System and method for producing ammonia

Solution Overview

Problem

Existing ammonia production processes are energy-intensive, particularly in the compression of nitrogen and hydrogen to synthesis pressure, and the liquefaction of ammonia, with limited efficiency and high energy consumption.

Innovation Solution

Integrate an electrolyzer with renewable energy and an air separation plant to reduce energy demand by pumping liquid nitrogen instead of compressing it, utilize refrigeration energy for partial liquefaction, and preheat reactants using waste heat from air compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If nitrogen and hydrogen are compressed to synthesis pressure using a synthesis gas compressor, then the required pressure for ammonia synthesis is achieved, but the energy consumption and compression intensity are very high

Engineering Contradiction:

Improvesynthesis pressureVSAvoidenergy consumption

Core Design Contradiction:

Stress or pressureVSUse of energy by moving object

Solution Approach 1:

The patent changes the physical state parameter of nitrogen from gas to liquid, enabling pumping instead of compression. Liquid nitrogen is pumped to synthesis pressure and then evaporated, consuming significantly less energy than compressing gaseous nitrogen to the same pressure

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transition of nitrogen between liquid and gas states. Nitrogen is cooled below its boiling point to become liquid, pumped in liquid state to achieve synthesis pressure, then evaporated back to gas for the synthesis reaction, leveraging phase change to avoid high-energy compression

Inventive Principle:

Principle #36Phase transitions

2Temperature

If a preheating unit is used to heat the synthesis gas to reaction temperature, then the required reaction temperature is achieved, but the energy consumption increases

Engineering Contradiction:

Improvereaction temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent implements self-service preheating where the hot synthesis gas exiting the reactor serves as the heating medium for preheating the incoming synthesis gas. This heat exchange within the system eliminates the need for external fuel-powered or electricity-powered heaters

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent converts the harmful waste heat from the ammonia synthesis reaction into a beneficial resource by using it to preheat the incoming synthesis gas through heat exchange, thereby reducing the overall energy consumption of the process

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Power

If steam is generated by the heat liberated during ammonia synthesis to drive the steam turbine, then the shaft power for the compressor is provided, but the amount of producible steam is reduced when preheating is done through external heaters

Engineering Contradiction:

Improveshaft powerVSAvoidsteam production

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The patent implements self-service preheating where the hot synthesis gas exiting the reactor serves as the heating medium for preheating the incoming synthesis gas. This heat exchange within the system eliminates the need for external fuel-powered or electricity-powered heaters

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent converts the harmful waste heat from the ammonia synthesis reaction into a beneficial resource by using it to preheat the incoming synthesis gas through heat exchange, thereby reducing the overall energy consumption of the process

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

Reduces overall energy consumption and improves the economic efficiency of ammonia production by optimizing energy use and integrating renewable energy sources.

Implementation Method 1

Integrate an electrolyzer with renewable energy

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Implementation Method 2

an air separation plant utilizing refrigeration to reduce the total energy demand

Methodology Applied

Scientific EffectRefrigeration: Cooling

Implementation Method 3

preheat reactants using waste heat from air compression

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS20250333316A1System and method for producing ammonia

Publication Date: 2025.10.30 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

The invention relates to a system and a method for generating ammonia, wherein, in an ammonia reactor, ammonia (NH3) is generated from a synthesis gas, wherein the synthesis gas contains hydrogen (H2) and nitrogen (N2), wherein a nitrogren supply flow and a first heat exchanger are used, which are designed in such a way that the hot ammonia (NH3) flowing out of the ammonia reactor heats the nitrogen used as synthesis gas in the nitrogen supply flow.