Calc Ammonia Plant Energy Consumption

GBH Enterprises, Ltd.
Calculation of an Ammonia Plant

Energy Consumption:
Case Study: #06023300
Plant Note Book Series: PNBS-0602
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CALCULATION OF 3300 T/D ACME AMMONIA PLANT
ENERGY CONSUMPTION Case Study: #06023300
CONTENTS
0 SCOPE
1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION
2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION
3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT

BURNERS OF FLARES
4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT
5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS
6 CALCULATION OF MP STEAM EXPORT
7 CALCULATION OF LP STEAM IMPORT
8 DETERMINATION OF ELECTRIC POWER CONSUMPTION
9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE

AMMONIA PLANT ISBL
10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST

RUN CONDITIONS
11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION

IN UTILITIES
12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER

CONSUMPTION IN UTILITIES

AMMONIA PLANT OSBL

AMMONIA PLANT

CALCULATION OF 3300 T/D ACME AMMONIA PLANT ENERGY
CONSUMPTION
0 SCOPE
The 3300 t/d ACME ammonia plant energy consumption shall be

calculated based on the measurements for import and export of process
and utility streams and electric power related to the ammonia production
listed below, for a test period of 72 hours.
Note: (ISBL) inside battery limits and (OSBL) outside battery limits
Streams Considered
Ammonia product
Process Feed
Process Fuel
Fuel for Flares
MP steam export for utilities
LP steam import from boiler BFW/FD turbine
Demin. water in
Demin. Water out
1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION
DCS indication of the flow measurement for natural gas feed consumption
is based on the following composition as per Design Basis.
CH4 87.5%
The natural gas composition during shall be used to determine molecular

weight and heating value of the gas. For molecular weights and heating
values of the individual components refer to GBHE_ PNBS-0601.
The influence of the instrument tolerance and the different molecular

weight on the orifice flow meter shall be accounted for by:
x MD
Vfeed = (V72 V0 )1
100 Mi

with:
MD design value for molecular mass of natural gas (xxx kg/kmol

as per Design Basis)
Mi actual molecular weight of natural gas
V0 reading from flow meter at the beginning of the 72-hour
test period
V72 reading from flow meter at the end of the 72-hour period
Vfeed actual feed consumption for 72 hours
x tolerance of flow meter
2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION:
The same gas specified under (1) is also used as reformer fuel. For the
same reasons as given above it might be necessary to correct the
measured flow by the actual molecular weight. For the time of the
performance test, a totalizer flow meter will be added to the existing
flow meter in the DCS.
Total consumption then is calculated by:
x MD
Vfuel = (V72 V0 )1
100 Mi
with:
test period
Vfuel actual fuel consumption for 72 hours

3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT
BURNERS OF FLARES:
The same gas specified under (1) is also used as fuel for the pilot burners
of the flares. For the same reasons as given above it might be necessary
to correct the measured flow by the actual molecular weight. For the time
of the test period, a totalizer flow meter will be added to the existing Flow
Meter in the DCS. Total consumption then is calculated by:
x MD
Vflare = (V72 V0 )1
100 Mi
with:

test period
Vfuel actual fuel consumption for 72 hours
As the fuel goes to two flares in the ammonia plant (syngas and ammonia)
and one belonging to the urea plant, the individual shares are allocated as
follows:
Vflare,NH3 = 32 Vflare , Vflare,urea = 31 Vflare
4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT:
Import of demin. water to the ammonia plant is measured at orifice flow

meter. For the time of the test period, a totalizer will be added in the DCS.
Temperature for enthalpy calculation is taken from the designated TI.

As temperature might vary over the course of time, enthalpy shall be
calculated separately for each 2-hour-period by
Hi = m h = VWPD,i h
where density and specific enthalpy h are calculated as function of

temperature and pressure using VDI steam tables. Temperature reading
shall be done at the end of each 2-hour interval. The demin water flow in
the interval is calculated as
x
VWPD,i = (VWPD,2 VWPD,0 )1
100
with:
VWPD,0 reading from the flow meter at the beginning of the 2-hour
time interval
VWPD,2 reading from the flow meter at the end of the 2-hour time
interval
VWPD,i actual demin. water consumption for the 2-hour time interval
x tolerance of the flow meter
Pressure is taken as 7 bar abs. fixed HOLD for this purpose as density
and enthalpy both are not significantly depending on the actual pressure in
the region of interest. Temperature tolerance of the designated TI is
neglected.
Total enthalpy flow to the plant over the 72-hour period of the test period is
then
36
H WPD,in = 1
36 H
I=1
WPD ,i

5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS
Export of preheated demin. water to utilities is measured at the designated

orifice flow meter with the totalizer flow meter. Temperature for enthalpy
calculation is taken from the designated TI.
As temperature might vary over the course of time, enthalpy shall be

calculated separately for each 2-hour-period by
Hi = mi hi = VWPD,i i hi
where density i and specific enthalpy hi are calculated as function of

temperature and pressure using VDI steam tables. Temperature reading
shall be done at the end of each 2-hour interval. The demin water flow in
the interval is calculated as
x
VWPD,i = (VWPD,2 VWPD,0 )1
100
with:
VWPD,0 reading from the designated flow meter at the

beginning of the 2-hour time interval
VWPD,2 reading from the designated flow meter at the end of
the 2-hour time interval
VWPD,i actual demin. water export for the 2-hour time interval
(negative because it is export)
x tolerance of the designated flow meter

Pressure is taken as 6 bar abs. fixed HOLD as return pressure from the
ammonia plant for this purpose as density and enthalpy both are not
significantly depending on the actual pressure in the region of interest.
Temperature tolerance of the designated TI is neglected.
Total enthalpy export from the ammonia plant over the 72-hour period of
the performance test run is then
36
H WPD,out = H WPD,i
I=1

6 Calculation of MP steam export:
MP steam export is determined as the difference
MP steam import to ammonia area

MP steam consumption of CO2 compressor turbine
MP steam export from ammonia plant
According to this definition, export (outbound flow) shall carry negative

sign. For the time of the test period, totalizers FMD_002 flow meter and
compressor turbine flow meter shall be added to the existing indications in
the DCS.
As temperature might vary over the course of time, enthalpy for both
streams shall be calculated separately for each 2-hour-period by
Hi = mi hi
where specific enthalpy hi is calculated as function of temperature and

pressure using VDI steam tables.
Flow Pressure Temperature measurement

measurement measurement
MP steam import to FMD_001 PMD- 01 A/B TI_001
ammonia area
design conditions 52 kg/cm2 g 424 C
MP steam FMD_002 PMD_02 TI_002
consumption of CO2
compr. turb.
Specific enthalpy under design conditions is h = 3253 kJ/kg.
Temperature reading shall be done at the end of each 2-hour interval. The
steam flows in the interval are calculated as below. As FMD_001 and
FMD_002 are not compensated by temperature and pressure this shall be
done using the following formula, when temperature and pressure are off
the above mentioned design conditions:
x D
mi = (m 2 m 0 )1
100 i

with:
D design value for steam density (17.25 kg/m3)

i actual steam density as function of pressure and
temperature by steam table
m0 reading from FMD_001 / FMD_002 at the beginning of the
2-hour period
m2 reading from FMD_001 / FMD_002 at the end of the 2-
hour period
mi actual steam flow for 2 hours
x tolerance of FMD_001 / FMD_002
Temperatures and pressures for the enthalpy calculation are taken from
the above table. Tolerance of temperature and pressure measurements
are neglected.
Total enthalpy of MP steam export from the ammonia plant over the 72-
hour period of the test period is then
(H Hsteam,CO2,i )
36
Hsteam,out = 1
36 steam,in,i
I=1
7 CALCULATION OF LP STEAM IMPORT
LP steam import is from utilities to the ammonia plant is measured at the

designated flow meters. Its DCS indication is corrected by pressure and
temperature. For the time of the test period, a totalizer shall be added to
the existing indication in the DCS.
As steam conditions might vary over the course of time, enthalpy for the
stream shall be calculated separately for each 2-hour-period by
Hi = mi hi
where specific enthalpy hi is calculated as function of pressure and

temperature using VDI steam tables. Pressure and temperature readings
shall be done at the end of each 2-hour interval.
Specific enthalpy under design conditions (p = 4.0 kg/cm2 g, T = 252 C)

is h = 2966 kJ/kg.

Tolerance of pressure and temperature measurements are neglected.
The steam flow in the interval is calculated by:
x
mi = (m 2 m 0 )1
100
with:
m0 reading from the designated flow meter at the beginning of

the 2-hour period
m2 reading from the designated flow meter at the end of the 2-
hour period
x tolerance of the designated flow meter
Total enthalpy of LP steam import from the ammonia plant over the 72-
hour test period is then
36
Hsteam,in = 1
36 H
I=1
i
8 DETERMINATION OF ELECTRIC POWER CONSUMPTION
The electric power consumption taken from the watt-hour meters for units
411 to 419 shall be added up.
For medium-voltage consumers these are marked by "+" in column in the

Table "Metering of medium-voltage motors" (in total 9 motors). Individual
readings can be taken for each consumer.
For low-voltage consumers these are marked by "+" in column of Table

"Metering of low-voltage switchgears and MCC" . Readings can be taken
from the receiving feeders for each switchgear. Individual consumers
marked by "" have to be subtracted by individual metering.

Summing all up, the tolerance of the measuring devices shall be
considered as follows:
x
P = (P72 P0 )1
100
with:
P0 sum of all relevant watt-hour meters at the beginning of the

72-hour period
P72 sum of all relevant watt-hour meters at the end of the 72-
hour period
P actual consumption figure for 72 hours
x tolerance of watt-hour meters (which is HOLD)

AMMONIA PLANT ISBL
The contributions from (1) to (8) are converted into energy equivalents of
consumed natural gas, then set into relation to the total ammonia
production mt and are then summed up.
As the energy equivalent of the natural gas flows, the higher heating value
(HHV) is calculated from the natural gas composition as per (1) using to
the table in GBHE_PNBS-0601, "Calculation of Caloric Value and other
Characteristic Data of Fuel Gas".
Steam and water streams are converted into their energy equivalents as
described earlier. Electric power measured in kWh is converted in kcal by
the fixed conversion factor.
1 KWh = 2885 kcal/kWh = 12.026 MJ/kWh

Total energy consumption inside battery limits (ISBL) is:
natural gas for process feed (1) HHV / mt

+ natural gas for process fuel (2) HHV / mt
+ natural gas for flares (3) HHV / mt
+ demin. water from demin. unit (4) / B HHV/LHV / mt
+ demin. water to pack. boilers (5) / B HHV/LHV / mt
+ MP steam export (6) / B HHV/LHV / mt
+ LP steam import (7) / B HHV/LHV / mt
+ electric power consumption (8) 2885 kcal/kWh / mt
= E ISBL = specific energy consumption per ton of ammonia
inside battery limits
10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST

PERIOD CONDITIONS:
According to the description in paragraph (8), the electric power

consumption taken from the watt-hour meters for
Designated A/B transfer pumps to storage (low voltage)
Designated A/B storage refrigeration compressor (medium voltage)

has to be added up.
Readings shall be taken from the MCC (low voltage) and from the
switchgear (medium voltage).
x
P = (P72 P0 )1
100
with:
P0 sum of the watt-hour meters at the beginning of the

72-hour period
P72 sum of the watt-hour meters at the end of the 72-hour
period
P actual consumption figure for 72 hours

11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION
IN UTILITIES
The share of the ammonia plant in the MP steam consumption of
designated seawater circulation pump turbines A/B, measured at

FI_001
designated closed loop circulation pump turbines A/B, measured at
FI_002 is calculated.
For the time of the test period, designated totalizer(s) flow meters shall be
added to the existing indications in the DCS.
As temperature might vary over the course of time, enthalpy for both
streams shall be calculated separately for each 2-hour-period by
Hi = mi hi
where specific enthalpy hi is calculated as function of temperature and

pressure using VDI steam tables. These readings shall be taken from:
Flow Pressure Temperature

measuremen measuremen measurement
t t
MP steam to FMD_001
A/B
MP steam to FMD_002
A/B
Specific enthalpy under design conditions is h = 3253 kJ/kg.
Temperature reading shall be done at the end of each 2-hour interval. The
steam flows in the interval are calculated as below. As the designated flow
meters are not compensated by temperature and pressure this shall be
done using the following formula, when temperature and pressure are off
the above mentioned design conditions:
x D
mi = (m 2 m 0 )1
100 i

with:
D design value for steam density (17.25 kg/m3)

i actual steam density as function of pressure and
temperature by steam table
m0 reading from the designated flow meters at the beginning of
the 2-hour period
m2 reading from the designated flow meters at the end of the 2-
hour period
x tolerance of the designated flow meters
Temperatures and pressures for the enthalpy calculation are taken from
the above table. Tolerance of temperature and pressure measurements
are neglected.
Total enthalpy of MP steam for each of the consumers over the 72-hour
test period is then
36
Ht,U = Hi , U = 435, 436
I=1
The share of the ammonia plant in this enthalpy is obtained by

multiplication with the appropriate factor fU for the respective utility unit
H435 = Ht,435 f435 , H436 = Ht,436 f436
with:
seawater pumps: f435 = 70 %

closed loop pumps: f436 = 52 %

12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER
CONSUMPTION IN UTILITIES
The electric power consumption of the following utility units has to be

considered in the ammonia plant consumption figure.
designated polished water pumps
designated cooling tower fans and seawater make-up pump
The readings of the respective watt-hour meters in the MCC (all low
voltage) have to be added up.
x
Pt = (P72 P0 )1
100
with:
P0 sum of the watt-hour meters at the beginning of the 72-hour
period
P72 sum of the watt-hour meters at the end of the 72-hour period
Pt actual consumption figure for 72 hours
The share of the ammonia plant in these powers is obtained by

multiplication with the appropriate factor fU for the respective utility unit
P433 = Pt,433 f433 , P435 = Ht,435 f435
with:
polished water pumps: f433 = 75 %

cooling tower and seawater pumps: f435 = 70 %


AMMONIA PLANT OSBL
The contributions from (10) to (12) are converted into energy equivalents
of consumed natural gas, then set into relation to the total ammonia
production mt and are then summed up, same as in paragraph (9) above.
Total energy consumption outside battery limits (OSBL) is:
electric power transfer pumps (k) 2885 kcal/kWh / mt
+ electric power storage refr. (k) 2885 kcal/kWh / mt

+ MP steam sea water (l) x f435 / B HHV/LHV / mt
+ MP steam closed loop (l) x f436 / B HHV/LHV / mt
+ electric power pol. w. (m) x f433 2885 kcal/kWh / mt
+ electric power CT (m) x f435 2885 kcal/kWh / mt
= E OSBL = specific energy consumption per ton of ammonia
outside battery limits

AMMONIA PLANT
The contributions from ISBL (9) and OSBL (13) are added. Total energy
consumption is
E = EISBL + EOSBL
Guaranteed value: 8.34 Gcal / t


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GBH Enterprises, Ltd.

Calculation of an Ammonia Plant

Process Information Disclaimer

Information contained in this publication or as otherwise supplied to Users is

Web Site: www.GBHEnterprises.com

1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION

2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION

3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT

4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT

5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS

6 CALCULATION OF MP STEAM EXPORT

7 CALCULATION OF LP STEAM IMPORT

8 DETERMINATION OF ELECTRIC POWER CONSUMPTION

9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE

10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST

11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION

12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER

13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE

14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE

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The 3300 t/d ACME ammonia plant energy consumption shall be

1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION

The natural gas composition during shall be used to determine molecular

The influence of the instrument tolerance and the different molecular

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MD design value for molecular mass of natural gas (xxx kg/kmol

2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION:

Total consumption then is calculated by:

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MD design value for molecular mass of natural gas (xxx kg/kmol

Vflare,NH3 = 32 Vflare , Vflare,urea = 31 Vflare

4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT:

Import of demin. water to the ammonia plant is measured at orifice flow

Temperature for enthalpy calculation is taken from the designated TI.

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where density and specific enthalpy h are calculated as function of

Temperature for enthalpy calculation is taken from the designated TI.

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Export of preheated demin. water to utilities is measured at the designated

As temperature might vary over the course of time, enthalpy shall be

where density i and specific enthalpy hi are calculated as function of

VWPD,0 reading from the designated flow meter at the

Temperature for enthalpy calculation is taken from the designated TI.

Temperature tolerance of the designated TI is neglected.

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MP steam export is determined as the difference

MP steam import to ammonia area

According to this definition, export (outbound flow) shall carry negative

where specific enthalpy hi is calculated as function of temperature and

Flow Pressure Temperature measurement

Specific enthalpy under design conditions is h = 3253 kJ/kg.

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D design value for steam density (17.25 kg/m3)

7 CALCULATION OF LP STEAM IMPORT

LP steam import is from utilities to the ammonia plant is measured at the

where specific enthalpy hi is calculated as function of pressure and

Specific enthalpy under design conditions (p = 4.0 kg/cm2 g, T = 252 C)

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The steam flow in the interval is calculated by:

m0 reading from the designated flow meter at the beginning of

8 DETERMINATION OF ELECTRIC POWER CONSUMPTION

For medium-voltage consumers these are marked by "+" in column in the

For low-voltage consumers these are marked by "+" in column of Table

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