Multi-Reaction Zone Reactor for Ammonia Synthesis
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Solution Overview
Problem
Current ammonia production methods, such as the Haber-Bosch process, face inefficiencies due to incomplete reaction conversion and high energy costs, particularly at small scales, and require large-scale economies and fossil fuel-based feedstocks, limiting the use of renewable non-fossil fuels and necessitating the development of more efficient, small-scale reactors with improved catalysts and heat/mass transfer efficiency.
Innovation Solution
A novel catalytic multi-reaction zone reactor system that integrates primary and secondary reaction zones without discrete physical barriers, utilizing Dielectric Barrier Discharge (DBD) nonthermal plasma reactors, controlled temperatures, and specific absorbents like sulphonated micro-porous polymer foams to enhance ammonia production and conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If small-scale reactors are used to produce ammonia, then the reactor footprint and energy efficiency are improved, but the reaction conversion and productivity are reduced
Solution Approach 1:
The reactor is divided into multiple reaction zones (primary reaction zone for ammonia synthesis, secondary reaction zone for product removal) that work together to achieve high conversion at small scale. The segmentation allows optimized conditions in each zone while maintaining compact overall size.
Solution Approach 2:
The patent implements continuous operation with recirculation of unreacted gases back to the primary reaction zone, ensuring continuous conversion of reactants to products. This continuous action maintains high productivity despite the small scale of individual reaction zones.
2Power
If multiple reaction zones are integrated without discrete physical barriers, then heat and mass transfer efficiency are improved, but device complexity increases
Solution Approach 1:
Multiple reaction zones are merged into a single integrated reactor structure without discrete physical barriers between them. The primary and secondary reaction zones share common walls and fluid pathways, enabling direct heat and mass transfer while simplifying the overall device structure.
Solution Approach 2:
Different regions of the integrated reactor are designed with locally optimized properties - the primary reaction zone has catalysts optimized for ammonia synthesis, while the secondary zone has absorbents optimized for product removal. Each zone maintains its specific functional quality within the unified structure.
3Productivity
If conventional Haber-Bosch process is used at large scale, then productivity is improved, but energy consumption and fossil fuel dependency increase
Solution Approach 1:
The patent changes the operating parameters from conventional high-temperature, high-pressure Haber-Bosch conditions to milder conditions enabled by advanced catalysts and plasma activation. This allows productive ammonia synthesis at lower energy consumption levels.
Solution Approach 2:
The patent replaces the mechanical intensive compression and heating systems of conventional Haber-Bosch with plasma-based activation and catalytic conversion. This substitution reduces energy consumption while maintaining productivity.
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 system increases reaction selectivity and conversion efficiency, enabling the production of ammonia and derivatives with higher yields and energy efficiency, potentially competing with large-scale Haber-Bosch processes while using renewable feedstocks and reducing costs.
Implementation Method 1
The main object of the present invention is to provide, a novel catalytic reactor system in order to increase the overall reaction efficiency in terms of selectivity and conversion
Implementation Method 2
producing at least some section of ammonia as a result of balance reaction of ammonia by means of nitrogen and hydrogen catalyst in at least one primary reaction zone
Implementation Method 3
realizing absorption by means of chemical or physical absorbents of at least some section of ammonia which is in gas form and which is produced in primary reaction zone
Implementation Method 4
realizing absorption by means of chemical or physical absorbents
Implementation Method 5
the temperatures of each reaction zone are controlled by means of at least one heating/cooling coil
Data Source
AI summary
The present invention is a production method for ammonia and ammonia derivatives in a Multi-Reaction Zone Reactor. Said production method comprising the steps of: a) producing at least some section of ammonia as a result of balance reaction of ammonia by means of nitrogen and hydrogen catalyst in at least one primary reaction zone (RZ-1), b) realizing absorption by means of chemical or physical absorbents of at least some section of ammonia which is in gas form and which is produced in primary reaction zone (RZ-1) in at least one secondary reaction zone (RZ-2) which is not separated by discrete physical barriers with the primary reaction zone (RZ-1).