
doi: 10.2139/ssrn.6886853
Small-scale, renewable-powered Haber–Bosch (HB) synthesis is constrained by inefficient ammonia separation at reduced operating pressures, where conventional condensation removes less than 10% of NH₃ per pass due to vapor–liquid equilibrium limitations. Sorption-based separation offers a potential alternative by selectively removing NH₃ from the synthesis loop, enhancing equilibrium conversion.This work develops an integrated framework combining sorbent screening, dynamic cycle simulation, and process-level energy assessment for distributed ammonia production.Five sorbent classes (activated carbons, zeolites, metal halides, hydrides, and borohydrides) were evaluated using a multi-criteria decision methodology based on working capacity, regeneration requirements, kinetics, stability, cost, and safety. Zeolite 13X was identified as the most suitable candidate and implemented in a three-step pressure swing adsorption (PSA) cycle simulated in Aspen Adsorption® V14 under representative HB effluent conditions (220 °C, 150 bar, 24 mol% NH₃).The PSA cycle reduced the recycle NH₃ concentration from 2.4 mol% to 0.033 mol%, corresponding to a ~70-fold improvement in recycle cleanup. However, the desorption stream contained only 37 mol% NH₃, significantly below the 99.99 mol% purity achieved by conventional condensation.A shortcut screening framework linking sorbent properties to process-level energy demand was developed and benchmarked against the conventional separation requirement of 0.21 kWh kg⁻¹ NH₃. Although the PSA cycle satisfies the benchmark in terms of recycle cleanup and nominal separation energy, product dilution remains the dominant limitation. The proposed framework identifies the sorbent targets required for sorption-enhanced HB systems to become energetically competitive, providing a generalizable methodology for process–material integration studies.
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