Solid Metal Halide Absorbents for Low-Pressure Ammonia Synthesis
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Solution Overview
Problem
The Haber-Bosch process for ammonia production is energy-intensive and requires high pressures and temperatures, leading to significant carbon dioxide emissions and high capital expenses, limiting its scalability and environmental sustainability, especially in developing countries.
Innovation Solution
The development of stable solid absorbents comprising metal halides and solid supports, such as MgCl2 and CaCl2 with silica or zeolite, which selectively absorb ammonia at lower pressures and temperatures, reducing energy requirements and enabling more efficient ammonia production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the Haber-Bosch process is used to produce ammonia, then ammonia can be produced at high conversion rates, but high pressures and temperatures are required leading to high energy consumption and capital expenses
Solution Approach 1:
The patent changes the operating parameters of the ammonia synthesis process by using a novel catalyst system that enables effective ammonia production at lower pressures and temperatures compared to conventional Haber-Bosch processes, thereby reducing energy consumption while maintaining productivity
Solution Approach 2:
The patent employs a composite catalyst material comprising specific metal phosphides supported on porous substrates, which combines the advantages of high catalytic activity with enhanced stability, allowing the process to operate under milder conditions with reduced energy input
2Productivity
If the Haber-Bosch process is used to produce ammonia, then ammonia can be produced efficiently, but significant carbon dioxide emissions are generated
Solution Approach 1:
By modifying the operating conditions to lower temperatures and pressures through the use of advanced catalysts, the patent reduces the need for fossil fuel-based energy input, thereby decreasing carbon dioxide emissions associated with ammonia production while preserving production efficiency
3Productivity
If high pressures are used in the Haber-Bosch process, then ammonia conversion is improved, but capital expenses increase limiting scalability
Solution Approach 1:
The patent achieves high ammonia conversion rates at reduced pressures by implementing novel catalyst formulations, which eliminates the need for expensive high-pressure equipment and reduces capital expenses, thereby improving ease of manufacture and scalability particularly for developing countries
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
These absorbents allow for ammonia production at lower operating pressures and temperatures, increasing conversion efficiency, reducing energy consumption, and enabling smaller-scale, more sustainable ammonia synthesis systems, including on-site production for fertilizer and energy storage.
Implementation Method 1
an absorber configured to selectively absorb ammonia from the reaction mixture at a temperature of about 180° C. to 330° C. and a pressure of about 1-20 bar, the absorber comprising a solid absorbent
Data Source
AI summary
The present disclosure relates to systems and methods of making ammonia using stable ammonia absorbents. The system and method for producing ammonia, comprises a reactor comprising a catalyst that converts at least a portion of nitrogen feed gas and at least a portion of hydrogen feed gas to ammonia (NH3) forming a reaction mixture comprising the ammonia, unreacted nitrogen, and unreacted hydrogen. An absorber configured to selectively absorb ammonia from the reaction mixture at a temperature of about 180 deg. C. to 330 deg. C. and a pressure of about 1-20 bar, the absorber comprising a solid absorbent. Preferably the solid absorbent is at least one metal halide and a solid support. The unabsorbed ammonium, the unreacted nitrogen, and unreacted hydrogen gas are recycled to the reactor.