Commodity Production Costs Report
Granulated Urea Production from Natural Gas (Self-Stripping Process)
Urea Operating Costs & Plant Construction Costs
This study approaches the economics of Granulated Urea manufacturing from natural gas in an industrial complex, located in the United States. Initially, natural gas is converted to syngas via a combined reforming. The syngas is mixed with nitrogen to produce ammonia. The ammonia formed is reacted with carbon dioxide, to form urea in a process similar to Saipem's (formerly Snamprogetti) process.
The report provides a comprehensive study of Urea production and related Urea production cost, covering three key aspects: a complete description of the Urea production process examined; an in-depth analysis of the related Urea plant capital cost (Capex); and an evaluation of the respective Urea plant operating costs (Opex).
The Urea 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 Urea 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 Urea 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) Steam Reforming; (2) Ammonia Synthesis; (3) Urea Reaction; and (4) Urea Concentration.
Steam Reforming. The natural gas is first desulfurized then mixed with steam for primary steam reforming. In a tubular fired heater filled with a Ni-based catalyst, the methane reacts with steam, generating crude syngas, which is fed to the Autothermal Reformer (ATR), to convert remaining methane into CO and H2.
Ammonia Synthesis. The outlet from the ATR is fed to a two-stage set of high and low temperature shift reactors, where carbon monoxide is converted into CO2 and H2. The shifted gas is then cooled, generating steam and condensing present water, that is removed in a knockout drum. Next, CO2 is removed from the gas stream by a MDEA wash. The gas stream, free from CO2, is heated and fed to the Methanator, where residual carbon oxides are converted to methane in the presence of catalysts. After being cooled and dried in molecular sieves, impurities are removed from the syngas and used as fuel. The purified syngas is then fed to an intercooled horizontal ammonia converter. The cooled down reactor outlet is then condensed.
Urea Reaction. CO2 and a liquid mixture of ammonia and carbamate are fed to a reactor, yielding ammonia carbamate and urea. The reactor effluent, is fed to a stripper where excess NH3 strips out the carbamate. The urea solution is directed to decomposers for the removal of residual carbamate and carbon dioxide. After decomposition of carbamate and evaporation of ammonia, a purified urea solution is obtained.
Urea Concentration. The urea-water mixture is concentrated in an evaporator, forming a urea melt. The vapor obtained is condensed and treated. The urea melt is sprayed from in the granulator into a fluid bed, where solid granules are formed. The granules are cooled and screened. The onsize granules are cooled again and sent to the Packing area, where they are packed in bags before being stored. Offspec materials are recycled to the granulator.
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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 Urea 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 Urea 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 Urea 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 Urea 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 Urea Production Cost Reports
Prilled Urea Production from Ammonia (CO2 Stripping Process)
This report examines the costs related to Prilled Urea production from ammonia and carbon dioxide in the USA. The process examined in this report is similar to Stamicarbon's carbon dioxide stripping process. In this process, ammonia and carbon dioxide are converted to Urea via ammonium carbamate intermediate. The non-converted carbamate is stripped from the Urea solution by carbon dioxide and decomposed back to ammonia and carbon dioxide, which are recycled to the Urea synthesis.
Details: 1300 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Granulated Urea Production from Ammonia (CO2 Stripping Process)
This report provides a techno-economic analysis of Granulated Urea production from ammonia and carbon dioxide in the United States through Stamicarbon’s carbon dioxide stripping technology. In this process, ammonia and carbon dioxide are converted to Urea via ammonium carbamate intermediate. The non-converted carbamate is stripped from the Urea solution by carbon dioxide and decomposed back to ammonia and carbon dioxide, which are recycled to the Urea synthesis.
Details: 1300 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
Prilled Urea Production from Natural Gas
This report examines the economics of Prilled Urea manufacturing from natural gas in an industrial complex located in the United States. Initially, natural gas is converted to syngas by steam and autothermal reforming. The syngas is mixed with nitrogen to produce ammonia. The ammonia formed is reacted with carbon dioxide, to form urea via ammonium carbamate.
Details: 1300 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $1,199 USD
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Other Related Production Cost Reports
Hexamethylene Diisocyanate from HMDA (Non-Phosgene Process)
This report presents a techno-economic analysis of Hexamethylene Diisocyanate (HDI) production from hexamethylene diamine (HMDA) in the United States. The process presented in this report is a non-phosgene process similar to BASF process. Initially, HMDA reacts with urea and butanol generating a carbamate intermediate. Then, the carbamate is thermally cracked producing HDI.
Details: 20 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
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