Prilled Urea Production from Ammonia (Self-Stripping Process)
Urea Production Costs Report | Issue A | Q2 2024
Report Details |
1,300 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
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.
Report Abstract
This report presents the economics of Prilled Urea production from ammonia and carbon dioxide in the United States, through a process similar to Saipem's (formerly Snamprogetti) ammonia stripping process. In this process, ammonia and carbon dioxide are reacted to form ammonium carbamate, which is converted to Urea. The non-converted carbamate is stripped from the Urea solution by excess ammonia and decomposed back to ammonia and carbon dioxide, which are recycled to the Urea synthesis.
The report provides a comprehensive study of Urea production and related Urea production cost, covering three key aspects: a complete description of the Urea production process examined; an in-depth analysis of the related Urea plant capital cost (Capex); and an evaluation of the respective Urea plant operating costs (Opex).
The Urea production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Urea plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Urea plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Reaction; (2) Carbamate Decomposition; and (3) Urea Concentration.
Reaction. Initially, carbon dioxide and a liquid mixture of ammonia and carbamate, recovered downstream, are fed to the urea reactor, part of the high pressure synthesis loop. Here the ammonia and the carbon dioxide react yielding ammonia carbamate and urea.
Carbamate Decomposition. The reactor effluent, containing carbamate, is fed to a falling-film stripper where excess NH3 strips out the carbamate from the effluent. The off-gas from the stripper is absorbed in a liquid carbamate stream and fed to a kettle-type boiler to be condensed and recycled to the reactor. The heat exchanged is used to produce steam. The urea solution is directed to two successive decomposers for the removal of residual carbamate and carbon dioxide. After decomposition of carbamate and evaporation of ammonia, a urea solution substantially free of carbamate is obtained. The off-gas from the decomposers is rectified in a medium pressure absorber, from which gaseous ammonia and a liquid ammonium carbamate stream are obtained. The ammonia is condensed, mixed with fresh ammonia and routed to urea synthesis; while the ammonium carbamate is directed to the condenser.
Urea Concentration. At this point the urea-water mixture is concentrated in a two-stage evaporator, forming a urea melt. The vapor obtained is condensed and directed to a condensate treatment. The treatment consists in stripping/hydrolyzer steps; the condensate obtained is used as process water and boiler feed water, while off-gas containing ammonia and carbon dioxide is recycled to urea synthesis. The urea melt is sprayed at the top of a prilling tower, forming spheroidal urea particles – prills –which are packed in bags and stored.
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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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Prilled Urea Production from Ammonia (Self-Stripping Process)
This report presents the economics of Prilled Urea production from ammonia and carbon dioxide in the United States, through a process similar to Saipem's (formerly Snamprogetti) ammonia stripping process. In this process, ammonia and carbon dioxide are reacted to form ammonium carbamate, which is converted to Urea. The non-converted carbamate is stripped from the Urea solution by excess ammonia and decomposed back to ammonia and carbon dioxide, which are recycled to the Urea synthesis.
Details: 1,300 kta United States-based plant | Q2 2024 | 107 pages | Issue A From $799 USD
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Details: 1,300 kta United States-based plant | Q2 2024 | 107 pages | Issue C From $799 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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Details: 1,300 kta United States-based plant | Q2 2024 | 107 pages | Issue D From $799 USD
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Details: 1,300 kta United States-based plant | Q2 2024 | 107 pages | Issue F From $1,199 USD
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Details: 1,300 kta United States-based plant | Q2 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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Details: 1,300 kta United States-based plant | Q2 2024 | 107 pages | Issue H 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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