Commodity Production Costs Report
Prilled Urea Production from Ammonia (CO2 Stripping Process)
Urea Operating Costs & Plant Construction Costs
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.
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 two major sections: (1) Urea Formation; and (2) Urea Treatment, Prilling and Packaging.
Urea Formation. Carbon Dioxide (CO2) is compressed and fed to a stripping column, where unconverted carbamate in the urea solution from reactor downstream is decomposed into ammonia (NH3) and CO2, which are stripped off by the CO2 feed. The urea solution is routed to a Low Pressure (LP) Decomposer downstream, while the off-gas is fed to the Pool Condenser, along with fresh NH3 and recovered carbamate solution from downstream. In this vessel, NH3 and CO2 react forming carbamate. A gas-liquid mixture is directed to a Reactor where urea is generated. An urea solution is routed to CO2 stripping, while a gaseous stream is directed to a High Pressure (HP) Scrubber, where water, unreacted CO2 and NH3 are absorbed in a carbamate solution and conveyed to the Pool Condenser. Non-condensables withdrawn from the HP Scrubber are directed to NH3 Absorbers downstream, where they are washed with process condensate, and the off-gas, virtually free of NH3, is purged.
Urea Treatment, Prilling and Packaging. The urea solution from the CO2 Stripping is fed to the LP Decomposer to remove residual NH3 and CO2, which are then condensed, generating a carbamate solution that is used in the HP Scrubber. The urea solution, virtually free of carbamate, is concentrated in Evaporators, and sent to the Prilling area, while the process condensate is directed to the Condensate Treatment area, where it is treated and can be used in other parts of the plant. Urea melt, from the evaporators, is sprayed from the top of the prilling tower, forming liquid droplets that cool and solidify as they fall forming the urea prills. The prills are conveyed and sent to the Packaging area, where they are packed in bags and 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 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
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
Granulated Urea Production from Natural Gas (Self-Stripping Process)
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.
Details: 1300 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $1,199 USD
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Other Related 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
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