GUIDANCE

Concept Paper Number [ENTER]

Project Title [ENTER]
Project Lead Applicant [ENTER]

PURPOSE

The purpose of this workbook is to facilitate the calculation of the co

spreadsheets within contain internal calculators, that may be bypass
information. The calculators include equipment pricing, installation
that CAPEX and OPEX may be determined in a standard way.

Success Checklist (before starting, make sure to have the following)

You will see the following fields herein

INPUTS
OUTPUTS
FLAG
ERROR

Naviagation through this workbook

 Process flow diagram and
supporting information are
entered in the "proposed" tab

Parameters Worksheet
This sheet may appear complex, but has the following structured format

"Detailed" Worksheet
If the need arises to provide input in the "detailed" worksheet, you will b
highlighted cell, or both. Expect to spend more time within this sheet if y
equipment, and rest assured that you only need to attend to the highligh
Reference Case 1

Throughout the workbook, one will be able to make inputs and

comparisons with reference to "Case 1". This reference case is a batc
fermenation to a C16 fatty acid, followed by centrifugation, acid wash
and hydrotreatment to a C15 hydrocarbon. The stochiometry, proces
parameters, and equipment requirements are described herein.

A representative process flow diagram for the reference case may be

found in the "case1" tab.

(The initial parameter set for the proposed case is identical to that of
reference case, until updated by the user.)

Caveats
This workbook is flexible to the proposed process and delivers the primar
way, provided that the user accurately and independently enters (1) the o
equipment list and associated requirements. It is the responsibility of the
upon separately completion of a detailed systems analysis (including mas

(1) Operational and

performance parameters

(2) Equipment list and

requirements
 Since proposed processes can take on many forms and configurations, t
above with a minor exception for batch fermenation systems, which can
For example, if the user changes the reactor pressure, then the user mus
independently by a systems analysis. Subsequently, this workbook will d

Bypassed Calculations

There are multiple types of formulas provided with this workbook: batch
heat generation calculator, operating expense calculators, and capital exp
"parameters" sheet. The user will be directed to provide alternative valu

Targeted Basis
 The purpose of this workbook is to facilitate the calculation of the costs and performance of a proposed process. The
spreadsheets within contain internal calculators, that may be bypassed for the user that wishes to input more detailed
information. The calculators include equipment pricing, installation factors, and the flexibility to make adjustments, so
that CAPEX and OPEX may be determined in a standard way.

uccess Checklist (before starting, make sure to have the following)

Process Flow Diagram
Mass & Energy Balances
Stream Tables
Equipment List
Equipment Loads, Volumes, Utility Requirements

ou will see the following fields herein

These fields require a value from your process. Some field were pre-populated with reference 'Case 1' values.
These fields output information to other sheets
These fields call your attention if needed
These fields call your attention if needed

aviagation through this workbook

More information about

the reference case
Most if not all inputs are entered Abbreviations and
on the “parameters” tab. supporting information
 Process flow diagram and Supporting calculations. Complex processes
supporting information are may require additional inputs on the “detailed
entered in the "proposed" tab tab. This tab computes opex and capex.

Calculation results may be viewed on the

green tabs (“capex”, “opex”, and “summary”).

Supporting calculations.
Input is not required.

arameters Worksheet
This sheet may appear complex, but has the following structured format with a few hyperlinks to guide you if the need arises:

process variables equipment list and sizing

stoichiometry

Detailed" Worksheet
If the need arises to provide input in the "detailed" worksheet, you will be guided to the requisite fields by either a hyperlink, a
highlighted cell, or both. Expect to spend more time within this sheet if you have a significant number of customized
equipment, and rest assured that you only need to attend to the highlighted areas.

capital costs

operating costs
 operating costs

supporting info (static) on pricing

eference Case 1

Throughout the workbook, one will be able to make inputs and

comparisons with reference to "Case 1". This reference case is a batch
fermenation to a C16 fatty acid, followed by centrifugation, acid washing,
and hydrotreatment to a C15 hydrocarbon. The stochiometry, process
parameters, and equipment requirements are described herein.

A representative process flow diagram for the reference case may be

found in the "case1" tab.

(The initial parameter set for the proposed case is identical to that of the
reference case, until updated by the user.)

This workbook is flexible to the proposed process and delivers the primary value of determining OPEX and CAPEX in a standard
way, provided that the user accurately and independently enters (1) the operational and performance parameters, and (2) the
equipment list and associated requirements. It is the responsibility of the user to enter (1) and (2) for the proposed process
upon separately completion of a detailed systems analysis (including mass and energy balances, and equipment performance).

(1) Operational and

performance parameters

OPEX, CAPEX Cost and Performance

consequences Summary

(2) Equipment list and

requirements
 Since proposed processes can take on many forms and configurations, there is no interaction between the areas (1) and (2)
above with a minor exception for batch fermenation systems, which can take advantage of the built-in batch volume calculator.
For example, if the user changes the reactor pressure, then the user must also change the compressor power as determined
independently by a systems analysis. Subsequently, this workbook will determine the CAPEX and OPEX.

ypassed Calculations

There are multiple types of formulas provided with this workbook: batch volume calculator, a heat generation estimator and a
heat generation calculator, operating expense calculators, and capital expense calculators. Each of these can be bypassed on the
"parameters" sheet. The user will be directed to provide alternative values and justification.

argeted Basis

The production rate of finished renewable diesel should be set to be 500

Barrel of Oil Equivalents per Day. A deviation from this value will trigger
an error signal at least in the "summary" sheet.
 cesses
detailed”
ex.
PROCESS FLOW DIAGRAM, DESCRIPTIONS OF UNIT OPERATIONS
Please copy/paste or construct a PFD below. If pasting, kindly ensure enough resolution to allow identification of each process
and associated text. An exemplary PFD is presented in the "case1" tab within this workbook.

Concept Paper Number: [ENTER]

Project Title: [ENTER]
Project Lead Applicant: [ENTER]
tification of each process stream
SUMMARY OF SYSTEM PARAMETERS AND EQUIPMENT
Concept Paper Number: [ENTER]
Project Title: [ENTER]
Project Lead Applicant: [ENTER]

Production Rate: BOE/d 500

Parameters Units Case 1

Stream Table Inputs

CH4 feed rate, fresh kg/hr 7,653
CH4 recycle to reactors kg/hr 403
H2 feed rate (for FA production) kg/hr -
H2 feed rate (for hydrotreating) kg/hr -
O2 feed rate kg/hr 24,257
Acid rate for FA wash kg/hr 10
Ammonia into reactors (when on-stream) kg/hr 339
Water, fresh to process kg/hr 18,185
Water, for FA wash kg/hr 686
Additional CH4 for heating kg/hr -

Reactor parameters
If batch, utilize the batch volume calculator? [SELECT] calculation
Use the reactor heat generation estimator? [SELECT] estimation
Manually-entered total required reaction volume L
Manually-entered number of reactor vessels
Manually-entered reactor heat generation GJ/hr
Per-pass CH4 conversion 90%
Reaction operating temperature °C 35

Metabolic parameters
Average Volumetric Productivity g FA/L/hr 0.369
Theoretical Yield FA/CH4 mol/mol 0.0417
CH4 toward FA production g/g 74.6%

Process parameters
Ammonia on-stream operating factor 90%
Overall fraction of FA converted to diesel 90%

General operational parameters

 Plant operating factor x 365 days days/yr 328.5
Labor operating cost (LOC) $/year 2,296,115
Labor burden of LOC 90%
Maintenance of ISBL 3%
Property Insur. & Tax of FCI 0.70%

Heats of combustion
LHV (CH4) kJ/mol 802.6
HHV (CH4) kJ/mol 889
HHV (H2) kJ/mol 286.1
LHV (FA product) kJ/mol 9316
LHV (refined renewable diesel) kJ/mol 9440
HHV (refined renewable diesel) kJ/mol 10050
Heats of Formation
H2O (l) kJ/mol -286
CO2 (g) kJ/mol -394
O2 (g) kJ/mol 0
CH4 (g) kJ/mol -75
Cell kJ/mol -368
FA (l) kJ/mol -892
Molecular Weights
MW (CH4) g/mol 16.04
MW (H2) g/mol 2.02
MW (FA product) g/mol 256.42
MW (hydrocarbon product) g/mol 212.47
 500
Proposed

7,653
403
-
-
24,257
10
339
18,185
686
-

calculation
estimation

90%
35

0.369
0.0417
74.6%

90%
90%
 328.5
2,296,115
90%
3%
0.70%

802.6
889
286.1
9316
9440
10050

-286
-394
0
-75
-368
-892

16.04
2.02
256.42
212.47
Target is 500 BOE/d at full capacity
Comments

Affects choice of cooling system in capex and opex calculations

FA mass productivity, Average reaction rate based on limiting reaction

See stoichiometry area
Fraction CH4 utilized for FA production / total CH4 consumed for both cell growth and FA production

Accounts for post-reaction losses during purification and hydrotreating stages

Equipment Quantity Pressure
[psig]

Fermentation/Synthesis
Reaction vessel (stirred tank) 17 125
Supplementary equipment for vessel
Fresh gas compressor
Recycle gas compressor
Seeding
Fermentor seed train 17 125
Fresh gas compressor
Recycle compressor
Additional pumps for liquid streams
Product Separation, Finishing
FA concentration: centrifuge
FA concentration/washing: decanter
FA upgrading: hydrotreating
Cooling
Chiller: utilities (applies if operating temperature <37 C)
Cooling tower: utilities (applies if operating temperature >37 C)
User Added
Additional equipment (ISBL)
Additional equipment (ISBL)
Additional equipment (ISBL)
Additional equipment (ISBL)
Additional equipment (ISBL)
Additional equipment (ISBL)

Stoichiometry
Case 1 stoichiometry
FA production (1 mol total FA): 24.00 CH4 +
Cell growth (1 mol cell) 4.97 CH4 +
Total combined: 32.18 CH4 +
PROPOSED stoichiometry
FA production (1 mol total FA): 24.00 CH4 +
Cell growth (1 mol cell) 4.97 CH4 +
Total combined: 32.18 CH4 +
 Capacity Electricity CH4 H2 Water
Total Working Power Flow FA feed Req'd Req'd Req'd Req'd
[L] [kW] [gpm] [kg/h] [kW] [kg/h] [kg/h] [kg/h]

878354 68%

3187
3899

1078
982

10.6023 52.8
33.1
3260

25.00 O2 = 1.00 C16H32O2 + 8 CO2 + 32.00

5.11 O2 = 1 cell + 0.97 CO2 + 6.44
33.41 O2 = 1.00 C16H32O2 1.65 cell + 9.60 CO2 + 42.60

25.00 O2 = 1.00 C16H32O2 + 8 CO2 + 32.00

 5.11 O2 = 1 cell + 0.97 CO2 + 6.44
33.41 O2 = 1.00 C16H32O2 1.65 cell + 9.60 CO2 + 42.60
 Other
Req'd Formulas for CAPEX determination
[Selection]

no accept
no accept
no accept
no accept

no accept
no accept
no accept
no n/a

no accept
no accept
no accept

no accept
no accept

no n/a
no n/a
no n/a
no n/a
no n/a
no n/a

H2O
H2O
H2O

H2O
H2O
H2O
Message
Acknowledge

[SELECT]
TOTAL CAPITAL INVESTMENT SUMMARY
Concept Paper Number: [ENTER]
Project Title: [ENTER]
Project Lead Applicant: [ENTER]

CAPEX Summary

Total Capital Investment (TCI)

Production Basis (BPD)
Process Area Installed Costs
Fermentation Equipment
Compressors
Separations Equipment
Product Upgrading
Gas Separations
Other ISBL Equipment
ISBL Total
Refrigeration
Wastewater Treatment
Balance of Plant 10% of ISBL
Total IBSL + OSBL

Warehouse 4% of ISBL
Site Development 9% of ISBL
Additional Piping 5% of ISBL
Total Direct Costs (TDC)
Prorateable Expenses 10% of TDC
Field Expenses 10% of TDC
Home Office & Construction Fee 20% of TDC
Project Contingency 10% of TDC
Other Costs (Start-Up, Permits, etc.) 10% of TDC
Total Indirect Costs
Fixed Capital Investment (FCI)
Land
Working Capital 5% of FCI
Case 1 Proposed
$ 229,319,371 $ 229,319,371
500 500

$ 72,549,885 $ 72,549,885
$ 20,833,936 $ 20,833,936
$ 813,224 $ 813,224
$ 8,018,074 $ 8,018,074
$ - $ -
$ - $ -
$ 102,215,119 $ 102,215,119
$ 5,074,159 $ 5,074,159
$ - $ -
$ 10,221,512 $ 10,221,512
$ 117,510,789 $ 117,510,789

$ 4,088,605 $ 4,088,605
$ 9,199,361 $ 9,199,361
$ 4,599,680 $ 4,599,680
$ 135,398,435 $ 135,398,435
$ 13,539,844 $ 13,539,844
$ 13,539,844 $ 13,539,844
$ 27,079,687 $ 27,079,687
$ 13,539,844 $ 13,539,844
$ 13,539,844 $ 13,539,844
$ 81,239,061 $ 81,239,061
$ 216,637,496 $ 216,637,496
$ 1,850,000 $ 1,850,000
$ 10,831,875 $ 10,831,875
Comments
TOTAL OPERATING EXPENSES SUMMARY
Concept Paper Number: [ENTER]
Project Title: [ENTER]
Project Lead Applicant: [ENTER]

OPEX Summary (first year)

Total Variable Costs

Total Fixed Costs
Variable Costs
Power (less chillers)
Chiller power
Total Power
CH4 supply
H2 supply
O2 supply
Water supply
Acid supply
Ammonia supply
Total Material
Fixed Costs
Labor and overhead
Total maint., insur., taxes
Total fixed costs
 Case 1 Proposed
$ 28,580,897 $ 28,580,897
$ 8,945,534 $ 8,945,534

$ 4,331,089 $ 4,331,089
$ 6,433,965 $ 6,433,965
$ 10,765,053 $ 10,765,053
$ 15,870,478 $ 15,870,478
$ - $ -
$ - $ -
$ 47,258 $ 47,258
$ 132,354 $ 132,354
$ 1,765,754 $ 1,765,754
$ 17,815,844 $ 17,815,844

$ 4,362,618 $ 4,362,618
$ 4,582,916 $ 4,582,916
$ 8,945,534 $ 8,945,534
Comments
COST AND PERFORMANCE SUMMARY
Concept Paper Number: [ENTER]
Project Title: [ENTER]
Project Lead Applicant: [ENTER]

Units Case 1
PERFORMANCE
Production Rate BPD 500
CH4 feed rate kg/hr 7653
Electricity input kW 22757
Heating value of raw inputs kW 119954
Heating value of diesel product kW 35413
Net Plant HHV Efficiency 24.8%
Process water input kg/hr 18871
Acid input kg/hr 10.3
Nutrient input kg/hr 339.1
COST
Total Capital Investment (TCI) 2011$ $ 229,319,371
Total Direct Costs 2011$ $ 135,398,435
ISBL Total 2011$ $ 102,215,119
Total Variable Costs 2011$ $ 28,580,897
Total Fixed Costs 2011$ $ 8,945,534
OTHER FIGURES OF MERIT
TCI / Production Rate 2011$/BPD 458,639
Gas Consumption Rate g/L/hr 0.783
Reactor Productivity g/L/hr 0.369
Specific Heat Generation kW/m3 6.96
 Proposed

500
7653
22757
119954
35413
24.8%
18871
10.3
339.1

$ 229,319,371
$ 135,398,435
$ 102,215,119
$ 28,580,897
$ 8,945,534

458,639
0.783
0.369
6.96
Comments

Daily rate at 100% plant capacity. Targeted Basis is 500 BPD.

HHV basis
HHV basis

CH4 for both FA and other processes (e.g., cell growth)

FA production only
Per total reactor volume
BIOCONVERSION CALCULATIONS
Concept Paper Number: [ENTER]
Project Title: [ENTER]
Project Lead Applicant: [ENTER]

Process Consequences
Mass FA out of reactors
Mass FA retained for diesel production
Mass refined diesel
Heating value of diesel product, HHV
Diesel production rate, at full capacity
Reactor Consequences
Volume
Total reactor volume if batch process
Total reactor volume used in calculations
Performance
Gas Consumption Rate
Reactor FA Productivity
Heat Generation
Estimation
Theoretical Metabolic Efficiency
Actual Metabolic Efficiency
Heat flow from reactors, estimate
Detailed calculation
Heat generated by FA production
Heat generated by cell growth
Heat flow from reactors, detailed
Manual entry
Heat flow from reactors, manual entry
Heat flow from reactors
Specific Heat Generation
Units Case 1 Proposed

kg/hr 3,602 3,602

kg/hr 3,253 3,253
kg/hr 2,695 2,695
kW 35,413 35,413
BOE/d 500 500

L 9,771,836 9,771,836
L 9,771,836 9,771,836

g/L/hr 0.783 0.783

g/L/hr 0.369 0.369

48.4% 48.4%
36.1% 36.1%
GJ/hr -244.82 -244.82

GJ/hr 159.98 159.98

GJ/hr 61.89 61.89
GJ/hr -221.86 -221.86

GJ/hr n/a n/a

GJ/hr -244.82 -244.82
kW/m3 6.96 6.96
Comments

Assuming 100% decarboxylation, 0% hydrodeoxygenation

Targeted basis is 500 BOE/d

DETAILED CAPEX AND OPEX CALCULATIONS
Concept Paper Number: [ENTER]
Project Title: [ENTER]
Project Lead Applicant: [ENTER]

CAPITAL COSTS
Case 1
Fermentor vessels
Reactor total volume 878354
Reactor operating pressure 125
Cost basis $1,330,828
Process basis 1
Scaling factor 1
Installation factor 2
# of total vessels (rounded up) 17
Installed capital cost, current year dollars $45,248,144

Fermentor supplementary equipment

Reactor total volume 878354
Cost basis $178,464
Process basis 1
Scaling factor 1
Installation factor 2
# of total vessels (rounded up) 17
Installed capital cost, current year dollars $6,067,775

Fermentor fresh gas compressor

Cost basis $9,359,000
Process basis 11093
Scaling factor 0.8
Installation factor 1
Production fresh gas compressor power demand 3187
Installed capital cost, current year dollars $3,872,546

Fermentor recycle compressor

Cost basis $1,215,100
Process basis 836
Scaling factor 0.8
Installation factor 1
Production recycle compressor power demand 3899
Installed capital cost, current year dollars $4,673,852
Seed train fresh gas compressor
Cost basis $1,991,700
Process basis 795
Scaling factor 0.8
Installation factor 1
Seed train fresh gas compressor 1077.78342100721
Installed capital cost, current year dollars $2,851,303

Seed train recycle compressor

Cost basis $910,800
Process basis 61
Scaling factor 0.8
Installation factor 1
Seed train recycle compressor 981.611371559104
Installed capital cost, current year dollars $9,436,235

TOTAL installed cost for compressors $20,833,936

Fermentor seed train

Reactor operating pressure 125
Cost basis $22,651,011
Process basis 22240000
Scaling factor 0.6
Installation factor 1.5
Reactor average working volume (if operating batch) 68.0409%
Reactor total volume 878354
# of total vessels (rounded up) 17
Installed capital cost, current year dollars $21,233,966

FA concentration: centrifuge
Cost basis $500,000
Process basis 250
Scaling factor 1
Installation factor 1
Flow rate 52.7744956908662
Installed capital cost, current year dollars $561,123

FA concentration/washing: decanter
Cost basis $224,640
Process basis 500
Scaling factor 1
Installation factor 1
Total flow rate to decanter 33.2835964336379
Installed capital cost, current year dollars $252,101
FA upgrading: hydrotreating
Cost basis $1,930,000
Process basis 2871
Scaling factor 0.7
Installation factor 1.5
Purified FA rate 3259.54131301644
Installed capital cost, current year dollars $8,018,074

Chiller: utilities (applies if operating temperature <37 C)

Cost basis $1,275,750
Process basis 14.2
Scaling factor 0.6
Installation factor 1.6
Total heat generated by reactions -245
Chiller electricity use
Installed capital cost, current year dollars $5,074,159

Cooling tower: utilities (applies if operating temperature >37 C)

Cost basis $1,525,000
Process basis 97.4
Scaling factor 0.6
Installation factor 1.5
Total heat generated by reactions -245
Installed capital cost, current year dollars $1,790,924

Reactor Operating Temperature 35

Cooling utility used here: Chiller
Cooling utility cost: $5,074,159

Additional Liquid Pumps

Cost basis
Installation factor
Installed capital cost, current year dollars

Additional Equipment (ISBL)

Cost basis
Installation factor
Installed capital cost, current year dollars

Additional Equipment (ISBL)

Cost basis
Installation factor
Installed capital cost, current year dollars
Additional Equipment (ISBL)
Cost basis
Installation factor
Installed capital cost, current year dollars

TOTAL additional equipment (ISBL) 0

OPERATING COSTS
Case 1
Power
Total compressor power demand 9145
Additional Liquid Pumping Loads 0
Centrifuge power demand 10.60
Electricity demand 9156
Electricity cost 0.06
Power operating cost $4,331,089

CH4
CH4 feed rate 7653.42674234068
CH4 cost $0.26
CH4 operating cost $15,870,478.50

H2 (feed to process)
H2 feed rate 0
H2 cost $1.75
H2 operating cost $0

H2 for hydrotreating
H2 feed rate 0
H2 cost $1.75
H2 operating cost $0

O2
O2 feed rate 24257
O2 cost $0.00
O2 operating cost $0

Process Water
Fresh water to process 18184.6331856078
Water rate for FA wash 686.219223792935
Makeup water rate 18871
Water cost 19.97
Water operating cost $47,258
Acid for FA washing
Acid rate for FA wash 10
Acid cost 1.47
Acid operating cost $132,354

Natural Gas (additional)

Natural gas heating demand, lhv basis -
Natural gas cost $5
Natural gas operating cost $0

Cooling water cost (electric chiller COP=5)

Total heat generated by reactions -245
Cooling demand 244824
COP 5
Electricity Use 13601
Electricity cost 0.06
Cooling water operating cost $6,433,965

Cell biomass nutrients

Ammonia into reactors 339
NH3 cost $450
On-stream operating factor 90%
Total nutrient cost $1,765,754

TOTAL ELECTRICITY USE 22757.17

CH4 gross heating value, hhv basis 117828.63
H2 gross heating value, hhv basis 0.00
NG gross heating value, hhv basis 0.00
Ammonia, gross heating value, hhv basis 2119.20
Acid, heat of mixing 5.87
TOTAL HEATING VALUE OF INPUTS 119953.70
TOTAL ENERGY INPUTS 142710.87

Fixed costs
Labor basis $2,091,754
Labor operating cost $2,296,115
Labor burden 90%
Total labor + overhead $4,362,618

Maintenance 3%
Property Insur. & Tax 0.7%
ISBL $ 102,215,119
Total maint., insur., taxes $4,582,916
Total fixed costs $8,945,534

Cost reference:
Electricity price 0.06
Natural gas price $5
H2 cost $1.75
Acid cost 1.47
NH3 cost $450
CH4 price $0.26
O2 cost $0.00
Water cost 19.97

Cost-year dollars 2011

Operating factor 328.5
 Case 1 Proposed

L 878354 L
psig 125 psig
$ each, 2011$ $1,330,828 $ each, 2011$
each 1 each
1
2
17
$45,248,144

L 878354 L
$ per vessel, 2011$ $178,464 $ per vessel, 2011$
each 1 each
1
2
17
$6,067,775

total, 2009$ $9,359,000 total, 2009$

KW 11093 KW
0.8
1
KW 3187 KW
$3,872,546

total, 2009$ $1,215,100 total, 2009$

KW 836 KW
0.8
1
KW 3899 KW
$4,673,852
total, 2009$ $1,991,700 total, 2009$
KW 795 KW
0.8
1
KW 1078 KW
$2,851,303

total, 2009$ $910,800 total, 2009$

KW 61 KW
0.8
1
KW 982 KW
$9,436,235

$20,833,936

psig 125 psig

$ total, 2011$ $22,651,011 $ total, 2011$
L total fermentor volume 22240000 L total fermentor volume
0.6
1.5
68.0409%
L 878354 L
17
$21,233,966

$ per unit, 2009$ $500,000 $ per unit, 2009$

gpm max cap per unit 250 gpm max cap per unit
1
1
gpm 52.7744956908662 gpm
$561,122.82

$ per vessel, 2009$ $224,640 $ per vessel, 2009$

gpm max cap per unit 500 gpm max cap per unit
1
1
gpm 33.1347309919888 gpm
$252,101
Hydrotreating plant, 2003$ $1,930,000 Hydrotreating plant, 2003$
lb/hr feed rate 2871 lb/hr feed rate
0.7
1.5
kg/h 3260 kg/h
$8,018,074

total, 2010$ $1,275,750 total, 2010$

MM kcal/hr 14.2 MM kcal/hr
0.6
1.6
MM KJ/hr -245 MM KJ/hr

$5,074,159

total, 2010$ $1,525,000 total, 2010$

MM kcal/hr 97.4 MM kcal/hr
0.6
1.5
MM KJ/hr -245 MM KJ/hr
$1,790,924

°C 35 °C
Chiller
$5,074,159
 0

Case 1 Proposed

KW 9145 KW
KW 0 KW
KW 10.6023194634551 KW
KW 9156 KW
$/KWh 0.06 $/KWh
$/year $4,331,089 $/year

kg/hr 7653.42674234068 kg/hr

$/kg $0.26 $/kg
$/year $15,870,478.50 $/year

kg/hr 0 kg/hr
$/kg $1.75 $/kg
$/year $0 $/year

kg/hr 0 kg/hr
$/kg $1.75 $/kg
$/year $0 $/year

kg/hr 24257 kg/hr

$/kg (2009$) $0.00 $/kg (2009$)
$/year $0 $/year

kg/hr 18184.6331856078 kg/hr

kg/hr 686.219223792935 kg/hr
kg/hr 18871 kg/hr
cents/ton (2004$) 19.97 cents/ton (2004$)
$/year $47,258 $/year
kg/h 10 kg/h
$/kg (2009$) 1.47 $/kg (2009$)
$/year $132,354 $/year

MJ/hr 0.0000 MJ/hr

$/MM BTU $5 $/MM BTU
$/year $0 $/year

GJ/hr -245 GJ/hr

MJ/hr 244824 MJ/hr
5
KW 13601 kW
$/KWh 0.06 $/KWh
$/year $6,433,965 $/year

kg/hr 339 kg/hr

$/ton (2009$) $450 $/ton (2009$)
90%
$/year $1,765,754 $/year

kW 22757.17 kW
kW 117828.63 kW
kW 0.00 kW
kW 0.00 kW
kW 2119.20 kW
kW 5.87 kW
kW 119953.70 kW
kW 142710.87 kW

$/year (2007$)
$/year (current-year dollars) $2,296,115 $/year (current-year dollars)
Percent of labor cost 90% Percent of labor cost
$/year $4,362,618 $/year

of ISBL costs 3% of ISBL costs

of FCI 0.7% of FCI
$ 102,215,119
$/year $4,582,916 $/year
$/year $8,945,534 $/year

$/KWh 0.06 $/KWh

$/MM BTU $5 $/MM BTU
$/kg $1.75 $/kg
$/kg (2009$) 1.47 $/kg (2009$)
$/ton (2009$) $450 $/ton (2009$)
$/kg $0.26 $/kg
$/kg (2009$) $0.00 $/kg (2009$)
cents/ton (2004$) 19.97 cents/ton (2004$)

2011
days/year 328.5 days/year
Proposed
561,123

$561,123

$252,101
Description / Explanation
Comments
2011 $/kWh

SMR-derived H2 using current natural gas price

Phosphoric acid cost, per SRI PEP cost report
Cost per 2011 NREL biochemical ethanol model

NA (air feed)
2011 NREL biochemical ethanol model
COST INDICES

Plant cost indices

Year Index
1990 357.6
1991 361.3
1992 358.2
1993 359.2
1994 368.1
1995 381.1
1996 381.7
1997 386.5
1998 389.5
1999 390.6
2000 394.1
2001 394.3
2002 395.6
2003 402
2004 444.2
2005 468.2
2006 499.6
2007 525.4
2008 575.4
2009 521.9
2010 550.8
2011 585.7

Inorganic chemical index

1980 89

1981 98.4
1982 100
 1983 100.3
1984 102.9
1985 103.7
1986 102.6
1987 106.4

1988 116.3
1989 123
1990 123.6
1991 125.6
1992 125.9
1993 128.2
1994 132.1

1995 139.5
1996 142.1
1997 147.1
1998 148.7
1999 149.7

2000 156.7
2001 158.4
2002 157.3
2003 164.6

2004 172.8
2005 187.3
2006 196.8
2007 203.3
2008 228.2
2009 224.7
2010 233.7
2011 249.3

Labor index

1980 11.829286
1981 12.127857
1982 12.426429
1983 12.725
1984 13.023571
1985 13.322143
1986 13.620714

1987 13.919286
1988 14.217857

1989 14.516429
1990 12.85

1991 13.3
1992 13.7
1996 15.37
1997 15.78
1998 16.23
1999 16.4
2000 17.09

2001 17.57
2002 17.97

2003 18.5
2004 19.17
 1993 13.97
1994 14.33
1995 14.86
1996 15.37

1997 15.78
1998 16.23
1999 16.4
2000 17.09
2001 17.57
2002 17.97
2003 18.5
2004 19.17
2005 19.67
2006 19.6
2007 19.55
2008 19.5
2009 20.3
2010 21.07
2011 21.46

Natural gas price fluctuations (H2A)

Year $/MM BTU (2007-dollar
2004 8.352401
2005 8.352401
2006 8.3524006
2007 7.8916066

2008 9.2420298
2009 5.0913786
2010 5.7742994
2011 6.1179317

Electricity price fluctuations (H2A)

Year $/MM BTU (2007-dollar
 2004 17.44161
2005 17.441606
2006 17.441606
2007 17.651841
2008 19.274322
2009 18.160651

2010 15.950875
2011 16.364274

GDP deflator
Year GDP deflator

2000 88.7
2001 90.7

2002 92.2
2003 94.1
2004 96.8
2005 100.0
2006 103.2
2007 106.2
2008 108.6
2009 109.5
2010 111.0

2011 113.4
 Source: (1)Chemical Engineering Magazine, March, 1997
(2)Chemical Engineering Magazine, March, 2000
(3)Chemical Engineering Magazine, January, 2001
(4)Chemical Engineering Magazine, April, 2002
(5) Chemical Engineering Magazine, December, 2003
(6) Chemical Engineering Magazine, May 2005

(7) Chemical Engineering Magazine, April 2009

Current indices @ http://www.che.com/ei

Source: SRI International Chemical Economics Handbook, Economic Environment of the Chemical Ind
Current indices @ https://www.sriconsulting.com/CEH/Private/EECI/EECI.pdf
Source: Bureau of Labor Statistics

Series ID: CEU3232500008

Chemicals
Average Hourly Earnings of Production Workers
Current indices @ http://data.bls.gov/cgi-bin/srgate
uations (H2A) Source: Natural gas price variations used in H2A model for calculating H2 cost (basis = 2007 dollars)
$/MM BTU (2007-dollars)

ations (H2A) Source: Electricity price variations used in H2A model for calculating H2 cost (basis = 2007 dollars)
$/MM BTU (2007-dollars)
 Source: EIA, http://www.eia.gov/forecasts/steo/query/
GDP deflator
nt of the Chemical Industry 2004
basis = 2007 dollars)

sis = 2007 dollars)

GENERAL INFORMATION
Concept Paper Number:
Project Title:
Project Lead Applicant:

Abbreviation
BOE
BPD
FA
FCI
ISBL
LHV
HHV
LOC
PFD
TDC
CH4
C16H32O2
[ENTER]
[ENTER]
[ENTER]

Description
barrel of oil equivalent
barrel of oil equivalent per day
fatty acid, target product
fixed capital investment
inside battery limits, defined as process equipment on PFD less auxiliary units
lower heating value
higher heating value
labor operating cost
process flow diagram
total direct costs
feedstock/starting material
target product (Case 1)
REFERENCE CASE 1 - PROCESS FLOW DIAGRAM

purge fraction = 0.5

CH4, kg/h 311
O2, kg/h 7116
N2, kg/h 70577 CH4, kg/h 621
CO2, kg/h 5055.8 O2, kg/h 14232
Total, kg/h 83060 N2, kg/h 141154
CO2, kg/h 7584
Total, kg/h 163591

CH4, kg/h 311

O2, kg/h 7116
N2, kg/h 70577 Waste Water, kg/h 20767 H2O, kg/h 686
CO2, kg/h 2528 acid, kg/h 10
Total, kg/h 80532 Total, kg/h 697
CO2, kg/h 559
H2O, kg/h 0
Total, kg/h 559

CO2, kg/h 0
C16H32O2, kg/h 3612
CO2, kg/h 0 H2O, kg/h 8427
C16H32O2, kg/h 3612 cell mass, kg/h 196 CO2, kg/h 0
H2O, kg/h 36117 Total,kg/h 12235 C16H32O2, kg/h 3431 CO2, kg/h 0
CH4, kg/h 5903 cell mass, kg/h 196 H2O, kg/h 3431 C16H32O2, kg/h 3260
O2, kg/h 18761 Total,kg/h 39925 Total,kg/h 6862 Total, kg/h 3260
N2, kg/h 70577
Fermentation + Seed Reactors Phase Separator Centrifuge Washer/Decanter Hydrotreater
Total, kg/h 95240 CH4, kg/h 6213
O2, kg/h 25877 H2, kg/h 0
N2, kg/h 141154
CO2, kg/h 2528

Total, kg/h 175772 H2O, kg/h 6922

Total,kg/h 6922

Makeup Water, kg/h 18545

Total, kg/h 18545 C16H32O2, kg/h 172 C15H32, kg/h 2700
H2O, kg/h 4117 C16H34, kg/h 0
acid, kg/h 10 Total, kg/h 2700
H20, kg/h 9192 Total, kg/h 4299
H2O, kg/h 2269
Total,kg/h 2269

CO2, kg/h 0
C16H32O2, kg/h 181
H2O, kg/h 2727
cell mass, kg/h 196
Total,kg/h 3104