Polyaluminum Chloride Solution from Aluminum Hydroxide
Polyaluminum Chloride Production Costs Report | Issue A | Q4 2024
| Report Details |
| 20 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 20 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 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.
Process Schematic
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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Production Process Information
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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 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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