Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: F
ICC - Volume: 261
ICC - Report ID: 261-F
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Syngas Production from Natural Gas (Steam Reforming)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 261-A,261-B,261-C,261-D,261-E,261-G,261-H,261-I
ICC - Related Reports List: 003-A,002-C,001-A,001-B
ICC - Report Location Code: USA
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ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/261-F.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Synthesis Gas</b>. Syngas (a.k.a. Synthesis Gas) is composed primarily of carbon monoxide, carbon dioxide, and hydrogen. It is a combustible gas used as a fuel source or as an intermediate for chemicals production. Syngas may be produced from several carbon sources, either fossil feedstocks (e.g. coal, petroleum or natural gas) or renewable feedstocks (e.g. biomass, wood). This gas can be produced on industrial scale via different routes, including steam methane reforming, partial oxidation, and dry reforming; its composition varies significantly according to the process technology, the feedstock and process operating conditions.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Natural Gas</b>. Natural gas is a naturally occurring mixture of hydrocarbon found in porous subsurface geologic formations. It is composed mainly of methane, but also contains varying amounts of higher hydrocarbons such as ethane, propane, and butane. Additionally, natural gas may also include non-hydrocarbon components considered impurities such as nitrogen, carbon dioxide, and hydrogen sulfide. Natural gas is primarily used as a source of heat energy for residential, commercial, and industrial applications. It may also be used in the production of important chemicals such as ammonia, methanol, and hydrogen. </p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/261-F.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises two major sections: (1) Steam reforming; and (2) Syngas purification.</p><p>Steam reforming. Initially, natural gas passes through a desulfurization step for removal of organic sulfur compounds that poison the catalysts used in downstream reactions. The desulfurized gas is mixed with steam and sent to the Pre-Reforming, where higher hydrocarbons found in the feed gas are converted into a methane-rich gas and hydrogen. This step prevents catalysts employed downstream from having its activity decreased by the presence of higher hydrocarbons. This pre-reformed gas is mixed with recycled carbon dioxide, and fed to the steam reformer, a tubular fired heater filled with a Ni-based catalyst, where methane is reacted with steam, generating CO and hydrogen.</p><p>Syngas purification. The steam reforming product is cooled - in order to condense the water present in the gas - and then fed to a column, where it is contacted countercurrently with a methyldiethanolamine (MDEA) solution that absorbs CO2. The overhead gas stream, free of CO2, is the Syngas product, with a H2/CO molar ratio of 3. The solution withdrawn as the column bottoms product is treated in a further column for solvent recovery (CO2 desorption). The recovered CO2 is recycled to the steam reforming, with a small purge to avoid the buildup of impurities in the process.</p>
ICC - Short Description: In this report, the economic analysis concerns a process in which Syngas (Synthesis Gas) is generated from natural gas. This study examines a conventional steam reforming process. The plant is located in the United States.
ICC - Main Product: Syngas
ICC - Plant Capacity: 600.00
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Syngas Production from Natural Gas (Steam Reforming)

Syngas Production Costs Report | Issue F | Q3 2024

Production Cost Report

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600 kta United States-based plant   |   Q3 2024   |   107 pages

This report presents a cost analysis of a 600 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.

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Production Process Information

Process Consumptions

Labor Requirements

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Production Costs Datasheet

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Production Process Information

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Production Process Information

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

Operating Cost Summary

Production Costs Datasheet

Plant Capital Cost Details

Operating Cost Details

Plant Cost Breakdowns

Plant Capacity Assessment

Process Flow Diagrams

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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Syngas production plant examined

Plant Capital Cost Details

Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements

Plant Cost Breakdowns

Breakdown of Syngas process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline

Operating Costs Summary

Summary presenting the operating variable costs and the total operating cost of the Syngas production plant studied

Operating Cost Details

Detailing of utilities costs, operating fixed costs and depreciation

Plant Capacity Assessment

Comparative analysis of capital investment and operating costs for different Syngas plant capacities

Production Process Information

Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)

Process Consumptions

Raw materials and utilities consumption figures, by-products credits, labor requirements

Process Diagrams

Process flow diagrams (PFD), equipment list and industrial site configuration

Other Syngas Production Cost Reports

Syngas Production from Natural Gas (Combined Reforming)

This report approaches the Syngas (Synthesis Gas) production from natural gas via a combined reforming process. In the steam reformer, the natural gas reacts with steam and, in the secondary (autothermal) reformer, it reacts with oxygen. The economic analysis provided assumes a plant constructed in the United States.

Details: 2,500 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue G   From $799 USD

The cost analyses presented in this report target a 2,500 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Syngas Production from Coal (H2/CO Ratio of 2)

This report approaches the construction of a plant producing Syngas in China via a coal gasification process. The final product obtained in the process under analysis is Syngas with a H2/CO ratio of 2.

Details: 1,000 kta China-based plant   |   Q3 2024   |   107 pages   |   Issue H   From $799 USD

The cost analyses presented in this report target a 1,000 kta (kilo metric ton per annum per annum) China-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Other Related Production Cost Reports

Methanol Production from Natural Gas (Steam Reforming)

This study presents the economics of large-scale Methanol production from natural gas in the United States. In the process examined, natural gas is first converted into synthesis gas (syngas) by means of conventional steam reforming and then the syngas is converted into Methanol.

Details: 1,000 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 1,000 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Methanol Production from Natural Gas (Combined Reforming)

This study presents the economics of large-scale Methanol production from natural gas in the United States. In this process, natural gas is first converted into synthesis gas (syngas) by means of conventional steam reforming and secondary autothermal reforming. Then, the syngas is converted into Methanol.

Details: 1,700 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 1,700 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Ethylene Glycol Production from Carbon Dioxide

This study presents the economics of Monoethylene Glycol (MEG) production from carbon dioxide (CO2) in the United States using an electrochemical process similar to Liquid Light process. Initially, CO2 is electrochemically reduced and acidified into oxalic acid. Then, oxalic acid is esterified with methanol producing dimethyl oxalate, which is hydrogenated forming MEG.

Details: 150 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue C   From $799 USD

The cost analyses presented in this report target a 150 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Maleic Anhydride from Butane (Fixed-Bed Reactor + Solvent-Based Recovery)

This feasibility study presents an analysis of Maleic Anhydride production from n-butane in the United States using a process similar to the one developed by Huntsman. In this process, maleic anhydride is produced by the partial oxidation reaction of n-butane with oxygen carried out in a fixed-bed reactor, using a vanadium–phosphorus oxide (VPO) catalyst supported on silica. The reactor effluent is directed to a solvent-based recovery system for Maleic Anhydride separation.

Details: 60 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 60 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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