LABSA Industry Calculator & Calculation Book

from pathlib import Path import zipfile, shutil, json, textwrap out = Path("/mnt/data/LABSA_Industry_Calculator") out.mkdir(exist_ok=True) html = r'''

LABSA Industry Calculator

Parametric calculation book for preliminary planning of LABSA 90% / acid-slurry plants

1. Design Inputs

Plant capacity — LABSA product (TPD)

TPD = metric tonnes of finished LABSA product per operating day.

Operating days / year

Operating hours / day

Raw-material basis

LAB consumption (kg / tonne LABSA)

Editable design assumption. The report gives 670–690 kg per tonne of 89 ± 1% acid slurry.

98% H₂SO₄ consumption (kg / tonne LABSA)

Editable design assumption. The report's mass-balance basis gives 1.500 MT acid per 1.470 MT LABSA.

Process water (kg / tonne LABSA)

Editable. Reported mass balance corresponds to 250 kg water / 1.470 MT LABSA.

Reported by-product / diluted acid (kg / tonne LABSA)

Editable. Reported annual figures imply a different ratio; keep this assumption explicit.

Utilities

Total water requirement (L / tonne LABSA)

Initial value derived from the report's 18 KLD / 72 TPD ratio.

Electric load (kVA / TPD)

Initial value = 100 kVA / 72 TPD from the report. Replace with an actual load study.

DG backup (%)

Report: 82 kVA DG against 100 kVA stated electrical requirement.

Storage assumptions

LAB storage days

Acid storage days

LABSA storage days

By-product storage days

Financial assumptions

Product selling price / MT

LAB price / MT

98% acid price / MT

By-product price / MT

Set commercial prices in your own currency. Zero means the financial section remains inactive.

2. Executive Results LIVE

Daily LABSA—

Annual LABSA—

LAB / year—

H₂SO₄ / year—

3. Production & Raw Materials

Item	Per day	Per month*	Per year

*Monthly values are annual quantity divided by 12, not a claim about actual monthly production scheduling.

4. Material-Balance Check

Stream	kg/t LABSA	TPD	MT/year

5. Utility Calculation

Utility	Daily	Annual	Basis

Utility values are preliminary planning calculations. Final electrical, water, cooling, ventilation, instrumentation and process-safety loads require an engineering design basis.

6. Preliminary Storage Sizing

Material	Assumed days	Inventory, MT	Suggested nominal capacity, MT

Nominal capacity shown = calculated inventory × 1.15 working allowance. Tank geometry, usable volume, density, freeboard and code requirements are not calculated here.

7. Indicative Economics

Item	Annual MT	Unit price	Annual value

8. Report-Derived Reference Notes

Your sample report: the reported reference project is 72 TPD LABSA, with 21,600 MT/year stated at 300 operating days/year. It also reports 1,300 MT/month LAB, 2,000 MT/month 98% sulphuric acid, 12 KLD process water and 18 KLD total water.

Important: the source contains inconsistencies. Examples include different land areas, highway identifiers, reaction times, terminology for the acid by-product, and 100 HP versus 100 kVA. This calculator deliberately does not silently “fix” those values. Instead, the user enters the design basis.

9. Calculation Book — Formula Sheet

Annual LABSA	Capacity TPD × operating days/year
Daily LAB	LAB kg/t × LABSA TPD ÷ 1000
Annual LAB	Daily LAB × operating days/year
Daily H₂SO₄	Acid kg/t × LABSA TPD ÷ 1000
Annual H₂SO₄	Daily H₂SO₄ × operating days/year
Daily process water	Water kg/t × LABSA TPD ÷ 1000
Storage inventory	Daily material consumption × storage days
Nominal tank allowance	Inventory × 1.15
Annual gross sales	Annual LABSA × product selling price
Annual raw-material cost	Annual MT × unit price

10. Engineering Boundary

This calculator is intended for pre-feasibility, comparison and educational planning. It is not a process design package. It does not calculate reactor dimensions, sulphonation kinetics, heat-transfer area, pressure drop, acid-resistant materials of construction, HAZOP/LOPA, relief devices, emissions compliance, detailed electrical distribution, fire protection, civil design, or statutory approvals.

LABSA Industry Calculator • Based initially on the supplied LABSA 90% pre-feasibility report • All design assumptions should be independently verified.

''' (out/"LABSA_Industry_Calculator.html").write_text(html, encoding="utf-8") readme = """# LABSA Industry Calculator Open `LABSA_Industry_Calculator.html` directly in Chrome, Edge or Firefox. ## Included - Variable LABSA capacity (TPD) - Operating days and hours - LAB, 98% sulfuric acid and water assumptions - By-product/diluted-acid assumption - Daily/monthly/annual production - Material-balance check - Water and preliminary electrical-load indicators - Storage inventory and nominal tank allowance - Optional indicative revenue/raw-material contribution - Formula sheet - Print / Save as PDF - Responsive mobile/desktop interface - Local browser saving of the user's last inputs ## Source handling The sample report was used as the initial reference basis, but conflicting source values were not silently merged. Key assumptions are exposed as inputs so an engineer/user can choose the verified design basis. The default 72 TPD reference is from the supplied report. The report also states 300 operating days/year and 21,600 MT/year. The calculator therefore starts at 72 × 300 = 21,600 MT/year. ## Important technical limitation This is a pre-feasibility calculation tool, not a detailed LABSA process-design package. It does not calculate sulphonation kinetics, reactor dimensions, heat-exchanger area, pressure drop, materials of construction, relief systems, HAZOP/LOPA, fire protection, emissions compliance, detailed electrical design, civil works or regulatory approvals. Before commercial/engineering use, replace every editable assumption with values from a verified process design basis and applicable standards. """ (out/"README.txt").write_text(readme, encoding="utf-8") zip_path=Path("/mnt/data/LABSA_Industry_Calculator.zip") with zipfile.ZipFile(zip_path,"w",zipfile.ZIP_DEFLATED) as z: for p in out.rglob("*"): z.write(p,p.relative_to(out.parent)) print(f"Created: {out/'LABSA_Industry_Calculator.html'}") print(f"Created: {zip_path}")