Methods and systems for efficiently and cleanly manufacturing ammonia, ammonium sulfate, nitric acid, ammonium nitrate, or combinations thereof from coal and petcoke products
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Solution Overview
Problem
The petrochemical industry faces challenges in reducing nitrogen oxides, sulfur oxides, and carbon dioxide emissions during the production of ammonia and other chemicals, particularly when using coal and petcoke, which are major contributors to air pollution and climate change.
Innovation Solution
The method involves capturing sulfur dioxide and carbon dioxide using carbon-free hydrogen as a fuel for ammonia synthesis, integrating a cryogenic air separation unit fluid stream as a refrigerant for liquefaction and carbon capture, and utilizing a pressure swing adsorption system to achieve high purity hydrogen and efficient carbon dioxide capture, followed by the conversion of hydrogen sulfide to sulfur dioxide for the production of ammonium sulfate, thereby reducing emissions to near-zero levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coal and petcoke are used as fuel for ammonia production, then productivity and cost-effectiveness are improved, but harmful emissions (nitrogen oxides, sulfur oxides, carbon dioxide) increase
Solution Approach 1:
The patent converts harmful emissions into valuable products: nitrogen oxides are converted to nitric acid and ammonium nitrate fertilizers, sulfur oxides are converted to sulfuric acid and ammonium sulfate fertilizers, and carbon dioxide is captured and sequestered. This transforms the harmful byproducts of coal and petcoke gasification into economically valuable commodities while eliminating environmental pollution.
Solution Approach 2:
The patent introduces multiple intermediary systems between the gasification process and final ammonia production: a gas cleaning system with electrostatic precipitators and scrubbers to remove particulates and gases, a carbon capture system using amine solvents, and selective catalytic reduction systems. These intermediaries enable the use of coal and petcoke while controlling emissions.
2Object-generated harmful factors
If emission capture technologies are implemented to reduce nitrogen oxides, sulfur oxides, and carbon dioxide, then environmental impact is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple emission control functions into integrated systems: the gas cleaning system combines electrostatic precipitators for particulate removal with wet scrubbers for gas absorption; the carbon capture system is integrated with the ammonia synthesis process; and the nitric acid and sulfuric acid production units serve dual purposes as both emission control devices and valuable product generation systems.
Solution Approach 2:
The patent designs multi-functional systems that perform multiple roles: the gas cleaning system removes particulates, sulfur compounds, and nitrogen compounds while preparing syngas for ammonia synthesis; the carbon capture system sequesters CO2 while generating carbonates for construction materials; the acid production systems control emissions while producing fertilizers and chemical feedstocks.
3Ease of manufacture
If traditional ammonia synthesis methods using natural gas are used, then manufacturing simplicity is maintained, but carbon dioxide emissions and fuel cost increase
Solution Approach 1:
The patent fundamentally changes the feedstock parameter from natural gas to coal and petcoke, and changes the hydrogen production method from steam methane reforming to gasification. This parameter change enables lower carbon emissions while maintaining process efficiency through optimized gasification conditions and integrated carbon capture.
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 results in greater than 90% carbon dioxide capture efficiency, near 100% sulfur dioxide capture, and significant reduction of nitrogen oxides, enabling the use of coal and petcoke in a cleaner, more efficient manner, transitioning from blue hydrogen to green hydrogen processes while minimizing environmental impact.
Implementation Method 1
utilizing a pressure swing adsorption system to achieve high purity hydrogen and efficient carbon dioxide capture
Implementation Method 2
integrating a cryogenic air separation unit fluid stream as a refrigerant for liquefaction and carbon capture
Implementation Method 3
carbon-free hydrogen as a fuel for ammonia synthesis
Data Source
AI summary
The disclosure relates generally to methods and systems for manufacturing ammonia, ammonium sulfate, nitric acid, ammonium nitrate, or combinations thereof, and particularly to clean and efficient methods and system configurations for manufacturing ammonia, ammonium sulfate, nitric acid, ammonium nitrate, or combinations thereof using coal, petcoke, asphaltenes and/or hydrocarbon waste products.