Ammonia Plant Direct Air Capture Integration
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Solution Overview
Problem
Current ammonia production systems face challenges in reducing CO2 emissions and energy consumption, particularly in integrating effective carbon capture technologies that are both sustainable and economically viable.
Innovation Solution
A system combining a direct air capture (DAC) system with an ammonia production system, utilizing an air contactor, pellet reactor, calciner, and slaker to capture CO2 from air streams used in the reforming and combustion processes, facilitating the conversion of CO2 into usable forms through chemical reactions and recycling of by-products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional ammonia production systems operate without carbon capture, then energy consumption is lower, but CO2 emissions are high
Solution Approach 1:
The patent combines a direct air capture (DAC) system with an ammonia production system by integrating the DAC air contactor into the existing ammonia plant's air supply infrastructure. The DAC system captures CO2 from ambient air using alkali solutions, and this captured CO2 is then utilized in the ammonia production process, merging two previously separate functions into a unified system that reduces both emissions and energy consumption
Solution Approach 2:
The patent converts the harmful CO2 emissions into a beneficial resource by capturing CO2 from the air and utilizing it as a feedstock in the ammonia production process. The captured CO2 is converted into carbonated water which is then used in the reforming process, transforming what would be a harmful emission into a valuable chemical input that reduces both CO2 emissions and energy consumption
2Productivity
If DAC system is integrated into ammonia production system, then CO2 capture efficiency increases, but system complexity increases
Solution Approach 1:
The patent applies multi-functionality by designing the DAC system to serve multiple purposes: the air contactor captures CO2 from ambient air, the captured CO2 is then utilized in the ammonia production process as a feedstock, and the system also serves as a heat recovery system. This multi-functional approach increases CO2 capture efficiency while managing system complexity by combining multiple functions into integrated units
Solution Approach 2:
The patent introduces carbonated water as an intermediary substance that mediates between the DAC capture process and the ammonia production process. The carbonated water serves as both the medium for CO2 transport and the reactant in the reforming process, simplifying the integration by using a single intermediary substance to connect the two processes
3Use of energy by moving object
If waste heat from ammonia production is utilized for DAC process, then energy consumption decreases, but heat recovery efficiency must increase
Solution Approach 1:
The patent implements a feedback mechanism where waste heat from the ammonia production process is recovered and reused in the DAC process. The heat from the ammonia synthesis reactor and combustion process is captured and used to facilitate the CO2 capture reactions, creating a closed-loop energy system that reduces overall energy consumption while maintaining high heat recovery efficiency through optimized heat exchange
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
The integration of the DAC system with ammonia production reduces CO2 flow rates in both reforming and combustion processes, decreases energy consumption, and promotes negative CO2 emissions by utilizing waste heat from the ammonia production system, achieving significant reductions in heat duty and overall power consumption.
Implementation Method 1
an air contactor configured to capture carbon dioxide in air
Implementation Method 2
the carbon dioxide is reacted with potassium hydroxide (KOH) to produce potassium carbonate (K2CO3)
Implementation Method 3
in the pellet reactor, the potassium carbonate (K2CO3) is reacted with calcium hydroxide (Ca(OH)) to produce potassium hydroxide (KOH) and calcium carbonate (CaCO3)
Implementation Method 4
in the calciner, the calcium carbonate (CaCO3) is transformed into carbon dioxide (CO2) and calcium oxide (CaO)
Implementation Method 5
in the slaker, the calcium oxide (CaO) is reacted with water (H2O) to produce calcium hydroxide (CaOH)
Implementation Method 6
a direct air capture (DAC) system... configured to capture carbon dioxide in air
Data Source
AI summary
A system includes a direct air capture (DAC) system, and an ammonia production system in communication with the DAC system. The DAC system includes an air contactor configured to capture carbon dioxide in air. The ammonia production system includes a reforming process and a combustion process. The ammonia production system is supplied with an air stream including a first air stream configured to be supplied into the reforming process. The DAC system is in communication with the ammonia production system through the first air stream.