Gas Generation for Industrial Use through Ammonia Cracking — Harsiddhi Air Solution
Harsiddhi Air Solution designs, manufactures, and supplies self-contained Ammonia Cracker systems. These systems take ammonia (NH₃) and turn it into higher value gases, mainly hydrogen (H₂) and nitrogen (N₂) or specific mixtures of nitrogen and hydrogen, for industrial, metallurgical, chemical, and heat-treating applications.
These systems produce a continuous flow of high-purity gas with engineered reliability, allowing you to be less reliant on bottled gases, manage your gas supply costs, and be flexible on-site. Our ammonia crackers are designed with the process industry in mind and customized to meet your flow, purity, pressure, and safety applications.
What Is an Ammonia Cracker?
An ammonia cracker, also known as an ammonia cracking unit, is a specific equipment process in which ammonia, is thermally, or catalytically dissociated (or cracked) into its components – hydrogen and nitrogen. The process typically involves:
- Pre-heating and vaporizing the ammonia feed
- Passing the ammonia over a high temperature catalyst or within a high-heat furnace to dissociate into H₂ + N₂
- Purifying the cracked gas vapor, often along with the seperation/mixing stages as needed based on the gas output.
- Providing the final gas to your process or gas storage.
The result is a controlled, on-site inventory of either high-purity hydrogen, or hydrogen/nitrogen mixtures – such as “forming gas”, applicable for heat treatment furnaces, sintering, brazing, and reducing atmospheres, etc…
Main Features of using Ammonia Cracker
- High Purity Gas Production: Our ammonia cracker technology provides high conversion rates and produces gases configured to your specifications, whether this means pure hydrogen or a particular ratio of H₂/N₂.
- On-Site Production & Control: You will generate your process gas on-site, on-demand, in your facility, avoiding logistical, cylinder handling and supplier issues.
- Cost & Supply Certainty: Your product will not incur an ongoing cost of bottled or delivered hydrogen or forming gas. That said, on-site ammonia cracker systems can assure low-cost and secured ongoing supply.
- Mixed-Gas Production Capability: Depending upon your process, hydrogen can be supplied alone or in a mixture of hydrogen and nitrogen (for example 75% H, and 25% N).
- Compact Engineered Systems: Systems are designed for industrial conditions — skid mounted modules, safety, control and square-footage are all engineered built into your system.
- Flexible Applications: Suitable for use in heat treatment, metallurgy, chemicals, electronics, cell supply and beyond.
- Robust Safety Systems: Modern ammonia cracker systems are implemented with catalyst cracking that anticipates waste-heat reclamation, advanced control systems, interlocks and safety systems — results in a reliable, effective and safe.
Applications and Sectors uses Ammonia Cracker
- Metallurgical and Heat Treating Facilities: Annealing, sintering, and brazing under controlled reducing atmospheres.
- Electronics and Semiconductor Manufacturing: Forming gas for sensitive operations (H₂/N₂).
- Chemical and Petrochemical Plants: Hydrogen manufactured on-site for downstream chemistry or hydrogenation.
- Fuel Cell and Hydrogen Supply Chains: Ammonia-to-hydrogen conversion for power or mobility.
- Glass and Ceramics Industry: Controlled atmosphere processing requiring H₂/N₂ mixtures.
- Research and Laboratory Facilities: Flexible small-scale cracker systems for gas generation.
How It Works – Ammonia Cracker
- Ammonia Feed and Pre-Treatment: The liquid ammonia is vaporised, filtered, and pre-conditioned.
- Cracking Furnace / Catalyst Reactor: The ammonia is thermally cracked (typically 700-900°C) over a catalyst to produce H₂ + N₂ and trace amounts of un-cracked NH₃.
- Purification and Separation: The cracked gas may be separated (to remove remaining ammonia or by-products) and mixed to obtain the required H₂/N₂ ratio.
- Gas Delivery: The gas will be compressed/ pressure regulated and supplied to the process or buffered.
- Control and Safety Systems: PLC/HMI control, gas-analyser monitoring, leak detection, flame arresters, and safety interlocks to ensure stable safe operation.
Technical Specifications – Ammonia Cracker
- Flow Capacity: 5 – 5,000 Nm³/h (tailored shared)
- Gas Purity: Pure molecular H₂ (>99.9 %) neutron H₂/N₂ blend
- Operating Pressure: Up to 10 kg/cm² (or per specification)
- Ammonia Feed pressure: Typically 1 – 10 bar (foe design)
- Conversion Efficiency: High (>90 % ammonia conversion)
- Control: PLC/Industrial PC with safety interlocks and monitoring
- Footprint: Skid mounted; modular design, for simpler installation.
Quality & Safety Assurance at Harsiddhi Air Solutions
Each ammonia cracker system that Harsiddhi Air Solutions manufactures will be performed under stringent quality systems:
- Industrial-grade catalyst and furnace designs
- Robust safety systems – flame arrestors, ammonia monitoring, gas leak detection, emergency shut-off
- International safety standards for pressure vessels and process-gases
- Verified performance – gas purity, flow, conversion efficiency and emissions.
What makes Harsiddhi Air Solution the ideal choice for ammonia cracker systems?
- Established experience in the manufacture of gas generation and process-gas systems
- Significant commitment to custom-engineered solutions to meet your plant flow, gas composition and pressures
- Complete turnkey solutions from design and build, to installation, commissioning and after-sales support
- Strong emphasis on energy efficiency, feedstock and lifecycle cost reduction
- Nationwide support network throughout India for operations and maintenance.
Frequently Asked Questions (FAQs)
Q1: What types of gases can be produced by an ammonia cracker?
A: Depending on your process requirements the system has the capability to produce either high purity hydrogen, or hydrogen – nitrogen mixtures (for example, forming gas).
Q2: What purity of hydrogen or blend can I expect?
A: Typical designs can provide hydrogen purity levels up to ~99.9%, or precisely controlled hydrogen – nitrogen blends as specified by the customer.
Q3: What are the feedstock requirements?
A: The system requires either liquid or gaseous ammonia, as well as utilities (electricity, compressed air, cooling water). Feed conditions are customized to design
Q4: Which industries would benefit most from ammonia cracker systems?
A: Industries including metallurgy, electronics, chemical processing, fuel cell supply, glass/ceramics and research labs utilize these systems extensively.
Q5: What’s the difference between an ammonia cracker and a PSA nitrogen or oxygen plant?
A: A PSA nitrogen/oxygen plant separates nitrogen or oxygen from air. An ammonia cracker is a reactor that breaks down ammonia into hydrogen (and nitrogen) and is used for hydrogen or mixed-gas output.
Q6: How safe are these systems?
A: Safety is the number one priority — systems have flame arrestors, leak sensors, emergency shut-off, robust control and are built to exacting specifications complying with industry safety standards.
Q7: What maintenance is required?
A: Routine checks of catalyst activity, integrity of furnace/tube, controls system, gas-analyser calibration & safe operation. Catalysts will need replacing after defined hours.
Q8: How do I size an ammonia cracker system for my process?
A: Provide gas flow (Nm³/h), purity requirement, output pressure, ammonia feed pressure, and space. We will then design a system for you.
Whenever you need a dependable, operationally efficient, high-performance ammonia cracker system to generate hydrogen or hydrogen-nitrogen gas, reach out Harsiddhi Air Solution. Our experienced engineering team will listen to your needs and design a system that is specifically designed for your unique process.
Location:
B-26, Ved Industrial Park-2, Kathwada, Ahmedabad, India
Talk to Us: +91 9023435128
Drop email: info@harsiddhiairsolution.com