Static-Mixer Ammonium Nitrate Reactor for Low Ammonia Slippage
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Solution Overview
Problem
Existing ammonium nitrate production processes face challenges in reducing ammonia slippage and nitrogen losses, achieving complete conversion of ammonia to ammonium nitrate, ensuring uniform mixing of nitric acid and ammonium nitrate solutions, and minimizing pressure drop to reduce energy consumption.
Innovation Solution
The introduction of improved static mixers, both upstream and downstream of the tube bundle, to enhance mixing efficiency and uniformity, combined with a gas/liquid separation zone and pressure reduction means to optimize the reaction process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If forced flow of the solution is used with a pump, then mixing efficiency is improved, but energy consumption increases
Solution Approach 1:
The patent replaces the mechanical pump-based forced flow system with a passive mixing system using static mixers. The static mixers create turbulent flow patterns and enhance mixing through their internal geometry without requiring external mechanical energy input, thus eliminating the need for a recirculation pump while maintaining effective mixing.
Solution Approach 2:
The static mixers are designed to utilize the natural flow of the solution to generate mixing action. The internal structure of the static mixers creates flow division, rotation, and recombination that automatically mix the solution without external energy input, making the system self-sufficient for mixing purposes.
2Temperature
If recirculation ratio is increased to control reaction temperature, then temperature control is improved, but ammonia slippage increases
Solution Approach 1:
The static mixers are positioned upstream of the reaction zone to pre-mix the nitric acid and ammonium nitrate solutions before they enter the reaction chamber. This preliminary mixing ensures homogeneous distribution of reactants, promoting complete reaction and reducing ammonia slippage even at lower recirculation ratios where temperature control is still effective.
Solution Approach 2:
The patent changes the flow distribution parameters within the reaction system by using static mixers to create more uniform flow patterns and residence time distribution. This improves reaction completeness and reduces ammonia slippage without requiring excessive recirculation for temperature control.
3Productivity
If complex reactor internals are used to achieve homogeneous reaction, then conversion efficiency is improved, but device complexity increases
Solution Approach 1:
The mixing function is segmented into multiple static mixer elements arranged in series. Each element performs a portion of the mixing task through simple internal geometry (baffles, flow distributors), achieving cumulative homogeneous mixing without requiring a single complex mixing mechanism. This modular approach maintains conversion efficiency while keeping individual components simple.
Solution Approach 2:
The static mixers use simple, inexpensive internal geometries (baffles, flow distributors) that can be easily manufactured and replaced if needed. These simple structural elements achieve effective mixing without requiring complex, expensive, or difficult-to-maintain reactor internals.
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 reduces ammonia slippage, enhances conversion efficiency, minimizes nitrogen losses, and lowers energy consumption by improving mixing and pressure management in the ammonium nitrate production process.
Implementation Method 1
The introduction of improved static mixers, both upstream and downstream of the tube bundle, to enhance mixing efficiency and uniformity
Implementation Method 2
Ammonia reacts rapidly and completely with nitric acid in aqueous solutions to form AN in an exothermic reaction
Implementation Method 3
a gas/liquid separation zone and pressure reduction means to optimize the reaction process
Implementation Method 4
pressure reduction means to optimize the reaction process
Data Source
AI summary
The disclosure pertains to an ammonium nitrate reactor with a first type static mixer in the mixing zone upstream of the tube bundle and/or a second type static mixer downstream of the tube bundle.