Commodity Production Costs Report
Diammonium Phosphate from Phosphate Rock, Sulfuric Acid and Ammonia
Diammonium Phosphate Operating Costs & Plant Construction Costs
This study presents the economics of a plant located in the United States producing Diammonium Phosphate (DAP formulation 18-46-0) from phosphoric acid and ammonia integrated the production of phosphoric acid from phosphate rock and sulfuric acid.
The report provides a comprehensive study of Diammonium Phosphate production and related Diammonium Phosphate production cost, covering three key aspects: a complete description of the Diammonium Phosphate production process examined; an in-depth analysis of the related Diammonium Phosphate plant capital cost (Capex); and an evaluation of the respective Diammonium Phosphate plant operating costs (Opex).
The Diammonium Phosphate 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 Diammonium Phosphate 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 Diammonium Phosphate 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 four major sections: (1) Phosphoric acid production; (2) Ammoniation-granulation; (3) Drying, cooling and sizing; and (4) Scrubbers.
Phosphoric acid production. Phosphate rock is first ground before being fed to the digestion reactor, which has two compartments. The first compartment receives the ground rocks and recycled phosphoric acid; sulfuric acid is added in the second compartment. The slurry formed in the reactor is filtered to remove dihydrate calcium sulfate (gypsum). The filtered acid proceeds to clarification, then concentration via two evaporators. The first one concentrates it to 40% P2O5 and the second one to 54% P2O5. A bypass stream of 40% P2O5 acid is used in the ammonia scrubbers downstream. The 54% P2O5 acid is clarified a second time, then fed to the pre-neutralizer.
Ammoniation-granulation. Phosphoric acid, gaseous ammonia, and scrubber liquor are fed to the pre-neutralizer reactor. An ammonium phosphate slurry is formed and sent to the pipe reactor, along with additional phosphoric acid and gaseous ammonia. The reaction mixture from the pipe-reactor is sprayed onto the rolling bed of the rotary ammoniator-granulator, where the slurry then reacts with additional liquid ammonia and recycled solids from the sizing and crushing area.
Drying, cooling and sizing. The Diammonium Phosphate granules formed in the granulator are dried, then distributed over screens to separate onsize material from the oversize and undersize material. The oversize material is sent to chain mills, then recycled along with the undersize material to the granulator. Finally, DAP granules are cooled and packed in bags to be stored in warehouses.
Scrubbers. A scrubbing system is used to capture fluorine compounds from the off-gases produced during phosphoric acid production. Another system is used to recover the unabsorbed ammonia gases from pre-neutralizer, granulator, dryer, and cooler. The aforementioned 40% P2O5 phosphoric acid is used in the second system. The scrubber liquor with recovered ammonia is recycled to the pre-neutralizer.
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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 Diammonium Phosphate 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 Diammonium Phosphate 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 Diammonium Phosphate 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 Diammonium Phosphate 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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Diammonium Phosphate from Phosphate Rock, Sulfur and Ammonia
This report concerns the production of Diammonium Phosphate (DAP formulation 18-46-0) via an integrated plant comprising: (1) sulfuric acid production from sulfur; (2) phosphoric acid production from phosphate rock; and (3) Diammonium Phosphate (DAP formulation 18-46-0) production from phosphoric acid and ammonia. The economic analysis performed is based on a plant constructed in the United States.
Details: 750 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $1,699 USD
Diammonium Phosphate from Phosphoric Acid and Ammonia
This feasibility study shows the economics of Diammonium Phosphate (DAP formulation 18-46-0) production from phosphoric acid and ammonia via an ammoniation-granulation process. The reaction occurs in a sequence of pre-neutralizer, pipe-reactor and granulator. The economic analysis presented is based on a plant constructed in the United States.
Details: 850 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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