Spray Cast Aluminum TF Shell

Data for melting and holding furnaces from SECO/WARWICK Corp.
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 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 + pump electrical $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, 90,000 lb capacity, nat. gas $750,000 Secondary use possible    
Installation of Melting Furnace $800,000      
Holding Furnace, 60,000 lb capacity, nat. gas $600,000 Secondary use possible    
Installation of Holding Furnace $500,000      
Furnace cost data provided by Al Reinhart, SECO/WARWICK, Meadville, PA        
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 $4,029,000      
         
Subtotal $9,711,588      
Contingency (20%) $1,942,318      
Prime contractor fee $1,398,469      
Total $13,052,375      
         
Unit Cost $4.85 $/kg    

Last Updated on 12/2/98
By Les Waganer