Process Intensification in Ammonia Synthesis Using Novel Coassembled Supported Microporous Catalysts Promoted by Nonthermal Plasma

Abstract

The Integrated Process Intensification approach is used for the synthesis of ammonia using novel coassembled microporous silica supported nickel catalysts and nonthermal plasma reactors operating at ca. 140 ± 10 °C and ambient pressure. The conversion levels of nitrogen and hydrogen to ammonia are similar to that achieved by the current industrial best practice which is, however, carried out at 100-250 bar and the temperatures 350-550 °C. In order to achieve continuous plasma generation, a novel catalyst, which has a surface area of ca. 200 m2/g in the form of lamellae with ca. 2 nm thick plates of nickel catalyst sandwiched between the silica support, has been used in the presence of plasma catalysis promoters in the form of spheres made from high permittivity material. In addition to process variables (flow rate, feed composition, and plasma power input), the effect of the electrode configuration on conversion was investigated. It is shown that the catalyst activity remained constant over a continuous period of 72 h when the reaction was terminated. © 2016 American Chemical Society.