Aluminum Sulfate Production
Aluminum Sulfate Production Costs Report | Issue A | Q4 2024
| Report Details |
| 60 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 60 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 Aluminum Sulfate production process from bauxite and sulfuric acid in the United States. In this process, prepared bauxite ore is subjected to reaction with sulfuric acid, producing Aluminum Sulfate.
The report provides a comprehensive study of Aluminum Sulfate production and related Aluminum Sulfate production cost, covering three key aspects: a complete description of the Aluminum Sulfate production process examined; an in-depth analysis of the related Aluminum Sulfate plant capital cost (Capex); and an evaluation of the respective Aluminum Sulfate plant operating costs (Opex).
The Aluminum Sulfate 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 Aluminum Sulfate 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 Aluminum Sulfate 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 Overview
Product
Aluminum Sulfate. Aluminum Sulfate (a.k.a. Alum) is an inorganic salt with white, odorless, and sweet tasted crystals that are soluble in water and insoluble in most organic solvents. It can be obtained by the reaction of hydrated aluminum oxide with sulfuric acid or the reaction of this same acid with metallic aluminum. Also, it is rarely found naturally in its free form; however, it is found in a number of hydrates in minerals.
Raw Materials
Sulfuric Acid. Sulfuric acid is one of the most widely used industrial chemicals, serving as a key component in fertilizer production, mineral processing, and chemical manufacturing. It is also used in the refining of petroleum and metal ores. Sulfuric acid is produced via the contact process, where sulfur dioxide is oxidized and absorbed in water. It is stored as a liquid and is crucial for processes like phosphate fertilizer production and in lead-acid batteries.
Bauxite. Bauxite is the primary ore used for aluminum production through the Bayer process. It is also used as an abrasive and in the production of refractory materials. Bauxite is mined and stored as a solid. The alumina extracted from bauxite is crucial for smelting aluminum, which is fundamental to industries such as transportation, packaging, and construction.
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Production Process Information
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Production Process Information
Process Consumptions
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Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
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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 Aluminum Sulfate 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 Aluminum Sulfate 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 Aluminum Sulfate 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 Aluminum Sulfate 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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This report presents the economics of spent sulfuric acid regeneration via wet sulfuric acid (WSA) process in the United States. In this process, spent acid is decomposed to form sulfur dioxide and water. The sulfur dioxide is oxidized to sulfur trioxide, which is then regenerated to sulfuric acid by vapor-phase reaction with water.
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