Ammonia Oxidation Reactor for Nitric Acid Production

Product Specifications

Technical details and manufacturing context for Ammonia Oxidation Reactor

Definition

The Ammonia Oxidation Reactor is a critical component within the Integrated Nitric Acid Production and Concentration System. It facilitates the high-temperature, catalytic oxidation of ammonia (NH₃) with atmospheric oxygen (from air) over a platinum-rhodium catalyst gauze. This exothermic reaction produces nitrogen monoxide (NO) and water vapor, which are the essential feed gases for the subsequent oxidation and absorption stages that ultimately yield nitric acid (HNO₃). The reactor's design is optimized for high conversion efficiency, temperature control, and catalyst management. The reactor typically operates at a design pressure of 1.0–1.6 MPa and a design temperature of 750–950°C, with a catalyst bed volume of 0.5–5 m³. The ammonia feed rate ranges from 100–1000 kg/h, and the air-to-ammonia ratio is maintained between 1.7–2.0 mol/mol to achieve a conversion rate of 95–98%. The pressure drop across the reactor is 0.05–0.2 MPa. The shell is typically made of carbon steel (SA-516 Gr.70) with a refractory lining, and the catalyst is a platinum-rhodium gauze (90% Pt, 10% Rh) with 10–30 gauzes. The reactor's weight ranges from 5–20 t, and its footprint is 10–50 m². These values are directory reference ranges and must be confirmed for the specific model and application. Standards such as ASME BPVC VIII are referenced for design and verification, but do not imply certification. Always verify model-specific values and standards with the legal manufacturer or supplier.

Working Principle

A mixture of preheated, filtered ammonia and air is passed through one or more layers of platinum-rhodium alloy catalyst gauze inside the reactor vessel. At temperatures typically between 850°C and 950°C, the ammonia reacts catalytically with oxygen to form nitrogen monoxide (NO) and water. The reaction is highly exothermic, and the heat generated is often recovered via waste heat boilers. The hot product gases (NO, N₂, O₂, H₂O) then exit the reactor to be cooled and processed further in the system.

Common Materials

Stainless Steel (e.g., 304/316L for shell), Platinum-Rhodium Alloy Catalyst Gauze, Refractory Lining

Technical Parameters

Parameter	Typical range	Notes & selection driver
Design Pressure	1.0–1.6 MPa	Above 1.6 MPa the catalyst bed may be damagedASME BPVC VIII
Design Temperature	750–950 °C	Above 950°C the catalyst sintersASME BPVC VIII
Catalyst Bed Volume	0.5–5 m³	Determines production capacity
Ammonia Feed Rate	100–1000 kg/h	Matches downstream nitric acid capacity
Air-to-Ammonia Ratio	1.7–2.0 mol/mol	Below 1.7 reduces conversion, above 2.0 increases NOx
Conversion Rate	95–98 %	Below 95% is uneconomical
Pressure Drop	0.05–0.2 MPa	High drop increases energy cost
Shell Material	SA-516 Gr.70	Carbon steel for high-temperature serviceASTM A516
Catalyst Type	Pt-Rh gauze	Platinum-rhodium alloy, 90% Pt, 10% Rh
Number of Catalyst Gauzes	10–30 pieces	More gauzes increase conversion but raise pressure drop
Weight	5–20 t	Affects foundation and lifting requirements
Footprint	10–50 m²	Includes piping and access space

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Reactor Shell/Vessel
Pressure-retaining containment vessel for the reaction, designed to withstand high temperatures and corrosive gases.

Material: Stainless Steel (e.g., 304/316L)
Catalyst Gauze Pack
The active catalytic surface where the ammonia oxidation reaction occurs. Typically multiple layers of platinum-rhodium alloy mesh.

Material: Platinum-Rhodium Alloy (e.g., Pt-10%Rh)
Gas Distributor/Inlet Nozzle
Ensures uniform distribution of the ammonia-air mixture across the catalyst bed to prevent hot spots and ensure even reaction.

Material: Stainless Steel
Thermocouple Wells
Housings for temperature sensors to monitor catalyst bed and gas temperatures at critical points.

Material: High-Temperature Alloy (e.g., Inconel)
Refractory Lining Part
Insulating layer inside the shell to protect the metal from extreme process temperatures and reduce heat loss.

Material: Ceramic Fiber or Castable Refractory
Outlet Nozzle/Duct Part
Directs the hot product gas stream (NO, N₂, O₂, H₂O) out of the reactor to the downstream waste heat boiler.

Material: Stainless Steel

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Frequently Asked Questions

What is the primary function of an ammonia oxidation reactor?

It converts ammonia and oxygen from air into nitrogen monoxide (NO) and water via catalytic oxidation, which is the first step in nitric acid production.

What are typical operating conditions for this reactor?

Design pressure is typically 1.0–1.6 MPa, design temperature 750–950°C, and air-to-ammonia ratio 1.7–2.0 mol/mol. These are reference ranges; actual values depend on the specific design.

Which materials are commonly used in the reactor construction?

The shell is often carbon steel (e.g., SA-516 Gr.70) with a refractory lining, and the catalyst is a platinum-rhodium gauze (90% Pt, 10% Rh).

How can I verify the reactor's compliance with standards?

Check the design and fabrication against applicable codes like ASME BPVC VIII, but always confirm with the manufacturer or supplier for the specific model and application.

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pressure:	1-10 bar (atmospheric to moderate pressure systems)
flow rate:	Varies by capacity: 100-100,000 Nm³/h ammonia-air mixture
temperature:	800-950°C (typical operating range for platinum-rhodium gauze catalysts)
ammonia concentration:	9.5-11.5 vol% in air (explosive limits consideration)
conversion efficiency:	94-98% ammonia to NO under optimal conditions

Ammonia Oxidation Reactor

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Reliability & Engineering Risk Analysis

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