Ammonia Converter With Co-Current Heat Exchange for Partial-Load Operation
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Solution Overview
Problem
Conventional ammonia converters struggle with reliability under varying loads, particularly when using regeneratively generated energy, as they either cool the product flow below the required temperature for further conversion or risk overheating due to inconsistent starting material flow, leading to halted reactions or device damage.
Innovation Solution
The ammonia converter employs a co-current flow heat exchanger with a tube bundle design, allowing for efficient temperature control and flexibility across partial and full loads by ensuring both gas streams maintain optimal temperatures for continuous conversion, using a casing with multiple catalyst beds and a deflection device to manage gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heat exchanger is designed for maximum efficiency with small configuration, then the converter achieves high conversion capacity at full load, but under partial loads the starting material flow cools the product flow below the required temperature for further conversion
Solution Approach 1:
The patent implements a variable geometry heat exchanger where the flow cross-section can be dynamically adjusted. The flow cross-section is made variable to adapt to different operating conditions, allowing the heat exchanger to maintain optimal heat transfer efficiency whether operating at full load or partial load, thus preventing the product flow from being cooled below the required temperature while preserving high conversion capacity
2Adaptability or versatility
If the heat exchanger configuration is reduced to handle partial loads, then the converter can operate at minimum partial loads, but at full load the converter becomes overheated and damaged since the gas emerging from the preceding stage is not sufficiently cooled
Solution Approach 1:
The patent implements a variable geometry heat exchanger where the flow cross-section can be dynamically adjusted. The flow cross-section is made variable to adapt to different operating conditions, allowing the heat exchanger to maintain optimal heat transfer efficiency whether operating at full load or partial load, thus preventing the product flow from being cooled below the required temperature while preserving high conversion capacity
3Adaptability or versatility
If a conventional converter is supplied with varying flow of starting material, then the converter can accommodate regenerative energy input, but the product flow temperature becomes unstable leading to halted reactions or device damage
Solution Approach 1:
The patent implements a variable geometry heat exchanger where the flow cross-section can be dynamically adjusted. The flow cross-section is made variable to adapt to different operating conditions, allowing the heat exchanger to maintain optimal heat transfer efficiency whether operating at full load or partial load, thus preventing the product flow from being cooled below the required temperature while preserving high conversion capacity
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
Ensures reliable operation across varying loads by maintaining optimal reaction temperatures, preventing overheating or cooling, and reducing downtime, making it suitable for small-scale 'green ammonia' production using regenerative energy sources.
Implementation Method 1
The heat exchanger is in the form of a tube bundle heat exchanger (first tube bundle heat exchanger). The tube bundle heat exchanger has a central tube and a plurality of heat exchanging tubes. The flow through the heat exchanging tubes is in the opposite direction to the flow through the central tube.
Implementation Method 2
The flow through the heat exchanging tubes is in the opposite direction to the flow through the central tube. The heat exchanging tubes are arranged parallel to the central tube and around the central tube.
Data Source
AI summary
An ammonia converter comprises a casing, a starting material inlet and a product outlet, a first catalyst bed and a second catalyst bed, wherein the flow passes through the first catalyst bed and the second catalyst bed radially from the outside to the center, a tube bundle heat exchanger, wherein the tube bundle heat exchanger has a central tube and a plurality of heat exchanging tubes, wherein the heat exchanging tubes are arranged parallel to the central tube and around the central tube, wherein the tube bundle heat exchanger is surrounded in a ring shape by the first catalyst bed, wherein the heat exchanger is a co-current flow heat exchanger, which is configured in such a way that, in said heat exchanger, the gas flow through the heat exchanging tubes is guided in the same direction as the gas flow flowing around the heat exchanging tubes, wherein the starting material inlet is directly connected to the heat exchanging tubes in terms of gas flow, wherein the central tube is directly connected to the space between the casing and the first catalyst bed in terms of gas flow.