Decarbonizing ammonia synthesis plants through retrofitting novel reformer technology

Abstract Decarbonizing ammonia production is crucial for reducing industrial greenhouse gas emissions; however, steam methane reforming (SMR) remains the dominant, carbon-intensive pathway. This study proposes a retrofit strategy for large-scale ammonia plants (1,268 tons/day) by replacing the conventional reformer with an advanced dual-reactor system that enables CO₂ utilization and carbon valorization. The novel configuration co-produces synthesis gas and multi-walled carbon nanotubes (MWCNTs), integrating ammonia and CNT production in a single process. Aspen Plus simulations compare the baseline SMR process with the retrofitted configuration, assessing energy demand, feedstock consumption, CO 2 emissions, and economic performance. The retrofitted system achieves a 76% reduction in plant-level (Scops 1–1) CO₂-equivalent emissions and an 18.2% decrease in total specific energy (with a 31.5% reduction in thermal/steam duties), despite a 2.6-fold increase in methane input. At 25% MWCNT recovery, the Levelized Cost of Ammonia (LCOA) increases to $736.3/ton (vs. $308.3/ton for SMR); however, substantial co-product revenue yields a 3.7-fold increase in Net Present Value (NPV), 52% Internal Rate of Return (IRR), and a 4.5-year payback period. Sensitivity analyses support the robustness of the economic potential, confirming the viability of integrated CNT-ammonia production as a pathway for sustainable, low-carbon manufacturing.