Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: D
ICC - Volume: 72
ICC - Report ID: 072-D
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Granulated Urea Production from Ammonia (CO2 Stripping Process)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 072-A,072-B,072-E,072-F,072-C,072-G,072-H
ICC - Related Reports List: 197-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/072-D.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Urea Granules </b>. Urea is a nitrogenous compound composed of a carbonyl group attached to two amine groups. This chemical plays an important role in many biological processes, but it is also an important material used in synthesis (e.g. resins and plastics), in fertilizers and animal rations. On industrial scale, Urea is produced almost exclusively by the dehydration of ammonium carbamate, derived in turn from the reaction between ammonia and carbon dioxide. Commercial manufacturing processes generate aqueous solutions containing 70–87% urea, that are further processed into granules.</p> <h6>Raw Materials</h6> <p><b>Carbon Dioxide</b>. Carbon dioxide is a colorless and incombustible gas with chemical formula CO2; a naturally occurring chemical present in the atmosphere. Formed during respiration, this gas is obtained by several ways and at various scales, based on carbon-based fuels combustion, carbohydrates fermentation, limestone thermal decomposition, as byproduct of the industrial production of hydrogen by steam reforming and ammonia synthesis, etc. Carbon dioxide is a versatile chemical with a number of applications, being widely used in the production of carbonated beverages, as an inert gas and as a pressurizing gas. In the chemical industry, it is mainly used in the production of urea, methanol, metal carbonates and bicarbonates.</p> <b>Chemicals</b>. </p> <b>Ammonia</b>. Ammonia is a pungent gas used as a fertilizer, refrigerant, and a key building block in the synthesis of numerous chemicals, including nitric acid and urea. It is also an essential precursor for producing explosives and plastics. Ammonia is synthesized via the Haber-Bosch process, combining nitrogen from the air with hydrogen under high pressure. Stored as a compressed gas or liquid, ammonia’s ability to act as a refrigerant makes it essential in large-scale cooling systems for industrial applications.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/072-D.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises two major sections: (1) Urea Formation; and (2) Urea Treatment, Granulation and Packing.</p><p>Urea Formation. Carbon Dioxide (CO2) is compressed and fed to a stripping column, where unconverted carbamate in the urea solution from reactor downstream is decomposed into ammonia (NH3) and CO2, which are stripped off by the CO2 feed. The urea solution is routed to a Low Pressure (LP) Decomposer downstream, while the off-gas is fed to a pool condenser, along with fresh NH3 and recovered carbamate solution from downstream. In this vessel, NH3 and CO2 react forming carbamate. A gas-liquid mixture is directed to a reactor where the Urea is generated. An Urea solution is routed to CO2 stripping, while a gaseous stream is directed to a High Pressure (HP) Scrubber, where water, unreacted CO2 and NH3 are absorbed in a carbamate solution and conveyed to the pool condenser. Non-condensables withdrawn from the HP Scrubber are directed to NH3 Absorbers downstream, where they are washed with process condensate, and the off-gas, virtually free of NH3, is purged.</p><p>Urea Treatment, Granulation and Packing. The urea solution from the CO2 Stripping is fed to the LP Decomposer to remove residual NH3 and CO2, which are then condensed, generating a carbamate solution that is used in the HP Scrubber. The urea solution, virtually free of carbamate, is concentrated in Evaporators, and sent to the Granulation area, while the process condensate is directed to the Condensate Treatment area, where it is treated and can be used in other parts of the plant. Urea melt, from the evaporators, is sprayed with atomization air from the bottom of the granulator into a fluid bed where the droplets are dried and granules are formed. The granules are subsequently cooled and screened. The onsize granules are cooled again and sent to the Packing area, where they are packed in bags before being stored. Both undersize and oversize materials are recycled to the granulator.</p>
ICC - Short Description: This report provides a techno-economic analysis of Granulated Urea production from ammonia and carbon dioxide in the United States through Stamicarbon’s carbon dioxide stripping technology. In this process, ammonia and carbon dioxide are converted to Urea via ammonium carbamate intermediate. The non-converted carbamate is stripped from the Urea solution by carbon dioxide and decomposed back to ammonia and carbon dioxide, which are recycled to the Urea synthesis.
ICC - Main Product: Urea
ICC - Plant Capacity: 1300.00
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Granulated Urea Production from Ammonia (CO2 Stripping Process)

Urea Production Costs Report | Issue D | Q3 2024

Production Cost Report

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1,300 kta United States-based plant   |   Q3 2024   |   107 pages

This report presents a cost analysis of a 1,300 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

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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 Urea 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 Urea 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 Urea 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 Urea 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

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This study approaches the economics of Granulated Urea manufacturing from natural gas in an industrial complex, located in the United States. Initially, natural gas is converted to syngas via a combined reforming. The syngas is mixed with nitrogen to produce ammonia. The ammonia formed is reacted with carbon dioxide, to form urea in a process similar to Saipem's (formerly Snamprogetti) process.

Details: 1,300 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue F   From $1,199 USD

The cost analyses presented in this report target a 1,300 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.

Granulated Urea Production from Natural Gas (Chemical Looping Process)

This study approaches the economics of Granulated Urea manufacturing from natural gas in an industrial complex with a novel plant configuration, where a unit that produces ammonia from natural gas using chemical looping reactors is integrated to a Urea production unit. The economic analysis provided assumes a complex located in the USA.

Details: 1,300 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue G   From $1,199 USD

The cost analyses presented in this report target a 1,300 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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This report presents a techno-economic analysis of Hexamethylene Diisocyanate (HDI) production from hexamethylene diamine (HMDA) in the United States. The process presented in this report is a non-phosgene process similar to BASF process. Initially, HMDA reacts with urea and butanol generating a carbamate intermediate. Then, the carbamate is thermally cracked producing HDI.

Details: 20 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue B   From $799 USD

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