Ammonia Synthesis Plant Design
Four-Quarter Capstone Project Series • UC San Diego • 2024-2025
Comprehensive design and optimization of a complete ammonia synthesis plant using the Haber-Bosch process. This year-long capstone project spanned four courses, progressing from fundamental thermodynamics through advanced reactor design, process integration, and economic analysis to deliver a complete industrial plant design with detailed engineering specifications and economic feasibility assessment.
Project Scope & Engineering Impact
Industrial Scale Design
Complete ammonia synthesis facility capable of producing 943.2 kmol/h NH₃ using natural gas feedstock. Integrated hydrogen production via steam methane reforming with advanced heat integration and recycle optimization.
Process Engineering Excellence
Multi-stage reactor system with interstage cooling achieving 45.21% hydrogen conversion. Advanced separation systems with comprehensive recycle streams and energy recovery optimization.
Economic Viability
Complete techno-economic analysis with capital cost estimation, operating expense optimization, and profitability assessment demonstrating commercial feasibility for large-scale ammonia production.
Four-Quarter Engineering Development
Thermodynamics & Material Balances
CENG 102Foundation quarter establishing complete plant mass and energy balances. Applied thermodynamic principles to calculate heating requirements, compression work, and phase equilibria throughout the process.
Key Engineering Calculations:
- Steam methane reforming: 10,771 kW heat duty
- Multi-stage compression: 19,099 kW recycle compressor work
- Water-gas shift reactor: -4,029 kW reaction heat
- Ammonia synthesis reactor: -11,021 kW exothermic heat
- Complete plant energy integration and utility requirements
Advanced Reactor Design & Kinetics
CENG 113Detailed reactor design using Temkin-Pyzhev kinetics for ammonia synthesis. Developed mathematical models for three reactor configurations with increasing complexity and heat integration.
Reactor Engineering Achievements:
- 48.9% production increase through interstage cooling design
- Stream tearing methodology for recycle convergence
- Heat exchanger optimization: 1,250.5 m² area
- Multi-reactor system with thermal integration
- Advanced kinetic modeling with MATLAB simulation
Separation Systems & Process Integration
CENG 120Design of advanced separation systems including distillation columns, condensers, and gas-liquid separators. Optimized process flowsheet with comprehensive material and energy integration.
Separation Engineering Design:
- Multi-stage distillation for product purification
- Condenser design with -6,379 kW heat duty
- Gas-liquid separation optimization
- Process flowsheet development and integration
- Equipment sizing and specification
Economic Analysis & Plant Optimization
CENG 122Complete techno-economic analysis with capital cost estimation, operating expense optimization, and profitability assessment. Final plant optimization for maximum economic return.
Economic Engineering Analysis:
- Complete CAPEX and OPEX estimation
- Net present value and IRR calculations
- Sensitivity analysis for key parameters
- Process optimization for maximum profitability
- Risk assessment and economic feasibility
Advanced Engineering Competencies Developed
Process Design & Simulation
- Complete plant flowsheet development
- Advanced process simulation and modeling
- Heat and mass integration optimization
- Multi-unit operation coordination
Reactor Engineering
- Packed bed reactor design and optimization
- Advanced kinetic modeling (Temkin-Pyzhev)
- Multi-stage reactor systems with heat integration
- Recycle stream optimization and convergence
Separation Processes
- Distillation column design and sizing
- Multi-phase separation systems
- Heat exchanger network synthesis
- Equipment specification and selection
Economic Analysis
- Capital and operating cost estimation
- Economic optimization and profitability analysis
- Risk assessment and sensitivity analysis
- Investment decision and feasibility studies
Engineering Performance Achievements
Industrial Engineering Impact
This comprehensive four-quarter capstone project demonstrates mastery of complete chemical plant design from fundamental principles through economic viability. The integrated approach spanning thermodynamics, reaction engineering, separation processes, and economic analysis provides critical skills for industrial process design and optimization. The project showcases ability to handle complex, multi-disciplinary engineering challenges typical of senior process engineering roles in chemical, petrochemical, and specialty chemical industries.