TEA Handbook

Concept

Capex

economic

Overview

Capital expenditure (capex) is the one-time cost to design, build, and install a plant before it produces anything — the physical asset itself, as distinct from the recurring opex of running it. At the maturity anchor it’s built bottom-up from the major equipment: size each item, scale its cost, factor up to an installed total.

Body

The factored build. Capex is estimated equipment-first, then grossed up:

  1. Per unit operation, pick the 2–3 items that dominate cost; approximate the rest.
  2. Size each to its design (nameplate) duty.
  3. Scale each from a reference cost with the six-tenths rule, using the class exponent from sizing scalars.
  4. Sum to purchased-equipment cost.
  5. Multiply by an installation factor (piping, steel, labor, field indirects) for installed cost.

The result is the inside-battery-limits (ISBL) cost — the process plant proper (see battery limits). Adding off-sites (OSBL) and indirects rolls it up to total capex, the figure that gets annualized. This page is the equipment build that feeds that roll-up.

Every figure carries its basiscurrency, cost year (prices drift; escalate old figures), location, and battery-limits scope. Two figures add or compare only on the same basis; a borrowed reference cost (see reference / comparable process) must be converted first.

Limits & typical error

Mini-example

ISBL capex of a green-ammonia synthesis section, costing the few items that dominate: the syngas compression train and the ammonia reactor in the loop, the electrolyzer in the H₂ front end. The compression train — sized to 8 MW and scaled from a $2.0M / 5 MW reference with the six-tenths rule — comes in ~$2.7M purchased. Sum the loop’s big items, multiply by an installation factor (~3.5 for fluids) for installed ISBL, then add OSBL and indirects toward total capex.

Edge case: the shortcut weakens for the electrolyzer front end, where capacity is met by many identical stacks rather than one dominant vessel — no single big item to anchor the factor on, and cost lives in a module count instead (the numbering-up regime).

See also