Ammonia Oxidation Reactor Internal Filter Element

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Solution Overview

Problem

The ammonia oxidation process to nitrogen monoxide in the presence of a catalyst results in significant metal loss due to high temperatures, leading to economic inefficiencies and downstream catalyst poisoning, with existing solutions either increasing pressure drop or requiring confined space maintenance.

Innovation Solution

A reaction vessel with an internal filter element, comprising a filter cage and medium, is integrated within the reactor to collect dislodged catalyst particles, enhancing filtration efficiency and allowing for maintenance without confined space entry, while maintaining a compact design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If an external filter housing and filtration device are provided downstream from the ammonia oxidation reaction vessel, then metal loss is reduced, but pressure drop increases and additional space is required

Engineering Contradiction:

Improvemetal lossVSAvoidpressure drop

Core Design Contradiction:

Loss of substanceVSStress or pressure

Solution Approach 1:

The patent combines the filtration function with the existing reaction vessel structure by integrating a filter element into the vessel's outlet system. This merging approach eliminates the need for separate external filter housing while maintaining filtration capability, thus reducing pressure drop and space requirements compared to external filtration systems

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reaction vessel is designed to serve multiple functions: it performs ammonia oxidation catalysis and simultaneously incorporates an integrated filter element that captures metal particles. This multi-functionality allows the vessel to reduce metal loss without requiring additional dedicated filtration equipment, thereby avoiding the pressure drop and space penalties of external filters

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of substance

If fibrous material is placed immediately adjacent to the precious metal gauze, then metal loss is reduced, but confined space entry is required for maintenance

Engineering Contradiction:

Improvemetal lossVSAvoidmaintenance accessibility

Core Design Contradiction:

Loss of substanceVSEase of operation

Solution Approach 1:

The filter element is designed as a removable, modular component that can be separated from the reaction vessel for maintenance. This segmentation allows the filter to be accessed and serviced without requiring confined space entry procedures, as the filter can be removed and replaced from the vessel exterior or through accessible openings

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The filter element is designed with dynamic accessibility - it can be positioned to allow easy removal and installation without fixed confinement. The filter structure enables maintenance personnel to service the filter material without entering confined spaces, transforming a static maintenance problem into a dynamically accessible system

Inventive Principle:

Principle #15Dynamics

3Productivity

If the reaction severity is increased to improve production rate, then productivity increases, but metal loss increases

Engineering Contradiction:

Improveproduction rateVSAvoidmetal loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent converts the harmful effect of high-temperature catalyst dislodgement (which increases with reaction severity) into a beneficial filtration process. The integrated filter element captures the metal particles that are inevitably dislodged during severe reactions, allowing the system to maintain high productivity while preventing metal loss and downstream catalyst poisoning

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 internal filter element effectively reduces metal loss, improves cost recovery, and minimizes downstream catalyst poisoning, while allowing for easy servicing and integration with existing designs.

Implementation Method 1

The internal filter element includes a filter cage defining an interior volume and a filter medium disposed about the filter cage. The internal filter element collects the catalyst dislodged during the oxidation of ammonia.

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

The oxidation of ammonia takes place in the presence of a catalyst with yields ranging from 93-98% depending on the operating conditions used.

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9663366B2Ammonia oxidation reactor with internal filter element

Publication Date: 2017.05.30 BASF SE

AI summary

A reaction vessel for oxidation of ammonia to nitrogen monoxide in the presence of a catalyst is provided. The catalyst can become dislodged during the oxidation. The reaction vessel includes a reactor body having a top portion, a bottom portion, and a middle portion. The top and middle portions cooperate to define a cavity where the ammonia is catalytically oxidized to provide the nitrogen monoxide. The reaction vessel also includes an internal filter element. The internal filter element includes a filter cage that defines an interior volume and a filter medium disposed adjacent to the filter cage. The internal filter element collects the catalyst dislodged during the oxidation.