256 APPENDIX 1

installed cost = purchase price x installation factor

A similar number that also includes all of the adjacent minor equipment and connec-
tions is sometimes listed in the literature (principally by Guthrie 1975 and Ulrich 1984)
covering the cost of purchase and installation of the major equipment as well as all of
the supporting equipment around each major unit. This is called the module factor, and
when available is also listed under the charts as the range given by different authors and
the average value.

cost of the installed module = purchase price x module factor

As a final item under the equipment cost graphs, often a simple factor can be used to
estimate the cost of some other material, pressure, size, or other variable for the equip-
ment, than is shown on the graph. For instance, the cost of a stainless steel agitated tank
is 1.7 times the cost of a mild steel tank (which is shown on the chart). These factors
have also been listed when available, and again, sometimes as a consensus of different
authors' estimates .

Adsorb.rs. Activated Carbon

Mild steel construction, including instruments and controls

80 .
;;;
Ii
o
u

10
, ,,
I 6 8 10 20 40 60 80 100 200

Weight of carbon. 1,000 lb.

Equations:
Cost = 15.200 + 1, 100WC O.4 81 for We > 250. < 10,000 lb.
Cost ~ 76,200 + O.422Wc 1.2 for We > 10.000, < 200 ,000 lb .
We == we ight of activated carbon, Ib,
258 APPENDIX 1

Agitated TankS'
Jacketed , ogitated, m i ld steel

lOOO ~ _ _ __
800 ~

20 40 60 80 tOO 200 400 600 tOOO 2000 4000 6000 10000 20000
Size, gal

Size exponent 0.53 Instal lation factor : Material factors :

Module factor 2.5 Range Avg . Stain Ie.. steel
Open tank 1.41 - 66 1.58 1.2·2.2, .",) . = 1.7
low pressure 1.30 · 57 1.44 GI... l ined
Autoclave 1.50 · 70 1.60 1.2 - 2.0, ."') . • 1.6
• See Reactors
 EQUIPMENT COST ESTIMATES 259

Air Cond itioning

Compressor, motor, controls, condenser. refrigerant

1000
800 1-- ' - 1- 1--
600
I- -

400
I ~-- 1- -
I:
1·-'-'-;"
200
1=-:- ..- .

~
iii 100
80
B
0
60
.::------
_ -'c---

-
,
40
,- -
20
-I-

1- ./ 1-
10
1 8 10 20 40 60 80 100 200 400 600 800 1000
Refr igeration, tons ·

Size exponent 0.73

Installalion. Module factor
1.38- 53 avg. 1.46

'One ton = 12,000 Btu

 260 APPENDIX 1

Blenders
Mi ld steel construction

o
8,
iii

20 40 60 60100 200 400 600 BOO 1000 2000

Capacity, ftl
(Approximately HP X 0.125)

Size exponent.s: Installation factor 1. 30

Ribbon, double arm, sigma,
twin shell 0.60 Modu Ie factor:
Double cone 0.42 H,DDon 2.0
Sigma 2.B
Material factor: Double arm, cone,
304 stain Ie" steel 1.6 twin shell 2.2
 262 APPENDIX 1

..
Boilers

10000
8000
6000
--ii-

4000
:

2000

-
---
100 1000
80
.. 800
~ 600

40 0" ::.. '00 g

;;;
~
20 200 U
I:
g -- 1--·
<Ii 10 100
8 80
0
u
60

.0
."..
;"
-r 20

1 10
I 8 10 20 40 60 80 100 200 '00 600 1000
1000 10000 100000 1000000
Steam generated, Ib/ hr (large I

Size exponents; Installalion factor ; Prl!'$$Ure factor : Coal fired

Package boilers 1.21 - 82 ''1 . 1.53 Large package Large package 1.6 1
5 - 1,000 HP 0.65 400 ps; 1.31 Field erected 1.36
6 - 600· 10' Iblhr 0.77 Module factor : 500 p.; 1.74
Field .rected 0.82 Package 1.8 Field eree~ed
Field erected 1.8 - 2.0 aVQ _ 1.9 l000p.; 1.35
'One HP - 33.5000 Btu 3000p.; 1.58
 EQUIPMENT COST ESTIMATES 263

Boilers, Waste Heat

1000
800

600

400

200

0
8.
;;; 100
80
S
<.>
60

40

20

20 40 60 80 100 200
Flue gas flow rate, 1,000 sclm

Size exponent 0.75 Factors:

High- temperature
I nstallation factor : operation 1.2
1.40- 82 a.g . 1.67 Finned tubes 1.5
Alloy- clad tube. 3.0
Modu le factor 1.81 M@chanical ash
remova l 1.8
Radiat ion section 2.0
 EQUIPMENT COST ESTIMATES 265

Centrifuges
Solid- bowl, screen-bowl, pusher types,
316 stainless steel

400

200

100

o
o 10 15 20 25 30 35 40 45 50 55 60 65
Capacity, t/hr

Installation factor : Material factors:

Range 1.20-2.02 allY . 1.54 Carbon steel 0.68
Monel 1.35
Nickel 1.7
Module factor: 2.0 Hastalloy C 2.6
 EQUIPMENT COST ESTIMATES 267

Classifier, Rake or Spiral

Mild steel construction

10000

8000
1:-:-: .- ,•... r-
6000 1- ' -

f- :-'"
4000
";:- :'.-'-"C
' .. '
§:~ ~~
2000
~:--=
'-- _.

=~ .. ~
,

1000
800 .... .. , ..
,

600

80 . c=..
_..
400
;;;
:;;'
-
0 :..;
U
200
!=;::::-:::.

100
I==: I ,

80
1- -
60
r--
~
I~': I~
40

F-.;.c
20
. . :;' f. "
~ :::-:- ... ~.. 1-' "- 1'"
1- - - r-
,.:: .... '-- 1-:- I:-=:::j-.... _+ . . :~ _:" I ~
10
,-- I·- 1- 1--
I 8 10 20 40 60 80100 200 400 600 800 1000
Solids handling capacity, t/h r

Size exponent 1.32 Installation factor Module faclor 2.3

1.63-2.61 avg.2. 12
 268 APPENDIX 1

Columns, Dls1i llation. Absorption Towers, etc.

Mild steel construction , 0- 50 psi , vertical

.c .8

~"" .6
c:
E
'8" .4

'0
0
0
D. .2
Vl

is
u
10'

o iam eter•ft
10 20
r

10' 10' 10·

Weight,lb

S ize exponent Material factors Pr.ssure factors (vertical)

10' - 1as Ib 0.78 Carbon steel 1.0 psi psi
Stainless 304 1.7 50 1.00 800 3.80
Instal lation cost: Stainle" 316 2.1 100 1.25 900 4.00
1.29- 2.03 avg. 1.72 Monel 400 3.6 200 1.55 1,000 4.20
Titanium 7.7 300 2.00 1,500 5.40
Modu le factor Carpenter 20 CB- 3 3.2 400 2.40 2,000 6.50
Nic ~el 200 5.4 500 2.80 3,000 8.75
Vertical 4.16 Inconel600 3.6 600 3.00 4,000 11.25
Horizontal 3.05 Incolcy 825 3.7 700 3.25 5,000 13.75
Ot her factors
Horizontal vessel 0.6
p 0 .44
Pressu re 50 or see chart
 EQUIPMENT COST ESTIMATES 269

Column Trays
Mild steel
100
80

60

40

20
8
'"
~ 10
t
Co 8
B
u 6

8 10 20 40

Column diameter, ft

Instaliation factor 1.20 Number factor: rray type factor; Material factor:
25 1 Turbo grid I,tamped) 0,8 Ijrass 1.2
20 1.05 Grid, plate, ",ive 1,0 304 ,tainless 1.5
15 1.25 Trough , valve 1,2 316 stainless 1.9
10 1.50 347 stainless 2. 1
5 2.30 Incone l 3.3
3.0 Monel 7.7
 270 APPENDIX 1

Column Packing

90

80

70

60

50

40

'".I:'
U.
~ 30
u

Size, in.

Material Factors; size exponents

Ratio for Ratio for
Material Size exponent other material Material Size exponent other material
Berl saddles 1.24 Stoneware I nterlox $Odd Ie.
Porcelain - 1.16 Porcelai n - 0.4 0.94 Stoneware
Pall ring 55 - 0.64 0.30 Carbon steel Polypropylene ...{J.95
Polypropylene - 0.95 Rasch ig rings 6. 11 Stainless steel
Porcelain - 0.5 2.35 Carbon
1.5B Mild steel
0.78 Stoneware
 EQUIPMENT COST ESTIMATES 271

Compressors, Medlum ~ Low Pressure

800

600

400

20 40 60 80 100 200 400 600 800 1000 2000 4000 6000 10000
Capacity. ",11m in

Size exponents: Installation factor : Factors:

Straight lobe 0.51 1.3C>-87 ; OV9. 1.49 Straight lobe:
SI id i ng van. 0.79
Helical screw 0.87 Modu le factor : Pressure (fo )0'.
Rec ip rocating (air) 0.34 2.2- 3.1 ; avg. 2.6
 272 APPENDIX 1

Compressors, High-Capacity and/or Pressure

1,000 psi; electric mOt.or dr i ~e. gear reducer, steel

10000
8000
c- -
I
. - -- [._ . .. . ".
I····
6000
f- -_ .... , -:
F '; . .. :.
r~ b:·~·
4000
1= I--::: .~
i== . ..

F==~·
:.:
2000
~ . 1:-:"
:
" , , I ~ = t'
1000 "' I
" I I I I

800
1' - ' ,,
" " , "
600

~
400

~~~ .
(fl

B
u 200
~
r----
1===1- ,
100
b "
I
I , ,
80
.. "

60

40
1-

20

1- ' - I- •. , 1-- ... ::.:: 1'::'

10
, ,

10 20 ~o 60 80 100 200 400 600 800 1000 2000 4000 6000 10000
HOrSepower

Size exponent 0,80 Installation factor : Factors:

1.30-87; avg, 1.49 Turbi n. drive 1.13
Equation : Gas engine 1.4 1
(I sothermal compression ) Modu le factor :
p ( P ) 0.1'
HP ~ O.0044P,Q, In P,/P, 2, 15-3. 1; avg. 2,6 ressure 1000
P, ;; inlet pressure, psi
P2 ..,.. outlet pressure, psi Stai nless steel 2.5
0 1 • inlet flow rate, cf m Nick le alloy 5, 0
 EQUIPMENT COST ESTIMATES 273

Conveyors
M ild steel construction
1000
800

600

400

200

100
80

60

80 . 40
iii
0
'-'
20

10

6 8 10 20 40 60 80 100 200 400 600 800 1000

Length, ft

Sile exponent : Size faclors:

Screw conveyor 0.7B dian:eter) 1.2
Belt conveyor 0.76 Screw conveyor ( 9 10 .
Bucket elevator. rol l 0.5
Pneumat ic conveyor 0 .37 width) D.6
Belt conveyor ( "i6Tr1."""
Vibrating 1.0
Installation factor : bucket wd . X hI. ) 0 .37
Bucket elevator ( 6 X 4 • 24 in.2
Range 1.40-2.15 avg . 1.72
(diameter) 0 .55
Modu Ie factors :
.
Pneumatic conveyor --nn.-
Screw . pneumat ic. ro ll 2.2
Belt, bucket, vibrat ing 2.4 Rol l (2~:~) 0 .55; 4 in. spacing X 0.B4

. . (width
Vibrating 36Tii":
)0.51
 274 APPENDIX 1

Coolers, Quenchers
Mild steel construction; Cascade cooler . 2 in. dia meter pipe

-
1000
800
- ,--
600
7"''- : ~: ' F~ , 'I
400
~~~~' =.. ,~
(;
c- '=---'t:,= ':: i -e I
'iii ;'; ~ ~~, , ;
c
"~
~
~
200
,,=--
,- ~:::c:
~
.J:J
E
100
==-- ~ _. ,
I I I I I
.:'1
"~ )faY cham_be r

..
80 c - - -
1--
9; 60
I

0;
'5
40
~

II I
~
a
8,
;;;
1i
20
:::Q~" ':~
0 I
0

i
"0 10
,
I
" , ~~ I 1'-

8
'"
'0

j
,-

~-;;;':co;;;;= II
6

~
in
,3
II "c.
I"
1:=

1
--
1
~.:....,-
'-'

8 10 20 40 60 80 100
I- -
200
= I~~.: ,:"--

400
= f=
1-

600 800 1000

Heat transfer surface, h ' Icascade cooler)
In,et flow rate, 1,000 elm (quencher, spray chamber)
Duct diameter, i n, (dilution air port)

I nstallation factor: Equations: Factors:

1.40-1,85; o.g. 1.62 Spray chamber: 5(358 X M scI + 65,000) Cascade cooler
Quencher 51 335 X M scI + 12,200) ( pipe d i~meter)O.6
Module Factor: 2 In,
Spray chamber, quencher 2.7
 EQUIPMENT COST ESTIMATES 275

Cooling Tower
15" F range, 10" F approach, 82" F weI bulb

1000
800

600

400

200

~
V> 100
1; 80
0
60

40

20

10
., .2 .6 .8 1 4 6 8 10 20 40 60 80 100
Capacity, 1,000 gpm

Size exponent 0.79 Wet bulb temperature

Ins-tallation factor 1.20 "F Factor Approach , .e.," F Factor
Module lac tor 1.70 68 0.65 6 1.60
Factors; 70 0 .68 8 1.20
"F t
Range: e"""'i"5""' 57 72
74
0.72
0.77
10
12
1.00
0.85
76 0.82 16 0.65
78 0 .87 20 0.50
80 0 .93 24 0.40
82 1.00
 276 APPENDIX 1

Crystallizers
Mild steel constructi on

800

600

80. 400

Vi
1i
0
u
200

100
80

60

40

20

10
1 8 10 20 40 60 80100
Capacity, tons per hour

Size exponent : Installation factor: Material factors:

Cooling, evaporative 0.68 1.30-2.03, avg. 1.80 Stain less steel 2.1
Growth, forced Copper alloy 1.3
circulation, OTB 0 .63 Modu le factor: Nickel alloy 2.6
Vapor recompression 0.75 2.4- 2.9, avg. 2.6 Titanium 6.0

·Courtesv of Swenson,
 EQUIPMENT COST ESTIMATES 277

Dryers
Mild steel construction

1000
800

600

400

200

100
80

60

80 . 40
y;
5
u
20

10
8

200 400 600 800 1000 2000 4000 6000 10000 20000 40000 60000 100000
Peripheral area, ft 2 (rotary dryer)
Volume, ft3 Wuid bed, spray dryer) + 10

Size exponents: Installat ion facto r: Factors:

Rotary dryer 0.45 1.25-96; avg. 1.64 Rotary to:
Fluid bed 0.48 Roto- Louvre 1.25
Spray dryer 0.29 Modu le factor: Vacuum shelf 0.35
Rotary 2.3 Ishelf area)
Fluid, spray 2.7 Materials::
Nickle alloy 3.7
8rick -lined.
stai nless ;teel 2.2
280 APPENDIX 1

Evaporalors '
Single effect; sta in less steel

40 60 60 100 200 400 600 800 1000 2000

Heat exchange area, ft2

Si~e exponents: Installation factor: Material factors:

Forced circu lation 0.7 1.5-2.50; avg. 2.09 Mild steel 0.44
Falling film, long, Copper alloy 0.57
s~on tube 0.53 Module factor : Nickle alloy 1.22
Forced circulation 2.9 Titanium 2.93
Falling Film 2.3

• Also, see Cyrstall izers

 282 APPENDIX 1

Filters
Stainless steel
1000

8.
V>

o
u

8 10 20 40 60 80 100 200 400 600 1000 2000 4000 6000 10000

Filter area, ft '
Size exponents: Installation factor : Factors :
Rotary vacuum drum, leaf 0.39 1.19-2.21 ; a"9. 1.69 Rotary drum; belt/ screw or
Vacuum table. tilt ing pan, belt 0.5 string discharge 1.22
Pressure leaf, plate Be frame 0.61 Modu Ie factor: General/ paper pu lp 2.' 7 -3 .38
Rotary table, belt , tilt ing pan Mild steel/stainle.. steel 0 .69
Vacuum table mild steel/55 0.48
1.4 - 2.8; a"9 . 2.4
Vacuum filter auxilliaries (vac . pump .
Others 2 .8
receivers. etc ." Often - 50%of filter cost
 284 APPENDIX 1

Furnaces
Mild Sleel tubes

10000
8000

800

8q
;;;

8 200

100
80

60
Type
Bo)( Furnace Factor Pressure Factors
40 - -(psi I 100 500 1000 2000
1.0 1.0 1.04 1.12 1.26
1.09 1.0 1.06 1.15 1.32
1.34 1.0 1.08 1.22 1.42
1.24
20
1.34

10
1 6 8 10 20 40 60 80 100 200 400 600 800 1000
T-ansterred h.at, MM Btu/ hr

Size ex.ponents: In,,", ll.tion f.ctor: Material factors:

Hershott 0.48 1.30- 71; a"9. 1.52 Cy, indric.', vertical tubes:
Box 0.70 Stainless Sleel 1.74
Cyli ndrical 0.78 Module factor: 2.1 Chrome/ moly 1.44
with Dowtherm 1.33
Hershott diameter:
6-19 It 10/61° 55
> 19 10/61°·65
 286 APPENDIX 1

Heat Exchangers; Shell and Tube, Double Pipe, A ir Cooled

Mild steel construction; Shell and tube f loat ing head
150 psig pressure, 3/4 X 1 in. square pitch, 16 ft tubes
1000
800 F == 1·-+-
I·;;

i-
600

400

=
200
F r.:- F
, "
~ .; , ,
I ,
" ~~f~
100
80
~\~.,~ ,
60 ~S~ ,

g 40
0.
Vi
of
0
0
20

f::--p:: ',oel ' ,

,
,
10
I
" I

8 ,'A,,"<j
6
", ,
;:;i1
.....-.:.
Pressure factor
Pressure, psi 200 400 600 800 1000 2000
Kettle 1. 16 1.17 1.185 1.20 1.23 1.45' 1
U Tube 1. 06 1.08 1. 10 1. I 2 1.15 1.35 :
Air cooled , floating 1.05 1.06 1.08 1.10 1.13 1. 35 ~
head
1_-=... DO~,b~~" p ipe
,
1.0 1.0
, 1.0 1. 10
1.1 =1'_/ ~I~r
, ,
"
.1 .2 .6 .8 8 10 20 40 60 80 100
Heat Excha ~e Are. (outside). 1,000 1t 2 ; Double pipe, 10 It '

Si ze exponen t Other factors: Exchanger type Shell & lube malerial faClor
Shell & tube, Shell & lube 10; a + (a/1 0m·
Double pipe 0.68 Kettle rebo iler 2.35 Shel l Tube a b
A ir cooled 039 U-Iube 1.85
Fixed tube sheet 1.79 CS SS 1.75 0.13
Installat ion factor SS SS 2.70 0.07
CS monel 2.1 0.13
1.23-2.10, avg. 1.61 monel monel 3.3 0.08
CS Ti 5.2 0.16
Modu le factor Ti Ti 9.6 0.06
Shell & tube 3.2 CS moly 1.40 0.05
Double pipe 1.8 moly moly 1.61 0.16
Air coo led 2.2 CS Adm iralty 1.08 O.OS
 EQUIPMENT COST ESTIMATES 287

Heat Exchangers: Spiral. Plate and Frame

304 stainless steel; no insu lation
100
60
: : :-:c:c 1-=
60
. ;:=. :::'=1:"
40
["::

20
r-- ,:"f~e: .
::...'
80. 1=-:.;- I'
:..'">. ' 0'

;;; 10
I I I

1);'
0
0 _-
C----- I--
..

-:c: .

..--. I.::: .;::

I
1
10 20 40 60 60 100 200 400 6008001000 2000 4000 6000 10000
Heat transfer area, ft2

Size exponent : I nstallatio n Factor: Materi al Factor:

Plate & frame 0.78 Plate & fra me : Mild steel 0.43
Mild steel 1. 70 316 stainless 1.1
Equations : Sta inle.. 1. 53 Nickel 1.2
Spira l plate : S · 660Ao." Titanium 2.6
Pla te & frame : S ~ l00AOJ8
 288 APPENDIX 1

Incinerators
Mild steel construction
10000

o
8.
II>

~.

8 10 20 40 60 80 100 200 400 600 SOO 1000

Heal input, 1()" Btu/ hr

Size exponents: Module factor 2.2 Factors:

Rotary ki ln 0.48 Corfosive material 1.5
Hearth 0.64 Toxic waste 2.0
Catalyt ic 0.75 316 stainless 2.7
Direc t flame 0.39 Monel 3.3
Nickel 3.5
 296 APPENDIX 1

Pumps. Centrifugal
Cast iron, horizontal, includes mOlor, coupling, base

:;
u

6 8 10 20 40 60 80 100 200 400 600 800 1000

Flow X pressure , gpm X psi X 1,000
{ approximatel '~ HP I

Factors: Pressure factor :

Conven· Ax ial Mix ed to 150 150- 500-
tiona l In-l ine Flow Flow psi 500 psi 1000 psi
Size exponent 0.79 0.79 In-line 1.00 1,48 1.92
Installation 1.30 1.27 1.58 1.32 Conventional 1.0 1.62 2.12
Module factor 1.5 1.75 2.05 1.70
Cast steel 1.4 1.3
316 sta in less 2.0 1.6 Factors:
Copper alloy 1.3 Conventional : APS/ AVS = 1.6
Nickel alloy 3.6 In-l ine: vertical/ horizontal . 0.89
Titanium 5.7 Mixed , ax ial flow : vertical / hori zontal · 1.12
 EQUIPMENT COST ESTIMATES 297

Pumps, Miscellaneous
Mild steel construction
100
80

0
60
0
u;
c0o 40
.~

:s
'5 20
.~
.s=
u
",'

Iii> 10
'"c:
'0
~

~
C)
a 4
~
en
Ii
8

1
1 20 40 60 80 100 200 400 600 800 1000
Flow X pressure, gpm X psi X 1,000 (approx imately HP)

Factors General installation factor: Other size e)(ponents:

Chemical 1.25 - 2.40; avg, 1.74 Diaphragm .43
Rec iprocating Turbine In jection Rotary .52
Size eXpOnent 0.59 0.47 0.52 Gear .75
Installation 1.38 1.58 Sump .15
Module factor 3.3 1.80 2.83
Cast iron 1.0 1.0
Cast steel 1.8 1.25
Factors:
Stain less 2.4 1.95
Nickel alloy 5.0 Reciprocat ing: .:l.P 11,000 - 5,000)/(0 - 1,000) ~ 3.8
0-150 psi 1.0 1.0 Sump: 3600/ 1800 rpm ~ 1.2
150-500 1.32 1.37 120011800 in. • 1.5
500-1000 1.53 1.79 Chem ica l injection: Fixedl variable speed · 1.67
 298 APPENDIX 1

Pressure Vessels'
Mild steel construction

1000 10000
800 8000

600 6000

400 aOOO

200 2000

100 1000
80 800

60 600

:; 40 400
~
8
8q 0.
;;; U;
:;;'
0
U
20 200 g
'0 100
8 80

6 60

40

20

10
6 8 10 20 40 60 80 100 200 400 600 800 1000
1000 4000 6000 10000 20000 40000 60000 100000 200000 400000 1000000
Vessel weight, Ib

Size exponent:
15 psi (gal) 0.64

·See columns for pressure and material correction factors.

 304 APPENDIX 1

Tanks, (Smal l)
304 sta inless steel

l00 _ _ _ _ _ ~

oo
O.
;;>
<>
U

.1 .2 .4 .6 ,8 10 20 40 60 80 100
Capacity. 1,000 g.1

Size exponent Factor

Dished head. 50 psi 0.68 316/ 304 st.i n less steel 1.39
Flanged. dished head 0.48
Cone toP. bottom, legs 0.57
FI.t toP. bottom 0.93