US20090148370A1 - Process to produce ammonia from urea - Google Patents

Process to produce ammonia from urea Download PDF

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Publication number
US20090148370A1
US20090148370A1 US11/999,952 US99995207A US2009148370A1 US 20090148370 A1 US20090148370 A1 US 20090148370A1 US 99995207 A US99995207 A US 99995207A US 2009148370 A1 US2009148370 A1 US 2009148370A1
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Prior art keywords
reactor
urea
pressure
ammonia
temperature
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US11/999,952
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English (en)
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Herbert W. Spencer, III
H. James Peters
William G. Hankins
Madoka Fujita
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EC&C Technologies
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EC&C Technologies
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Assigned to EC&C TECHNOLOGIES, INC. reassignment EC&C TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJITA, MADOKA, HANKINS, WILLIAM G., PETERS, H. JAMES, SPENCER, III, HERBERT W.
Priority to US11/999,952 priority Critical patent/US20090148370A1/en
Application filed by EC&C Technologies filed Critical EC&C Technologies
Priority to TW097103581A priority patent/TWI406813B/zh
Priority to CN2008100093693A priority patent/CN101450807B/zh
Priority to CN201310094872.4A priority patent/CN103183360B/zh
Priority to CN201310094814.1A priority patent/CN103214007B/zh
Priority to AU2008243180A priority patent/AU2008243180B2/en
Priority to IL195335A priority patent/IL195335A0/en
Priority to ZA2008/09877A priority patent/ZA200809877B/en
Priority to KR1020080122465A priority patent/KR101326343B1/ko
Priority to ES14195497.4T priority patent/ES2629497T3/es
Priority to EP08253887.7A priority patent/EP2070872B1/en
Priority to ES08253887.7T priority patent/ES2592717T3/es
Priority to EP14195497.4A priority patent/EP2842915B1/en
Priority to JP2008312567A priority patent/JP5693811B2/ja
Publication of US20090148370A1 publication Critical patent/US20090148370A1/en
Priority to HK09110168.6A priority patent/HK1131602B/xx
Priority to HK13110615.9A priority patent/HK1183286B/xx
Priority to HK13110616.8A priority patent/HK1183287B/xx
Priority to US12/963,334 priority patent/US8313722B2/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01C—AMMONIA; CYANOGEN; COMPOUNDS THEREOF
    • C01C1/00—Ammonia; Compounds thereof
    • C01C1/02—Preparation, purification or separation of ammonia
    • C01C1/08—Preparation of ammonia from nitrogenous organic substances
    • C01C1/086—Preparation of ammonia from nitrogenous organic substances from urea
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01C—AMMONIA; CYANOGEN; COMPOUNDS THEREOF
    • C01C1/00—Ammonia; Compounds thereof
    • C01C1/02—Preparation, purification or separation of ammonia
    • C01C1/04—Preparation of ammonia by synthesis in the gas phase
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07B—GENERAL METHODS OF ORGANIC CHEMISTRY; APPARATUS THEREFOR
    • C07B63/00—Purification; Separation; Stabilisation; Use of additives
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion
    • F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
    • F01N3/208—Control of selective catalytic reduction [SCR], e.g. by adjusting the dosing of reducing agent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2251/00—Reactants
    • B01D2251/20—Reductants
    • B01D2251/206—Ammonium compounds
    • B01D2251/2062—Ammonia
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/40—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a hydrolysis catalyst
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/06—Adding substances to exhaust gases the substance being in the gaseous form
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/10—Adding substances to exhaust gases the substance being heated, e.g. by heating tank or supply line of the added substance
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/14—Arrangements for the supply of substances, e.g. conduits
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2900/00—Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06—Parameters used for exhaust control or diagnosing
    • F01N2900/18—Parameters used for exhaust control or diagnosing said parameters being related to the system for adding a substance into the exhaust
    • F01N2900/1806—Properties of reducing agent or dosing system
    • F01N2900/1808—Pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2900/00—Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06—Parameters used for exhaust control or diagnosing
    • F01N2900/18—Parameters used for exhaust control or diagnosing said parameters being related to the system for adding a substance into the exhaust
    • F01N2900/1806—Properties of reducing agent or dosing system
    • F01N2900/1811—Temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2900/00—Details of electrical control or of the monitoring of the exhaust gas treating apparatus
    • F01N2900/06—Parameters used for exhaust control or diagnosing
    • F01N2900/18—Parameters used for exhaust control or diagnosing said parameters being related to the system for adding a substance into the exhaust
    • F01N2900/1806—Properties of reducing agent or dosing system
    • F01N2900/1814—Tank level
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the process entails feeding an aqueous urea solution to or creating and aqueous urea solution in a hydrolyser (reactor) where it is heated under pressure to produce ammonia gas mixture of ammonia, water and carbon dioxide.
  • a hydrolyser reactor
  • the reactor operating pressures and temperatures are allowed to vary to match ammonia demand requirements.
  • the reactor pressure is set either to vary with ammonia demand or with reactor operating temperature.
  • the operating pressure is varied such that during normal operation the concentration of these gases remains in equilibrium with the composition of the solution in the reactor and equal to the conversion products of the feed composition.
  • the feed solution is in range of 40 to 50 weight percent urea to water.
  • Utilities and A/E firms have shown keen interest in technology for urea-to-ammonia conversion.
  • Utilities are increasingly adopting urea as a preferred alternative to anhydrous and aqueous ammonia for their SCR projects, with several major utilities committing to the urea-to-ammonia alternative and many potential users actively evaluating systems for current and future projects.
  • Other processes such as SO 2 scrubbing with ammonia are evaluating the use of urea to ammonia.
  • the improvements of this invention make this more feasible by providing the means to significantly reduce the heat requirements for the production of ammonia from urea.
  • Other applications are also evaluating the use of ammonia production to reduce the onsite storage of ammonia.
  • urea-to-ammonia technologies are in response to the greatly increased requirements for utilities to control NOx emissions and their implementation of SCR projects that require ammonia as the reducing agent.
  • Anhydrous ammonia is regarded as a hazardous and toxic chemical and is subject to stringent regulations imposed by the EPA as well as OSHA.
  • Aqueous ammonia although less concentrated, poses similar risks, and is also becoming increasingly regulated or subject to restrictions by local authorities.
  • the use of aqueous ammonia as an alternative to anhydrous significantly increases operating costs for chemical and energy, and increases transport and storage requirements. These disadvantages are exacerbated as more dilute aqueous solutions are considered.
  • the urea to ammonia and other on demand urea to ammonia system uses urea as the feedstock chemical and thereby entirely avoids risks associated with the transportation and storage of ammonia.
  • the process transforms urea solution to an ammonia gas mixture on demand to meet the dynamic requirements of the NOx control system and other systems using ammonia.
  • the initial systems were designed for operating temperatures of 300 deg F. and operating pressure of 60 to 80 psig with a urea feed concentration of 40%. Higher urea feed concentrations reduce the operating cost by decreasing the energy required to evaporate the water in the feed solution. As the market matures higher temperature designs and higher 50% urea feed concentrations can reduce the capital cost of the system as well as reduce energy consumption.
  • Brooks et al. U.S. Pat. No. 6,761,868 describes a means to address the issue by controlling both temperature and pressure.
  • reactor temperature is not controlled and pressure is adjusted as function of ammonia demand or temperature.
  • the Brooks patent does show the pressure and temperature to maintain the concentration in the reactor at the feed concentration but does not show, as shown in this patent application, how the concentration in the reactor can be maintained at a desired value independent of the feed concentration.
  • a secondary issue is the additional heat needed to maintain higher urea concentration in solution. At 40% urea concentration the requirements for heat tracing of the urea feed system are reduced but reactor energy consumption is increased.
  • This invention identifies design considerations needed to be taken into account in order to maintain water balance in the reactor. This has the advantage that the product gas composition remains nearly constant during changes in gas production rate. Another of the advantages of the invention is the reactor can be operated such that for all demand conditions the product gas temperature is always above the gas dew point calculations for urea to ammonia generation processes. This result is in less corrosion and longer lasting reactors.
  • the present invention comprises in a process for producing ammonia from urea, which process comprises:
  • step (d) withdrawing the gaseous ammonia and carbon dioxide-containing product separated in step (b) at a controlled rate to meet demand requirements;
  • the temperature in the hydrolysis reactor is not controlled but is allowed to vary to match the demand requirement for ammonia and in which the pressure is varied as function of the demand requirement for ammonia or reactor operating temperature.
  • This invention further comprises in a process for removing nitrogen oxides from a combustion gas stream which process comprises:
  • step (d) withdrawing the gaseous ammonia and carbon dioxide-containing product separated in step (b) at a controlled rate;
  • the temperature in the hydrolysis reactor is not controlled but is allowed to vary to match the demand requirement for ammonia and in which the pressure is varied as function of the demand requirement for ammonia or reactor operating temperature.
  • the temperature is matched to the demand requirement for ammonia by regulating the heat added to the hydrolysis reactor.
  • the demand signal from the source of the demand for ammonia such as a chemical reaction consuming ammonia, e.g., a combustion gas stream containing NO x is used to open and close a restriction on the off take from the reactor to allow for flow of the product gas to match the ammonia demand requirements.
  • a valve in the ammonia gas takeoff line from the hydrolysis reactor is opened to increase the flow of gas. Likewise if there is decrease in demand the valve is closed. An increase in demand for a given operating temperature will cause the pressure in the reactor to decrease and a decrease in demand will cause the pressure to increase.
  • the heat input into the reactor is increased if the pressure decreases and decreased if the pressure increased. Because of the endothermic nature of the reaction process and heat of water evaporation, a decrease in heat input will decrease the reactor temperature and an increase in heat input will increase the reactor temperature.
  • the pressure was maintained at constant value with changes in operating temperature or demand by controlling the heat input to the reactor.
  • the pressure is not maintained constant but is adjusted according to the ammonia demand or reactor temperature. In practice, this can be done by establishing a pressure set point. In the prior art, the pressure is maintained constant.
  • the pressure set point is changed in relation to the temperature or ammonia demand to maintain the desired or predetermined amount of water in the hydrolysis reactor.
  • the heat input is adjusted to have the reactor pressure match the new set point which then causes the temperature to change.
  • an iterative procedure is developed that results in a nearly constant water balance in the reactor.
  • FIG. 1 shows a plot of the ammonia generation rate as a function of temperature and the exponential increase as a function of temperature.
  • FIGS. 2 and 3 show the urea-carbamate equilibrium concentration for 40 and 50% urea feed solutions.
  • FIG. 4 shows dew points for 40 and 50% feed solutions with and without fugacity.
  • the water dew point line is shown for reference.
  • FIG. 5 shows the cross section of a typical reactor.
  • FIG. 6 shows a process control configuration to execute the invention.
  • FIGS. 7 and 8 show the pressure needed to maintain a constant 20%, 30%, 40% and 50% concentration in the reactor as a function of temperature for 40% and 50% feed solution.
  • FIG. 9 shows an example of an operating line for pressure set points.
  • Raoult's law states that the vapor pressure of each component in an ideal solution is related to the vapor pressure of the individual component and the mole fraction of the component present in the solution.
  • the total vapor pressure of the solution is:
  • the urea and ammonia carbamate dissolved in a reactor solution is treated as has having zero vapor pressure.
  • the partial pressure is defined as:
  • y J is the mole fraction of the gas J, the ratio of its amount in moles to the total number of moles of gas molecules present in the mixture.
  • the total pressure of a mixture of any kind of gases is the sum of their partial pressures.
  • FIGS. 2 and 3 show the estimated equilibrium urea-carbamate concentration for 40% and 50% urea feed solutions for typical operating pressures and temperatures for a urea to ammonia reactor.
  • FIG. 2 shows the urea-carbamate concentration would be approximately 50% of the solution in the reactor. At minimum load (10%) and lower reactor temperatures, the urea-carbamate concentration decreases to approximately 20% for an operating pressure of 60 psig.
  • the typical control range is from about 33% to 100% load, in which case, the reactor liquor urea-carbamate concentration varies from 38% to 50% and excess water (62% to 50%) is maintained.
  • the urea-carbamate concentration ranged from 15 to 25%.
  • the measured concentration of urea, carbamate, and urea-formaldehyde compounds ranged from 44 to 57% operating with temperatures up to 305 deg F. with 40% feed solutions and operating at a constant pressure set point of 60 psi. Both of these units were typical daily cycling boilers and field measurements are in good agreement with the estimated water balance.
  • the urea-carbamate concentration will increase while water decreases to the limit of insufficient water. In that case, the rate of the hydrolysis reaction will also decrease and higher temperature operation is needed to maintain ammonia production. For this situation, the reactor operating pressure needs to be increased while also considering the pressure effect on product gas dew point temperature as discussed in the next section.
  • the urea to ammonia reactor should be set up to operate with a pressure for which the dew point is less than the normal minimum operating temperature, to avoid condensation products which increase general corrosion rates in the system. Corrosion allowances included in the normal design allow for extended operation below the dew point, but it is recommended to maintain operations above the dew point. The operating procedure of this invention allows this to be done for a larger range of operation than could be previously obtained. Phase equilibrium considerations on the NH 3 —CO 2 —H 2 O gas system allow the determination of a dew point temperature as a function of pressure and concentration as explained below.
  • the algorithm given below provides a procedure applicable for calculating dew point temperatures for condensation from a gas mixture of NH 3 —CO 2 —H 2 O.
  • Equations for property estimation are found in the technical literature for NH 3 —CO 2 —H 2 O and in articles specific for urea production and are valid for a wide range of temperatures and pressures including those experienced in the urea to ammonia system.
  • liquid phase concentrations For equilibrium of product gas with the reactor liquid, the determination of liquid phase concentrations assumes that the presence of urea, carbamate, and urea formaldehyde species in the liquid does not incorporate additional non-ideality, i.e. a solution of urea in water interacts with ammonia in the same manner as if only water were present in the liquid. To further refine these calculations activity coefficients for urea, and other ionic species in the liquid phase would have to be incorporated.
  • Dew points were also estimated more simply using Raoult's Law without fugacity considerations. The results of both are compared with water dew points in the following FIG. 4 . As would be expected the dew points of the UREA TO AMMONIA product take gas are less than pure water. When we consider fugacity to account for the interaction between water, ammonia and carbon dioxide, slightly higher dew points are estimated.
  • urea to ammonia reactors operate with a controlled constant liquid level, resulting in a fixed liquid space and vapor space as shown below in FIG. 5 .
  • the pressure in the reactor is controlled at nominally 40 to 120 psig while the temperature varies with production rate from 250 to 315° F.
  • the reactor liquid typically contains from 15-50% urea, 0-18% higher urea derivatives, and 3-6% ammonia. At temperatures above 250° F., any ammonium carbamate in the liquid formed immediately decomposes to ammonia and carbon dioxide and hence very small concentrations (1-2%) of ammonium carbamate will be present in the reactor liquor. The balance is water.
  • product gas temperatures 250-275° F.
  • product gas temperatures 250-275° F.
  • the reactor can operate below the gas mixture dew points at the operating pressure of 80 psig.
  • a weak ammoniacal solution in water condenses out of the gas stream whenever it comes in contact with colder surfaces. Inspection of reactor internals has shown such liquid condensation stains on the gas-side reactor surface. These condensing vapors on cold surfaces also contribute to the slightly higher corrosion rates on the gas side surfaces and therefore should be minimized where possible by adjusting operating pressures. By using the procedures of this invention the condensation is avoided.
  • Heat is provided to the reaction process to maintain pressure where the pressure is set as a function of the temperature or the ammonia demand.
  • the pressure can also be set using a demand signal by using the relationship that the temperature of the reactor is a function of the ammonia demand, that is, the temperature T will follow the relationship:
  • T ⁇ b/k (ln( G/A )) where G is the generation rate (quantity per time) and B, k and A are constants.
  • Theoretical relationships of pressure and temperature to maintain a constant solution concentration are shown in FIGS. 7 & 8 .
  • the function f(T) can be developed from these curves or from measured concentration as a function of temperature and pressure. Pilot test data showed that operating near the higher solution concentrations give the greater generation for given reactor liquid volume up to a point where the reaction becomes water starved. Any solution greater than 78% will have insufficient water for complete hydrolysis.
  • a urea solution is feed to or created in a hydrolysis reactor and the urea is quantitatively convert to ammonia and carbon dioxide producing an ammonia, carbon dioxide and water vapor product gas that is stoichiometrically equivalent to the converted feed solution.
  • Heat is provided to maintain the temperature and pressure in the reactor.
  • the improvement in the invention is to adjust the pressure in the reactor to be a function of either the generation rate or the temperature in the reactor. The pressure is adjusted in such a way that the excess water in the reactor stays at a relatively uniform value with varying ammonia generation rates with the temperature allowed to adjust to meet the ammonia demand.
  • Example 1 a 40% feed solution is feed to the reactor or created in the reactor by feeding urea, concentrated urea, and separate stream of water or steam. (The dry urea is normally prilled and formaldehyde coated.)
  • a heater is provided to heat the solution in the reactor.
  • the heat input is adjusted to maintain the pressure in the reactor at set pressure setting.
  • the pressure setting is initially set at start up a value above 30 psia. Once the reactor is heated up to generate gas at 30 psia, the pressure set point is set to a pressure corresponding to reactor temperature according to the data shown in FIG. 7 . This can be done by various means such as table look up or by the means of computing from an equation that fits the data in FIG. 7 .
  • a desired dissolved content is selected initially for the process such as 30%. This will provide a large excess of water to urea and give a low salt out temperature for the solution in the reactor.
  • the reactor off take valve is opened or closed to match the desire ammonia generation rate.
  • the heat input to the reactor is increased or decreased as required to maintain the reactor at the pressure set point. Because higher temperatures are required to produce gas at higher loads more heat will be required to be input with higher demands and the temperature of the reactor will automatically adjusts to maintain the pressure at the pressure set point. As rate of gas withdrawn from the reactor is changed the pressure set point is adjusted to a new value either according to the demand rate or as function of the reactor temperature.
  • the pressure set point As the temperature increases the pressure set point is increased which will cause more heat to be input in to the reactor which will help quickly bring the system to the new higher production rate.
  • demand decreases the pressure will start to raise causing heat input to decrease.
  • Heat is used by the process because, the reaction for the process is endothermic and because of evaporation of water.
  • the reactor temperature decreases. This will now result in the pressure set point being reduced. Since the set pressure set point is reduced, the control for heat input will further reduce the heat input to the reactor which will further allow the temperature to decrease reducing gas production to match the new demand requirement.
  • the off take gas composition can remain nearly constant with increases and decrease in the ammonia demand.
  • a reactor is operated with a constant pressure and constant feed concentration typically there will be excess water in the gas product during a load increase and insufficient water in the product gas during a load decrease until a new water balanced is obtained in the reactor. Only in an incrementally slow change does the water stay in balance with a fixed pressure set point.
  • the gas composition exiting the reactor can be keep at a composition that is at the equilibrium value for the feed concentration being feed or created in the reactor.
  • the pressure in the reactor can be measured and the valve opening needed calculated for the desired flow.
  • Another advantage of the method is ability to always have the product gas temperature above the gas dew point.
  • the dew point of the product gas is 296 deg F. at 80 psig for 40% feed solution.
  • the gas will temperature will drop in this example to 270 deg F., which is below the dew point. This can result in corrosion on the gas side of the reactor.
  • the pressure is decreased with demand or reactor temperature as in this example to 30 psig, the product gas which is now at a temperature of 270 deg F. remains above the dew point since the dew point of the product gas with the reduced pressure is now 256 deg F.
  • Example 2 is similar to Example 1 except that in this case a pressure ammonia demand load curve is developed from the temperature demand relationship in FIG. 1 and the temperature pressure relationships for constant water balance in the reactor as shown in FIGS. 7 and 8 .
  • Similar curves and relationships can be developed for other feed concentrations or the relationship for setting the pressure set points as function of temperature or ammonia production rate can be determined by those skilled in the art from measured values of the reactor solution concentration for various pressures and temperatures operating at fixed feed concentration.
  • the operating pressure set point could be manually adjusted for various fixed loads and the reactor solution concentration measured. Density measurement could be used to obtain a measure of the solution concentration.
  • the pressure set point is set by the demand signal instead of the reactor temperature. This has the advantage over the temperature which due the mass of the reactor and liquid in the reactor can lag the demand change.
  • the reaction process uses heat for the hydrolysis of the urea and the evaporation of water that the reactor temperature follows closely with the demand requirement.
  • a 70% feed is feed to reactor.
  • the reactor would be initially charged with water so that an initial filling with 70% with solution would result in an initial solution in the reactor that is say 40% urea.
  • the product off gas will be the equivalent composition of the 70% feed.
  • the reactor pressure is adjusted in this example such that the water balance in the reactor is maintained at a 40% concentration that is lower than the feed concentration. The advantage of this approach is that the heat for evaporating water is significantly reduced.
  • the heat consumption is reduced from 4526 Btu/lb of ammonia produced to 2193 But/lb ammonia.
  • the disadvantage is that the salt out temperature of the 70% feed solution is 133 deg F. compared to 30.5 deg F. for a 40% feed solution. If the feed solution is maintained at a high temperature such as 133 deg F. some of the urea will convert to biuret. Biuret in the reactor feed increases the required operating temperature of the reactor for ammonia production.
  • FIGS. 7 and 8 show that higher operating pressures are needed to maintain water balance. Operating according to example one would automatically correct the operating pressure to handle higher biuret contents.
  • FIG. 9 a simple operating line is shown in FIG. 9 .
  • a linear line is shown.
  • a power function could also be used.
  • Four set points are established low pressure (p 1 ) and low temperature (t 1 ) and high pressure (p 2 ) and high temperature (t 2 ) below (t 1 ), pressure is held at (p 1 ) and above (t 2 ) pressure is held at (p 2 ).
  • the pressure set point pressure is a calculated variable between the low and high points.
  • Pset p 1 +(p 2 ⁇ p 1 )*(t ⁇ t 1 )/(t 2 ⁇ t 1 ). Heat is applied to the process to maintain the reactor at the pressure set point.
  • the operating line in this example was selected to follow closely the pressure-temperature relationship developed by Raoult's law to maintain a 20% solution in the reactor.
  • operating data indicates a higher concentration should be maintained to increase reaction rate. Theoretically the solution concentration must be maintained below 76.9% to have sufficient water for complete hydrolysis of the urea in the reactor. In practice a lower concentration must be maintained.
  • Operating data indicates the optimum is in the range of 30 to 50% depending to some extent on urea purity.
  • the operating procedures described in this patent allow an operator to maximize the solution concentration in the reactor and to maintain a nearly constant concentration over a desired ammonia production range. This results in maintaining better control of the fluid equilibrium and water balance than could previously be obtained.

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US11/999,952 US20090148370A1 (en) 2007-12-06 2007-12-06 Process to produce ammonia from urea
TW097103581A TWI406813B (zh) 2007-12-06 2008-01-30 由尿素製造氨之改良方法
CN2008100093693A CN101450807B (zh) 2007-12-06 2008-02-28 由尿素生产氨的改进方法
CN201310094872.4A CN103183360B (zh) 2007-12-06 2008-02-28 从燃烧气流中移除NOx的方法
CN201310094814.1A CN103214007B (zh) 2007-12-06 2008-02-28 从燃烧气流中移除NOx的方法
AU2008243180A AU2008243180B2 (en) 2007-12-06 2008-11-10 Improved process to produce ammonia from urea
IL195335A IL195335A0 (en) 2007-12-06 2008-11-17 Improved process to produce ammonia from urea
ZA2008/09877A ZA200809877B (en) 2007-12-06 2008-11-19 Improved process to produce ammonia from urea
KR1020080122465A KR101326343B1 (ko) 2007-12-06 2008-12-04 요소로부터의 암모니아 제조 방법
ES14195497.4T ES2629497T3 (es) 2007-12-06 2008-12-05 Producción de amoniaco a partir de urea y proceso para retirar óxidos de nitrógeno de corrientes de gases de escape
EP14195497.4A EP2842915B1 (en) 2007-12-06 2008-12-05 Production of ammonia from urea for removing nitrogen oxides from exhaust gas streams
ES08253887.7T ES2592717T3 (es) 2007-12-06 2008-12-05 Producción de amoníaco a partir de urea y proceso para retirar óxidos de nitrógeno de corrientes de gases de escape
EP08253887.7A EP2070872B1 (en) 2007-12-06 2008-12-05 Production of ammonia from urea and process for removing nitrogen oxides from exhaust gas streams
JP2008312567A JP5693811B2 (ja) 2007-12-06 2008-12-08 尿素からアンモニアを製造するための改良方法
HK09110168.6A HK1131602B (en) 2007-12-06 2009-11-02 Improved process to produce ammonia from urea
HK13110615.9A HK1183286B (en) 2007-12-06 2009-11-02 Process of removing nox from a combustion gas stream
HK13110616.8A HK1183287B (en) 2007-12-06 2009-11-02 Process of removing nox from a combustion gas stream
US12/963,334 US8313722B2 (en) 2007-12-06 2010-12-08 Process to produce ammonia from urea

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CN116078302A (zh) * 2022-12-02 2023-05-09 西安西热锅炉环保工程有限公司 一种压力调节的碳酸氢铵制氨反应器控制系统及方法

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JP5315491B1 (ja) * 2012-06-13 2013-10-16 武史 畑中 次世代カーボンフリー燃焼器、これを利用した次世代カーボンフリーエンジン及び次世代カーボンフリー発電装置並びに次世代カーボンフリー燃焼器、次世代カーボンフリーエンジン及び次世代カーボンフリー発電装置に利用される尿素水
US9428449B2 (en) 2013-01-16 2016-08-30 Alstom Technology Ltd Method of forming urea by integration of an ammonia production process in a urea production process and a system therefor
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US20150353370A1 (en) * 2014-06-09 2015-12-10 Wahlco, Inc. Urea to Ammonia Process
US9586831B2 (en) * 2014-06-09 2017-03-07 Wahlco, Inc. Urea to ammonia process
CN113155668A (zh) * 2021-04-21 2021-07-23 西安热工研究院有限公司 一种尿素水解产物测量系统及方法
CN116078302A (zh) * 2022-12-02 2023-05-09 西安西热锅炉环保工程有限公司 一种压力调节的碳酸氢铵制氨反应器控制系统及方法

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