Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 72
ICC - Report ID: 072-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Prilled Urea Production from Ammonia (Self-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-C,072-D,072-E,072-F,072-G,072-H
ICC - Related Reports List: 070-B
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"799","2":"799","3":"799"},"2":{"1":"1599","2":"1599","3":"1599"},"3":{"1":"2699","2":"2699","3":"2699"}},"currency":"USD"}
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-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Urea Prills</b>. Urea (a.k.a. Carbamide) is an nitrogenous organic compound composed of a carbonyl group attached to two amine groups, which plays an important role in many biological processes, being a product of the decomposition of proteins. Carbamide is found as white and odorless solid, soluble in water, with very low toxicity. Urea has the highest nitrogen content between all solid nitrogen-based fertilizers, and for that, it is mostly used as a nitrogen-release fertilizer.</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>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-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Reaction; (2) Carbamate Decomposition; and (3) Urea Concentration.</p><p>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.</p><p>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.</p><p>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.</p><p></p>
ICC - Short Description: 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.
ICC - Main Product: Urea
ICC - Plant Capacity: 1300.00
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Prilled Urea Production from Ammonia (Self-Stripping Process)

Urea Production Costs Report | Issue A | Q2 2024

Production Cost Report

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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.

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Production Process Information

Process Consumptions

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Production Costs Datasheet

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Production Process Information

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Production Costs Datasheet

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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

Other Urea Production Cost Reports

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

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.

Prilled Urea Production from Ammonia (CO2 Stripping Process)

This report examines the costs related to Prilled Urea production from ammonia and carbon dioxide in the USA. The process examined in this report is similar to Stamicarbon's carbon dioxide stripping process. 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.

Details: 1,300 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   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.

Granulated Urea Production from Ammonia (Self-Stripping Process)

This study approaches the economics of Granulated Urea production from ammonia and carbon dioxide in the United States through Saipem's (formerly Snamprogetti) ammonia 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 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 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.

Granulated Urea Production from Ammonia (CO2 Stripping Process)

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.

Details: 1,300 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   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.

Prilled Urea Production from Natural Gas

This report examines the economics of Prilled Urea manufacturing from natural gas in an industrial complex located in the United States. Initially, natural gas is converted to syngas by steam and autothermal reforming. The syngas is mixed with nitrogen to produce ammonia. The ammonia formed is reacted with carbon dioxide, to form urea via ammonium carbamate.

Details: 1,300 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue E   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 (Self-Stripping Process)

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   |   Q2 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   |   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.

Granulated Urea Production from Natural Gas (CO2 Stripping Process)

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 Stamicarbon’s carbon dioxide stripping technology.

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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Other Related Production Cost Reports

Ammonia Production from Natural Gas (Combined Reforming)

This report presents the economics of Ammonia production from natural gas in the United States using a process similar to KBR Purifier process. In the process examined, syngas is initially produced from natural gas via a combined reforming. The syngas is purified through several steps into nitrogen and hydrogen which are synthesized to ammonia.

Details: 800 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $1,199 USD

The cost analyses presented in this report target a 800 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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