Comprehensive energy consumption for ammonia synthesis
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Comprehensive energy consumption for ammonia synthesis! ! ! Everyone, share! ! ! ! ! ! !
LZ, please first share information on your consumption of coal, steam, recycled water, and electricity. It would also be good to describe the characteristics of your production process as well as its scale
Cost Items, Unit Quantity, Unit Price (RMB 000/RMB/mt), % Variation Cost
Raw Materials, Synthesis Gas (Nm3): 11970, 000000, 0.746892, 6281, 98391.22
Subtotal: 892,6281,98391.22
Circulating Water, △t=10℃: t10,586.00, 0.16914,31231.81, 1.46
Desalinated Water: 7.00, 3.00, 1680.37, 0.02
Fresh Water: 2.08, 0.63, 6110.02, 0.00
11. Boiler Feed Water, 5.6MPa: 52.70, 4.00, 1,6863.75, 0.17
Electricity: 487.00, 0.31, 51,2272.73, 0.13
Medium-Pressure Steam, 3.82MPa: at79.90, 121.40, 77,599172.44, 7.93
By-product Medium-Pressure Steam, 3.9MPa: -51.12, 119.70, -48,953-108.78, -5.00
Low-Pressure Steam, 0.6MPa: 9.50, 107.50, 8,17018.16, 0.83
Instrument Air, 0.7MPaNm3: 200.00, 0.068109, 0.24, 0.01
Subtotal: 54,330120.73, 5.55
Total: 946,9582,10497
Fixed Costs
Direct Labor/Year: 3350,000, 1650, 3.67, 0.17
Indirect Labor/Year: 4150,000, 600, 1.33, 0.06
Depreciation/Year: 22,167, 49.26, 2.27
Maintenance Costs/Year: 7,223, 16.05, 0.74
Consumables:
Taxes:
Basic Fees:
Others:
Subtotal: 31,64070.31, 3.23
Manufacturing Costs: 978,5982,174100
Selling, Administration, and Financial Expenses:
Financial Expenses:
Subtotal:
Total Manufacturing and Selling Costs:
Net Profit Before Income Tax:
Income Tax Withheld:
Net Profit After Tax:
Break-Even Point, Quantity:
Amount:
Total Investment Amount:
Payback Period
Raw Materials, Synthesis Gas (Nm3): 11970, 000000, 0.746892, 6281, 98391.22
Subtotal: 892,6281,98391.22
Circulating Water, △t=10℃: t10,586.00, 0.16914,31231.81, 1.46
Desalinated Water: 7.00, 3.00, 1680.37, 0.02
Fresh Water: 2.08, 0.63, 6110.02, 0.00
11. Boiler Feed Water, 5.6MPa: 52.70, 4.00, 1,6863.75, 0.17
Electricity: 487.00, 0.31, 51,2272.73, 0.13
Medium-Pressure Steam, 3.82MPa: at79.90, 121.40, 77,599172.44, 7.93
By-product Medium-Pressure Steam, 3.9MPa: -51.12, 119.70, -48,953-108.78, -5.00
Low-Pressure Steam, 0.6MPa: 9.50, 107.50, 8,17018.16, 0.83
Instrument Air, 0.7MPaNm3: 200.00, 0.068109, 0.24, 0.01
Subtotal: 54,330120.73, 5.55
Total: 946,9582,10497
Fixed Costs
Direct Labor/Year: 3350,000, 1650, 3.67, 0.17
Indirect Labor/Year: 4150,000, 600, 1.33, 0.06
Depreciation/Year: 22,167, 49.26, 2.27
Maintenance Costs/Year: 7,223, 16.05, 0.74
Consumables:
Taxes:
Basic Fees:
Others:
Subtotal: 31,64070.31, 3.23
Manufacturing Costs: 978,5982,174100
Selling, Administration, and Financial Expenses:
Financial Expenses:
Subtotal:
Total Manufacturing and Selling Costs:
Net Profit Before Income Tax:
Income Tax Withheld:
Net Profit After Tax:
Break-Even Point, Quantity:
Amount:
Total Investment Amount:
Payback Period
It’s not very comprehensive. The consumption of coal, water, electricity, and steam needs to be mentioned, as well as the production volumes of ammonia, ammonium carbonate, urea, sulfur, etc. Your scale isn’t that large after all
Approximately 1300 kg of standard coal per ton; natural gas consumption is 880–900 Nm3 per ton, while electricity consumption is 875–890 kwh per ton. Steam consumption totals around 700 kg per ton, and river water usage is 5–7 tons per ton. Desalinated water consumption is 1.8–2.5 tons per ton.
Different gasification technologies and process routes should be employed; it is recommended to classify them into two categories based on the currently popular gasification processes: fixed-bed and fluidized-bed. Purification processes: NHD and low-temperature methanol washing. Refining: Alkoholization and methanation
Serial Number, Name and Specifications, Unit, Hourly Consumption, Annual Consumption (based on 330 production days per year), Remarks
I. Consumption
1. Raw gas, Nm3: 164,334; Annual consumption: 1.302×109
2. Methanol, Kg: 110; Annual consumption: 8.712×105
3. Desalinated water, tons: 363; Annual consumption: 2.875×106. Of this, 113 tons/hour is provided by the power plant.
4. Circulating cooling water, tons: 14,943.4; Annual consumption: 1.184×107
5. Electricity, kWh: 6,239.2; Annual consumption: 4.942×107
6. Medium-pressure nitrogen, Nm3: 27,993.2; Annual consumption: 2.217×108
7. Low-pressure nitrogen, Nm3: 18,600; Annual consumption: 1.473×108
8. Steam at 10.0 Mpa (G), tons: 268.3; Annual consumption: 2.125×106. This includes the amount supplied to the joint venture portion. Steam at 4.0 Mpa (G), tons: 171.7; Annual consumption: 1.36×106. This includes amounts supplied to both the joint venture and the urea production unit.
9. Auxiliary materials
Pre-reformation catalyst QBS-01, m3: 15. Lifespan: 2 years.
Mid-reformation catalyst QCS-03, m3: 40.45. Lifespan: 4 years.
Low-reformation catalyst QCS-04, m3: 15.2. Lifespan: 4 years.
Methanation catalyst, m3: 2.9. Lifespan: 7 years.
ZnO desulfurization catalyst, m3: 3.82. Lifespan: 4 years.
Ammonia synthesis catalyst, m3: 4.29. Lifespan: 7 years.
II. Outputs
1. Hydrogen (purity: 90.09%), Nm3: 27,614; Annual consumption: 2.187×108. Supply to the chemical processing area: 26,000; Supply to the joint venture plant: 1,614.
2. Acidic gas, Nm3: 4,628; Annual consumption: 3.665×107. All of it is supplied to the sulfuric acid production unit.
3. Boiler water at 7.3 Mpa and 160°C, tons: 129; Annual consumption: 1.022×106. Supplied to the gasifier of the joint venture plant. Water at 0.4 Mpa and 96.5°C, tons: 515.7; Annual consumption: 4.084×106. This water is recycled to the power plant.
4. Turbine condensate, tons: 220.16; Annual consumption: 1.744×106. This is the condensate generated by the air separation unit and the new ice machine.
5. Process waste heat, Kcal: 38.21×106
6. Cooling capacity, Kcal: 0.6×106. Supplied to the air separation unit of the joint venture plant.
7. Process water, tons: 30; Annual consumption: 2.38×105
8. Steam at 1.10 Mpa (G), tons: 60; Annual consumption: 4.75×105. Supplied to the chemical processing area
I. Consumption
1. Raw gas, Nm3: 164,334; Annual consumption: 1.302×109
2. Methanol, Kg: 110; Annual consumption: 8.712×105
3. Desalinated water, tons: 363; Annual consumption: 2.875×106. Of this, 113 tons/hour is provided by the power plant.
4. Circulating cooling water, tons: 14,943.4; Annual consumption: 1.184×107
5. Electricity, kWh: 6,239.2; Annual consumption: 4.942×107
6. Medium-pressure nitrogen, Nm3: 27,993.2; Annual consumption: 2.217×108
7. Low-pressure nitrogen, Nm3: 18,600; Annual consumption: 1.473×108
8. Steam at 10.0 Mpa (G), tons: 268.3; Annual consumption: 2.125×106. This includes the amount supplied to the joint venture portion. Steam at 4.0 Mpa (G), tons: 171.7; Annual consumption: 1.36×106. This includes amounts supplied to both the joint venture and the urea production unit.
9. Auxiliary materials
Pre-reformation catalyst QBS-01, m3: 15. Lifespan: 2 years.
Mid-reformation catalyst QCS-03, m3: 40.45. Lifespan: 4 years.
Low-reformation catalyst QCS-04, m3: 15.2. Lifespan: 4 years.
Methanation catalyst, m3: 2.9. Lifespan: 7 years.
ZnO desulfurization catalyst, m3: 3.82. Lifespan: 4 years.
Ammonia synthesis catalyst, m3: 4.29. Lifespan: 7 years.
II. Outputs
1. Hydrogen (purity: 90.09%), Nm3: 27,614; Annual consumption: 2.187×108. Supply to the chemical processing area: 26,000; Supply to the joint venture plant: 1,614.
2. Acidic gas, Nm3: 4,628; Annual consumption: 3.665×107. All of it is supplied to the sulfuric acid production unit.
3. Boiler water at 7.3 Mpa and 160°C, tons: 129; Annual consumption: 1.022×106. Supplied to the gasifier of the joint venture plant. Water at 0.4 Mpa and 96.5°C, tons: 515.7; Annual consumption: 4.084×106. This water is recycled to the power plant.
4. Turbine condensate, tons: 220.16; Annual consumption: 1.744×106. This is the condensate generated by the air separation unit and the new ice machine.
5. Process waste heat, Kcal: 38.21×106
6. Cooling capacity, Kcal: 0.6×106. Supplied to the air separation unit of the joint venture plant.
7. Process water, tons: 30; Annual consumption: 2.38×105
8. Steam at 1.10 Mpa (G), tons: 60; Annual consumption: 4.75×105. Supplied to the chemical processing area