Detailed Calculations:

1. Estimating the Capital Cost

Heat Exchangers

There are 8 heat exchangers in the unit of each one operation at different pressure and has
different area so the cost of each one has to be done.

Sample calculations for E-201:

-Where K1 and K2 K3 for heat exchangers from appendix A(Turton et al)

= 4.8306, -0.8509,0.3187 respectively.
-A=99.4 m2
- Pressure of 15 bar

So plugging all the values, Cp(2001)= $25263.54 so Cp(2019)= $396149.08

Since the pressure is not atmospheric so it has it be corrected.

We have to calculate the Bare module cost to get the total cost:

Where

The values of B1 and B2 for floating-head heat exchangers from Table A.4 are 1.63 and 1.66,
respectively.

The pressure factor is obtained from Equation A.3.

(A.3)

From Table A.2, for pressures >15 barg, C1 = 0.1587C2 = -0.2992 C3 = 0.1413, and from
Equation A.3, Fp = 1.00521. Using data in Table A.3 for shell-and-tube heat exchangers with
both shell and tubes made of carbon steel (Identification Number = 1) and Figure A.8, FM =
1. Plugging all the values, Fbm = 3.298
 So CBM = $396149.08(3.29) = $1303330.48

The following tables shows all the prices for all 8 heat exchangers.
Heat Exchagers Cpº (2001)($) Cpº (2019)($) FBM CBM
E-201 252263.54 396149.08 3.29 1303330.48
E-202 833083.27 1308255.54 3.29 4304160.72
E-203 25521.34 40078.15 3.29 131857.11
E-204 18308.8 28751.73 3.29 94593.21
E-205 181056.47 284327.08 3.29 935436.08
E-206 23517.1 36930.73 3.29 121502.11
E-207 18317.6 28765.55 3.29 94638.67
E-208 18315.2 28761.78 3.29 94626.27
Total CBM 7080144.66

Towers

There are 2 towers in our process, the sample calculations will done of T-201.

For T-201 there are 22 ss trays with a height of 15.8 m and D= 0.79m and operating at 10.6
bar.

The costs of the tower and trays are calculated separately and then added together to obtain
the total cost.

For the tower,

Volume = πD2L/4 = (3.14159) (0.79)2(15.8)/4 = 7.7446 m3

By using the equation but instead of A it will be the volume founded:

From Table A.1 Equipment Cost Data to Be Used with

K1= 3.9474, K2=0.

4485 , K3=0.1075 for V= 7.7446 m3

So Cp (2019) = $15026.47 and

For Trays,
 K1= 2.9949 ,K2=0.4465 , K3=0.3961 From Table A.1

Tray (tower) area = πD2/4 = 0.49 m2

So using this equation:

Cp(2019) = $1231.655

The following tables is for both towers prices in our process:

Towers Cpº (2001) Cpº (2019)($) FBM CBM

($)
T-201 10356.35 16263.38 6.51 105874.62
T-202 12563.17 19728.92 5.89 116203.36
Total CBM 222077.99

2. Manufacturing Cost
To Calculate the COM this equation has been used without Depreciation.

The following variables has to be estimated:

Where FCI is the Grass root cost which is found in the previous calculations which has a
value of $4827048.578.

1.To Find Cost of operation Labor COL:

This equation has been used where Nnp is the summation of all equipment in the process.

Nnp= 17

NOL= (6.29+0.23(17))0.5 = 3.1937 number of operators per shift.

Operating Labor = (3.1937)(4.5)= 14.37  15

Note: Where 4.5 is the number of operators needed to provide this number of shifts is [(1095
shifts/yr)/(245 shifts/operator/yr)] or approximately 4.5 operators. Four and one-half
operators are hired for each operator needed in the plant at any time

Labor Cost COL(2001)= 14.37($52900)= $740600/yr

Labor Cost COL(2019)= $740600(1.57)= $ 1193608.65/yr

Cost Of Operating Labor (COL)

NoL 3.1937  
Opearting Labor 14.37165  
Cost (2001) 760260.285  
Cost(2019)/yr 1193608.65  
2.Finding Cost of Utilities & Waste Treatment

CUT= 2% of FCI
CWT= 1% of FCI

Where FCI= $4827048.04

96540.960
Utilities Cost ($/YR)(CUT) 8

Waste Treatment Cost ($/yr) 48270.480

(CWT) 4

3.Finding Cost of raw material CRM:

Since fresh methanol is the first fresh feed of a molar flow rate of 259.7 kmol/h and a
stream factor of 0.9.

Cost of methanol (2006)= 0.295$/kg

619.2
Cost of methanol (2019)= 0.295$/kg( )= 0.3656$/kg
499.6

So, Mass flow rate (kg/hr) = 259.7 kmol/h * 32.0416 kg/kmol = 8321.089 kg/hr

Yearly Cost of methanol = 8321.089 kg/hr (24)(365)(0.90)(3656$/kg)= 23916399.5/yr

so, by plugging all the values into the equations:

COM= $33722709.65