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Ammonia & Urea Plant Energy Consumption Calculation: January 2015

This document provides an example calculation of the energy consumption for an ammonia and urea production plant. It outlines the key parameters and equations used to calculate the natural gas, steam, and power energy for the ammonia and urea processes. Specific energy consumption is calculated for both the ammonia and urea plants, as well as the direct specific energy for the overall complex if only natural gas is used.

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96 views5 pages

Ammonia & Urea Plant Energy Consumption Calculation: January 2015

This document provides an example calculation of the energy consumption for an ammonia and urea production plant. It outlines the key parameters and equations used to calculate the natural gas, steam, and power energy for the ammonia and urea processes. Specific energy consumption is calculated for both the ammonia and urea plants, as well as the direct specific energy for the overall complex if only natural gas is used.

Uploaded by

IRON MAN
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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AMMONIA & UREA PLANT ENERGY CONSUMPTION CALCULATION

Article · January 2015

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Technical Paper January 2015

 
AMMONIA & UREA PLANT ENERGY CONSUMPTION CALCULATION
 
 
 
Author
Prem Baboo, Sr. Manager (Prod)
National Fertilizers Ltd., Vijaipur, India

Introduction
This Technical Paper describes how one can calculate the energy consumption of an ammonia and
urea plant.  
 

AMMONIA PLANT ENERGY CALCULATION


(This is just example)

Ammonia Energy depends upon following parameters:


1. Natural gas energy
2. Steam energy
3. Power energy

1. Natural Gas (NG) energy

NG energy

= NG consumed for ammonia plant (feed + fuel) X NG LHV


(Ammonia daily production)

= G. Cal / T NH3

NG Consumption for ammonia Plant (feed + fuel) = 1.8415 M. sm3


NG LHV = 8134 K Cal/sm3
Ammonia production = 1850 mtpd

= 1841500 X 8134
1850 X 1000000

= 8.097 G. Cal/T NH3

2. Steam Energy export

= [(SH Export to Urea-II - SH import from CPP) X805 + (SM to CT + SM to Urea hydrolyser)
X750 + (SL export to CPP) X650 - (SM import from CPP) X716)] divided by the ammonia daily
production

1
Technical Paper January 2015

KS  (100  ata)  ENTHALPY   K.CAL/KG   805  

SM(40  ata)  ENTHALPY   K.CAL/KG   750  

SM(24  ata)  ENTHALPY  


K.CAL/KG   716  
(CPP)  

SL(4.5  ata)  ENTHALPY   K.CAL/KG   650  

= (3250-1829)X805 + 150X750 + 200X650 - 54X716


1850 X 1000

= - 0.729 G Cal/ T NH3

3. Power Energy Calculation

Power consumed for ammonia plant per day = 98 MW/ day


NG/ MW = 175 sm3/MW

Power Consumed per ton of ammonia =

= (Power consumed per day for ammonia plant X NG per MW X NG LHV)


Ammonia production X 106

= 98 X 175 X 8134
1850 X 106

= 0.075 G Cal/T NH3

Now total energy for ammonia energy:

= NG energy + Steam energy + Power energy


= 8.097 - 0.729 + 0.075 G Cal/ T NH3
= 7.444 G Cal /T NH3

2
Technical Paper January 2015

UREA PLANT ENERGY CALCULATION


(This is just example)

Urea Energy depends upon following parameters:


1. Ammonia Energy
2. Steam energy
3. Power energy

1. Ammonia energy

= Specific consumption of ammonia X ammonia energy


= 0.575 X 7.444
= 4.280 G. Cal/T Urea

2. Steam energy

(i) KS energy

= KS consumption for urea plant X Enthalpy of KS


Urea production X 103

= 3500 X 805
3590 X 103

= 0.785 G. Cal/T Urea

(ii) HS Energy

= HS consumption for urea plant X Enthalpy of HS


Urea production X 103

= 160 X 750
3590 X 103

= 0.033 G. Cal/T Urea

3. Power energy

= (Power consumed per day for urea plant X NG per MW X NG LHV)


urea production X 106

= (177 X 175 X 8134)


3590 X 106

= 0.07 G. Cal /T Urea

Now total energy for specific energy of urea plant:


= Ammonia energy + Steam energy + Power energy
= 4.280 + (0.785+0.033) + 0.07
= 5.168 G. Cal/T Urea

(Power energy of urea plant is including total power consumed in town ship, CDR 50% power energy
etc.)

3
Technical Paper January 2015

This is the day energy; if any interruption (planned and unplanned shut down) than month and year
energy will be increased in terms of unproductive energy.

DIRECT SPECIFIC ENERGY CALCULATION OF COMPLEX


(If only NG is used)

Specific Energy, G Cal/MT of urea

= Hourly NG consumption for primary reformer [(feed + fuel) + GTG)] X LHV


Urea production per hour x 106

e.g. (29 November 2014)

= 180848.2 X 8161
277.75 X 106

= 5.296 G. Cal/T of Urea

______________

Legends:
CPP Captive Power Plant
CT Cooling Tower
CDR Carbon Dioxide Recovery Plant
G. Cal Giga Cal
GTG Gas Turbine Generator for power generation in Captive Power Plant
LHV Lower Heating Value
KS (100 ata steam) used in ammonia plant
HS (40 ata steam) used in urea plant
MS (24 ata steam) used in urea plant
LS (4.5 ata steam) used in urea plant
MW Mega Watt
NG Natural Gas
T metric ton

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