Conversion of urea to reactants for NOx reduction

Abstract

The invention provides a system for converting urea into reactants useful for removing NO X from industrial emissions. The system includes a urea inlet, a steam inlet, and a reactor in fluid communication with the urea inlet and the steam inlet. The reactor is configured and adapted to inject urea from the urea inlet into a steam flow from the steam inlet to convert the urea into at least one reactant for NO X reduction within a substantially gaseous mixture. The invention also provides a method of converting urea into reactants for reducing NO X out of industrial emissions. The method includes injecting urea into a steam flow to convert the urea into at least one reactant for NO X reduction within a substantially gaseous mixture.

1 . A system for converting urea into reactants for removing NO X  from industrial emissions, the system comprising:
 a) a urea inlet;   b) a steam inlet; and   c) a reactor in fluid communication with the urea inlet and the steam inlet, the reactor being configured and adapted to inject urea from the urea inlet into a steam flow from the steam inlet to convert the urea into at least one reactant for NO X  reduction within a substantially gaseous mixture.   
     
     
         2 . A system for converting urea as recited in  claim 1 , further comprising a urea source in fluid communication with the urea inlet. 
     
     
         3 . A system for converting urea as recited in  claim 2 , further comprising a steam source in fluid communication with the steam inlet. 
     
     
         4 . A system for converting urea as recited in  claim 1 , wherein the reactor is configured and adapted to convert urea into at least one reactant for NO X  reduction through a chemical process including hydrolysis. 
     
     
         5 . A system for converting urea as recited in  claim 1 , wherein the reactor is configured and adapted to convert urea into at least one reactant for NO X  reduction through a chemical process including decomposition. 
     
     
         6 . A system for converting urea as recited in  claim 1 , wherein the reactor is configured and adapted to convert urea into at least one reactant for NO X  reduction through a chemical process including hydrolysis and decomposition. 
     
     
         7 . A system for converting urea as recited in  claim 1 , wherein the urea inlet includes a nozzle configured and adapted to inject urea into the reactor. 
     
     
         8 . A system for converting urea as recited in  claim 7 , wherein the nozzle is configured and adapted to atomize urea being injected into the reactor. 
     
     
         9 . (canceled) 
     
     
         10 . A system for converting urea as recited in  claim 8 , wherein the nozzle is configured and adapted to atomize aqueous urea with assistance from another fluid. 
     
     
         11 . A system for converting urea as recited in  claim 8 , wherein the urea inlet is configured and adapted to inject an aqueous solution of 1-75% urea into the reactor. 
     
     
         12 . A system for converting urea as recited in  claim 7 , wherein the nozzle is configured and adapted to inject molten urea into the reactor. 
     
     
         13 . A system for converting urea as recited in  claim 1 , wherein the reactor and steam inlet are configured and adapted to supply a flow of superheated steam for converting urea in the reactor. 
     
     
         14 . (canceled) 
     
     
         15 . A system for converting urea as recited in  claim 1 , wherein the reactor includes an internal flow passage of sufficient volume to provide residence time to convert substantially all of the urea from the substantially gaseous mixture flowing therethrough. 
     
     
         16 . A system for converting urea as recited in  claim 1 , wherein the urea inlet includes a heat source for pre-heating urea prior to injection into the reactor. 
     
     
         17 - 19 . (canceled) 
     
     
         20 . A system for converting urea as recited in  claim 1 , wherein the reactor is configured and adapted to accommodate the substantially gaseous mixture at a temperature in the range of about 500° F. to about 1600° F. 
     
     
         21 . A system for converting urea as recited in  claim 1 , wherein the reactor is configured and adapted to accommodate the substantially gaseous mixture at a temperature in the range of about 1000° F. to about 1050° F. 
     
     
         22 . (canceled) 
     
     
         23 . A system for converting urea as recited in  claim 22 , wherein the reactor includes a heater configured and adapted to maintain at least a portion of the surface of the reactor at an elevated temperature to prevent condensation thereon. 
     
     
         24 - 48 . (canceled)