*. M '* ^ o. : W .'^; % UNITED STATES DEPARTMENT OF THE INTERIOR Information Circular 8958 u Cost Estimate of the Bayer Process for Producing Alumina— Based on 1982 Equipment Prices By Deborah A. Kramer and Frank A. Peters UNITED STATES DEPARTMENT OF THE INTERIOR James G. Watt, Secretary BUREAU OF MINES Robert C. Horton, Director * 1 v* / Library of Congress Cataloging in Publication Data: Kramer, Deborah A Cost estimate of the Bayer process for producing alumina, based on 1982 equipment prices. (Bureau of Mines information circular ; 8958) Bibliography: p. 9. Supt. of Docs, no.: I 28.27:8958. 1. Aluminum industry— United States— Costs. 2. Aluminum— Metal- lurgy— Economic aspects— United States. 3. Aluminum ores — Economic aspects-United States. I. Peters, Frank A., 1931- . II. Title. III. Series: Information circular (United States. Bureau of Mines) ; 8958. TN295,U4 [HD9539.A63U491 622s [669'. 722] 83-600317 5 CONTENTS Page Abstract 1 Introduction 2 Process description 2 Bauxite handling and slurry preparation section 3 Digestion section 3 Clarification section 4 Precipitation and decomposition section 4 Caustic regeneration section 5 Economics 5 Capital costs 5 Operating costs 7 References 9 Appendix. — Utility requirements, equipment cost summaries, and material balances 10 ILLUSTRATIONS 1 . Bayer process flowsheet 3 A-l. Material balance, bauxite handling and slurry preparation section 18 A-2. Material balance, digestion section 18 A-3 . Material balance , clarification section 19 A-4. Material balance, precipitation and decomposition section 19 A-5. Material balance, caustic regeneration section 20 TABLES 1 . Composition of hypothetical bauxite (dry basis) 3 2. Estimated capital cost 6 3. Estimated annual operating cost 8 A-l . Raw material and utility requirements 10 A-2. Direct labor requirements, operators per shift 10 A-3 . Maj or items of equipment 10 A-4. Equipment cost summary, bauxite handling and slurry preparation section.. 11 A-5. Equipment cost summary, digestion section 13 A-6. Equipment cost summary, clarification section 14 A-7. Equipment cost summary, precipitation and decomposition section 15 A-8. Equipment cost summary, caustic regeneration section 16 UNIT OF MEASURE ABBREVIATIONS USED IN THIS REPORT Btu/d British thermal unit kW'h kilowatt -hour per day Mgal thousand gallons °C degree Celsius min minute d/wk day per week pet percent d/yr day per year psia pound per square inch, °F degree Fahrenheit - absolute ft foot ton/d short ton per day ft 2 square foot ton/h short ton per hour gal gallon ton/yr short ton per year h hour wt pet weight percent h/d hour per day yr year in inch COST ESTIMATE OF THE BAYER PROCESS FOR PRODUCING ALUMINA-BASED ON 1982 EQUIPMENT PRICES By Deborah A. Kramer and Frank A. Peters ABSTRACT This Bureau of Mines report presents a cost estimate of the Bayer process, which is used for virtually all cell-grade alumina production. The report will serve as a reference point to determine the economic merits of processes that have evolved from Bureau of Mines investiga- tions on technology for producing alumina from domestic nonbauxitic raw materials. The Bayer process involves dissolving the alumina present in bauxite in a caustic solution at high temperature and pressure. After the un- dissolved impurities are removed, the solution is seeded to produce an alumina trihydrate precipitate. This precipitate is filtered, washed, and calcined to produce the cell-grade alumina product. This cost estimate is for a plant producing 1 million tons of alumina per year. The estimated operating cost is approximately $250 per ton of alumina. ^ Chemist, Avondale Research Center, Bureau of Mines, Avondale, MD. 2 Chief, Process Evaluation, Avondale Research Center, Bureau of Mines, Avondale, MD, INTRODUCTION Since the United States has very lim- ited high-grade bauxite deposits, it is dependent on imported bauxite to supply virtually all its alumina needs-. To pro- vide technology that may help reduce this country's dependence on imported bauxite, the Bureau of Mines has conducted re- search on methods for recovering alumina from domestic raw materials such as clay, anorthosite, alunite, dawsonite, and coal shale and ash. To determine the relative economic attractiveness of the technology being considered, a reference point is needed. A cost estimate of the Bayer process was prepared to provide the reference point, since this method is used for virtually all commercial alumina production. The same estimating techniques are used in this cost estimate as are being used in the economic studies of proposed pro- cesses for producing alumina from non- bauxitic raw materials in order to pro- vide greater confidence in comparing various technologies. This cost estimate is based on a previ- ous one prepared by the Bureau of Mines (_1_) , 3 incorporating additional technical information to update the technology. This information includes data on current Bayer practice such as a higher digestion temperature and pressure, an increased number of flash stages , impurity removal through bleed stream treatment, and solu- tion composition. Equipment design and costing methods reflect current evalua- tion techniques. The Bayer process was patented in 1894 by Karl Josef Bayer GO . Although modi- fications have been made, the process is basically the original one. Most modifi- cations have centered on leaching and solid-liquid separation conditions that have been required to adapt the process to different bauxite feeds. Jamaican bauxite is used as the feed for the pro- posed plant in this study. PROCESS DESCRIPTION Bauxite is mixed with a caustic leach solution and then pumped to digestion vessels where the temperature and pres- sure are increased in order to dissolve the alumina. Undissolved impurities are removed from the solution, and alumina trihydrate is precipitated by seeding the solution with fine trihydrate crystals. The trihydrate crystals are separated from the solution and calcined to produce the final alumina product. A basic pro- cess flowsheet is shown in figure 1. equipment , which allows for downtime for maintenance without reducing plant capac- ity. For convenience, the plant has been divided into five major sections. The material balance for each section is pre- sented in the appendix. Jamaican baux- ite, a mixture of alumina monohydrate and trihydrate, is used as a feed for the proposed plant. An analysis on a dry basis is given in table 1. The bauxite also contains moisture equal to 15 pet of the dry components. New Bayer plants are being built with capacities exceeding 800,000 ton/yr. Large plants can be built without techni- cal risk because of the maturity of the Bayer technology. Therefore, the pro- posed plant has been designed to produce 1 million tons of alumina per year and to operate 3 shifts per day, 365 d/yr at a gulf coast location. For economic rea- sons, Bayer plants are designed for continuous operation by adding spare The bauxite handling and crushing fa- cilities consist of one line of equip- ment ; however , the remainder of the plant is designed with three operating lines and spare equipment to insure continuous production when maintenance is required. 3 Under lined numbers in parentheses re- fer to items in the list of references preceding the appendix. Bau) 1 ite 1 Lime 1 Steam 1 quor Recovered steam PUG MIXING DIGESTION J I II Digestion li 1 1 FLASH COOLING " Flocculant * THICKENING FILTRATION Filter cake ,. . wash watpr 1 " 1 Filtrate and washings ' • liquor V V Wash water WASHING PRECIPITATION THICKENING FILTRATION AND WASHING < * n ' 1 Red mud Seed c rystals Spent liquor A1 2 3 -3H 2 v , , Ti Iter cake EVAPORATION CALCINATION Makeup Water caustic vapor Stack gases -n Alumina Recycle caustic FIGURE 1. - Bayer process flowsheet. For convenience, only one line of equip- ment is described in the plant description. TABLE 1. - Composition of hypothetical bauxite (dry basis) 1 Component wt pet A1 2 3 49.0 Fe 2 3 20.0 Si0 2 2.5 Ti0 2 2.5 Loss on ignition 25.0 Other 1.0 Total 100.0 ^Also contains moisture equal to 15 pet of the dry components. it is fed to an outdoor stockpile con- taining a 60-day supply. Equipment is included to transport bauxite from the outdoor stockpile into the storage build- ings when necessary. Bauxite is with- drawn from a storage building and sent to a hammer mill, where it is crushed from minus 6 in to minus 1 in, and then sent to intermediate storage bins. Crushed bauxite is conveyed to a rod mill for wet grinding to minus 20 mesh with a portion of the recycle caustic so- lution. This slurry is then pumped to pug mixers and mixed with lime produced by calcining limestone. The resulting slurry is pumped to storage tanks in the digestion section. BAUXITE HANDLING AND SLURRY PREPARATION SECTION Upon delivery to the plant, bauxite is conveyed to a hopper from where it is sent to one of two covered storage build- ings, each containing a 30-day supply, or DIGESTION SECTION Stored slurry is pumped to a line of four digestion vessels, which operate at 243° C (470° F) and 525 psia. The slurry is mixed with the remainder of the re- cycle caustic solution, and steam is injected into the tanks to maintain the temperature and to agitate this slurry. Under these conditions , alumina in the bauxite forms soluble sodium aluminate in the following manner: A1 2 3 'H 2 + 2NaOH + 2NaA10 2 + 2H 2 and A1 2 3 '3H 2 + 2NaOH ■*■ 2NaA10 2 + 4H 2 0. Ninety percent of the alumina is assumed to react in 30 rain. In addition, each ton of silica in the bauxite combines with the dissolved alu- mina and caustic soda, causing losses in the residue equivalent to 1 ton of alu- mina and 1 ton of sodium carbonate. The reaction to which these losses are usu- ally attributed is 6NaA10 2 + 5Si0 2 + 5H 2 ■* Na 6 Al 6 Si 5 22 *5H 2 0. A study showing the many compounds found in red mud has been reported in "Extractive Metallurgy of Aluminum" (3). At the same time, carbonate buildup is controlled and the caustic concentration is increased in the system by the follow- ing mechanism: Na 2 C0 3 + Ca(0H) 2 + 2NaOH + CaC0 3 . Exiting slurry from the digestion ves- sels flows to a series of nine flash tanks where the temperature and pressure are gradually reduced. Steam is recov- ered at the pressures shown in the mate- rial balance. The cooled slurry is then pumped to the clarification section. Re- covered steam is used to preheat the re- cycle caustic solution. The equipment required for preheating the solution is detailed in the caustic regeneration section. CLARIFICATION SECTION Slurry from caustic digestion is pumped to sand tanks, where the plus 100-mesh particles of red mud are removed. Over- flow from the sand tanks is pumped to thickeners , where the remainder of the red mud is removed. Starch is added as a flocculant. Depending on plant location and flocculant cost, flocculants other than starch may be used. Overflow from these thickeners is pumped to filter presses to remove any traces of solids. The underflow, containing 18 pet solids, is pumped to a series of eight wash thickeners , where the red mud is washed to recover soluble alumina and soda. Overflow from the wash thickeners is also pumped to filter presses. Filter cake, containing 40 pet solids , is combined with the underflow from the wash thicken- ers, reslurried, and pumped to a tailings pond. Green liquor from the filters is pumped to the precipitation and decompo- sition section. PRECIPITATION AND DECOMPOSITION SECTION Green liquor is pumped to 30 precipita- tors, 30 ft in diameter by 64-ft high. The supersaturated solution is seeded to precipitate the alumina as alumina trihy- drate by the following reaction: 2NaA10 2 + 4H 2 -» A1 2 3 -3H 2 + 2NaOH. Seed crystals, equal to 150 pet of the trihydrate produced, are added to the precipitation tanks , and 40 h are allowed for precipitation. Alumina trihydrate slurry is pumped to primary thickeners , where the overflow containing 9 pet crystals is separated. Underflow from the primary thickeners is pumped to a fluidized-bed calciner system (4). There the solids are filtered, washed, and converted to alumina by the following calcination reaction, which occurs at 950° to 1,050° C (1,740° to 1,920° F): A1 2 3 '3H 2 ■+ A1 2 3 + 3H 2 0. The alumina product, which contains about 25 pet alpha-alumina, is conveyed to silos with a 60-day storage capacity to await shipment. Washings from the calciner filters are combined with the overflow from the pri- mary thickener and sent to secondary thickeners. The overflow from the sec- ondary thickeners , containing 1 pet sol- ids , flows by gravity to tertiary thick- eners, where the solids are separated in the underflow. Overflow from the terti- ary thickeners is pumped to the caustic regeneration section. Underflows from the secondary and tertiary thickeners are combined and recycled to the precipita- tion tanks to provide the seed crystals. CAUSTIC REGENERATION SECTION control of organic compounds and other minor impurities in the caustic solution. Water vapor is condensed and returned to the storage tanks along with purified bleed stream. Concentrated solution is pumped to mix- ing tanks, where makeup caustic is added to replace process losses. A portion of the recycle caustic solution is pumped to the rod mills; the remainder is preheated in heat exchangers, using some of the steam recovered from flash cooling the digestion liquor. The preheated recycle caustic is pumped to the digestion tanks. Clarified solution from the tertiary thickeners is concentrated in a six- effect evaporator and pumped to storage tanks. Water vapor is condensed and re- cycled to the process. A bleed stream is pumped from the storage tanks to a single-effect evaporator, where concen- tration allows for the removal and Equipment has been provided for clean- ing and removing scale from the heat ex- changers. This equipment consists of tanks to hold the solution that is re- moved from the heat exchangers , tanks containing a sulfuric acid cleaning solu- tion, tanks for the spent acid, and the necessary pumps and feed tanks. ECONOMICS The following cost estimate is based on data from literature and other nonpub- lished sources. (6) in 1980 of $800 to $1,200 per annual metric ton (fourth quarter 1982 equiva- lent $800 to $1,200 per short ton). CAPITAL COSTS The capital cost estimate is of the general type called a study estimate by Weaver and Bauman (_5) . This type of es- timate, prepared from a flowsheet and a minimum of equipment data, can be ex- pected to be within 30 pet of the actual cost for the plant described. Although the degree of confidence in any specific study estimate is not great with respect to the actual cost, greater confidence is justified when comparing a group of simi- lar processes evaluated by identical methods. The estimated fixed capital cost on a fourth quarter 1982 basis (Mar- shall and Swift (M and S) index of 749.3) for a plant producing 1 million tons of alumina per year is about $820 million as shown in table 2. This translates to a cost of about $820 per annual ton. The plant is designed to operate 3 shifts per day, 7 d/wk. This capital cost is within the range estimated by Hill and Robson Equipment costs for the process are based on cost-capacity data and manu- facturers' costs quotations. Cost data are brought up to date by use of infla- tion indexes. Capital costs for the fluidized-bed flash calciner are based on a paper by Lussky (4^) . A lined tailings pond for waste disposal, with a 2-yr life, is included in table 2. Additional cost will be required to construct addi- tional tailings pond capacity during the life of the plant. In developing the plant capital costs, corrosion-resistant materials of construction were used where appropriate. For example, the pressure- digestion vessels and the evaporators are nickel clad in order to withstand the high temperature and high caustic concen- tration of the solution. An additional line of equipment is included to allow for continuous operation of the plant when maintenance and scale removal are required for the operating equipment. TABLE 2. - Estimated capital cost 1 Fixed capital: Bauxite handling and slurry preparation section $28,724,700 Digestion section 87,002,000 Clarification section 64,586,800 Precipitation and decomposition section 107,336,100 Caustic regeneration section 224 , 700 , 400 Tailings pond 5,008,400 Steamplant 27,138,500 Subtotal 544,496,900 Plant facilities, 10 pet of above subtotal 54,449,700 Plant utilities, 12 pet of above subtotal 65,339,600 Total plant cost 664,286,200 Land cost Subtotal 664,286,200 Interest during construction period 157,151,000 Fixed capital cost 821,437,200 Working capital: Raw material and supplies 8,031, 000 Product and in-process inventory 20 , 609 , 900 Accounts receivable 20,609, 900 Available cash 14,882,600 Working capital cost 64,133,400 Capitalized startup costs 8,214,400 Subtotal _ 72,347,800 Total capital cost. 893,785,000 1 Basis: M and S equipment cost index of 749.3. Factors for piping, etc. , except for the foundation and electrical factors, are assigned to each section, using as a basis the effect fluids, solids, or a combination of fluids and solids may have on the process equipment. The foundation cost is estimated for each piece of equipment individually , and a factor for the entire section is calculated from the totals. The electrical factor is based on motor horsepower requirements for each section. A factor of 10 pet, referred to as miscellaneous, is added to each sec- tion to cover minor equipment and con- struction costs that are not shown with the equipment listed. For each section, the field indirect cost, which covers field supervision, inspection, temporary construction, equipment rental, and payroll overhead, is estimated at 10 pet of the direct cost. Engineering cost is estimated at 10 pet, and administration and overhead cost is estimated at 5 pet of the con- struction cost. A contingency allowance of 15 pet and a contractor's fee of 5 pet are included in the section cost. The costs of plant facilities and plant utilities are estimated as 10 and 12 pet, respectively, of the total process sec- tion costs and include the same field in- direct costs, engineering, administration and overhead, contingency allowance, and contractor's fee as are included in the section costs. Included under plant fa- cilities are the costs of material and labor for auxiliary buildings such as of- fices, shops, laboratories, and cafete- rias, and the cost of nonprocess equip- ment such as office furniture, together with safety, shop, and laboratory equip- ment. Also included are labor and mate- rial costs for site preparation such as site clearing, grading, drainage, roads, and fences. The cost of water, power, and steam distribution systems is in- cluded under plant utilities. The cost for interest on the capital borrowed for construction is included as interest during construction. Land in- vestment and docking facilities are not included in this estimate. Cost for the plant owner's supervision is not included in the capital cost of the proposed plant. oil, and coal are purchased utilities. The temperature of the water from the cooling tower is assumed to be 33° C (92° F) . Raw material and utility re- quirements per ton of alumina are shown in table A-l (appendix). The direct labor assignments are shown by sections in table A-2. The direct la- bor cost is estimated on the basis of as- signing 4.2 employees to each position that operates 24 h/d, 7 d/wk. The cost of labor supervision is estimated as 15 pet of the labor cost. Plant maintenance is separately esti- mated for each piece of equipment and for the buildings, electrical system, piping, plant utility distribution systems, and plant facilities. Working capital is defined as the funds in addition to fixed capital, land investment, and startup costs that must be provided to operate the plant. Work- ing capital, also shown in table 2, is estimated from the following items : (1) Raw material and supplies inventory (cost of raw material and operating sup- plies for 30 days) , (2) product and in- process inventory (total operating cost for 30 days) , (3) accounts receivable (total operating cost for 30 days) , and (4) available cash (direct expenses for 30 days). Capitalized startup costs are estimated as 1 pet of the fixed capital, which is shown in table 2. OPERATING COSTS The estimated operating costs are based on 365 days of operation per year over the life of the plant. The operating costs are divided into direct, indirect, and fixed costs. Direct costs include raw materials, utilities, direct labor, plant mainte- nance, payroll overhead, and operating supplies. The raw material costs, except for bauxite, do not include transporta- tion costs. Electricity, water, fuel Payroll overhead, estimated as 35 pet of direct labor and maintenance labor, includes vacation, sick leave, social security, and fringe benefits. The cost of operating supplies is estimated as 10 pet of the cost of plant maintenance. Indirect costs are estimated as 25 pet of the direct labor and maintenance costs. The indirect costs include the expenses of control laboratories , ac- counting, plant protection and safety, plant administration, marketing, and com- pany overhead. Research and overall com- pany administrative costs outside the plant are not included. Fixed costs include the cost of taxes (excluding income taxes), insurance, and depreciation. The annual costs of both taxes and insurance are each estimated as 1 pet of the plant construction cost. Depreciation is based on a straight-line, 20-yr period. The estimated annual operating cost for the proposed plant is about $250 million, or approximately $250 per ton of alumina produced, as shown in table 3. This operating cost would be expected to vary from that in an existing Bayer plant be- cause of several factors. The design of an older Bayer plant generally would be less efficient, depreciation charges would be less in an older plant, and costs such as raw materials, transporta- tion, and utility rates would differ de- pending on plant location. In addition, infrastructure costs have not been con- sidered in this evaluation, since they are dependent on the individual plant site. TABLE 3. - Estimated annual operating cost Annual cost Cost per ton alumina Direct cost: Raw materials: $81,931,900 471,600 9,900,600 1,248,300 373,200 476,000 $81.92 .47 Starch at $180 per ton 9.90 1.25 Replacement rods for grinding at $0.23 per .37 .48 94,401,600 94.39 Utilities: 9,858,400 710,400 11,832,100 14,504,700 9.86 .71 Coal at $24.50 per ton 11.83 14.50 36,905,600 36.90 Direct labor: 4,542,700 681,400 4.54 .68 5,224,100 5.22 Plant maintenance: 15,039,400 3,007,900 15,039,300 15.04 3.01 15.04 Total 33,086,600 8,145,000 3,308,700 33.09 Operating supplies, 10 pet of plant maintenance. 8.14 3.31 181,071,600 15,324,300 6,642,900 6,642,900 41,071,900 181.05 Indirect cost, 40 pet of direct labor and 15.32 Fixed cost: 6.64 6.64 41.07 250,753,600 250.72 REFERENCES 1. Peters, F. A., P. W. Johnson, and R. C. Kirby. A Cost Estimate of the Bay- er Process for Producing Alumina. Bu- Mines RI 6730, 1966, 23 pp. 2. Bayer, K. J. Process of Making Alumina. U.S. Pat. 515,895, Mar. 6, 1894. 3. Gerard, G. V., and P. T. Stroup. Extractive Metallurgy of Aluminum. In- terscience Publishers, New York, v. 1, 1963, 355 pp. 5. Weaver, J. B., and H. C. Bauman. Cost and Profitability Estimation. Sec. 25 in Perry's Chemical Engineers' Handbook, ed. by R. H. Perry and C. H. Chilton. McGraw-Hill, 5th ed. , 1973, p. 46. 6. Hill, V. G. , and R. J. Robson. The Classification of Bauxites From the Bayer Plant Standpoint. Light Metals, 1981, pp. 15-28. 4. Lussky, E. W. Experience With Operation of the Alcoa Fluid Flash Cal- ciner. Light Metals, 1980, pp. 69-79. 10 APPENDIX.— UTILITY REQUIREMENTS, EQUIPMENT COST SUMMARIES, AND MATERIAL BALANCES Raw material and utility requirements per ton of alumina are shown in table A-l, and the direct labor requirements for each section are shown in table A-2. Major items of equipment for each section are shown in table A-3. The equipment costs for each section of the process are contained in tables A-4 to A-8. Material TABLE A-l. - Raw material and utility requirements Quantity per ton alumina Raw materials: Bauxite ton. . 2.643 Limestone ton. . .118 Sodium hydroxide, 50-pct ton. . .057 Starch ton. . .007 Replacement rods for grinding lb . . 1.622 balances are shown for each section in figures A-l to A-5. TABLE A-2. - Direct labor requirements, operators per shift Section Bauxite handling and slurry preparation section Digestion section Clarification section Precipitation and decompo- sition section Caustic regeneration section Steamplant General plant Total Shifts per week 121 5 11 36 27 *3 shifts per day, 7 d/wk. 2 1 shift per day, 7 d/wk. 3 1 shift per day, 5 d/wk. TABLE A-3. - Major items of equipment 3 5 Section and item Bauxite handling and slurry preparation section: Hammer mill , Rod mills , Pug mixers , Digestion section: Digestion tanks , Clarification section: Thickeners , Wash thickeners , Filter presses , Precipitation and decomposition section: Precipitation tanks , Primary thickeners , Fluid-flash calciners , Secondary thickeners , Tertiary thickeners , Caustic regeneration section: Multief f ect evaporators , Evaporator , Unit size 72 by 70 in. 7,965 ton/d. 85 ton/h. 12-ft diam by 37 ft, 100-ft diam. 100-ft diam. 2,500 ft 2 . 30-ft diam by 64 ft, 25-ft diam. 2.9 billion Btu/d. 55-ft diam. 110-ft diam. 21,105 ft 2 /effect. 23,833 ft 2 /effect. 11 TABLE A-4.-£qui pment cost summary* bauxite handling and slurry preparation section Item Equi pment CostCl) Labor Total Belt conveyor ........ • hopper......... Apron feeders*. • •• belt conveyors............. Belt conveyor.............. Apron feeders belt conveyors ••••••• Belt conveyors........ Reclaimer feeders.......... Belt conveyor ............. • Belt conveyor rtopper. .................... Apron feeder • Hamper mi 1 i ............... • Belt conveyor.............. Storage bins... Belt feeders Belt conveyors Koo mills.... Bridge crane Pumps Belt feeders... Belt conveyor...... Belt f eeoer ............... . belt conveyor. Hopper Belt feeder • Lime ki 1 n. ................ . Rotary cooler bag dust collectors celt conveyor.. • Surge tanks.... Pumps • • Pug mixers Pumps., Bag dust collector Bag dust collector bag dust collector......... Bag dust collector... Total Hoppers Limestone unloading hoppers Limestone storage silo..... Lime storage silo. Lime slakers.... Front-ena loaders ••••• Dump trucxs rront-end loaders 3b 1 6 32 36 a 8 69 10 2 6 1 3 28 14 9a 4 13 73 5 a l 7 29 10 8 5 31 2 343 14 2 9400, 6600, 2400. 0000. 1600. 1600. 8600, 6300. 3100. 1000. oeoo. 5400, 9100. 2400. 7600. 0400. 0400. 9900, 6000, 4200. 9200, 5500. 6300. 5200. 7300. 600. 5200. 7000. 0200. 7800, 4400, 6400. 9600. 0000. 6S00. 4400. 6200. 2200. 620 0. 9227400. 82800. 4000. 9400. 73800. 81700. 6200. 11100. 45800. 15500. 4200. 12900. 3500. 5900. 39500. 23600. 186600. 6100. 31200. 44200. 1700. 9200. 2300. 14400. 800. 6300. 100. 800. 89100. 16000. 800. 9600. 66400. 7500. 128300. 26200. 300. 200. 300. 200. 442200. 20600. 71800, 393800. 443300. 47800. 99700. 742100, 118600. 25200. 73700. 18900. 45000. 321900, 171200. 1127000. 46500. 171100. 780200, 55900, 58400, 17600. 90700. 6000. 33600. 700. 6000. 386100. 116200. 88600. 64200. 382800. 37100. 3558300. 173100. 24700. 6400. 22500. 6400. 1068700 (2) (2) (2) (2) U) 10296100. 35700. 53600. 382000. 188400. 131800. 300800, 204200. 62000. 12 TAbLE A-4 .-Equi pment cost summary* oauxite handling and slurry Preparation section (cont i nued) Total equipment cost x factor indicated: Foundations* x .185 Buildings* x .255... Structures* x .050 Instrumentation* x .050.......... Electrical* x .055... Piping* x .050....... Painting* x .030 Miscellaneous* x .100. Total Total di rect cost Field indirect* 10.0 pet of total direct cost Total construction cost Engineering* 10.0 pet of total construction cost Administration and overhead* 5.0 pot of total construction cost... Suototal..... Contingency* 15.0 pet of above subtotal Subtotal Contractor's fee* 5.0 pet of above subtotal Section cost... 1707300. 2354700. 461400. 461400. 504900. 461400. 276500. 922700. 7150600. 18805200. 1880500. 20685700. 2068600. 1034300. 23788600. 3568300. 27356900. 1367800. 28724700. (1) Equipment costs are based on the to and S index of 749.3. (2) Instal 1 ed cost . 13 TABLE A-5,-Eoui pment cost summary/ digestion secticr I tern Equipment costcn Labor Total Slurry storage tanks Slurry pumps Digestion tanks F 1 ash tanks 1 • tanks tanks tanks tanks tanks tanks tanks tanks Flash Plash Flash Flash Flash Flash Flash Flash Pumps 2 3 a 5 6 7 8 ' 'v^v T "v^v v^v.. v^y S* o. 7 * A o ° " ° •» "^ -r t*> >^.^ A' -<,'*; <$°* *i V _* ^ r « vv • ^ r ^ *\j a ft " \ ^^ * 'Kr \Y i^* ^ >: * v- A - * "^6 y C A ^ *bV" 1 *^6* a5^> -i ,^ N 'V'" fv&SC''''/ \viS- "" o5°^ - A* ^* ^ ^ kV- HECKMAN BINDERY INC. 4&* APR 84 vv ° . • *■ ' * 9 *, INDIANA 46962 -*\^ ^./ . ^-o^ \b, *o . „ * 'A V^ ' * • • » r ^o<