Spray Cast Aluminum TF Shell

Data on melting and holding furnaces from Frank W. Schaefer Inc.
Cost Elements Metric Units English Units
Mass of three shell components (new CAD weight values) 2.69E+06 kg 5.92E+06 lb
Mass including 5% wastage 2.82E+06 kg 6.21E+06 lb
Deposition rate per head 0.50 kg/s 1.10 lb/s
Number of spray heads, operational 4   4  
Deposition rate, 4 heads 2.00 kg/s 4.40 lb/s
Elapsed time (including 50% efficiency and 10% startup) 35.96 d    
Setup time 120.00 h    
Build labor time at 50% effcny, 1 operator + 1 assct or inspector 1569.17 h    
Inspection and rework 400.00 h    
Total labor hours 2089.17 h    
Fabrication cost @ $150/h include site premium and overtime $313,375 $    
         
Material unit cost ($0.60/lb + $0.25/lb for alloying & shipping) $1.87 $/kg $0.85 $/lb
Material cost, aluminum $5,281,815      
Coolant tubes, SS $50,000      
         
Energy cost, natural gas for furnaces (use elapsed time) $800 $/d    
Energy cost for pumps $240 $/d    
Energy cost total $37,398 $    
         
Assume construction within Reactor Building See Act 21.02      
Furnaces located in temporary buildings See Act 91      
Melting Furnace, 126,000 lb capacity, nat. gas $550,000 Secondary use possible    
Installation of Melting Furnace $225,000      
Holding Furnace, 60,000 lb capacity, nat. gas $140,000 Secondary use possible    
Installation of Holding Furnace $70,000      
Furnace cost data provided by Dave Nelson, Frank W. Schaefer, Inc, Dayton, OH        
T-bar handling system $25,000      
Transfer pumps, 4 @ $16k each + 1 spare $80,000      
Heated transfer piping $100,000      
Spray robots, 4 @ $100k each $400,000 Secondary use possible    
Atomizing heads with high pressure pumps, 4 @$100k each $400,000 Secondary use possible    
Spare parts, robots and atomizing heads (10% factor) $80,000      
Argon shields, 4 $24,000      
Argon supply and recovery system $20,000      
Robot rail system $100,000      
Spray casting computer and installation $50,000      
Shell handling fixtures $100,000      
Hardware costs $2,364,000      
         
Subtotal $8,046,588      
Contingency (20%) $1,609,318      
Prime contractor fee $1,158,709      
Total $10,814,615      
         
Unit Cost $4.02 $/kg    

Last Updated on 12/2/98
By Les Waganer