Miscellaneous materials, cost

An accurate estimate can be made by detailing and costing all the items needed, based on experience with similar plants. As a rough guide the cost of miscellaneous materials can be taken as 10 per cent of the total maintenance cost. 

Variable costs 1. Raw materials 2. Miscellaneous materials 3. Utilities 4. Shipping and packaging Typical values from flow-sheets 10 per cent of item (5) from flow-sheet usually negligible... 

New methods and products are constantly being developed in the chemical industries. These accomplishments are brought about by emphasis on research and development. Research and development costs include salaries and wages for all personnel directly connected with this type of work, fixed and operating expenses for all machinery and equipment involved, costs for materials and supplies, direct overhead expenses, and miscellaneous costs. In the chemical industry, these costs amount to about 2 to 5 percent of every sales dollar. 

A small water treatment system is generally sized to treat water volumes up to at least 0.044 m /s (1 MGD). For small solution-feed systems treating from 9.5 m /d to 0.044 m /s (2500 gpd to 1 MGD), operating and maintenance costs for gas chlorination systems are approximately the same. About 1630 kWh each year is required to run the booster pump and approx 2560 kWh annually is required for the building housing the system, assuming a 58.1-m (625-ft ) building. Maintenance labor cost and material costs for miscellaneous repair of valves, electrical switches, and other equipment replacement cost will be the extra. 

Miscellaneous. Materials to be considered in cost estimation under the miscellaneous category are factory supplies, including such items as gaskets, lubricants, paint, test chemicals, janitor supplies, rags, etc. Unless demands for any of these items are excessively high, a cost alloca-... 

Total Direct Materials and Labor Costs 785,700 Miscellaneous Installation Costs 0 Material and Labot G A Overhead and Contractor Fees 69,700 Contractor Engineering Costs 558,300 Indirect Costs 482,600... 

Reinforcing fillers used are carbon black and non-black fillers such as silica, clay, and calcium carbonate although the latter two are used more in lower cost industrial applications and not in tires. Protectant systems consist of antioxidants, antiozo-nants, and waxes. The vulcanization system essentially ensures that the optimum mechanical properties of the polymer system are achieved. Finally, the tire compound can contain various miscellaneous materials such as processing aids and resins. The materials scientist when designing a tire compound formulation has a range of objectives and restrictions within which to operate. Product performance objectives define the initial selection of materials. These materials must not raise environmental concerns, be processable in tire production plants, and be cost effective for the end user [4]. 

Precautions. Care should be taken not to impair the quaUty of the metal as a result of the melting operation. The best practice is to select scrap of known good quaUty. The use of miscellaneous scrap may not be economical, despite the lower cost of such material however, it is not common practice to make much use of virgin metals. 

A popular overall factor refinement, known as the Hand factor approach, uses a different factor to estimate overall costs for each class of equipment to cover all labor field materials, eg, piping, insulation, electrical, foundations, stmctures, and finishes and indirect costs, but not contingencies. Hand factors range from 4 for fractionating towers down to 2.5 for miscellaneous equipment. 

Direct Manufacturing Costs Direct manufacturing costs include raw materials, operating labor, utihties, and some miscellaneous items. A summary of the characteristics of each follows. 

Miscellaneous Direct Costs Estimates for the cost of maintenance and repairs, operating supplies, royalties, and patents are best based on company records for similar processes. A rough average value for the annual cost of maintenance is 6 percent of the capital cost of the plant. This percentage can vaiy from 2 to 10 percent, depending on the severity of plant operation. Approximately half of the maintenance costs are for materials and half for labor. Royalty and patents costs are in the order of 1 to 5 percent of the sales price of the product. 

In this chapter brief information on the origin and cost of titanium will be discussed. A definition of the term unique properties will be given and how these properties are exploited in the membrane, diaphragm and in the mercury cell processes will be considered and miscellaneous applications touched upon. The chapter will conclude with a summary of the financial benefits which, after all, propel the use of this challenging material. 

Including 20 ft2 for miscellaneous items not identified in this section, 110.3 ft2 must be rented, at an annual cost of 44,100/yr. Note that this moderately sized complex is added to an existing electronic materials manufacturing facility. Hence, no direct charges are added for infrastructure, such as non-clean room and office space. The total purchase cost, 6,492,100, provides equipment modules that require small installation costs, on the order of 1% that is, 65,000. Note also that two PECVD reactors are provided to assure uninterrupted operation when the plant is in operation, around the clock, 330 day/yr. While the robot loads and unloads one of the reactors, the other reactor is in operation. 

The solubility of DDT in twenty materials—ketones, petroleum fractions, and several miscellaneous solvents—over the temperature range —30° to 76° F. was determined by the rapid density method developed by Mauke and Sheard. DDT was found to be most soluble in cyclohexanone and less soluble in aromatic petroleum fractions, but the solvent cost per unit of DDT dissolved with them was only one half that for cyclohexanone. Cyclic ketones were better solvents than acyclic ketones with the same number of carbon atoms and the solubility in ketones was found to decrease with increasing molecular weight. 

In a typical 80,000 tons/year plant, capital costs were about 220 per metric ton in 1974. To produce 1000 kg of polymer, 1030 kg of monomer is needed, together with 1 kg of hydrogen and 25 kg of diluent. Catalyst and miscellaneous chemicals cost about 4 per 1000 kg of polyethylene pellets produced. For production, 300 kg of medium-pressure steam, 800 kg of low-pressure steam, 530 kWh of electrical energy, 200 m3 of water, 30 m3 of nitrogen, and 600 m3 of air are also required. To polymerize propylene in suspension, the same technology can be used. Catalysts now available [based on TiCl3 (see Table II)] make it unnecessary to separate isotactic from atactic materials. 

The chemical engineer (or cost engineer) must be certain to consider all possible factors when making a cost analysis. Fixed costs, direct production costs for raw materials, labor, maintenance, power, and utilities must all be included along with costs for plant and administrative overhead, distribution of the final products, and other miscellaneous items. 

Construction costs in the petroleum industry are the basis of the Nelson-Farrar construction index. The total index percentages are weighted as follows skilled labor, 30 common labor, 30 iron and steel, 20 building materials, 8 and miscellaneous equipment, 12. An index value of 100 is used for the base year of... 

In any manufacturing operation, many miscellaneous supplies are needed to keep the process functioning efficiently. Items such as charts, lubricants, test chemicals, custodial supplies, and similar supplies cannot be considered as raw materials or maintenance and repair materials, and are classified as operating supplies. The annual cost for this type of supplies is about 15 percent of the total cost for maintenance and repairs. 

Inventory and storage charges may be neglected. If necessary, the plant can be operated 24 h per day for 300 days per year. The annual production is 1 million kg of product. At this capacity, raw-material and miscellaneous costs, other than those already mentioned, amount to 260,000 per year. Determine the cycle time for conditions of minimum total cost per year. 

Metis161 reported a preliminary cost study on a 500-L scaled-up modular photobioreactor, and outlined the following cost distribution for the unit based on operating it for a period of 6 months photobioreactor materials, 45% mineral nutrients, 39% labor 4% water supply, 4% land lease, 2% power, 1% and miscellaneous expenses, 5%. He reported the actual cost of the materials for the pilot photobioreactor unit as 0.75 m 2, but the material used and the lifetime of the unit was not stated. This cost is much lower that the often quoted estimates of up to 100 per meter square using glass covered structures. Glass does not appear to be a realistic material to use in a commercial photobioreactor system because of both initial and replacement costs. 

Contractor s support and miscellaneous maintenance materials are usually covered by 7% of total labor costs. 

---