Ammonia Urea Process Integration for CO2 Capture Energy Reduction
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Solution Overview
Problem
Solvent-based carbon dioxide capture systems for ammonia production have high energy consumption and capital expenditure due to the need for solvent regeneration in regeneration columns, which is not efficiently addressed by existing methods.
Innovation Solution
Integrating an ammonia production process with a urea production process, where ammonia and carbon dioxide from synthetic gas formed during steam reforming or gasification are used directly in the urea synthesis, eliminating the need for carbon dioxide desorption by binding carbon dioxide with ammonia, thus reducing energy demands and capital costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solvent-based carbon dioxide capture systems use regeneration columns for carbon dioxide desorption, then carbon dioxide can be separated from the solvent, but energy consumption and capital expenditure increase significantly
Solution Approach 1:
The patent extracts the carbon dioxide separation function from the traditional regeneration column system and relocates it to the urea synthesis reactor. Instead of desorbing CO2 from solvent in a separate high-energy regeneration step, the CO2 is directly utilized in the urea synthesis reaction, eliminating the need for thermal regeneration and significantly reducing energy consumption while maintaining effective CO2 separation.
Solution Approach 2:
The patent merges the carbon dioxide capture system with the urea production process by integrating the solvent absorption unit with the urea synthesis reactor. The rich solvent stream containing absorbed CO2 is directly fed to the urea synthesis reactor where CO2 reacts with ammonia to form urea, combining two previously separate processes into one integrated system that eliminates the regeneration column.
2Reliability
If solvent-based carbon dioxide capture systems use regeneration columns for carbon dioxide desorption, then carbon dioxide can be separated from the solvent, but capital expenditure increases due to high energy requirements
Solution Approach 1:
The patent removes the regeneration column from the process flow and replaces it with a direct integration to the urea synthesis reactor. This extraction of the regeneration step eliminates the need for high-capacity reboilers and associated balance-of-plant equipment, significantly reducing capital expenditure while maintaining CO2 separation through the chemical reaction in the urea synthesis process.
Solution Approach 2:
The patent combines the CO2 capture and urea production processes into a single integrated system. The absorber unit and urea synthesis reactor are directly connected, with the rich solvent stream flowing directly to the reactor. This merging eliminates the need for separate regeneration equipment and reduces overall plant complexity and capital costs.
3Use of energy by moving object
If ammonia and carbon dioxide are bound together in the solvent stream, then carbon dioxide desorption is eliminated, but the system requires integration with urea production process
Solution Approach 1:
The patent merges the CO2 capture system with the urea production process, creating an integrated system where the solvent absorption unit is directly coupled with the urea synthesis reactor. This integration allows the bound CO2 in the solvent stream to be directly utilized in urea synthesis without requiring separate desorption equipment, reducing energy consumption while maintaining process flexibility through the chemical reaction pathway.
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 integration significantly reduces energy consumption and capital expenses by eliminating the need for carbon dioxide desorption, as the bound carbon dioxide is used as a reactant in the urea production process, enhancing the efficiency and cost-effectiveness of the system.
Implementation Method 1
carbon dioxide absorption into a mixed stream comprising the second ammonia stream and a lean solvent stream containing ammonia and a relatively low content of carbon dioxide
Implementation Method 2
binding carbon dioxide with ammonia
Implementation Method 3
carbon dioxide and ammonia are reacted for the production of urea
Data Source
AI summary
A method of forming urea by integration of an ammonia production process with that of a urea production process, as well as a system for the method is disclosed. Also, an alternative method of forming urea by integration of a part of an ammonia production process with that of a urea production process, as well as a system for the alternative method.