Synthesis Loop Pressure Control Using Recirculation Gas Feedback
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Solution Overview
Problem
The use of renewable energy in ammonia or methanol synthesis leads to variable energy supply, causing significant fluctuations in the flow of fresh synthesis gas, resulting in mechanical stress and pressure variations that can lead to equipment failure due to the lack of effective pressure control in traditional ammonia and methanol loops.
Innovation Solution
Implementing an anti-surge control valve and/or compressor flow regulation valve in the loop recirculation system to manage the flow of recirculation gas, combined with temperature control in a loop separator, to maintain a constant pressure in the ammonia or methanol synthesis loop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If renewable energy is used for ammonia or methanol synthesis, then sustainability and green production are improved, but pressure stability and equipment reliability deteriorate due to variable energy supply causing significant flow fluctuations
Solution Approach 1:
The patent implements a feedback control system where loop pressure is continuously monitored and used to adjust the recirculation gas flow through the anti-surge control valve. This closed-loop control automatically compensates for pressure deviations caused by variable renewable energy supply, maintaining stable operating conditions while enabling green production.
Solution Approach 2:
The recirculation gas flow acts as an intermediary mechanism to stabilize loop pressure. By adjusting the recirculation flow through the anti-surge valve, the system mediates between variable fresh synthesis gas flow from renewable sources and the need for stable loop pressure, preventing direct transmission of fluctuations to pressure-bearing equipment.
2Reliability
If anti-surge control valve is used for pressure control, then pressure stability is improved, but device complexity increases due to additional control mechanisms
Solution Approach 1:
The anti-surge control valve serves dual functions: protecting the compressor from surge conditions and simultaneously controlling loop pressure stability. By making the valve multi-functional, the patent avoids adding a separate dedicated pressure control valve, thus maintaining pressure stability without significantly increasing device complexity.
3Reliability
If recirculation gas flow is increased to maintain pressure, then pressure stability is improved, but energy consumption increases
Solution Approach 1:
The recirculation gas flow is dynamically adjusted based on actual loop pressure conditions and fresh synthesis gas flow variations. Rather than maintaining constant high recirculation flow, the system optimizes flow rates in real-time, increasing recirculation only when necessary to maintain pressure stability, thereby reducing unnecessary energy consumption.
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 method stabilizes loop pressure and reduces mechanical stress, preventing equipment damage by ensuring consistent operation despite variable energy supply, while utilizing renewable energy sources for ammonia or methanol production.
Implementation Method 1
flow of the loop recirculation gas through the anti-surge valve and/or the recirculation compressor flow regulation valve is controlled to obtain a substantially constant pressure in the ammonia or methanol synthesis loop
Implementation Method 2
pressurizing the loop recirculation gas from step (e) in the loop recirculation compressor
Implementation Method 3
temperature control in a loop separator, to maintain a constant pressure in the ammonia or methanol synthesis loop
Data Source
AI summary
Method for the control of pressure in a loop for the preparation of ammonia or methanol by means of an anti-surge control valve of a compressor and/or a compressor flow regulation valve for the recirculation of loop recirculation gas at variating flow supply of fresh synthesis gas.