Calcined Zeolite Production via Gel Preparation, Crystallisation, Separation, Drying and Calcination

This report provides an exhaustive cost evaluation of the production of calcined zeolite via gel preparation, crystallisation, separation, drying and calcination. The process starts with mixing silica and alumina sources with an organic structure directing agent, water and inorganic minerals, thus resulting in gel formation led by crystallisation using hydrothermal conditions. The zeolite crystals then undergo agglomeration if required, followed by separating liquid and solid components and washing off the crystals to remove the excess of OSDA and other by-products, after which the resulting filtered zeolite is dried and calcined at higher temperatures to give the zeolite powder finally. The thus-formed zeolite powder can undergo an ion exchange step followed by solid/liquid separation, washing, drying and calcination to obtain an active zeolite catalyst.

The project economic analysis provided in the report discusses a Germany-based plant:

• Manufacturing Process
  • Process Flow
  • Material Flow
  • Material Balance
• Raw Material and Product's Specifications
  • Raw Material Consumption
  • Product and Co-Product Generation
  • Capital Investment
• Land and Site Cost
  • Offsites/Civil Works
  • Equipment Cost
  • Auxiliary Equipment Cost
  • Contingency
  • Engineering and Consulting Charges
  • Working Capital
• Variable Cost
  • Raw Material
  • Utilities
• Fixed Cost
  • Labor Requirement & Wages
  • Overhead Expenses
  • Maintenance Charges
• Financing Costs
  • Interest on Working Capital
  • Interest on Loans
• Depreciation Charges
• General Sales and Admin Costs
• Production Cost Summary