GBH Enterprises, Ltd.

Calculation of an Ammonia Plant
Energy Consumption:
Case Study: #06023300
Plant Note Book Series: PNBS-0602

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Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries

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WATER FROM DEMIN. 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.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .com . 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 13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL 14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology .GBHEnterprises. UNIT 5 CALCULATION OF DEMIN.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.

Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. CH4 87. water in Demin. 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 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology .GBHEnterprises. 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. For molecular weights and heating values of the individual components refer to GBHE_ PNBS-0601. 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.5% The natural gas composition during shall be used to determine molecular weight and heating value of the gas.com . 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.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology . for a test period of 72 hours.

com .Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. 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. Total consumption then is calculated by:  x  MD Vfuel = (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 Vfuel actual fuel consumption for 72 hours x tolerance of flow meter Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology . a totalizer flow meter will be added to the existing flow meter in the DCS. For the same reasons as given above it might be necessary to correct the measured flow by the actual molecular weight.GBHEnterprises. For the time of the performance test.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .

Vflare. water to the ammonia plant is measured at orifice flow meter.urea = 31 Vflare 4 CALCULATION OF DEMIN. For the same reasons as given above it might be necessary to correct the measured flow by the actual molecular weight.GBHEnterprises. UNIT: Import of demin.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. For the time of the test period.com . For the time of the test period. Temperature for enthalpy calculation is taken from the designated TI. a totalizer flow meter will be added to the existing Flow Meter in the DCS. the individual shares are allocated as follows: Vflare. Total consumption then is calculated by:  x  MD Vflare = (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 Vfuel actual fuel consumption for 72 hours x tolerance of flow meter As the fuel goes to two flares in the ammonia plant (syngas and ammonia) and one belonging to the urea plant. WATER FROM DEMIN.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology . 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. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology . a totalizer will be added in the DCS.NH3 = 32 Vflare .

Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .i = (VWPD.i ρ h where density ρ and specific enthalpy h are calculated as function of temperature and pressure using VDI steam tables.com .2 reading from the flow meter at the end of the 2-hour time interval VWPD.in = 1 36 ∑H I=1 WPD .i Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology . Temperature reading shall be done at the end of each 2-hour interval. Total enthalpy flow to the plant over the 72-hour period of the test period is then 36 H WPD.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.0 )1 −   100  with: VWPD. 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. enthalpy shall be calculated separately for each 2-hour-period by Hi = m h = VWPD.0 reading from the flow meter at the beginning of the 2-hour time interval VWPD.2 − VWPD. Pressure is taken as 7 bar abs. As temperature might vary over the course of time.i actual demin.GBHEnterprises. The demin water flow in the interval is calculated as  x  VWPD. water consumption for the 2-hour time interval x tolerance of the flow meter Temperature for enthalpy calculation is taken from the designated TI.

Temperature for enthalpy calculation is taken from the designated TI.2 − VWPD.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .i I=1 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology . Total enthalpy export from the ammonia plant over the 72-hour period of the performance test run is then 36 H WPD.i actual demin.0 )1 −   100  with: VWPD. 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.i = −(VWPD. water export for the 2-hour time interval (negative because it is export) x tolerance of the designated flow meter Temperature for enthalpy calculation is taken from the designated TI. enthalpy shall be calculated separately for each 2-hour-period by Hi = mi hi = VWPD.GBHEnterprises. Temperature reading shall be done at the end of each 2-hour interval.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.com . WATER TO PACKAGE BOILERS Export of preheated demin. water to utilities is measured at the designated orifice flow meter with the totalizer flow meter. 5 CALCULATION OF DEMIN. As temperature might vary over the course of time.i ρi hi where density ρi and specific enthalpy hi are calculated as function of temperature and pressure using VDI steam tables.out = ∑ H WPD. Pressure is taken as 6 bar abs. Temperature tolerance of the designated TI is neglected.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. The demin water flow in the interval is calculated as  x  VWPD.

– design conditions 52 kg/cm2 g 424 °C Specific enthalpy under design conditions is h = 3253 kJ/kg. totalizers FMD_002 flow meter and compressor turbine flow meter shall be added to the existing indications in the DCS.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology . turb. Temperature reading shall be done at the end of each 2-hour interval.GBHEnterprises. As FMD_001 and FMD_002 are not compensated by temperature and pressure this shall be done using the following formula.com . export (outbound flow) shall carry negative sign. 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. when temperature and pressure are off the above mentioned design conditions:  x  ρD mi = (m 2 − m 0 )1 −   100  ρi Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology . The steam flows in the interval are calculated as below. 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.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. Flow Pressure Temperature measurement measurement measurement MP steam import to FMD_001 PMD. For the time of the test period. As temperature might vary over the course of time.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.

a totalizer shall be added to the existing indication in the DCS.i ) 36 Hsteam.25 kg/m3) ρi 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. T = 252 °C) is h = 2966 kJ/kg.GBHEnterprises. Tolerance of temperature and pressure measurements are neglected. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology .0 kg/cm2 g. For the time of the test period. Total enthalpy of MP steam export from the ammonia plant over the 72- hour period of the test period is then ∑ (H − Hsteam. Pressure and temperature readings shall be done at the end of each 2-hour interval. As steam conditions might vary over the course of time.CO2.com .out = 1 36 steam. with: ρD design value for steam density (17. Specific enthalpy under design conditions (p = 4.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .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.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.in. 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.

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 mi actual steam flow for 2 hours 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.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology . Tolerance of pressure and temperature measurements are neglected.GBHEnterprises. • For low-voltage consumers these are marked by "+" in column of Table "Metering of low-voltage switchgears and MCC" . Individual consumers marked by "–" have to be subtracted by individual metering.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).com . Individual readings can be taken for each consumer. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology .Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. Readings can be taken from the receiving feeders for each switchgear.

"Calculation of Caloric Value and other Characteristic Data of Fuel Gas". 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) 9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT ISBL The contributions from (1) to (8) are converted into energy equivalents of consumed natural gas. As the energy equivalent of the natural gas flows. Electric power measured in kWh is converted in kcal by the fixed conversion factor.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .GBHEnterprises.026 MJ/kWh Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology . then set into relation to the total ammonia production mt and are then summed up. the higher heating value (HHV) is calculated from the natural gas composition as per (1) using to the table in GBHE_PNBS-0601. Steam and water streams are converted into their energy equivalents as described earlier. 1 KWh = 2885 kcal/kWh = 12.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. Summing all up.com .

 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 x tolerance of watt-hour meters (which is HOLD) Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology .com . 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.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. water from demin. Readings shall be taken from the MCC (low voltage) and from the switchgear (medium voltage). unit (4) / ηB × HHV/LHV / mt + demin. boilers (5) / ηB × HHV/LHV / mt + MP steam export (6) / ηB × HHV/LHV / mt + LP steam import (7) / ηB × 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). water to pack. 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.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .GBHEnterprises.

As temperature might vary over the course of time. Temperature reading shall be done at the end of each 2-hour interval. These readings shall be taken from: Flow Pressure Temperature measuremen measuremen measurement t t MP steam to FMD_001 A/B – design conditions 52 kg/cm2 g 424 °C MP steam to FMD_002 A/B – design conditions 52 kg/cm2 g 424 °C Specific enthalpy under design conditions is h = 3253 kJ/kg. 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.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology . 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_002 is calculated. when temperature and pressure are off the above mentioned design conditions:  x  ρD mi = (m 2 − m 0 )1 −   100  ρi Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology .com . 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. designated totalizer(s) flow meters shall be added to the existing indications in the DCS.GBHEnterprises.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. measured at FI_001 • designated closed loop circulation pump turbines A/B. For the time of the test period.

com . Total enthalpy of MP steam for each of the consumers over the 72-hour test period is then 36 Ht. with: ρD design value for steam density (17.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .25 kg/m3) ρi 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 mi actual steam flow for 2 hours x tolerance of the designated flow meters Temperatures and pressures for the enthalpy calculation are taken from the above table.U = ∑ Hi . H436 = Ht. U = 435.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.435 f435 .436 f436 with: • seawater pumps: f435 = 70 % • closed loop pumps: f436 = 52 % Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology . Tolerance of temperature and pressure measurements are neglected. 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.GBHEnterprises.

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.433 f433 .Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.435 f435 with: • polished water pumps: f433 = 75 % • cooling tower and seawater pumps: f435 = 70 % • Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology .GBHEnterprises. • 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. P435 = Ht.  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 x tolerance of watt-hour meters (which is HOLD) 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.com .

GBHEnterprises. 13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL The contributions from (10) to (12) are converted into energy equivalents of consumed natural gas. Total energy consumption outside battery limits (OSBL) is: electric power transfer pumps (k) × 2885 kcal/kWh / mt + electric power storage refr.Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www. then set into relation to the total ammonia production mt and are then summed up.34 Gcal / t Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology . (k) × 2885 kcal/kWh / mt + MP steam sea water (l) x f435 / ηB × HHV/LHV / mt + MP steam closed loop (l) x f436 / ηB × 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 14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT The contributions from ISBL (9) and OSBL (13) are added. same as in paragraph (9) above.Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .com . Total energy consumption is E = EISBL + EOSBL Guaranteed value: 8.

GBHEnterprises.Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology .Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology .Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.com .