Power-to-Chemicals Process Integration: Green Hydrogen Utilization in Ammonia Synthesis Loop Optimization

Abstract

The transition toward low-carbon industrial production has accelerated the development of sustainable process integration strategies for chemical manufacturing systems. This study investigates power-to-chemicals process integration through the utilization of green hydrogen in ammonia synthesis loop optimization for energy-efficient and environmentally sustainable ammonia production. The proposed framework integrates renewable energy-driven hydrogen generation with advanced ammonia synthesis process modeling to enhance operational efficiency, reduce carbon emissions, and improve resource utilization within industrial chemical plants. A comprehensive thermodynamic and process simulation analysis was conducted to evaluate the influence of hydrogen purity, reactor operating conditions, pressure optimization, recycle flow configuration, and energy integration strategies on ammonia synthesis performance. Green hydrogen produced through renewable-powered electrolysis was incorporated into the synthesis loop to assess its impact on process stability, conversion efficiency, and environmental sustainability. Simulation results demonstrated that optimized integration of green hydrogen significantly improves ammonia yield, reduces fossil fuel dependency, and lowers greenhouse gas emissions compared to conventional ammonia production systems. The study further revealed that effective heat recovery and process energy optimization contribute to enhanced operational efficiency and reduced energy consumption within the synthesis loop. Comparative evaluation indicated improved economic and environmental performance through optimized process integration and adaptive operational control strategies. Additionally, the integration of renewable energy resources supported greater flexibility in ammonia production under dynamic energy supply conditions.