Integration of hydrogen liquefaction with gas processing units
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Solution Overview
Problem
The high capital and operating expenditures in hydrogen liquefaction and ammonia production units are largely attributed to compression equipment, with limited synergies between these processes due to integration limitations, leading to inefficiencies and increased costs.
Innovation Solution
Integrating hydrogen and nitrogen compression requirements to share equipment and optimize refrigeration processes, using a single compressor for both ammonia production and hydrogen liquefaction, and utilizing nitrogen refrigeration streams to reduce the number of compression and expansion stages, thereby decreasing equipment costs and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate compression equipment is used for hydrogen liquefaction and ammonia production, then each process can be optimized independently, but capital and operating expenditures increase significantly
Solution Approach 1:
The patent combines the compression functions for both hydrogen liquefaction and ammonia production into a single integrated compression system. The compressor is configured to compress hydrogen feed gas while also providing high-pressure nitrogen for ammonia synthesis, thereby reducing the number of separate compression equipment needed and lowering capital expenditures while maintaining process optimization through integrated control
Solution Approach 2:
The compression equipment is designed to perform multiple functions: compressing hydrogen for liquefaction, compressing nitrogen for ammonia production, and providing refrigeration cycles. This multi-functional approach eliminates the need for dedicated separate equipment for each process, reducing overall device complexity and investment costs
2Use of energy by moving object
If multiple compression and expansion stages are used for hydrogen liquefaction, then refrigeration efficiency is optimized, but the number of equipment components and operating costs increase
Solution Approach 1:
The patent merges the refrigeration compression and expansion functions with the main hydrogen compression system. The same compressor and expander units used for hydrogen processing are utilized to provide refrigeration cycles, eliminating the need for separate dedicated refrigeration equipment and reducing overall system complexity while maintaining refrigeration efficiency
Solution Approach 2:
The compression and expansion equipment performs dual functions: processing hydrogen for liquefaction and providing refrigeration cycles. By using the same equipment for both purposes, the system reduces the total number of components needed while maintaining optimal refrigeration performance through integrated operation
3Quantity of substance
If nitrogen compression is performed separately for ammonia production, then nitrogen supply is ensured, but equipment costs and operating expenditures increase
Solution Approach 1:
The patent combines nitrogen compression for ammonia production with the hydrogen compression system. The same compressor that processes hydrogen also compresses nitrogen to the required high pressure for ammonia synthesis, thereby ensuring adequate nitrogen supply while eliminating the need for separate nitrogen compression equipment and reducing overall device complexity
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 reduces the number of compression and expansion stages, lowers equipment costs, and enhances overall system efficiency by increasing operating pressure and optimizing the LH2/NH3 production ratio, minimizing venting of nitrogen and oxygen from air separation units.
Implementation Method 1
compressing a first hydrogen stream, and expanding a portion to produce a hydrogen refrigeration stream
Implementation Method 2
cooling a second hydrogen stream thereby producing a cool hydrogen stream, wherein at least a portion of the refrigeration is provided by a nitrogen refrigeration stream
Implementation Method 3
mixing the balance of the compressed first hydrogen stream with a high-pressure gaseous nitrogen stream to form an ammonia synthesis gas stream
Data Source
AI summary
A method including, compressing a first hydrogen stream, and expanding a portion to produce a hydrogen refrigeration stream, cooling a second hydrogen stream thereby producing a cool hydrogen stream, wherein at least a portion of the refrigeration is provided by a nitrogen refrigeration stream, further cooling at least a portion of the cool hydrogen stream thereby producing a cold hydrogen stream, and a warm hydrogen refrigeration stream wherein at least a portion of the refrigeration is provided by the hydrogen refrigeration stream, compressing the warm hydrogen refrigeration stream, mixing the balance of the compressed first hydrogen stream with a high-pressure gaseous nitrogen stream to form an ammonia synthesis gas stream, and wherein the first hydrogen stream and the warm hydrogen refrigeration stream are compressed in the same compressor.