Diammonium Phosphate from Phosphate Rock, Sulfur and Ammonia
Diammonium Phosphate Production Costs Report | Issue C | Q4 2024
| Report Details |
| 750 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 750 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 report concerns the production of Diammonium Phosphate (DAP formulation 18-46-0) via an integrated plant comprising: (1) sulfuric acid production from sulfur; (2) phosphoric acid production from phosphate rock; and (3) Diammonium Phosphate (DAP formulation 18-46-0) production from phosphoric acid and ammonia. The economic analysis performed is based on a plant constructed in the United States.
The report provides a comprehensive study of Diammonium Phosphate production and related Diammonium Phosphate production cost, covering three key aspects: a complete description of the Diammonium Phosphate production process examined; an in-depth analysis of the related Diammonium Phosphate plant capital cost (Capex); and an evaluation of the respective Diammonium Phosphate plant operating costs (Opex).
The Diammonium Phosphate 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 Diammonium Phosphate 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 Diammonium Phosphate 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 four major sections: (1) Sulfuric acid production; (2) Phosphoric acid production; (3) Ammoniation-granulation; and (4) Drying, cooling and sizing.
Sulfuric acid production. Sulfur is burnt in a combustion furnace with air to produce sulfur dioxide (SO2). The resulting SO2 is then directed to a converter, where it is oxidized to sulfur trioxide (SO3) in five catalyst beds. The SO3 is absorbed with weak acid, resulting in sulfuric acid (98.5 wt%). An intermediate absorption step between the third and fourth beds increases overall conversion.
Phosphoric acid production. Phosphate rock is ground then digested in a reactor with two compartments. The first uses recycled phosphoric acid and the second uses sulfuric acid. The slurry formed is filtered to remove gypsum. The filtered acid is clarified, then evaporated in two stages. The first concentrates it to 40% P2O5 and the second to 54% P2O5. The 54% acid is fed to the pre-neutralizer.
Ammoniation-granulation. Phosphoric acid, gaseous ammonia, and scrubber liquor are fed to the pre-neutralizer. An ammonium phosphate slurry is formed and sent to the pipe reactor, along with additional phosphoric acid and gaseous ammonia. The reaction mixture from the pipe-reactor is sprayed onto the rolling bed of the rotary ammoniator-granulator, where the slurry reacts with additional liquid ammonia and recycled solids from the sizing and crushing area.
Drying, cooling and sizing. The Diammonium Phosphate granules formed in the granulator are dried, then distributed over sizing screens. The oversize material is sent to chain mills, then recycled along with the undersize material to the granulator. Finally, DAP granules are cooled and packed in bags to be stored.
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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 Diammonium Phosphate 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 Diammonium Phosphate 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 Diammonium Phosphate 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 Diammonium Phosphate 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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Diammonium Phosphate from Phosphoric Acid and Ammonia
This feasibility study shows the economics of Diammonium Phosphate (DAP formulation 18-46-0) production from phosphoric acid and ammonia via an ammoniation-granulation process. The reaction occurs in a sequence of pre-neutralizer, pipe-reactor and granulator. The economic analysis presented is based on a plant constructed in the United States.
Details: 850 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 850 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.
Diammonium Phosphate from Phosphate Rock, Sulfuric Acid and Ammonia
This study presents the economics of a plant located in the United States producing Diammonium Phosphate (DAP formulation 18-46-0) from phosphoric acid and ammonia integrated the production of phosphoric acid from phosphate rock and sulfuric acid.
Details: 800 kta United States-based plant | Q4 2024 | 107 pages | Issue B From $1,399 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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