A dual-route ammonia process: Combining renewable and low-carbon pathways

• Dual-route ammonia process combining blue (CCS) and green (renewable) pathways. • Aspen HYSYS simulation of the entire plant: SMR, ATR, CO₂ capture, synloop, utilities. • Achieves 98.5 % CO₂ capture with compression to 60 bar for export or EOR use. • Steam network redesign, condensate recovery, and methanation heat recycling. • Electrification of the main compressor enables renewable compatibility and flexibility. Ammonia is increasingly recognized as a versatile hydrogen carrier and energy vector with the potential to decarbonize industrial processes and global energy trade. Among the emerging production routes, blue ammonia—derived from natural gas with integrated carbon capture and storage (CCS)—offers a transitional pathway toward low-carbon energy systems. This work presents the development and assessment of a hybrid ammonia production scheme capable of generating both blue and green ammonia within a single flexible framework. The proposed configuration couples a conventional methane-based synthesis loop equipped with a high-efficiency CO₂ capture system to a parallel renewable-driven synthesis loop, thereby enabling dynamic operation across fossil-based and renewable feedstocks. Process simulations demonstrate that, under a natural gas feed of 1660 metric tons per day (MTPD), the hybrid plant achieves a fuel-to-feedstock ratio of approximately 49 % and an overall CO₂ capture efficiency of up to 98.5 %. Captured CO₂ is compressed to 60 bar, allowing downstream utilization for enhanced oil recovery (EOR) or export via pipeline infrastructure. Beyond process performance, the study highlights the potential role of hybrid ammonia in supporting large-scale decarbonization strategies, strengthening energy security, and bridging the technological gap between blue hydrogen and renewable hydrogen production. In particular, the approach aligns with ongoing energy transition initiatives such as Germany’s Energiewende while offering a scalable solution for global low-carbon fuel supply chains.