Designated laboratories costs

The two broad classes of photochemical reactors are the batch processors and the continuous processors. The batch processor is simple in design, but costly in operation, because it requires the loading of the reactant, the unloading of the product and the cleaning of the reactor vessel all operations which involve human intervention. Batch processing is used as a rule in laboratory synthesis, but industrial applications prefer continuous systems for reasons of efficiency. Still, it must be accepted that batch processing will be used for many small-scale industrial syntheses. 

Ernst et al.5 indicate that the Super Pro Designer contains models to help estimate the direct fixed capital cost based on 1995 dollars. These numbers may be suitably updated using the current CPI or other suitable index. Maintenance cost were set at 25% of the purchase cost of the equipment per year. Laboratory costs were allocated to capital costs. Labor costs were carefully calculated based on number of operator hours per equipment hour. This was done after analyzing scheduling of the entire process as well as noting that the operator time on each equipment was reasonable. 

When these factors are considered, cost comparisons bear little resemblance to first costs. Table 11 presents a typical analysis of comparative costs for alternative materials when based on return on investment. One difficulty with such a comparison is the uncertainty associated with estimated life. Well-designed laboratory and plant tests can at least give order-of-magnitude estimates. Another difficulty arises in estimating the annual maintenance cost. This can only be predicted from previous experience with the specific materials. 

For the sizing and estimation of purchase costs, when designing laboratory-scale equipment, data are provided by Ernst et al. (1999). Note that such data are based upon similar laboratory-scale equipment. 

In the original planning of this book we were at pains to ensure that the preparations in particular were designed to afford a minimum expenditure of time, materials and heating. We hope that the economy thus introduced will be especially appreciated in view of the recent heavily increased cost of chemicals, fuel and laboratory service. This increased cost, incidentally, must necessarily increase the attraction of the small-scale preparations referred to above. 

Time, Cost, and Equipment Automated chemical kinetic methods of analysis provide a rapid means for analyzing samples, with throughputs ranging from several hundred to several thousand determinations per hour. The initial start-up costs, however, may be fairly high because an automated analysis requires a dedicated instrument designed to meet the specific needs of the analysis. When handled manually, chemical kinetic methods can be accomplished using equipment and instrumentation routinely available in most laboratories. Sample throughput, however, is much lower than with automated methods. 

After development of a new process scheme at laboratory scale, constmction and operation of pilot-plant faciUties to confirm scale-up information often require two or three years. An additional two to three years is commonly required for final design, fabrication of special equipment, and constmction of the plant. Thus, projections of raw material costs and availabiUty five to ten years into the future become important in adopting any new process significantly different from the current technology. 

Electrodes. At least three factors need to be considered ia electrode selection as the technical development of an electroorganic reaction moves from the laboratory cell to the commercial system. First is the selection of the lowest cost form of the conductive material that both produces the desired electrode reactions and possesses stmctural iategrity. Second is the preservation of the active life of the electrodes. The final factor is the conductivity of the electrode material within the context of cell design. An ia-depth discussion of electrode materials for electroorganic synthesis as well as a detailed discussion of the influence of electrode materials on reaction path (electrocatalysis) are available (25,26). A general account of electrodes for iadustrial processes is also available (27). 

Much of the experience and data from wastewater treatment has been gained from municipal treatment plants. Industrial liquid wastes are similar to wastewater but differ in significant ways. Thus, typical design parameters and standards developed for municipal wastewater operations must not be blindly utilized for industrial wastewater. It is best to run laboratory and small pilot tests with the specific industrial wastewater as part of the design process. It is most important to understand the temporal variations in industrial wastewater strength, flow, and waste components and their effect on the performance of various treatment processes. Industry personnel in an effort to reduce cost often neglect laboratory and pilot studies and depend on waste characteristics from similar plants. This strategy often results in failure, delay, and increased costs. Careful studies on the actual waste at a plant site cannot be overemphasized. 

The cost estimate should include provisions for any required satellite boiler water analysis laboratories. The central control lab cannot normally handle analyses of widely spread boilers satisfactorily. The designers, while remembering satellite water laboratory facilities for the utilities area, might overlook similar facilities for the steam generation in the process area. 

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