Ammonia Synthesis Loop: A Dynamic Simulation‐Based HAZOP Study

ABSTRACT Ammonia (NH₃) is a crucial industrial chemical used mostly in agriculture, with a global production of approximately 150 million metric tons by 2023. Despite its significance, ammonia manufacturing poses significant safety risks because of its high pressure, hydrogen content, and potential for hazardous accidents. To improve the safety analysis of ammonia synthesis, this study uses a dynamic simulation with Honeywell UniSim Design software. The simulation models the dynamic behavior of a 1000 TPD ammonia synthesis loop, based on the Haber‐Bosch process, at the Fertilizers and Chemicals Travancore Limited plant in Udyogamandal, Kerala, India. This study evaluated two primary risk scenarios: leakage in the ammonia synthesis pipeline and abnormal liquid levels in the ammonia separator, using dynamic simulation‐based Hazard and Operability Analysis (HAZOP). These results suggest that high liquid levels in the separator can cause liquid ammonia entrainment, compressor failure, and toxic leakage in the event of equipment failure. The pipeline leakage study points out the possibility of explosions and ammonia poisoning, with ammonia concentrations exceeding hazardous levels within minutes. This dynamic simulation‐based method provides important insights for process safety management in industrial ammonia production by better identifying risks and quantifying safety concerns than traditional steady‐state models.