Economic-energy-exergy-risk (3ER) assessment of novel integrated ammonia synthesis process and modified sulfur-iodine cycle for co-production of ammonia and sulfuric acid

• Published in: The Korean journal of chemical engineering Vol. 38; no. 12; pp. 2381 - 2396
• Main Authors: Park, JunKyu, Jeon, Junsung, Um, Wooyong
• Format: Journal Article
• Language: English
• Published: New York Springer US 01.12.2021; Springer Nature B.V; 한국화학공학회
• Subjects: Accidents; Ammonia; Biotechnology; Catalysis; Chemistry; Chemistry and Materials Science; Cogeneration; Decomposition; Exergy; Failure rates; Fire damage; Flow velocity; Industrial Chemistry/Chemical Engineering; Iodine; Materials Science; Process Safety; Process Systems Engineering; Structural damage; Sulfur; Sulfuric acid; Temperature gradients; 화학공학; Ammonia; 3ER Analysis; Sulfuric Acid; Polygeneration; Hydrogen
• DOI: 10.1007/s11814-021-0896-z
• ISSN: 0256-1115

A novel integrated modified sulfur cycle and ammonia production process was suggested for the co-generation of sulfuric acid. Exergy analysis, heat integration, and safety assessment were conducted to investigate the feasibility and analyze the process. The exergy analysis showed that the highest exergy destruction occurred in the section with the most considerable temperature difference involved with a large flow rate. The heat integration — an economic assessment, confirmed that the total cost was estimated to be reduced by 10.9% at the minimum temperature difference of 39 °C. The failure rate contribution to the overall system was 19%, 11%, 22%, and 47% from the Bunsen section, H 2 SO 4 concentration section, HI decomposition section, ammonia production section explosion, fire, and structural damage contributed 82%, 16%, and 2% to the overall system in terms of accident scenario. The accident cost contributed 84% and 16% of accident injury costs to the overall system, respectively. For the sectional based contribution, section 1 (Bunsen process), SA concentration, section 3, and ammonia production process contributed 45%, 29%, 19%, and 6% to the accident injury cost in the overall system, respectively. As a result of individual section failure to the whole section, failure in Bunsen process and HI decomposition led to failure in production of all the products. Failure in NH 3 production section led to production in concentrated H 2 SO 4 and H 2 . The failure in H 2 SO 4 section leads to production in NH 3 and diluted H 2 SO 4 concentration. The failure in H 2 SO 4 concentration, NH 3 production, and Bunsen process and HI decomposition contributed to the higher failure rate in ascending order.