System and method for ammonia synthesis

Abstract

Systems and methods are disclosed herein for synthesizing ammonia using nano-size metal or metal alloy catalyst particles. Hydrogen and nitrogen gases are passed through a system comprising, for example, a bed of magnetite supporting nano-size iron or iron alloy catalyst particles having an optional oxide layer that forms the catalyst.

1 . A method of synthesizing ammonia comprising reacting a supply of nitrogen gas in the presence of nano-sized metal catalyst particles disposed on a ferrous support and in the presence of a nano-sized promoter. 
     
     
         2 . The method of  claim 1 , wherein the metal catalyst comprises an oxide layer. 
     
     
         3 . The method of  claim 1 , wherein the promoter comprises molecules from Groups 1, 2, 6, 9, 13, 14 and/or the lanthanide series on the periodic table. 
     
     
         4 . An ammonia synthesis reactor comprising:
 nano-sized iron catalyst particles and a nano-sized promoter disposed on a ferrous support material within the reactor;   at least one inlet configured to introduce hydrogen gas and nitrogen gas to the nano-sized metal catalyst particles; and   at least one outlet configured to remove ammonia gas generated in the presence of the nano-sized metal catalyst particles, wherein the reactor is configured to operate at a pressure less than about 500 atm.   
     
     
         5 . The method of  claim 4 , wherein the metal catalyst comprises an oxide layer. 
     
     
         6 . The method of  claim 4 , wherein the promoter comprises molecules from Groups 1, 2, 6, 9, 13, 14 and/or the lanthanide series on the periodic table.