Commodity Production Costs Report
Ammonia Production from Natural Gas (Chemical Looping Process)
Ammonia Operating Costs & Plant Construction Costs
This study approaches the economics of Ammonia manufacturing from natural gas in the United States. This report assumes a novel plant configuration reported in the literature, in which three chemical looping reactors, respectively fed by natural gas, steam and air are used. The outlet from the looping reactors is passed through compression and water separation steps to generate pure streams of nitrogen, hydrogen and carbon dioxide. Nitrogen and hydrogen react to generate Ammonia.
The report provides a comprehensive study of Ammonia production and related Ammonia production cost, covering three key aspects: a complete description of the Ammonia production process examined; an in-depth analysis of the related Ammonia plant capital cost (Capex); and an evaluation of the respective Ammonia plant operating costs (Opex).
The Ammonia 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 Ammonia 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 Ammonia plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Key reference(s): ?
The process under analysis comprises two major sections: (1) Chemical-looping and (2) Ammonia Synthesis.
Chemical-looping. After being compressed and desulfurized, the natural gas is fed into the first of three chemical-looping reactors. Via an oxidation reaction, the natural gas is converted into CO2 and water, that are discarded in further steps. Along with the oxidation reaction, there is the regeneration (reduction) of the iron catalyst, which goes to the next reactor. In this second reactor, steam is converted into hydrogen, by the partial oxidation of the catalyst. Hydrogen produced is sent to a Purification system to remove water (by compression and condensation). The catalyst is transferred to the third reactor, where ambient air is fed into. The catalyst is fully oxidized by all the oxygen present in air, remaining almost-pure nitrogen, which is sent to Ammonia Synthesis area, where it is mixed with purified hydrogen. Excess nitrogen is purged to prevent its accumulation.
Ammonia Synthesis. Hydrogen and nitrogen are compressed, heated, and fed into the Ammonia Reactor, an intercooled horizontal converter. The cooled down reactor outlet is then directed to a multistream heat exchanger that causes the condensation of the Ammonia (recovery). Residual gases are recycled to the compressor, before being fed into the Ammonia synthesis reactor.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Ammonia 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 Ammonia 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 Ammonia 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 Ammonia 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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Other Ammonia 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 | Q3 2024 | 107 pages | Issue B | From $1,199 USD
Ammonia Production from Coal
This report examines the costs related to Ammonia production from coal in China. In this process, coal undergoes pyrolysis, producing coke. It is then subjected to a gasification process. Coke reacts with steam and oxygen yielding mainly carbon monoxide (CO), hydrogen and carbon dioxide (CO2). CO and water are shifted to CO2 and hydrogen. Finally, nitrogen and hydrogen react to produce ammonia.
Details: 800 kta China-based plant | Q3 2024 | 107 pages | Issue D | From $1,199 USD
Ammonia Production from Fuel Oil
This report examines the costs related to Ammonia production from heavy fuel oil. The process under analysis integrates a heavy fuel oil partial oxidation process for synthesis gas production with a unit that produces ammonia from hydrogen and nitrogen. The economic analysis provided assumes a plant located in the United States.
Details: 800 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $1,199 USD
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