Ammonium Nitrates. Table of Contents

Transcription

1 Ammonium Nitrates Table of Contents A Report by Nexant Process Evaluation/Research Planning (PERP) Program PERP Report 2013S6 Published December 2013 Section 1 Executive Summary PRODUCTION PROCESS AND TECHNOLOGIES COST OF PRODUCTION COMMERCIAL MARKET ANALYSIS Introduction BACKGROUND VALUE CHAIN CURRENT USE OF AMMONIUM NITRATES FEEDSTOCK AND UPSTREAM PROCESSES CRYSTALLINE STATES OF PRODUCT TECHNOLOGY LICENSING STATUS Environmental and Safety Considerations OPERATIONAL CONSIDERATIONS Neutralization Concentration/Evaporation Solidification STORAGE AND HANDLING ENVIRONMENTAL CONSIDERATIONS Neutralization Evaporation Solidification Commercial Technologies i

2 4.1 NEUTRALIZATION PROCESSES Vacuum Neutralization Atmospheric Neutralization Pressure Neutralization PIPE REACTOR NEUTRALIZATION CONCENTRATION PROCESSES SOLIDIFICATION PROCESSES Granulation Prilling HANDLING AND STORAGE AMMONIUM NITRATE PRODUCTS Urea Ammonium Nitrate (UAN) Calcium Ammonium Nitrate (CAN) TECHNOLOGY LICENSORS GPN SNC Lavalin ThyssenKrupp Uhde GmbH Process Economics COSTING BASIS Investment Basis Pricing Basis Cost of Production Basis VACUUM NEUTRALIZATION PROCESS (N.W. EUROPE, S. KOREA, AND USGC BASES) PRESSURE NEUTRALIZATION PROCESS SENSITIVITY ANALYSES Sensitivity of Ammonium Nitrate Cost of Production to Ammonia Price (USGC Basis) Sensitivity of Ammonium Nitrate Cost of Production to Plant Scale (USGC Basis) CONCLUDING REMARKS Commercial Market Analysis ii

3 6.1 COMMERCIAL APPLICATIONS GLOBAL SUMMARY Consumption Supply Global Supply, Demand, and Trade CHINA Consumption Supply Regional Supply, Demand, and Trade NORTH AMERICA Consumption Supply Global Supply, Demand, and Trade WESTERN EUROPE Consumption Supply Supply, Demand, and Trade AUSTRALIA Consumption Supply Supply, Demand, and Trade Glossary References Appendix A Definitions of Capital Cost Terms Used in Process Economics... A-1 B Definitions of Operating Cost Terms Used in Process Economics... B-1 C About the Authors... C-1 D PERP Program Title Index ( )... D-1 iii

4 Figure 2.1 Ammonium Nitrate Value Chain and Production Overview Typical Vacuum Neutralization Flow Diagram (Source: Fertilizer Manual) Typical Pressure Neutralization with Direct Heat Utilization (Uhde) Typical Pressure Neutralization with Additional Steam Generation (Uhde) Typical Flow Diagram for Pipe Reactor Neutralization (GPN) Batch Production of UAN Solution Continuous Production of Urea Ammonium Nitrate Solution Block Diagram of the GPN Pipe Reactor Process Philosophy of ph Monitoring in the Pipe Reactor Typical Prilling Flow Diagram for Use Downstream of a Pipe Reactor (Source: Fertilizer Manual) Typical Fluidized Drum Granulation Process Flow Scheme (SNC Lavalin) Uhde s Vacuum Neutralization Process Uhde s Stand-Alone UAN Process Variation of Ammonium Nitrate Production Cost with Ammonia Price Variation of Ammonium Nitrate Production Cost + 10 percent ROCE with Plant Scale Global AN/CAN Consumption Global AN/CAN Capacity Global Supply, Demand, and Trade China Supply, Demand, and Trade North America Supply, Demand, and Trade Western European Supply, Demand, and Trade Australia Supply, Demand, and Trade iv

5 Table 2.1 Technology Licensors Prices of Raw Materials, Products, Utilities and Labor Cost of Production Estimate for: Ammonium Nitrate Process: Vacuum Neutralization/Evaporation/ Prilling (N.W. Europe) Cost of Production Estimate for: 60 percent Nitric Acid (data on a 100 percent HNO 3 contained basis); Process: Dual Pressure Ammonia Oxidation (N.W. Europe) Cost of Production Estimate for: Ammonium Nitrate Process: Vacuum Neutralization/Evaporation/ Prilling (South Korea) Cost of Production Estimate for: 60 percent Nitric Acid (data on a 100 percent HNO 3 contained basis); Process: Dual Pressure Ammonia Oxidation (South Korea) Cost of Production Estimate for: Ammonium Nitrate Process: Vacuum Neutralization/Evaporation/ Prilling (USGC) Cost of Production Estimate for: 60 percent Nitric Acid (data on a 100 percent HNO 3 contained basis); Process: Dual Pressure Ammonia Oxidation (USGC) Pressure Neutralization Process Cost of Production Estimate for: Ammonium Nitrate Global AN/CAN Consumption Global AN/CAN Supply Global Supply, Demand, and Trade China AN Capacity China Supply, Demand, and Trade North American AN/CAN Consumption North America Ammonium Nitrate Capacity North America Supply, Demand, and Trade Western European AN Capacity Western European CAN Capacity Western Europe Supply, Demand, and Trade Australia Ammonium Nitrate Capacity Australia Supply, Demand, and Trade v

6 NexantThinking The NexantThinking s Process Evaluation/Research Planning (PERP) program is recognized globally as the industry standard source for information relevant to the chemical process and refining industries. PERP reports are available as a subscription program or on a single report basis. Contact Details: New York: Marcos Nogueira Cesar, Vice President, Global Products, E&CA: NexantThinking Phone: , mcesar@nexant.com New York: Heidi Junker Coleman, Global Programs Support Manager Phone: , hcoleman@nexant.com Nexant, Inc. ( is a leading management consultancy to the global energy, chemical, and related industries. For over 38 years, ChemSystems has helped clients increase business value through assistance in all aspects of business strategy, including business intelligence, project feasibility and implementation, operational improvement, portfolio planning, and growth through M&A activities. Nexant has its main offices in San Francisco (California), White Plains (New York), and London (UK), and satellite offices worldwide. Copyright by Nexant Inc All Rights Reserved. PERP REPORT 2013S6, Ammonium Nitrates A