U.S. patent application number 10/840323 was filed with the patent office on 2004-10-21 for apparatus for quantitatively converting urea to ammonia on demand.
This patent application is currently assigned to The Chemithon Corporation. Invention is credited to Brooks, Burton, Jessup, Walter A., MacArthur, Brian W., Sheats, W. Brad.
Application Number | 20040208813 10/840323 |
Document ID | / |
Family ID | 26966907 |
Filed Date | 2004-10-21 |
United States Patent
Application |
20040208813 |
Kind Code |
A1 |
Brooks, Burton ; et
al. |
October 21, 2004 |
Apparatus for quantitatively converting urea to ammonia on
demand
Abstract
Processes and apparatus for quantitatively converting urea to
ammonia on demand are disclosed. One process includes the steps of:
receiving a demand rate signal for ammonia; feeding reactants
including urea and water into a reactor to provide a reaction
mixture; and controlling temperature and pressure in the reactor to
produce a gaseous product stream including ammonia and carbon
dioxide at substantially constant concentrations. Another process
includes the steps of: feeding molten urea or solid urea to a
reactor; feeding water (liquid or steam) to the reactor; and
reacting the urea and water at elevated temperature and pressure to
form a gaseous product stream including anmmonia and carbon
dioxide.
Inventors: |
Brooks, Burton; (Bellevue,
WA) ; Jessup, Walter A.; (Seattle, WA) ;
MacArthur, Brian W.; (Redmond, WA) ; Sheats, W.
Brad; (Federal Way, WA) |
Correspondence
Address: |
MARSHALL, GERSTEIN & BORUN LLP
6300 SEARS TOWER
233 S. WACKER DRIVE
CHICAGO
IL
60606
US
|
Assignee: |
The Chemithon Corporation
|
Family ID: |
26966907 |
Appl. No.: |
10/840323 |
Filed: |
May 6, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10840323 |
May 6, 2004 |
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|
09951287 |
Sep 12, 2001 |
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6761868 |
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60291661 |
May 16, 2001 |
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Current U.S.
Class: |
423/355 ;
422/106; 422/148; 422/198; 422/600 |
Current CPC
Class: |
C01B 32/50 20170801;
C01C 1/086 20130101; B01D 53/79 20130101 |
Class at
Publication: |
423/355 ;
422/148; 422/188; 422/198; 422/106 |
International
Class: |
C01C 001/02; C01C
001/00 |
Claims
1-68. (cancelled).
69. An apparatus for quantitatively converting urea to ammonia on
demand, comprising: an ammonia demand rate signal receiver; a
reactor vessel to contain reactants comprising urea and water at
elevated temperature and pressure and to release a gaseous product
stream comprising ammonia, carbon dioxide, and water; a feeder
responsive to the demand rate signal for feeding urea into the
vessel; a heater responsive to the demand rate signal for heating
the reactants to elevated temperature; and a variable restriction
device in fluid communication with the reactor for maintaining the
reactants at elevated pressure and releasing the gaseous product
stream.
70. The apparatus of claim 69, further comprising a controller
operatively associated with the heater to heat the reactants to a
substantially constant temperature.
71. The apparatus of claim 70, further comprising a controller
operatively associated with the variable restriction device to
maintain the reactor at a substantially constant pressure.
72. The apparatus of claim 69, further comprising a temperature
sensor and wherein the variable restriction device is responsive to
the temperature sensor.
73. The apparatus of claim 69, further comprising a demister.
74. The apparatus of claim 73, wherein the demister is at least one
member selected from the group consisting of mechanical degassers,
mist filters, and mesh pads.
75. The apparatus of claim 69, further comprising a urea
melter.
76. An apparatus for quantitatively converting urea to ammonia on
demand, comprising: an ammonia demand rate signal receiver; a
reactor vessel to contain reactants comprising urea and water at
elevated temperature and pressure and to release a gaseous product
stream comprising ammonia, carbon dioxide, and water; a feeder
responsive to the demand rate signal for feeding urea into the
vessel; a heater responsive to the feeder for heating the reactants
to elevated temperature; and a variable restriction device in fluid
communication with the reactor for maintaining the reactants at
elevated pressure and releasing the gaseous product stream.
77. The apparatus of claim 76, further comprising a demister.
78. The apparatus of claim 77, wherein the demister is at least one
member selected from the group consisting of mechanical degassers,
mist filters, and mesh pads.
79. The apparatus of claim 76, further comprising a urea
melter.
80. An apparatus for quantitatively converting urea to ammonia on
demand, comprising: an ammonia demand rate signal receiver; a
reactor vessel to contain reactants comprising urea and water at
elevated temperature and pressure and to release a gaseous product
stream comprising ammonia, carbon dioxide, and water; a level
sensor; a feeder responsive to the level sensor for feeding urea
into the vessel; a heater responsive to the demand rate signal for
heating the reactants to elevated temperature; a temperature
sensor; and a variable restriction device in fluid communication
with the reactor and responsive to the temperature sensor for
maintaining the reactants at elevated pressure and releasing the
gaseous product stream.
81. The apparatus of claim 80, further comprising a demister.
82. The apparatus of claim 81, wherein the demister is at least one
member selected from the group consisting of mechanical degassers,
mist filters, and mesh pads.
83. The apparatus of claim 80, further comprising a urea
melter.
84. The apparatus of claim 69, further comprising a controller
operatively associated with the variable restriction device to
maintain the reactor at a substantially constant pressure.
85. In an apparatus for quantitatively converting urea to ammonia,
the improvement comprising: a variable speed solid urea feeder; a
vessel for continuously receiving a feed comprising solid urea,
said vessel comprising an inlet for receiving solid urea and a
fluid outlet in fluid communication with a fluid inlet of a urea
hydrolysis reactor; and a heater disposed in operational
relationship with the vessel capable of heating vessel contents to
a temperature of at least 133.degree. C.
86. The improvement of claim 85, further comprising a controller
operatively associated with the heater to heat the vessel contents,
and wherein the heater is capable of heating vessel contents to a
temperature in a range of 135.degree. C. to 150.degree. C.
87. The improvement of claim 85, wherein the heater comprises a
jacket.
88. The improvement of claim 85, wherein the heater comprises
tracing.
89. The improvement of claim 85, wherein the fluid outlet of the
vessel is in direct, controllable fluid communication with the
fluid inlet of the hydrolysis reactor.
90. The improvement of claim 85, wherein the feeder is a variable
speed screw feeder.
91. The improvement of claim 85, further comprising a level sensor
operatively associated with the vessel.
92. The improvement of claim 85, further comprising a recirculation
conduit having an inlet disposed in fluid communication with the
fluid outlet of the vessel, and having an outlet disposed in fluid
communication with the vessel interior.
93. The improvement of claim 85, wherein the vessel further
comprises a gas phase outlet in communication with a gas phase
product outlet of the urea hydrolysis reactor.
94. The improvement of claim 85, wherein the vessel further
comprises a gas phase outlet in communication with an ammonia
scrubber.
95. In an apparatus for quantitatively converting urea to ammonia
comprising a urea hydrolysis reactor adapted to contain a liquid
reaction mixture and discharge a gas phase product comprising
ammonia, the improvement comprising a demister in operational
relationship with the reactor.
96. The improvement of claim 95, wherein the demister is at least
one member selected from the group consisting of mechanical
degassers, mist filters, and mesh pads.
97. In an apparatus for quantitatively converting urea to ammonia
comprising a urea hydrolysis reactor adapted to contain a liquid
reaction mixture and discharge a gas phase product comprising
ammonia, the improvement comprising a mechanical agitator disposed
in the urea hydrolysis reactor for operational relationship with a
liquid reaction mixture contained therein during operation.
98. In an apparatus for quantitatively converting urea to ammonia
comprising a urea hydrolysis reactor containing an acid catalyst
and adapted to contain a liquid reaction mixture and discharge a
gas phase product comprising ammonia, the improvement comprising an
agitator comprising a steam injector disposed in the urea
hydrolysis reactor for agitating a liquid reaction mixture
contained therein during operation.
99. In an apparatus for quantitatively converting urea to ammonia
comprising a urea hydrolysis reactor adapted to contain a liquid
reaction mixture and discharge a gas phase product comprising
ammonia, the improvement comprising an analytical sensor, selected
from at least one of a pH sensor and a conductivity sensor,
disposed to contact a liquid reaction mixture contained in the urea
hydrolysis reactor during operation.
100. The improvement of claim 99, further comprising a control
system for the apparatus in communication with the analytical
sensor.
101. The improvement of claim 99, wherein the analytical sensor is
a pH sensor.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The benefit under 35 U.S.C. .sctn. 119(e) is claimed based
on provisional application Serial No. 60/291,661, filed May 16,
2001, the entire disclosure of which is hereby incorporated by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to methods of converting
urea to ammonia. In particular, the invention relates to
quantitative conversion of urea to ammonia in response to a demand
for ammonia. More specifically, the invention relates to
quantitatively converting urea to ammonia at a rate closely
following the instant demand rate for ammonia, for example in a
system for quantitative chemical treatment applications, such as
removal of oxides of nitrogen from or conditioning fly ash present
in fuel combustion tailgas streams.
[0004] 2. Brief Description of Related Technology
[0005] Ammonia has long been known to be useful in the treatment of
stack gases (also referred to herein as flue gases or tail gases)
from fossil fuel combustion processes, for example, coal-fired
electric power generating plants. The boiler effluent gas stream
from such a process contains oxides of nitrogen (NO.sub.x) that are
well known air pollutants, contributing to photochemical smog and
causing other deleterious consequences to the environment. Under
the right conditions, ammonia will react with NO.sub.x, converting
the nitrogen oxides to nitrogen and water. The most familiar
methods for NO.sub.x destruction using amnionia are known as
Selective Catalytic Reduction (SCR) and Selective Non-Catalytic
Reduction (SNCR). Of these, the SCR methods achieve the highest
removal efficiency. The boiler flue gases from electric generating
plants also contain fly ash, which is often collected by means of
electrostatic precipitators. Ammonia conditioning (controlled
injection into the flue gas stream) is often beneficial in such
systems to improve fly ash collection efficiency and improve
performance. In both of these applications, the treatment process
requires precise quantitative delivery of ammonia at a rate that
follows a variable demand.
[0006] Ammonia may be obtained as an anhydrous liquid or as an
aqueous solution, but in either case the safety issues are quite
severe. The daily quantities of ammonia required to support a large
industrial application may be very substantial, necessitating large
capacity storage facilities at the site. Ammonia is a dangerous
chemical with a noxious odor, it is very toxic to most life forms,
highly volatile, and is also potentially explosive. Numerous
regulations apply to the safe transport, storage and handling of
ammonia. Storage facilities require containment and deluge systems,
continuous safety monitoring, periodic inspections, specialized
training programs, and special operating permits. Ammonia is
classified as a hazardous material, and storage of large quantities
of such a chemical in many locations, for example, near urban
population centers, is highly undesirable.
[0007] In contrast to ammonia, urea is an innocuous raw material,
which may be hydrolyzed to form ammonia and carbon dioxide gases.
Several urea hydrolysis processes have been described with the
intent to generate a gaseous stream of ammonia, carbon dioxide, and
water vapor at a temperature and pressure useful for removal of
nitrogen oxides, treatment of fly ash or for other compatible
process applications.
[0008] Young U.S. Pat. No. 5,252,308 (Oct. 12, 1993), the
disclosure of which is incorporated herein by reference, describes
two variations of a process that performs urea hydrolysis in the
presence of an acid. The Young patent discloses the use of certain
protic mineral acids (e.g., hydrochloric acid) and polyprotic
mineral acids, such as phosphoric or sulfuric acid, and
monoammonium dihydrogen phosphate (also referred to herein as MAP).
The Young patent teaches that the chemical reaction mechanism
employs the acid and its monoammonium salt as intermediates, and
that the reaction results in a quantitative production of ammonia
from urea. The Young patent does not disclose how to control the
apparatus to quantitatively produce a gaseous ammonia stream at a
variable rate suitable for quantitative chemical treatment
applications, such as removal of oxides of nitrogen from or
conditioning fly ash present in fuel combustion tailgas
streams.
[0009] Lagana U.S. Pat. No. 5,985,224 (Nov. 16, 1999), the
disclosure of which is incorporated herein by reference, describes
an apparatus that hydrolyzes an aqueous urea feed (from dissolved
solid urea) in a heated and pressurized reactor vessel, and that
uses steam to strip the ammonia and carbon dioxide product gases.
The inlet urea solution flows through a series of divided chambers
in the reactor, becoming gradually more dilute, and emerges from
the reactor for recycle back to the urea dissolving portion of the
system. The Lagana patent does not disclose the use of any
compounds to enhance the rate of reaction, but does disclose steam
stripping. The process according to the Lagana patent requires a
large energy input for steam to heat the reactor contents and strip
the product gases from solution. The Lagana patent does not
disclose how to control the apparatus to quantitatively produce an
ammonia stream at a variable rate suitable for quantitative
chemical treatment applications, such as removal of oxides of
nitrogen from or conditioning fly ash present in fuel combustion
tailgas streams.
[0010] Cooper et al. U.S. Pat. No. 6,077,491 (Jun. 20, 2000), the
disclosure of which is incorporated herein by reference, describes
a process and apparatus for producing a gaseous ammonia stream from
aqueous solutions of urea and/or biuret. In the methods disclosed
and claimed in the Cooper et al. patent, the product gas flow rate
is regulated in response to the demand for ammonia by the external
process. Withdrawing gas from the reactor in this manner causes
corresponding variation in the reactor pressure and temperature,
which would necessarily change the rate of reaction. For example,
when gas is released at an increased rate in response to an
increase in demand, the pressure inside the reactor will drop,
causing more water to flash to the vapor phase, which will lower
the temperature of the reactants and slow the rate of urea
conversion to ammonia. In addition, the concentration of ammonia in
the product gas stream will drop in relation to the steady-state
concentration that existed just prior to the change (e.g.,
increase) in demand and concomitant release of product gas. The
disclosed control scheme compensates by varying the heat input to
the reactor to raise the temperature (increasing the rate of
reaction) which, in turn, will eventually restore the pressure. As
the liquid level in the reactor begins to fall, a level control
loop increases the flow of aqueous urea fed to the reactor to
restore a balance at the higher production rate. By controlling the
process in this manner, the rate of reaction and concentration of
ammonia in the product gases (and, thus, the amount of ammonia
delivered to the external use) are variable, even though the
product stream mass flow rate is matched to the external demand for
ammonia. The process must reach a full steady state before the
ammonia production matches the demand. Large and sudden changes in
ammonia demand will cause a significant upset in the process, and
can require additional control means, such as a quench-cooling
system to effect a rapid reduction in production. Restoration of a
sudden large demand following such a quench-cooling event would
require reheating the entire reactor and its contents, which
requires a significant amount of time.
[0011] To successfully employ urea hydrolysis for quantitatively
generating ammonia for use in applications for removal of NO.sub.x
from stack gas streams using selective catalytic reduction (SCR) or
selective non-catalytic reduction (SNCR) process technology
(referred to herein as a deNO.sub.x system or a deNO.sub.x
application), the rate of ammonia produced and discharged by the
urea hydrolysis process must closely follow an ammonia demand
signal. The ammonia demand rate signal can be a function of a
boiler load, a measured ammonia slip (defined below), the
efficiency of the reaction of ammonia with nitrous oxides, a
combination of such measurements, or any other suitable
measurement. The ammonia demand rate is the instantaneous
requirement from the ammonia-consuming application that provides a
moving target that a urea hydrolysis system attempts to
satisfy.
[0012] Changes in the ammonia demand signal can be dramatic in real
applications. For example, in an electric generating plant the
boiler load alone can change as much as four times in magnitude
(25% to 100% for example), over the course of a typical 24-hour
operating day. A urea hydrolysis process must be able to quickly
adjust to large changes in ammonia demand, and the quicker the
response time, the better the urea hydrolysis process. It is also
important to consider the effect of a sudden increase in demand as
compared to a sudden decrease in demand. With a sudden increase in
demand, the ammonia generation system (urea hydrolysis system) will
be increasing the ammonia production, and therefore any lag results
in a temporary under-feeding to the deNO.sub.x system. The
consequence is a temporary increase in NO.sub.x concentration in
the stack gases (assuming ammonia is properly distributed, etc.).
With a sudden decrease in demand, a more serious situation can
result. In this case, as the ammonia generator (urea hydrolyzer)
reduces the ammonia production to the new, lower, requirement, a
transitory over-feeding of ammonia can occur. If excess ammonia is
supplied (assuming good distribution), then some residual ammonia
can pass through the deNO.sub.x system unreacted and go up the
stack to the atmosphere. The presence of unreacted ammonia vapor in
the stack discharge is referred to as "ammonia slip," and it is a
performance measure that has governmental regulatory significance,
since ammonia is a poisonous and obnoxious-smelling gas. Typical
performance guarantees on deNO.sub.x process systems are in the
range 1 ppm to 3 ppm of ammonia slip.
[0013] In a commercial scale deNO.sub.x system the rate of ammonia
consumption is quite large. Therefore, it would be very costly
(impractical) to provide a large "surge tank" (or pressurized
storage reservoir) for ammonia and carbon dioxide gases and water
vapor produced in a urea hydrolysis reaction, which gases would
also have to be maintained at a temperature above 60.degree. C. to
avoid formation of ammonium carbonate, and from which a flow of
these gases could be withdrawn to meet the instant demand. Instead,
it would be desirable to provide a urea hydrolysis process and
apparatus that enables a simple fast-acting control to produce
ammonia in a reactor at a rate equivalent to the instantaneous
demand of an ammonia-consuming process, for example.
[0014] Accordingly, it would be desirable to have an
energy-efficient process and apparatus for converting urea to
ammonia and producing an ammonia-containing product stream at a
rate that can be quickly changed in response to a demand for
quantitative chemical treatment applications.
SUMMARY OF THE INVENTION
[0015] It is an objective of the invention to overcome one or more
of the problems described above.
[0016] Accordingly, one aspect of the invention is a process for
quantitatively converting urea to ammonia on demand including the
steps of: receiving a demand rate signal for ammonia; feeding
reactants including urea and water into a reactor to provide a
reaction mixture; and controlling temperature and pressure in the
reactor to produce a gaseous product stream including ammonia and
carbon dioxide at substantially constant concentrations.
[0017] Another aspect of the invention provides a process for
quantitatively converting urea to ammonia on demand, including the
steps of: feeding reactants including molten or solid urea and
water into a reactor; and reacting the reactants at elevated
temperature and pressure to form a gaseous product stream including
ammonia and carbon dioxide.
[0018] Yet another aspect of the invention provides an apparatus
for quantitatively converting urea to ammonia on demand including:
a reactor vessel adapted to contain reactants including urea and
water at elevated temperature and pressure and to release a gaseous
product stream including ammonia, carbon dioxide, and water; a
feeder for feeding molten urea into the vessel (or a feeder for
feeding solid urea into the vessel); a heater for heating the
reactants to elevated temperature; and a variable restriction
device in fluid communication with the reactor for maintaining the
reactants at elevated pressure and releasing the gaseous product
stream.
[0019] Still another aspect of the invention provides an apparatus
for quantitatively converting urea to ammonia on demand including:
an ammonia demand rate signal receiver; a reactor vessel adapted to
contain reactants including urea and water at elevated temperature
and pressure and to release a gaseous product stream including
ammonia, carbon dioxide, and water; a feeder for feeding urea into
the vessel; a heater for heating the reactants to elevated
temperature; and a variable restriction device in fluid
communication with the reactor for maintaining the reactants at
elevated pressure and releasing the gaseous product stream.
[0020] Further aspects and advantages of the invention may become
apparent to those skilled in the art from a review of the following
detailed description, taken in conjunction with the appended
claims. While the invention is susceptible of embodiments in
various forms, described hereinafter are specific embodiments of
the invention with the understanding that the disclosure is
illustrative, and is not intended to limit the invention to the
specific embodiments described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 depicts theoretical equilibrium lines relating steady
state operating pressure and operating temperature for
non-catalyzed hydrolysis of 40 wt. %, 50 wt. %, and 60 wt. % urea
solutions.
[0022] FIG. 2 is a plot of average reaction time (minutes) versus
reaction temperature (degrees Celsius) for various measured
reaction temperatures in steady-state, equilibrium condition,
catalyzed and non-catalyzed, urea hydrolysis processes and for two
extrapolated values of non-catalyzed reactions.
[0023] FIG. 3 depicts the data of FIG. 2 as the natural logarithm
(ln) of reaction rate constant k versus inverse temperature
(degrees Kelvin) to illustrate the substantially constant slope of
a line fitted to the data.
[0024] FIG. 4 shows the average reaction time (minutes) versus
pressure (psig) for two series of steady-state, equilibrium
condition, MAP/DAP-catalyzed reactions at constant temperature, and
versus the corresponding reaction rate constant k for one series of
data.
[0025] FIG. 5 is a plot of the measured ratio of MAP to DAP versus
temperature (degrees Celsius) in several series of steady-state
urea hydrolysis experiments carried out at various pressures (psig)
with 40 weight percent (wt. %) and 50 wt. % aqueous urea feed;
estimated isobars are provided.
[0026] FIG. 6 is a plot of the measured ratio of MAP to DAP at
various temperatures for the same series of experiments illustrated
in FIG. 5, but plotted against reactor pressure (psig); estimated
isotherms are provided.
[0027] FIG. 7 is a plot of MAP/DAP ratio at equilibrium versus pH
in dilute aqueous solutions.
[0028] FIG. 8 is a plot of measured water concentration in a
catalyzed (MAP/DAP) urea hydrolysis reaction mixture at
steady-state for various temperatures at 100 psig and 120 psig;
theoretical water concentration values based on the vapor pressure
of water at similar temperatures and pressures are also presented
for comparison.
[0029] FIG. 9 is a flow diagram of an apparatus according to the
invention.
[0030] FIG. 10 is a flow diagram of an apparatus according to the
invention.
[0031] FIG. 11 is a flow diagram of an apparatus according to the
invention.
[0032] FIG. 12 is a flow diagram of an apparatus according to the
invention.
[0033] FIGS. 13a and 13b are illustrations of the transient
response during a sudden increase and sudden decrease in demand,
respectively, for an embodiment of a process according to the
invention.
[0034] FIG. 14 depicts recorded transient response data for a urea
hydrolysis process with aqueous urea feed according to the
invention undergoing a step change in demand.
[0035] FIG. 15 depicts recorded transient response data for a urea
hydrolysis process with molten urea feed according to the invention
during a system start up.
[0036] FIG. 16 depicts recorded transient response data for a urea
hydrolysis process with molten urea feed according to the invention
during several changes in urea and steam injection flow rates.
DETAILED DESCRIPTION OF THE INVENTION
[0037] The invention is directed to processes and apparatus for
quantitatively converting urea to ammonia, optionally with the use
of a catalyst.
[0038] As recited herein, the term "substantially" is used to
modify the term "constant," recognizing that there can be small
fluctuations in real-world, practical control processes and
apparatus. Thus, for example, maintaining the temperature in a
reactor "substantially constant" means that temperature is
controlled to a constant set point. As another example, a process
step of maintaining temperature in a reactor "substantially
constant" also encompasses a process of continuously or
intermittently changing a temperature set point, so long as the
actual (i.e., measured) temperature varies no more than if the
temperature set point were held constant. Similarly, while a
constant concentration of aqueous urea can be fed to a reactor (by
virtue of having dissolved a quantity of urea in a quantity of
water), the feed rate will only be as constant as the pump will
allow.
[0039] As recited herein, the term "steady state" is used to refer
to a process wherein all control variables are set to constant
values (e.g., constant reactants feed, constant energy (e.g., heat)
input, substantially constant reactor temperature and pressure).
The term "equilibrium" is used to refer to state or condition of
balance; thus, when the rate of evaporation of a liquid into the
vapor phase and the rate of condensation of the vapor back into the
liquid phase are equal, the amount of pressure is referred to as
the equilibrium vapor pressure. Often, a reactor as described
herein can be operated at steady state, but will not necessarily be
at equilibrium. For example, after a change from one steady state
set of conditions to a second steady state set of conditions (e.g.,
doubling rate of reactants feed and heat input, maintaining
substantially constant temperature and pressure), the system will
go through a change before it reaches equilibrium again (e.g.,
gradual increase in gas flow out).
[0040] In non-catalyzed and catalyzed processes according to the
invention, certain fundamental reaction mechanisms, reaction
kinetics, and vapor-liquid equilibria are at work during the
conversion of urea to ammonia, and are described below.
Reaction Mechanisms
[0041] The net reaction in a urea hydrolysis process is described
in equation 1, below. 1 NH 2 CONH 2 + H 2 O + heat -> 2 NH 3 +
CO 2 urea water ammonia carbon dioxide [ 1 ]
[0042] Equation 1 expresses the overall observed effect. Urea
combines with water, consuming necessary heat to drive the overall
endothermic reaction, and produces ammonia and carbon dioxide
gases. The reaction proceeds readily at a temperature of at least
145.degree. C. and occurs over a wide range of pressure from
atmospheric to several hundred psig.
[0043] The Non-catalyzed Reaction
[0044] In several studies (e.g., E. A. Wemer, "The Constitution of
Carbamides," Journal of the Chemical Society Transactions (London),
vol. 113, p. 84-99 (1918) and George Tsei-Yu Chao, Urea, Its
Properties and Manufacture, Taipei, Taiwan, p. 97-118 (1967))
examining the non-catalyzed hydrolysis of urea at temperatures of
at least 145.degree. C., the conversion of urea to ammonia and
carbon dioxide proceeds according to equations 2 through 4, below.
2 NH 2 CONH 2 -> NH 4 OCN urea ammonium cyanate [ 2 ] NH 4 OCN
NH 3 + HOCN ammonium cyanate ammonia cyanic acid [ 3 ] HOCN + H 2 O
+ heat -> NH 3 + CO 2 cyanic acid water ammonia carbon dioxide [
4 ]
[0045] The reactions in equations 2 and 3 are relatively fast,
whereas the reaction in equation 4 is relatively slower. As shown
in equations 2 and 3, the urea molecule first rearranges itself
into ammonium cyanate, which then rapidly decomposes at elevated
temperature to yield one molecule of ammonia and one molecule of
cyanic acid. The reaction in equation 3 is an equilibrium reaction
as long as ammonia remains in solution. However, at elevated
temperature the reaction conditions shift the equilibrium to
formation of cyanic acid, since the ammonia readily desorbs from
the solution to the gas phase, leaving the cyanic acid behind. As
shown in equation 4, the cyanic acid requires energy (endothermic
step) to combine with a water molecule to release a second molecule
of ammonia and carbon dioxide.
[0046] Catalyzed Reaction
[0047] It is known that certain acids and strong bases can promote
the urea hydrolysis reaction (see Chao, Urea, Its Properties and
Manufacture, Taipei, Taiwan, p. 97-118 (1967)), resulting in
significantly faster rates of reaction. For example, addition of
sodium hydroxide (strong base) increases the rate of hydrolysis,
but results in formation of sodium carbonate as a by-product. Thus,
sodium hydroxide must be continually added as a reactant and sodium
carbonate must be removed as a by-product to sustain the process,
both of which present significant disadvantages in process
complexity and operation costs, for example.
[0048] Young U.S. Pat. No. 5,252,308 teaches that using an acid
catalyst at elevated temperature results in the formation of an
ammonium salt of the acid that is subsequently thermally decomposed
to yield ammonia and the acid. Thus, in the general case, the
reaction proceeds according to equations 5 and 6, below. 3 NH 2
CONH 2 + H 2 O + 2 HA -> urea water acid 2 NH 4 + A - + CO 2
ammonium salt carbon dioxide [ 5 ] 2 NH 4 + A - + heat -> 2 NH 3
+ 2 HA ammonium salt ammonia acid [ 6 ]
[0049] The Young patent discloses that when the acid is phosphoric
acid, the reaction proceeds according to equations 7 and 8, below.
4 NH 2 CONH 2 + 2 H 3 PO 4 + H 2 O -> urea phosphoric acid water
2 NH 4 H 2 PO 4 + CO 2 MAP carbon dioxide [ 7 ] 2 NH 4 H 2 PO 4
-> 2 NH 3 + 2 H 3 PO 4 MAP ammonia phosphoric acid [ 8 ]
[0050] Accordingly, the Young patent teaches that the reaction
vessels must be made from a material that can withstand hot
(greater than 145.degree. C.), concentrated phosphoric acid.
[0051] It has been discovered that introducing a polyprotic acid,
specifically the polyprotic mineral acid phosphoric acid, into an
aqueous urea solution at elevated temperature and pressure results
in the deprotonation of phosphoric acid to first form the
monoammonium salt and then the diammonium salt, the diammonium salt
subsequently being thermally decomposed to yield ammonia and the
monoammonium salt. Thus, for example, when phosphoric acid is used,
after initial formation of MAP, diammonium hydrogen phosphate
(referred to herein as DAP) is formed and then DAP is thermally
decomposed according to the reactions shown in equations 9 and 10,
below. 5 NH 2 CONH 2 + H 2 O + 2 NH 4 H 2 PO 4 -> urea water MAP
2 ( NH 4 ) 2 HPO 4 + CO 2 DAP carbon dioxide [ 9 ] 2 ( NH 4 ) 2 HPO
4 + heat -> 2 NH 3 + 2 NH 4 H 2 PO 4 DAP ammonia MAP [ 10 ]
[0052] In this process, the MAP is acting as a Lewis acid in the
reaction mechanism.
[0053] Thus, MAP reacts with urea to form DAP and gaseous carbon
dioxide in the reaction shown in equation 9 and then, with supply
of sufficient heat, the DAP releases gaseous anmmonia according to
equation 10, reforming MAP. At steady state production, controlling
to constant temperature and pressure in a reactor, the combination
of these two reactions requires the input of energy (heat) in
proportion to the total production of ammonia plus the amount of
any water evaporated from the reaction mixture. At equilibrium, the
composition of the liquid reaction mixture will become
substantially constant, and will include a certain fraction of MAP
and DAP, unreacted urea, and water, with a small contribution from
dissolved ammonia and carbon dioxide. A reaction mixture including
urea, water, MAP, DAP, and dissolved gases has a pH that will vary
depending on the temperature and pressure maintained in the
reactor, but is generally neutral in one preferred embodiment where
the temperature is about 171.degree. C. (about 340.degree. F.) and
about 120 psig.
Reaction Kinetics
[0054] The hydrolysis of urea to form ammonia and carbon dioxide
behaves as a first order reaction in the range of concentration of
practical interest (e.g., less than about 76 wt. % urea), wherein
the reaction rate is directly proportional to the amount of
reactants present. Whether considering an acid-catalyzed or
non-catalyzed system, in the methods according to the invention
both catalyst and water in the former instance and water in the
latter will be present in a large molar excess with respect to
urea. Thus, the reaction rate is effectively proportional to the
amount of urea present in the reactor, as expressed in equation 11,
below:
r=kx [11],
[0055] wherein r represents the rate of reaction, k represents the
reaction rate constant, and x represents the amount of urea present
in the reactor. The reaction rate represents the rate at which urea
is consumed by the reaction, and its units depend on the choice of
units for x (e.g., mass, moles, or a concentration such as
mass/unit volume). If x is a concentration such as mass/unit
volume, then the reaction rate represents the mass of urea reacting
per minute per unit volume of reactor.
[0056] The reaction rate constant k is defined herein as the ratio
of urea reacting per unit time (e.g., typically in minutes, thus k
has units minutes.sup.-1) to the total urea present in the reactor.
Put another way, the reaction rate constant is the fraction of urea
that is reacting per minute. The reaction rate constant in the
reaction systems according to the invention is primarily a function
of temperature, but other factors such as pressure, pH, reactants
concentration, and particularly the presence of catalyst can also
influence the reaction rate constant.
[0057] The reaction time is defined as the inverse of the reaction
rate constant (e.g., 1/k) and has units of time (e.g., minutes).
The reaction time is the average time a molecule of urea is in the
reactor before conversion to ammonia when operating continuously at
steady state conditions.
[0058] The value of the reaction rate constant at a particular set
of conditions in a catalyzed system can be determined
experimentally by a number of different methods. One of the
simplest methods is to carry out the urea hydrolysis reaction at
steady state with a constant feed rate of a constant concentration
of reactants being fed to a reactor, operating at constant
temperature and pressure, and performing a material balance around
the reactor. When operating continuously at steady state, the
amount of urea in the reactor is constant, so the rate of ammonia
and carbon dioxide leaving the reactor is directly proportional to
the rate of urea entering the reactor. When using a catalyst such
as MAP (or mixture-of MAP and DAP), the reaction rate is extremely
fast and the urea concentration in the reactor is very small (e.g.,
typically 1 wt. % to 10 wt. %), which, upon a change in demand,
allows the urea concentration to quickly equilibrate to a value
proportional to the new urea feed rate. When this occurs, the urea
feed rate is then equal to the hydrolysis rate, i.e., the reaction
rate in equation 11. Knowing the reaction rate, the reaction rate
constant can be calculated by equation 11 if the mass (or
concentration) of reactants is known. The mass of urea (or
concentration) can be determined by first weighing the catalyst
originally charged to the reactor, and then by sampling the
reaction mixture during continuous operation and analyzing for urea
and catalyst salts. It is then possible to calculate the mass of
urea in the reactor by multiplying the mass of catalyst by the mass
fraction of urea in the sample and dividing by the mass fraction of
catalyst in the sample. Combining this with equation 11, the
reaction rate constant can then be calculated by equation 12,
below: 6 k = Q ( f c ) m c ( f u ) [ 12 ]
[0059] wherein Q represents the mass flow rate of urea fed to the
reactor, m.sub.c represents the mass of catalyst charged to the
reactor, f.sub.c represents the measured mass fraction of catalyst,
and f.sub.u represents the measured mass fraction of urea in the
sample.
[0060] The reaction rate constant is a function of temperature but
is independent of the urea feed rate. However, at equilibrium the
reaction rate is equal to the urea feed rate, and is independent of
temperature. When the temperature is changed, there is an inversely
proportional change in the urea concentration, until the reaction
rate returns to equilibrium with the urea feed rate, which happens
quickly, because of the small quantity of urea in the reactor.
[0061] Reaction rate constants for non-catalyzed urea hydrolysis
were determined experimentally by a different procedure. In
comparison with catalyzed urea hydrolysis, the reaction rate in
non-catalyzed urea hydrolysis is relatively slow. Therefore, to
achieve similar ammonia production rates, the quantity of urea
present in the non-catalyzed reactor is relatively large. Changing
the heat input to the reactor and consequently changing the
reaction temperature more conveniently regulates the reaction rate
in this system. Unlike the catalyzed system, in this case the
reaction rate at any time is not closely related to the urea feed
rate (only at full equilibrium and steady state conditions). To
determine the reaction rate constant, first the mass of urea
initially charged to the reactor is accurately measured. The
reaction rate constant is determined with greater accuracy by
measuring the rate of gas flow leaving the reactor at a constant
reactor pressure. Thus, if the concentration of ammonia in the exit
gas mixture is accurately measured, then the reaction rate constant
k can be determined.
[0062] The gas mixture leaving the reactor is composed of ammonia,
carbon dioxide and water vapor. The percentage of ammonia and
carbon dioxide are stoichiometrically related to the amount of urea
reacting, and the percentage of water vapor is proportional to the
ratio of water to urea in the feed when the reactor is operated at
equilibrium and steady state conditions. When the reaction
temperature is changed, the concentration of water in the reaction
solution changes until a new equilibrium balance between the inlet
and outlet water flow rates is-established. The reactor volume must
be relatively large for non-catalyzed urea hydrolysis processes,
and therefore it can take a long period of time (e.g., about three
hours for 95% of fill equilibrium) for the water inlet and outlet
flows to equilibrate, during which time the outlet gas flow rate by
itself is not an accurate measurement proportional to the ammonia
production rate, since the concentration of the ammonia (and other
species) is changing. Based on measured reaction rate constants,
the non-catalyzed hydrolysis process of the prior art required
about seven hours to reach 80% of the equilibrium water
concentration after a change in temperature.
[0063] Much-improved performance in non-catalyzed urea hydrolysis
processes is possible by operating the reactor in a different
manner, namely by keeping the water concentration in the reaction
solution substantially constant as the process reacts to a change
in temperature.
[0064] The water content in the reaction mixture depends on the
reaction temperature, pressure, and ratio of water to urea in the
feed. If the feed concentration remains constant and the
temperature changes, then it is necessary to make a change in the
system pressure in order to keep the water content of the reaction
mixture substantially constant. The pressure can be determined by
means of either a theoretical or experimental vapor-liquid
equilibrium model, such as is illustrated in FIG. 1.
[0065] When the water content of the reaction mixture is kept
substantially constant, then the urea hydrolysis rate (reaction
rate) can be calculated by multiplying the fraction of water in the
urea feed with the mass flow rate of the outlet gas. The rate
constant is calculated by dividing the hydrolysis reaction rate by
the mass of urea in the reactor according to equation 11.
[0066] The relationship between the temperature and the rate
constant, known as the Arrhenius equation, can be expressed as in
equation 13, below: 7 ln k 2 k 1 = E R [ 1 T 1 - 1 T 2 ] [ 13 ]
[0067] wherein: T.sub.1 and T.sub.2 are steady state operating
temperatures (.degree. K);
[0068] k.sub.1 is the reaction rate constant at temperature
T.sub.1;
[0069] k.sub.2 is the reaction rate constant at temperature
T.sub.2;
[0070] E is the activation energy; and
[0071] R is the ideal gas law constant.
[0072] If the natural logarithm of k (ln(k)) is plotted against
1/T, a straight line should result with slope equal to -E/R. Thus,
if the reaction rate constant is determined at two temperatures,
the value of k and the energy of activation can be predicted at any
temperature.
[0073] A series of steady-state catalyzed (MAP/DAP) experiments was
conducted at a reactor pressure of 120 psig and various
temperatures to determine the reaction rate constant k and the
average reaction time 1/k. For comparison, experiments were also
conducted without catalyst, varying temperature and pressure (using
a vapor-liquid equilibrium model to select the pressure in response
to the temperature) as described. The results of both series of
experiments are presented in FIG. 2, in addition to extrapolated
values for the un-catalyzed system at 167.2.degree. C. and
171.1.degree. C. (i.e., 1000/T (.degree. K) of 2.29 and 2.25,
respectively), for comparison. In the preferred temperature range,
about 165.degree. C. to about 170.degree. C., the rate constants
and reaction times for the MAP/DAP reaction are approximately
fifteen times faster than the non-catalyzed process. FIG. 3 is a
graph of the same data (measured and extrapolated) plotted as the
natural logarithm of k versus the reciprocal of the absolute
temperature. As predicted by the Arrhenius equation, the data are
well correlated with a straight line.
[0074] Additional series of steady-state catalyzed (MAP/DAP) urea
hydrolysis reactions were carried out at various pressures, and
mass balance calculations were performed according to the foregoing
description to determine reaction rate constants, k, and average
reaction times (1/k). The results are presented in FIG. 4, which
shows that the reaction rate constant is relatively independent of
pressure at 163.degree. C. (325.degree. F.) over the range of
pressures tested, compared with results at 157.degree. C.
(315.degree. F.). The reaction rate constant decreases with lower
temperature and also decreases with increasing pressure.
[0075] In an acid-catalyzed hydrolysis process according to the
invention, the reaction rate is sufficiently high that when there
is a change in anmmonia demand, the urea feed rate to the reactor
can be changed proportionally, and within a matter of minutes the
flow of ammonia and carbon dioxide leaving the reactor is
proportional to the flow of urea entering the reactor, even when
the temperature of the reactants is held constant. In the
acid-catalyzed system wherein temperature and pressure are
controlled to constant values, when the feed rate is changed in
response to a change in ammonia demand, the reaction rate will
change as the concentration of urea in the reactor changes to a new
steady state, at which time the new production rate equilibrates
with the new feed rate and, therefore, the new production rate
equals the new demand rate.
[0076] The time necessary for a constant temperature and pressure
hydrolysis system (catalyzed or non-catalyzed) to reach equilibrium
after a change in demand is inversely proportional to the reaction
rate constant (i.e., in the acid-catalyzed case the reaction rate
constant is large and the time to reach equilibrium is small). At
higher temperatures, the reaction rate constant is higher, and the
time required to reach equilibrium is shorter. In a non-catalyzed
hydrolysis process, the reaction rate constant is very small in a
range of practical temperatures (e.g., 145.degree. C. to
200.degree. C.), so that a process employing constant temperature
and pressure control would not achieve the same response time as an
acid-catalyzed process, but such a process would still benefit from
a predictable, substantially constant ammonia concentration in the
gaseous product stream.
[0077] The time to reach equilibrium after a change in demand for a
system controlled to constant temperature and pressure can be
predicted from the foregoing. Thus, if "f" represents the fraction
of change between the initial mass of urea in the reactor and the
mass of urea in the reactor after a period of time "t" then the
time required for a fractional change in urea mass (and, thus,
reaction rate) can be calculated from equation 14, below. 8 t = 1 k
ln [ 1 ( 1 - f ) ] [ 14 ]
[0078] From equation 14, it can be seen that the time necessary to
make any fraction of the change between the initial mass of urea in
the reactor and the final mass of urea in the reactor, regardless
of the magnitude of change and as long as temperature and pressure
are substantially constant, is a function of 1/k. For example, at a
reaction temperature of 171.degree. C. (340.degree. F.) with a
mixture of MAP and DAP as catalyst, the value of 1/k is 4.7
minutes. Thus, the time necessary to achieve 80% of a change in
reaction rate (f=0.8) is about 8 minutes, and to achieve 95% of a
change in reaction rate is about 14 minutes. For a non-catalyzed
system operating at the same temperature, 1/k is about 60 minutes
(extrapolated from measured data, see FIG. 3), which results in
about 96 minutes necessary to achieve 80% of a change in reaction
rate and about 180 minutes to achieve 95% of a change in reaction
rate.
[0079] With a molar excess of MAP/DAP catalyst present, chemical
equilibrium is established quickly with a constant feed rate of
urea when temperature and pressure in the reactor are held
constant. The composition of the liquid reaction mixture at
equilibrium can be characterized by the ratio of MAP to DAP, and
this ratio only depends on the temperature and pressure at which
the process is carried out. The MAP to DAP catalyst ratio reflects
the amount of chemically bound ammonia held in the catalyst. If the
temperature and/or pressure are varied, then the MAP to DAP ratio
will change, changing the amount of ammonia absorbed and thereby
affecting the ammonia production rate until a new equilibrium is
reached. However, by operating the reactor at constant temperature
and pressure, the MAP to DAP ratio remains constant and will not
interfere with the ammonia production rate at all. Since the
operating temperature and pressure affect the MAP to DAP ratio, and
these variables also affect the reaction rate constant k, it is
difficult to determine if the MAP to DAP ratio exerts any influence
on the reaction rate constant. Experimentally, we have determined
that we can operate at a pressure at which the catalyst is nearly
pure DAP and observe similar rapid reaction kinetics. Thus, we
conclude that the various observed MAP to DAP mixtures are
approximately equivalent as catalysts for urea hydrolysis.
[0080] Increasing the reactor temperature at constant pressure will
increase the amount of MAP in the equilibrium mixture, so the MAP
to DAP ratio increases with increasing temperature at constant
pressure. FIG. 5, in which data generated at various steady-state
temperature and pressure combinations for 40 wt. % and 50 wt. %
aqueous urea feed solutions are presented, illustrates this effect.
To assist in visualizing the effect, lines have been added to
represent approximate correlations at various constant pressures.
Higher pressure appears to depress the correlation line, but the
slope of the line remains substantially constant.
[0081] Increasing the reactor pressure at constant temperature will
increase the relative amount of DAP at equilibrium, decreasing the
ratio of MAP to DAP. FIG. 6 shows the measured MAP to DAP ratio
versus reactor pressure for selected data at narrow bands of
constant temperature, with approximate correlation lines. FIG. 6
shows a general trend of increasing negative slope of the
correlation line with increasing temperature, which reveals the
greater sensitivity of the MAP to DAP ratio to pressure as the
reaction temperature increases.
[0082] The pH of MAP/DAP catalyst mixtures was measured for various
samples in dilute (about 1 wt. %) aqueous solutions, and is
illustrated in FIG. 7. Generally, the pH is in the neutral range,
with the pH decreasing as the MAP to DAP ratio increases. The
measured trend correlates well to the pH values for pure MAP (4.1,
in 10 wt. % aqueous solution) and pure DAP (8.2, in 10 wt. %
aqueous solution). Thus, the relationship between pH and the MAP to
DAP ratio shows that pH can be used in process control schemes as
an indicator of catalyst composition and, thus, reaction mixture
composition.
Vapor-Liquid Equilibria: Effect on Water Content of the Reaction
Mixture
[0083] The operating temperature and pressure of the reaction
vessel along with the excess water added (over the stoichiometric
amount needed to hydrolyze urea) will determine the concentration
of water in the catalyst mixture at equilibrium. The gas
discharging from the reactor will leave saturated with water vapor.
FIG. 8 depicts the measured concentration of water in a catalyzed
(MAP/DAP) urea hydrolysis reaction mixture at steady state for
various temperatures at reactor pressures of 100 psig and 120 psig,
when 50 wt. % urea solution is fed to the reactor. Theoretical
water concentration values (determined by using Raoult's Law and
Dalton's Law) based on the vapor pressure of water in the same
range of temperatures are presented for comparison. If the mass
ratio of water to urea is more than 1:1 (i.e., less than 50 wt. %
urea), then lower reactor pressure is required for comparable
concentrations, and if the mass ratio is less than 1:1 (i.e., more
than 50 wt. % urea), then higher reactor pressure is required for
comparable concentrations.
[0084] Theoretical Models for Vapor-Liquid Equilibrium
[0085] In either a catalyzed or a non-catalyzed urea hydrolysis
reaction process at equilibrium, we have described the benefits of
operating at a pressure uniquely related to the operating
temperature for a specified concentration of aqueous urea feed. We
have mentioned use of theoretical or experimental vapor-liquid
equilibrium models to predict the operating pressure for a given
operating temperature that will maintain the composition of the
produced gas stream constant and, in particular, will ensure that
the excess water supplied to the reactor with the feed solution
will be discharged in the product gas stream.
[0086] The following demonstrates the theoretical calculation of
the required operating pressure in an ammonium phosphate
salt-catalyzed process, assuming a 50 wt. % aqueous urea feed, an
operating temperature of 170.degree. C., and 80 wt. % solids in the
reaction mixture. Further, for simplicity, we will assume ideal
molecular behavior, and thus the vapor liquid equilibria may be
modeled using Raoult's Law and Dalton's Law. More sophisticated
theoretical models may, of course, be employed if desired, as may
empirical correlations developed by experimental means.
[0087] At 170.degree. C., the corresponding vapor pressure of water
is 114.9 psia (taken from steam tables). With these data and
assumptions, Raoult's Law is written as follows:
P.sub.i=x.sub.iP.sub.i [15]
[0088] and Dalton's Law is:
p.sub.i=Py.sub.i [16]
[0089] wherein p.sub.i is defined as the partial pressure of
component i, P.sub.i is defined as the vapor pressure of component
i at the operating temperature of the system (170.degree. C. in
this case), x.sub.i is the mole fraction of component i in the
liquid phase, y.sub.i is the mole fraction of component i in the
vapor phase, and P is the total pressure, which is equal to the sum
of the partial pressures of all components of the vapor phase
(i.e., P=p.sub.1+P.sub.2+ . . . +p.sub.n, where n is the number of
components in the vapor phase). Since these equations employ mole
fractions, Table 1 below describes the various streams for the case
in this example as mole fractions for an experimental result
consistent with the case in this example.
1 TABLE 1 Wt. % Molecular Weight Mole Fraction Feed Urea 49.3 60
0.2258 Water 50.7 18 0.7742 Product Ammonia 27.9 17 0.3685 Water
35.9 18 0.4473 Carbon Dioxide 36.2 44 0.1842 Reaction Mass MAP 17.2
115 0.0869 DAP 61.8 132 0.2721 Urea 1.5 60 0.0145 Water 19.4 18
0.6264 Carbon Dioxide 0 44 0 Ammonia 0 17 0
[0090] The net reaction in a urea hydrolysis process is described
in equation 1 below.
NH.sub.2CONH.sub.2+H.sub.2O+heat.fwdarw.2NH.sub.3+CO.sub.2 [1]
[0091] At steady state, all water in excess of the molar amount
required for the reaction must exit with the product gases.
Allowing for the excess water in a 50% solution, we can write the
equation showing the excess water as follows:
NH.sub.2CONH.sub.2+H.sub.2O+2.33H.sub.2O.fwdarw.2NH.sub.3+2.33H.sub.2O+CO.-
sub.2 [17]
[0092] It can be calculated from Raoult's Law that the partial
pressure due to water should be,
p.sub.water=0.6264.times.114.9 psia=71.97 psia,
[0093] and by rearranging Dalton's Law, the total pressure is given
by:
P=p.sub.i/y.sub.i;
[0094] thus
P=71.97 psia/0.4473=160.9 psia=146.2 psig.
[0095] This value for P (146.2 psig) is the predicted operating
pressure, subject to the stated assumptions, that should enable
continuous operation at the selected temperature, while maintaining
a substantially constant composition and mass of urea in the
reactor.
[0096] This calculation can be performed for various temperatures
in a range of interest to determine a theoretical "equilibrium
line" relating operating temperature and pressure (see FIG. 1, for
example). This equilibrium relationship can also be determined by
experimental means.
[0097] In an actual process experiment conducted with 50 wt. % urea
and operating at a temperature of 171.degree. C., we observed that
a water balance was achieved at about 120 psig. The difference
between the predicted and experimentally determined value is most
likely caused by non-ideality inherent in the real molecular
behavior, which is not modeled accurately using Raoult's and
Dalton's Laws.
Preferred Embodiments
[0098] Based on the relationships between reactor temperature,
pressure, reaction mixture composition, and reactant feed
composition, which determine the reaction rate and reaction rate
constant as described above, various embodiments of processes for
acid-catalyzed and non-catalyzed urea hydrolysis according to the
invention are described below.
[0099] Acid-Catalyzed Hydrolysis Using Aqueous Urea
[0100] One embodiment of the invention provides a process for
acid-catalyzed hydrolysis of aqueous urea to quantitatively produce
ammonia on demand, which maintains the liquid reactants at
substantially constant solids concentration and produces a product
gas mixture of substantially constant composition, e.g., during a
change in ammonia demand, including the steps of: receiving a
control signal proportional to the demand rate for ammonia; feeding
aqueous reactants including urea of a known and substantially
constant composition and water to a reactor at a rate proportional
to the demand rate to provide a reaction mixture in the reactor
that contains an excess quantity of acid catalyst; reacting the
reaction mixture including urea, water and acid catalyst at
substantially constant temperature and substantially constant
pressure to produce a gaseous product stream including ammonia,
carbon dioxide, and water vapor at a substantially constant
composition; supplying necessary heat to the reactants (heat of
reaction plus latent heat of vaporization for the excess water fed
to the reactor) at a rate proportional to the urea feed rate to
maintain a substantially constant reaction temperature; and
controlling the pressure of the reactor by means of a pressure
control valve, for example, which maintains the operating pressure
of the reactor substantially constant while venting the produced
gases into a conduit for supply to the external use.
[0101] An apparatus according to this embodiment is illustrated in
FIG. 9. In this system, the demand rate signal for ammonia 10
received from an external process can be, for example, proportional
to the fuel combustion rate, the concentration of NOx detected in
the flue gas stream in one or more locations, or many other similar
measurements that correlate with the demand for ammonia in that
process. The ammonia demand rate signal 10 is connected to a urea
hydrolysis control system 12 as a primary process control input.
Following a change in demand rate signal 10, the control system 12
responds by making a proportional change in input of aqueous urea
14 and energy (e.g., heat) input to the reactor vessel 16 via a
heater 20. Changing the aqueous urea feed rate will bring about a
change in the urea concentration of the reaction mixture 22, which
in turn changes the reaction rate (see equation 11). After a matter
of minutes, the urea concentration will equilibrate and the new
reaction rate will equal the demand rate. Maintaining constant
temperature and pressure during the change will keep the
composition of the catalyst and particularly the water content
constant.
[0102] In a preferred control system for this embodiment, the
ammonia demand rate signal 10 is input to the process controller
12. A supply of aqueous urea 14 of known and constant concentration
is continuously pumped to the reactor in response to the demand
rate signal 10 by means of a metering pump 24, a mass flow monitor
26, a mass flow controller 30, and a flow control device, such as a
flow control valve 32, that responds to the flow controller 30
output. The demand rate signal 10 provides the set point for the
urea flow controller 30, and the flow controller 30 adjusts the
flow control valve 32 by monitoring the mass flow delivered to the
reactor via the flow monitor 26 to match the requirement. An excess
of process water is supplied in a substantially constant mass ratio
as part of the urea feed solution 14.
[0103] Heat input to the reaction mixture 22 inside the reactor
vessel 16 can be effected by means of the heater 20 with electric
heating coils as a heat transfer device 34, or steam or other heat
transfer fluids supplied to the heat transfer device 34 (e.g. a
tubular heat exchange coil) submerged in or in thermal contact with
the liquid reactants. In the case of electric means, the supply of
heat to the reactants is regulated in proportion to the urea mass
flow by controlling the power applied to the heat transfer device
34 (electric resistance coils) with a temperature control device
36. In the case of a steam (or other heat transfer fluid) heater,
the flow of steam to a heat transfer device 34 (heat transfer coil)
is varied in proportion to the mass flow rate of aqueous urea 14 to
the reactor vessel 16 using a mass flow sensor, flow controller and
flow control valve (not shown in FIG. 9).
[0104] A temperature sensing device, such as a thermocouple 40, can
be used to provide trim control on the heater 20 to enhance control
over the temperature of the reaction mixture 22. The operating
pressure in the reactor vessel 16 is monitored by a pressure
transmitter 42, and is changed by a variable restriction device
(e.g., a control valve 44) mounted in a product gas (46) discharge
pipeline 50 and controlled by a pressure controller 52. In a most
preferred embodiment of the invention, such a pressure control
valve 44 is operated to maintain a selected substantially constant
pressure in the reactor vessel 16 independent of the ammonia demand
rate signal 10. Thus, the pressure control valve 44 is normally
closed (e.g., when the system is off-line or on stand-by) and is
controlled to open as necessary to discharge product gas 46 to
maintain a substantially constant pressure in the reactor vessel 16
and in the discharge line 50 immediately upstream (with respect to
the gas flow direction) of the control valve 44. Other control
sensors for monitoring temperatures, pressures, liquid level of
reaction mixture 22, pH of reaction mixture 22, conductivity of
reaction mixture 22, product gas 46 mass flow (e.g., a mass flow
monitor 54 with a flow indicator 56) or other measurements may be
valuable to enhance process control in various ways.
[0105] The principal advantages of the acid-catalyzed processes are
evident in comparison with the non-catalyzed urea hydrolysis
processes, and derive from the chemical reaction mechanism and much
faster reaction rate. The acid-catalyzed process may be
advantageously operated at a substantially constant temperature and
pressure in a control scheme that provides improved performance
(e.g., ability for ammonia production to meet demand, especially
quickly changing in response to changes in demand, and without
changing the product gas composition). The acid-catalyzed
production of ammonia in a product gas stream of substantially
constant composition closely follows the demand, and the reactor
reaches equilibrium after a change in demand much faster and more
efficiently than in a non-catalyzed hydrolysis process.
[0106] In general, this embodiment is quite flexible and may be
operated successfully over reasonably broad ranges of the key
process operating variables. For example, the aqueous urea
concentration may vary from an arbitrary low value such as 10 wt. %
up to and including a nearly equimolar solution at about 76 wt. %.
However, in consideration of the energy required to evaporate any
water fed to the reactor fed in excess of the stoichiometric amount
required for hydrolysis (which provides a practical constraint on
the more dilute end of the concentration range) and the solubility
of urea in water (which requires maintaining the solution at an
elevated temperature as it becomes more and more concentrated), it
is preferable to use aqueous urea in a concentration range from
about 35 wt. % to about 60 wt. %. The most preferred concentration
range is from about 40 wt. % to 50 wt. %, wherein 40 wt. % arguably
provides a useful standard for comparison of process embodiments,
since this concentration is particularly advantageous for systems
using aqueous urea. The reactor operating temperature should be
greater than about 150.degree. C., and to achieve a reasonably fast
reaction time (under about 10 minutes) a temperature of at least
155.degree. C. is more preferred. A preferred temperature range is
about 155.degree. C. to about 175.degree. C., and the most
preferred range is about 168.degree. C. to about 172.degree. C. The
operating pressure affects the solids concentration of the reactant
solution, as has been described previously. With a MAP/DAP catalyst
mixture, to keep the solids concentration in the range from about
70 wt. % to about 80 wt. % (equivalent to about 20 wt. % to 30 wt.
% water), the reactor pressure should be controlled in the range of
about 80 psig to about 200 psig.
[0107] Acid-Catalyzed Hydrolysis Using Molten Urea and Separate
Water Feed
[0108] Another embodiment of the invention provides a process for
quantitative conversion of urea to ammonia on demand that employs a
supply of molten urea as a primary feed stream and a separate
supply of water for the process water requirement, including the
steps of: receiving a control signal proportional to the demand
rate for ammonia; feeding molten urea to a reactor at a rate
proportional to the demand rate; feeding process water to the
reactor at a rate proportional to the urea feed rate to provide a
reaction mixture containing an excess quantity of acid catalyst;
reacting the reaction mixture including urea, water and acid
catalyst at substantially constant temperature and substantially
constant pressure to produce a gaseous product stream including
ammonia, carbon dioxide, and water vapor at a substantially
constant composition; supplying necessary heat to the reactants
(heat of reaction plus latent heat of vaporization for the excess
water fed to the reactor) at a rate proportional to the urea feed
rate to maintain a substantially constant reaction temperature; and
controlling the pressure of the reactor by means of a pressure
control valve, for example, which maintains the operating pressure
of the reactor substantially constant while venting the produced
gases into a conduit for supply to the external use.
[0109] In a preferred method according to this embodiment, purified
and de-ionized water is employed for the process water supply to
avoid contamination of the reaction solution.
[0110] An apparatus according to this embodiment is illustrated in
FIG. 10, which is similar to FIG. 9, but has been adapted for
supply of urea in molten form and process water 58 as separate
streams. In a preferred control scheme for this embodiment, an
ammonia demand signal 60 is input to a process controller 62. A
supply of molten urea 64 is continuously pumped to a reactor 66 in
response to the demand signal 60 by means of a continuous melting
system 70, a metering pump 72, a mass flow sensor 74, a mass flow
controller 76, and a flow control device that responds to the flow
controller 76 output, such as a flow control valve 80.
[0111] It is advantageous to provide recirculation of molten urea
64 to the melter 70 using a back pressure regulating valve 82 to
control the supply pressure of the molten urea 64 to the reactor
66. All of these components and fluid conduits 84 and 86 are heated
by tracing (or jacketing) 90 and maintained above the melting point
of the molten urea 64 with a heat transfer fluid, such as a
regulated supply of steam, or by electric heat tracing. Solid urea
92 in the form of a granule or prill is conveyed to a hopper 94,
from which it is fed to the melter vessel 70 using, for example, a
level sensor 96 in the melter 70 to provide a control signal to
govern the rate of addition of solid urea 92 to the melter 70. A
variable speed screw feeder 100 (or equivalent feeding device)
meters the solid urea 92 into the melter 70 at a controlled rate in
response to a signal generated by the level sensor 96. This can be
done using a level controller 102 and a variable speed drive 104
for a screw feeder 100 motor 106. Additional useful control items
for the feeder 100 can include level sensors 110 and 112 for a
smaller hopper 114 of the variable speed screw feeder 100, a switch
116 to operate a rotary valve 120, enabling periodic refilling of
the smaller hopper 114.
[0112] The melter 70 is sized to minimize the retention time of the
molten urea 64. Preferably, the retention time of the molten urea
64 in the melter 70 is less than two hours, and most preferably the
retention time is less than one hour. The ammonia demand signal 60
provides the set point for the molten urea flow controller 76, and
the controller 76 adjusts the control valve 80 by monitoring the
mass flow (via flow element 74) delivered to the reactor to match
the requirement.
[0113] In this preferred embodiment, process water 58 (e.g.,
deionized water) is supplied in a substantially constant mass ratio
to the urea 64 using a separate metering pump 122, a mass flow
sensor 124, a flow controller 126, and a flow control valve
130.
[0114] Heat input to the reactants 132 in the reactor 66 may be
effected by means of electric heating coils, steam or other heat
transfer fluids supplied to a heater 134 (e.g., with a tubular beat
exchange coil 136) submerged in or in thermal contact with the
liquid reactants 132, as described above. If steam is used (as
shown in FIG. 10), the heat input is regulated by controlling the
flow of steam 140 with a flow sensor 142, a flow controller 144 and
a control valve 146 in response to the ammonia demand signal 60,
and a steam condensate outlet 149 is fitted with an appropriate
trap 150. For practical purposes, the steam supply can have a main
shut off valve 151 and a pressure indicator 152. A temperature
sensor 153, such as a thermocouple, may be used to provide trim
control via a controller 154 to enhance control over the
temperature of the reactants 132.
[0115] The operating pressure in the reactor vessel 66 is monitored
by means of a pressure transmitter 156, and is controlled by means
of a variable restriction device (e.g., a control valve) 160
mounted in a product gas 162 discharge pipeline 164 and controlled
by a controller 166.
[0116] In a most preferred embodiment of the invention, such a
pressure control valve 160 is operated by the controller 166 to
maintain a selected, substantially constant pressure in the reactor
independent of the ammonia demand signal 60. Thus, the pressure
control valve 160 is normally closed and is controlled to open as
necessary to discharge produced gas 162 to maintain a substantially
constant pressure in the reactor 66 and in the discharge line 164
immediately upstream (with respect to the gas flow direction) of
the valve 160. Other sensors for monitoring the temperature,
pressure, liquid level, pH, conductivity, product gas mass flow
(e.g., a flow sensor 170 and a controller 172) or other
measurements may be valuable to enhance the process control in
various ways.
[0117] This embodiment employs molten urea with a separate process
water stream, and affords several unique advantages in comparison
with aqueous urea processes. Use of molten urea, for example,
enables a significant reduction in equipment and facilities. Solid
urea storage and handling systems are required, but urea dissolving
equipment and storage equipment and handling systems are not
required. Also, because the process water is supplied separately,
the ratio of urea to water in the feed may be easily varied, and
doing so does not impact the raw materials feed systems. In an
aqueous urea system, changing the concentration of the solution
could require heating of the storage and supply system. Therefore,
the process system of this embodiment is more space efficient and
less complicated.
[0118] This embodiment is just as flexible as the aqueous urea
embodiment and, in general, may be operated in the same ranges for
the principle process variables, allowing for the separate supply
of urea and process water. The preferred and most preferred
operating conditions are generally the same as were described
previously for the acid-catalyzed, aqueous urea system. Preferred
operating conditions for the molten urea feed system are discussed
separately below.
Acid-Catalyzed Hydrolysis Using Molten Urea Feed and Steam: Reduced
Reactor Volume
[0119] Another embodiment of the invention provides a process for
quantitatively converting urea to ammonia on demand in a reactor of
significantly reduced volume, including the steps of: feeding
molten urea to a reactor at a rate proportional to the ammonia
demand; feeding process water in the form of steam to the reactor
at a rate proportional to the urea supply rate; using the sensible
heat of the molten urea and the latent heat of condensation of a
portion of the steam to supply a portion of the necessary process
heat; using the uncondensed steam to supply the water vapor for the
equilibrium mixture in the discharged gas (which saves the heat of
vaporization of this water); supplying the balance of the process
heat in proportion to the urea supply rate to control the
temperature in the reactor at a desired temperature; reacting the
urea and water with an acid catalyst in the reactor to form a
gaseous product stream including ammonia, carbon dioxide, and water
vapor; and discharging the product gases into a conduit to the
external use while maintaining a substantially constant pressure in
the reactor by means of a pressure control valve (or equivalent
device). The operating temperature and pressure are maintained at
substantially constant values as has been described previously. One
advantage of this embodiment is the use of the sensible heat of the
molten urea and the latent heat of condensation of the steam, and
avoiding the need to evaporate water from the liquid reactants
solution which, when when combined, provides about 65% of the
process heat requirement with these reactant feed streams. This
reduces the supplemental heat requirement to only about 35% of that
required in the aqueous urea case (at constant urea to water mass
ratio). The much smaller heat requirement (and, hence, smaller heat
transfer device required) in this embodiment enables a reduction of
the volume of reactant solution, and provides a process system that
allows for a significantly smaller reactor vessel with all of the
associated benefits.
[0120] An apparatus according to this low volume reactor embodiment
is illustrated in FIG. 11, which is the same as FIG. 10, except
that it-has been adapted for supply of process water in the form of
steam and FIG. 11 does not show a smaller reactor 66, which is
possible in this embodiment.
[0121] In a preferred control scheme for this embodiment, the
ammonia demand signal 60 is input to the process controller 62 and
a supply of molten urea 64 is continuously pumped to the reactor 66
as in the embodiment described above in connection with FIG.
10.
[0122] Process water in the form of steam 180 is supplied in a
substantially constant mass ratio to the molten urea 64 mass flow
rate using a separate mass flow sensor 182, a flow ratio controller
184, and a flow control valve 186. For practical purposes the
process steam line can have a shut off valve 190 and a pressure
indicator 192.
[0123] Supplemental heat input to the reactants 132 may be effected
by means of a heater 134, for example using a tubular heat exchange
coil 136 (e.g., electric or with a heat transfer fluid such as
steam, as shown in FIG. 11) submerged in or in thermal contact with
the liquid reactants 132, as described above. If steam 140 is used,
as shown, the heat input is regulated by controlling the flow of
steam with a mass flow sensor 142, a flow controller 144 and a flow
control valve 146 responding to the ammonia demand signal 60. A
temperature sensor, such as a thermocouple 153, may be used to
provide trim control on the reactants 132 temperature with a
temperature controller 154.
[0124] Reactor pressure and product gas flow are controlled as
described above in connection with FIG. 10.
[0125] This embodiment may be operated at conditions equivalent to
the previously described embodiments with equivalent ratio of urea
to process water fed to the reactor (urea feed concentration) and
identical temperature and pressure ranges. The most significant
difference is the reduction in the supplemental heat required, as
has been described, which enables use of a smaller heat transfer
device and a smaller reactor vessel.
[0126] Acid-Catalyzed Hydrolysis--Energy Efficient Process
Embodiment
[0127] Another embodiment of the invention provides an energy
efficient process for acid-catalyzed hydrolysis of urea to
quantitatively produce ammonia on demand, in which the mass ratio
of urea to water as continuously fed to the reactor is increased,
requiring less process heat input to the reactor to evaporate
excess water, and which operates with relatively higher solids
concentration in the liquid reaction mixture. In this embodiment,
several variations are possible.
[0128] Thus, in a typical aqueous urea process as illustrated in
FIG. 9, more concentrated aqueous solutions (e.g. greater than 40
wt. % to about 76 wt. %, preferably greater than about 40 wt. % to
about 50 wt. %) of urea may be supplied as the feed stream up to a
concentration corresponding to nearly an equimolar mixture of about
76 wt. %. In such an embodiment, the feed solution storage and
handling temperature must be adjusted based on the solubility of
the urea in the aqueous solution. Thus, for 76 wt. % urea, the
temperature of the solution must be maintained above 70.degree. C.
The storage and handling equipment would all need to be maintained
at a temperature somewhat above the saturation temperature for the
given concentration of aqueous urea.
[0129] Another variation, based on process equipment illustrated in
FIG. 10, uses molten urea and liquid water (e.g., de-ionized water)
fed separately to the reactor, but (at steady state) in a ratio
equivalent to a more concentrated aqueous solution, preferably
about 50 wt. % to about equimolar. Still another variation, based
on process equipment illustrated in FIG. 11, uses molten urea and
steam fed in a ratio (at steady state) equivalent to a more
concentrated aqueous solution, preferably about 50 wt. % to about
equimolar. As described below, the urea feed (aqueous, solid, or
molten urea) rate can be changed in an amount disproportionate to a
change in the ammonia demand rate (e.g., halted or significantly
increased).
[0130] The common requirement is the reduction of excess process
water (amount greater than is needed just for the urea hydrolysis
reaction) in the feed to the reactor, which otherwise must be
removed at steady state with the ammonia and carbon dioxide gases
to avoid accumulation or depletion of water in the reaction
mixture. The chief advantage of this embodiment in its various
forms is energy efficiency calculated per unit mass of ammonia
generated. As the ratio of urea and water fed to the reactor
approaches equimolar flow rates of urea and water, the excess water
in the system is minimized, and therefore the extra energy required
to evaporate excess water is also minimized.
[0131] Increasing the ratio of urea to water fed to the reactor is
possible in an acid-catalyzed urea hydrolysis reactor because the
reaction kinetics remain very fast, even when the solids
concentration of the reactant solution is relatively high. The
operating temperature and pressure in the catalyzed process remain
in a reasonable range.
[0132] In the non-catalyzed urea hydrolysis process, in which the
reaction rate is much slower, the reaction rate constant decreases
with increasing solids concentration in the reaction solution. To
control the solids concentration in a favorable range, for example
from about 35 to 40 wt. % solids, the required operating pressure
increases as the ratio of urea to water fed to the reactor
increases. FIG. 1 shows calculated equilibrium temperature vs.
pressure curves for non-catalyzed urea hydrolysis using urea to
water feed ratios equivalent to 40 wt. %, 50 wt. %, and 60 wt. %
urea.
[0133] Thus, one advantage of the acid-catalyzed embodiment
relative to the non-catalyzed system is the relative tolerance to a
wide range of urea-to-water feed ratios. To further illustrate this
effect, consider a comparison standard system employing 40 wt. %
aqueous urea (urea to water weight ratio 0.667:1.0), operating the
reactor at constant temperature in the range 168.degree. C. to
172.degree. C. and constant pressure in the range 80 psig to 100
psig. The heat requirement of the process may be reported as BTU
per pound of ammonia generated (BTU/(lb NH.sub.3)). In this case,
the total heat requirement (not including loss to the environment)
is 4554 BTU/(lb NH.sub.3), and all of this heat is supplied by a
heater (e.g., an internal heating coil). The energy efficiency of
various cases may now be illustrated by comparison.
[0134] In a first case, the urea-to-water weight ratio is 1.0:1.0
(corresponding to 50 wt. % aqueous solution). The acid-catalyzed
reactor is operated at a constant temperature in the range
168.degree. C. to 172.degree. C., and a constant pressure in the
range 115 psig to 125 psig. The corresponding water content of the
equilibrium reaction mixture is in the range 18 wt. % to 25 wt. %.
The total heat requirement (not including loss to the environment)
for this case is 3504 BTU/(lb NH.sub.3). The supplemental heat
supplied by the heater (e.g., heating coil) depends on the process
variation. When steam and molten urea are fed as reactants, the
value is 1091 BTU/(lb NH.sub.3), but for aqueous urea the value is
the full 3504 BTU/(lb NH.sub.3).
[0135] In a second case, the urea-to-water weight ratio is 1.51:1.0
(corresponding to about 60 wt. % aqueous urea solution). The
acid-catalyzed reactor is operated at a constant temperature in the
range 168.degree. C. to 172.degree. C., and a constant pressure in
the range 190 psig to 210 psig. The corresponding water content of
the equilibrium reaction mixture is in the range 15 wt. % to 20 wt.
%. The total heat requirement (not including loss to the
environment) for this case is 2805 BTU/(lb NH.sub.3). The
supplemental heat supplied by the heater (e.g., heating coil) when
steam and molten urea are fed as reactants is 1097 BTU/(lb
NH.sub.3), and for aqueous urea the value is the full 2805 BTU/(lb
NH.sub.3).
[0136] In a third case, the urea-to-water weight ratio is 2.63:1.0
(corresponding to 72.5 wt. % aqueous urea solution). The
acid-catalyzed reactor is operated at a constant temperature in the
range 190.degree. C. to 200.degree. C., which is above the melting
point of the catalyst mixture, and a constant pressure in the range
115 psig to 125 psig. At these conditions, the corresponding water
content of the equilibrium reaction mixture is in the range 1 wt. %
to 2 wt. %. The total heat requirement (not including loss to the
environment) for this case is 2244 BTU/(lb NH.sub.3). The
supplemental heat supplied by the heater (e.g., heating coil) steam
and molten urea are fed as reactants is 1140 BTU/(lb NH.sub.3), and
for aqueous urea the value is the full amount 2244 BTU/(lb
NH.sub.3). These comparison cases demonstrate the flexibility of
the acid-catalyzed process and the energy savings associated with
this process embodiment.
[0137] Acid-Catalyzed Hydrolysis--Low Pressure Embodiment
[0138] Still another embodiment of the invention provides a process
for acid-catalyzed urea hydrolysis for quantitative production of
ammonia on demand, that is operated at a reactor pressure below 20
psig, which may employ variations in the reactor feed adapted to
aqueous urea (see FIG. 9), molten urea and water fed separately
(see FIG. 10), or molten urea and steam fed separately (see FIG.
11); which employs a molten catalyst mixture of MAP and DAP to
achieve rapid reaction kinetics; and which operates at a
temperature at least slightly above the melting point temperature
of the catalyst mixture (e.g., at least about 190.degree. C.), to
produce a product gas stream of ammonia, carbon dioxide and water
vapor for supply to an external use. The process may be operated
over a broad range of urea-to-water feed ratios, as in the previous
embodiments. The reactor for this system (or, at a minimum, the
wetted and/or interior surfaces thereof) preferably is constructed
of more corrosion-resistant materials such as HASTELLOY alloy
(Haynes International, Inc.); chromium, molybdenum, nickel,
niobium, tantalum, titanium, and alloys thereof; and
fiberglass-reinforced plastics, instead of, for example, typical
alloys of stainless steel. Process controls are adapted to the feed
system requirements and otherwise are as described in previous
embodiments. The primary advantage of this embodiment is the low
operating pressure of the reactor, which enables the design of the
reactor and associated equipment to be less robust with respect to
pressure. A carrier gas (e.g., warm air) can be used to aid in the
injection of the product gas stream into the flue gas stream, for
example by increasing the volume and velocity of the product gas
stream.
[0139] Thus, in an example of a most preferred method of operating
according to this embodiment, a 1.0:1.0 weight ratio of
urea-to-water is fed to a reactor using molten urea and steam fed
separately. The reactor is controlled at a substantially constant
temperature in the range 190.degree. C. to 200.degree. C., at which
temperature the MAP/DAP catalyst is molten, and a substantially
constant pressure in the range 10 psig to below 20 psig. The
equilibrium water content of the reaction mixture is in the range
1.0 wt. % to 2.0 wt. %, and ammonia, carbon dioxide and water vapor
are produced with rapid reaction kinetics, as in the previously
described embodiments.
[0140] Non-Catalyzed Urea Hydrolysis--Improved Control Process
[0141] Another embodiment of the invention provides an improved
process for non-catalyzed hydrolysis of aqueous urea to
quantitatively produce ammonia on demand, which maintains the
liquid reactants at substantially constant composition and produces
a product gas mixture of substantially constant composition, and
which includes the steps of: receiving a control signal
proportional to the demand rate for ammonia; supplying heat to the
reaction mixture in response to the ammonia demand to change the
temperature of the reactants and thereby to change the reaction
rate; adjusting the pressure of the reactor according to a
vapor-liquid equilibrium model with, for example, a pressure
control valve, in response to the temperature of the reactants to
maintain the product gas composition substantially constant and the
discharged water vapor under control; using the liquid level in the
reactor to govern the addition rate of urea and process water which
are supplied in a substantially constant ratio; whereby the
produced gases discharge from the reactor through the pressure
control valve for supply to the external use.
[0142] A typical apparatus according to this embodiment, using
aqueous urea, is illustrated in FIG. 12. Other feed system
variations using molten urea with either water or steam supplied
separately may also be employed. In this system an ammonia demand
rate signal 200 is connected to a process control system 202, which
regulates the urea hydrolysis reaction rate by adjusting the input
of heat to a reactor 204 in response to the ammonia demand rate
signal 200 to change the temperature of reactants 206. In the
illustrated system, heat input is accomplished by controlling the
flow of steam 210 a heater 212 having a steam coil 214 submerged in
the reactants 206, using a mass flow sensor 216, a flow controller
220 and a flow control valve 222, and a condensate line 224 is
fitted with an appropriate trap 226. For 30 practical purposes, the
steam supply can be fitted with a shut off valve 228 and a pressure
indicator 229.
[0143] The temperature of the reactants 206 is monitored with a
sensor 230, such as a thermocouple, which enables the process
control system 202 to trim the heat input using a temperature
controller 232 and to determine the set point for a pressure
controller 234.
[0144] A pressure transmitter 236 enables the process control
system 202 to monitor the pressure in the reactor 204, and the
pressure controller 234 governs a pressure control valve 240,
enabling the control of the reactor 204 pressure to be correlated
to the temperature of the liquid reaction mixture 206 The process
controller 202 applies a known functional relationship to determine
an instantaneous set point for the pressure controller 234 in
relation to the instant temperature of the reaction mixture 206 to
maintain a substantially constant composition in a product gas
stream 242.
[0145] The mass flow of the product gas 242 is monitored using a
flow sensor 246. Since the product gas 242 is maintained at
substantially constant composition, the control system 202 can
continuously determine the mass rate of production of ammonia and,
by manipulating the heat input to the reactor 204, match the
ammonia production to the demand rate input by the demand rate
signal 200.
[0146] A level sensor 250 and a level controller 252, which
operates a flow control valve 254, function to maintain a
substantially constant volume of reactants 206 in the reactor 204.
The mass flow of aqueous urea 256 pumped to the reactor 204 via a
pump 260 is monitored by a mass flow sensor 262 and indicated by a
flow indicator 264.
[0147] Unlike prior art technologies that control the temperature
and pressure independently, and in which the concentration of
ammonia in the produced gases may vary (especially in response to a
change in ammonia demand) an improved hydrolysis control system of
the invention, such as in this embodiment, uses the instantaneous
operating temperature of the liquid reaction mixture to set and
control the instantaneous operating pressure of the reactor. In
particular, for a fixed concentration of aqueous urea (or a
substantially constant ratio if fed separately) as the process feed
stream, and a substantially constant concentration of urea in the
reaction mixture, a vapor liquid equilibrium model (or an
experimentally derived correlation) relating the operating pressure
to the operating temperature is employed in the process control
scheme. Examples of theoretical equilibrium lines plotting pressure
versus temperature for several different feed compositions are
shown in FIG. 1. Thus, the operating pressure is controlled in
relation to the temperature of the reactants to maintain the
reaction mixture on an equilibrium line for the particular urea
feed ratio being used. By controlling the process according to this
method, a substantially constant composition is maintained in the
reaction solution and the composition of the produced gas mixture
is substantially constant, even during changes in ammonia
demand.
[0148] As discussed previously, non-catalyzed hydrolysis requires
much longer reaction time than acid-catalyzed systems, when
compared at the same temperature and pressure and when using the
same feed ratio of urea and water. Therefore, to achieve the same
rate of production of ammonia, the non-catalyzed reactor must
contain a great deal more urea than the acid-catalyzed reactor.
This has an influence on the best way to bring about a rapid change
in ammonia production. In the non-catalyzed system, controlling the
reaction rate by changing the aqueous urea feed rate (or separate
urea and water/steam feed rates) to bring about a change in the
mass (or concentration) of reactants requires a relatively long
time (e.g., hours) and is impractical process control scheme in the
applications of interest (e.g., deNOx and flue gas
conditioning).
[0149] However, changing the reaction temperature in the
non-catalyzed system, which in turn directly affects the reaction
rate constant and thereby changes the reaction rate, is a much more
practical means to quickly change the ammonia production rate in
response to a change in ammonia demand. Thus, in prior art the
process control system regulated the input of heat to the reactor
in response to the ammonia demand, which resulted in a controlled
change in the temperature of the reactant mixture. This in turn
determined the reaction rate constant and the rate of ammonia
production. However, the reactor pressure was not controlled in
relation to the temperature at all. The improved method according
to the invention includes the step of varying the operating
pressure in response to the instant operating temperature according
to a vapor-liquid equilibrium model (at all times, including during
such a change in production rate), which provides the benefit of
maintaining the produced gas composition substantially constant and
prevents substantial accumulation or depletion of water from the
reaction mixture. In addition, when controlling the process by
controlling the temperature and pressure at equilibrium values and
thereby controlling the composition of the discharged gases, the
measured flow of the produced gas correlates directly with the
ammonia delivered to the external use, even during a change in
production rate in response to a change in demand. The result is
improved performance (measured, for example, as the ability to
match the instantaneous ammonia production rate to the demand
rate), particularly during a changes in ammonia demand.
[0150] As in the catalyzed process embodiments, the non-catalyzed
process has various embodiments that take advantage of different
reactant feed schemes, such as the use of molten urea with a
separate supply of liquid process water, or use of molten urea with
a separate supply of steam. Unlike the catalyzed process, which
operates over a wide range of urea-to-water feed composition, the
experimental evidence suggests that a non-catalyzed process may be
limited, for practical purposes, to aqueous urea feed
concentrations in the range of 40 wt. % to 50 wt. %. This is
primarily the result of the energy requirements of the process,
which increase as the aqueous solution is diluted because the
excess water fed to the reactor must be evaporated to maintain a
steady state operation (i.e., prevent accumulation of water). In
addition, at concentrations above about 50 wt. %, the aqueous urea
feed solution storage must be maintained at temperatures greater
than about 20.degree. C. to avoid solubility problems. For example,
an equimolar mixture of urea and water at 76 wt. % urea requires a
temperature of at least 70.degree. C., and this is not advantageous
or convenient. The respective solubility (saturation temperatures)
for 40 wt. % and 50 wt. % aqueous urea are 0.degree. C. and
17.degree. C., respectively. The concentration of solids in the
reactor is another consideration, since more dilute solutions
enhance the rate of reaction at any particular temperature. The
most preferred solids content of the reactant solution is in the
range of about 35 wt. % to about 60 wt. % (i.e., about 40 wt. % to
65 wt. % water if no catalyst is added). A preferred set of
temperature and corresponding pressure ranges for selected feed
compositions are illustrated in FIG. 1.
[0151] Non-Catalyzed Hydrolysis Using Molten Urea
[0152] Another embodiment of the invention is a process for
quantitatively converting urea to ammonia on demand in a
non-catalyzed urea hydrolysis process with improved energy
efficiency, including the steps of: receiving an ammonia demand
rate signal; providing a reaction mixture in a reactor vessel
containing urea and water; reacting the urea and water in the
reaction mixture to produce a gaseous stream including ammonia,
carbon dioxide and water vapor; supplying heat to the liquid
reaction mixture at a rate in response to the demand rate for
ammonia to raise or reduce the temperature of the reaction mixture
and thereby change the rate of reaction and production of ammonia
to match the demand; monitoring the temperature of the reaction
mixture; adjusting the pressure of the reactor in response to the
temperature of the reaction mixture by a predetermined functional
relationship (experimental or theoretical vapor-liquid equilibrium
model) to maintain the composition of the product gas substantially
constant; monitoring the liquid level in the reactor vessel and
employing this signal in a control system to adjust the feed rate
of molten urea and process water supplied to the reactor in a
substantially constant mass ratio; whereby the produced gases
discharge from the reactor through a pressure control valve into a
conduit for supply to the external use.
[0153] In this process embodiment it is advantageous to divide the
process heat supply means between (a) a heater (e.g., with a heat
transfer fluid-filled heating coil) submerged in or in thermal
contact with the reactants and (b) the process water supply stream,
particularly when in the form of saturated steam at sufficient
pressure. To raise the reaction temperature, sufficient heat input
is required to satisfy the ongoing, endothermic reaction and the
requirement for evaporation of excess water supplied in the feed
stream, plus the additional heat needed to raise the temperature of
the reaction mixture to increase the rate of reaction. To reduce
the reaction temperature, supply of heat by the heater is reduced
or interrupted, and supply of molten urea and injected steam
(process water) is temporarily reduced or interrupted, enabling the
endothermic hydrolysis reaction to cool the reaction mixture,
thereby reducing the reaction rate and production of ammonia. (A
non-catalyzed molten urea feed process can also be operated at
substantially constant temperature and substantially constant
pressure, but will not respond as quickly to a change in demand as
the preferred embodiment described herein.)
[0154] In this configuration, the sensible and latent heat of the
condensing steam and the sensible heat of the molten urea feed
streams supply a large fraction of the total process heat
requirement, the balance being made up by the heat transfer coil.
Further, this embodiment may be operated conveniently over a broad
range of urea-to-process water feed ratios. Energy efficiency of
the process is improved by reduction of the excess process water
supplied to the reactor. Since a large portion of the process heat
requirement is supplied by the inlet reactants, the supplemental
heat transfer device may be smaller. However, with non-catalyzed
hydrolysis this may not enable a significant reduction in the
volume of reactants or the size of the reactor itself, since a
relatively large amount of urea is required to achieve the desired
ammonia production. In such a system operating with a mass ratio of
urea to water of 1:1 (corresponding to 50 wt. % aqueous urea), and
in which the water is supplied as steam injected at the pressure of
the reactor, about 65% of the process heat is supplied by the
reactant streams. Thus, the supplemental heat duty is reduced to
about 35% of the total. The heat transfer coil is therefore much
smaller, and the reactor cost may be correspondingly reduced. A
preferred set of temperature and corresponding pressure ranges for
selected feed compositions are illustrated in FIG. 1.
Further Process Improvements
[0155] Disproportionate Feeding of Urea
[0156] An aspect of the invention, particularly advantageous for
acid-catalyzed embodiments adapted for supply of urea and process
water as separate streams, is a control scheme for minimization of
the transient response time following a change in ammonia demand.
Thus, in acid-catalyzed embodiments it is beneficial to operate the
reactor at a constant temperature and pressure, for reasons that
have been described previously. To illustrate the method, it is
important to consider the case of a sudden increase and also the
case of a sudden decrease in ammonia demand.
[0157] When the ammonia demand changes, for example in a step
increase to double the initial ammonia production rate, then a
predictable new equilibrium condition will be required,
characterized by the following conditions: the urea feed rate will
be double the initial rate, the process water supply rate will be
double the initial rate, heat input to the reactor will be double
the initial rate, the mass of urea in the reactor at equilibrium
will be double the initial amount, and the temperature and pressure
of the reactor will remain unchanged. Therefore, if the amount of
urea present in the reactor is known prior to the change, then the
transient response time may be minimized by supplying urea to the
reactor at the maximum possible rate until the required mass of
urea is added (e.g., double the initial amount, in this example),
then reducing the urea flow from the maximum to the new feed rate,
thus bringing about the fastest feasible change in the mass of urea
present in the reactor. During the period of maximum urea supply,
the process water supply rate and the heat input to the reactor are
stepped up to the new steady state supply rates.
[0158] Where the production rate is doubled, this method minimizes
the time required to double the mass of urea in the reactor, which
is essential for the new equilibrium condition. By operating in
this manner, the ammonia production will reach the new production
rate in the least amount of elapsed time. Thus it is advantageous
to equip the process system with a urea supply means with
sufficient capacity to rapidly feed a quantity of urea into the
reactor. The control method of this example is illustrated further
in FIG. 13a, which illustrates an increase in ammonia production
from 50% to 100% capacity. The illustration shows the urea feed
rate temporarily increasing to 250% (value representing a
hypothetical maximum feed rate) until the new quantity of urea is
present in the reactor. Measuring the urea mass flow and
calculating the accumulation enables the time required to be
determined until a target quantity has been added.
[0159] When the ammonia demand drops, for example to half the
current production rate, then similarly a predictable new
equilibrium condition will be required, characterized by the
following conditions: the urea feed rate will be half the initial
rate, the process water supply rate will be half the initial rate,
heat input to the reactor will be approximately half the initial
rate, the mass of urea in the reactor at equilibrium will be half
the initial amount, and the temperature and pressure of the reactor
will remain unchanged. Therefore, if the amount of urea present in
the reactor is known prior to the change, then the transient
response time may be minimized by interrupting (e.g., halting)
supply of urea until the mass of urea in the reactor has fallen
(consumed by the on-going reaction) to the new requirement, then
setting the urea flow to the new feed rate, thus bringing about a
fast change in the mass of urea present in the reactor.
[0160] During the period of interrupted urea supply, the process
water supply rate and the heat input to the reactor are ramped down
to the new steady state supply rates. A "ramp down" algorithm for
reduction of the water supply and heat input to the reactor from
the initial to the final rates may be programmed based on, for
example, a linear function of elapsed time or proportional to a
calculated instant urea content. In the present example (halving
the ammonia production rate), this control method minimizes the
time required to halve the mass of urea in the reactor, which is
essential for the new equilibrium condition. By operating in this
manner the ammonia production will reach the new production rate in
the least amount of elapsed time. The control method of this
example is illustrated further in FIG. 13b, which illustrates a
decrease in ammonia production from 100% to 50% capacity. Thus, the
urea supply is shut off for a controlled period of time, during
which the urea present in the reactor continues to react. Based on
the 30 known reaction rate, the urea depletion rate can be
predicted, and the time required can thus be determined. The
illustration shows process water (e.g., injection steam) and heat
input to the reactor (e.g., heating steam) ramping down linearly
with time.
[0161] Other Sensors
[0162] An aspect of the invention that may be adapted to all of the
processes of the invention and the embodiments illustrated in FIGS.
9 to 12 employs mass flow sensors to precisely measure the mass
flow rate of all feed and product streams. These devices enable
continuous, real-time monitoring of the material balance around the
hydrolysis reactor, and may be employed in a control scheme to
adjust the set point of process controls in various ways to enhance
the process control or even replace other control devices. For
example, the difference between the total mass discharged from and
total mass fed to the reactor provides a measurement directly
reflecting the steady state mass balance. This can be used to trim
the operating temperature or pressure (or urea and water feed(s))
to enhance the performance of the process control system. For
example, mass flow sensors can be used in the disproportionate
feeding improvement described above to monitor the material balance
when increasing or decreasing the flow rate of urea to the reactor
to maintain a substantially constant mass of liquid reactants.
[0163] Another aspect of the invention includes use of analytical
sensors, such as a pH monitor. In an acid-catalyzed process
according to the invention, for example, the pH of the reaction
mixture provides a measurement that directly correlates to the
ratio of ammonium salts including the catalyst, for example
MAP:DAP, present in the reaction mixture. Use of such a sensor will
enable operation of the reactor at conditions that provide
beneficial performance, such as enhanced reaction efficiency,
reduced corrosion rate, or other such benefits.
[0164] Preferably, reactants are fed at a substantially constant
ratio of urea to water regardless of ammonia demand, but this need
not be the case. Thus, for example, the concentration of urea in
the feed can be increased in response to an increase in ammonia
demand rate. In one embodiment of the invention, this can be
accomplished by dissolving solid urea in water to a known and
relatively high concentration, storing the concentrated aqueous
solution, and diluting it to various concentrations when withdrawn
for feeding to a reactor vessel. In another embodiment of the
invention wherein urea (in the form of solid or molten urea) and
process water (in the form of liquid water or steam) are introduced
into the reactor as separate feed streams, the urea and water feed
rates can be increased or decreased relative to one another to
provide the desired ratio of urea to water.
[0165] The hydrolysis reactor vessel and all wetted components in
either MAP/DAP catalyzed or non-catalyzed embodiments can be
constructed of a material such as 316 series stainless steel, as
long as the operating temperature is maintained below about
175.degree. C., preferably below about 170 .degree. C. In this
range, the corrosion rate begins to increase and would generally be
unacceptable at temperatures greater than 175.degree. C. If
operating at temperatures above 175.degree. C. is required,
especially for MAP/DAP-catalyzed hydrolysis, then the reactor
preferably is constructed of more corrosion-resistant materials
such as HASTELLOY alloy or an alloy with higher molybdenum content.
Otherwise, the apparatus and process controls described above can
be adapted to this operating temperature.
[0166] In the preferred operating ranges of a MAP/DAP-catalyzed
process according to the invention, the concentration of urea in
the reaction mixture is quite small, typically from about 1 wt. %
to about 6 wt. %, whereas the concentration of catalyst is about 55
wt. % to about 80 wt. %.
Variations on Feeding Urea and Water
[0167] In a process according to the invention, the feeding step
can include: feeding an aqueous solution including urea and water;
feeding molten urea and steam; feeding solid urea and steam;
feeding molten urea and water; and feeding solid urea and water.
Feeding an aqueous solution including urea and water has the
advantage that the solution can be prepared with a known
concentration of urea. One drawback of the use of aqueous urea as a
reactant feed stream is that solutions of a concentration that can
be maintained at room temperature (e.g., up to about 50 wt. % urea)
contain far more water than is necessary for the hydrolysis
reaction. Consequently, the water must be evaporated from the
reactor, which requires significant additional energy consumption
by the process. Otherwise, storing highly concentrated aqueous urea
(e.g., greater than 50 wt. %) would require heating the entire
storage system (e.g., reservoir and related equipment) to a
temperature above the saturation temperature at the given
concentration to prevent precipitation of solid urea.
Molten or Solid Urea Systems
[0168] A process of the invention wherein molten urea and steam are
fed to the reactor is preferred, and has several advantages which
have been described above. Optionally, solid urea can be fed
directly to the reactor (e.g., by a single screw feeder
(pressurized) or by a twin screw extruder) with a separate steam
feed, which also makes possible several advantages. A dry air purge
can be used to keep the pressure of the screw feeder in excess of
the reactor operating pressure, which would prevent the reactants
from flowing out of the reactor into the urea feeder. Using solid
urea, the flow rate of urea into the reactor can be measured by
using a weight loss metering device to the screw feeder, for
example.
[0169] Preferably, when molten urea is used in a process according
to the invention, a low-volume melter is used, and the melter has a
residence time preferably of about 30 minutes or less and a
temperature preferably of about 135.degree. C. to about 150.degree.
C. , to minimize decomposition and/or polymerization of urea. Urea
melts at 133.degree. C., where it immediately begins to decompose
and sublimate at a rate proportional to the temperature, up to
about 168.degree. C., where it rapidly decomposes. Likewise, when
molten urea is used in a process according to the invention, stored
solid urea preferably is maintained in a low-humidity environment
to prevent agglomeration of urea prills and to minimize urea
hydrolysis upon melting. Urea hydrolysis in a urea melter can
present the additional problem of making pumping difficult because
the vapor production makes it difficult to keep the pump primed.
Preferably, a pump and piping system used for conveying molten urea
will be designed or selected to eliminate or minimize pockets where
vapor can accumulate.
[0170] When molten urea is used in a process according to the
invention, preferably any vapors (primarily ammonia) given off by
the urea melter are collected and combined with the
ammonia-containing reactor product stream or a dilution air stream
for feeding to the process that requires ammonia, such as a
nitrogen oxides removal or flue gas conditioning process. The
vapors alternatively can be sent to an ammonia scrubber unit prior
to discharge to the atmosphere.
[0171] In an embodiment of the invention wherein the equilibrium
temperature and pressure are controlled to constant values, a
change in ammonia demand requires that the total heat input be
controlled in direct proportion to the urea feed rate. Therefore,
the amount of heat supplied to the reactor is changed in direct
proportion to the urea feed rate in response to a change in ammonia
demand. This will result in the process temperature remaining
substantially constant during a transient period after a change in
ammonia demand, and when full equilibrium at the new production
rate is achieved, the temperature will be the same as before the
change. When a constant temperature is desired, a trim control can
be provided in addition to the primary proportional control. Thus,
a direct measurement of the temperature of the liquid reaction
mixture, for example, can be used in a trim control that works in
conjunction with the proportional control to assist in fine-tuning
to a substantially constant temperature.
[0172] During the urea hydrolysis process, with or without a
catalyst, the evolution of gases from the reaction mixture can
create a foam on the surface of the reaction mixture. Preferably,
the foam is minimized to keep all reactants (and catalyst, if used)
in the reaction mixture and to minimize the potential for formation
of undesirable products in the reactor via side reactions and to
prevent entrainment of solids in the gaseous product stream.
[0173] Foam can be reduced by several different methods, such as
agitating the reactants in the reactor, for example by a mechanical
device such as a stirrer, and by injecting steam directly into the
reactor. A defoaming agent such as DOW CORNING brand Anti foam
1510-US can also be added to the reactants prior to feeding into
the reactor or to the reaction mixture. The formation of foam can
be reduced by selecting process conditions wherein the reaction
mixture contains a relatively high concentration of water, for
example about 20 wt. % to about 60 wt. %. Using a smaller volume of
catalyst, especially when a MAP/DAP catalyst mixture is used, can
also reduce the formation of foam. Using less catalyst also
provides relatively more volume in a reactor of fixed size, which
reduces the probability of foam being entrained in the product gas
stream.
[0174] The reactor can be designed to reduce the probability of
reactants (and catalyst, if used) being entrained in the product
gas stream. For example, the reactor can be designed to provide a
large liquid surface area for vapor disengagement, and to lower the
vapor velocity. The path length from the surface of the liquid
reaction mixture can be maximized to minimize the probability of
reactants (and catalyst, if used) being entrained in the product
gas stream. Additional apparatus can be installed inside the
reactor to promote vapor disengagement, such as a mist filter or
mesh pad in the gas flow path, or a centrifugal degasser,
preferably in the vicinity of the vapor outlet from the
reactor.
[0175] A catalyst can optionally, but preferably, be used in a
process according to the invention. A polyprotic acid catalyst is
preferred, particularly a polyprotic mineral acid catalyst, more
particularly a mono- and/or di-ammonium salt of a polyprotic
mineral acid, such as MAP and/or a mixture of MAP and DAP. The MAP
and/or DAP can be charged to the reactor as dry crystals prior to
startup, or can be generated in-situ by charging the reactor with
phosphoric acid prior to startup. Preferably, a mixture of MAP and
DAP is charged to the reactor as dry crystals prior to startup to
prevent corrosion of the reactor by phosphoric acid.
[0176] Urea hydrolysis according to the invention using a MAP/DAP
catalyst mixture preferably is carried out with a large excess of
catalyst. The molecular weight of urea is 60, MAP is 115, and DAP
is 132. Thus, to have an equimolar amount of MAP/DAP catalyst
requires approximately 1.92 to 2.2 times the mass of the urea in
the reaction mixture. However, to ensure an excess of catalyst, the
weight of catalyst in the reaction mixture preferably is in a range
of about 2.5:1 to about 50:1 ratio (theoretically without upper
limit) with the urea content on a mass basis, and more preferably
in a range of about 2.5:1 to about 20:1 ratio.
[0177] Another aspect of the invention is an apparatus for
quantitatively converting urea to ammonia on demand. The apparatus
will include at least an ammonia demand signal receiver, a reactor,
a urea feeder, a valve for controlling the reactor pressure and
release of product gases, and a heater. Preferably an apparatus
according to the invention will include a combination of the
various elements described above, such as a heater, a direct steam
injection feeder, pressure and temperature monitors, an agitator, a
degasser, a urea melter, a reaction mixture sampling valve, gas and
liquid flow meters, pumps, metering devices, control devices (e.g.,
proportional, integer, etc.), and safety devices such as an
emergency pressure relief valve. Preferably, an apparatus according
to the invention will connect the various elements described above
according to a combination of relationships described above, such
as a urea feeder that is responsive to an ammonia demand signal. In
one embodiment of the invention, the urea feeder can also serve as
a water feeder, such as when aqueous urea is used as a reactant
feed stream. In another embodiment of the invention, a separate
water (steam) feeder is present in addition to the urea feeder.
[0178] Thus, one embodiment of an apparatus according to the
invention, includes an ammonia demand signal receiver; a reactor
vessel adapted to contain reactants including urea and water at
elevated temperature and pressure and to release a gaseous product
stream including water, carbon dioxide, and ammonia; a feeder
responsive to the demand signal for feeding urea to the reactor; a
heater responsive to the demand signal for heating the reactants to
elevated temperature; and a valve in fluid communication with the
reactor for maintaining the reactants at a substantially constant
elevated pressure.
[0179] Examples of flow diagrams for apparatus according to the
invention are depicted in FIGS. 9 to 12, which have been described
above. In an apparatus according to the invention the heater
preferably is adapted for heating the reactants to a substantially
constant elevated temperature. An apparatus according to the
invention also preferably includes a defoaming or demisting
apparatus, such as a degasser, a mist filter, or a mesh pad. An
apparatus according to the invention also preferably includes a
urea melter and a steam feeder responsive to the demand signal.
Contaminant Removal
[0180] In a process disclosed herein, one or more contaminants
(e.g., from urea feed or formed in the reactor) may accumulate, and
preferably are removed continuously or intermittently, for example
according to the methods and apparatus disclosed in co-pending U.S.
application Ser. No. 09/708,897 filed Nov. 8, 2000, which is
incorporated herein by reference.
EXAMPLES
[0181] The following examples are provided to illustrate the
invention but are not intended to limit the scope of the
invention.
Example 1
[0182] In this example, 50 wt. % aqueous urea was employed as the
form of the liquefied urea and, as a consequence, sufficient
process water was supplied to the reactor as part of the aqueous
stream.
[0183] The apparatus used included a process control system that
received a signal proportional to an instant demand signal for
ammonia in an external process, and employed the demand signal to
set the flow rate of urea solution to the reactor in direct
proportion to the demand signal. The aqueous urea feeder was a
process pump capable of continuous delivery of aqueous urea at a
pressure greater than the operating pressure of the reactor (about
150 psig). The discharge capacity of the urea feed pump was
oversized to enable a continuous circulation of the excess portion
back to an aqueous urea storage reservoir, while a side stream was
continuously metered by mass flow into a urea hydrolysis reactor
(316 stainless steel construction) at a rate stoichiometrically
equivalent to the ammonia demand.
[0184] In the test apparatus, a flow sensor (for example, mass flow
by Coriolis force) was used in combination with a flow controller
and mass flow control valve to govern the urea flow rate to the
reactor inlet at a rate directly proportional to the instant demand
signal. The process controller was programmed to use the instant
measured mass flow rate and predetermined concentration of the urea
feed solution to calculate the instant quantity of urea flowing to
the reactor. The rate of heat input to the reactor was supplied in
direct proportion to the flow rate of urea to the reactor. Thus the
rate of heat input was automatically adjusted to supply the
combined instant heat of reaction plus the heat required to
evaporate excess water and thereby maintain the reactor at a
substantially constant operating temperature.
[0185] The operating pressure of the reactor was maintained
substantially constant by means of a pressure control valve placed
in the discharge gas line and operated by means of a standard
pressure control loop. The pressure control valve was normally
closed and was operated in response to the reactor pressure,
opening to release the produced gases once the set point pressure
was attained. At steady state, the mass flow of gaseous product
leaving the reactor was equal to the mass flow of reactants
supplied to the reactor. When the concentration of the inlet urea
solution was constant, the concentration of the ammonia in the
product gas stream was substantially constant, and independent of
the ammonia production rate.
[0186] At steady state, the composition of the liquid reaction
mixture reaches a full chemical equilibrium, characterized by a
particular ratio of MAP to DAP at constant temperature, and was
measured as 20.85 wt. % MAP, 56.22 wt. % DAP, 1.90 wt. % un-reacted
urea, and 19.70 wt. % water, based on laboratory analyses. The
amount of catalyst mass was fixed at 160 kg, and the amount of urea
that was present in the liquid reaction mixture varied in relation
to the production rate. The actual value of the urea concentration
depended on the quantity of catalyst mass (MAP plus DAP) present in
the reactor. The reaction rate constant was independent of ammonia
production rate, because the temperature and pressure were
substantially constant. The reaction rate varied in response to the
variation in steady state urea concentration. To double the ammonia
production, the amount of urea in the reaction mixture must double.
Given the fast reaction kinetics and fast response of the process
controls, equilibration and approach to a new steady state
condition after a rate change occur quickly.
[0187] FIG. 14 depicts the recorded transient response data for
this example at a sampling interval of six samples per minute. The
figure shows the process initially operating at steady state with a
set point for 50 wt. % aqueous urea flow rate to the reactor of
about 41 kg/hr, and the transient response following a step change
in the aqueous urea flow rate to 124 kg/hr. As FIG. 14 shows, the
temperature was substantially constant at about 170.degree. C.
throughout the change. The pressure (not shown) was also
substantially constant during the run at 120 psig. The line marked
"reactor outlet flow" depicts the mass flow of product gases and
water vapor leaving the reactor. The product gas flow rate began to
increase immediately, and reached about 75% of the new steady state
requirement within about two minutes. Within 12 to 15 minutes, the
system reached steady state at the new production rate. FIG. 14
compares the aqueous urea mass flow rate set point with the
measured reactor outlet mass flow, which should be equal at steady
state. The mass flow sensor on the product gas flow, though quite
sensitive, was used in a range in this experiment where it tended
to read a high value (calibration error), as reflected in FIG. 14,
but the rapid leveling of the measured flow illustrates the
equilibration.
Example 2
[0188] In this example, pure molten urea was employed as the
liquefied urea, and as a consequence, process water was supplied to
the reactor as a controlled flow of saturated steam. It was
calculated that the latent heat of a portion of the steam that
condensed contributed about 60% to 70% of the total heat
requirement for the process. The balance of the required heat was
supplied in this experiment by a steam-supplied heating coil
submerged in the liquid reactants.
[0189] The apparatus in this experiment was essentially the same as
in FIG. 11: solid granular urea was dropped in small batches from a
bulk handling system into a hopper of a feeder device
(speed-controlled screw feeder) to meter the granular urea at a
controlled rate into a melter vessel. The speed of the screw feeder
was adjusted in response to the liquid level of molten urea inside
the melter using a conventional level control process loop. The
melter was designed to minimize the residence time of the molten
urea (about 30 minutes or less) and the heating temperature in the
melter (slightly above the melting point of urea, about 146.degree.
C. to about 152.degree. C.) and to enable plug flow of the molten
urea, so that formation of urea decomposition by-products was
minimized.
[0190] In response to an external demand for ammonia, molten urea
was fed at a directly proportional rate to the demand by a jacketed
pump with a mass flow sensor and a flow control valve. Any excess
flow was returned to the melter to maintain an active circulation
and to melt incoming urea. Contaminant-free 200 psig saturated
steam was used as process and utility steam, since the reactor was
operated at 120 psig and the flow controls resulted in a small
pressure loss. A portion of the steam was regulated down to a
pressure in the range of about 48 psig to about 58 psig for use in
the melter heating jacket and for tracing the molten urea supply
equipment and piping. Separate steam pressure regulation for use in
the melter jacket and the supply system tracing was provided to
enable some adjustment of supply pressure. Insulation losses and
heat input from the metering pump affected the optimum adjustment
in the desired range of pressure. The flows of steam used for
injection as a process water source and for use in the heating coil
were supplied through individual mass flow sensors and flow control
valves. The set points for these flow control loops determined in
response to the urea supply rate to the reactor.
[0191] FIG. 15 depicts data recorded during a system start up,
setting the desired reactor conditions at constant 170.degree. C.
and constant 120 psig. The figure shows the urea flow rate, the
total reactants (urea plus process water) inlet flow rate, the
reactor outlet mass flow rate, and the reactor liquid temperature
versus the elapsed time. At time zero, the flows of urea, injection
steam, and supplemental heat were started. Prior to startup, a
charged mixture of catalyst was preheated to about 155.degree. C.
The process reached the desired temperature (170.degree. C.) in
about 12 minutes to 15 minutes and remained steady thereafter. The
urea and process steam injected to the reactor increased to their
respective set points in a series of step adjustments over this 12
to 15 minute period. The initial reactor outlet gas flow remained
essentially zero as pressure in the reactor built up to 120 psig,
and then produced gas began to be detected in the outlet line and
rapidly increased at about seven minutes. The reactor outlet gas
flow rate achieved about 75% of the desired steady state flow rate
at about 10 minutes to 12 minutes, and reached the full steady
state production rate at about 20 minutes after startup (change in
ammonia demand).
[0192] FIG. 16 depicts data recorded during an experiment operating
with molten urea at 170.degree. C. and 120 psig, and shows the
transient response to several changes in urea and steam injection
flow rates. The apparatus employed is illustrated in FIG. 11
(configured for a small volume of reactants. In this case the mass
of catalyst used was 60 kg. The same four variables as in FIG. 15
are plotted versus elapsed time. The operating temperature remained
substantially constant at 170.degree. C., and the inlet urea flow
initially was 40 kg/hr, then was increased to 60 kg/hr, and then
was increased again to 70 kg/hr. The line depicted for the reactor
inlet flow is the sum of the urea flow and the injected steam flow,
and this total inlet flow shown for comparison with the reactor
outlet mass flow. At about 40 minutes, the urea and steam injection
flows were increased for the first time, and the transient response
required about 12 minutes to about 15 minutes. At about 75 minutes,
the injection steam flow rate was deliberately reduced while
maintaining a substantially constant urea flow rate, and again the
process reacted quickly to this change. Then, at about 100 minutes,
the injection steam flow rate was returned to the former value, and
the apparatus and process control system reacted to this
adjustment, coming back to the former operating conditions.
Finally, the urea flow and steam injection flow rates were
increased again to the highest rate, and the ammonia production
rate followed this change. The transient response is shown to begin
immediately and to follow the variation in the urea supply in
either direction, and achieve a new full steady state in about. 12
minutes to 15 minutes at these reactor conditions.
Example 3
[0193] The apparatus of Example 1 was employed to investigate the
reaction kinetics of urea hydrolysis in a non-catalyzed liquid
reaction mixture. A series of experiments were performed using 40
wt. % aqueous urea as a feed. The object of the experiments were to
establish a steady state condition, operating the reactor at a
selected constant temperature and at a pressure determined from
vapor-liquid equilibrium calculations using a combination of
Raoult's Law and Dalton's Law. The intent was to maintain the
concentration of reactants in the reactor constant, while
simultaneously avoiding any loss or accumulation of mass.
Therefore, the excess water supplied in the feed solution will be
discharged from the reactor along with the produced ammonia and
carbon dioxide. When the reaction process is controlled in this
manner, the system is at a steady state and full chemical
equilibrium, and the reaction rate constant can be determined
accurately. The object of the experiment was to determine the
reaction rate constant k so that the kinetics of the non-catalyzed
hydrolysis can be compared to the process using the phosphate
catalyst.
[0194] In the series experiments tabulated below, a reactor was
charged with a carefully measured mass of urea and process water so
that the starting concentration of urea and the total starting mass
of urea present in the reactor were known. The urea concentration
was set near the 40 wt. % of the feed urea used in these reactions.
An operating temperature was arbitrarily chosen for each
experiment. FIG. 1 was generated from vapor-liquid equilibrium
calculations using Roault's Law and Dalton's Law, and enables a
predicted operating pressure to be selected from the selected
operating temperature to maintain constant composition and total
mass in the liquid reaction mixture. Results are summarized in
Table 2, below.
2TABLE 2 Non-catalyzed Reaction Rate Constant vs. Temperature Temp
(.degree. C.) Pressure (psig) 1/T k (min-1) 1/k (min) ln(k) 149 80
2.37E-03 0.0051 196.1 -5.28 153 100 2.35E-03 0.0065 153.8 -5.04 160
118 2.31E-03 0.0095 105 -4.66 *163 126 2.29E-03 0.0111 90.0 -4.50
*171 158 2.25E-03 0.0156 60.34 -4.10 *indicates extrapolated data;
see FIGS. 2 and 3 and the discussion above.
[0195] These results can be compared with results from experiments
using a MAP/DAP phosphate catalyst, which are tabulated below in
Table 3 and plotted in FIG. 3.
3TABLE 3 Catalyzed reaction Rate Constant vs. Temperature Temp
(.degree. C.) Temp (.degree. K.) 1/T k (min-1) 1/k (min) ln(k)
MAP/DAP **157.2 431 2.32E-03 0.039 25.64 -3.24 0.17 163 436
2.29E-03 0.078 12.82 -2.55 0.25 169 442 2.26E-03 0.15 6.667 -1.90
0.32 171 444 2.25E-03 0.2 5.000 -1.61 0.39 **indicates a single
data point.
[0196] FIG. 3 provides a plot of ln(k) versus (1/T).times.1000
using the data points from the non-catalyzed and catalyzed
hydrolysis experiments tabulated above. The tabulated data at
171.degree. C., for example, indicate that the phosphate catalyst
reaction rate constant is approximately 12 times faster than the
non-catalyzed reaction at this temperature. At 163.degree. C., the
catalyzed process is about seven times faster.
Example 4
[0197] It is possible to operate the urea hydrolysis process using
a phosphate catalyst over a broad range of pressure. At low
operating pressures (e.g., below about 20 psig) the liquid reaction
mixture has a composition that is dramatically different. The
reaction does not proceed significantly until the temperature is
above about 145.degree. C. At such temperatures and low pressure,
water is driven out of the reaction mixture to such an extent that
the reaction must be carried out at nearly the melting point of the
catalyst mixture.
[0198] In an experiment that molten urea feed and the apparatus of
Example 2, the MAP:DAP ratio in the equilibrium catalyst mixture
was 1.134, and the composition of the reaction mixture was 51.94
wt. % MAP, 45.82 wt. % DAP, 1.2 wt. % urea and 1.09 wt. % water
when the reactor was operated at 19 psig and 187.degree. C. The
flow rate of urea was 11.8 kg/hr. Saturated steam at about 200 psig
was injected directly into the reactor through a flow control valve
at a rate of 15.3 kg/hr.
[0199] The foregoing description is given for clearness of
understanding only, and no unnecessary limitations should be
understood therefrom, as modifications within the scope of the
invention may be apparent to those having ordinary skill in the
art.
* * * * *