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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
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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
DCS indication of the flow measurement for natural gas feed consumption
is based on the following composition as per Design Basis.
CH4 87.5%
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 - 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
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.
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 - 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
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:
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:
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
Hi = m h = VWPD,i h
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
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
Hi = mi hi = VWPD,i i hi
x
VWPD,i = (VWPD,2 VWPD,0 )1
100
with:
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
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
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
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
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
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
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
x
mi = (m 2 m 0 )1
100
with:
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
The electric power consumption taken from the watt-hour meters for units
411 to 419 shall be added up.
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
x
P = (P72 P0 )1
100
with:
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.
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
Readings shall be taken from the MCC (low voltage) and from the
switchgear (medium voltage).
x
P = (P72 P0 )1
100
with:
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
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
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
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
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
with:
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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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
x tolerance of watt-hour meters (which is HOLD)
with:
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
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.
The contributions from ISBL (9) and OSBL (13) are added. Total energy
consumption is
E = EISBL + EOSBL
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