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1.

Electricity Requirements
In the plant, there are several equipment which need electricity to operate. So it is
necessary to calculate and determine the plants electricity demand. In this
assignment, the requirements calculated are only for equipments that are involved
directly with the process, so the requirements for other needs such as for the offices
and the manufacturing units will be excluded. The calculation for electricity
requirements must consider the power consumption of each equipment. There will
be two calculations made, which are the electricity requrements before the
installment of heat exchanger networks and after the installment of heat exchanger
networks. The calculation are made by using HYSYS simulation. Shown below is
the table for the electricity requirements for the plants process equipment before
heat exchanger network installment:
No. Equipment Power Usage Power Required
Code (kJ/h) Time (h) (kJ/day)
1 P-101 33,278.4 24 798,681.6
2 P-102 34,099.2 24 818,380
3 P-103 161,856 24 3,884,544
TOTAL 5,501,606.4
And shown below is the table for the electricity requirements for the plants process
equipment after heat exchanger network installment:
No. Equipment Power Usage Power Required
Code (kJ/h) Time (h) (kJ/day)
1 P-101 32,099.616 24 770,390.784
2 P-102 38,260.08 24 918,241.92
3 P-103 193,442 24 4,642,617.6
TOTAL 6,331,250.304
To summarize, total demand of electricity for the plants process equipment shown
by the table below:
Before Heat Exchanger Network 5,501,606.4 kJ/day
After Heat Exchanger Network 6,331,250.304 kJ/day
The total demand of electricity needed after heat exchanger network installment is
higher than the total demand before heat exchanger network installment, with
differential of 829,643.904 kJ/day. This raise in electricity requirement after heat
exchanger installation is because by installing heat exchanger network there will be
higher need of electricity due to the pumps raising duty needed to pump streams to
heat exchangers. To operate the plant continously, stable electricity must be
supplied continously. This plants electricity is generated a gas turbine generator
(GTG) as the main power supply. In addition to the main power supply, the plants
electricity is also supported by emergency power provided by emergency diesel
generator sets and uninterruptible power supply (USP). Emergency diesel generator
will be operated to provide critical electricity if any disruption or failure occurs to
the main power supply.
2. Fuel Requirements
Fuel are needed in the plant to generate power for some equipment, such as
steam reformer and gas turbine generator. In steam generator, natural gas will be
used as fuel for combustion of water in furnace to provide steams that would be
used as the reboilers heater in heat exchanger. Gas turbine generator (GTG) will
need natural gas as its fuel to generate electricity for the plant. There are also a
furnace which is needed to heat a stream which outlet temperature is too high for
heating using steam. The furnace also needs natural gas as its fuel for the
combustion process.
The calculation of fuel requirements for the conversion of water to steam is
made using Microsoft Excel, using assumptions such as:
1. Inlet water temperatures are 30 oC
2. Outlet steam temperature are 250 oC
3. There are zero pressure drops
4. All water boiled converted into steam based on HHV of fuel calculations
5. Water composition and steam composition are 100% H2O
6. Combustion efficiency is at 80%
By using the formula of:
= . . 100 + . + . . 250
There also are two calculations made for fuel requirements, with the first being
the fuel requirements before installation of heat exchanger network and the second
being the fuel requirements after installation of heat exchanger networks. Both
calculations have the same calculation steps and method.
The calculations of fuel requirements before heat exchanger networks could be
described as:
Heat of boiler needed for conversion (Q) : 650,625,308.9 kJ/hr
Higher Heating Value (HHV) of natural gas : 48,620 kJ/kg

Mass of natural gas needed : = 16,727.30638 kg/hr =

401,455.3531 kg/day
The calculation of fuel requirements for turbine gas generator could be
calculated using the same formula based on the assumption that generator efficiency
is at 40% without cogeneration. This calculation could be described as:
Plant electricity demand : 229,233.6 kJ/hr
Higher Heating Value (HHV) of natural gas : 48,620 kJ/kg

Mass of natural gas needed : = 11.7870 kg/hr = 282.8880 kg/day

The calculation of fuel requirements for furnace firing could be calculated by


using the assumption of 80% combustion efficiency. The heat of furnace is
caculated by Microsoft Excel using certain formula. This calculation could be
described as:
Heat of furnace needed (Q) : 351,981,229.3 kJ/hr
Higher Heating Value (HHV) of natural gas : 48,620 kJ/kg

Mass of natural gas needed : = 9,049.291169 kg/hr =

217,182.9881 kg/day
From all the calculations, the total of natural gas needed for one day could be
determined:
Total natural gas needed = Natural gas for boiler + Natural gas for GTG + Natural
gas for furnace
Total natural gas needed = 401,455.3531 kg/day + 282.8880 kg/day +
217,182.981 kg/day = 618,921.2292 kg/day
The calculations of fuel requirements after heat exchanger network installment
can be described as:
Heat of boiler needed for conversion (Q) : 632,475,034.9 kJ/hr
Higher Heating Value (HHV) of natural gas : 48,620 kJ/kg

Mass of natural gas needed : = 16,260.67038 kg/hr =

390,256.0890 kg/day
The calculation of fuel requirements for turbine gas generator could be
calculated using the same formula based on the assumption that generator efficiency
is at 40% without cogeneration. This calculation could be described as:
Plant electricity demand : 263,801.696 kJ/hr
Higher Heating Value (HHV) of natural gas : 48,620 kJ/kg

Mass of natural gas needed : = 13.5645 kg/hr = 325.5471 kg/day
The calculation of fuel requirements for furnace firing could be calculated by
using the assumption of 80% combustion efficiency. The heat of furnace is
caculated by Microsoft Excel using certain formula. This calculation could be
described as:
Heat of furnace needed (Q) : 16,804,800 kJ/hr
Higher Heating Value (HHV) of natural gas : 48,620 kJ/kg

Mass of natural gas needed : = 432.044 kg/hr = 10,369.066

kg/day
From all the calculations, the total of natural gas needed for one day could be
determined:
Total natural gas needed = Natural gas for boiler + Natural gas for GTG + Natural
gas for furnace
Total natural gas needed = 390,256.0890 kg/day + 325.5471 kg/day + 10,369.066
kg/day = 400,950.7024 kg/day
To summarize, table ... shows the comparison between both fuel requirements:
Before Heat Exchanger Network 618,921.2292 kg/day
After Heat Exchanger Network 400,950.7024 kg/day

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