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This report presents a cost analysis of Hydrogen production from natural gas. The process examined is a typical steam reforming process. This report examines one-time costs associated with the construction of a United States-based plant and the continuing costs associated with the daily operation of such a plant. More specifically, it discusses: * Capital Investment, broken down by: - Total fixed capital required, divided in production unit (ISBL); infrastructure (OSBL) and contingency - Alternative perspective on the total fixed capital, divided in direct costs, indirect costs and contingency - Working capital and costs incurred during industrial plant commissioning and start-up * Production cost, broken down by: - Manufacturing variable costs (raw materials, utilities) - Manufacturing fixed costs (maintenance costs, operating charges, plant overhead, local taxes and insurance) - Depreciation and corporate overhead costs * Raw materials consumption, products generation and labor requirements * Process block flow diagram and description of industrial site installations (production unit and infrastructure) This report was developed based essentially on the following reference(s): (1) US Patent 6110979, issued to Air Products in 2000; (2) "Hydrogen", Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition Keywords: H2, NG, Water-gas Shifting, Reformer, Steam Methane Reforming, SMR
This report presents a cost analysis of Hydrogen production from natural gas. The process examined is a typical steam reforming process. This process comprises the following main steps: natural gas steam reforming for syngas production; shift conversion, i.e., reaction of carbon monoxide with steam, producing carbon dioxide and additional Hydrogen; Hydrogen purification by means of a pressure swing adsorption (PSA) system. This report was developed based essentially on the following reference(s): (1) "Hydrogen, 2. Production", Ullmann's Encyclopedia of Industrial Chemistry, 2011 (2) "Hydrogen", Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition Keywords: H2, NG, Water-gas Shifting, Reformer, Steam Methane Reforming, SMR
This report presents a cost analysis of Syngas (Synthesis Gas) production from natural gas. The process examined is a typical autothermal reforming process. The final product obtained is Syngas with a H2/CO ratio of 2. This report was developed based essentially on the following reference(s): "Gas Production", Ullmann's Encyclopedia of Industrial Chemistry, 7th edition Keywords: Methane, Carbon Monoxide, Catalytic Reforming
This report presents a cost analysis of Hydrogen Cyanide production via a direct synthesis method involving the reaction of ammonia, methane (natural gas), and air. The process examined is similar to Andrussow process. This report was developed based essentially on the following reference(s): (1) "Cyanides," Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition (2) "Hydrogen Cyanide," McKetta, J., Inorganic Chemicals Handbook. Vol. 2 Keywords: Prussic Acid, DuPont, Reactor Waste-Heat Boiler, Air, Methane, Combustion
This report presents a cost analysis of 2-Propylheptanol (2-PH) production from butenes and syngas. The process examined is similar to the LP OXO technology jointly licensed by Johnson Matthey Davy and Dow. This process involves three main steps: hydroformylation of butenes to valeraldehyde (pentanal), aldolization of valeraldehyde to Propyl-2-heptenal; hydrogenation of Propyl-2-heptenal to 2-PH, which is then submitted to a fractional distillation for separation of both light and heavy impurities. This report was developed based essentially on the following reference(s): (1) "OXO Synthesis", Ullmann's Encyclopedia of Industrial Chemistry, 7th edition (2) US Patent 5001274 issued to Union Carbide (now Dow Chemical Company) in 1991 (3) WO1993020034 issued to Davy (now subsidiary of Johnson Matthey) in 1993 Keywords: Oxo Alcohol, Johnson Matthey, Dow, LP OXO
This report presents a cost analysis of a typical Ammonia production process from synthesis gas. In this process, hydrogen, recovered from syngas feedstock, and nitrogen, recovered from air, react producing Ammonia. This report was developed based essentially on the following reference(s): "Ammonia", Kirk-Othmer Encyclopedia of Chemical Technology, 4th edition; Keywords: Haber-Bosch, Haldor Topsoe, Uhde GmbH, Ammonia Casale and KBR
This report presents a cost analysis of Carbon Monoxide (CO) production from synthesis gas. The process examined is a typical cryogenic partial condensation process. This report was developed based essentially on the following reference(s): (1) "Cryogenic Technology", Ullmann's Encyclopedia of Industrial Chemistry, 2013; (2) Industrial Gases in Petrochemical Processing, 1998 Keywords: Cryogenic separation, partial condensation
This report presents a cost analysis of Cyclohexane from benzene and hydrogen. The process examined is a liquid phase hydrogenation process. In this process, benzene is hydrogenated in a liquid-phase reactor in the presence of a nickel-based catalyst. The reactor's overhead is sent to a second reactor to convert the non-reacted benzene. This report was developed based essentially on the following reference(s): US Patent 5,668,293, issued to Institut Francais du Petrole in 1997 Keywords: Benzene Hexahydride, Cycloalkane, Liquid-Phase Reaction, Hydrogenation Reaction, IFP
This report presents a cost analysis of Hydrogen Peroxide production from hydrogen. The process examined is a conventional anthraquinone auto-oxidation (AO) process. In this process, 2-ethyl anthraquinone is sequentially hydrogenated and oxidized generating Hydrogen Peroxide. This report was developed based essentially on the following reference(s): (1) "Hydrogen Peroxyde", Ullmann's Encyclopedia of Industrial Chemistry, 7th edition (2) "Hydrogen Peroxyde", McKetta, J., Inorganic Chemicals Handbook. Vol. 2 (3) US Patent 7238335, issued to Degussa in 2007(assigned to Evonik Degussa in 2010) Keywords: H2O2, AO Process, Riedl-Pfleiderer, EAQ, Evonik, Degussa, BASF, Dow, Solvay, Alkyanthraquinone
This report presents a cost analysis of Urea production from ammonia and carbon dioxide. The process examined is similar to Saipem's (formerly Snamprogetti) self-stripping process. In this process, ammonia and carbon dioxide are reacted to form ammonium carbamate intermediate, which is converted to Urea. The non-converted carbamate is stripped from the Urea solution by excess ammonia and decomposed back to ammonia and carbon dioxide, which are recycled to the Urea synthesis. After concentration and prilling steps, Urea Prills are obtained as final product. This report was developed based essentially on the following reference(s): (1) "Urea," Ullmann's Encyclopedia of Industrial Chemistry, 2010 (2) "Urea," Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition Keywords: NH3 Stripping, Self-Stripping, Fertilizers, Snamprogetti, Saipem, Urea Prills