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Retrofit of ammonia plant for improving energy efficiency

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  • Panjeshahi, M.H.
  • Ghasemian Langeroudi, E.
  • Tahouni, N.

Abstract

The aim of this work is to perform a retrofit study of an ammonia plant, in purpose of improving energy efficiency. As a common practice, one can divide an ammonia plant into two parts: the hot-end and the cold-end. In the hot section, two different options are investigated that both lead to a threshold condition and achieve maximum energy saving. The first option covers only process-to-process energy integration, while the second option considers some modification in the convection section of the primary reformer through a new arrangement of the heating coils. Thus, a considerable reduction in cooling water, HP steam and fuel gas consumption is achieved. In the cold section, retrofit study is dominated by reducing the amount of shaft work or power consumption in the refrigeration system. Application of the Combined Pinch & Exergy Analysis revealed that part of the shaft work, which was originally being used, was inefficient and could have been avoided in a well-integrated design. Therefore, by proposing optimum refrigeration levels, reasonable saving (15%) in power consumption was observed without the need for new investment.

Suggested Citation

  • Panjeshahi, M.H. & Ghasemian Langeroudi, E. & Tahouni, N., 2008. "Retrofit of ammonia plant for improving energy efficiency," Energy, Elsevier, vol. 33(1), pages 46-64.
    • Handle: RePEc:eee:energy:v:33:y:2008:i:1:p:46-64
    DOI: 10.1016/j.energy.2007.08.011
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    References listed on IDEAS

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    1. Liu, Meng & Zhang, Na, 2007. "Proposal and analysis of a novel ammonia–water cycle for power and refrigeration cogeneration," Energy, Elsevier, vol. 32(6), pages 961-970.
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    1. Soltani, Hadi & Shafiei, Sirous, 2011. "Heat exchanger networks retrofit with considering pressure drop by coupling genetic algorithm with LP (linear programming) and ILP (integer linear programming) methods," Energy, Elsevier, vol. 36(5), pages 2381-2391.
    2. Flórez-Orrego, Daniel & de Oliveira Junior, Silvio, 2017. "Exergy assessment of single and dual pressure industrial ammonia synthesis units," Energy, Elsevier, vol. 141(C), pages 2540-2558.
    3. Kirova-Yordanova, Zornitza, 2017. "Exergy-based estimation and comparison of urea and ammonium nitrate production efficiency and environmental impact," Energy, Elsevier, vol. 140(P1), pages 158-169.
    4. Du, S. & Wang, R.Z. & Xia, Z.Z., 2014. "Optimal ammonia water absorption refrigeration cycle with maximum internal heat recovery derived from pinch technology," Energy, Elsevier, vol. 68(C), pages 862-869.
    5. Fatemeh Goodarzvand-Chegini & Esmaeil GhasemiKafrudi, 2017. "Application of exergy analysis to improve the heat integration efficiency in a hydrocracking process," Energy & Environment, , vol. 28(5-6), pages 564-579, September.
    6. Chen, Yuhong & Lyu, Yanfeng & Yang, Xiangdong & Zhang, Xiaohong & Pan, Hengyu & Wu, Jun & Lei, Yongjia & Zhang, Yanzong & Wang, Guiyin & Xu, Min & Luo, Hongbin, 2022. "Performance comparison of urea production using one set of integrated indicators considering energy use, economic cost and emissions’ impacts: A case from China," Energy, Elsevier, vol. 254(PC).
    7. Flórez-Orrego, Daniel & de Oliveira Junior, Silvio, 2017. "Modeling and optimization of an industrial ammonia synthesis unit: An exergy approach," Energy, Elsevier, vol. 137(C), pages 234-250.
    8. Mei-Ling, Zheng & Wen, Wang, 2010. "Seasonal energy utilization optimization in an enterprise," Energy, Elsevier, vol. 35(9), pages 3932-3940.
    9. Wang, Yufei & Feng, Xiao & Cai, Yan & Zhu, Maobin & Chu, Khim H., 2009. "Improving a process's efficiency by exploiting heat pockets in its heat exchange network," Energy, Elsevier, vol. 34(11), pages 1925-1932.
    10. Sardarmehni, Mojtaba & Tahouni, Nassim & Panjeshahi, M. Hassan, 2017. "Benchmarking of olefin plant cold-end for shaft work consumption, using process integration concepts," Energy, Elsevier, vol. 127(C), pages 623-633.
    11. Flórez-Orrego, Daniel & de Oliveira Junior, Silvio, 2016. "On the efficiency, exergy costs and CO2 emission cost allocation for an integrated syngas and ammonia production plant," Energy, Elsevier, vol. 117(P2), pages 341-360.
    12. Huang, Kefeng & Karimi, I.A., 2016. "Work-heat exchanger network synthesis (WHENS)," Energy, Elsevier, vol. 113(C), pages 1006-1017.
    13. Mehdizadeh, Fariba & Tahouni, Nassim & Panjeshahi, M. Hassan, 2022. "Total site exergy analysis, using a new conceptual method," Energy, Elsevier, vol. 250(C).
    14. Zhang, Di & Lv, Donghui & Yin, Changfang & Liu, Guilian, 2020. "Combined pinch and mathematical programming method for coupling integration of reactor and threshold heat exchanger network," Energy, Elsevier, vol. 205(C).
    15. Hackl, Roman & Harvey, Simon, 2013. "Applying exergy and total site analysis for targeting refrigeration shaft power in industrial clusters," Energy, Elsevier, vol. 55(C), pages 5-14.
    16. Longyu Shi & Lingyu Liu & Bin Yang & Gonghan Sheng & Tong Xu, 2020. "Evaluation of Industrial Urea Energy Consumption (EC) Based on Life Cycle Assessment (LCA)," Sustainability, MDPI, vol. 12(9), pages 1-17, May.
    17. Michalsky, Ronald & Parman, Bryon J. & Amanor-Boadu, Vincent & Pfromm, Peter H., 2012. "Solar thermochemical production of ammonia from water, air and sunlight: Thermodynamic and economic analyses," Energy, Elsevier, vol. 42(1), pages 251-260.

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