Cyclic Biocement Process for Low-Energy Ammonia and Urea Production
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Solution Overview
Problem
Current industrial processes for ammonia and urea production are energy-intensive and contribute significantly to CO2 emissions, with incomplete conversion and high energy consumption, and lack efficient recycling of by-products.
Innovation Solution
A cyclic industrial process that decomposes calcium carbonate into calcium oxide and carbon dioxide at elevated temperatures, reacts calcium oxide with ammonium chloride to form calcium chloride and ammonia, and reacts ammonia and carbon dioxide to produce urea, which are then used to form biocement, utilizing existing industrial processes combined with biocementation technologies and co-culture with urea-producing organisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional industrial processes are used for ammonia and urea production, then production capacity is achieved, but energy consumption is high and CO2 emissions are significant
Solution Approach 1:
The patent combines multiple industrial processes (ammonia production, urea production, and biocementation) into an integrated cyclic system where outputs from one process become inputs for another, enabling resource efficiency and reduced energy consumption across the entire production chain
Solution Approach 2:
The system recovers and recycles by-products that would otherwise be discarded or emitted as waste. Specifically, CO2 from ammonia production is captured and used in urea synthesis, while ammonia from urea hydrolysis is recovered and fed back into the ammonia production process, eliminating waste streams and reducing the need for fresh raw materials
2Productivity
If conventional ammonia production is used, then ammonia is produced, but CO2 emissions increase significantly
Solution Approach 1:
The patent converts the harmful CO2 emissions from ammonia production into a useful resource by capturing the CO2 and using it as a feedstock for urea production. This transforms a waste product that contributes to greenhouse gas emissions into a valuable intermediate chemical, simultaneously reducing emissions and enabling additional product production
3Ease of manufacture
If incomplete conversion is accepted in urea production, then process simplicity is maintained, but production efficiency decreases
Solution Approach 1:
The system maintains continuous operation by recycling unreacted materials. Urea that undergoes hydrolysis back to ammonia and CO2 is not discarded but rather the ammonia is recovered and fed back into the urea synthesis process, ensuring that the conversion process operates continuously with maximum utilization of feedstocks and maintaining high overall efficiency
4Device complexity
If by-products are not recycled, then process complexity is reduced, but material waste increases
Solution Approach 1:
The system implements feedback loops where process outputs are monitored and fed back as inputs. Specifically, ammonia generated from urea hydrolysis is captured and returned to the ammonia production process, and CO2 from ammonia synthesis is returned to urea production, creating a closed-loop system that minimizes material waste while maintaining process efficiency
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 process achieves a cyclical production of biocement, reducing energy consumption, minimizing waste, and providing a sustainable, carbon-neutral method for producing calcium carbonate, ammonia, ammonium chloride, urea, and calcium chloride, while enabling the use of local and recycled materials, thereby lowering production costs and environmental impact.
Implementation Method 1
decomposing calcium carbonate into calcium oxide and carbon dioxide at an elevated temperature
Implementation Method 2
The biocementation reaction relies on the metabolic hydrolysis of urea, producing ammonium and carbonate ions in a solution containing calcium chloride
Implementation Method 3
Calcium cations react with the carbonate anions at the surface of the bacterial membrane, forming calcium carbonate of the polymorph calcite
Data Source
AI summary
The invention is directed to kits, compositions, tools and methods comprising a cyclic industrial process to form biocement. In particular, the invention is directed to materials and methods for decomposing calcium carbonate into calcium oxide and carbon dioxide at an elevated temperature, reacting calcium oxide with ammonium chloride to form calcium chloride, water, and ammonia gas; and reacting ammonia gas and carbon dioxide at high pressure to form urea and water, which are then utilized to form biocement. This cyclic process can be achieved by combining industrial processes with the resulting product as biocement. The process may involve retention of calcium carbonate currently utilized in the manufacture of Portland Cement.