Techno-economic assessment of an intensified ammonia production to promote energy efficiency and greenhouse gas reductions in chemical industry

Ammonia synthesis is a crucial industrial process, but its high energy consumption and greenhouse gas emissions highlight the need for advanced modelling to optimise and develop sustainable pathways. This review provides a comprehensive analysis of multiscale modelling in ammonia synthesis, specifically integrating Computational Fluid Dynamics (CFD) and process simulation. A systematic literature review of Web of Science and Scopus databases, up to March 31, 2025, was conducted, focusing on kinetic models, CFD applications, and process simulation studies. The findings reveal the widespread use of various kinetic models (Temkin-Pyzhev, LHHW, microkinetic) to describe reaction rates, while CFD simulations primarily focus on reactor-level details like flow, heat, and mass transfer, evaluating geometry and operating conditions. Process simulation is extensively applied for plant-wide analysis, techno-economic assessment, and dynamic studies, often utilising simplified reactor representations. A significant gap identified is the absence of published studies explicitly integrating CFD and process simulation for ammonia synthesis, despite its demonstrated value in other chemical engineering contexts. Addressing this critical gap through future research is crucial for a more comprehensive understanding and the effective optimisation of sustainable ammonia production