Ammonia Production via Dual Converter Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ammonia production systems face inefficiencies due to the accumulation of inert components like argon, methane, and excess hydrogen/nitrogen in the ammonia synthesis loop, which reduces ammonia production efficiency.
Innovation Solution
The system incorporates a second ammonia converter to react the purge gas from the first converter, along with a product separator and ammonia recovery unit to enhance ammonia production by recycling and separating these components, thereby increasing overall ammonia yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single ammonia converter is used, then the system is simpler to operate, but ammonia production efficiency decreases due to accumulation of inert components
Solution Approach 1:
The single ammonia converter is divided into two separate converters operating in series. The first converter handles the main ammonia synthesis, while the second converter processes the purge gas from the first converter to produce additional ammonia. This segmentation allows each converter to be optimized for specific functions and enables recovery of valuable components that would otherwise be lost.
Solution Approach 2:
Instead of discarding the purge gas containing unreacted hydrogen, nitrogen, and ammonia from the first converter, the system recovers these components by feeding them to the second converter. The second converter converts additional ammonia from this purge gas, which is then separated and combined with the first converter's product, thereby recovering material that would otherwise be wasted.
2Productivity
If more syngas is fed to increase ammonia production, then ammonia yield increases, but energy consumption increases proportionally
Solution Approach 1:
The system implements a feedback mechanism where the purge gas from the first converter, which contains unreacted hydrogen and nitrogen along with some ammonia, is fed to the second converter. This feedback loop allows the system to recover and reuse components that would otherwise be lost, increasing overall ammonia production efficiency without requiring proportional increases in fresh syngas input or energy consumption.
Solution Approach 2:
The second converter operates continuously to process the purge gas stream from the first converter, ensuring that valuable unreacted components are continuously converted to additional ammonia. This continuous useful action maximizes the utilization of feedstock and energy inputs throughout the system.
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 increases ammonia production by up to 38% with a smaller increase in syngas input and reduces energy consumption per tonne of ammonia produced, improving the overall efficiency of the ammonia synthesis process.
Implementation Method 1
Ammonia is commonly produced by reacting hydrogen and nitrogen in the presence of a catalyst
Implementation Method 2
The product separator can be in fluid communication with the second ammonia converter and can be adapted to separate the effluent to produce a second ammonia product
Data Source
AI summary
Systems and methods for producing ammonia. The system can include a first ammonia converter, a second ammonia converter, a product separator, and an ammonia recovery unit. The first ammonia converter can be adapted to react a syngas to produce a first ammonia product and a first purge gas. The second ammonia converter can be in fluid communication with the first ammonia converter and can be adapted to react the first purge gas to produce an effluent. The product separator can be in fluid communication with the second ammonia converter and can be adapted to separate the effluent to produce a second ammonia product and a second purge gas. The ammonia recovery unit can be in fluid communication with the product separator and can be adapted to separate at least a portion of the second purge gas to produce a third ammonia product and a third purge gas.