Ammonia Production from Natural Gas (Chemical Looping Process)
Ammonia Production Costs Report | Issue C | Q4 2024
| Report Details |
| 800 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 800 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study approaches the economics of Ammonia manufacturing from natural gas in the United States. This report assumes a novel plant configuration reported in the literature, in which three chemical looping reactors, respectively fed by natural gas, steam and air are used. The outlet from the looping reactors is passed through compression and water separation steps to generate pure streams of nitrogen, hydrogen and carbon dioxide. Nitrogen and hydrogen react to generate Ammonia.
The report provides a comprehensive study of Ammonia production and related Ammonia production cost, covering three key aspects: a complete description of the Ammonia production process examined; an in-depth analysis of the related Ammonia plant capital cost (Capex); and an evaluation of the respective Ammonia plant operating costs (Opex).
The Ammonia 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 Ammonia 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 Ammonia plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises two major sections: (1) Chemical-looping and (2) Ammonia Synthesis.
Chemical-looping. After being compressed and desulfurized, the natural gas is fed into the first of three chemical-looping reactors. Via an oxidation reaction, the natural gas is converted into CO2 and water, that are discarded in further steps. Along with the oxidation reaction, there is the regeneration (reduction) of the iron catalyst, which goes to the next reactor. In this second reactor, steam is converted into hydrogen, by the partial oxidation of the catalyst. Hydrogen produced is sent to a Purification system to remove water (by compression and condensation). The catalyst is transferred to the third reactor, where ambient air is fed into. The catalyst is fully oxidized by all the oxygen present in air, remaining almost-pure nitrogen, which is sent to Ammonia Synthesis area, where it is mixed with purified hydrogen. Excess nitrogen is purged to prevent its accumulation.
Ammonia Synthesis. Hydrogen and nitrogen are compressed, heated, and fed into the Ammonia Reactor, an intercooled horizontal converter. The cooled down reactor outlet is then directed to a multistream heat exchanger that causes the condensation of the Ammonia (recovery). Residual gases are recycled to the compressor, before being fed into the Ammonia synthesis reactor.
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Production Process Information
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Ammonia 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 Ammonia 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 Ammonia 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 Ammonia 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
Other Ammonia Production Cost Reports
Ammonia Production from Syngas
This report presents the economics of Ammonia production from synthesis gas (syngas). In this process, hydrogen, recovered from syngas feedstock, and nitrogen, recovered from air, react producing Ammonia. The economic analysis performed assumes a plant located in the United States.
Details: 800 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 800 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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 | Q4 2024 | 107 pages | Issue B From $1,199 USD
The cost analyses presented in this report target a 800 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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