Iron catalysts for ammonia synthesis/nanocrystalline iron promoted with oxides of potassium, aluminum and calcium were characterized by studying the nitriding process with ammonia in kinetic area of the reaction at temperature of 475 °C. Using the equations proposed by Crank, it was found that the process rate is limited by diffusion through the interface, and the estimated value of the nitrogen diffusion coefficient through the boundary layer is 0.1 nm2/s. The reaction rate can be described by Fick's first equation. It was confirmed that nanocrystallites undergo a phase transformation in their entire volume after reaching the critical concentration, depending on the active specific surface of the nanocrystallite. Nanocrystallites transform from the α-Fe(N) phase to γ'-Fe4N when the total chemical potential of nitrogen compensates for the transformation potential of the iron crystal lattice from α to γ; thus, the nanocrystallites are transformed from the smallest to the largest in reverse order to their active specific surface area. Based on the results of measurements of the nitriding rate obtained for the samples after overheating in hydrogen in the temperature range of 500-700 °C, the probabilities of the density of distributions of the specific active surfaces of iron nanocrystallites of the tested samples were determined. The determined distributions are bimodal and can be described by the sum of two Gaussian distribution functions, where the largest nanocrystallite does not change in the overheating process, and the size of the smallest nanocrystallites increases with increasing recrystallization temperature. Parallel to the nitriding reaction, catalytic decomposition of ammonia takes place in direct proportion to the active surface of the iron nanocrystallite. Based on the ratio of the active iron surface to the specific surface, the degree of coverage of the catalyst surface with the promoters was determined.
Keywords: ammonia; iron catalyst; kinetics; morphology; nitriding process.