Air → Brain → Energy

Tauhid Nur Azhar

Photo by Milad Fakurian on Unsplash

This morning until now, I have been entrusted with the task of serving at PT Rekayasa Industri (Rekind), a company involved in industrial design and construction, also known as Engineering, Procurement, & Construction (EPC), which provides integrated industrial solutions. Rekind’s shares are owned by Pupuk Indonesia (90.06%), Pupuk Kalimantan Timur (4.97%), and the Indonesian Government (4.97%).

Conceived by Mr. Hartarto during his tenure as Director General of Basic Chemical Industry at the Ministry of Industry and Trade during President Suharto’s era in 1981, Rekind was officially established on August 12, 1981.

In 1982, Rekind began participating in the construction of the Pabrik Pupuk Iskandar Muda 1 as part of the EPC technology transfer process from foreign contractors. Later, in 1986, the company was appointed as the EPC contractor for the construction of the Pabrik Pupuk Kalimantan Timur III, designed to produce 1,000 tons of ammonia and 1,725 tons of urea per day.

To date, Rekind has provided various large-scale integrated industrial solutions in the fields of petrochemicals, fertilizers, oil and gas (onshore and offshore), minerals/mining, electricity (including renewable energy), agro-industry, other industrial infrastructure, and more, both in Indonesia and abroad.

What is particularly fascinating and astonishing to me as I study Rekind’s EPC-focused business model is the fact that humans, with all their cognitive abilities and logic housed in their brains, can imagine, study, and observe various natural phenomena, develop concepts through hypothesis testing, use mathematical algorithm-based tools, discover various chemical reactions and material properties, formulate physical laws in axioms and formulas, and do not stop there. Humans then engineer and replicate natural phenomena in multi-scale factories, gaining benefits and added value that contribute to improving their comfort and quality of life.

For example, fertilizers. As the human population continues to grow and even explode, according to Malthus’s prediction, the issues of food and energy become fundamental and crucial.

Although the cultivation and domestication of various plant and animal species supporting food have been carried out, the exponentially increasing demand brings human civilization into an unwanted simulacrum condition: a crisis of land and food due to high demand and limited resources.

At that point, humans unleash their creative power. Brilliant ideas, sometimes absurd, often become solutions to problems that, if not addressed, would inevitably lead to the elimination of human existence from the Earth’s surface.

A book by Thomas Hager titled “The Alchemy of Air,” which I read around 2014, made me realize the uniqueness of human thought. Fritz Haber, with his profound knowledge of basic chemistry, thought of making fertilizer from air, the abundant air around us, to convert it into ammonia, a nitrogen-rich fertilizer that has traditionally been obtained from natural sources like guano, bird or bat droppings, which are naturally limited.

The book describes how Fritz Haber and Carl Bosch successfully created a method to produce bread from air. How is that possible? It is possible; they developed a system to produce nitrogen-rich fertilizer by utilizing a series of chemical reactions to extract nitrogen from the air and convert it into urea raw material. Although it cannot be denied that the nitrogen or nitrate they produced also became the raw material for trinitrotoluene (TNT), also known as dynamite, an explosive.

The Haber-Bosch reaction is a significant achievement in chemical engineering that enables the large-scale/industrial production of ammonia (NH₃). This process is the main foundation for nitrogen fertilizer production, supporting modern agriculture, and increasing global food production.

Discovered by Fritz Haber at the beginning of the 20th century and industrialized by Carl Bosch, this process combines scientific theory with technological innovation to meet the growing needs of the world.

Fritz Haber developed a method for synthesizing ammonia from atmospheric nitrogen (N₂) and hydrogen (H₂) in 1908. Previously, the main source of nitrogen for fertilizer was guano and sodium nitrate from Chile, which were limited and expensive. Haber utilized atmospheric nitrogen for ammonia synthesis, although the main challenge was the high energy required to break the triple bond in N₂.

Carl Bosch, a chemical engineer from BASF, developed this process on an industrial scale in the 1910s. Bosch discovered an effective catalyst and materials that could withstand high pressure, enabling mass ammonia production.

The Haber-Bosch reaction itself is based on several chemical principles:

1. Chemical Equilibrium: This reaction is exothermic, following Le Chatelier’s principle:
   N₂(g) + 3H₂(g) ⇌ 2NH₃(g) + ΔH = -92.4 kJ/mol
   Low temperatures increase the equilibrium towards ammonia formation but slow down the reaction rate.
2. Reaction Kinetics: An iron-based catalyst with promoters (such as potassium or alumina) is used to accelerate the reaction at pressures of 150–200 atm and temperatures of 400–500°C.
3. Ideal Gas Law: High pressure increases the concentration of reactants, driving the equilibrium towards the product.

The main chemical reaction in ammonia synthesis in the Haber-Bosch process is as follows:

N₂(g) + 3H₂(g) → 2NH₃(g)

The Haber-Bosch reaction has revolutionized the chemical and food industries worldwide. We know that fertilizers support land intensification, which can meet food needs by increasing plant productivity. Most of the ammonia from the Haber-Bosch reaction is used for nitrogen fertilizers such as urea, ammonium nitrate, and ammonium sulfate.

Ammonia is also a raw material for producing nitric acid (HNO₃), polymers, and explosives. On the other hand, ammonia is being considered as a clean energy carrier in hydrogen technology.

My admiration does not stop at the success of humans in applying basic science, which has been collected by thousands of scientists in various research centers around the world for centuries, into practical products, but also in how humans can then engineer their production processes.

While learning at Rekind, let’s look at the process of designing and building a fertilizer plant. The design and construction of a fertilizer plant require comprehensive planning to ensure production efficiency, operational safety, and environmental sustainability. Here is a step-by-step explanation:

1. Chemical Reaction Stages in Fertilizer Production
   a. Ammonia (NH₃) Production — Haber-Bosch Process

Main Reaction:
N₂(g) + 3H₂(g) → 2NH₃(g) (exothermic, ΔH = -92.4 kJ/mol)
Raw materials: Nitrogen (N₂) from air and hydrogen (H₂) from natural gas reforming or water electrolysis.
Operating conditions: Pressure 150–200 atm, temperature 400–500°C, with an iron-based catalyst.

2. Supporting Processes:
Steam Methane Reforming (SMR) to produce hydrogen:
CH₄ + H₂O → CO + 3H₂ (endothermic)
CO + H₂O → CO₂ + H₂ (exothermic)

b. Nitrogen Fertilizer Production

Urea:
Ammonia reacts with carbon dioxide:
2NH₃ + CO₂ → NH₂CONH₂ (urea) + H₂O

Ammonium Nitrate (NH₄NO₃):
Ammonia reacts with nitric acid:
NH₃ + HNO₃ → NH₄NO₃

Ammonium Sulfate ((NH₄)₂SO₄):
Ammonia reacts with sulfuric acid:
2NH₃ + H₂SO₄ → (NH₄)₂SO₄

So, how can all these reactions be replicated with technology and manufacturing engineering to produce large quantities of fertilizer? The complex story behind ammonia and fertilizer production is fascinating, isn’t it?

Have you ever thought that the simple granules of fertilizer you see in a farmer’s field are the result of a very complex industrial process? Behind the production of ammonia and fertilizer lies a perfect combination of science, engineering technology, and sustainable innovation. Allow me to explain the concept and technology of a fertilizer plant through a story. Here is the story behind the process.

Ammonia production begins with the transformation of methane gas into a high-value raw material. This process involves three main steps that occur in an advanced industrial system, starting with the Primary Reformer, where methane (CH₄) from natural gas is converted into syngas, a mixture of hydrogen (H₂) and carbon monoxide (CO), through a nickel-catalyzed chemical reaction. This reaction is the gateway to producing hydrogen, the main ingredient in ammonia production.

Then, through the Air Separation Unit (ASU), nitrogen (N₂) is obtained from the air. Using air separation technology, nitrogen is isolated with high efficiency for use in subsequent chemical reactions. This process utilizes high pressure and temperature to isolate nitrogen efficiently.

Next, the Haber-Bosch Reactor will carry out the reaction to combine nitrogen and hydrogen into ammonia (NH₃). Using an iron-based catalyst, nitrogen and hydrogen are processed at pressures up to 200 atmospheres and temperatures of 400–500°C. This reaction produces the basic compound that is the backbone of the fertilizer industry.

After ammonia is formed, the next step is to convert it into fertilizer that is easy to use and efficient for agriculture. This process requires a Urea Reactor, where ammonia meets carbon dioxide (CO₂) produced from steam methane reforming. The two react to form urea, a high-nitrogen compound that is the main raw material for fertilizer.

Then, liquid urea is converted into solid granules through a granulation process using a granulator. These granules facilitate storage, transportation, and application in agricultural land.

Industrial processes are not free from emission challenges. Scrubbers are used to control waste gas, ensuring the plant remains environmentally friendly.

What supporting technologies and machines are behind all these processes?

1. Boilers and Steam Turbines
   Energy to run the entire plant is generated through boilers and steam turbines. This system ensures that the production process runs smoothly without interruption.
2. Heat Exchangers
   Heat generated from chemical reactions is reused to increase energy efficiency. In this way, the plant not only saves energy but is also environmentally friendly.

To address the challenges and needs of the modern era, the ammonia and fertilizer production system is designed to be increasingly integrated and sustainable. A Recirculation Loop is used to ensure that unreacted ammonia is recycled to minimize waste. Heat Integration, which uses heat from exothermic reactions, reduces the need for external energy.

Waste Minimization is also carried out by utilizing carbon dioxide as a raw material for urea production, reducing the carbon footprint.

To ensure that the production process is safe, efficient, and optimal, a Distributed Control System (DCS) is developed, allowing real-time monitoring and control of plant operations to ensure consistent and prime system performance. In further developments, with the application of artificial intelligence-based technology, Advanced Process Control (APC) is introduced to optimize processes through advanced data analysis. Simultaneously, a Safety Instrumented System (SIS) is implemented to ensure operational safety and protect workers and the environment.

Liquid waste is also treated before disposal to ensure environmental protection. Carbon Capture Technology or Carbon Capture System (CCS) is also increasingly applied to reduce emissions and carbon footprint.

From the story of the journey of natural gas to fertilizer granules, we can see that at every stage of the production process, there is a reflection of the collaboration between science, technology, and commitment to sustainability. With continuously evolving innovation, this industry not only meets global food needs but also contributes to a greener future. Behind every granule of fertilizer you see in the field, there is a long story about human intelligence and dedication to a better world.

And it would be even better if the use of its products could also become cross-sectoral added value, such as green energy based on hydrogen. Is that possible? Yes, it is possible, which is why there are Faculties of Chemical Engineering at ITB and UGM, as well as various other universities, so that science and its application in technology can continue to develop continuously.

Because ammonia has a high hydrogen content, it can be directed as a source of hydrogen fuel for fuel cell technology machines in the future.

Ammonia (NH₃) is a chemical compound containing a high hydrogen content (17.6% by weight) and can be used as a source of hydrogen fuel for fuel cells. The process of converting ammonia to hydrogen involves several chemical reactions and industrial technologies designed for efficiency and sustainability.

Chemical Process of Ammonia to Hydrogen Conversion

a. Ammonia Decomposition (Ammonia Cracking)

Ammonia can be broken down into nitrogen (N₂) and hydrogen (H₂) through thermal decomposition:

2NH₃ → N₂ + 3H₂ (ΔH = +46.1 kJ/mol)

Reaction conditions: Decomposition is carried out at temperatures of 700–900°C using a metal-based catalyst such as nickel (Ni), cobalt (Co), or ruthenium (Ru).

b. Hydrogen Purification

After decomposition, the gas mixture (N₂ and H₂) is separated. Pure hydrogen is obtained using separation technologies such as:

• Pressure Swing Adsorption (PSA), and
• Hydrogen-selective membranes.

c. Reforming Process for Fuel Cells

The hydrogen produced can then be used directly in Proton Exchange Membrane Fuel Cells (PEMFC) to generate electricity.

Indonesia has a comparative and competitive advantage in this regard because the ammonia production process in our country has been ongoing for a long time with mature technology. The advantages of ammonia as a source of hydrogen fuel include its higher volumetric energy density compared to liquid hydrogen.

Liquid ammonia is also easier to store and transport than hydrogen because its storage temperature and pressure are lower.

A Decomposition Reactor can also be designed to convert NH₃ to H₂ on-site, similar to a gas station, to avoid the complex handling issues of hydrogen transportation.

So, this concept has great potential, doesn’t it? Allow me to conclude this writing hastily, as it is almost time for my class at Rekind. We must be ready and start working smartly and sincerely

Happy working, INDONESIA

References

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