Calcium Borohydride Manufacturing Plant Project Report: Key Insights and Outline

Calcium Borohydride Manufacturing Plant Project Report by Procurement Resource thoroughly focuses on every detail that encompasses the cost of manufacturing. Our extensive cost model meticulously covers breaking down Calcium Borohydride plant capital cost around raw materials, labour, technology, and manufacturing expenses. This enables precise cost structure optimization and helps in identifying effective strategies to reduce the overall Calcium Borohydride manufacturing plant cost and the cash cost of manufacturing.

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Calcium borohydride is an inorganic compound that has good hydrogen storage capabilities and reducing properties. It is utilised in the fields of clean energy and advanced materials. It has a high gravimetric hydrogen density that makes it useful in solid-state hydrogen storage systems. It is also used as a powerful reducing agent in organic synthesis and is utilised in the production of metal borides and specialised boron compounds.
 

Industrial Applications of Calcium Borohydride

Calcium borohydride finds its applications in various industries because of its high hydrogen content and strong reducing power.

• Hydrogen Storage and Energy Applications: It has a high theoretical hydrogen storage capacity (11.5 wt%) that makes it a useful material for storing hydrogen for fuel cells in vehicles and stationary power generation. It can release hydrogen gas upon controlled heating or hydrolysis and offers a compact and efficient on-demand hydrogen source. Its ionic conductivity, which comes from borohydride anions, makes it useful in advanced battery systems.
• Reducing Agent in Organic Synthesis: It is a powerful and more selective reducing agent than some other borohydrides.
  • Selective Reductions: It is used in the pharmaceutical and fine chemical industries for the reduction of aldehydes, ketones, esters, and other functional groups.
  • Catalysis: It also works as a component in certain catalytic systems.
• Rocket Propulsion: It works as a component in solid propellants because of its high energy content and hydrogen release properties.
• Production of Metal Borides and Boron-based Compounds: It is used as a precursor for synthesising various metal borides and other complex boron compounds.
   

Top 5 Industrial Manufacturers/Suppliers of Calcium Borohydride

The calcium borohydride manufacturers or suppliers are companies that focus on hydride chemistry and advanced materials.

• American Elements: This company is a leading manufacturer and supplier of advanced materials that include various hydrides and boron compounds.
• Sigma-Aldrich (Merck KGaA): It is a major supplier of research chemicals and offers calcium borohydride in high-purity material for specialised industrial processes and R&D at various scales.
• Solvay Specialities India Private Limited: It provides an industrial-scale supply of calcium borohydride across different regions.
• Ascensus Specialties LLC: It is a global leader in borohydride chemistry and has the deep technical expertise, infrastructure, and safety protocols necessary for handling and potentially producing highly reactive hydrides.
• Nanochemazone: This company is an international supplier of advanced nanomaterials and speciality chemicals.
   

Feedstock for Calcium Borohydride and Its Market Dynamics

The feedstock for calcium borohydride production depends on the chosen manufacturing process.
 

Feedstock for Production via Reaction with Diborane:

The primary feedstock for this process is diborane and either calcium hydride or calcium alkoxides.

• Diborane: It is a highly reactive and toxic gas that is produced by the reaction of hydride donors (like sodium borohydride or lithium aluminium hydride) with boron halides. The industrial procurement of diborane involves sourcing from highly specialised chemical manufacturers, and it is often sold in small quantities because of its reactivity and hazards.
• Calcium Hydride: It is produced by reacting calcium metal with hydrogen gas at elevated temperatures. Its prices are influenced by calcium metal prices and energy costs for hydrogenation.
• Calcium Alkoxides: They are synthesised by reacting calcium metal or calcium carbide with alcohols. Their prices are influenced by the cost of calcium metal/carbide and the specific alcohol used.
   

Feedstock for Production via Ball Milling Technique:

The feedstock for this process is calcium chloride and sodium borohydride.

• Calcium Chloride: It is obtained as a by-product of the Solvay process or produced from the neutralisation of hydrochloric acid with calcium carbonate (limestone) or calcium hydroxide. Its price is influenced by soda ash demand and energy costs.
• Sodium Borohydride: It is industrially produced by reacting sodium hydride with trimethyl borate. Its price is influenced by its complex synthesis route and demand from pharmaceuticals, pulp & paper, and other chemical industries.
   

Dynamics Affecting Raw Materials

The dynamics affecting these raw materials are critical for the cash cost of production and overall manufacturing expenses of calcium borohydride.

• High Reactivity and Purity Requirements: The feedstock materials (like diborane, calcium hydride, sodium borohydride) are highly reactive, moisture-sensitive, or pyrophoric. This requires specialised manufacturing, handling, and storage that increases their raw material costs and overall manufacturing expenses.
• Niche Market Status: Diborane, calcium hydride, and calcium alkoxides are not high-volume commodity chemicals. Their production involves specialised chemistry and smaller market sizes, leading to higher unit costs compared to more common industrial chemicals.
• Energy and Metal Prices: The cost of metallic calcium (for calcium hydride/alkoxides) and boron (for borohydrides) influences raw material costs.
• Safety and Environmental Regulations: Strict regulations regarding the handling, storage, and disposal of highly reactive hydrides and boranes contribute to the production cost.
   

Market Drivers for Calcium Borohydride

The market for calcium borohydride is driven by emerging technologies and specialised applications.

• Hydrogen Economy and Energy Storage Research: The strong global research and development into hydrogen as a clean energy carrier contributes to its demand as a material with high hydrogen storage capacity.
• Demand for Advanced Reducing Agents: The pharmaceutical and fine chemical industries need highly selective and efficient reducing agents for complex organic syntheses that fuel their market.
• Growth in Specialised Materials: The development of new metal borides and boron-based compounds for high-performance materials (e.g., in ceramics, semiconductors) contributes to its demand as a precursor.
• Geographical Research Hubs:
  • North America and Europe: These regions have strong research institutions and significant government funding for clean energy technologies and advanced materials that drive the calcium borohydride market.
  • Asia-Pacific (APAC): This region’s market is supported by a rise in hydrogen energy research and advanced materials.
     

Capital and Operational Expenses for a Calcium Borohydride Plant

Setting up a calcium borohydride manufacturing plant involves a significant total capital expenditure (CAPEX) and careful management of ongoing operating expenses (OPEX). A detailed cost model and production cost analysis are crucial for determining economic feasibility and optimising the overall calcium borohydride plant cost. Due to the high reactivity and sensitive nature of borohydrides and their precursors, specialised equipment and stringent safety measures are mandatory, significantly impacting costs.
 

CAPEX: Comprehensive Calcium Borohydride Plant Capital Cost

The total capital expenditure (CAPEX) for a calcium borohydride plant covers all fixed assets required for reaction, separation, and product finishing. This is a major component of the overall investment cost.

• Site Acquisition and Preparation (5-8% of Total CAPEX):
  • Land Acquisition: Purchasing suitable industrial land, ensuring isolated areas or robust safety measures due to hazardous materials.
  • Site Development: Specialised foundations for containment, robust ventilation systems, inert atmosphere facilities, and explosion-proof electrical systems.
• Raw Material Storage and Handling (15-25% of Total CAPEX):
  • Diborane Storage (for Diborane route): Highly specialised, leak-proof, inert-atmosphere gas cylinders or vessels for diborane gas. This includes precision gas handling and safety monitoring systems due to its toxicity and pyrophoric nature.
  • Calcium Hydride/Alkoxide Storage (for Diborane route): Airtight, moisture-free storage facilities, often glove boxes or inert atmosphere warehouses, for highly reactive solids/liquids. Includes specialised feeders.
  • Calcium Chloride/Sodium Borohydride Storage (for Ball Milling route): Sealed, moisture-free storage for solid calcium chloride and sodium borohydride. Sodium borohydride requires careful handling due to its reactivity with moisture.
  • THF Storage (for Ball Milling route): Solvent storage tanks for tetrahydrofuran (THF), which is flammable, requiring explosion-proof design.
• Reaction Section (25-35% of Total CAPEX):
  • For Diborane Route (Diborane + Calcium Hydride/Alkoxides):
    • Reaction Vessels: High-pressure, corrosion-resistant reactors, often glass-lined or special alloys, capable of operating under inert atmosphere (e.g., argon) and precise temperature control. Gas-solid or gas-liquid reactors.
    • Gas Handling Systems: For accurate diborane dosing, gas recirculation, and unreacted diborane scrubbing/disposal.
    • Heating/Cooling Systems: For precise temperature control.
  • For Ball Milling Route:
    • High-Energy Ball Mills: Specialised ball mills (e.g., planetary ball mills, high-energy attritors) capable of operating under inert atmosphere (e.g., argon) to prevent oxidation/hydrolysis. These machines are a significant calcium borohydride plant's capital cost.
    • Glove Box/Inert Atmosphere Chamber: For loading and unloading reactive solids into the ball mill without exposure to air or moisture.
    • Solvent Handling System: If THF is used, a closed-loop solvent addition and recovery system.
• Separation and Purification Section (20-30% of Total CAPEX):
  • Filtration/Centrifugation: For separating solid calcium borohydride from impurities or reaction by-products (e.g., NaCl for ball milling route, unreacted materials). Filtration systems must be designed for an inert atmosphere.
  • Washing Systems: For washing the product with inert solvents.
  • Solvent Recovery/Distillation (for Ball Milling route): Equipment to recover and purify THF or other solvents for recycling.
  • Vacuum Drying: Specialised vacuum dryers to remove residual solvent and moisture from calcium borohydride without decomposition.
• Finished Product Storage and Packaging (5-8% of Total CAPEX):
  • Storage: Airtight, inert-atmosphere containers or glove boxes for calcium borohydride to prevent reaction with air or moisture.
  • Packaging: Specialised packaging equipment for handling highly sensitive powders in controlled environments.
• Utility Systems (10-15% of Total CAPEX):
  • Inert Gas Generators: High-purity nitrogen or argon generators and distribution systems for process blanketing.
  • Vacuum Systems: High-capacity vacuum pumps for drying and process operations.
  • Cooling Systems: For exothermic reactions.
  • Electricity: For motors, mills, pumps, and instrumentation.
  • Wastewater Treatment: Specialised systems for treating any hazardous aqueous or solvent waste streams.
• Automation and Instrumentation (5-10% of Total CAPEX):
  • Advanced DCS/PLC systems for precise control of parameters in inert environments.
  • Specialised sensors for monitoring hydrogen, oxygen, and moisture levels for safety.
• Safety and Environmental Systems: Extremely robust fire suppression (e.g., inert gas flooding), explosion protection, emergency ventilation, gas detectors, and hazardous waste handling/disposal infrastructure. Given the high reactivity and potential for hydrogen evolution, these systems are critical and expensive.
• Engineering, Procurement, and Construction (EPC) Costs (10-15% of Total CAPEX):
  • Includes specialised process design for reactive chemistry, material sourcing, construction of sealed and inert facilities, and commissioning.

The aggregate of these components defines the total capital expenditure (CAPEX), significantly impacting the initial calcium borohydride plant capital cost and the viability of the investment cost. Due to the hazards and specific requirements, these plants are significantly more expensive than those for commodity chemicals.
 

OPEX: Detailed Manufacturing Expenses and Production Cost Analysis

Operating expenses (OPEX) are the recurring manufacturing expenses necessary for the continuous production of calcium borohydride. These costs are crucial for the production cost analysis and determining the cost per metric ton (USD/MT) of calcium borohydride.

• Raw Material Costs (Approx. 50-70% of Total OPEX):
  • For Diborane Route: Cost of high-purity diborane gas (very expensive) and calcium hydride or calcium alkoxides. Industrial procurement for these niche, reactive materials is a major cost driver.
  • For Ball Milling Route: Cost of calcium chloride (relatively cheap) and sodium borohydride.
  • Inert Gases: Continuous consumption of high-purity nitrogen or argon for blanketing reactors and glove boxes.
  • Solvents (for Ball Milling): Cost of THF or other solvents and their make-up losses after recycling.
• Utility Costs (Approx. 15-25% of Total OPEX):
  • Energy: Primarily electricity for ball mills (which are energy-intensive), pumps, vacuum systems, and HVAC for inert environments. Heating/cooling for reactions.
  • Cooling Water: For process cooling.
• Labour Costs (Approx. 10-20% of Total OPEX):
  • Salaries, wages, and benefits for highly skilled and specialised personnel trained in handling pyrophoric and reactive chemicals in inert atmospheres. Due to the inherent hazards, this represents a significant fixed cost.
• Maintenance and Repairs (Approx. 5-10% of Fixed Capital):
  • Routine preventative maintenance programs, unscheduled repairs, and replacement of specialised, corrosion-resistant, or high-wear equipment (e.g., ball mill media, reactor linings). This includes lifecycle cost analysis for all equipment.
• Waste Management and Environmental Compliance (5-10% of Total OPEX):
  • Costs associated with treating and disposing of highly hazardous waste streams (e.g., spent catalyst, contaminated solvents, unreacted hydrides), particularly challenging for boron-containing waste. Strict regulations necessitate expensive treatment.
• Depreciation and Amortisation (Approx. 8-15% of Total OPEX):
  • Non-cash expenses account for the wear and tear of the high total capital expenditure (CAPEX) assets over their useful life. These are important for financial reporting and break-even point analysis.
• Indirect Operating Costs (Variable):
  • High insurance premiums due to the hazardous nature of operations, property taxes, general administrative overhead, and expenses for research and development aimed at improving production efficiency metrics or exploring new cost structure optimisation strategies.
• Logistics and Distribution: Costs for transporting highly sensitive raw materials and finished calcium borohydride in specialised, inert-atmosphere containers.

Effective management of these operating expenses (OPEX) through highly efficient process design, stringent safety protocols, and continuous innovation is paramount for ensuring the long-term profitability and competitiveness of calcium borohydride manufacturing in its niche market.
 

Calcium Borohydride Industrial Manufacturing Processes

This report comprises a thorough value chain evaluation for calcium borohydride manufacturing and consists of an in-depth production cost analysis revolving around industrial calcium borohydride manufacturing. We will examine two distinct processes for its synthesis.
 

Production via Reaction with Diborane: Direct Hydride Synthesis

The manufacturing process of calcium borohydride involves a reaction between diborane gas and solid calcium hydride or liquid calcium alkoxides. In this process, diborane gas reacts with solid calcium hydride or liquid calcium alkoxides under inert conditions because of the high reactivity of the materials. The reaction takes place in a sealed, inert atmosphere at controlled temperatures and pressures that resulting in the formation of calcium borohydride. The product is then isolated, purified by filtration and solvent evaporation, and dried to get pure calcium borohydride as the final product.
 

Production via Ball Milling Technique: Solid-State Exchange Reaction

The manufacturing process of calcium borohydride involves a ball milling technique.  In this process, calcium chloride and sodium borohydride are mixed and loaded into a ball mill under an inert atmosphere. The milling jar, containing the reactants and grinding media, is sealed and subjected to high-energy milling. After milling, the mixture is treated with tetrahydrofuran (THF) to dissolve the calcium borohydride. The THF solution is concentrated to get pure calcium borohydride as the final product.
 

Properties of Calcium Borohydride

Calcium borohydride is an inorganic compound that has a molecular formula of Ca(BH4)2 with a molecular weight of 69.76 g/mol. The following physical and chemical properties make it valuable in advanced chemical and energy applications.
 

Physical Properties

• Appearance: White crystalline powder.
• Odor: Odorless.
• Melting Point: Decomposes around 200 °C, releasing hydrogen gas.
• Density: ~1.15 g/cm³.
• Solubility: Soluble in THF, diglyme, triglyme; reacts with water and alcohols.
• Stability: Stable when dry and under inert atmosphere; reacts violently with moisture.
• Hydrogen Storage: High capacity of up to 11.5 wt% hydrogen by mass.
   

Chemical Properties

• Formula: Ca(BH4)2 (ionic: Ca²? and BH4?).
• Reducing Agent: Reduces aldehydes, ketones, esters, and acids in organic synthesis.
• Hydrogen Evolution: Reacts with water/acids to release H2 gas.
• Air Reactivity: Not pyrophoric but reacts if exposed to moisture.
• Thermal Behaviour: Decomposes above 200 °C, forming CaB2 and releasing hydrogen.
   

Calcium Borohydride Manufacturing Plant Report provides you with a detailed assessment of capital investment costs (CAPEX) and operational expenses (OPEX), generally measured as cost per metric ton (USD/MT). This approach ensures that your investment decisions are aligned with the latest industry standards and economic feasibility metrics, enhancing your manufacturing efficiency and financial planning.

Apart from that, this Calcium Borohydride manufacturing plant report also covers the leading technology providers that help you plan a robust plan of action related to Calcium Borohydride manufacturing plant and its production process(es), and also by helping you with an in-depth supplier database. This report provides exclusive insights into the best manufacturing practices for Calcium Borohydride and technology implementation costs. This report also covers operational cash flow, fixed and variable costs, and detailed break-even point analysis, ensuring that your manufacturing process is not only efficient but also economically viable in the competitive market landscape.

In addition to operational insights, the Calcium Borohydride manufacturing plant report also comprehensively focuses on lifecycle cost analysis, maintenance costs, and energy consumption costs, which are critical for maintaining long-term sustainability and profitability. Our manufacturing cost analysis extends to include regulatory compliance costs, inventory holding costs, and logistics and distribution costs, providing a holistic view of the potential expenses and savings.

We at Procurement Resource ensure that this report is not only cost-efficient, environmentally sustainable, and aligned with the latest technological advancements but also that you are equipped with all necessary tools to optimize supply chain operations, manage risks effectively, and achieve superior market positioning for Calcium Borohydride.
 

Key Insights and Report Highlights

Report Features	Details
Report Title	Calcium Borohydride Manufacturing Plant Project Report
Preface	Overview of the study and its significance.
Scope and Methodology	Key Questions Answered, Methodology, Estimations & Assumptions.
Executive Summary	Global Market Scenario, Production Cost Summary, Income Projections, Expenditure Projections, Profit Analysis.
Global Market Insights	Market Overview, Historical and Forecast (2019-2029), Market Breakup by Segment, Market Breakup by Region, Price Trends (Raw Material Price Trends, Calcium Borohydride Price Trends, Competitive Landscape (Key Players, Profiles of Key Players).
Detailed Process Flow	Product Overview, Properties and Applications, Manufacturing Process Flow, Process Details.
Project Details	Total Capital Investment, Land and Site Cost, Offsites/Civil Works Cost, Plant Machinery Cost, Auxiliary Equipment Cost, Contingency, Consulting and Engineering Charges, Working Capital.
Variable Cost Analysis	Raw Material Specifications, Raw Material Consumption, Raw Material Costs, Utilities Consumption and Costs, Co-product Cost Credit, Labour Requirements and Costs.
Fixed Cost Analysis	Plant Repair & Maintenance Cost, Overheads Cost, Insurance Cost, Financing Costs, Depreciation Charges.
General Sales and Administration Costs	Costs associated with sales and administration
Project Economics	Techno-economic Parameters, Income Projections, Expenditure Projections, Financial Analysis (Payback Period, Net Present Value, Internal Rate of Return), Profit Analysis, Production Cost Summary.
Report Format	PDF for BASIC and PREMIUM; PDF+Dynamic Excel for ENTERPRISE.
Pricing and Purchase Options	BASIC: USD 2999 PREMIUM: USD 3999 ENTERPRISE: USD 5999
Customization Scope	The report can be customized based on the customer’s requirements.
Post-Sale Analyst Support	10-12 Weeks of support post-sale.
Delivery Format	PDF and Excel via email; editable versions (PPT/Word) on special request.

Key Questions Covered in our Calcium Borohydride Manufacturing Plant Report

• How can the cost of producing Calcium Borohydride be minimized, cash costs reduced, and manufacturing expenses managed efficiently to maximize overall efficiency?
• What is the estimated Calcium Borohydride manufacturing plant cost?
• What are the initial investment and capital expenditure requirements for setting up a Calcium Borohydride manufacturing plant, and how do these investments affect economic feasibility and ROI?
• How do we select and integrate technology providers to optimize the production process of Calcium Borohydride, and what are the associated implementation costs?
• How can operational cash flow be managed, and what strategies are recommended to balance fixed and variable costs during the operational phase of Calcium Borohydride manufacturing?
• How do market price fluctuations impact the profitability and cost per metric ton (USD/MT) for Calcium Borohydride, and what pricing strategy adjustments are necessary?
• What are the lifecycle costs and break-even points for Calcium Borohydride manufacturing, and which production efficiency metrics are critical for success?
• What strategies are in place to optimize the supply chain and manage inventory, ensuring regulatory compliance and minimizing energy consumption costs?
• How can labor efficiency be optimized, and what measures are in place to enhance quality control and minimize material waste?
• What are the logistics and distribution costs, what financial and environmental risks are associated with entering new markets, and how can these be mitigated?
• What are the costs and benefits associated with technology upgrades, modernization, and protecting intellectual property in Calcium Borohydride manufacturing?
• What types of insurance are required, and what are the comprehensive risk mitigation costs for Calcium Borohydride manufacturing?