Abstract:
The present invention is an integrated process for converting light hydrocarbon gas to heavier hydrocarbon liquids. In each embodiment, a Fischer-Tropsch (FT) process comprising a thermal reformer and a reactor containing an FT catalyst is combined with one or more additional processes to achieve operational synergies. In a first embodiment, an FT process is integrated with a cryogenic liquefied natural gas (LNG) process wherein tail gas from the FT reaction is used to drive a refrigeration compressor in the LNG process. The tail gas, optionally supplemented with natural gas, may be fed directly to a gas turbine or may be combusted in steam boiler, which in turn provides steam to a steam turbine. The natural gas may be processed prior to its being fed to the LNG process and the FT process in order to remove any impurities and/or condensate. The process may be further integrated with a fertilizer production process comprising an ammonia synthesis process and a urea synthesis process. To produce ammonia, hydrogen separated from synthesis gas produced in a primary and/or secondary reformer in the FT process is combined with nitrogen produced in the LNG process. Nitrogen may also be supplied to the ammonia synthesis process from an optional air separation process, which also provides oxygen enrichment to the thermal reformer in the FT process. To produce urea, the ammonia is subsequently reacted with carbon dioxide removed during processing of the gas prior to its liquefaction. The integrated FT/LNG/Fertilizer process may be further integrated with a carbon dioxide removal process which separates flue gas from a gas turbine or steam generator driving the refrigeration compressor in the LNG process into nitrogen which is used in the ammonia synthesis process and carbon dioxide which is used in the urea synthesis unit. Alternatively, the FT process may be integrated directly with the fertilizer production process, in the absence of an LNG process. In an alternative embodiment, an FT process is integrated with a methanol synthesis process wherein tail gas from the FT reaction is used to fuel burners in a secondary thermal reformer.
Abstract:
A reactor for two-phase reaction, in particular for urea synthesis at high pressure and temperature of the type wherein a co-current flow of a gaseous phase and a liquid phase takes place, comprises a substantially cylindrical vertical external shell (2) in which is supported a plurality of superimposed horizontal perforated plates (6a-6e) in mutually spaced relationship and at least one opening (12a-12e) for liquid flow being defined in correspondence of each of the perforated plates. Advantageously the openings (12a-12e) for liquid flow are mutually offset so as to obtain a substantially zigzag preferential flow path for the liquid phase in the reactor.
Abstract:
The present invention provides an improved process for synthesizing urea from ammonia and carbon dioxide while preventing corrosion of sites, that are to be in contact with a condensate, of the joints of a tube plate and cooling tubes in a condenser installed vertically or horizontally. According to this process, the sites, that are to be in contact with the condensate, of the joints of the tube plate and the cooling tubes in the condenser are prevented from corrosion by enveloping the sites with liquid ammonia or a solution rich in ammonia in the synthesis of urea comprising separating unreacted ammonia and carbon dioxide as a gaseous mixture thereof from a urea synthesis solution at a pressure substantially equal to the urea synthesis pressure, bringing the gaseous mixture into contact with an absorption medium in the condenser to form a condensate, and recirculating the condensate to the synthesis column.
Abstract:
An improved process for urea production as well as a method of retrofitting a pre-existing urea plant based on the Stamicarbon process are disclosed. According to the invention, a high-yield reactor with partial removal of the reaction heat and a urea recovery section of the solution leaving the high-yield reactor, are added to the pre-existing urea plant unreacted ammonia and carbon dioxide vapors as well as a carbamate solution obtained in the urea recovery section are recycled to the pre-existing reactor.
Abstract:
A urea production process combining lower pressure urea concentration and carbamate recovery steps into a single non-vacuum operation. Following high pressure stripping wherein a bulk of unreacted carbamate is recovered from the reaction effluent, remaining carbamate is stripped by heated air at atmospheric pressure wherein urea is concurrently concentrated without the use of vacuum evaporators. Weak carbamate solution subsequently formed is stripped of water (and residual urea is hydrolyzed) using air and steam at a medium pressure single tower hydrolyzer/stripper to obtain a concentrated carbamate stream suitable for recycle to the reactor. The process employs heat integration for enhanced energy efficiency and produces a good quality aqueous condensate suitable for direct use as boiler feed water. Thus the aqueous condensate produced requires no additional cooling and ammonia treatment. The process employs simplified and reduced process unit operation to eliminate equipment for cost reduction.
Abstract:
Urea is formed by the synthesis of ammonia with carbon dioxide at high pressure and temperature in an internal space of reactors through which flow a liquid phase cocurrently with a gas phase. The reactors are divided into compartments to avoid excessive mixing of the entire liquid phase and to allow the intermittent redistribution of the gas in bubbles of a suitable size for increasing the exchange of heat and matter between the two phases. At each passage from one compartment to the next, the liquid phase and the gas phase are made to flow on separate routes and are distributed in each compartment with a continuous, permanent, and even flow.
Abstract:
A process to modernize existing urea plants which use a stripping with carbon dioxide, and to increase urea yields and flexibility under overload conditions while at the same time reducing energy consumption, corrosion phenomena and possible risks of explosive mixtures. The plant includes: a passivation stage with the introduction of an oxidizing agent and reduction of the air fed to the system; a medium pressure distillation stage of the products leaving the stripping section, and a condensation of the products of the distillation, effected in a pre-evaporation phase to concentrate at low pressure the urea solution.The modernized plant, includes at the start at least a reactor, a scrubber, a condenser, a stripper and the evaporators, includes also a passivation section, a medium pressure distillation section, and a distillation section with double-effect technique.
Abstract:
The present invention is directed to a method for producing carbon dioxide and nitrogen from combustion exhaust gas containing less than about 10% oxygen by weight which comprises the steps of (a) treating the exhaust gas to remove particulate matter, (b) compressing the exhaust gas to a pressure in the range from about 25 psia to about 200 psia, (c) purifying the exhaust gas to remove trace contaminants, (d) separating the exhaust gas to produce a carbon dioxide rich fraction and a nitrogen rich fraction, (e) liquifying the carbon dioxide rich fraction and distilling off volatile contaminants to produce pure carbon dioxide, (f) purifying the nitrogen rich fraction to remove contaminants, and (g) cryogenically fractionally distilling the nitrogen rich fraction to produce pure nitrogen. In another embodiment, the invention is directed to a method for producing carbon dioxide, nitrogen, and argon from a combustion exhaust gas. The combustion exhaust gas in the present invention may be obtained from an ammonia plant reformer furnace and the nitrogen produced may be employed as a synthesis gas in the ammonia reactor.
Abstract:
Process and apparatus for the production of urea, wherein the carbamate decomposers and/or condensers are equipped with stainless steel tubes internally lined with zirconium.