Costing examples

Thermoforming is perhaps the process with the lowest unit cost. Examples of thermoformed articles are refrigerator-door and food-container liners, containers for dairy products, and luggage. Some of the largest formed parts are camper/trader covers and liners for refrigerated-radroad-car doors (236). 

Fig. 9-5 Cost example of injection molding high-volume and precision products.

The data in this section are in my opinion the best available. They were developed from data presented by Kenneth M. Guthrie and first appeared in the March 24, 1969 and Jan. 13, 1969, issues of Chemical Engineering. I am very indebted to Mr. Guthrie and Chemical Engineering for allowing me to reproduce this material. All these data are based on mid 1968 costs. Examples 9-6, 9-7, and 9-8, along with the capital cost estimation of a 150,000,000 lb/yr polystrene plant, show how to use the figures and tables. 

PEMFC R D areas include slightly higher temperature (120°C) and lower cost membrane materials, resistant and low-cost catalyst materials, long life. The technology must meet all the basic criteria for performance, durability and cost. Examples of projects include ... 

Decision and state variables for minimizing cost, example 3... 

In some cases cost may be the dominant approval criterial. In applications where color is only an identifying attribute, the customer may be interested in just a close match to target, preferring that the colorist formulate for lowest cost. Examples of such applications could be wire and cable coatings, automotive dunnage applications, pallets, bread trays, and beverage crates. 

To simplify these calculations, the capital cost of the instrument may be amortized over 5 or 6 years and maintenance costs ignored. The average daily cost can then be calculated and will be the same whether the instrument is used or not. Reagent costs are simple to calculate and are usually small in relation to other costs. Examples of labor and equipment costs of 5 commercial flame photometers, used to measure plasma sodium and potassium simultaneously, were given by Broughton and Dawson (B18). With small numbers of analyses, the least expensive instrument was the cheapest to run, but despite wide differences in capital outlay and labor requirements, the cost per analysis for the 5 instruments... 

We are grateful to Aspen Technology Inc. and Honeywell Inc. for permission to include the screen shots that were generated using their software to illustrate the process simulation and costing examples. Laurie Wang of Honeywell also provided valuable review comments. The material safety data sheet in Appendix I is reproduced with permission of Eischer Scientific Inc. Aspen Plus , Aspen Kbase, Aspen ICARUS,... 

Another consideration in choosing equipment is cost. Examples of cost analyses of drying processes may be found in the engineering literature (12,13). 

Catalytic reactions are becoming increasingly important to increase productivity and minimize waste disposal costs. Examples of catalytic reactions are provided in Chapters 3 and 5. There is a broad diversity of catalysts and means to remove catalysts from reaction products (Table 9.1). 

Phase separation is controlled by phase equilibrium relations or rate-based mass and heat transfer mechanisms. Chemical reactions are controlled by chemical equilibrium relations or by reaction kinetics. For reactive distillation to have practical applications, both these operations must have favorable rates at the column conditions of temperature and pressure. If, for instance, the chemical reaction is irreversible, it may be advantageous to carry out the reaction and the separation of products in two distinct operations a reactor followed by a distillation column. Situations in which reactive distillation is feasible can result in savings in energy and equipment cost. Examples of such processes include the separation of close-boilers, shifting of equilibrium reactions toward higher yields, and removal of impurities by reactive absorption or stripping. 

Troubleshooting has been defined as the search for the hidden cause or causes that leads to inadequate performance. A troubleshooting response is appropriate when there is no anticipated danger to personnel and when there is little chance of any significant equipment damage usually the main concerns are about product quality, production rates, productivity, and equipment repair costs. Examples of trouble include ... 

In SAMIS, indirect requirements are nonprocess costs. Examples are the foreman for the machine shop and the cafeteria attendant. These are resources that are not directly involved with the process. The indirect requirements matrix, shown in Figure 27.4, contained relationships... 

This level of duty Is more often used than the absolute duty as far as the provision of safeguards is concerned and, in many ways, has the same effect. A duty that the employer ensure, so far as is practicable, that any control measure is maintained in an efficient state means that if the duty is technically possible or feasible then it must be done irrespective of any difficulty, inconvenience or cost. Examples of this duty may be found in the Provision and Use of Work Equipment Regulations (Regulation 11(2) (a and b)) and the Control of Lead at Work Regulations where Regulation 14 states, Every employer who provides any control measure. .. shall ensure, so far as is practicable, that it is maintained in an efficient state. .. and in good repair . 

Cost example for total lead pipe replacement... 

If there is no functional reason to remove the connection during normal operation, a permanent connection is recommended because of the small mounting space and lower costs. Examples of this type of connection include ... 

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