Use Case: Ammonia Process Energy Minimization

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<div class="text-blue-900 uppercase">• April 2024</div> </div> </div> </div> <div class="w-full h-full"> <picture> <img src="data:image/svg+xml;charset=utf-8,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%2716%27%20height%3D%279%27%20style%3D%27background%3Atransparent%27%2F%3E" srcset="https://craft-ferolabs.transforms.svdcdn.com/production/AdobeStock_523127495.jpeg?w=2500&h=1000&q=80&fm=webp&fit=crop&crop=focalpoint&fp-x=0.5&fp-y=0.5&dm=1711116264&s=e229e61f45d41c9a955aaa6974734114 2500w" sizes="100vw" class="w-full h-full object-cover" alt="Adobe Stock 523127495" > </picture> </div> </div> </section> <section id="content"> <section class="padding-t-small padding-b-small container"> <div class="max-w-content mx-auto"> <div class="flex flex-col lg:gap-12 lg:flex-row lg:justify-between"> <aside class="order-last lg:order-first lg:sticky lg:top-32 lg:h-min"> <div> <div class="overline-2 text-blue-500">Share</div> <ul class="flex flex-row items-center gap-4 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class="blog-share-svg" title="Copy link to clipboard" x-on:click="$nextTick(() => { navigator.clipboard.writeText('https://www.ferolabs.com/insights/post/ammonia-process-energy-minimization'); })"> <svg xmlns="http://www.w3.org/2000/svg" width="24" height="24" viewBox="0 0 24 24" fill="none" stroke="currentColor" stroke-width="1.25" stroke-linecap="round" stroke-linejoin="round"><path stroke="none" d="M0 0h24v24H0z" fill="none"/><path d="M9 15l6 -6" /><path d="M11 6l.463 -.536a5 5 0 0 1 7.071 7.072l-.534 .464" /><path d="M13 18l-.397 .534a5.068 5.068 0 0 1 -7.127 0a4.972 4.972 0 0 1 0 -7.071l.524 -.463" /></svg> </button> </li> </ul> </div> </aside> <article class="lg:max-w-[720px] mx-auto large-letter"> <section class=" bg-white " > <div class="container padding-t-default padding-b-default"> <div class="max-w-content mx-auto"> <div class="w-full"> <div class=" text-neutral-900 rich-text text-base"><h2>Use Case Description</h2><h4><strong>Background</strong></h4><p>The Haber process, a continuous chemical reaction, trades off yield maximization and energy efficiency. Through regulating parameters like temperature and pressure in the reaction between nitrogen and hydrogen over iron catalysts, ammonia production can be optimized. This process is highly energy-intensive, with ammonia synthesis accounting for 1.8% of global energy consumption. It's recognized as the largest carbon dioxide-emitting chemical process.</p><h4><strong>Problem</strong></h4><p><strong>Process engineers</strong> are aware of production conditions that promote the forward reaction in the Haber process to maximize yield. This awareness will be in the form of experience as well as empirical historical data. Energy efficiency steps may be in place too but again these are typically implemented based on experience and historical trends.</p><p>Yield maximization is a critical aspect of the Haber process. The reaction is highly exothermic and reversible, and the ultimate yield of ammonia is influenced by various factors, including temperature, pressure, catalyst selection, and gas composition. Adapting these factors to maximize high yields <strong>under varying production conditions, is challenging to do in real-time</strong>.</p><p>While maximizing yield, process engineers also endeavor to maximize energy efficiency. Typically this is tackled by minimizing the cost of compressing feed gas by controlling for recycle and feed compressor ratios, operating conditions, etc. Additionally, engineers wish to reduce CO₂ emissions by minimizing the amount of methane burned to produce steam for the steam reforming reaction.</p><blockquote><p>Maximize ammonia yield while minimizing energy consumption and CO₂ emissions.</p></blockquote><p>Ammonia production is incredibly energy intensive, predominantly due to steam methane reforming. Improving the energy efficiency of ammonia production is critical to producers. Not least because ammonia, primarily used for fertilizer production today, is increasingly being seen as a zero-carbon fuel. This is because ammonia can act as a medium store and transport for chemical energy, as a transport fuel, and as a store for thermal energy.</p><p>The current approach to ammonia yield maximization can lead to:</p><ul><li>financial loss due to unnecessary usage of fuel, and</li><li>environmental cost of incurring Scope 2 emissions due to unnecessary consumption of fuel.</li></ul><p><a href="https://craft-ferolabs.files.svdcdn.com/production/PDF/Fero-Playbook-Ammonia-Process-Energy-Minimization.pdf?dm=1712589586"><span class="text-orange-500"><strong>Click here to download the entire Playbook</strong></span></a></p><p> </p><h2>Fero Labs Solution</h2><p>Ammonia producers can use Fero Labs software to ensure maximum yield of ammonia during the continuous Haber process while minimizing energy usage and CO₂ emissions. Fero can adapt to process restrictions such as minimum and maximum permitted temperatures and pressures in reactors, while adapting to variable production conditions.</p><p>A “Live Fero Analysis” for this use case presents two screens:</p><ul><li>Detailed View: for <strong>process engineers</strong> to monitor production and take action at any moment. Here, Fero recommends how yield can be maximized under current production conditions. Restrictions can be placed on the maximum allowed values for temperature and pressure, enabling engineers to safely explore energy minimization objectives while continuing to maximize yield.</li></ul><figure class="image"><img src="https://craft-ferolabs.transforms.svdcdn.com/production/Graphics/Screenshot-2024-01-12-at-11.05.21.png?w=914&h=468&auto=compress%2Cformat&fit=crop&dm=1711116544&s=c96c748e2a70a2b26a2d1df35a222245" alt="" width="914" height="468" /></figure><ul><li><span>Simplified View</span>: for <strong>plant operators</strong> to know exactly what action to take to maximize yield and minimize energy consumption.</li></ul><figure class="image"><img src="https://craft-ferolabs.transforms.svdcdn.com/production/Graphics/Screenshot-2024-01-12-at-11.05.30.png?w=912&h=425&auto=compress%2Cformat&fit=crop&dm=1711116624&s=8728d570ae962b30ec6d2fd063104238" alt="" width="912" height="425" /></figure><p> </p><h2>Process & Business Outcomes</h2><p><span class="text-orange-500"><strong>Increased production line profitability</strong></span></p><p>Maximizing ammonia yield makes the production line more profitable for two reasons: fewer reactants are wasted creating by-products and increased profit potential due to a higher volume of end product being produced.</p><p>Ammonia plants leveraging Fero across their operations can expect <strong>up to 1.5%</strong> yield improvement, providing top-line growth opportunity.</p><p> </p><p><span class="text-orange-500"><strong>Tightened yield control and stability</strong></span></p><p>With Fero Labs providing optimal recommendations for maximizing ammonia yield, the variability of process yield over time will be reduced, allowing for a more efficient and stable process.</p><p>With full adoption of Fero Labs on the production line, ammonia plant operators can see up to <strong>10% reduction</strong> in yield variability.</p><p> </p><p><span class="text-orange-500"><strong>Energy cost minimization</strong></span></p><p>Ammonia plant operators seek to minimize the amount of energy consumed during production. Overly aggressive reduction campaigns deliver diminishing returns as the trade-off involves reduced yields. In turn, unnecessarily high temperatures accelerate catalyst deterioration and carry high costs.</p><p>With Fero deployed on an average-sized production line with average energy cost of $0.14/kWh, plant operators can easily surpass <strong>$1 million</strong> <strong>in</strong> <strong>savings per year.</strong></p><p> </p><p><span class="text-orange-500"><strong>Commensurate Scope 2 carbon minimization</strong></span></p><p>Reducing energy consumption directly reduces the Scope 2 carbon footprint of ammonia production. Since Scope 2 accounts for about one-third of traditional ammonia production’s footprint, reducing energy consumption leads to a commensurate <strong>3–4%</strong> <strong>reduction</strong> in Scope 2 emissions. Fero can provide reporting capabilities that directly track and account for this reduction.</p></div> </div> </div> </div> </section> <section class=" bg-white " > <div class="container padding-t-default padding-b-default"> <div class="max-w-content mx-auto"> <div class="w-full"> <div class=" text-neutral-900 rich-text text-base"><h2>Fero Labs Adoption Timeline</h2><p>Plant teams can collaborate to set up and deploy Fero Labs. Below is a timeline highlighting typical steps. With Fero’s easy-to-use, no-code interface, this can be achieved in a matter of weeks, not months or years.</p></div> <ul class="flex flex-col md:flex-row items-start md:items-center flex-wrap gap-x-5 gap-y-8 mt-5 md:mt-8 justify-left"> <li> <a href="https://www.ferolabs.com/index.php/actions/asset-count/count?id=76204" target="_blank" class="link text-lg font-bold underline text-orange-500 hover:text-blue-200" >Download the Playbook for Timeline details </a> </li> </ul> </div> </div> </div> </section> <section class=" bg-white " > <div class="container padding-t-default padding-b-default"> <div class="max-w-content mx-auto"> <div class="w-full"> <div class=" text-neutral-900 rich-text text-base"><h2>Data Requirements</h2><p>Plant teams can collaborate to set up and deploy Fero. Below is a timeline highlighting typical steps. With Fero’s easy-to-use, no-code interface, this can be achieved in a matter of weeks, not months or years.</p></div> <ul class="flex flex-col md:flex-row items-start md:items-center flex-wrap gap-x-5 gap-y-8 mt-5 md:mt-8 justify-left"> <li> <a href="https://www.ferolabs.com/index.php/actions/asset-count/count?id=76204" target="_blank" class="link text-lg font-bold underline text-orange-500 hover:text-blue-200" >Only available in the Playbook - download now! </a> </li> </ul> </div> </div> </div> </section> <section class=" bg-white " > <div class="container padding-t-default padding-b-default"> <div class="max-w-content mx-auto"> <div class="w-full"> <div class=" text-neutral-900 rich-text text-base"><h2><span class="text-blue-500"><strong>Activating This Use Case</strong></span></h2><p>Consider our Industrial Use Case Playbooks as inspiration and tactical ideas for your team to align on to maximize the efficiencies of your plant.<br /> </p><p>Each Playbook has a matching <span class="text-blue-500"><strong>Use Case Blueprint</strong></span> which provides more detailed steps to activate each use case within the Fero Labs platform.</p><p>If you’re curious to see these in action please <a href="https://www.ferolabs.com/get-in-touch">book a free feasibility study</a> with our team!</p><p>Together, let us continue to push the boundaries of what's possible, driving towards a future where industrial manufacturing is not just efficient and sustainable but truly transformative in its impact on society and the world at large.</p><p>Thank you for joining us on this journey, and we look forward to continuing to partner with you in your pursuit of excellence.<br /><br />Download the entire <span class="text-blue-500"><strong>Ammonia Process Energy Minimization Playbook</strong></span><strong> </strong>to access additional tables and details about this industrial use case.</p></div> <ul class="flex flex-col md:flex-row items-start md:items-center flex-wrap gap-x-5 gap-y-8 mt-5 md:mt-8 justify-left"> <li> <a href="https://www.ferolabs.com/index.php/actions/asset-count/count?id=76204" target="_blank" class="link text-lg font-bold underline text-orange-500 hover:text-blue-200" >Click here to download the entire Playbook </a> </li> </ul> </div> </div> </div> </section> </article> <aside class="hidden lg:block lg:sticky lg:top-40 lg:h-min"> <div class="overline-2 text-blue-500">See more insights</div> <ul class="flex flex-col gap-5"> <li> <a href="/insights?category=chemicals" class="text-neutral-900 transition-classes hover:text-orange-500"> Chemicals </a> </li> <li> <a href="/insights?category=use-case" class="text-neutral-900 transition-classes hover:text-orange-500"> Use case </a> </li> </ul> </aside> </div> </div> </section> <section class="padding-t-default padding-b-default bg-neutral-50"> <div class="container"> <div class="max-w-content mx-auto"> <div class="flex flex-col md:flex-row md:items-center md:justify-between gap-6 mb-8 md:mb-12"> 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data-src="data:image/svg+xml;charset=utf-8,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%2716%27%20height%3D%279%27%20style%3D%27background%3Atransparent%27%2F%3E" data-srcset="https://craft-ferolabs.transforms.svdcdn.com/production/AdobeStock_119443055_2024-03-27-004647_rwwh.jpeg?w=950&h=534&q=80&fm=webp&fit=crop&crop=focalpoint&fp-x=0.5&fp-y=0.5&dm=1711500408&s=4140768d1b157f650a435fdb15603a85 950w" sizes="100vw" class="lazyload w-full transform transition-all duration-300 ease-out group-hover:scale-105" alt="Adobe Stock 119443055" > </picture> </div> <div class="p-7 border border-neutral-100 bg-white flex-grow"> <div class="flex flex-row gap-3 flex-wrap"> <div class="bg-neutral-50 text-blue-900 py-[2px] px-[5px]"> Chemicals </div> <div class="bg-neutral-50 text-blue-900 py-[2px] px-[5px]"> Use case </div> </div> <h3 class="text-neutral-900 h4 line-clamp-3 mt-[7px]">Use Case: Pesticide Batch Yield Maximization</h3> <span class="absolute bottom-4 right-5"> <svg class="transition-all duration-300 ease-out group-hover:translate-x-1 fill-neutral-900" width="14" height="11" viewBox="0 0 14 11" version="1.1" xmlns="http://www.w3.org/2000/svg" xmlns:xlink="http://www.w3.org/1999/xlink"> <title>Right Arrow</title> <desc>An arrow pointing right</desc> <g id="Canvas" transform="translate(-8270 -4747)"> <g id="Group"> <g id="Vector"> <use xlink:href="#path0_stroke" transform="matrix(6.12323e-17 -1 1 6.12323e-17 8271 4752.73)"/> </g> <g id="Vector"> <use xlink:href="#path1_stroke" transform="matrix(6.12323e-17 -1 1 6.12323e-17 8278.77 4757.46)"/> </g> </g> </g> <defs> <path id="path0_stroke" d="M 0.5 0C 0.5 -0.276142 0.276142 -0.5 0 -0.5C -0.276142 -0.5 -0.5 -0.276142 -0.5 0L 0.5 0ZM -0.5 12.5C -0.5 12.7761 -0.276142 13 0 13C 0.276142 13 0.5 12.7761 0.5 12.5L -0.5 12.5ZM -0.5 0L -0.5 12.5L 0.5 12.5L 0.5 0L -0.5 0Z"/> <path id="path1_stroke" d="M 9.81301 0.353553C 10.0083 0.158291 10.0083 -0.158291 9.81301 -0.353553C 9.61775 -0.548816 9.30117 -0.548816 9.10591 -0.353553L 9.81301 0.353553ZM 4.72973 4.72973L 4.37618 5.08328C 4.57144 5.27855 4.88802 5.27855 5.08328 5.08328L 4.72973 4.72973ZM 0.353553 -0.353553C 0.158291 -0.548816 -0.158291 -0.548816 -0.353553 -0.353553C -0.548816 -0.158291 -0.548816 0.158291 -0.353553 0.353553L 0.353553 -0.353553ZM 9.10591 -0.353553L 4.37618 4.37618L 5.08328 5.08328L 9.81301 0.353553L 9.10591 -0.353553ZM 5.08328 4.37618L 0.353553 -0.353553L -0.353553 0.353553L 4.37618 5.08328L 5.08328 4.37618Z"/> </defs> </svg> </span> </div> </a> <a href="https://www.ferolabs.com/insights/post/use-case-vinyl-chloride-monomer-purity-forecasting" class="flex flex-col group relative"> <div class="overflow-hidden"> <picture> <img data-src="data:image/svg+xml;charset=utf-8,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%2716%27%20height%3D%279%27%20style%3D%27background%3Atransparent%27%2F%3E" data-srcset="https://craft-ferolabs.transforms.svdcdn.com/production/AdobeStock_762421107_2024-03-26-235343_ftwd.jpeg?w=950&h=534&q=80&fm=webp&fit=crop&crop=focalpoint&fp-x=0.5&fp-y=0.5&dm=1711497223&s=ff3c5234df7fcc5dc8d36a879dabd63a 950w" sizes="100vw" class="lazyload w-full transform transition-all duration-300 ease-out group-hover:scale-105" alt="Adobe Stock 762421107" > </picture> </div> <div class="p-7 border border-neutral-100 bg-white flex-grow"> <div class="flex flex-row gap-3 flex-wrap"> <div class="bg-neutral-50 text-blue-900 py-[2px] px-[5px]"> Chemicals </div> <div class="bg-neutral-50 text-blue-900 py-[2px] px-[5px]"> Use case </div> </div> <h3 class="text-neutral-900 h4 line-clamp-3 mt-[7px]">Use Case: Vinyl Chloride Monomer Purity Forecasting</h3> <span class="absolute bottom-4 right-5"> <svg class="transition-all duration-300 ease-out group-hover:translate-x-1 fill-neutral-900" width="14" height="11" viewBox="0 0 14 11" version="1.1" xmlns="http://www.w3.org/2000/svg" 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class="h4 mb-0">Speed to Solution: Where AI Delivers Its Greatest Value</h2> </div> </a> </li> </ul> </div> </div> </div> </div> </div></div> </div> </div> <script type="application/ld+json">{"@context":"http://schema.org","@graph":[{"@type":"WebSite","author":{"@id":"https://www.ferolabs.com/#identity"},"copyrightHolder":{"@id":"https://www.ferolabs.com/#identity"},"copyrightYear":"2024","creator":{"@id":"https://camelcasecollective.com#creator"},"dateCreated":"2024-03-22T10:03:36-04:00","dateModified":"2024-06-03T11:28:39-04:00","datePublished":"2024-04-08T11:22:00-04:00","description":"Use this technical AI use case playbook to maximize ammonia yield while minimizing energy consumption and CO₂ emissions. 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