Ammonia Synthesis Reactor with PSA Nitrogen and Electrolysis Hydrogen
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Solution Overview
Problem
Conventional ammonia production processes rely on converting organic materials, resulting in environmentally unfriendly by-products.
Innovation Solution
A system comprising a pressure-swing-adsorption nitrogen generator, an electrolysis cell for hydrogen production, and a reactor with a catalyst for reacting nitrogen and hydrogen to form ammonia, operating under high pressures and temperatures to produce ammonia from air and water, with a catalyst bed containing materials like ruthenium, iron, or titanium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional processes convert organic materials (natural gas or petroleum) to produce ammonia, then ammonia production is achieved, but carbonaceous pollutants are generated
Solution Approach 1:
The invention extracts and eliminates the harmful carbonaceous element from the ammonia production process by replacing organic feedstocks with inorganic sources (air and water), thereby producing ammonia without generating carbon pollutants
Solution Approach 2:
The invention changes the fundamental parameters of the production process by switching from organic-based feedstocks to inorganic feedstocks (N2 from air, H2 from water), fundamentally altering the chemical composition pathway and eliminating carbon emissions
2Productivity
If high pressure (up to 2,800 psi) and temperature (450-500°C) are applied in the reactor to synthesize ammonia, then reaction efficiency is improved, but system complexity and energy consumption increase
Solution Approach 1:
The invention employs periodic compression cycles where the compressor alternates between compression strokes and expansion strokes, allowing the system to build pressure incrementally while utilizing the expansion phase to recover some energy and reduce overall power consumption
Solution Approach 2:
The system utilizes the exothermic nature of the ammonia synthesis reaction to generate heat that is then used to maintain the required reaction temperature, reducing the external energy input needed for heating while still achieving high conversion rates
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 method produces ammonia without carbonaceous pollutants, offering an environmentally friendly alternative by utilizing air and water as inputs and achieving efficient ammonia synthesis.
Implementation Method 1
a pressure-swing-adsorption (PSA) nitrogen generator for extracting nitrogen gas from air
Implementation Method 2
a hydrogen generator comprising an electrolysis cell for producing hydrogen gas from water
Implementation Method 3
a catalyst in the third compressor for catalyzing a reaction of nitrogen and hydrogen in the mixture to form ammonia
Data Source
AI summary
A system for producing ammonia includes sources of hydrogen and nitrogen gas, a hydrogen gas booster for producing produce pressurized hydrogen gas, a nitrogen gas booster for producing pressurized nitrogen gas, and a synthesis reactor that receives a mixture of the pressurized hydrogen and nitrogen gases. The synthesis reactor includes an inlet for receiving the pressurized gas mixture, a heating zone adjacent the inlet for heating the gas mixture, a catalyst zone downstream from the heating zone for catalyzing a reaction of the mixture to form ammonia and a by-product, and a cooling zone downstream from the catalyst zone for cooling the ammonia and the by-product. The system has a separator for separating the ammonia from the by-product, an ammonia storage tank for collecting the ammonia, and a recycle loop for re-circulating the by-product back to the synthesis reactor.