Commodity Production Costs Report
Syngas Production from Natural Gas (Autothermal Reforming)
Syngas Operating Costs & Plant Construction Costs
This report presents the economics of Syngas (Synthesis Gas) production from natural gas using a typical autothermal reforming process. In this process, methane present in natural gas is converted to syngas by steam and oxygen. The economic analysis is based on the construction of a plant located in the United States.
The report provides a comprehensive study of Syngas production and related Syngas production cost, covering three key aspects: a complete description of the Syngas production process examined; an in-depth analysis of the related Syngas plant capital cost (Capex); and an evaluation of the respective Syngas plant operating costs (Opex).
The Syngas 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 Syngas 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 Syngas 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) Autothermal reforming; and (2) Syngas purification.
Autothermal reforming. First, natural gas passes through a desulfurization step for removal of organic sulfur compounds that poison the catalysts used in the reaction downstream. The desulfurized gas is then preheated and sent to the Pre-Reforming, where higher hydrocarbons found in the feed gas are converted into a methane-rich gas and hydrogen. This step prevents catalysts employed downstream from having its activity decreased by the presence of higher hydrocarbons. This pre-reformed gas is mixed with steam and carbon dioxide, and fed to an autothermal reformer. Inside the reactor, methane is converted to CO and hydrogen, using oxygen as the reforming agent.
Syngas purification. The autothermal reforming product is cooled - in order to condense the water present in the gas - and then fed to a column, where it is contacted countercurrently with a methyldiethanolamine (MDEA) solution that absorbs CO2. The overhead gas stream, free of CO2, is the Syngas product. The solution withdrawn as the column bottoms product is treated in a further column for solvent recovery (CO2 desorption). Part of the recovered CO2 is recycled to autothermal reforming, while the remainder is purged.
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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 Syngas 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 Syngas 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 Syngas 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 Syngas 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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Details: 600 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $799 USD
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It presents a techno-economic analysis of Syngas production from heavy fuel oil in the United States using a partial oxidation process. In this process, heavy oil is reacted with oxygen and steam to produce syngas.
Details: 110 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
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This study presents the costs associated with the construction of a plant for Syngas production from wood chips via a typical gasification process. Initially, the wood chips are dried. It is then followed by pyrolysis and partial oxidation. The economic analysis provided assumes a plant constructed in the United States.
Details: 1500 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
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