Process for Producing Ammonium Nitrate

• US 20150203360A1
• Filed: 12/19/2014
• Published: 07/23/2015
• Est. Priority Date: 12/01/2010
• Status: Active Grant

• Current Assignee: University of Sydney, YARA International ASA
• Original Assignee: Orica International Pte Ltd., University of Sydney
• Inventors: Johnston, Anthony Matthew, Haynes, Brian Scott, Conroy, Gregory Lawrence
• Granted Patent: US 9,493,364 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C01B 21/26 Preparation by catalytic or non-catalytic oxidation of ammonia
• CPC Class Codes: C01C 1/185 Preparation
• CPC Class Codes: F28D 20/00 Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00
• CPC Class Codes: Y02E 60/14 Thermal energy storage

Abstract

A process for producing ammonium nitrate is disclosed, which process comprises exposing a gaseous oxidiser feed composed at least substantially of ammonia, steam and an oxidising gas to conditions whereby the ammonia is oxidised to produce a reaction mixture including nitrogen monoxide and water vapour. The reaction mixture is cooled in a heat exchanger whereby the nitrogen monoxide is oxidised, the water vapour is condensed and the products of the nitrogen monoxide oxidation react with and are absorbed by the condensed water to form a nitric acid stream, with substantially all of the nitrogen monoxide in the reaction mixture being converted to nitric acid. The nitric acid stream is reacted with a stream of ammonia to form the ammonium nitrate. Also disclosed is ammonium nitrate per se (in any of its various possible forms) when produced by the disclosed process.

Claims

1-57. -57. (canceled)

58. A method for producing ammonium nitrate, comprising:

providing a non-explosive gaseous oxidiser feed comprising ammonia, steam and an oxidising gas to a reactor;

in the reactor, oxidising the ammonia of the non-explosive gaseous oxidiser feed to produce a reaction mixture comprising nitrogen monoxide and water vapour;

providing the reaction mixture to a heat exchanger;

in the heat exchanger, cooling the reaction mixture and conducting a reaction-absorption process in which (i) the nitrogen monoxide is oxidised to produce one or more oxidation products, (ii) the water vapour is condensed to liquid water and (iii) the one or more oxidation products react with and are absorbed by the liquid water to form nitric acid in a nitric acid stream, wherein substantially all of the nitrogen monoxide in the reaction mixture is converted to the nitric acid in the nitric acid stream, and wherein the concentration of nitric acid in the nitric acid stream is from about 20% to 40% on a weight basis (w/w);

providing the nitric acid stream to an additional reactor; and

in the additional reactor, reacting the nitric acid in the nitric acid stream with ammonia to form an ammonium nitrate solution comprising the ammonium nitrate and water,

wherein heat available from the reaction mixture above its dew point is sufficient to concentrate the ammonium nitrate solution to a concentration of about 75% to 85% w/w upon application to the ammonium nitrate solution, and

wherein water that is evaporated from the ammonium nitrate solution is recycled so as to comprise at least a portion of the steam of the non-explosive oxidiser feed.

59. The method of claim 58, wherein the oxidising gas comprises a gas containing at least 90% oxygen.

60. The method of claim 59, wherein at least 95% of the nitrogen monoxide in the reaction mixture is converted to nitric acid.

61. The method of claim 60, wherein the non-explosive gaseous oxidiser feed comprises oxidising gas in an amount that is sufficient to oxidise all of the ammonia to nitrogen monoxide.

62. The method of claim 58, wherein water that is evaporated from the ammonium nitrate solution is recycled so as to comprise the predominant portion of the steam of the non-explosive gaseous oxidiser feed.

63. The method of claim 58, wherein water that is evaporated from the ammonium nitrate solution is recycled so as to comprise the total amount of steam of the non-explosive gaseous oxidiser feed.

64. The method of claim 61, wherein water that is evaporated from the ammonium nitrate solution is recycled so as to comprise the total amount of steam of the non-explosive gaseous oxidiser feed.

65. The method of claim 61, further comprising continuing the reaction-absorption process in a reactor-absorber subsequent to the heat exchanger.

66. The method of claim 65, wherein the reactor-absorber is an adiabatic reactor-absorber.

67. The method of claim 58, further comprising, prior to providing the non-explosive oxidiser feed, (i) providing an aqueous ammonia starting feed comprising ammonia and water, and (ii) heating the aqueous ammonia starting feed to a temperature that permits at least partial vaporisation of the ammonia and water of the aqueous ammonia starting feed.

68. The method of claim 67, wherein the heating of the aqueous ammonia starting feed is effected in a counterflow feed-effluent heat exchanger by heat exchange with the reaction mixture which is cooled from a temperature above its dew point to a temperature below its dew point, wherein heat exchanged in the feed-effluent heat exchanger is predominantly low-grade heat exchanged below the dew point of the reaction mixture.

69. The method of claim 68, wherein about 90% of the heat exchanged in the feed-effluent heat exchanger is low-grade below the dew point of the reaction mixture.

70. The method of claim 58, further comprising concentrating the ammonium nitrate solution by exchanging heat between the reaction mixture and the ammonium nitrate solution directly.

71. The method of claim 58, further comprising concentrating the ammonium nitrate solution by exchanging heat between the reaction mixture and the ammonium nitrate solution indirectly using an intermediate coupling loop of a heat transfer medium.

72. The method of claim 71, wherein the heat transfer medium comprises a boiling/condensing water circuit or a single-phase pressurized water circuit.

73. The method of claim 58, wherein no external source of heat is applied to the ammonium nitrate solution.

74. The method of claim 63, wherein no external source of heat is applied to the ammonium nitrate solution.

75. The method of claim 64, wherein no external source of heat is applied to the ammonium nitrate solution.

76. The method of claim 58, wherein an external source of heat is applied to the ammonium nitrate solution in addition to the heat recovered from the reaction mixture.

77. The method of claim 63, wherein an external source of heat is applied to the ammonium nitrate solution in addition to the heat recovered from the reaction mixture.

78. The method of claim 64, wherein an external source of heat is applied to the ammonium nitrate solution in addition to the heat recovered from the reaction mixture.