The Haber-Bosch ammonia synthesis is the foundational industrial process for producing ammonia (NH₃), which is the key starting point for nearly all nitrogen fertilizers. It combines hydrogen and nitrogen under high pressure and temperature. Hydrogen is generated from natural gas through steam reforming, while nitrogen is separated from air. These gases are mixed in a 3:1 ratio and compressed to about 200 atmospheres, then passed over an iron catalyst at around 450–500°C. The exothermic reaction forms ammonia, which is then cooled and condensed into liquid form, while unreacted gases are recycled back into the system to maximize efficiency. This process is vital for large-scale fertilizer production and supports global food supply.

Badotherm’s pressure measurement and diaphragm seal systems ensure accurate and reliable monitoring of the high pressures and temperatures in the Haber-Bosch process. This keeps the reaction stable, maximizes efficiency, and protects both equipment and operators — even in the toughest conditions.

Urea fertilizer is synthesized from ammonia and CO2. It is the world’s most produced nitrogen fertilizer. During this process, ammonia carbamate liquid is formed, which is highly corrosive. This process uses ammonia directly from the Haber-Bosch process + CO₂ from syngas operations and turns them into solid urea granules used globally for fertilizing crops.

Badotherm engineers have designed special extended versions of Zirconium Diaphragm Seal Systems for pressure and level measurement in high, middle, and low-pressure sections of all existing urea production processes..

The high-pressure production process for melamine (C₃H₆N₆) involves thermally decomposing urea at high temperatures (350–400°C) and pressures (150–200 bar) in a liquid-phase reactor that does not require a catalyst. In this process, urea breaks down into melamine, ammonia, and carbon dioxide according to the reaction 6CO(NH₂)₂ → C₃N₆H₆ + 6NH₃ + 3CO₂. The reaction mixture is then rapidly cooled (quenched) to stop the reaction and stabilize the melamine. Subsequent hydrolysis removes any residual urea and byproducts, after which the melamine is crystallized and dried to achieve a high-purity final product. This method is widely used in industry because it is efficient, produces high-quality melamine, and can be cost-effectively integrated into existing urea production plants.

Badotherm’s diaphragm seal systems and high-temperature pressure instrumentation play a vital role by providing accurate and stable pressure measurements, protecting sensitive instruments from high temperatures and corrosive chemicals, and ensuring process control and safety compliance throughout the reactor and separation stages.

The production of nitric acid begins with preparing ammonia (NH₃) and air as feedstocks; ammonia is synthesized from natural gas and air supplies the oxygen. In the first step, ammonia is oxidized over a platinum-ruthenium catalyst at high temperatures and pressures to form nitric oxide (NO), which is then further oxidized to nitrogen dioxide (NO₂). This nitrogen dioxide is absorbed in water to produce nitric acid (HNO₃), which can be optionally concentrated to over 98% purity through distillation or by using concentrated sulfuric acid as a dehydrating agent. To reduce environmental impact, waste gases containing nitrogen oxides (NOₓ) are treated using technologies like selective catalytic reduction (SCR) and alkaline absorption.

Badotherm’s robust diaphragm seal systems and high-accuracy pressure and temperature instruments ensure reliable process control and monitoring in this demanding production environment, protecting measurement devices from corrosive media and extreme conditions, which is critical for safe, efficient, and environmentally compliant nitric acid production.

The process starts with the preparation of feedstocks, ammonia (NH₃) and nitric acid (HNO₃). Ammonia is synthesized from natural gas and air, while nitric acid is produced by oxidizing ammonia in the presence of a catalyst to form nitrogen oxides, which are then absorbed in water. In the reactor, ammonia gas reacts with concentrated nitric acid to form ammonium nitrate solution in a highly exothermic reaction. This solution is then concentrated through evaporation to achieve the desired concentration. Finally, the concentrated ammonium nitrate solution is cooled and solidified into prills or granules, depending on the production method.

Badotherm’s specialized instrumentation supports the safe and efficient production of ammonium nitrate by providing accurate pressure and temperature measurements throughout the process. Badotherm’s diaphragm seal systems protect instruments from corrosive and high-temperature conditions.

Urea Ammonium Nitrate (UAN) is a widely used liquid fertilizer, prized for its high nitrogen content and ease of application. The urea and ammonium nitrate solutions are mixed together in specific proportions to form UAN. The most commonly used grade is UAN 32, which consists of 45% ammonium nitrate, 35% urea, and 20% water. To prevent corrosion, inhibitors are added to the UAN solution. This is important because UAN is quite corrosive towards mild steel and other materials.

In these UAN plants, pressure and level measurement are critical in:
· Urea off-gas systems (high and low pressure);
· Nitric acid and ammonium nitrate loops;
· UAN blending and storage tanks.
Whether you’re monitoring HP reactor pressure, safeguarding critical loops, or ensuring accurate tank level readings, Badotherm provides the instrumentation backbone that plant engineers can trust—day in, day out.