Commodity Production Costs Report
Ammonia Production from Syngas
Ammonia Operating Costs & Plant Construction Costs
This report presents the economics of Ammonia production from synthesis gas (syngas). In this process, hydrogen, recovered from syngas feedstock, and nitrogen, recovered from air, react producing Ammonia. The economic analysis performed assumes a plant located in the United States.
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 three major sections: (1) Syngas Treatment; (2) Ammonia Synthesis; and (3) Ammonia Purification.
Syngas Treatment. Syngas is initially introduced in an absorption column, which utilizes a methyldiethanolamine (MDEA) wash for the removal of CO2. Residual carbon oxides are then converted to methane in the Methanator. The methane formed is going to be removed from the main process stream in the nitrogen wash downstream. The treated gas is then cooled through a series of heat exchangers and dried in molecular sieve beds.
Ammonia Synthesis. The dried syngas is washed with nitrogen. The process removes remaining carbon monoxide and methane. Part of the nitrogen stream is used to adjust the ratio hydrogen/nitrogen in the purified syngas, to almost 3, as required for the ammonia synthesis. After, the resulting gas is compressed and directed to the Ammonia Reactor, an intercooled horizontal converter, where hydrogen and nitrogen reacts at the correct stoichiometric ratio yielding Ammonia.
Ammonia Purification. Ammonia is liquified by means of a multistream heat exchanger. Part of the residual gases are directed to synthesis, but a small fraction of this stream is recycled to the nitrogen in order to recover hydrogen and nitrogen. The liquid Ammonia product is sent to stored.
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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 Natural Gas (Chemical Looping Process)
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.
Details: 800 kta United States-based plant | Q3 2024 | 107 pages | Issue C | 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
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