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Xuping Sun - One of the best experts on this subject based on the ideXlab platform.

Robert Schlogl - One of the best experts on this subject based on the ideXlab platform.

  • the haber bosch Process revisited on the real structure and stability of ammonia iron under working conditions
    Angewandte Chemie, 2013
    Co-Authors: Timur Kandemir, Manfred Erwin Schuster, Anatoliy Senyshyn, Malte Behrens, Robert Schlogl
    Abstract:

    Ammonia synthesis is one of the largest Processes in chemical industries. It was first operated at BASF one hundred years ago based on the fundamental work of Fritz Haber and Process engineering by Carl Bosch. Haber combined feed gas recycling with application of high pressure (P = 200 bar) and a Ruthenium catalyst to achieve sufficiently high conversions of nitrogen according to N2 + 3 H2 .2 NH3. This success enabled the large scale production of artificial fertilizers, which was a prerequisite to face the world’s increase in population and is known as the “extraction of air from bread” – a term that was coined later by Max von Laue. Today, contrary to the generation of syngas for ammonia, only little has changed in the industrial Process for the actual synthesis of ammonia.The Process is operated at typical temperatures of 500 °C and pressures around 200 bar, resulting in ammonia concentrations in the exhaust gas of up to 17 vol.%. Approximately 80% of the worldwide ammonia output of 136 Mtons (2011) is used for the production of fertilizers. A key development for the modern Haber-Bosch Process, however, has been the catalyst development at BASF that was led by Alwin Mittasch in the early 20 century. After testing 22 000 different formulations in a gigantic effort, the work was concluded in 1922 with the identification of a very unique catalyst synthesis. To achieve a highly active iron catalyst, magnetite, Fe3O4, was promoted by fusing it together with irreducible oxides (K2O, Al2O3, later also CaO) in an oxide melt at temperatures around 1000 °C. The fused magnetite is mechanically granulated and its reduction need to be conducted with great care in the syngas feed to finally give the active α-Fe catalyst. This special synthesis leads to certain crucial properties of the resulting α-Fe phase, which is commonly termed “ammonia iron”. In addition to its outstanding economic relevance, ammonia synthesis acts as a “drosophila reaction” for catalysis research and has always been a test case for the maturity of catalysis science in the context of a technologically mature application. Today, due to the enormous efforts in surface science, physical and theoretical chemistry, and chemical engineering a consistent picture of the reaction mechanism and the role of the Fe catalyst and its promoters has emerged. Key contributions to the modern understanding of the ammonia synthesis reactions came from the teams lead by Gerhard Ertl, Michel Boudart, Gabor Somorjai, Haldor Topsoe and Jens K. Norskov, just to mention a few. However, even after 100 years of application and research there still is scientific interest in the Haber-Bosch Process, mainly because of two aspects. Firstly, catalysts with improved lowtemperature activity, higher specific surface area and higher tolerance against poisons and on-off operations are generally desirable. Also the development of a more elegant synthesis route for the Fe-based catalyst without the melting step and the extremely critical activation procedure could foster the potential application of ammonia as an energy storage molecule. Secondly, there still is a gap between the model studies conducted with well-defined simplified materials with clean surfaces at low pressures to elaborate the current knowledge of ammonia synthesis and the industrial Process. These so-called pressure and materials gaps often prevent straightforward extrapolation of model studies to real industrial Processes. Thus, the question of a dynamical change of the catalyst under true reaction conditions remains to be studied and calls for in situ experimentation. This point requires special attention in case of the ammonia synthesis over iron catalysts, because it is well known and has been studied for decades in the context of steel hardening and catalytic ammonia decomposition that iron can be easily nitrided by ammonia. Ertl and co-workers described the reaction mechanism of ammonia synthesis. 14] He and other authors showed that the reaction is structure sensitive. The dissociative chemisorption of di-nitrogen on the iron surface is the rate limiting step in ammonia synthesis and opens possibilities for sub-surface diffusion of the atomic nitrogen. Ertl et al. proposed the surface dissolution of nitrogen into iron forming a surface nitride of the approximate composition Fe2N and the presence of in-situ formed metastable γFe4N. [6a] Thus, for experimental conditions remote from the HaberBosch Process, participation of stoichiometric bulk nitrides like FeN has been excluded. Instead, Herzog et al. proposed formation of [∗] Timur Kandemir, Dr. Manfred.E. Schuster, Dr. Malte Behrens, Prof. Dr. Robert Schlogl Department of Inorganic Chemistry Fritz-Haber-Institut der Max-Planck-Gesellschaft Faradayweg 4-6, D-14195 Berlin, Germany Fax: (+)49-(0)30-8413-4401 E-mail: behrens@fhi-berlin.mpg.de, acsek@fhi-berlin.mpg.de

  • The Haber–Bosch Process Revisited: On the Real Structure and Stability of “Ammonia Iron” under Working Conditions
    Angewandte Chemie (International ed. in English), 2013
    Co-Authors: Timur Kandemir, Manfred Erwin Schuster, Anatoliy Senyshyn, Malte Behrens, Robert Schlogl
    Abstract:

    Ammonia synthesis is one of the largest Processes in chemical industries. It was first operated at BASF one hundred years ago based on the fundamental work of Fritz Haber and Process engineering by Carl Bosch. Haber combined feed gas recycling with application of high pressure (P = 200 bar) and a Ruthenium catalyst to achieve sufficiently high conversions of nitrogen according to N2 + 3 H2 .2 NH3. This success enabled the large scale production of artificial fertilizers, which was a prerequisite to face the world’s increase in population and is known as the “extraction of air from bread” – a term that was coined later by Max von Laue. Today, contrary to the generation of syngas for ammonia, only little has changed in the industrial Process for the actual synthesis of ammonia.The Process is operated at typical temperatures of 500 °C and pressures around 200 bar, resulting in ammonia concentrations in the exhaust gas of up to 17 vol.%. Approximately 80% of the worldwide ammonia output of 136 Mtons (2011) is used for the production of fertilizers. A key development for the modern Haber-Bosch Process, however, has been the catalyst development at BASF that was led by Alwin Mittasch in the early 20 century. After testing 22 000 different formulations in a gigantic effort, the work was concluded in 1922 with the identification of a very unique catalyst synthesis. To achieve a highly active iron catalyst, magnetite, Fe3O4, was promoted by fusing it together with irreducible oxides (K2O, Al2O3, later also CaO) in an oxide melt at temperatures around 1000 °C. The fused magnetite is mechanically granulated and its reduction need to be conducted with great care in the syngas feed to finally give the active α-Fe catalyst. This special synthesis leads to certain crucial properties of the resulting α-Fe phase, which is commonly termed “ammonia iron”. In addition to its outstanding economic relevance, ammonia synthesis acts as a “drosophila reaction” for catalysis research and has always been a test case for the maturity of catalysis science in the context of a technologically mature application. Today, due to the enormous efforts in surface science, physical and theoretical chemistry, and chemical engineering a consistent picture of the reaction mechanism and the role of the Fe catalyst and its promoters has emerged. Key contributions to the modern understanding of the ammonia synthesis reactions came from the teams lead by Gerhard Ertl, Michel Boudart, Gabor Somorjai, Haldor Topsoe and Jens K. Norskov, just to mention a few. However, even after 100 years of application and research there still is scientific interest in the Haber-Bosch Process, mainly because of two aspects. Firstly, catalysts with improved lowtemperature activity, higher specific surface area and higher tolerance against poisons and on-off operations are generally desirable. Also the development of a more elegant synthesis route for the Fe-based catalyst without the melting step and the extremely critical activation procedure could foster the potential application of ammonia as an energy storage molecule. Secondly, there still is a gap between the model studies conducted with well-defined simplified materials with clean surfaces at low pressures to elaborate the current knowledge of ammonia synthesis and the industrial Process. These so-called pressure and materials gaps often prevent straightforward extrapolation of model studies to real industrial Processes. Thus, the question of a dynamical change of the catalyst under true reaction conditions remains to be studied and calls for in situ experimentation. This point requires special attention in case of the ammonia synthesis over iron catalysts, because it is well known and has been studied for decades in the context of steel hardening and catalytic ammonia decomposition that iron can be easily nitrided by ammonia. Ertl and co-workers described the reaction mechanism of ammonia synthesis. 14] He and other authors showed that the reaction is structure sensitive. The dissociative chemisorption of di-nitrogen on the iron surface is the rate limiting step in ammonia synthesis and opens possibilities for sub-surface diffusion of the atomic nitrogen. Ertl et al. proposed the surface dissolution of nitrogen into iron forming a surface nitride of the approximate composition Fe2N and the presence of in-situ formed metastable γFe4N. [6a] Thus, for experimental conditions remote from the HaberBosch Process, participation of stoichiometric bulk nitrides like FeN has been excluded. Instead, Herzog et al. proposed formation of [∗] Timur Kandemir, Dr. Manfred.E. Schuster, Dr. Malte Behrens, Prof. Dr. Robert Schlogl Department of Inorganic Chemistry Fritz-Haber-Institut der Max-Planck-Gesellschaft Faradayweg 4-6, D-14195 Berlin, Germany Fax: (+)49-(0)30-8413-4401 E-mail: behrens@fhi-berlin.mpg.de, acsek@fhi-berlin.mpg.de

Jens K. Nørskov - One of the best experts on this subject based on the ideXlab platform.

  • A theoretical explanation of the effect of oxygen poisoning on industrial Haber-Bosch catalysts
    Journal of Catalysis, 2019
    Co-Authors: Brian A. Rohr, Aayush R. Singh, Jens K. Nørskov
    Abstract:

    Abstract The Haber-Bosch Process has been studied extensively, yet a low-temperature, low-pressure Process remains elusive. As has been shown many times, this stems in part from the difficulty of breaking the N-N triple bond. In this work, we highlight an additional reason for the lack of a low-temperature ammonia synthesis Process: the effect of oxygen poisoning at low temperature. Using density functional theory (DFT), we have created a new model for the active site of industrial Haber-Bosch catalysts which explicitly includes the potassium promoter. Furthermore, we present a new micro-kinetic model for ammonia synthesis that includes the effect of oxygen poisoning due to trace water content in the input gas stream. Our model agrees well with previous experiments and shows that devising a strategy to avoid oxygen poisoning is crucial to creating a low-temperature Haber-Bosch Process. Additionally, the model suggests that using a weaker-binding catalyst is one way to avoid oxygen poisoning if it is impractical to remove all water from the reactor.

  • Exploring the limits: A low-pressure, low-temperature Haber–Bosch Process
    Chemical Physics Letters, 2014
    Co-Authors: Aleksandra Vojvodic, Andrew J. Medford, Felix Studt, Frank Abild-pedersen, Tuhin Suvra Khan, Thomas Bligaard, Jens K. Nørskov
    Abstract:

    Abstract The Haber–Bosch Process for ammonia synthesis has been suggested to be the most important invention of the 20th century, and called the ‘Bellwether reaction in heterogeneous catalysis’. We examine the catalyst requirements for a new low-pressure, low-temperature synthesis Process. We show that the absence of such a Process for conventional transition metal catalysts can be understood as a consequence of a scaling relation between the activation energy for N 2 dissociation and N adsorption energy found at the surface of these materials. A better catalyst cannot obey this scaling relation. We define the ideal scaling relation characterizing the most active catalyst possible, and show that it is theoretically possible to have a low pressure, low-temperature Haber–Bosch Process. The challenge is to find new classes of catalyst materials with properties approaching the ideal, and we discuss the possibility that transition metal compounds have such properties.

William A. Goddard - One of the best experts on this subject based on the ideXlab platform.

Timur Kandemir - One of the best experts on this subject based on the ideXlab platform.

  • the haber bosch Process revisited on the real structure and stability of ammonia iron under working conditions
    Angewandte Chemie, 2013
    Co-Authors: Timur Kandemir, Manfred Erwin Schuster, Anatoliy Senyshyn, Malte Behrens, Robert Schlogl
    Abstract:

    Ammonia synthesis is one of the largest Processes in chemical industries. It was first operated at BASF one hundred years ago based on the fundamental work of Fritz Haber and Process engineering by Carl Bosch. Haber combined feed gas recycling with application of high pressure (P = 200 bar) and a Ruthenium catalyst to achieve sufficiently high conversions of nitrogen according to N2 + 3 H2 .2 NH3. This success enabled the large scale production of artificial fertilizers, which was a prerequisite to face the world’s increase in population and is known as the “extraction of air from bread” – a term that was coined later by Max von Laue. Today, contrary to the generation of syngas for ammonia, only little has changed in the industrial Process for the actual synthesis of ammonia.The Process is operated at typical temperatures of 500 °C and pressures around 200 bar, resulting in ammonia concentrations in the exhaust gas of up to 17 vol.%. Approximately 80% of the worldwide ammonia output of 136 Mtons (2011) is used for the production of fertilizers. A key development for the modern Haber-Bosch Process, however, has been the catalyst development at BASF that was led by Alwin Mittasch in the early 20 century. After testing 22 000 different formulations in a gigantic effort, the work was concluded in 1922 with the identification of a very unique catalyst synthesis. To achieve a highly active iron catalyst, magnetite, Fe3O4, was promoted by fusing it together with irreducible oxides (K2O, Al2O3, later also CaO) in an oxide melt at temperatures around 1000 °C. The fused magnetite is mechanically granulated and its reduction need to be conducted with great care in the syngas feed to finally give the active α-Fe catalyst. This special synthesis leads to certain crucial properties of the resulting α-Fe phase, which is commonly termed “ammonia iron”. In addition to its outstanding economic relevance, ammonia synthesis acts as a “drosophila reaction” for catalysis research and has always been a test case for the maturity of catalysis science in the context of a technologically mature application. Today, due to the enormous efforts in surface science, physical and theoretical chemistry, and chemical engineering a consistent picture of the reaction mechanism and the role of the Fe catalyst and its promoters has emerged. Key contributions to the modern understanding of the ammonia synthesis reactions came from the teams lead by Gerhard Ertl, Michel Boudart, Gabor Somorjai, Haldor Topsoe and Jens K. Norskov, just to mention a few. However, even after 100 years of application and research there still is scientific interest in the Haber-Bosch Process, mainly because of two aspects. Firstly, catalysts with improved lowtemperature activity, higher specific surface area and higher tolerance against poisons and on-off operations are generally desirable. Also the development of a more elegant synthesis route for the Fe-based catalyst without the melting step and the extremely critical activation procedure could foster the potential application of ammonia as an energy storage molecule. Secondly, there still is a gap between the model studies conducted with well-defined simplified materials with clean surfaces at low pressures to elaborate the current knowledge of ammonia synthesis and the industrial Process. These so-called pressure and materials gaps often prevent straightforward extrapolation of model studies to real industrial Processes. Thus, the question of a dynamical change of the catalyst under true reaction conditions remains to be studied and calls for in situ experimentation. This point requires special attention in case of the ammonia synthesis over iron catalysts, because it is well known and has been studied for decades in the context of steel hardening and catalytic ammonia decomposition that iron can be easily nitrided by ammonia. Ertl and co-workers described the reaction mechanism of ammonia synthesis. 14] He and other authors showed that the reaction is structure sensitive. The dissociative chemisorption of di-nitrogen on the iron surface is the rate limiting step in ammonia synthesis and opens possibilities for sub-surface diffusion of the atomic nitrogen. Ertl et al. proposed the surface dissolution of nitrogen into iron forming a surface nitride of the approximate composition Fe2N and the presence of in-situ formed metastable γFe4N. [6a] Thus, for experimental conditions remote from the HaberBosch Process, participation of stoichiometric bulk nitrides like FeN has been excluded. Instead, Herzog et al. proposed formation of [∗] Timur Kandemir, Dr. Manfred.E. Schuster, Dr. Malte Behrens, Prof. Dr. Robert Schlogl Department of Inorganic Chemistry Fritz-Haber-Institut der Max-Planck-Gesellschaft Faradayweg 4-6, D-14195 Berlin, Germany Fax: (+)49-(0)30-8413-4401 E-mail: behrens@fhi-berlin.mpg.de, acsek@fhi-berlin.mpg.de

  • The Haber–Bosch Process Revisited: On the Real Structure and Stability of “Ammonia Iron” under Working Conditions
    Angewandte Chemie (International ed. in English), 2013
    Co-Authors: Timur Kandemir, Manfred Erwin Schuster, Anatoliy Senyshyn, Malte Behrens, Robert Schlogl
    Abstract:

    Ammonia synthesis is one of the largest Processes in chemical industries. It was first operated at BASF one hundred years ago based on the fundamental work of Fritz Haber and Process engineering by Carl Bosch. Haber combined feed gas recycling with application of high pressure (P = 200 bar) and a Ruthenium catalyst to achieve sufficiently high conversions of nitrogen according to N2 + 3 H2 .2 NH3. This success enabled the large scale production of artificial fertilizers, which was a prerequisite to face the world’s increase in population and is known as the “extraction of air from bread” – a term that was coined later by Max von Laue. Today, contrary to the generation of syngas for ammonia, only little has changed in the industrial Process for the actual synthesis of ammonia.The Process is operated at typical temperatures of 500 °C and pressures around 200 bar, resulting in ammonia concentrations in the exhaust gas of up to 17 vol.%. Approximately 80% of the worldwide ammonia output of 136 Mtons (2011) is used for the production of fertilizers. A key development for the modern Haber-Bosch Process, however, has been the catalyst development at BASF that was led by Alwin Mittasch in the early 20 century. After testing 22 000 different formulations in a gigantic effort, the work was concluded in 1922 with the identification of a very unique catalyst synthesis. To achieve a highly active iron catalyst, magnetite, Fe3O4, was promoted by fusing it together with irreducible oxides (K2O, Al2O3, later also CaO) in an oxide melt at temperatures around 1000 °C. The fused magnetite is mechanically granulated and its reduction need to be conducted with great care in the syngas feed to finally give the active α-Fe catalyst. This special synthesis leads to certain crucial properties of the resulting α-Fe phase, which is commonly termed “ammonia iron”. In addition to its outstanding economic relevance, ammonia synthesis acts as a “drosophila reaction” for catalysis research and has always been a test case for the maturity of catalysis science in the context of a technologically mature application. Today, due to the enormous efforts in surface science, physical and theoretical chemistry, and chemical engineering a consistent picture of the reaction mechanism and the role of the Fe catalyst and its promoters has emerged. Key contributions to the modern understanding of the ammonia synthesis reactions came from the teams lead by Gerhard Ertl, Michel Boudart, Gabor Somorjai, Haldor Topsoe and Jens K. Norskov, just to mention a few. However, even after 100 years of application and research there still is scientific interest in the Haber-Bosch Process, mainly because of two aspects. Firstly, catalysts with improved lowtemperature activity, higher specific surface area and higher tolerance against poisons and on-off operations are generally desirable. Also the development of a more elegant synthesis route for the Fe-based catalyst without the melting step and the extremely critical activation procedure could foster the potential application of ammonia as an energy storage molecule. Secondly, there still is a gap between the model studies conducted with well-defined simplified materials with clean surfaces at low pressures to elaborate the current knowledge of ammonia synthesis and the industrial Process. These so-called pressure and materials gaps often prevent straightforward extrapolation of model studies to real industrial Processes. Thus, the question of a dynamical change of the catalyst under true reaction conditions remains to be studied and calls for in situ experimentation. This point requires special attention in case of the ammonia synthesis over iron catalysts, because it is well known and has been studied for decades in the context of steel hardening and catalytic ammonia decomposition that iron can be easily nitrided by ammonia. Ertl and co-workers described the reaction mechanism of ammonia synthesis. 14] He and other authors showed that the reaction is structure sensitive. The dissociative chemisorption of di-nitrogen on the iron surface is the rate limiting step in ammonia synthesis and opens possibilities for sub-surface diffusion of the atomic nitrogen. Ertl et al. proposed the surface dissolution of nitrogen into iron forming a surface nitride of the approximate composition Fe2N and the presence of in-situ formed metastable γFe4N. [6a] Thus, for experimental conditions remote from the HaberBosch Process, participation of stoichiometric bulk nitrides like FeN has been excluded. Instead, Herzog et al. proposed formation of [∗] Timur Kandemir, Dr. Manfred.E. Schuster, Dr. Malte Behrens, Prof. Dr. Robert Schlogl Department of Inorganic Chemistry Fritz-Haber-Institut der Max-Planck-Gesellschaft Faradayweg 4-6, D-14195 Berlin, Germany Fax: (+)49-(0)30-8413-4401 E-mail: behrens@fhi-berlin.mpg.de, acsek@fhi-berlin.mpg.de