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14
Estimation of Capital Investment Cost of Bioprocessing
A B C D E F G H
1 Description Range % Ave Used of Costs
I. Direct Costs (DC) FCI
2
A. Equipment plus FCI
3
1. Purchased equipment ( )
4 PEC FCI $300,000
2. Installation, insulation, painting 20-150 50 50% PEC $150,000
5
3. Instrumentation & control, installed 20-60 35 35% PEC $105,000
6
4. Piping, installed 30-60 40 40% PEC $120,000
7
5. Electrical, installed 10-20 15 15% PEC $45,000
8
B. Buildings including services 10-200 45 45% PEC $135,000
9
C. Service facilities 20-100 50 50% PEC $150,000
10
D. Yard Improvement 5-20 15 PEC
11
12 Total Direct Costs (TDC) $1,005,000
II. Indirect costs (IDC)
13
A. Engineering & supervision 20-30 25 25% TDC $0
14
B. Legal expenses 1-3 2 2% FCI $0 H19*F15
15
C. Construction & contractor's fee 35-50 40 40% FCI $402,000 H19*F16
16
D. Contingency 7-15 10 10% FCI $0 H19*F17
17
18 Total Indirect Costs $402,000
(H12+H14)/(1-
III. Fixed Capital Investment ( )=DC+IDC
19 FCI 0.4-1 $2,093,751 sum(f15:f17))
IV. Working Capital (WC) 10-20 15 15% TCI $369,485
20
V. Total Capital Investment (
21 TCI)=FCI+WC $2,463,236 H19/(1-F20)
Source: Peters, et al., Plant Design and Economics for Chemical Engineers (2003)
Harrison, et al., Bioseparations Science and Engineering (2003)
1
Estimation of Total Production Cost
A B C D E F G
1 Description Range % Used of
Fixed Capital Inv (FCI) 2,500,000
2
Total Capital Inv (TCI) 110-120 115% FCI 2,875,000
3
I. Manufacturing cost
4
A. Direct Production Costs 66 TPC
5
1. Raw materials 10-80 TPC 500,000
6
2. Operating labor 20-50 TPC 1,000,000
7
3. Direct supervisory labor 10-20 15% Op Labor 150,000
8
4. Utilities 1-30 15% TPC 701,937
9
5. Maintenance and Repair 2-10 6% FCI 150,000
10
6. Operating supplies 10-20 15% Mainten. 22,500
11
7. Lab/QCont/QAssurance 10-20 15% Op Labor 22,500
12
8. Patents and royalty 0-6 3% TPC 140,387
13
9. Waste Disposal 1-20 1% TPC 46,796
14
B. Fixed Charges 10-20 FCI
15
1. Depreciation 10% FCI 250,000
16 Depends
2. Local taxes 1-4 2.5% FCI 62,500
17
3. Insurance 0.4-1 0.7% FCI 17,500
18
19 4. Rent 8-12 Value
20 5. Financing 0-10 6% TCI 172,500
C. Plant overhead 50-70 60% Labor+Maint 780,000
21
22 Total Manufacturing Cost 4,016,620
II. General Expense `
23
A. Administrative costs 20 15% Labor+Maint 195,000
24
B. Distribution & selling 2-20 5% TPC 233,979
25
C. R&D 2-5 5% TPC 233,979
26
III. Total Product Cost (TPC) =TMC+Gen Exp
27 4,679,577 G29/(1-E28
Factor depending on TPC 29%
28
Term not depending on TPC 3,322,500
29
Source: Peters, et al., Plant Design and Economics for Chemical Engineers (2003)
Harrison, et al., Bioseparations Science and Engineering (2003)
2
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