NPK Fertilizer Production (Phosphonitric Process)
NPK Fertilizer Production Costs Report | Issue A | Q4 2024
| Report Details |
| 300 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 300 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 presents the economics of a typical phosphonitric process for NPK Fertilizer production in the United States from rock phosphate, phosphoric acid, ammonia, and nitric acid. Initially, rock phosphate is digested with nitric acid and phosphoric acid. The NP solution generated is then neutralized with gaseous ammonia. To produce NPK potassium chloride or sulfate is finally admixed. The product formulation is 15-15-15 (15% N, 15% P2O5, 15% K2O).
The report provides a comprehensive study of NPK Fertilizer production and related NPK Fertilizer production cost, covering three key aspects: a complete description of the NPK Fertilizer production process examined; an in-depth analysis of the related NPK Fertilizer plant capital cost (Capex); and an evaluation of the respective NPK Fertilizer plant operating costs (Opex).
The NPK Fertilizer 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 NPK Fertilizer 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 NPK Fertilizer 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 three major sections: (1) Digestion-granulation; (2) Finishing and packing; and (3) Scrubbing system
Digestion-granulation. Initially, phosphate rock and nitric acid are directed to the first reactor to be digested, resulting in a solution of calcium nitrate and phosphoric acid. This slurry is fed into another digester where phosphoric acid is admixed to formulate the right quantity of water soluble P2O5 in the final product. From the second digester the slurry goes to the neutralizer, where gaseous ammonia is injected for the neutralization of the acids added and formed. Thereafter, potassium chloride is added in a mixing vessel to compose the final NPK composition. The NPK mixture feeds the Spherodizer, which is a spray drum granulator that promotes granulation and drying simultaneously.
Finishing and packing. This section comprises the final steps to ensure the specification of the final product - screening, cooling and coating with an anticaking agent. The finished product is packed in bags and then sent to warehouses at the facility’s outside battery limits to be stored.
Scrubbing system. Here, a scrubbing system captures the gases released in digestion and neutralization areas as well as any dust released from cyclones throughout the process. The scrubber liquor containing the recovered nutrient salts is recycled to the neutralizer.
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Production Process Information
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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 NPK Fertilizer 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 NPK Fertilizer 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 NPK Fertilizer 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 NPK Fertilizer 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 NPK Fertilizer Production Cost Reports
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