Development and multi-objective optimization of a newly proposed industrial heat recovery based cascaded hydrogen and ammonia synthesis system

Abstract

The industrial flue gas emitted to the atmosphere is considered not only harmful to the environment but also a waste of plentiful resources of thermal energy. The thermal energy extracted from the industrial flue gas can be employed for multiple purposes. This study proposes a new configuration to integrate the thermal management of industrial flue gas for thermochemical copper-chlorine (Cu-Cl) cycle based ammonia synthesis. A reverse osmosis desalination unit is employed to supply the freshwater required by the thermochemical Cu-Cl cycle. To recover the heat from high-temperature oxygen stream, thermoelectric generators (TEGs) and organic Rankine cycle (ORC) are integrated with the proposed configuration to utilize the low-grade waste heat for power production. A portion of produced hydrogen through the thermochemical Cu-Cl cycle is supplied to the cascaded system for ammonia production. A double-stage cascaded ammonia synthesis system is integrated with the proposed configuration to achieve high fractional conversion. A multi-objective optimization using genetic algorithm is implemented to the proposed system using the MATLAB to investigate and determine the best-operating temperatures and pressures for the ammonia synthesis system. The proposed configuration produces 518.4 kmol/day of hydrogen and 226.8 kmol/day of ammonia. The overall exergetic and energetic efficiencies are found to be 28.7% and 40.8%. Moreover, the results obtained from the comprehensive sensitivity analyses are presented and discussed.