Chilled Condensation Section for Lower-Energy Urea Production

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Solution Overview

Problem

Existing urea production processes are energy-intensive due to the high steam consumption in condensate treatment, and the use of booster ejectors leads to bulky and heavy equipment.

Innovation Solution

Implementing a chilled condensation section in the evaporation process of a urea plant, which eliminates or reduces the need for booster ejectors by using a chilled cooling medium, such as ammonia or halogenated hydrocarbons, to condense vapors directly, thereby reducing energy consumption and condensate volume.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a booster ejector is used to transport vapor from the evaporator to the condenser, then the vapor can be pressurized and transported, but the equipment becomes bulky and heavy and energy consumption increases

Engineering Contradiction:

Improvevapor pressureVSAvoidequipment weight

Core Design Contradiction:

PowerVSWeight of stationary object

Solution Approach 1:

The patent removes the booster ejector from the system entirely by redesigning the condensation section to operate at low pressure, allowing vapor to be condensed directly without mechanical pressurization equipment

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical booster ejector system is replaced with a thermal field-based condensation system operating at low pressure, eliminating the need for mechanical pressurization

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If a booster ejector is used to transport vapor from the evaporator to the condenser, then the vapor can be pressurized and transported, but the equipment becomes bulky

Engineering Contradiction:

Improvevapor pressureVSAvoidequipment size

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical booster ejector system is replaced with a thermal field-based condensation system operating at low pressure, eliminating the need for mechanical pressurization

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If steam is used in the wastewater treatment section for hydrolysis and desorption, then condensate can be purified, but energy consumption increases significantly

Engineering Contradiction:

Improvecondensate purityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the operating parameters of the condensation section to low pressure and low temperature, which reduces the energy required for subsequent condensate treatment while maintaining purification effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different operating conditions to different sections: the condensation section operates at low pressure/temperature to minimize energy use, while the wastewater treatment section uses targeted steam injection only where needed for hydrolysis and desorption

Inventive Principle:

Principle #3Local quality

4Temperature

If the condensation section uses cooling water at ambient temperature, then condensation can occur, but vapor from deep vacuum evaporators cannot be condensed efficiently

Engineering Contradiction:

Improvecooling temperatureVSAvoidcondensation efficiency

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The patent changes the pressure parameter of the condensation section to low pressure, which allows vapor from deep vacuum evaporators to be condensed efficiently at lower temperatures without requiring high-energy cooling systems

Inventive Principle:

Principle #35Parameter changes

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 significantly reduces energy consumption in the wastewater treatment process, minimizes equipment size, and allows for efficient production of high-purity urea melts with low water content, suitable for prilling or granulation, while avoiding contamination of wastewater treatment systems.

Implementation Method 1

condensing said vapor in a first condensation section... The chilled condensation section... uses a chilled cooling medium... to condense vapors directly

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 2

The first condensation section is a heat exchanger having said vapor to be condensed on a first side and said chilled cooling medium on a second side

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

uses a chilled cooling medium, such as ammonia or halogenated hydrocarbons, to condense vapors directly

Methodology Applied

Scientific EffectHeat absorption: Conduction (thermal)

Implementation Method 4

concentrating a first urea solution in a first vacuum evaporator... to give a urea melt and vapor

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 5

the first evaporator is operated at vacuum (a pressure less than 100 kPa)

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentEP4085050B1Urea plant with chilled condensation section

Publication Date: 2025.10.08 STAMICARBON BV

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AI summary

The disclosure pertains to a urea production process comprising concentrating a first urea solution in a first vacuum evaporator in an evaporation section to give a urea melt and first vapor, and condensing said first vapor in a first condensation section, wherein the first condensation section is a chilled condensation section.