Ammonia Synthesis Mixed Gas Distribution Plate
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Solution Overview
Problem
Existing ammonia synthesis systems face challenges in managing changes in flow rate during production cycles and maintaining uniform flow rate distribution before the catalyst bed, especially when the flow rate of raw materials like hydrogen is decreased.
Innovation Solution
The ammonia synthesis system incorporates a mixed gas distribution plate with openings that have covers which open under fluid pressure, allowing for adjustable flow regulation. This plate is designed to maintain uniform flow distribution and prevent backflow, even at varying flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the flow rate of raw material is decreased, then energy consumption is reduced, but non-uniform flow rate distribution before the catalyst bed is increased
Solution Approach 1:
The distribution plate is segmented into multiple opening regions (first opening region, second opening region, third opening region) with different opening ratios. This segmentation allows different portions of the plate to provide different flow resistance, compensating for the non-uniform flow distribution that occurs at decreased flow rates and maintaining more uniform gas distribution across the catalyst bed.
Solution Approach 2:
Different regions of the distribution plate are designed with locally optimized opening ratios. The first opening region has a higher opening ratio than the second opening region, which in turn has a higher opening ratio than the third opening region. This local quality variation creates differential flow paths that compensate for the overall reduced flow rate, ensuring uniform distribution across the catalyst bed even when total flow is decreased.
2Productivity
If the opening ratio of the distribution plate is increased, then flow rate is improved, but backflow of raw material occurs
Solution Approach 1:
The distribution plate is divided into multiple opening regions with progressively decreasing opening ratios from the first to the third region. This segmentation creates a flow resistance gradient that allows high flow rates while preventing backflow by ensuring that the cumulative resistance across all regions maintains proper flow direction through the catalyst bed.
Solution Approach 2:
The opening ratio parameter is varied across different regions of the distribution plate. By changing the opening ratio from the first region (higher) to the third region (lower), the system optimizes both flow rate and backflow prevention, as the gradient creates appropriate pressure distribution to maintain unidirectional flow through the catalyst bed.
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 system effectively manages flow rate changes during production cycles, maintains uniform flow distribution before the catalyst bed, and prevents backflow, thereby enhancing ammonia synthesis performance and stability.
Implementation Method 1
some openings among the plurality of openings are mounted with a cover at the bottom, and the cover is opened under a fluid pressure
Data Source
AI summary
Provided is an ammonia synthesis system including an ammonia synthesis reactor; a single or two or more catalyst beds included in the ammonia synthesis reactor; a distribution device disposed upstream from each of the catalyst beds and distributing mixed gas to the catalyst bed; a mixed gas supply line disposed to supply the mixed gas to the distribution device; and each mixed gas distribution plate is disposed between the catalyst bed and the distribution device and includes a plurality of openings, wherein some openings among the plurality of openings are mounted with a cover at the bottom, and the opening mounted with the cover normally maintains the cover to be closed and to be opened under a fluid pressure.