Commodity Production Costs Report
Aluminum Chloride Production
Aluminum Chloride Operating Costs & Plant Construction Costs
This report presents the economics of Aluminum Chloride production from aluminum metal and chlorine in the United States. In the process, chlorine gas is passed through molten aluminum, producing Anhydrous Aluminum Chloride.
The report provides a comprehensive study of Aluminum Chloride production and related Aluminum Chloride production cost, covering three key aspects: a complete description of the Aluminum Chloride production process examined; an in-depth analysis of the related Aluminum Chloride plant capital cost (Capex); and an evaluation of the respective Aluminum Chloride plant operating costs (Opex).
The Aluminum Chloride 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 Chloride 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 Chloride plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Key reference(s): ?
The process under analysis comprises three major sections: (1) Reaction; (2) Crushing and sizing; and (3) Scrubber.
Reaction. The reaction takes place in ceramic-lined, tube-shaped reactors containing molten aluminum. The chlorine gas is injected below the surface of the molten aluminum pool, leading to the formation of aluminum chloride vapors in a highly exothermic and practically instantaneous reaction. The reaction occurs at 670 – 850°C and the temperature is maintained in this range by the control of chlorine and aluminum admission rates and by cooling reactors walls with water. The AlCl3 vapor from the reactors is fed to air-cooled condensers, which are vertical cylinders with conical bottoms. As the aluminum chloride vapor gets in contact with condenser walls, it loses its heat of sublimation, and gets deposited in the walls. Such deposited solid is withdrawn from the condenser walls at regular intervals, and subsequently conveyed to holding silos.
Crushing and sizing. The aluminum chloride crystals from the holding silos are crushed and sized by sieving under a dry air atmosphere. After sizing, aluminum chloride product is obtained.
Scrubber. The condensing, crushing and sizing operations, as well as storage facilities, are designed to avoid the entrance of moist atmospheric air. In this way, a vent system tied to such pieces of equipment directs the off-gas removed, containing unreacted chlorine and uncondensed gases, to a caustic scrubber. The scrubbed gas is vented to the atmosphere, while the scrubber’s bottom stream comprises wastewater.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Aluminum Chloride 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 Chloride 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 Chloride 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 Chloride 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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