In the world of advanced metallurgy and precision heat treatment, the need for high-purity hydrogen gas cannot be overstated. One of the most cost-effective and efficient ways to generate hydrogen on-site is through the Ammonia Cracker Unit for Heat Treatment Furnaces. These specialized systems are designed to produce a consistent, clean, and dry hydrogen-nitrogen gas mixture, essential for preventing oxidation, decarburization, and maintaining material integrity during the heat treatment process.
As demand increases across India’s heat treatment and engineering industries, companies are shifting from cylinder-based hydrogen to on-site generation. Alkeynes Global Projects, a renowned engineering and gas plant solutions provider, offers customized ammonia cracker units built to meet the rigorous demands of heat treatment furnaces used in sectors like automotive, aerospace, tool manufacturing, and heavy engineering.
Understanding the Role of Hydrogen in Heat Treatment
Heat treatment is a controlled process used to alter the physical and sometimes chemical properties of metals and alloys. Processes such as annealing, sintering, brazing, and carburizing are used to improve strength, hardness, ductility, and wear resistance.
A protective or reducing atmosphere is essential during these high-temperature operations to prevent oxidation and ensure uniform metallurgical transformation. This is where hydrogen plays a vital role.
Benefits of Hydrogen in Heat Treatment:
- Prevents surface oxidation
- Maintains bright and clean component surfaces
- Acts as a carrier gas for carburizing or nitriding
- Enhances uniformity in microstructure
- Supports faster heating and cooling cycles
Given hydrogen’s high reactivity, its consistent purity and supply become crucial—both of which are achieved with a reliable Ammonia Cracker Unit for Heat Treatment Furnaces.
What is an Ammonia Cracker Unit?
An ammonia cracker is a process unit that thermally decomposes anhydrous ammonia (NH₃) into a mixture of hydrogen (H₂) and nitrogen (N₂) using a nickel-based catalyst.
Cracking Reaction:
2NH3→3H2+N22NH₃ \rightarrow 3H₂ + N₂2NH3→3H2+N2
Output Gas Composition:
- 75% Hydrogen
- 25% Nitrogen
This mixture is ideal for most heat treatment applications where a reducing atmosphere is required. It’s also much more economical and safer to transport and store ammonia compared to pure hydrogen cylinders.
How the Cracker Unit Works
The Ammonia Cracker Unit for Heat Treatment Furnaces operates in the following stages:
- Ammonia Storage & Vaporization
Liquid ammonia is stored under pressure in a tank and passed through a vaporizer to convert it into gaseous form. - Preheating Zone
The gaseous ammonia is preheated before entering the cracking chamber. - Cracking Reactor
In the reactor chamber, the ammonia passes over a nickel-based catalyst bed at around 800–850°C, where it decomposes into H₂ and N₂. - Cooling Section
The cracked gas is cooled to remove heat and prevent back-reactions. - Purification/Drying (optional)
To ensure a dry and clean output, the gas may pass through a molecular sieve dryer or deoxo unit, depending on application requirements. - Delivery to Furnace
The cracked gas is fed directly into the furnace, ensuring a reducing atmosphere throughout the process cycle.
Why Alkeynes for Ammonia Cracker Units?
When investing in a system that plays a critical role in the quality of your heat-treated products, reliability, performance, and support are key. Alkeynes Global Projects stands out as a leading manufacturer of Ammonia Cracker Unit for Heat Treatment Furnaces across India.
Key Advantages of Alkeynes Systems:
- 🛠️ Custom-Built Units tailored to your flow rate, furnace design, and temperature requirements.
- 🔥 High-Performance Catalysts ensure complete cracking with extended life.
- 📊 PLC/SCADA Control Systems with HMI for real-time process monitoring.
- 🧱 Heavy-Duty Design with stainless steel internals and safety interlocks.
- 💧 Integrated Gas Drying Options to ensure moisture-free delivery.
- 📦 Compact & Skid-Mounted for ease of installation and portability.
- 🔄 Quick Startup & Auto Shut-Off to suit batch and continuous operations.
Applications of Ammonia Crackers in Heat Treatment
The output hydrogen-nitrogen gas blend from the cracker unit is extensively used in several heat treatment applications, including:
| Process | Purpose | Industry |
| Bright Annealing | Prevent oxidation, enhance surface finish | Automotive, Tool & Die |
| Sintering | Uniform alloying, reduce metal oxides | Powder Metallurgy |
| Brazing | Flux-free joining, clean joints | HVAC, Aerospace |
| Carburizing | Case hardening of steels | Gear, Transmission Manufacturing |
| Hardening & Nitriding | Improved hardness & fatigue strength | Defence, Bearings |
The ability to maintain a consistent and clean gas flow at high temperatures is essential for each of these processes. That’s why more companies are shifting to the dependable Ammonia Cracker Unit for Heat Treatment Furnaces offered by Alkeynes.
Technical Specifications
| Parameter | Specification |
| Gas Flow Rate | 5 Nm³/hr to 500 Nm³/hr |
| Operating Temperature | 800–850°C |
| Catalyst | Nickel-based (high-efficiency grade) |
| Construction | SS/CS with refractory lining |
| Output Gas | 75% H₂ + 25% N₂ |
| Power Supply | 230V/415V |
| Automation | PLC/HMI/SCADA (optional) |
| Safety Features | Pressure relief valves, gas leak detectors, auto shut-off |
| Drying Option | Molecular sieve dryer, deoxo unit (optional) |
Each unit undergoes rigorous testing and QA/QC before dispatch, with performance trials and certifications as per industrial standards.
Case Study: Crack-Free Results for a Pune-Based Auto Parts Manufacturer
Client: Vardhan Auto Components Pvt. Ltd.
Industry: Automotive Gear Manufacturing
Challenge: Inconsistent hydrogen quality from cylinders causing blackened surfaces during annealing
Solution: Installed a 100 Nm³/hr fully automated Ammonia Cracker Unit for Heat Treatment Furnaces with built-in dryer and alarm system
Result:
- Surface finish improved by 30%
- Reduced downtime due to cylinder logistics
- ROI achieved within 18 months
- Full integration with SCADA-based furnace system
Safety First: Alkeynes Design Philosophy
Handling ammonia and hydrogen comes with risks. Alkeynes incorporates industry-best safety mechanisms to ensure safe and reliable operations:
- Flameproof electrical components
- Interlock-based heater protection
- Gas leak detection and alarms
- Pressure relief valves and rupture discs
- Grounding and earthing as per IEC codes
- Fully enclosed systems with minimal operator exposure
Our designs comply with PESO, CE, and ASME standards wherever applicable.
Post-Installation Support
Beyond delivering equipment, Alkeynes ensures total lifecycle support:
- 📅 AMC & Health Checks
- 🔁 Catalyst Replacement & Regeneration
- 🔧 Component Upgrades & Retrofitting
- 🧪 Performance Testing & Calibration
- 📚 On-Site Operator Training & Manuals
We also provide spare part kits, sensor recalibration, and remote diagnostics for advanced units.
Testimonials
“The ammonia cracker from Alkeynes has improved our annealing line drastically. Consistent gas purity, easy to operate, and their team is very responsive.”
— Mr. Rajiv Mehta, Plant Head, SteelCast Engineers, Hyderabad
“With Alkeynes’ ammonia cracker, we’ve moved away from unreliable hydrogen cylinders. Their technical team helped us install and train our staff with precision.”
— Mrs. Anjali Bansode, Director, Bansode Metallurgy, Pune
Environmental and Economic Benefits
Switching to an on-site cracker unit not only improves gas reliability but also cuts down environmental impact and operational costs.
- 🌱 Lower Carbon Footprint: No transport of high-pressure cylinders
- 💰 Cost Saving: Ammonia is significantly cheaper per unit of hydrogen
- 🔋 Energy Efficient: Systems with regenerative heating save up to 20% energy
- 🏗️ Reduced Storage Hazards: Ammonia tanks are easier to manage than hydrogen bundles
Final Thoughts
If your business involves heat treatment, metallurgical processing, or brazing, investing in an Ammonia Cracker Unit for Heat Treatment Furnaces is a strategic move toward better quality, operational independence, and long-term savings. With Alkeynes Global Projects, you’re not just buying a system—you’re gaining a committed partner in your gas generation journey.
We ensure safety, engineering precision, and responsive support so that your furnaces never run out of pure, reliable hydrogen.
Connect with Alkeynes Global Projects
📞 Call Us: +91 7827503269
🌐 Website: www.alkeynesprojects.com
📧 Email: sales@alkeynesprojects.com
Need a dependable Ammonia Cracker Unit for Heat Treatment Furnaces? Reach out today for a custom solution tailored to your plant, process, and productivity goals.