Capital Cost Estimating

ISBL Plant Cost

The cost which includes the major equipment which was calculated by Towler

(2013) via Cost Curve Method, Matches, and Wallace.

Equipment Quantity Cost/equipment TOTAL COST

(USD) (PHP)

Storage

Tank(Ammonia) 10.00 569,200.00 296,780,880.00

Phosphate Rock

Hopper 6.00 35,650.73 11,152,974.37

Reactor

R-100

1.00 707,853.86 36,907,500.00

R-200

1.00 162,400.00 8,467,536.00

R-201

1.00 162,400.00 8,467,536.00

Heat Exchanger

E-100

1.00 6,400.00 333,696.00

E-101

1.00 6,400.00 333,696.00

E-102

1.00 6,400.00 333,696.00

E-103

1.00 6,400.00 333,696.00

E-104

1.00 900.00 46,926.00

E-105

1.00 300.00 15,642.00

E-200

1.00 259,300.00 13,519,902.00

Pumps

P-100

1.00 7,300.00 380,622.00

P-101

1.00 7,300.00 380,622.00

P-103

1.00 7,300.00 380,622.00

P-104

1.00 10,200.00 531,828.00

P-105

1.00 10,200.00 531,828.00

P-106

1.00 10,200.00 531,828.00

Compressors

C-100

6.00 401,000.00 125,448,840.00

Grinder

G-100

1.00 568,752.38 29,654,749.09

Crystallizer

CR-100

1.00 48,244.36 2,515,460.93

Cooling tower

CT-100

3.00 202,252.33 31,636,309.38

Absorber

A-100

2.00 87,358.15 9,109,707.83

Turbine

TR-100

3.00 364,456.28 57,008,251.54

TR-200

1.00 110,277.72 5,749,880.44

Granulator

GR-100

1.00 10,700.00 557,898.00

 The Cost was escalated using the chemical engineering index was accurately

measured using the location factor ratio from Towler (2013)

Total Cost(PHP) Total Cost(PHP) of

Equipment escalated and located Shipping and Packaging

Storage Tank(Ammonia)
394,773,014.23 97,992,134.23

Phosphate Rock Hopper 16,956,975.46 5,804,001.09

Reactor

R-100
49,093,745.60 12,186,245.60

R-200
11,263,376.23 2,795,840.23

R-201
11,263,376.23 2,795,840.23

Heat Exchanger

E-100
443,876.90 110,180.90

E-101
443,876.90 110,180.90
E-102
443,876.90 110,180.90

E-103
443,876.90 110,180.90

E-104
62,420.19 15,494.19

E-105
20,806.73 5,164.73

E-200
17,983,949.86 4,464,047.86

Pumps

P-100
506,297.08 125,675.08

P-101
506,297.08 125,675.08

P-103
506,297.08 125,675.08

P-104
707,428.80 175,600.80

P-105 707,428.80 175,600.80

P-106 707,428.80 175,600.80

Compressors

C-100
166,869,970.53 41,421,130.53

Grinder

G-100
45,087,062.50 15,432,313.40

Crystallizer

CR-100 3,824,505.27 1,309,044.34

Cooling tower

CT-100 48,099,825.55 16,463,516.17

Absorber

A-100 13,850,394.25 4,740,686.42

Turbine

TR-100 80,891,572.34 23,883,320.81

TR-200 8,158,763.99 2,408,883.55

Granulator

GR-100 742,106.69 184,208.69

 Total Cost(PHP) 874,358,550.89 233,246,423.31

𝑇𝑜𝑡𝑎𝑙 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 = 𝐸𝑠𝑐𝑎𝑙𝑎𝑡𝑒𝑑 𝑎𝑛𝑑 𝐿𝑜𝑐𝑎𝑡𝑒𝑑 𝐶𝑜𝑠𝑡 + 𝑆ℎ𝑖𝑝𝑝𝑖𝑛𝑔 𝑎𝑛𝑑 𝑃𝑎𝑐𝑘𝑎𝑔𝑖𝑛𝑔

𝑇𝑜𝑡𝑎𝑙 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 = 874,358,550.89 𝑃𝐻𝑃 + 233,246,423.31 𝑃𝐻𝑃

𝑇𝑜𝑡𝑎𝑙 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 = 1,107,604,974.20 𝑃𝐻𝑃

The Total ISBL was calculated using the Lang Factor of Towler (2013).

FIXED CAPITAL COST ESTIMATION Php

Total equipment cost with shipping 1,107,604,974.20

Equipment erection

553,802,487.10

Instrumentation and Control

332,281,492.26

Electical

221,520,994.84

Civil

332,281,492.26

Structure and building

221,520,994.84

Lagging and Paint

110,760,497.42
 Piping

1,010,544,046.19

Permit Cost

548,470.71

Land Cost

284,900,000.00

Total ISBL

4,175,765,449.82

OSBL Plant Cost

Wastewater treatment facility

The wastewater treatment facility was assumed to be working on secondary treatment alone

since no grits and other unnecessary solids are present in the wastewater. SBR/ Sequential Batch

Reactor was used for this treatment. The sequencing batch reactor was developed in the early

1900’s but did not become popular until reliable and cost-effective mechanical equipment and

digital controls became available in the late 1970’s. The SBR is a fill-and-draw system. In this

system, wastewater is added to the reactor, treated to remove undesirable components, and then

discharged. For larger flows, two or more tanks can be used in an alternating sequence. SBR

systems consist of several treatment phases that make up a complete treatment cycle. Most systems

operate from between 3 and 6 cycles per day. Our Sabre package sequencing batch reactor (SBR)

plants are typically provided in buried fiberglass tanks designed to be out of sight and out of mind.
 According to EarthTec, the Sabre SBR provides complete nitrification of the influent

ammonia during the aerated-fill and the react phases of treatment. During the beginning of a

treatment cycle, wastewater is fed into the SBR with only mixing and no aeration. This is an anoxic

mixed-fill phase and provides denitrification of the nitrified effluent from the previous batch.

Table.

Wastewater Treatment Facility 3,829,130 PHP

Cooling Tower 48,099,825.55 PHP

Boiler 1,006,400 PHP

Transportation 51,079,940.20 PHP

Laboratory Equipment 1,524,678 PHP

Tanker Farm 352475905.6 PHP

Hopper 15140156.66 PHP

Total Cost 473,156,036 PHP

Table. Laboratory Equipment

Equipment Quantity Price (PHP) Source

NDIR 1.00 157,200.00 Nanjing Technology

FTIR 1.00 468,980.00 LabX Shop

Photomultiplier 10.00 198,072.00 Ushio

Tubes

Bandpass Filter 5.00 2,468.04 eBay

AAS 1.00 508,280.00 Zhejiang Lichen Instrument

Technology

Ion Selective 1.00 62,880.00 Shanghai Boku Instrument

Electrode

Analytical Balance 2.00 126,798.00 ph.rs-online

1,524,678.04

Contingency Cost

For contingency cost, a rule of thumb of 0.1 of the sum of the ISBL and OSBL was

used which was base on Towler (2013).

𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦 𝐶𝑜𝑠𝑡 = 0.1 (𝑂𝑆𝐵𝐿 + 𝐼𝑆𝐵𝐿)

𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦 𝐶𝑜𝑠𝑡 = 0.1 (349,743,420.40 PHP

+1,684,979,892.92 PHP)
 𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦 𝐶𝑜𝑠𝑡 = 203,472,331.33𝑃𝐻𝑃

𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝐼 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 𝐼𝑆𝐵𝐿 + 𝑂𝑆𝐵𝐿 + 𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦 𝐶𝑜𝑠𝑡

𝐹𝐶𝐼 = 1,684,979,892.92 PHP + 349,743,420.40 PHP + 203,472,331.33𝑃𝐻𝑃

𝑭𝑪𝑰 = 𝟐, 𝟐𝟑𝟖, 𝟏𝟗𝟓, 𝟔𝟒𝟒. 𝟔𝟏 𝐏𝐇𝐏

Working Capital

The Working capital was calculated using the rule of thumbs on chapter 9 Towler

(2013) as a function of cash cost of production and raw material cost.

WORKING CAPITAL Php

Cash Cost of Production at 2024

1,761,376,152.54

Value of product and by-product

70,455,046.10

Cash on hand

35,227,523.05

Accounts receivable

140,910,092.20

Credits for account payable

67,048,405.05

Value of raw material inventory

33,524,202.52

Spare part inventory

461,880,743.95

Working Capital

809,046,012.88
WORKING CAPITAL Php
Cash Cost of Production at 2024
1,761,376,152.54
Value of product and by-product
452,925,296.37
Cash on hand
226,462,648.18
Accounts receivable
905,850,592.74
Credits for account payable
431,025,461.02
Value of raw material inventory
215,512,730.51
Spare part inventory
196,199,650.66
Working Capital
2,427,976,379.48

Total Capital Cost

𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 + 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐶𝑎𝑝𝑖𝑡𝑎𝑙

𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐶𝑜𝑠𝑡 = 2,238,195,644.61 PHP + 550,637,600.25 PHP

𝑻𝒐𝒕𝒂𝒍 𝑪𝒂𝒑𝒊𝒕𝒂𝒍 𝑪𝒐𝒔𝒕 = 𝟐, 𝟕𝟖𝟖, 𝟖𝟑𝟑, 𝟐𝟒𝟒. 𝟖𝟔 𝐏𝐇𝐏