Power-to-ammonia synthesis process with membrane reactors: Techno- economic study

This work aims at investigating the potential of catalytic membrane reactors (CMRs) for ammonia production from renewable hydrogen. To achieve this objective, computer-aided process simulation is deployed using Aspen plus v14 simulation tool. A 1D model is developed to describe the integration of a ruthenium catalyst into a CMR equipped with inorganic membranes that are selective to NH₃ over N₂ and H₂. First, the CMR performance is studied across a broad spectrum of membrane properties and operating conditions. Subsequently, the CMR model is integrated into several Power-to-Ammonia (PtA) process layouts, which are optimized and techno-economically compared against a traditional PEM-based PtA production process, employing condensation for the purification stage. Key findings at the reactor level confirmed that beyond a selectivity threshold towards hydrogen of 10–20, both the degree of conversion and recovery tend to be generally independent of the membrane's selectivity. However, for producing pure ammonia permeate, highly selective membranes (>1000 towards H₂) depending on the pressure drop are found essential making this alternative elusive based on existing membranes. At the PtA level, results in terms of efficiency indicates that the use of membrane reactor increases the system efficiency by around ∼8% with respect to reference case while ∼15% enhancement is achieved with this process when using SOEC technology. When examining the final Levelized Cost of Ammonia (LCOA), incorporating a membrane reactor in conjunction with condensation separation results in a cost that nearly matches the reference case. Future research should focus on replacing the condensation process with a method of purification at lower pressures. This could potentially further improve efficiency and reduce the cost of the membrane reactor compared to the traditional one.