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

Technical Paper January 2015

KS (100 ata) ENTHALPY

K.CAL/KG

805

SM(40 ata) ENTHALPY

K.CAL/KG

750

SM(24 ata) ENTHALPY

(CPP)

K.CAL/KG

716

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

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.)

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