Sr

No
BC
(Current Density = 4.5KA/m2)
BC
(Current Density = 4.8KA/m2) BCCL
120 120 Conversion 225 TPD
I
1 Cost of land 0 0 0.00
2 Site development 45 45 15.00
3 Factory Building 553 553 590.05
4 Residential 120 120 109.96
718 718 715.01
II Plant & Machinery
a)
1994.36 1871.42 3468.83
b)
1 Brine Plant 691.00 691.00 753.70 For BC, though capacity is less , Primary brine is additional.
2 Salt Handling 79 79 27.00
3 Electrolyzer Plant 328 244.7 117.60
4 Caustic Concentration 0 0 690.59
5 De-Chlorination & Chlorate Destruction 200.00 200.00 72.45 Most of the exisitng facilities are considered in BCCL.
6 Hydrogen Handling & hook-up 239 239 11.00 In BC, Hydrogen compression is additional.
7 Catholyte Circulation 40.00 40.00 59.05
8 Chlorine treatment 62 62 69.00
9 Chlorine liquefaction 435 435 57.00 Existing facilities are considered for BCCL.
10 Chlorine evaporation 0 0 0.00
11 Chlorine Filling 35 35 10.00
12 Chlorine tonners 780 780 400.00
13 HCl Plant 359 359 7.90
14 Sodium Hypo 125 125 171.05
15 Utilities 192 192 114.21 Most of the exisitng facilities are considered for BCCL.
16 Piping & Valves and structurals 450 450 309.05
17 Electricals 995 963 1106.37
18 Instruments including DCS 548.2 545.8 322.45
19 Insulation & Painting 78 78 43.50
20 Miscellenous 24 24 24.00
21
Duties P&F transport, Insurance etc @ 10% of the
Indigenous items only. 566.02 554.25 436.59
6226.27 6096.80 4802.51
III
300.00 300.00 439.81
IV
426.03 413.41 435.56
V Pre-Operative Expenses
a) 46.47 46.47 43.56
b) 18.14 18.14 87.11
c) 18.14 18.14 15.00
d) 7.25 7.25 260.70
For BCCL: Estimate for fixed cost and customer retention cost during shut
down
VI
a) 219.48 213.52 336.19 Calculated actual
b) Working capital margin (25% of the net working capital) 120.0 120.0 110.00
VII Contingencies (5% of total cost before contingency) 504.71 491.16 535.71
10,598.84 10,314.30 11,249.99 GRAND TOTAL
Insurance
Start-up exp.
Travelling
Other
Others
Interest during construction period (3% of project cost)
CIVIL
Imported Equipment (Landed cost of proprietory
equipment including engineering.
Indigenous equipment
Total
Detailed Engg., Supervision, overseas travel (other than
engg. Know-how included in II (a)
Erection ( 5% of expenses excluding land & buildings
and civil cost)
BLOCK COMPARISON FOR MEMBRANE CELL PLANTS
Estimate in (Rs. In Lacs)
DESCRIPTION
Remarks
Plant Capacity (TPD)
A
S. No. Description
Birla Cellulosic 120 TPD (Kharach) BCCL (225 TPD)
Civil Work
1 Buildings
1.1 Salt godown 120.0 0 existing
1.2 Brine Plant 28.0 61.18
2 Electrolyser Room & Rectifier Room 180.0 201.9
3 Cl2 & H2 processing compression,
liquification & storage (Including filling
shed)
108.0 25.0
4 Utilities like Chilled water DM plant , Air,
boiler, etc (500 m2 @ Rs 6000 m2)
18.0 13.2
5 Foundations
5.1 For Storage tanks (Caustic,Cl2 & HCl ) 11 15.35
5.2 Other than considered in respective areas 5.0 34.00
5.3 Aux transformers & MCC etc. 11.0 41.50 **
6 Others (Sludge Pits, Drains , Sludge to
collection pits, Epoxy paints & pump etc.)
27.0 77.06
***
7 Caustic Concentration
Plant not required
76.45
8 Roads for Plant 30.0 25.02
9 RCC Pipe rack Column 15.0 19.33
Total 553.0 590.05
B Residential Building
1 Residential Building 120 109.96
** This also includes the control room.
*** This also includes the demercuriser.
Amounts in Lacs (INR)
Back
D6 Cell:
Area 2000 m2 @ Rs. 6000 / m2 Comment:
D7 Cell:
Area 400 m2 @ Rs 7000/m2 Comment:
E7 Cell:
Area 1107 m2 @ Rs 5740/m2 Comment:
D9 Cell:
Area 1500m2 @ Rs 12000/m2 Comment:
E9 Cell:
Area 2111m2 @ Rs 12075/m2 Comment:
D11 Cell:
Area 1440m2 @ Rs 7500/m2 Comment:
E11 Cell:
Area 350m2 @ Rs 7143/m2 Comment:
D13 Cell:
Area 300m2 @ Rs 6000/m2 Comment:
E13 Cell:
Area 264m2 @ Rs 488.5/m2 Comment:
C26 Cell:
35 Lacas for Jr block+85 Lacs for 2E Blocks + 30 Lacs for D block Comment:
D26 Cell:
35 Lacas for Jr block+85 Lacs for 2E Blocks + 30 Lacs for D block Comment:
E26 Cell:
16.85 - A type one block, 27.65 -B type one block, 20.18-C type one block, 19.31-W family one block, 26.00 Comment:
modification of guard barrack & A type.
Sr. No Description
BCCL (225 TPD)
At Current Density 4.8 KA/m2 At Current Density 4.5 KA/m2 At Current Density 4.8 KA/m2
1 Proprietary Equipment -
Electrolysers along with
associated components including
membrane
1871.42 1994.36 3468.83
Total 1871.42 1994.36 3468.83
3
Proprietary Equipment
Amount in lacs (INR)
Birla Cellulosic 120 TPD (Kharach)
Back
D6 Cell:
Current Density = 4.8 KA/m2 & 274 elements X Rs6.83 Lacs/ element (See backup for detail) Comment:
2 Electrolyzers -13 KA
E6 Cell:
Current Density = 4.5 KA/m2 & 292 elements X Rs6.83 Lacs/ element (See backup for detail) Comment:
3 Electrolyzers -13 KA
F6 Cell:
Current Density = 4.8 KA/m2 Comment:
& 508 elements @ Rs6.83Lacs
GRCD (For 50 Elements) BCCL 508 element
1 547500 5484150
2
27375
3
574875
4
57
4
50
5
11498
6
655358
7
32768
8
688125
9
110100
8
798225
9
110100
10
688125
11
13763
12
701888
13
7.02 6.830
14
0.90 0
7.92
6.83
Handling cost including transport @ 2%
Landed cost per element without membrane
Average cost per element in Rs Lacs
Membranes
Total per element
Total per element considered by BCCL (Refer Sheet BCCL Prop)
Add Duty @ 5%
Sub Total
CVD @ 16%
Sub Total
Less Modvat of CVD
Cost
Add frieght & Insurance @ 5%
Total
Exchange Rate
No of elements
Total cost per element ( In Euro at CIF Mumbai)
Total cost per element (In Rs at CIF Mumbai) @ 1E = Rs 57
Frame Gaskets
Gore-Tex sealing cord
Flange bolting system
Inlet & outlet hoses
Cost of elements
Break-up of an Element cost
Basis UHDE's Offer No. 05-96-50401/008 dt 27.10.2003
Cost of 50 Nos Uhde IIIrd generation element includes 50 Nos Anode half shells with coated electrodes 50 Nos
Cathode halfshells with coated electrodes 50 sets accessories, consisting of :
Spacers
Insert Pipes
Steel Frames
I15 Cell:
FOB 547,500 EURO at German sea port Comment:
J15 Cell:
EURO 5223000X105% at CIF India port including cost of membrane Comment:
ANNEXURE - I
Calculations for Element Cost Rs. In Lacs
A
1 3,180.81
2 3,212.62
3 160.63
4 539.72
5 117.39
6 539.72
7 10.00
3,468.83
B Imported Electrical Items (Isolators/Breakers/Shunts)
C
Total 3468.83
Cost per Element 6.83
Less ED
Travelling Expenses
SUB TOTAL - I
Indigenous Mechanical Estimate for Cell House, Cell Work Shop and
Rectifier Area
IMPORTED (508 Elements including Membrane)
License, Basic Engg and Proprietary supply including supervision (CIF Indian Port
basis) ( 5223000 X 105% Euro)XRs.58.00
Assessable Value @1% of 1
Custom duty @5% of 2
Excise duty @ 16% of (2+3+4)
Bank charges, custom clearance, inland transport and misc.@ 3% of (2+3+4+5+6)
Sr. No Description
Birla Cellulosic 120 TPD
(Kharach)
BCCL (225 TPD)
1
Brine Saturators 20
15.00
2
Reaction Tank 32
12.00
3
Agitator With motor 18
15.00
4
Air Blower for Agitation 4
not required
5
Reagent tanks with agitators for
BaCO3, Na2CO3, NaOH, HCl,
NaHSO3 & Alfa cellulose
12
8.00
6
Reagent Dosing pumps with motors
for BaCO3, Na2CO3, NaOH, HCl,
NaHSO3 & Alfa cellulose
10
6.00
7
Charging device for BaCO3,
Na2CO3, NaHSO3 & Alfa cellulose
8
manual
8
Water seal clarifier with accessories 70
75.00
9
Sludge Decanter (For 100 TPD) 30
existing
10
Slurry Pump with motor 2
existing
11
Clarified Brine Tank 8
8.00
12
Clarified Brine pump with motor 12
existing
Brine Filtration
13
Anthracite filters & piping 50
25.00
14
Filtered brine pump with motor 12
15.00
17
Polishing filters (Schumacher) 192
212.00
18
Polished brine pump with motor 12
16.00
19
Recuperator 16
22.00
Secondary Brine Purification
20
Ion Exchange column with all
accessories
90 225.00
21
Recovered brine pump with motor 2
existing
22
Pure brine head tank 3
3.60
23
Brine Heat Exchanger 13
existing
24
Alkaline Waste brine tank
7 9.00
25
Ion Exchange Effluent tank 8
10.00
26
Effluent Pump 1
1.00
27
Seal Pressurization pump 2
2.50
28
Seal water tank 1
1.50
29
Polishing Filter sludge tank 7
9.00
30
Ion Exchange Sludge pump 4
5.00
31
Cell Drain Tank 4
5.00
32
Cell Drain pump 1
1.00
33
Body Feed Tank 2
2.50
34
32% HCl head tank 2
3.00
35
UPSV Tank 3
4.00
36
H2 Condensate Tank 1
1.00
37
H2 Cooler 8
10.00
38
H2 Recuperator 10
14.00
39
Body Feed Pump 2
2.60
40
Precoat Pump 6
7.50
41
H2 Condensate Pump 2
2.50
42
Precoat Tank 4
5.00
43
Demercuriser 0
15.00
Total
691.00 753.70
Brine Plant
Amounts in Lacs (INR)
Back
Sr No Description
Birla Cellulosic120
TPD (Kharach)
BCCL (225 TPD)
1 Bucket Elevator with Gear
& motor (10 - 15 T/Hr)
16
19.00
2 Hopper (MOC SS) with
vibration feeder & its
power unit (10-15 T/hr)
8
6.00
3 Belt Conveyor
(Reversible)
2
existing
4 Platform 1
existing
5 Foundations 2
existing
6 Pay Loader 15
considered in P&B
7 Steel structures 5
2.00
8 Salt Godown conveyors
with trippers
30
existing
79 27
Salt Handling
Amount in Lacs (INR)
Back
Sr No Description
Birla Cellulosic
120 TPD (Kharach)
2 electrolysers
Birla Cellulosic
120 TPD (Kharach)
3 electrolysers
BCCL (225
TPD)
1 Catholyte Header (PP-FRP)
40 60
2 Anolyte Header (FRP-HT)
20 30
3 Anolyte Header / Catholyte feed header (PP)
8 12
4 Cell Rack ( MS / Copper Conductor)
46 69
5 Imported Valves (PFA)
43.2 64
6 Indegeneous Valves (MSRL)
6 9
7 Filters (PFA)
5 7.5
8 Cell Workshop items eg. Hoist, tables etc.
40 40
9
32% Caustic Cooler 4.5 4.5
6.00
10
Overhead Crane (EOT) 30 30
30.00
11
Cl2 Seal 2 2
2.00
Total 244.7 328 117.6
Cell House
Amount in Lacs (INR)
79.6
Back
Sr.
No.
Item MOC
Qty./
Electrolyser
Cost /
Electrolyser
(Rs. In Lacs)
Total
Qty.
Total Cost
(2 electrolysers)
(Rs. In Lacs)
Total Cost
(3electrolysers) (Rs.
In Lacs)
1 Cell Catholyte Header PP/ FRP 1 Set 20.00 2 Set 40.00 60.00
2 Cell Anolyte Header FRP-HT 1 Set 10.00 2 Set 20.00 30.00
3 Brine & Catholyte Feed Header PP 1 Set 4.00 2 Set 8.00 12.00
4 Cell Rack MS/ Copper
Conductor
3 Nos 23.00 6 Nos. 46.00 69.00
5 Imported Valves PFA Lot 21.60 Lot 43.20 64.00
6 Indegeneous Valves MSRL Lot 3.00 Lot 6.00 9.00
7 Filters PFA 2 Nos. 2.50 4 Nos. 5.00 7.50
8 Cell Workshop 40.00 40.00
Grand Total 84.10 208.20 291.50
Estimate of Mechanical Items for Electrolyser
Sr. No Description
Birla Cellulosic 120
TPD (Kharach)
BCCL (225 TPD)
1
Anolyte tank (Depleted brine) 5
19.95
2
Vacuum Tank (Dechlorinator) 6
existing
3
Vacuum pumps with motors 13
12.00
4
Separator with cooler 1
1.50
5
Vapour Condenser (Dechlorination
Cooler)
7.0 6.0
6
Lean Brine pump with motor 12
existing
7
Chlorinated water pump (Condensate
) with motor
1
existing
8
Overhead tank for NaOH & NaHSO3 3
2.00
9
Chlorate Destruction tank 15
15.00
10
Chlorate feed Pump with motor 16
16.00
11
Pipe & Support for entire brine plant 33
12
Valves in brine areas other than
Secondary brine purification
13
13
Structures 25
Structurals Head
14
Foundations for various equipments
like saturator, purifier, clarifier, filters
etc.
50
Civil head
Total 200.00 72.45
Dechlorination
Amounts in Lacs (INR)
Piping & Valves
Head
Back
Sr No Description
Birla Cellulosic 120 TPD
(Kharach)
BCCL (225 TPD)
1 Gas Holder Buffer vessel is considered
in place of Gas holder
existing
2 Buffer Vessel 6
0
3 Safety Seal 1
1.00
4 Flame arrestor 2
2.00
5 Heat Exchanger 5
8.00
6 H2 Compressor with all associated
equipments & manifolds
225
0
Total 239 11
Hydrogen Handling
Amounts in Lacs (INR)
Back
E10 Cell:
15 manifoldsX 10 Lacs= 150 + 75 for piping, washing, foundation etc. Comment:
Total = 225 lacs
Sr. No Description
Birla Cellulosic 120
TPD (Kharach)
BCCL (225
TPD)
1
Catholyte Tank 6
16.00
2
Catholyte Pump 12
13.46
3
Caustic Heat Exchanger 16
20.00
4
Caustic OH tank for cell house 2
3.75
5
Intermediate Caustic Tanks 4
5.84
Total
40.00 59.05
Catholyte Circulation
Amounts in Lacs (INR)
Back
Sr No Description
Birla Cellulosic
120 TPD
(Kharach)
BCCL (225 TPD)
1 Absorption Towers complete with internals
25
2 Titanium Centrifugal pumps
15
3 Ti plate heat exchanger
5
4
Piping & Fittings
4.1 FRP
15
4.2 CS
3
5 Refrigeration System
7
6 Valves
11
4 Tanks
13.5
7 Insulation
3
8 Structural supports
2
9 Instruments - Lot
5
10 Electricals- Lot
8
11 Civil Work ( Building, Foundations, Brick lining
& other works)
7.5
12 Misc. & Contengencies
5
Total 125 0
Sodium Hypo
Amount in lacs (INR)
Back
Cost Estimation of Sodium Hypo Plant for Mercury Cell Plant.
In place of secondary tower existing lime scrubber will be used,therefore partial generetion of
Calcium Hypo will take place.
1 FRP absorption towers complete 5.00 In place of secondary tower existing lime scrubber
with internals, etc. - 1 No. will be used
2a Titanium centrifugal pumps - 2 Nos 4.75 One pump to be arranged in house
with motors.
2b Dilute caustic pump with motor- 2 nos. 0.00 Inhouse (CSF condensate water storage tank with
pump will be used)
2c Hypo transfer pump with motor-2 Nos. 1.43
2d Chilled water pump with motor- 2 nos 1.34
3a Titanium plate heat exchanger 1.67
- 1 Nos.
3b SS plate heat exchanger 0.31
- 1 Nos.
4 Piping & Fittings
FRP 6.00 For Cl2 service PVC piping considered.
CS 4.00
5 Refrigeration System 50 TR 0.00 Existing chilled water system considered.
- 1 Nos.
6 Valves 4.00 Tower, heat exchanger & dump tank
isolation valve not considered
7a Tanks FRP Hypo circulation for main 4.20
tower 2 nos
7b Tank FRP Hypo circulation for second 0.00 Not required
tower 1 nos
7c Tank hypo storage 1 No 3.25
7d Tank MS 1 No. 0.00 Inhouse (CSF condensate water storage tank with
pump will be used)
8 Insulation 3.00
9 Structural supports 2.00
10 Instruments - Lot 2.00
11 Electrical cables. - lot 4.00
MCC 2.30 Spare feeders not available
with existing MCC
12 Civil works,
Building 2.00 Minimized building cost
Foundations 1.50
Brick Lining & Other works 1.00
13 Misc. & contingencies 2.70
GRASIM INDUSTRIES LIMITED
CHEMICAL DIVISION
OPTION-2
S.No. Items
Amount
(Rs. in
Lakhs)
Remarks
Grand Total (1 to 13) 56.45
In place of secondary tower existing lime scrubber will be used,therefore partial generetion of
In place of secondary tower existing lime scrubber
One pump to be arranged in house
Inhouse (CSF condensate water storage tank with
For Cl2 service PVC piping considered.
Existing chilled water system considered.
Tower, heat exchanger & dump tank
isolation valve not considered
Inhouse (CSF condensate water storage tank with
Spare feeders not available
GRASIM INDUSTRIES LIMITED
CHEMICAL DIVISION
OPTION-2
Remarks

Sr No Description
Birla Cellulosic
120 TPD
(Kharach)
BCCL (225 TPD)
1 Heat Exchanger (Cl2 Gas / Brine) Shell & tube
16 22.00
2 Heat Exchanger (Cl2 Gas / Cooling Water)
Shell & tube
15 20.00
3 Heat Exchanger (Cl2 Gas / Chilled Water)
Shell & tube
10 12.00
4 Mist Eliminator
13 15.00
5 H2SO4 handling system inclusive of tanks &
pumps with motors & piping
8 existing
Total 62 69
Chlorine Treatment
Amount in lacs (INR)
Back
Sr No Description
Birla Cellulosic 115
TPD (Kharach)
BCCL (225 TPD)
1 Drying tower (5 Tray tower with
distributor, acid circulation pump, motor,
Acid cooler, acid separators, piping
valves & instruments etc.
existing
2 Chlorine compressor unit (Liquid ring
compressor, acid coolers, acid separators
, piping, valves & instruments etc.
32.00
3 Chlorine Liquification unit (Screw
compressors , Oil cooler, Oil Separators ,
Refrigerant condenser, Refrigerant
receiver, Cl2 Liquefier , Surge Drum,
22.00
4 Chilled Water Unit / VAM ( Chilled water
tank, pumps , valves & piping with
instruments
44 3.00
5 Chlorine storage tank (60 T) 100 existing
6 Chlorine valves for Cl2 storage tanks
(Calobri-Italy or Descote - France)
41
not required
Total
435 57
Chlorine Liquifacation
Amount in lacs (INR)
250
Back
E5 Cell:
1x45 TPD Liq. Cl2 capacity. Comment:
F5 Cell:
2x50TPD liq. Cl2 capacity Comment:
E9 Cell:
3 tanks are considered Comment:
F9 Cell:
4 tanks are considered Comment:
Sr No Description
Birla Cellulosic 120 TPD
(Kharach)
BCCL (225
TPD)
1 Filling Post with auto
weighing
15 5.00
2 Cranes 20 5.00
Total
35 10
Filling Station
Amount in lacs (INR)
Back
Sr No Description
Birla Cellulosic 120 TPD
(Kharach)
BCCL (225 TPD)
1 Chlorine tonners 780 400
Total
780 400
Chlorine Tonners
Amount in lacs (INR)
Back
C4 Cell:
RK SHAH: Comment:
100 TPD NaOH =45TPD Liquid Cl2 =50Tonners per day =1000Tonners required.
D4 Cell:
1) 100 TPD NaOH = 45 TPD Liq Cl2 prodn & 45 TPD HCl Prodn)= 50 Tonner per day = 1500 tonners Comment:
required
2) Rotation / month = 1
3) Cost / Tonner= Rs 44,000
E4 Cell:
1) 120 TPD NaOH = 86.25 TPD Liquid Cl2 = 96 tonners per day = 1950 tonners required Comment:
2) Rotation / Month = 1.5
3) Cost / tonner = Rs 40000
F4 Cell:
1000 Nos. @ Rs 40000 Comment:
Sr No Description
Birla Cellulosic
120 TPD
(Kharach)
BCCL (225 TPD)
1 Furnace with all
accessories with civil cost
of plant
350
existing
2 Acid transferring pump 3
existing
3 DM water tank 3 4.50
4 DM water pumps 3 3.40
Total
359 7.9
HCl Plant
Amount in Lacs (INR)
Back
F5 Cell:
2 furnace of 50 TPD Comment:
G5 Cell:
2 furnace of 50 TPD Comment:
H5 Cell:
2 furnace of 25 TPD Comment:
Sr No Description
Birla Cellulosic
120TPD (Kharach) BCCL (225 TPD)
1 DM water plant 55 53.00
2 Cooling tower (Additional cell, Cold water
pump, Piping , Valve & motor
30 19.36
3 Air Compressor with motor 16 12.00
4 Air Drying Unit 4 2.50
5 Nitrogen Unit 5 8.00
TANK FARM
1 Caustic storage tank (MS) 30 existing
2 Caustic Transfer Pump with motor 4 5.00
3 HCl storage tank (FRP) 26 existing
4 HCl Transfer pump with motor 5 existing
5 DM water supply pump 2 2.35
6 DM water Storage tank (MSRL) 15 12.00
Total
192 114.21
UTILITIES
Amt in Lacs (INR)
Back
E13 Cell:
4 tanks considered Comment:
F13 Cell:
4 tanks considered Comment:
G13 Cell:
2 tanks considered Comment:
Sr. No. Description
Birla Cellulosic 120
TPD (Kharach)
BCCL (225 TPD)
1 Pipe Rack - Structural Steel
50 Civil Head
2 Piping for Brine , Caustic, Cl2, HCl
including cell house except
individual cell headers
350 295.05
3 Piping for Air , N2, Water, steam
etc.
50 14.00
Total 450 309.05
General Piping
Amount in Lacs (INR)
Back
Sr No Description
Birla Cellulosic 120 TPD
(2electrolyser)
Birla Cellulosic 120 TPD
(3electrolyser)
BCCL (225 TPD)
1 Rectiformer with associated accessories
and DC bus bars, breakers, isolators, pol.
Rectifier, voltage monitoring systems etc.
688.00 720.00 909.38
2 Breaker Panel 35 35
37.80
3 Aux. Transformer 10 10
existing
4 Control Cables, Push button station, panel
etc
16 16
5.25
5 Cable for I/C Rectifier , Aux. Transformer 27 27
21.00
6 Main DB 27 27
21.59
7 Bus Duct - 2 Nos. 5 5
not required
8 MCCs 50 50
41.00
9 L.T. Cables for MCCs & power & control
cables for motors
40 40
26.25
10 Misc. (Earthing , Cable trays, structures,
insulators, lighting & protection system)
25 25
31.50
11 Capacitor Bank for Power factor
improvement
10 10
12.60
12 Harmonic Filter 15 15
integeral part of 11
13 Emergency power - 500 KVA DG Set 10 10
existing
14 Telephones & PA System 5 5
existing
Total 963 995 1106.37
Electrical
Amount in Lacs (INR)
Back
C5 Cell:
( 33 KV 50 Hz. 3 Ph & 30- KA, 400 V DC Thyrister type ) with Bus Bars, Isolators etc. (Including Polarisation rectifier if required) Comment:
D5 Cell:
( 33 KV 50 Hz. 3 Ph & 40- KA, 400 V DC Thyrister type ) with Bus Bars, Isolators etc. (Including Polarisation rectifier if required) Comment:
E5 Cell:
(11 KV, 50 Hz, 3 Ph & 2x20 KA , 400 V DC thyrister type) with bus bars, isolators etc. Comment:
F5 Cell:
(11 KV, 50 Hz, 3 Ph & 2x20 KA , 400 V DC thyrister type) with bus bars, isolators etc. Comment:
G5 Cell:
(22 KV, 50 Hz, 3 Ph & 2x30 KA , 430 V DC thyrister type) with bus bars, isolators etc. Comment:
C6 Cell:
33 KV , 6 Nos Comment:
D6 Cell:
33 KV , 6 Nos Comment:
E6 Cell:
11 KV , 4 nos Comment:
C7 Cell:
1000 KVA- 2 nos Comment:
D7 Cell:
1000 KVA- 2 nos Comment:
E7 Cell:
1600 KVA - 2nos Comment:
1x 40 KA 2 x 20 KA 1x 40 KA 2 x 20 KA
Rectiformer 350.00 550.00 350.00 550.00
DC Halmar System 14.00 16.00 14.00 16.00
DC Breaker Isolator & Shunt 36.00 36.00 24.00 24.00
Copper/Aluminium Bus bar flexible 60.00 66.00 40.00 46.00
Voltage monitoring system 25.00 25.00 25.00 25.00
DC Battery station 3.00 3.00 3.00 3.00
Polarisation rectifier 2.00 2.00 2.00 2.00
Air washery system 5.00 7.00 5.00 7.00
Mulsifire fire/Fire Hydrant 10.00 15.00 10.00 15.00
Total 505.00 720.00 473.00 688.00
ESTIMATE FOR RECTIFORMER
Rs. In lacs
Birla Cellulosic
11 KV
3Electrolyzers
Birla Cellulosic
11 KV
2Electrolyzers
Sr No Description
Birla Cellulosic
120TPD (2
electrolysers)
Birla Cellulosic
120TPD (3
electrolysers)
BCCL (225 TPD)
1 Instruments other than considered in respective
areas (DCS, Control Valves, Load cells, pressure
gauges, temperature gauges, level gauge,
transmitters, rotameters, pH meters, Gas detector,
Safety valves, Cables etc.
548 545.8 322.45
Total
548.2 545.8 322.45
Instruments & DCS
Amounts in Lacs (INR)
Back
Sno Description Qty Unit Price Total
1 I/P Converter 25 0.150 3.75
2 Temperature Transmitters 13 0.400 5.20
3 Pressure & Level switch 20 0.100 2.00
4 Rotameters(Glass Tube) 16 0.100 1.60
5 Magnetic Flow Meter (+2) 8 1.750 14.00
6 PH & ORP Transmittters 5 1.000 5.00
7 Density Transmiter 1 7.000 7.00
8 Control Valves( Chemtrol & Xomox) 29 0.700 20.30
9 On-Off Butterfly control valves 2 1.900 3.80
10 Metal tube Rotameter with Transmitter( 3 electroly) 6 1.000 6.00
11 Metal tube Rotameter without Transmitter 10 0.700 7.00
12 Pressure & Level Transmitters 34 1.250 42.50
13 Pressure Gauges 65 0.050 3.25
14 Air Headers 12 0.200 2.40
15 Imported Control valves 33(On/off)+8(Control Valves) 41 1.650 67.65
16 Dial Thermometer 43 0.015 0.65
17 Thermowell 48 0.050 2.40
18 Manometers 35 0.075 2.63
19 24X1.5 mm2 Armoured cable @ Rs.125/- 5000 125 6.25
20 12 pair X 0.75 Armoured shielded cable @ Rs.125/- 3000 125 3.75
21 2 pair x 0.75 mm2 armoured cable@ Rs. 60.00 2160 60.000 1.30
22 I pair x 0.75 mm2 Unarmoured shielded cable @ Rs.25/- 2000 25 0.50
23 I pair x 0.75 mm2 Armoured shielded cable @ Rs.35/- 4500 35 1.58
24 3 core x 1.5 mm2 Unarmoured cable @ Rs.30/- 500 30 0.15
25 3 core x 1.5 mm2 Armoured cable @ Rs.45/- 3000 45 1.35
26 1x0.2 mm2 wire @ Rs.2.5 1000 2.5 0.03
27 Steel for cable trays 35 0.3 10.50
28 Fitings (ss & brass) Lot 0.75
29 Copper tube 2000 50 1.00
30 SS Tubing 500 75 0.38
31 DCS & its accessories Lot 150.00
32 Erection & Mislenious Lot 12.00
33 UPS for control (Redundant) 18.00
34 Primary brine Transmitter (Level & pressure) 6 1.5 9.00
35 Temp.Transmitters (+1) 3 0.4 1.20
36 Ph Transmitters 1 1 1.00
37 Control Valves (0-100%) 5 1.5 7.50
38 On-Off control valves for 3 filters 18 1 18.00
39 Pressure gauges & Rotameters 40 0.05 2.00
40 Junction Boxes 30 0.15 4.50
447.84
41 65 TPD Compressor scheme ( 3 Cl2 + 2 Freaon) Lot 30.00
42 25x2 Tpd HCl Furnace (2 Nos) Lot 68.00
545.84 Lacs 322.45
0
GRAND TOTAL 2 Electrolysers
322.45
0
Instrumentation Cost
BCCL
BCCL's estimate is
prepared by
technology supplier
Sr. No. Description
Birla Cellulosic
120 TPD
(Kharach)
BCCL (225 TPD)
1
Insulation for Cl2
Liqufication & storage units,
steam lines & Boiler piping.
38 30.00
2
Painting 40 13.50
Total 78 43.5
Painting & Insulation
Amount in Lacs (INR)
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Sr No Description
Birla Cellulosic
120 TPD
(Kharach)
BCCL (225 TPD)
1 Safety appliances
8 6
2 Other Items (Vehicles, Stores/ Office furniture
/Equipments, etc)
5
5
3 Laboratory
11 13
4 Weigh bridge
0 existing
5 Fire Fighting
0 existing
Total
24 24
MISCELLANEOUS EQUIPMENT
Amounts in Lacs (INR)
Back
Sr. No Description
Birla Cellulosic 120 TPD (2
electrolysers)
Birla Cellulosic 120 TPD
(3electrolysers)
BCCL (225 TPD)
IEC FABCHEM
(5 TPD)
10 TPD
1 Salt Handling 79.00 79.00 27.00 19.75
2 Brine Plant 691.00 691.00 753.70 172.8
3 Catholyte Circulation 40.00 40.00 59.05 10
4 Dechlorination 200.00 200.00 72.45 50
5 Proprietory equipment 1871.42 1994.36 3468.83 460.4 553.4971
6 Cell House 244.70 328.00 117.60 61.2
7 Cl2 Treatment 62.00 62.00 69.00 0
8 Cl2 Liquifaction 435.00 435.00 57.00 0
9 Cl2 Filling 35.00 35.00 10.00 0
10 Cl2 tonners 780.00 780.00 400.00 0
11 H2 Handling 239.00 239.00 11.00 59.8
12 HCl 359.00 359.00 7.90 0
13 Sodium Hypo 125.00 125.00 171.05 31.25
14 Caustic Concentrator Plant 0.00 0.00 690.59 0
15 CSF Plant 0.00 0.00 0.00 0
16 General Piping 450.00 450.00 309.05 112.5
17 Electrical 963.00 995.00 1106.37 240.8
18 Instruments + DCS 545.84 548.24 322.45 136.5
19 Utilities 192.00 192.00 114.21 49.6
20 Misc Equipment 24.00 24.00 24.00 6
21 Paint & Insulation 78.00 78.00 43.50 19.5
Total 7413.96 7654.60 7834.75 1354.78
Total 10% of Indigenous Part 554.25 566.02 436.59
61.78300833 63.78834167 34.82111556
15.59516667 16.61966667 15.41702222 92.078 55.34971
FREIGHT, FORWARDING, INSURANCE, HANDLING CHARGES & DUTIES
Amt in lacs (INR)
Back
Sr No Description
Birla Cellulosic
120 TPD (Kharach)
BCCL (225 TPD)
1 Supervisory fee
2 Basic Engineering & Know How
3 Detailed engineering fee
Total 300.00 439.81
Detailed Engg, Supervision
Amount in Lacs (INR)
300.00 439.81
Back
Sr No Description
Birla Cellulosic 120
TPD (2 electrolysers)
Birla Cellulosic 120
TPD (3electrolysers)
BCCL (225 TPD)
1 Salt Handling
79 79
27.00
2 Brine Plant
691.00 691.00
753.70
3 Catholyte Circulation 40.00 40.00 59.05
4 Dechlorination 200.00 200.00 72.45
5 Cell House 244.7 328 117.60
6 Proprietory Equipment 1871.42 1994.36 3468.83
7 Cl2 Treatment 62 62 69.00
8 Cl2 Liquifaction 435 435 57.00
9 Cl2 Filling 35 35 10.00
10 Cl2 tonners 780 780 400.00
11 H2 Handling 239 239 11.00
12 HCl 359 359 7.90
13 Sodium Hypo 125 125 171.05
14 Caustic Concentrator Plant 0 0 690.59
15 CSF Plant 0 0 0.00
16 General Piping 450 450 309.05
17 Electrical 963 995 1106.37
18 Instruments + DCS 545.841 548.241 322.45
19 Utilities 192 192 114.21
20 Misc Equipment 24 24 24.00
21 Paint & Insulation 78 78 43.50
22 Packing & Forwarding 554.25 566.02 436.59
23
Detailed Engg , Supervision &
Travelling expenses
300.00 300.00 439.81
Total 8268.22 8520.63 8711.15
Erection Charges @ 5% 413.41 426.03 435.56
ERECTION EXPENSES
Amount in Lacs (INR)
Back
Sr No Description
Birla Cellulosic
120TPD (Kharach)
BCCL (225 TPD)
1 Insurance 46.47 43.56
2 Travelling 18.14 15.00
3 Start up 18.14 87.11
4 Other 7.25 260.70
Total 90.00 406.37
Preoperation
Amount in Lacs (INR)
Back
Description Amount in Lacs (INR)
Imported Items
Furnace along with accessories like
preheater, gas train, burner etc. 175
Flaker & Flaker Vat 125
Custom duty , freight , Insurance etc @10
% of 300 30
Sub Total 330
Critical Ni Items
HE-01 50
EV-01 30
HE-02 60
EV-02 45
EV-03 30
Double Syphon with Piping 15
HE-03 35
HE-04 8
HE-06 15
HE-08 10
Molten Salt Tank 10
Molten Salt Pump 35
Interstage Pump 15
Various Level Pots 3
Seal Pots 5
EV-03 Outlet Pipe 5
Break Tank, Sugar Tank,Sugar
Preparation Tank, Condensate Tank 6
Ni Piping 20
Sub Total 397
Indigenous Equipment
Air Fan (2 Nos) 3
H2 Blowers 2 nos 4
Air Compressors 2 nos 4
Cooling tower 1 no Bigger size 15
Air Drying Unit 2
HE-801 5
Cranes 2 nos 5
DM Water Pumps (1 no) 0.5
Caustic & condensate pumps ( 8 nos) 4
Vacuum Pumps (2 nos) 3
Sugar Dosing pump (2 nos) 1
Effluent Pump (2 nos) 1
Cold Water Pumps (2 Nos) 1
Screw conveyor with bagging system 10
Stitching machine 3
Caustic storage tanks 25
Air Recievers (2 nos) 4
Fuel Oil Tanks (2 nos) 10
Sniff blower with motor (2 nos) 0.5
Prilling Tower 534.00
CSF PLANT (50 TPD)
44
Description Amount in Lacs (INR)
Sub Total 635
Piping Valves & Structures
SS Piping 10
MS Piping (Air, Water, Cooling Tower,
Natural Gas) 25
Molten Salt piping 20
Steam Piping ( HP) 6
Valves 15
Structures, Primary supports, Pipe racks
etc. 15
Insulation 15
Painting 15
Lab Equipment & Molten salt 8
Sub Total 129
Electricals
Motors (33 Nos) 9.75
MCC 9
Emergency MCC 2
Cables 10.2
Cables for Emergency Power 11
Push Buttons 0.75
Steel Strucures 5
Labours 4.8
Lightening 0.5
Sub Total 53
Civil
Civil Bldg. 18 MtrX12MtrX4 floors &
foundation for tanks, equipment & pipe
rack etc.
75
Instruments 40
Duties, P&F, Transport, insurance etc
@ 10% for indigenous items
125.4
Detailed Engg, Superviison, travel
5
Erection( 5% excluding land, bldg &
civil cost.
62.7
Intrest during construction period @
3% of project cost
56
Contingency @ 5% of total cost before
contingency
93
Grand Total 2000
45