Commodity Production Costs Report
Polyaluminum Chloride Solution from Aluminum Hydroxide
Polyaluminum Chloride Operating Costs & Plant Construction Costs
This report presents the economics of Polyaluminum Chloride (PAC) production from aluminum hydroxide, sulfuric acid, hydrochloric acid, and calcium carbonate in the United States. Initially, aluminum hydroxide is digested with sulfuric acid and hydrochloric acid, generating PAC. The polymer solution is then neutralized with calcium carbonate to remove sulfate ions.
The report provides a comprehensive study of Polyaluminum Chloride production and related Polyaluminum Chloride production cost, covering three key aspects: a complete description of the Polyaluminum Chloride production process examined; an in-depth analysis of the related Polyaluminum Chloride plant capital cost (Capex); and an evaluation of the respective Polyaluminum Chloride plant operating costs (Opex).
The Polyaluminum 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 Polyaluminum 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 Polyaluminum 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 is divided into two main areas: (1) reaction; and (2) products recovery.
Reaction. Aluminum hydroxide is charged into a reactor containing sulfuric acid (98 wt%) and hydrochloric acid (32 wt% solution). The mixture is heated and after the reaction temperature is achieved, water and additional sulfuric acid are added to the reactor. Volatile chlorine-containing gases leave the reactor and are routed to a scrubber for preventing chlorine gaseous emissions. The scrubber liquid effluent is further used in the products recovery section. When the desired conversion is achieved, the solution is transferred to a neutralizer, to which a calcium carbonate slurry is added for removing excess sulfates in the polymer formed. The neutralization reaction generates gypsum (CaSO4 * 2 H2O), which must be separated from the Polyaluminum Chloride (PAC) solution.
Products Recovery. The PAC solution, still containing gypsum, is fed to a filter press. Gypsum cake obtained from the filtration is washed with the aqueous solution obtained from the scrubber. After washing, gypsum is ready for storage. The filtration mother liquor, comprising the PAC solution, is still routed to a conditioning step, where the correct solution concentration is achieved by means of adding the water used in the gypsum washing step.
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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 Polyaluminum 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 Polyaluminum 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 Polyaluminum 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 Polyaluminum 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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