Ammonia-Urea Gas Compressor Hybrid Power for Lower CO2 Emissions
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Solution Overview
Problem
Ammonia and urea plants rely heavily on natural gas boilers to generate steam for gas compressors, leading to high CO2 emissions and environmental impact, despite ammonia-producing units often being net exporters of steam.
Innovation Solution
Integrate an electric motor connected to the gas compressor, supplementing power from a steam turbine with electricity, particularly from renewable sources, to reduce steam consumption and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If natural gas boilers are used to generate steam for the gas compressor, then the gas compressor can operate reliably, but CO2 emissions increase
Solution Approach 1:
The power supply to the gas compressor is segmented into two independent sources: a steam turbine powered by process steam and an electric motor powered by external electricity. This segmentation allows the plant to maintain reliable compressor operation while reducing reliance on natural gas boilers, thereby lowering CO2 emissions.
Solution Approach 2:
An electric motor is introduced as an intermediary power source between the electricity supply and the gas compressor. This intermediary device enables the compressor to operate without requiring steam from natural gas boilers, thus reducing CO2 emissions while maintaining operational reliability.
2Use of energy by moving object
If steam turbines are used to power the gas compressor, then energy efficiency improves, but steam consumption increases
Solution Approach 1:
The power demand of the gas compressor is segmented and divided between two sources: the steam turbine handles base load operation, while the electric motor supplements during high demand periods. This segmentation reduces the steam consumption required from the ammonia-producing unit while maintaining energy efficiency.
Solution Approach 2:
The steam turbine operates at partial capacity rather than full capacity, with the electric motor making up the difference. This partial action approach allows the steam turbine to operate more efficiently at lower loads while reducing overall steam consumption from the process.
3Quantity of substance
If the ammonia-producing unit produces more steam, then steam availability increases, but production cost increases
Solution Approach 1:
The electric motor acts as an intermediary that decouples the steam demand from the ammonia production process. By introducing this external power source, the plant can meet steam requirements without proportionally increasing ammonia production, thereby controlling production costs while maintaining steam availability.
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
Reduces natural gas consumption and CO2 emissions by balancing power from both electric and steam sources, optimizing energy use and maintaining stable compressor operation.
Implementation Method 1
a steam turbine fluidly connected to the ammonia-producing unit for receiving steam produced by the ammonia-producing unit, the steam turbine being also connected to the gas compressor, and configured to provide power to the gas compressor
Implementation Method 2
an electric motor, wherein the electric motor is connected to the gas compressor and configured to provide power to the gas compressor
Data Source
AI summary
The present disclosure provides a plant comprising an ammonia-producing unit and a urea-producing unit. The urea-producing unit comprises a gas compressor, a steam turbine fluidly connected to the ammonia-producing unit for receiving steam produced by the ammonia-producing unit, and connected to the gas compressor for providing power to the gas compressor, and an electric motor, wherein the electric motor is connected to the gas compressor and configured to provide power to the gas compressor. The present disclosure also provides a method for operating an ammonia and urea plant, and a method to revamp an ammonia and urea plant.