122] The reactor was simulated to have 60 tubes, each with an internal diameter of 4.313 in (0.11 m) and containing a 40 ft (12.2 m) catalyst bed containing a nickel-based catalyst as the only catalyst.

[0123] The activity of the ruthenium-based catalyst in the adiabatic reactor and the nickel-based catalyst in both the adiabatic reactor and the reactor tube was modeled using the rate equation No. 9 given by Lamb et al. (Int. J. Hydrogen Energy, 44 (2019) pp3726-3736) as a basis. For the purpose of the simulation, the activity of the ruthenium-based catalyst was fitted to the rate equation, while the activity of the nickel-based catalyst was assumed to be 20% of the activity predicted by the rate equation.

[0124] The various temperatures and mole fractions of ammonia are plotted as a function of cracker length in Figure 2. The results show that the tubes have a maximum outer wall temperature of about 750°C and a maximum inner wall temperature of about 724°C.

[0125] Example 1 The simulation according to the comparative example was repeated using a catalyst arrangement within the reactor tubes according to the invention, with each tube simulated to have a 15 ft (4.6 m) upstream layer of ruthenium-based catalyst and a 25 ft (7.6 m) downstream layer of the same nickel-based catalyst, as in the comparative example.

[0126] All other aspects of the simulation were unchanged, including the placement of the catalyst in the adiabatic reactor bed and the assumed activity of both types of catalyst.

[0127] Various temperatures and ammonia mole fractions are plotted as a function of cracker length in Figure 3. The results show that the tubes had a maximum outer wall temperature of 668°C and a maximum inner wall temperature of 648°C, both significantly lower than the equivalent figures of 750°C and 724°C, respectively, from the comparative example.

[0128] At lower temperatures, the nitriding elongation of the metal from which the tube is formed will be significantly lower.

[0129] Heat and mass balance data for the simulation of Example 1 are provided in Table 2. Table 2 [Table 2-1] [Table 2-2]

[0130] The data show that with a 1.33 mol % ammonia slip (Stream 24) from the cracker (tube furnace 201) and 95% recovery of hydrogen in the PSA unit, 7626 kg / hr of ammonia (Stream 2) is required as feed, and 472.7 kg / hr of natural gas (Stream 70) is required as fuel in addition to the PSA off-gas (Stream 60) to fire the cracker.

[0131] For a given hydrogen recovery and ammonia slip, the effect of using cracked gas (instead of flue gas) to provide the duty required to heat the partially cracked gas (Stream 20) to the feed temperature of the catalyst-packed tubes of the cracker (F201) is to reduce the overall carbon intensity (CI) of the process.

[0132] Although the invention has been described with reference to the preferred embodiments illustrated in the drawings, it will be understood that various modifications can be made within the spirit and scope of the invention as defined in the following claims.

[0133] In this specification, unless expressly indicated otherwise, the word "or" is used in the sense of an operator that returns a value of true when either or both of the stated conditions are met, as opposed to the operator "exclusive or," which requires only one of the conditions to be met. The word "comprising" is used in the sense of "including" and incorporates "consisting of," but not exclusively.

[0134] All prior teachings set forth above are incorporated herein by reference. Any acknowledgement of a prior-published document herein should not be taken as an admission or representation that the teachings were general knowledge in Australia or elsewhere at that date. Examples of embodiments of the present invention are listed in the following items [Aspect 1] to [Aspect 22]. [Aspect 1] 1. A process for decomposing ammonia, comprising: providing heated ammonia gas at superatmospheric pressure; combusting a fuel with an oxidant gas in a furnace to heat reactor tubes containing catalyst, each tube containing an upstream layer of a first catalyst and a downstream layer of a second catalyst, and to produce flue gas; feeding the heated ammonia gas, or partially decomposed ammonia gas derived therefrom, into a reactor tube containing the catalyst to cause decomposition of the ammonia and produce a decomposed gas comprising hydrogen gas, nitrogen gas, and residual ammonia gas; The process wherein the first catalyst is more active for decomposing ammonia than the second catalyst. [Aspect 2] 2. The process of embodiment 1, wherein the first catalyst is a ruthenium-based catalyst. [Aspect 3] 2. The process of embodiment 1, wherein the second catalyst is a nickel-based catalyst. [Aspect 4] 2. The process of embodiment 1, wherein the reactor tube containing the catalyst comprises a layer of a third catalyst downstream of the layer of the second catalyst, the third catalyst being more active for decomposing ammonia than the second catalyst. [Aspect 5] 5. The process of embodiment 4, wherein the third catalyst contains the same catalytically active metal as the first catalyst. [Aspect 6] 5. The process of embodiment 4, wherein the third catalyst is a ruthenium-based catalyst. [Aspect 7] pumping liquid ammonia containing at least 0.1 mole percent water to produce pumped liquid ammonia; preheating the pumped liquid ammonia to form preheated liquid ammonia; vaporizing the preheated liquid ammonia to produce ammonia gas; heating the ammonia gas to produce the superatmospheric pressure heated ammonia gas; 2. The process of claim 1, wherein the water from the liquid ammonia is present in the heated ammonia gas. [Aspect 8] 8. The process of embodiment 7, wherein at least a portion of the heating duty required to provide the heated ammonia gas is provided by heat exchange with the cracked gas. [Aspect 9] 8. The process of embodiment 7, wherein the water is present in the heated ammonia gas in an amount of 1 mol % or less. [Aspect 10] 2. The process of embodiment 1, wherein the catalyst-containing reactor tube does not contain an iron-based catalyst. [Aspect 11] 2. The process of embodiment 1, comprising partially decomposing the heated ammonia gas in an adiabatic reaction unit comprising at least one catalyst bed to produce the partially decomposed ammonia gas for feeding to catalyst-packed reactor tubes. [Aspect 12] 12. The process of embodiment 11, wherein the at least one catalyst bed of the adiabatic reaction unit comprises at least one catalyst selected from a nickel-based catalyst and a ruthenium-based catalyst. [Aspect 13] 12. The process of embodiment 11, wherein the at least one catalyst bed of the adiabatic reaction unit does not contain an iron-based catalyst. [Aspect 14] 1. A furnace for decomposing heated ammonia gas, comprising: a radiant section comprising at least one inlet for fuel and oxidant gas in fluid flow communication with at least one burner, an ammonia supply inlet, and catalyst-containing reactor tubes having an upstream end in fluid flow communication with the ammonia supply inlet and a downstream end in fluid flow communication with an outlet for cracked gases, each tube comprising an upstream layer of a first catalyst and a downstream layer of a second catalyst; a convection section in fluid flow communication with the radiant section and comprising an outlet for flue gas; The furnace, wherein the first catalyst is more active for decomposing ammonia than the second catalyst. [Aspect 15] 15. The furnace of embodiment 14, wherein the first catalyst is a ruthenium-based catalyst. [Aspect 16] 15. The furnace of claim 14, wherein the second catalyst is a nickel-based catalyst. [Aspect 17] 15. The furnace of claim 14, wherein each catalyst-containing reactor tube comprises a layer of a third catalyst downstream of the layer of the second catalyst, the third catalyst being more active for decomposing ammonia than the second catalyst. [Aspect 18] 18. The furnace of embodiment 17, wherein the third catalyst has the same catalytically active metal as the first catalyst. [Aspect 19] 18. The furnace of embodiment 17, wherein the third catalyst is a ruthenium-based catalyst. [Aspect 20] 15. The furnace of embodiment 14, wherein the catalyst-containing reactor tube does not contain an iron-based catalyst. [Aspect 21] 1. An apparatus for decomposing heated ammonia gas, comprising: a source of liquid ammonia; a pump in fluid flow communication with said source of liquid ammonia for pumping liquid ammonia; 15. The furnace defined in claim 14, wherein the ammonia supply inlet is in fluid flow communication with the pump; The device, at least one heat exchanger arranged to preheat liquid ammonia upstream of said pump; and at least one heat exchanger positioned to vaporize pumped liquid ammonia and heat ammonia gas by heat exchange with flue gas and / or cracked gas positioned between the pump and the ammonia feed inlet of the furnace. [Aspect 22] an adiabatic reaction unit for partially decomposing heated ammonia gas at superatmospheric pressure, the adiabatic reaction unit comprising: an inlet for heated ammonia gas at superatmospheric pressure in fluid communication with the pump; and at least one catalyst bed having an upstream end in fluid communication with the inlet and a downstream end in fluid communication with an outlet for partially decomposed ammonia gas; 22. The apparatus of claim 21, wherein the ammonia feed inlet of the furnace is in fluid flow communication with the outlet for partially decomposed ammonia gas of the adiabatic reaction unit.

Claims

1. 1. A process for decomposing ammonia, comprising: providing heated ammonia gas at superatmospheric pressure; combusting a fuel with an oxidant gas in a furnace to heat reactor tubes containing catalyst, each tube containing an upstream layer of a first catalyst and a downstream layer of a second catalyst, and to produce flue gas; feeding the heated ammonia gas, or partially decomposed ammonia gas derived therefrom, into a reactor tube containing the catalyst to cause decomposition of the ammonia and produce a decomposed gas comprising hydrogen gas, nitrogen gas, and residual ammonia gas; the first catalyst is more active for decomposing ammonia than the second catalyst; the catalyst-containing reactor tubes include a layer of a third catalyst downstream of the layer of the second catalyst, the third catalyst being more active for decomposing ammonia than the second catalyst; process.

2. 10. The process of claim 1, wherein the first catalyst is a ruthenium-based catalyst.

3. 10. The process of claim 1, wherein the second catalyst is a nickel-based catalyst.

4. 10. The process of claim 1, wherein the third catalyst contains the same catalytically active metal as the first catalyst.

5. 10. The process of claim 1, wherein the third catalyst is a ruthenium-based catalyst.

6. pumping liquid ammonia containing at least 0.1 mole percent water to produce pumped liquid ammonia; preheating the pumped liquid ammonia to form preheated liquid ammonia; vaporizing the preheated liquid ammonia to produce ammonia gas; heating the ammonia gas to produce the superatmospheric pressure heated ammonia gas; 2. The process of claim 1, wherein the water from the liquid ammonia is present in the heated ammonia gas.

7. 7. The process of claim 6, wherein at least a portion of the heating duty required to provide the heated ammonia gas is provided by heat exchange with the cracked gas.

8. 7. The process of claim 6, wherein the water is present in the heated ammonia gas in an amount of 1 mole percent or less.

9. 10. The process of claim 1, wherein the catalyst-containing reactor tube does not contain an iron-based catalyst.

10. 10. The process of claim 1, comprising partially decomposing the heated ammonia gas in an adiabatic reaction unit comprising at least one catalyst bed to produce the partially decomposed ammonia gas for feeding to catalyst-packed reactor tubes.

11. 11. The process of claim 10, wherein the at least one catalyst bed of the adiabatic reaction unit comprises at least one catalyst selected from a nickel-based catalyst and a ruthenium-based catalyst.

12. 11. The process of claim 10, wherein the at least one catalyst bed of the adiabatic reaction unit does not contain an iron-based catalyst.

13. 1. A furnace for decomposing heated ammonia gas, comprising: a radiant section comprising at least one inlet for fuel and oxidant gas in fluid flow communication with at least one burner, an ammonia supply inlet, and catalyst-containing reactor tubes having an upstream end in fluid flow communication with the ammonia supply inlet and a downstream end in fluid flow communication with an outlet for cracked gases, each tube comprising an upstream layer of a first catalyst and a downstream layer of a second catalyst; a convection section in fluid flow communication with the radiant section and comprising an outlet for flue gas; The furnace wherein the first catalyst is more active for decomposing ammonia than the second catalyst.

14. 14. The furnace of claim 13, wherein the first catalyst is a ruthenium-based catalyst.

15. 14. The furnace of claim 13, wherein the second catalyst is a nickel-based catalyst.

16. 14. The furnace of claim 13, wherein each catalyst-containing reactor tube includes a layer of a third catalyst downstream of the layer of the second catalyst, the third catalyst being more active for decomposing ammonia than the second catalyst.

17. 17. The furnace of claim 16, wherein the third catalyst has the same catalytically active metal as the first catalyst.

18. 17. The furnace of claim 16, wherein the third catalyst is a ruthenium-based catalyst.

19. 14. The furnace of claim 13, wherein the catalyst-containing reactor tubes do not contain an iron-based catalyst.

20. 1. An apparatus for decomposing heated ammonia gas, comprising: a source of liquid ammonia; a pump in fluid flow communication with said source of liquid ammonia for pumping liquid ammonia; a furnace as defined in claim 13, wherein the ammonia feed inlet is in fluid flow communication with the pump; The device, at least one heat exchanger arranged to preheat liquid ammonia upstream of said pump; and at least one heat exchanger positioned to vaporize pumped liquid ammonia and heat ammonia gas by heat exchange with flue gas and / or cracked gas positioned between the pump and the ammonia feed inlet of the furnace.

21. an adiabatic reaction unit for partially decomposing heated ammonia gas at superatmospheric pressure, the adiabatic reaction unit comprising: an inlet for heated ammonia gas at superatmospheric pressure in fluid communication with the pump; and at least one catalyst bed having an upstream end in fluid communication with the inlet and a downstream end in fluid communication with an outlet for partially decomposed ammonia gas; 21. The apparatus of claim 20, wherein the ammonia supply inlet of the furnace is in fluid flow communication with the outlet for partially decomposed ammonia gas of the adiabatic reaction unit.

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