XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 985
Capital Cost Estimation
This work expands capital and project costing capabili-
ties developed by the IDAES-IP and the Carbon Capture
Simulation for Industry Impact (CCSI2) projects, leverag-
ing decades of NETL experience in developing a powerful
costing methodology that allows comparison of technology
options on a consistent basis and an extensive data base of
vendor quotes for advanced energy systems. (Lee, et al.,
2021) (Theis, 2021) The standardized set of assumptions
from the costing methodology and the costing information
for each component of the system are integrated into all of
the PrOMMiS unit models and flowsheets.
Figure 2 shows the workflow to leverage existing data-
bases (public studies, FEED studies, and/or private data) for
cost estimates. Once the library of vendor quotes is added
to the repository, a set of costing correlations is developed.
The PrOMMiS built-in costing library was devel-
oped using this workflow and supports capital cost, oper-
ating cost, and revenue calculations. (National Energy
Technology Laboratoratory, 2024) The costing data in the
repository was seeded with cost estimates from a public
report describing the University of Kentucky pilot testing
and preliminary technoeconomic analysis of a typical REE
plant. (Honaker, et al., 2021) This data was expanded upon
and refined through discussions with the authors of that
report. (Noble, Paul, &Fritz, 2023) Recent additions have
expanded the breadth of the estimates and at present the
framework supports costing for a wide range of unit opera-
tions including solids loading, crushing &screening, dry
grinding, roasting, leaching, rough and clean solvent extrac-
tion, saponification, metal precipitation, REE precipita-
tion, oxalate precipitation, water treatment, bio-oxidation,
and hard drive disk (HDD) recycling via shredding and
hydrogen decrepitation.
The flexibility of the IDAES-IP means this frame-
work can easily leverage vendor quotes or costing corre-
lations developed by other projects like WaterTAP (i.e.,
membrane costing correlations, solvent extraction) as well.
Consequently, costing for reverse osmosis, ion exchange,
and nanofiltration membranes are imported directly from
WaterTAP with capital and membrane material costs.
(National Energy Technology Laboratoratory, 2024)
PrOMMiS Application Examples
While PrOMMiS is very early in its development cycle,
there are a number of nascent examples of how it can be
applied for CMM process modeling and optimization. The
first example is the replication of a pilot project for REE
recovery from coal waste, being operated at steady state.
The second two examples examine how PrOMMiS can be
used for the conceptual design of a novel separation process
for battery recycling.
Integrated Process Flowsheet for REE Recovery from
Coal Waste
An early and exciting example of a PrOMMiS application is
the development of an integrated process flowsheet for the
extraction and separation of REEs from bituminous coal
refuse. The flowsheet, shown in Figure 3, integrates sev-
eral unit operation models into a single model for leaching
and REE separation. The model replicates the steady-state
operation of a pilot plant developed and operated by the
University of Kentucky, shown in Figure 4, and funded by
FECM’s Office of Resource Sustainability. (Honaker, et al.,
2019) (Honaker, et al., 2021) The green arrows represent
Figure 3. PrOMMiS flowsheet for University of Kentucky pilot process to recover REE from coal-waste
Capital Cost Estimation
This work expands capital and project costing capabili-
ties developed by the IDAES-IP and the Carbon Capture
Simulation for Industry Impact (CCSI2) projects, leverag-
ing decades of NETL experience in developing a powerful
costing methodology that allows comparison of technology
options on a consistent basis and an extensive data base of
vendor quotes for advanced energy systems. (Lee, et al.,
2021) (Theis, 2021) The standardized set of assumptions
from the costing methodology and the costing information
for each component of the system are integrated into all of
the PrOMMiS unit models and flowsheets.
Figure 2 shows the workflow to leverage existing data-
bases (public studies, FEED studies, and/or private data) for
cost estimates. Once the library of vendor quotes is added
to the repository, a set of costing correlations is developed.
The PrOMMiS built-in costing library was devel-
oped using this workflow and supports capital cost, oper-
ating cost, and revenue calculations. (National Energy
Technology Laboratoratory, 2024) The costing data in the
repository was seeded with cost estimates from a public
report describing the University of Kentucky pilot testing
and preliminary technoeconomic analysis of a typical REE
plant. (Honaker, et al., 2021) This data was expanded upon
and refined through discussions with the authors of that
report. (Noble, Paul, &Fritz, 2023) Recent additions have
expanded the breadth of the estimates and at present the
framework supports costing for a wide range of unit opera-
tions including solids loading, crushing &screening, dry
grinding, roasting, leaching, rough and clean solvent extrac-
tion, saponification, metal precipitation, REE precipita-
tion, oxalate precipitation, water treatment, bio-oxidation,
and hard drive disk (HDD) recycling via shredding and
hydrogen decrepitation.
The flexibility of the IDAES-IP means this frame-
work can easily leverage vendor quotes or costing corre-
lations developed by other projects like WaterTAP (i.e.,
membrane costing correlations, solvent extraction) as well.
Consequently, costing for reverse osmosis, ion exchange,
and nanofiltration membranes are imported directly from
WaterTAP with capital and membrane material costs.
(National Energy Technology Laboratoratory, 2024)
PrOMMiS Application Examples
While PrOMMiS is very early in its development cycle,
there are a number of nascent examples of how it can be
applied for CMM process modeling and optimization. The
first example is the replication of a pilot project for REE
recovery from coal waste, being operated at steady state.
The second two examples examine how PrOMMiS can be
used for the conceptual design of a novel separation process
for battery recycling.
Integrated Process Flowsheet for REE Recovery from
Coal Waste
An early and exciting example of a PrOMMiS application is
the development of an integrated process flowsheet for the
extraction and separation of REEs from bituminous coal
refuse. The flowsheet, shown in Figure 3, integrates sev-
eral unit operation models into a single model for leaching
and REE separation. The model replicates the steady-state
operation of a pilot plant developed and operated by the
University of Kentucky, shown in Figure 4, and funded by
FECM’s Office of Resource Sustainability. (Honaker, et al.,
2019) (Honaker, et al., 2021) The green arrows represent
Figure 3. PrOMMiS flowsheet for University of Kentucky pilot process to recover REE from coal-waste