System and method for obtaining pure hydrogen from synthesis reactors using hydrochloric acid for chemical production

Abstract

This invention relates to a system and method for producing hydrogen gas (H2) from the reaction of hydrochloric acid and aluminum (10), purifying the obtained hydrogen gas (H2) using a palladium alloy membrane (50), and reacting the purified hydrogen gas (H2)with nitrogen gas (N2) to produce ammonia (NH3).

Description

[0001] DESCRIPTION

[0002] SYSTEM AND METHOD FOR OBTAINING PURE HYDROGEN FROM SYNTHESIS REACTORS USING HYDROCHLORIC ACID FOR CHEMICAL PRODUCTION

[0003] Technical Field

[0004] This invention relates to a system and method for producing hydrogen gas (H2) from the reaction of aluminum and hydrochloric acid (HCI), purifying the produced hydrogen gas using a palladium alloy membrane, and reacting the purified hydrogen gas with nitrogen gas (N2) to produce ammonia (NH3).

[0005] In particular, the invention focuses on a synthesis reactor that uses hydrochloric acid for chemical production, a palladium alloy membrane that separates exhaust gases (H2) from the reactor into moisture and other gases, and a cryogenic compressor system integrated with an ammonia production unit. The invention is specifically designed for the production of high-purity hydrogen gas, followed by ammonia production, through an innovative system and method.

[0006] State of the Art

[0007] Currently, there are several methods for producing hydrogen gas, with the most common being steam reforming of natural gas, coal gasification, and water electrolysis. In natural gas steam reforming, methane reacts with steam at high temperatures to produce hydrogen gas and carbon monoxide. This process is followed by a water-gas shift reaction to produce additional hydrogen and separate carbon dioxide. In coal gasification, coal reacts with oxygen and steam at high temperatures to generate synthesis gas (syngas), from which hydrogen gas is extracted.

[0008] The electrolysis method is based on applying an electric current to water to separate it into oxygen and hydrogen gases. While this method offers environmental advantages, especially when combined with electricity from renewable sources, its high energy requirements make it more expensive. Technologies used for hydrogen purification include pressure swing adsorption (PSA), membrane technologies, and cryogenic distillation. PSA separates hydrogen from other gases by utilizing the different adsorption capacities of gases on an adsorbent material. Membrane technologies purify hydrogen by exploiting differences in molecular size or diffusion rates of gases. Cryogenic distillation separates hydrogen from other components by liquefying the gases based on their boiling points.

[0009] The most widely used method for ammonia production is the Haber-Bosch process, which involves the reaction of hydrogen and nitrogen gases under high pressure and temperature with a catalyst. Ammonia is an important chemical compound used in agricultural fertilizers, explosives, and cleaning products. However, the Haber-Bosch process is energy-intensive and typically relies on hydrogen gas derived from fossil fuels. Each of these methods is usually conducted in large-scale facilities and requires high energy consumption. These processes are also criticized for their environmental impacts, particularly in terms of carbon emissions and fossil fuel consumption, raising sustainability concerns.

[0010] Natural gas steam reforming and coal gasification processes rely on fossil fuels, resulting in significant carbon dioxide emissions, which contribute to climate change. Additionally, these methods involve energy-intensive processes, leading to high operational costs.

[0011] Although the electrolysis method is environmentally friendly when renewable energy is used, its high energy costs make it economically unattractive for large-scale applications. Moreover, the installation and maintenance of electrolysis units entail significant financial burdens.

[0012] Technologies such as pressure swing adsorption and cryogenic distillation used for hydrogen purification also require high energy consumption, and their energy efficiency is low. Membrane technologies, on the other hand, often fail to achieve sufficiently high- purity hydrogen and require frequent replacements due to membrane degradation over time.

[0013] The Haber-Bosch process for ammonia production is an energy-intensive process due to its high pressure and temperature requirements, leading to increased operational costs. Its sustainability is also questioned due to its reliance on fossil fuels as the hydrogen source. In this context, alternative methods for hydrogen production and ammonia synthesis are being explored. Innovative approaches, such as producing hydrogen using waste aluminum and hydrochloric acid, have the potential to reduce fossil fuel usage and minimize carbon emissions. Additionally, advancements like the use of palladium alloy membranes for achieving high-purity hydrogen gas and cryogenic compressors for enhanced efficiency are significant for reducing energy costs and the environmental impact of these processes.

[0014] These innovative approaches aim to address the challenges of current technologies while offering sustainable and economically advantageous alternatives.

[0015] Objectives of The Invention

[0016] The primary purpose of the invention is to eliminate the use of fossil fuels in hydrogen production. The system and method for producing hydrogen gas through the reaction of aluminum and hydrochloric acid reduce dependence on fossil fuels, thereby minimizing the environmental impact of energy production. This method represents an important step toward sustainable energy solutions while contributing to carbon footprint reduction goals.

[0017] Another objective of the invention is to maximize energy efficiency in hydrogen production processes. This new approach, which consumes less energy compared to traditional methods, reduces energy costs while utilizing energy resources more effectively. The palladium alloy membrane technology provides an energy-efficient purification process, serving this purpose.

[0018] Another objective of the invention is to enhance efficiency and sustainability in the ammonia production process. By using locally produced high-purity hydrogen, ammonia production costs are reduced, while the cryogenic compressor technology optimizes process control and energy savings, improving the overall efficiency of industrial-scale ammonia production.

[0019] Another objective of the invention is to support environmental sustainability by developing a production process aligned with green chemistry principles. The use of waste aluminum offers innovative solutions to waste management issues, while the low- waste reaction with hydrochloric acid makes this method an environmentally friendly alternative.

[0020] Another objective of the invention is to obtain high-purity hydrogen gas. The use of a palladium alloy membrane provides a long-lasting, low-maintenance solution preferred in industrial and commercial applications. This high-purity hydrogen offers significant advantages, particularly in energy storage systems and fuel cells.

[0021] The invention achieves these objectives through a system for obtaining pure hydrogen gas from exhaust gases emitted by synthesis reactors using hydrochloric acid and aluminum for chemical production. The system includes at least one exhaust gas processing unit that receives the exhaust gases from the synthesis reactor and separates them into pure hydrogen, moisture, and other gases using a palladium alloy membrane, thereby obtaining pure hydrogen.

[0022] An alternative configuration of the invention involves producing ammonia by using a portion of the pure hydrogen obtained through the exhaust gas processing unit, in conjunction with a cryogenic compressor that separates nitrogen gas from the air. The ammonia production unit combines pure nitrogen gas from the cryogenic compressor and pure hydrogen gas from the exhaust gas processing unit to produce ammonia.

[0023] In another alternative configuration of the invention, the amount of hydrogen gas used by the ammonia production unit constitutes 3% to 10% of the pure hydrogen obtained from the exhaust gas processing unit.

[0024] Description of Figures

[0025] Figure 1 : A schematic representation of the system for obtaining pure hydrogen from synthesis reactors using hydrochloric acid for chemical production.

[0026] Explanation of Part References

[0027] 10. Hydrochloric Acid and Aluminum 70. Air

[0028] 20. Synthesis Reactor 80. Cryogenic Compressor 30. Exhaust Gases 90. Ammonia Production Unit

[0029] 40. Exhaust Gas Processing Unit N2. Nitrogen

[0030] 50. Palladium Alloy Membrane H2. Hydrogen

[0031] 60. Moisture and Other Gases NH3. Ammonia

[0032] Detailed Description of the Invention

[0033] Referring to Figure 1 , the reaction of hydrochloric acid and aluminum (10) forms the basis of hydrogen (H2) production and represents an innovative process in the energy sector. This chemical reaction takes place in a synthesis reactor (20) designed for high energy efficiency. The process involves aluminum atoms "stealing" hydrogen atoms from hydrochloric acid molecules, resulting in the release of hydrogen gas (H2). This reaction also produces heat and aluminum chloride as by-products.

[0034] The synthesis reactor (20) is specially designed to enable the controlled mixing of reactants and the efficient execution of the reaction. It also manages the hydrogen gas (H2) generated during the reaction, as well as the moisture and other gases released as by-products. The design of the synthesis reactor (20) is critical for safety and efficiency, taking into account factors such as high pressure and temperature generated during the reaction.

[0035] Exhaust gases (30) refer to the mixture of hydrogen (H2), moisture, and other gases exiting the synthesis reactor (20). These gases are directed to an exhaust gas processing unit (40) for safe removal and processing before being released into the atmosphere. This step is crucial for meeting environmental regulations and purifying hydrogen for subsequent stages.

[0036] The palladium alloy membrane (50) lies at the heart of this process and serves as the key component for hydrogen (H2) purification. This membrane technology provides molecular-level selectivity, allowing only hydrogen (H2) molecules to pass through while retaining moisture and other gases (60). This stage is essential for obtaining high-purity hydrogen (H2), and the efficiency of purification depends on the material properties and structural design of the palladium alloy membrane (50). The cryogenic compressor (80) also plays a vital role, working in conjunction with air (70) intake. Air (70) primarily consists of nitrogen (N2) and oxygen (02). During the cryogenic process, the air (70) is cooled, and its components are separated through fractional distillation to produce high-purity nitrogen gas (N2). This nitrogen (N2) is subsequently directed to the ammonia production unit (90).

[0037] In the final stage, the ammonia production unit (90) combines the purified hydrogen gas (H2) from the palladium alloy membrane with the purified nitrogen gas (N2) from the cryogenic compressor (80). This reaction can be considered a modern version of the Haber-Bosch process, conducted under high pressure, temperature, and with the aid of a catalyst. The catalyst facilitates the combination of hydrogen (H2) and nitrogen (N2) molecules to form ammonia (NH3). This reaction is carried out with high efficiency under controlled conditions, optimizing energy consumption and minimizing production costs.

[0038] The method underlying the operation of the invention consists of the following steps:

[0039] 1. Producing hydrogen gas (H2) through the reaction of hydrochloric acid and aluminum (10) in the synthesis reactor (20).

[0040] 2. Directing the exhaust gases (30) from the synthesis reactor (20) to the exhaust gas processing unit (40) for removal of moisture and other components.

[0041] 3. Purifying hydrogen gas (H2) using the palladium alloy membrane located in the exhaust gas processing unit (40) to obtain high-purity hydrogen.

[0042] 4. Separating atmospheric air (70) using the cryogenic compressor (80) to produce high-purity nitrogen gas (N2).

[0043] 5. Combining a portion of the purified hydrogen gas (H2) from the palladium alloy membrane (50) and the purified nitrogen gas (N2) from the cryogenic compressor (80) in the ammonia production unit (90) to produce ammonia (NH3).

[0044] The ammonia (NH3) produced can be stored or directly used as a critical component in various industrial processes, such as fertilizers in agriculture and raw materials in manufacturing. The ammonia production unit (90) is equipped with all the necessary control and monitoring systems to ensure efficient and safe reactions. The entire production process complies with environmental and safety standards and is carefully managed to optimize performance. This innovative process represents a sustainable and eco-friendly alternative in the energy sector. By eliminating the use of fossil fuels, utilizing waste aluminum, and enabling the production of high-purity hydrogen (H2) and ammonia (NH3), the system aims to improve energy efficiency, reduce operational costs, and minimize environmental impact. The palladium alloy membrane (50) ensures high efficiency in hydrogen purification, while the cryogenic compressor (80) optimizes energy savings. This innovative approach provides solutions to the sustainability and cost challenges faced by existing processes.

Claims

CLAIMS1. A system for obtaining pure hydrogen gas (H2) from exhaust gases (30) emitted by synthesis reactors (20) using hydrochloric acid and aluminum (10) for chemical production, characterized by: at least one exhaust gas processing unit (40) that receives the exhaust gases (30) from the synthesis reactor (20) and separates them into pure hydrogen (H2), moisture, and other gases (60) using a palladium alloy membrane (50), thereby obtaining pure hydrogen (H2).

2. A system according to claim 1 , characterized by: at least one cryogenic compressor (80) that separates air (70) into pure nitrogen gas (N2) and delivers the nitrogen to an ammonia production unit (90), an ammonia production unit (90) that combines a portion of the pure hydrogen gas (H2) from the exhaust gas processing unit (40) with pure nitrogen gas (N2) from the cryogenic compressor (80) to produce ammonia (NH3).

3. A system according to claim 2, characterized by the amount of hydrogen gas (H2) used by the ammonia production unit (90) being 3% to 10% of the pure hydrogen gas (H2) obtained from the exhaust gas processing unit (40).4.• at least one exhaust gas processing unit (40) that receives the exhaust gases (30) emitted by the synthesis reactor (20) and separates them into pure hydrogen (H2), moisture, and other gases (60) using at least one palladium alloy membrane (50), thereby obtaining pure hydrogen (H2),• at least one cryogenic compressor (80) that separates atmospheric air (70) into pure nitrogen gas (N2) to produce ammonia (NH3), wherein the cryogenic compressor (80) provides pure nitrogen gas (N2), and the ammonia production unit (90) combines a portion of the pure hydrogen (H2) from the exhaust gas processing unit (40) with the pure nitrogen gas (N2) to produce ammonia (NH3),characterized by a method for obtaining pure hydrogen gas (H2) from exhaust gases (30) emitted by synthesis reactors (20) using hydrochloric acid and aluminum (10) for chemical production, comprising the process steps of: • reacting hydrochloric acid and aluminum (10) in the synthesis reactor (20) to produce hydrogen gas (H2),• directing the exhaust gases (30) emitted by the synthesis reactor (20) to the exhaust gas processing unit (40) for the removal of moisture and other components, • purifying the hydrogen gas (H2) using the palladium alloy membrane located in the exhaust gas processing unit (40) to obtain high-purity hydrogen,• Separating atmospheric air (70) using the cryogenic compressor (80) to produce pure nitrogen gas (N2), and • combining a portion of the purified hydrogen gas (H2) from the palladium alloy membrane (50) with the pure nitrogen gas (N2) obtained from the cryogenic compressor (80) in the ammonia production unit (90) to produce ammonia (NH3).

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