BioCarb TEA v2 — SI_2_4.xlsx
Process Flow Diagram — current saved layout from material/flow/result/biocarb-mortar-current-layout.svg
Process
Input
Utility
Output
BioCarb Mortar Process Saved layout from material/flow/result. Click a node for details. RCFTATA and WCO2slurryBiocarb mortarmakeup electricitymakeup electricityEle WCDisCrushingGrindingEleSoakingEleWCarbonationEleSettlingMortar mixingEleSandOPCTA extractionPower plantwithout CCPower plantwith CCCombined OutputSystem ExitBiocarb mortarSystem WideEle
BioCarb Mortar Workflow — baseline process flow
Techno-Economic Analysis · SI_2_4_TEA_BioCarb.xlsx
BioCarb Mortar — TEA Dashboard
University of Alabama · DOE DE-FE0032263 · Chen et al. 2024
DCFROR Model · 2020 USD · 10-yr plant life · IRR 10%
Production: 2,646,288 kg/yr · 8 hr/day · 300 days/yr
Minimum Selling Price
6.664
¢ / kg BioCarb mortar (2020 USD)
Output
Total Capital Investment
$111,362
TCI
Output
Fixed Capital Investment
$106,059
FCI
Output
Total Variable OPEX
2.776
¢/kg
Output
Total Fixed OPEX
3.188
¢/kg
Output
Annual Product Sales
$176,340
$/yr at MSP
At MSP
Economic Assumptions Rows 1–25, Col A–D
ParameterValueUnit / Note
Equity fraction
40%
Loan interest rate TEA_BioCarb!B6
%
input
Loan term TEA_BioCarb!B7
yr
input
Working capital (% of FCI)
5%
Depreciation period
7 yr
 MACRS (IRS Pub 946)
Construction period
1 yr
Start-up time
0.1 yr
Start-up production rate
75%
Discount rate (IRR) TEA_BioCarb!B23
%
input
Income tax rate TEA_BioCarb!B24
%
input
Cost year
2020
Technical Assumptions Rows 1–25, Col G–L
ParameterValueUnitNotes
Mixer size / cycle time
0.085 m³
 m³/batch
Mortar density
2,162
 kg/m³
Working efficiency TEA_BioCarb!H4
hr/yr 8 hr/day × 300 days
Batch size
183.77
 kg/batch
Production rate
1,102.62
 kg/hr
Daily production
8,821
 kg/day
Annual production
2,646,288
 kg/yr key denominator
Plant lifetime TEA_BioCarb!H7
years
Carbonated slurry volume
~0.57
 m³
CAPEX — Capital Expenditure
Capital Costs ($)
Section / ItemInstalled Cost ($)
Equipment Groups
Tannic Acid Extraction$18,816
RCF Preparation$24,998
Soaking / Carbonation$6,080
Settling Tank$1,330
Slurry Mixing Tank$8,152
Storage$7,665
Total Installed Equipment Cost$67,041
Added Direct + Indirect Costs (40% of TCI)$39,021
Fixed Capital Investment (FCI)$106,059
Land$0
Working Capital (5% FCI)$5,303
Total Capital Investment (TCI)$111,362
Equipment Detail — Scaled Purchase & Install Costs
Equipment Scaled Purchase ($) Install Cost ($) Inst. Factor
Tannic Acid Production (Rows 30–39)
Transfer Conveyor $7,253 $12,331×1.7
Dust Collection System $376 $640×1.7
Biomass Disc Refiner $3,897 $5,845×1.5
Leaching / Nanofiltration / Heating$0Included—
TA Subtotal$11,526$18,816—
BioCarb Mortar Production (Rows 41–49)
RCF Jaw Crusher $4,917 $5,409×1.1
RCF Cement Ball Mill $17,809 $19,590×1.1
Soaking / Carbonation Tank $1,630 $3,587×2.2
Tank Agitator $1,662 $2,493×1.5
Settling Tank $739 $1,330×1.8
Mortar Mixing Tank (3 ft³) $8,152 $8,152×1.0
Product Storage Tank (CRCF slurry) $7,665 $7,665×1.0
BioCarb Subtotal$42,574$48,226—
Grand Total$54,101$67,041—
CAPEX Breakdown — Installed Cost by System
TA Extraction ($18,816)
RCF Prep ($25,000)
Soak/Carb ($6,080)
Settling ($1,330)
Mixing ($8,152)
Storage ($7,665)
Indirect ($30,303)
TCI vs FCI — Capital Structure
OPEX — Operating Expenditure
Variable Operating Costs Rows 55–82, K col = ¢/kg product
Material / Stream Flow (kg/hr) Price ($/mt) ¢/kg product
Tannic Acid Process (rows 58–61)
Feedstock biomass for TA TEA_BioCarb!E59 1.24
0.0096
Methanol 0.07 $350 0.0024
Water (TA process) 1.54 $0.22 0.0000
BioCarb Mortar Process (rows 62–70)
Tannic acid (internal) 0 $4,730 0.0000
Recycled cement fines (RCF) TEA_BioCarb!E64 74.50
0.0000
Sand TEA_BioCarb!E65 699.83
0.6322
Cement TEA_BioCarb!E66 173.83
1.9706
Water (biomortar) 122.80 $0.22 0.0025
CO₂ (SubPC capture) TEA_BioCarb!E68 29.80
0.1081
Recycled concrete ($0 waste) 372.49 $0 0.0000
Diesel (jaw crusher)~0.042$1,079 0.0041
Subtotal (materials) 2.7294
Electricity (rows 77–81)
WORK.W-TOT (all steps, 4.478 kW) 4.478 $0.0682/kWh 0.0277
WORK.W-RCF (2.511 kW) 2.511$0.0682/kWh 0.0155
WORK.TANACID (0.479 kW) 0.479$0.0682/kWh 0.0030
Electricity subtotal 0.0462
Total Variable OPEX (K82) 2.7756
Fixed Operating Costs
Item$/yr¢/kg product
Labor & Supervision (rows 86–89)
Yard Employees (2 × $40,800/yr) $81,600 3.0836
Labor Burden (90%) $0 0.0000
Other Overhead (rows 90–92)
Maintenance (3% ISBL) ~$2,011 0.0760
Property Insurance & Tax (0.7% FCI) ~$742 0.0281
Total Fixed OPEX 3.1876
Total Operating Costs 5.9632
MSP Summary — ¢/kg Product
Cost Component¢/kg
Feedstock + Handling0.0096
Sand0.6322
Binder (cement)1.9706
CO₂0.1081
C&D Waste0.0000
Other Raw Materials0.0048
Waste Disposal0.0000
Utility (electricity + diesel)0.0503
Fixed Costs (labor + O&M)3.1876
Capital Depreciation0.4008
Average Income Tax0.0000
Average Return on Investment0.2721
MSP 6.664
OPEX Breakdown (¢/kg) — Variable vs Fixed
Cement
Sand
CO₂
Electricity
Labor
Other Fixed
MSP Component Breakdown
Operation Summary — ¢/kg Product
Item¢/kg (K col)
Materials (rows 134–143)
  Feedstock biomass for TA0.0096
  Methanol0.0024
  Water (TA process)0.0000
  Sand0.6322
  Cement1.9706
  Water (biomortar)0.0025
  CO₂0.1081
  Recycled concrete0.0000
Total Materials2.7294
Utility (rows 144–149)
  Diesel (jaw crusher)0.0041
  Electricity (TA acid)0.0030
  Electricity (RCF pretreatment)0.0155
  Electricity (BioCarb production)0.0277
Total Utility0.0503
Waste Treatment (rows 150–153)
  Biomass waste0.0000
  Unused concrete waste0.0000
Total Waste0.0000
Fixed Operating (rows 154–158)
  Salary (2 yard employees)3.0836
  O&M (maintenance)0.0760
  Property tax0.0281
Total Fixed3.1876
SUM TOTAL (K159) 5.9632
Manufacturing Costs ($/yr)
Item$/yr
Feedstock + Handling$252
Sand$16,718
Binder (cement)$52,149
CO₂$2,861
Other Raw Materials$128
Utility$1,330
Fixed Costs$84,354
Capital Depreciation$10,606
Average Income Tax$0
Avg. Return on Investment$7,202
Total $157,803
DCFROR — Discounted Cash Flow Rate of Return
DCFROR Cash Flow Table · MSP = price at NPW = 0 (B129)
Item Yr 0Yr 1Yr 2Yr 3Yr 4 Yr 5Yr 6Yr 7Yr 8
Cumulative NPV Over Project Life
Annual Cash Flow Breakdown
Sensitivity Analysis — Impact on MSP
MSP Sensitivity — ±10% Parameter Variation
Sensitivity to Key Prices Drag sliders to explore
$125
$40
$9.96
10%
10
Adjusted MSP
6.664
¢ / kg mortar
Source: SI_2_4_TEA_BioCarb.xlsx — TEA_BioCarb sheet Model: DCFROR at IRR = 10% · MSP = price where NPW = 0 Blue highlight = spreadsheet-linked or updated field in this HTML Yellow cells = editable spreadsheet inputs e.g. TEA_BioCarb!B6, B7, B23, B24, E65–E68 Production: 2,646,288 kg/yr = J11
BioCarb Dry Mortar Workflow — TEA_BioCarb_Drying sheet
Techno-Economic Analysis · SI_2_4.xlsx · TEA_BioCarb_Drying

BioCarb Dry Mortar

Dry-mortar scenario with the added spray-drying unit operation and TEA_BioCarb_Drying sheet values.

Minimum Selling Price
9.278
¢ / kg BioCarb dry mortar (2020 USD)
Output
Total Capital Investment
$423,077
2020 USD
U18
Fixed Capital Investment
$402,931
2020 USD
U15
Variable OPEX
3.109
¢/kg
K84
Fixed OPEX
3.479
¢/kg
K95
Annual Product Sales
$245,516
$/yr at MSP
At MSP
Dry-Mortar Assumptions Rows 1-25
ParameterValueUnit / Note
Equity fraction40%
Loan interest rate TEA_BioCarb_Drying!B6
%
input
Loan term TEA_BioCarb_Drying!B7
yr
input
Discount rate (IRR) TEA_BioCarb_Drying!B23
%
input
Income tax rate TEA_BioCarb_Drying!B24
%
input
Working efficiency TEA_BioCarb_Drying!H4
hr/yr
Batch size183.77kg/batch
Production rate1,102.62kg/hr
Daily production8,821kg/day
Annual production2,646,288kg/yr
Plant lifetime TEA_BioCarb_Drying!H7
yr
Capital Investment TEA_BioCarb_Drying
ItemCost ($)
Tannic Acid Production$18,816
BioCarb Dry Mortar Production$235,881
Total Installed Equipment Cost$254,697
Total Direct Cost (TDC)$287,808
Total Indirect Costs$115,123
Fixed Capital Investment (FCI)$402,931
Working Capital (5% FCI)$20,147
Total Capital Investment (TCI)$423,077
Dry-Mortar Equipment Detail Rows 30-50
EquipmentScaled Purchase ($)Installed Cost ($)Inst. Factor
Tannic Acid Production
Transfer Conveyor$7,253$12,331x1.7
Dust Collection System$376$640x1.7
Biomass Disc Refiner$3,897$5,845x1.5
TA Subtotal$11,527$18,816
BioCarb Dry Mortar Production
RCF Jaw Crusher$4,917$5,409x1.1
RCF Cement Ball Mill$17,809$19,590x1.1
Soaking / Carbonation Tank$1,630$3,587x2.2
Tank Agitator$1,662$2,493x1.5
Settling Tank$739$1,330x1.8
Drying system (spray dryer)$125,104$187,656x1.5
Mortar Mixing Tank$8,152$8,152x1.0
Product Storage Tank$7,665$7,665x1.0
Dry Mortar Subtotal$167,678$235,881
Variable Operating Costs K column = c/kg product
Material / StreamFlow (kg/hr)Price ($/mt)c/kg
Feedstock biomass for TA TEA_BioCarb_Drying!E601.24
0.0096
Methanol0.07$348.550.0024
Water from TA process1.54$0.240.0000
Recycled cement fines (RCF) TEA_BioCarb_Drying!E6574.50
0.0000
Sand TEA_BioCarb_Drying!E66699.83
0.6322
Cement TEA_BioCarb_Drying!E67173.83
1.9706
Water - biomortar process122.80$0.220.0025
CO2 TEA_BioCarb_Drying!E6929.80
0.1081
Diesel for jaw crusher0.042$1,078.750.0041
Materials subtotal2.7294
Electricity - total process4.478 kW$0.0682/kWh0.0277
Electricity - RCF pretreatment2.511 kW$0.0682/kWh0.0155
Electricity - drying53.894 kW$0.0682/kWh0.3334
Electricity - tannic acid0.479 kW$0.0682/kWh0.0030
Total Variable OPEX3.1089
MSP Summary c/kg product
Cost Componentc/kg
Feedstock + Handling0.0096
Sand0.6322
Binder (cement)1.9706
CO20.1081
Other raw materials0.0048
Waste disposal0.0000
Utility0.3836
Fixed Costs3.4789
Capital Depreciation1.5226
Average Income Tax0.1059
Average Return on Investment1.0614
Minimum Selling Price9.2777
Operation Summary K column = c/kg product
Itemc/kg
Materials
Feedstock biomass for TA0.0096
Methanol0.0024
Water from TA process0.0000
Sand0.6322
Cement1.9706
Water - biomortar process0.0025
CO20.1081
Total Materials2.7253
Utility
Diesel for jaw crusher0.0041
Electricity for tannic acid extraction0.0030
Electricity for RCF pretreatment0.0155
Electricity for BioCarb mortar production0.0277
Total Utility0.0503
Fixed Operating
Salary3.0836
O&M0.2887
Property Tax0.1066
Total Fixed3.4789
SUM TOTAL6.2545
Dry CAPEX Breakdown — Installed Cost by System
Dry TCI vs FCI — Capital Structure
Dry OPEX Breakdown (c/kg) — Variable vs Fixed
Dry MSP Component Breakdown
Dry DCFROR Cash Flow Table Expanded export includes this table
Item Yr 1Yr 2Yr 3Yr 4Yr 5 Yr 6Yr 7Yr 8Yr 9Yr 10
Dry Cumulative NPV Over Project Life
Dry Annual Cash Flow Breakdown
Dry MSP Sensitivity — ±10% Parameter Variation
Dry Sensitivity to Key Prices Drag sliders to explore
$125
$40
$9.96
10%
10
Adjusted Dry MSP
9.278
c / kg dry mortar