Commodity Production Costs Report
Syngas Production from Natural Gas (Steam Reforming)
Syngas Operating Costs & Plant Construction Costs
In this report, the economic analysis concerns a process in which Syngas (Synthesis Gas) is generated from natural gas. This study examines a conventional steam reforming process. The plant is 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) Steam reforming; and (2) Syngas purification.
Steam reforming. Initially, natural gas passes through a desulfurization step for removal of organic sulfur compounds that poison the catalysts used in downstream reactions. The desulfurized gas is mixed with steam 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 recycled carbon dioxide, and fed to the steam reformer, a tubular fired heater filled with a Ni-based catalyst, where methane is reacted with steam, generating CO and hydrogen.
Syngas purification. The steam 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, with a H2/CO molar ratio of 3. The solution withdrawn as the column bottoms product is treated in a further column for solvent recovery (CO2 desorption). The recovered CO2 is recycled to the steam reforming, with a small purge to avoid the buildup of impurities in the process.
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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: 1000 kta China-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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