Integrated Urea Formaldehyde Concentrate Production With Autothermal Reforming
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Solution Overview
Problem
Existing methods for producing urea formaldehyde concentrate are inefficient and require extensive equipment and multiple unit operations, making them costly and complex.
Innovation Solution
A cost-effective process involving autothermal reforming, sequential gas shifts, nitrogen addition, ammonia synthesis, methanol and urea production, followed by formaldehyde oxidation and absorption in an aqueous urea solution to produce urea formaldehyde concentrate, minimizing equipment and operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional methods are used for producing urea formaldehyde concentrate, then the production can be achieved, but the process requires extensive equipment and multiple unit operations making it costly and complex
Solution Approach 1:
The patent combines multiple production processes into a single integrated system where autothermal reforming, methanol synthesis, formaldehyde oxidation, and urea formaldehyde concentrate production occur in a unified flow. This merging of previously separate unit operations reduces equipment requirements and operational complexity while maintaining production efficiency
Solution Approach 2:
The reformate gas serves multiple functions within the process: it provides process heat, serves as feedstock for methanol synthesis, and the unreacted gas is recycled back to the reformer. This multi-functionality reduces the need for separate equipment for heating, feedstock preparation, and gas handling, thereby simplifying the overall process
2Productivity
If existing production methods are employed, then urea formaldehyde concentrate can be produced, but the process is inefficient and requires extensive equipment
Solution Approach 1:
The process maintains continuous operation where reformate gas is continuously produced, partially oxidized to formaldehyde, and the unreacted gas is immediately recycled back to the reformer. This continuous action eliminates idle time and intermediate storage requirements, improving productivity while reducing equipment needs
Solution Approach 2:
Instead of discarding unreacted reformate gas from the formaldehyde oxidation step, the process recycles it back to the autothermal reformer where it serves as additional feedstock. This recovery and reuse improves overall carbon conversion efficiency and reduces the need for fresh feedstock input
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
The process achieves efficient production of urea formaldehyde concentrate with reduced equipment needs and operational complexity, enhancing cost-effectiveness and simplicity.
Implementation Method 1
producing a synthesis gas containing hydrogen, carbon monoxide and carbon dioxide by partial combustion and steam reforming the hydrocarbon feedstock in an autothermal reforming stage
Implementation Method 2
producing a synthesis gas containing hydrogen, carbon monoxide and carbon dioxide by partial combustion and steam reforming the hydrocarbon feedstock
Implementation Method 3
subjecting the second synthesis gas from step (b) in series to a high temperature water gas shift and a medium temperature water gas shift conversion
Implementation Method 4
catalytically converting the nitrogen and hydrogen in the purified second synthesis gas from step (e) in an inert free ammonia synthesis stage
Implementation Method 5
converting the ammonia in the effluent to urea product by reaction with at least part of the carbon dioxide being removed from the synthesis gas in step (d)
Implementation Method 6
catalytically converting the carbon monoxide, carbon dioxide and hydrogen of the first synthesis gas from step (c) in a once through methanol synthesis stage
Implementation Method 7
oxidizing at least a part of the purified methanol from step (J) to formaldehyde
Implementation Method 8
absorbing the formaldehyde from step (k) in water and in an aqueous urea solution prepared from the urea product in step (g) to obtain the urea formaldehyde concentrate
Data Source
AI summary
Parallel co-production process for the production of methanol and urea product from a hydrocarbon containing feedstock by means of autothermal reforming, intermediary methanol and ammonia formation and conversion of the ammonia to urea product and catalytic oxidation of the methanol to formaldehyde.