Ammonium Nitrate Porous Prills Production
Ammonium Nitrate Production Costs Report | Issue B | Q3 2024
| Report Details |
| 400 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 400 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
In this study, the production costs of Ammonium Nitrate porous prills (AN-PP) are reviewed. The process examined is a typical vacuum neutralization process using ammonia and nitric acid for ammonium nitrate production. It is then evaporated and transformed into AN-PP. The economic analysis presented assumes a plant constructed in the United States.
The report provides a comprehensive study of Ammonium Nitrate production and related Ammonium Nitrate production cost, covering three key aspects: a complete description of the Ammonium Nitrate production process examined; an in-depth analysis of the related Ammonium Nitrate plant capital cost (Capex); and an evaluation of the respective Ammonium Nitrate plant operating costs (Opex).
The Ammonium Nitrate 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 Ammonium Nitrate 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 Ammonium Nitrate 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 the following major sections: (1) neutralization; and (2) finishing.
* Neutralization. Initially, liquid ammonia is evaporated, superheated and sent to a neutralization reactor, along with a nitric acid solution and circulating Ammonium Nitrate solution. The ammonia reacts with nitric acid producing Ammonium Nitrate. The reaction occurs under a slightly pressurized atmosphere, in order to prevent the Ammonium Nitrate solution from boiling and minimize ammonia losses. The Ammonium Nitrate solution, heated by the highly exothermic neutralization, overflows to a flash vessel under vacuum, in which water is partially evaporated. The vapor obtained is used to heat neutralization feed streams, while the concentrated ammonium nitrate is split: part is circulated to the neutralizer, while the rest is fed to a second neutralizer with additional ammonia. The product from the second neutralizer is routed to a thermosyphon evaporation system, in which the solution is steam heated, under vacuum. The Ammonium Nitrate melt obtained is directed to a prilling step downstream.
* Finishing. The Ammonium Nitrate melt is initially mixed with a solution of dry magnesium oxide (MgO) to improve storage properties. Subsequently, The Ammonium Nitrate melt is mixed with a prilling additive and sprayed at the top of a prilling tower. The Ammonium Nitrate prills are dried in rotating drums, screened, cooled and coated with an anticaking agent. Off-spec material is recycled to the process. Finally, the AN prills are packed in bags and stored. Also, waste air from prilling and drying steps are scrubbed before being discharged to the atmosphere.
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Production Process Information
Process Consumptions
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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 Ammonium Nitrate 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 Ammonium Nitrate 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 Ammonium Nitrate 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 Ammonium Nitrate 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 Ammonium Nitrate Production Cost Reports
Ammonium Nitrate Solution Production
This report presents the economics of a typical neutralization under vacuum process for the production of Ammonium Nitrate solution. The study examines a plant located in the United States using gaseous ammonia and nitric acid as raw materials.
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Granulated Ammonium Nitrate Production
This report presents the economics of a plant producing granulated Ammonium Nitrate in the United States. The starting materials used in the plant are ammonia and nitric acid, which undergo vacuum neutralization to produce ammonium nitrate. It is then evaporated and granulated. The granulated Ammonium Nitrate generated is also known as emulsion grade Ammonium Nitrate.
Details: 400 kta United States-based plant | Q3 2024 | 107 pages | Issue C From $1,199 USD
The cost analyses presented in this report target a 400 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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