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Compressor (C-101)
a) Bare module cost for both at process and base conditions
Where:
m = 394.8 mol/s
1 = 1 (assume air in ideal gas condition)
R = 8.314 J/mol.K
1 = 293K
1 = 101 kPa
2 = 275 kPa
= 1.3967 (assume)
= 0.2857
= (394.8)(1)(8.314)(293){[(275/101)0.2857 ] 1}/0.2857
= 1115.30 kW
100
= 1115.30
65
= 1715.85
Referring to Appendix A in Turton, the values of K1, K2, K3 for compressor are as follows:
K1 2.2897
K2 1.3604
K3 -0.1027
10 0 = 1 + 2 10 () + 3 [10 ()]2
10 0 = 2.2897 + 1.360410 (1715.85) 0.1027[10 (1715.85)]2
10 0 = 2.2897 + 4.4002 1.0744
10 0 = 5.6155
0 = 412572.24
=
The value of is taken from the table A.6 from Turton textbook
= 2.8
2016 2016
=
2001 2001
2016 556.8
=
412572.24 394
2016 = 583046.25
=
= 583046.25(2.8)
= $ , , .
A. Calculation of CPo
Reactor
R-101 & R-102
The reactor is considered as a vertical vessel, with assumed sizing of diameter D=2.17 m, and length
L=4m. Thus, volume is:
D2 2.17 2
V L (4) 14.79m3
4 4
Referring to Appendix A in Turton, the values of K1, K2, K3 for vertical vessel are as follows:
K1 3.4974
K2 0.4485
K3 0.1074
10 0 = 1 + 2 10 () + 3 [10 ()]2
10 0 = 3.4974 + 0.4485 10 (14.79) + 0.1074[10 (14.79)]2
0 = 14761.91
2016 2016
=
2001 2001
2016 556.8
=
14761.91 394
2016 = 20861.50
B. Calculation of CBM:
In calculation of CBM, the FM and FP are calculated based on the process conditions. For this process, the
reactor is made up of stainless steel material, and operating pressure of 275 kPa. Referring to Section A.3
in Appendix A in Turton, the FM for this vertical vessel with MOC of stainless steel (SS) is 3.1,
identification number of 20.
The FP is also calculated, by using the same formula shown above during calculation of FP at standard
pressure. Only this time, the pressure is 275 kPa, which is equivalent to 1.737 barg.
(2.737)2.17
0.00315
2[850 0.6(2.737)]
FP 1.0556
0.0063
To find Fp:
log10 FP = C1 + C2 log10(P) + C3 [log10(P)]2
Referring to Table A.2 in Turton, the values of C1, C2, C3 for heat exchanger are as follows:
C1 0
C2 0
C3 0
To find FM:
Based on table A.3, from Turton textbook, No of identification = 2, =1.4
= = Cp(B1 + B2FMFp)
= 96,917.68 ( 1.63 + 1.66 (1.4)1)
= $ , .
Tower (T-101)
Bare module cost for tower:
Equation for Bare Module Cost,
=
2
Volume of tower =
4
( 3.0 )2
= 4
(12)
Volume of the tower= parameter of the tower, A = 84.82m3
K1 3.4974
K2 0.4485
K3 0.1074
log10 Cp0 = K1 + K 2 log10 (A) + K 3 [log10 (A)]2
log10 Cp0 = 3.4974 + 0.4485log10 (84.82) + 0.1074[log10 (84.82)]2
log10 Cp0 = 3.4974 + 0.8650 + 0.3994
log10 Cp0 = 4.7618
Cp0 = $ 57,783.00
2016 2016
=
2001 2001
2016 556.8
=
57783.00 394
2016 = 81,658.80
, = 1.09
From Table A3 from Turton textbook,
Identification number: 20
Figure A18 from Turton textbook,
Fm =3.1
FBM = 2.25 + 1.82 (3.1)(1.09)
FBM= 8.40
2
Area of tray =
4
( 3)2
Area of tray = 4
Area of tray = parameter of the tray, A =7.0686m2
K1 2.9949
K2 0.4465
K3 0.3961
To find Fp:
log10 FP = C1 + C2 log10(P) + C3 [log10(P)]2
Referring to Table A.2 in Turton, the values of C1, C2, C3 for heat exchanger are as follows:
C1 0.03881
C2 -0.11272
C3 0.08183
To find FM:
Based on table A.3, from Turton textbook, No of identification = 2, =1.4
= = Cp(B1 + B2FMFp)
= 40,541.80 ( 1.63 + 1.66 (1.4)1.17)
= $ , .
Vessel (V-101)
Vertical vessel
D = 4.00 m
L = 11.3 m
Carbon steel
Design Pressure= 110 kPa
2
Volume of vessel: = 4
(4.00)2 (11.3)
=
4
= 142 3
To find FM:
From Table A.3, identification number=18, FM= 1.
To find Fp:
( + 1 )
+ 0.00315
2[850 0.6( + 1)]
, =
0.0063
( 1.1 + 1 )4.00
+ 0.00315
2[850 0.6(1.1 + 1)]
, =
0.0063
, = 1.2855
= = Cp(B1 + B2FMFp)
= 128,944.55 ( 2.25 + 1.82 (1.0)1.2855)
= $ , .
Tower (T-102)
Bare module cost for tower:
Equation for Bare Module Cost,
=
2
Volume of tower = 4
( 1.02 )2
= 4
(18.6)
Volume of the tower= parameter of the tower, A = 15.20m3
K1 3.4974
K2 0.4485
K3 0.1074
, = 0.7 = 1.0
From Table A3 from Turton textbook,
Identification number: 20
Figure A18 from Turton textbook,
Fm =3.1
FBM = 2.25 + 1.82 (3.1)(1.0)
FBM= 7.90
2
Area of tray = 4
( 1.02 )2
Area of tray =
4
Area of tray = parameter of the tray, A =0.8171 m2
K1 2.9949
K2 0.4465
K3 0.3961
log10 Cp0 = K1 + K 2 log10 (A) + K 3 [log10 (A)]2
log10 Cp0 = 2.9949 + 0.4465log10 (0.8171) + 0.3961[log10 (0.8171)]2
Cp0 = $ 909.45
2016 2016
=
2001 2001
2016 556.8
=
909.45 394
2016 = 1285.23
Main Equipment
No
1 C-101 $ 1,632,529.51
2 R-101 $ 171,272.93
3 E-101 $ 383,212.51
4 T-101 $ 899,135.65
5 E-102 $ 176,319.53
6 V-101 $ 591,805.20
7 R-102 $ 171,272.93
8 T-102 $ 265,171.43
TOTAL $ 4,290,719.69
Table 1 Purchased Cost For Main Equipment
No Other Equipment
1 E-103 $ 63,456.57
2 V-102 $ 32,827.61
3 P-101 $ 17,896.89
TOTAL $ 114,181.07
Table 2 Purchased Cost For Other Equipment
=RM 32,709,031.10
Cost Of Manufacturing:
6.3 Manufacturing cost per year
Utilities are used to help complement the main process stream. Most common utilities
used in industries are electricity, usually for compressors, pumps and drives, cooling water,
saturated steam and boiler feed water (bfw). Each of these utilities has their own cost. Since
calculating the true cost of utilities can be very complicated, this section shows the calculations
for the cost of supply of the utility, or the cost to generate the utility.
350
= 365 = 0.96
24hr 365day
Cost Q * Cost utilitystream * ( . )
1day 1year
Where:
- Q is heat duty of heat exchanger or fired heater in GJ/hr, or flowrate of bfw in kg/hr
- Costutilitystream is the standard cost of the utility stream supply per GJ, or per 1000 kg
for bfw
E-101:
Duty: 86.90 GJ/h
Cost of Cooling Water = $ 0.354/GJ
COST = QtCcw
COST = (86.9)(24)(365)(0.96)(0.354)
COST = $ 258,701.16
E-102:
Duty: 19.15 GJ/h
Cost of Hot Pressurized Stream = $ 17.70/GJ
COST = QtChps
COST = (19.15)(24)(365)(0.96)(17.70)
COST = $ 2,850,476
E-103:
Duty: 3.05 GJ/h
Cost of Cooling Water = $ 0.354/GJ
COST = QtCcw
COST = (3.05)(24)(365)(0.96)(0.354)
COST = $ 9,079.85
Equipment Type of Utility Used Cost of Utility Heat Duty/ Yearly Cost (in
($ per GJ)/ ($ per 1000kg) Flowrate $)
E-101 Cooling Water (cw) 0.354 $ per GJ 86.9 GJ/hr 258,701.16
E-102 Hot Pressurized Steam (hps) 17.70 $ per GJ 19.15 GJ/hr 2,850,476
E-606 Cooling Water (cw) 0.354 $ per GJ 3.05 GJ/hr 9,079.85
of cost $ 3,118,257.01
Table 3 Cost of Heat Exchanger Utility
2. Electricity
In this plant, the electricity is mainly focused on equipments that require work, such as
pumps, compressors and drives. Therefore, the calculation of electricity utility is based on how
much work, or power is required to run those equipments. The table below shows the
calculations of the electric cost for the usage of all pumps, drives and compressors used in the
process. The formula used is based on efficiency:
W 24hr 365day
Cost * Cost Electric * ( . )
1day 1year
Where:
C-101:
Duty: 1715.85 kW
From Figure 8.7 Turton 2013, the efficiency of an electric drive is 90%
Cost of electric = 0.06/kWh
Duty: 0.7kW
The efficiency of an electric drive is 86%
Cost of electric = 0.06/kWh
Therefore, the total utility cost, CUT is the total cost of electric summed up with cost of
heat exchanger.
The technique used to calculate operating labor requirements is based on data obtained from five
chemical companies and correlated by Alkhayat and Gerrard. According to this method, the
operating labor requirement for chemical processing plants is given by equation
Where:
Nnp = number of nonparticulate processing steps handling steps includes compression, heating
and cooling, mixing, and reaction
In general, for the processes considered in this text, the value of P is zero and the value of Nnp is
given by,
Nnp =
Compressor 1 1
Tower 2 2
Reactor 2 2
Heater 0 0
Heat Exchanger 2 2
Vessel 1 -
Pump 2 -
Total 10 7
NOL = 2.81
The value of NOL is the number of operators required to run the process unit per shift. A single
operator works on the average 49 weeks (3 week time off for vacation and sick leave) a year,
five 8-hour shift a week.
Number of operator required for one operator per shift = 49 week/year 5 shift/week
Hence,
= 2.81 4.5
= 12.65 13 operators
= $ 774,540/y
= RM 3,423,466.80
Cost of Raw Material, CRW
= 0.96
= $ 4,541,184/year
= RM 20,072,033.28 / year
3
= 5,061,000 1
3 $ 41
CWT = 5,061,000 1000 3
4.42
= $ 207,501 $1
= RM 917,154.42
Industrial land located at Terengganu currently cost at RM 5.60/ft2. The estimated land size
required for construction of this plant is 1,500 m2.
= , , .
4.46059(1.500456) 1
Payback Period : =
4.460596(0.020456) 10
X = 0.33 year
Cumulative Cash Ratio (CCR) =
65.90075
= 8.900686
= 7.4040
1
Rate of Return On Investment (ROROI) =
65.90074/15 1
= 15
7.400233
= 0.5270 or 52.70%
70
60
50
40
Cash Flow ($million)
CCP = $57
30
20
10
-20
Time after project start (years)
3.881446(1.1395) 1
Discounted Payback Period = 3.881446(0.020456) = 10
X = 0.29 years
19.71124
= 7.238793
= 2.723
15
10
Discounted cash flow $million
NPV =
DPBP = 0.29
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
-5
-10
Time after project start (years)
0% 57.000062
15% 12.472442
30% 2.63263
X 0
45% -0.439770
0.4397700 0.45
DCFROR = 0.4397702.63263 = 0.450.3
X= 0.428 , 42.85%
Comparison Between Non-Discounted and Discounted Profitability:
Non-Discounted Discounted
Non-discounted cash flow does not consider Discounted cash flow represents discounts
the time value of money. Each dollar earned in future cash flows to the present in order to
the future is assumed to have the same value reflect the time value of money. Each of the
as each dollar that was invested many years yearly cash flow is discounted back to time
earlier. zero
The cumulative cash position (CCP) is a solid With 15% interest in discounted cash flow, the
$57.00006 million because there were no net present value (NPV) obtained is
interest or discount rates introduced. The value $12.47244153 million which is much lower
obtained is the worth of the project at the end compared to non-discounted cash flow. The
of its life. action or investment with larger NPV is the
better decision.
Interest rate criterion for non-discounted is Interest rate criterion for discounted cash flow
seen from ROROI, where it compares returns is viewed from DCFROR and the calculated
to costs by calculating a ratio or percentage. DCFROR is to be at 42.85%. The greater the
The ROROI is determined as 52.70%. ROROI DCFROR from its interest rate means, the
essentially compares the magnitude and timing project is profitable as it could be break even.
of investment gains directly with the
magnitude and timing of costs. A high ROROI
means that gains compare favorably to costs.
Table 9 Comparison between Non Discounted and Discounted Profitability