Techno-economic analysis of blue ammonia synthesis using cryogenic CO2 capture Process-A Danish case investigation

Ammonia is a vital chemical with numerous applications. Currently, the primary methods for generating the necessary reactants for ammonia production involve steam methane reforming (SMR) and cryogenic air separation unit (CASU), while the Haber-Bosch process converts these reactants into ammonia. However, the SMR process releases substantial amounts of CO2, making it imperative to employ an efficient and cost-effective CO2 capture technology to mitigate emissions. This investigation focuses on evaluating the cryogenic CO2 capture (CCC) process for blue ammonia production and provides a thorough economic analysis, estimating both the initial investment costs and operational expenses involved in producing blue ammonia. The results indicated that the CCC process can capture 90% of the CO2 content in the flue gas emitted by the SMR, incurring an energy penalty of 0.724 MJe/kgCO2 while capturing CO2 in the liquid phase with purities exceeding 99.9%. In this case, the estimated CO2 capture costs would be 18.05, 45.1, and 16.65 USD/ton in 2021, 2022, and 2023, respectively. This represents a 40% reduction compared to the CO2 capture costs associated with conventional amine-based technology. The results of this study indicate that the annual electricity costs for ammonia production increase by 38.5% and 64.2% when employing the CCC and amine-based processes, respectively. This investigation employed an isothermal reactor for ammonia synthesis, using the heat from the exothermic reaction in a water ammonia absorption refrigeration cycle (ARC) to condense and purify ammonia. The results show that the ARC system can effectively condense ammonia at −6 °C, producing a liquid ammonia stream with 99.3% purity. This leads to a 95% reduction in power consumption compared to a vapor compression refrigeration cycle (VCRC). Consequently, this method has the potential to decrease the annual operational costs for ammonia production by 2.92%, 2.69%, and 3.13% in 2021, 2022, and 2023, respectively. This study indicated that the hydrogen production unit incurs the highest initial investment costs, as well as operating costs, in the blue ammonia production process, followed by CASU and the Haber-Bosch process.