Synthesis Gas Cooling Assembly for Ammonia Plant Leakage Risk
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Solution Overview
Problem
In dual pressure level ammonia plants, achieving efficient and reliable cooling of synthesis gas in the once through (OT) synthesis section is challenging due to the interaction of plant components, which limits flexibility and increases the risk of cooling medium leakage into the high-pressure section.
Innovation Solution
A synthesis gas cooling assembly utilizing medium pressure steam generated from boiler feed water, which is used in a dual phase heat exchanger to cool synthesis gas at a pressure level below the high-pressure section, reducing the risk of leakage and enhancing plant flexibility by allowing efficient heat transfer and ammonia yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high pressure boiler feed water is used for cooling synthesis gas in the OT synthesis section, then heat removal efficiency is improved, but the risk of cooling medium leakage into the high-pressure section increases
Solution Approach 1:
The patent introduces an intermediary cooling medium (condensate or process water at lower pressure) to transfer heat from the high-pressure synthesis gas cooling process, thereby mediating between the high-pressure synthesis section and the cooling system, which eliminates direct leakage risks while maintaining cooling efficiency
2Productivity
If additional plant components are added to optimize plant configuration, then production output and energy efficiency are improved, but device complexity increases
Solution Approach 1:
The patent makes existing plant components multi-functional by enabling them to serve both as cooling medium sources and as part of the steam generation system, thereby achieving optimization of plant configuration and increased productivity without adding complex new components
Solution Approach 2:
The patent merges the cooling function with the steam generation function by using the same heat exchanger system to both cool synthesis gas and generate steam for power generation, thereby simplifying plant configuration while increasing overall efficiency and output
3Use of energy by moving object
If cooling medium pressure is increased to improve heat transfer efficiency, then heat removal performance is improved, but the risk of leakage into synthesis gas increases
Solution Approach 1:
The patent inverts the traditional approach by using lower pressure cooling medium instead of high pressure cooling medium, thereby achieving heat transfer through a pressure differential in the opposite direction while eliminating the harmful leakage effect into the high-pressure synthesis gas
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 solution provides efficient and reliable cooling of synthesis gas in the OT synthesis section, increasing ammonia yield and plant flexibility while maintaining high energy efficiency and reducing the risk of cooling medium leakage, thus optimizing plant configuration and operation.
Implementation Method 1
heat exchange with high pressure boiler feed water (BFW) at a comparatively high heat exchanger pressure level
Implementation Method 2
dual phase heat exchanger to cool synthesis gas
Implementation Method 3
efficient heat transfer
Data Source
AI summary
A method of producing synthesis gas in a dual pressure level ammonia plant having a first synthesis section operated in once through fashion at a first relatively lower high pressure and having a second synthesis section operated in recirculating fashion at a second relatively higher high pressure. In the first synthesis section downstream of an OT reactor of the first synthesis section the synthesis gas is cooled using cooling medium at a pressure below the first high pressure, wherein the cooling medium is provided at a pressure below the first high pressure level by means of a medium pressure steam generator or wherein the cooling is effected by means of the medium pressure steam generator. The disclosure further relates to a synthesis gas cooling assembly in such a dual pressure level ammonia plant and at least one plant component for providing or for utilizing the cooling medium.