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The ammonia synthesis tower is a critical equipment in the nitrogen fertilizer industry, directly affecting the efficiency and yield of ammonia production. Its internal parameters play a decisive role in reaction performance. First, catalyst packing is a core parameter. The catalyst, typically iron-based with promoters like K2O and Al2O3, must have uniform particle size (1-5 mm) and sufficient active sites to maximize reaction rate. Proper packing height (2-5 m) ensures complete reaction, while porosity (30%-50%) of the packing prevents excessive pressure drop. Second, tower internals, such as gas distributors and heat exchangers, are essential. Gas distributors ensure uniform gas flow, avoiding channeling and hot spots. Heat exchangers, often using water cooling, maintain the optimal reaction temperature (400-500°C) and pressure (15-30 MPa). Third, operating conditions like space velocity and steam ratio also interact with internal parameters. A moderate space velocity (50,000-100,000 h⁻¹) balances conversion and yield, while steam in the feed reduces catalyst deactivation. By optimizing these internal parameters, the ammonia synthesis tower can achieve higher conversion rates (up to 15%-20%) and energy efficiency, reducing production costs and environmental impact.
