Shell and Tube Heat Exchangers for Green Ammonia Plants

Green ammonia production integrates electrolyzers, air separation units (ASU), hydrogen compression, and Haber–Bosch synthesis loops. Each stage generates or requires precise heat control to ensure efficiency and process stability.

Shell and tube heat exchangers are commonly used for:

• Hydrogen and nitrogen preheating

• Electrolyzer cooling and heat recovery

• Inter-stage cooling in compressors

• Ammonia synthesis loop heat recovery

• Product ammonia cooling and condensation

• Waste heat recovery for steam or hot water generation

Why Shell and Tube Heat Exchangers Are Ideal for Green Ammonia

Green ammonia plants operate under high pressure, hydrogen-rich environments, where safety and durability are essential. Shell and tube heat exchangers offer proven advantages:

• High pressure and temperature resistance

• Excellent compatibility with hydrogen service

• Flexible thermal design for fluctuating renewable power loads

• Low leakage risk and robust mechanical strength

• Ease of inspection, cleaning, and maintenance

Their modular design makes them suitable for both large-scale industrial plants and modular green ammonia units.

Case Study 1: Green Ammonia Pilot Plant – Hydrogen & Nitrogen Preheating

• Project Type: Green Ammonia Pilot Facility

• Plant Capacity: 5–10 TPD Green Ammonia

• Application: Feed gas preheating before ammonia synthesis loop

• Challenge

The pilot plant operates with variable hydrogen flow due to renewable power fluctuations from solar and wind sources. Stable temperature control was required to protect the ammonia catalyst and ensure reliable synthesis under part-load conditions.

Solution

A custom shell and tube heat exchanger was supplied for hydrogen–nitrogen feed gas preheating, designed for frequent load changes and hydrogen service.

• Key Design Features:

U-tube configuration to handle thermal expansion

Austenitic stainless steel tubes for hydrogen compatibility

ASME-compliant pressure design

Optimized baffle spacing for low pressure drop

• Results

Stable feed gas temperature across variable loads

Improved catalyst protection and longer catalyst life

Reduced energy losses during start-up and shutdown

Proven performance under intermittent renewable operation

Case Study 2: Industrial-Scale Green Ammonia Plant – Synthesis Loop Heat Recovery

• Project Type: Industrial Green Ammonia Plant

• Plant Capacity: 600–1,000 TPD Green Ammonia

• Application: Ammonia synthesis loop heat recovery and cooling

• Challenge

The ammonia synthesis loop operates at high pressure and elevated temperatures, requiring reliable heat removal while maximizing heat recovery for plant efficiency.

Solution

A heavy-duty shell and tube heat exchanger was engineered to recover waste heat from the synthesis loop and preheat process streams.

• Key Design Features:

Floating head design for mechanical flexibility

Cr-Mo alloy steel shell for high-temperature resistance

High-pressure tube sheets with hydrogen-tight joints

Designed to ASME, TEMA R standards

• Results

Significant reduction in overall electrical consumption

Improved heat integration within the plant

Enhanced operational safety in hydrogen-rich service

Long-term reliability in continuous operation

Energy Efficiency and Heat Recovery

Energy efficiency is a key objective in green ammonia production. Shell and tube heat exchangers enable effective waste heat recovery, allowing plants to:

• Reduce overall electricity consumption

• Recover heat from synthesis loops and compressors

• Preheat feed gases and boiler feedwater

• Improve overall plant efficiency and sustainability

Efficient heat integration helps maximize the value of renewable energy input.

Quality, Safety, and Compliance

Given the critical nature of green ammonia plants, shell and tube heat exchangers are manufactured with rigorous quality standards:

• Full material traceability and certification

• Non-destructive testing (RT, UT, PT)

• Pressure and leak testing

• Compliance with international codes and hydrogen safety guidelines

Shell and tube heat exchangers are a core thermal solution for green ammonia production, offering unmatched reliability, safety, and efficiency in hydrogen-rich and high-pressure environments. Their proven design, material flexibility, and energy recovery capabilities make them essential for supporting the global transition to low-carbon and renewable ammonia production.