Regenerator Reactor Layout for High-Yield Nitric Oxide Synthesis
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Solution Overview
Problem
Existing methods for producing nitric oxide, such as the Ostwald and Birkeland-Eyde processes, face high energy demands and inefficiencies due to back-reactions, particularly in the direct synthesis of nitric oxide using electric arcs, which leads to reduced yield and increased greenhouse gas emissions.
Innovation Solution
A reactor design incorporating a reaction zone with a heat input device and at least two regenerator zones, each with high and low temperature sections, fluidically connected to the reaction zone, allows for a periodic-continuous operation to minimize back-splitting by rapidly cooling and preheating the reactant mixture, using channels with specific hydraulic diameters and oxide ceramic walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If direct synthesis of nitric oxide is performed in an electric arc at high temperature, then the reaction rate increases, but back-reactions occur and yield decreases
Solution Approach 1:
The reactor is divided into distinct functional zones: a reaction zone for NO formation and separate regenerator zones for cooling and heat recovery. This segmentation allows the reaction zone to operate at high temperature for optimal reaction rate while the regenerator zones handle the cooling and heat integration functions, preventing back-reactions and improving overall yield.
Solution Approach 2:
The regenerator zones are designed to rapidly cool the product gas stream before it can undergo back-reactions. By preliminarily cooling the hot product gas in the regenerator zones, the system prevents the decomposition of NO that would occur if the gas remained at high temperature, thus improving yield.
2Speed
If high temperature is used to drive the reaction, then reaction rate increases, but energy consumption increases
Solution Approach 1:
The system converts the harmful effect of excess heat in the product stream into a beneficial resource by using it to preheat the reactant stream in the regenerator zones. This heat integration reduces the external energy input required to maintain the reaction temperature, thereby reducing overall energy consumption while maintaining high reaction rate.
Solution Approach 2:
Instead of discarding the heat energy from the hot product gas as waste, the system recovers this thermal energy in the regenerator zones and transfers it to the incoming reactant stream. This recovery and reuse of thermal energy significantly reduces the external heating requirement and overall energy consumption of the process.
3Productivity
If rapid cooling is applied to prevent back-reactions, then yield increases, but heat integration becomes difficult
Solution Approach 1:
The system merges the cooling function and heat recovery function into a single integrated operation within the regenerator zones. The hot product gas and cold reactant gas exchange heat directly in these zones, achieving both rapid cooling of products to prevent back-reactions and efficient heat integration to reduce energy consumption simultaneously.
Solution Approach 2:
The regenerator zones act as intermediary structures that facilitate both rapid cooling and heat integration. These zones provide the necessary surface area and flow paths for the hot and cold gas streams to interact thermally, enabling simultaneous heat transfer for cooling and energy recovery without compromising either function.
4Productivity
If continuous operation is implemented, then productivity increases, but operational complexity increases
Solution Approach 1:
The system employs periodic reversal of gas flow direction through the regenerator zones to achieve continuous operation. By alternating the flow direction in a controlled manner, the reactor can continuously produce NO while the regenerator zones alternately cool products and preheat reactants, maintaining continuous productivity without requiring complex multiple reactors or intricate control systems.
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 significantly reduces energy consumption and increases the yield of nitric oxide production by minimizing back-splitting and enabling heat integration within the process, while maintaining efficient temperature control.
Implementation Method 1
supplying heat through the heat input device to the reaction zone until a temperature of from 1500°C to 2500°C is reached in the reaction zone
Implementation Method 2
The resulting products of combined nitrogen are rapidly cooled in a unique heat transfer unit which rapidly transfers the heat of the product gases to the reactant gases
Implementation Method 3
reactant mixture reacts to form a product mixture
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a method for the production of nitric oxide from a gaseous reactant mixture containing oxygen and nitrogen in a reactor comprising a reaction zone (1) with a heat input device (2) and at least two regenerator zones (3, 4, 5, 6), each regenerator zone having a low temperature section on one end and a high temperature section at the other end of the regenerator zone, the high temperature sections being fluidically connected to the reaction zone (1), the method comprising the steps of: e) supplying heat through the heat input device (2) to the reaction zone (1) until a temperature of from 1500°C to 2500°C is reached in the reaction zone (1); f) passing the reactant mixture through a first regenerator zone (3) into the reaction zone (1) in which the reactant mixture reacts to form a product mixture, passing the product mixture from the reaction zone (1) through a second regenerator zone (4) and withdrawing at least part of the product mixture from the second regenerator zone (4); g) reversing the direction of flow and passing the reactant mixture through the second regenerator zone (4) into the reaction zone (1) in which the reactant mixture reacts to form a product mixture, passing the product mixture from the reaction zone (1) through the first regenerator zone (3) and withdrawing at least part of the product mixture from the first regenerator zone (3); and h) reversing the direction of flow and periodically repeating steps b) and c); wherein the high temperature sections of the regenerator zones (3, 4, 5, 6) comprise a plurality of channels with a hydraulic diameter of 0.5 mm to 5 mm each, the inner walls of which are made of oxide ceramics.