Fertilizer facts Ammonia production: moving towards maximum efficiency and lower GHG emissions Why is ammonia so energy intensive?
How much energy does the ammonia sector consume?
The synthesis of ammonia through the Haber Bosch process is the source of nearly all nitrogen fertilizers. On a worldwide basis, natural gas and other hydrocarbon feedstock such as coal (mostly in China) are used.
Fertilizer production consumes approximately 1.2% of the world’s total energy on an annual basis. Ammonia production accounts for the bulk, or approximately 90% of the industry’s total, with approximately 166 million tonnes produced annually.
1
4
%
65
1,2
20
80
6,8
%
Fertilizers
3,4
Pulp and paper
47,5
6,8
30 Natural gas
Coal China
Anthracite
Coal
Other
Other coal
Nonmetallic minerals
15,0
The fertilizer industry has made great strides Large gains in energy efficiency in ammonia production have been achieved over the past 30 years. Ammonia plants have been equipped with the most advanced available technologies, leading to enhanced throughput and lower overall energy consumption and reduced GJplant per tonne of ammonia CO2 emissions. For example, a typical nitrogen plant built today typically 70 uses 30% less energy per tonne of ammonia produced than one Design efficiency constructed 40 years ago (IFA).
World energy consumption by sector (eia, 2010) GJ per industrial tonne of ammonia 70
Design efficiency
60
GJ per tonne of ammonia 70
50
Design efficiency
Average of 78 plan in 2012 benchma
60
40 50
Average of 78 plants in 2012 benchmark
30 40
10 Best-in-class plants in 2012 benchmark
20 30 10 Best-in-class plants inlimit 2012 benchmark Thermodynamic 20 10
Association benchmark report indicates that the most efficient plants are 50
10
to encourage members to improve their performance. The latest
Thermodynamic limit
performing close to maximum efficiency and that incremental Average advances of 78 plants in energy efficiency have resulted in significant reduction in greenhouse in 2012 benchmark0 40 gas (GHG) emissions by nearly all the plants surveyed.
10 Best-in-class plants in 2012 benchmark
Other
19,3
60 IFA tracks progress in ammonia plant efficiency and CO2 emissions
30
Iron and steel Chemicals (including feedstocks)
Global ammonia capacity by feedstock (IFA, 2014) Energy efficiency in ammonia production is critical, since it accounts for most of the manufacturing cost and has a significant impact on the reduction of carbon dioxide (CO2) emissions from the sector.
Refining
%
0 1955 1955
1965 1965
1975
1975 1985
1985 1995
1995 2005
2005 2010
Global energy efficiency benchmark (IFA, 2012)
20 10
Thermodynamic limit www.fertilizer.org
July 2014
20