Ammonia Synthesis Plant with CO2 Recycling Loop
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Solution Overview
Problem
The existing ammonia production processes release nitrogen and carbon dioxide from flue gas directly into the environment, leading to energy inefficiency and increased emissions.
Innovation Solution
The integration of a further hydrogen source, such as water electrolysis using renewable energies, and the utilization of a second carbon dioxide separator to recycle nitrogen and carbon dioxide within the process, allowing for their efficient reuse in ammonia and urea synthesis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If flue gas is released directly into the environment, then emissions are reduced to zero, but energy efficiency deteriorates and valuable resources are lost
Solution Approach 1:
The patent recovers nitrogen and carbon dioxide from flue gas that would otherwise be discarded, and reuses them in ammonia and urea synthesis processes. This transforms waste streams into valuable feedstocks, simultaneously improving energy efficiency and reducing emissions.
Solution Approach 2:
The patent converts harmful emissions (nitrogen and carbon dioxide in flue gas) into beneficial resources by injecting them into the reformer and synthesizer units. The flue gas components become feedstocks for additional hydrogen and ammonia production, turning an environmental problem into a process advantage.
2Use of energy by moving object
If nitrogen is obtained from air separation, then nitrogen supply for ammonia synthesis is ensured, but energy consumption increases
Solution Approach 1:
The patent makes the process self-sufficient for nitrogen by using nitrogen from the plant's own flue gas production. The reformer and combustion processes generate nitrogen-rich flue gas that is recycled back into the system, eliminating the need for external air separation and reducing energy consumption.
3Object-generated harmful factors
If carbon dioxide from reformer is used in urea synthesis, then resource utilization is improved, but carbon footprint is reduced
Solution Approach 1:
The patent creates a multi-functional system where carbon dioxide serves dual purposes: it is separated and used in urea synthesis (productive use), and the flue gas containing carbon dioxide is also injected into the reformer to enhance hydrogen production (process intensification). This maximizes resource utilization while minimizing carbon footprint.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces energy consumption and emissions by utilizing 'green' hydrogen and recycling nitrogen and carbon dioxide, thereby enhancing the overall efficiency and sustainability of the ammonia and urea production process.
Implementation Method 1
The plant includes a further hydrogen source. The further hydrogen source is preferably a water electrolysis. The water electrolysis is preferably operated using renewable energies.
Implementation Method 2
hydrogen is produced by steam reforming, in which a hydrocarbon is reacted with steam to form carbon monoxide and hydrogen
Implementation Method 3
subsequent conversion of the carbon monoxide into carbon dioxide and hydrogen in a water-gas shift reaction
Implementation Method 4
the synthesis gas is conveyed in a recirculation loop so as to be able to return unreacted reactants to the converter. The process is known as the Haber process.
Data Source
AI summary
The present invention relates to a plant for the synthesis of ammonia, wherein the plant includes at least one reformer for converting a hydrocarbon into hydrogen, wherein the plant includes a converter for converting hydrogen and nitrogen into ammonia, wherein the converter is integrated into a recirculation loop, wherein a first carbon dioxide separator is arranged between the reformer and the recirculation loop, wherein the recirculation loop includes an ammonia separator.