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6.0 APPENDIX

VAPORIZER PURCHASED COST ESTIMATION

Specifications; D=1.8 m, L=3 m, P=30 bar

Purchased cost of vaporizer, Cp, is read from the Figure A.13 [Ref1] as 20000 $. Since P=

30 bar=29 barg pressure factor FP is read from the Table A.19 as Fp=2.492.5 [Ref1].

Carbon-steel can be selected as construction material. From Table A.20 bare module

factor for vaporizer is found as FBM=2.8 [Ref1].

Then, purchased cost for the vaporizer is calculated:

based on mid-1996.

Hence, the purchased cost of the vaporizer is estimated to be 97219 $.

REACTOR PURCHASED COST ESTIMATION

For the reactor used in cumene plant of 3 m length and 1 m diameter, volume is 2.36 m3.

Selecting carbon steel as manufacturing material.

Ce=CSn where Ce is purchased equipment cost and C is cost constant from [Ref.2] in $.

2004 Chemical engineering cost index is taken as 457.4 [Ref2]

Ce= CSn =9300$ (2.36)0.4 =13111 $ based on mid-2004.

Reactor includes cooler section so cooler economic design is required for all cost analysis

of reactor. For the cooler used in cumene plant of 18.84 m2 heat transfer area:

Purchased Cost= (bare cost from figure)* Type factor*Pressure factor

Bare cost is taken from figure A.1, pressure factor is taken from Table A.19 type factor is taken

from Table A.2 [Ref1].

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Purchased Cost=8000*1.0*1.0=27000 based on mid-1996

Hence, the purchased cost of the reactor is estimated to be 33236 $.

COOLER-CONDENSER PURCHASED COST ESTIMATION

For the cooler-condenser used in cumene plant of 367.31 m2 heat transfer area, totally:

Purchased Cost= (bare cost from figure)* Type factor*Pressure factor

Bare cost is taken from figure A.1, pressure type factor is taken from Table A.19 [Ref1].

Purchased Cost=25000*1.0*1.0=25000 based on mid-1996

Cost index in year A 539Cost in year A= Cost in year B* 25000* 35275

Cost index in year B 382

Hence, the purchased cost of the cooler-condenser is estimated to be 35275$.

FURNACE COST ESTIMATION

The heat duty of furnace is 41376 kW and area of furnace is 181.7 m 2.

From Table A12;

BENZENE DISTILLATION COLUMN

Assuming the column is a vertical pressure vessel including plates, for the column

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designed of 2.18 m diameter and 3 m height, working at 1.75 atm, plate cost can be

estimated as:

Sieve trays cost is read 580 $ from Figure A.7. Pressure factor (Fq) is selected as 2.33

respected to number of trays [Ref.1]. Material of construction (FBM) is selected as 1.2.

Number of trays is 5.

For the condenser used in cumene plant of 249 kW driver power,

CP is read as 60000$ from Figure A.12. Fp is read as 1 from Table A.17. Bare module

factor (FBM) is read as 2.1 from Table A.17 [Ref.1].

* * 2.1*60000*1 126000BM BM P P

C F C F $ based on mid-1996


Cost index in year B 382 $

For the boiler used in cumene plant of 1469 kW driver power,

CP is read as 100000$ from Figure A.12. Fp is read as 1 from Table A.17. Bare module

factor (FBM) is read as 2.1 from Table A.17 [Ref.1].

* * 2.1*100000*1 210000BM BM P PC F C F $ based on mid-1996



Total HCL tower purchased cost is found as 482560$.

PROPYLENE TOWER PURCHASED COST ESTIMATION

Assuming the column is a vertical pressure vessel including plates, for the column

designed of 0.527 m diameter and 4 m height, working at 1.5 atm, plate cost can be

estimated as:

Sieve trays cost is read 270$ from Figure A.7. Pressure factor (Fq) is selected as 2

respected to number of trays [Ref.1]. Material of construction (FBM) is selected as 1.2.

Number of trays is 7.

* * * 1.2*270*2*7 4536BM BM P qC F C F N $

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Vertical vessel cost is read 8000$ from Figure A.4. Pressure factor (FP) is selected as 1 in

range of -0.5

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Vertical vessel cost is read 9000$ from Figure A.4. Pressure factor (FP) is selected as 1 in

range of -0.5

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in range of -0.5

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3

3

3

0.0257

(24 )

36000.0257 50 24 *1

704

157.7

mix

mix

kmolF

s

F MW hV

kmol kg shs m hV

kg

m

V m

Select; DT =2

H T

V = TT HD 2

4

3

TD2

V

3

2

10 1 2 10 3 10

157.72

4.64

9.3

log *log *(log )

T

T

T

p

D

D

H

C K K A K A

Mixer is selected as vertical orientation process vessel.

Cost index in year A 539Cost in year A= Cost in year B* 293000* 413421$


MIXER II PURCHASED COST ESTIMATION

1 2 3 1 2

1 2

2

10 10 10

4.3919; 0.2859; 0.1842; 2.5; 1.72; 1; .3 & .4 [Re 1] 9.3

1 0.5 3.7 arg

*( * * )

log 4.3919 0.2859*log 9.3 0.1842*(log 9.3)

69432$

M T

P

BM P P M

p

p

BM

K K K B B F TableA TableA f A H

F is selected in range of P b

C C B B F F

C

C

C

69432* (2.5 1.72*1*1) 293000$

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3

3

3

0.0308

(24 )

36000.0308 46.7 24 *1

672

185

mix

mix

kmolF

s

F MW hV

kmol kg shs m hV

kg

m

V m

Select; DT =2

H T

V = TT HD 2

4

3

TD2

V

3

2

10 1 2 10 3 10

1852

4.9

9.8

log *log *(log )

T

T

T

p

D

D

H

C K K A K A


1 2 3 1 2

1 2

2

10 10 10

4.3919; 0.2859; 0.1842; 2.5; 1.72; 1; .3& .4 [Re 1] 9.8

1 0.5 3.7 arg

*( * * )

log 4.3919 0.2859*log 9.8 0.1842*(log 9.8)

71824$

M T

P

BM P P M

p

p

BM



C C B B F F

C

C

C

71824* (2.5 1.72*1*1) 303100$



MIXER III PURCHASED COST ESTIMATION

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3

3

3

0.026

(24 )

36000.026 41 24 *1

583

158

mix

mix

kmolF

s

F MW hV

kmol kg shs m hV

kg

m

V m

Select; DT =2

H T

V = TT HD 2

4

3

TD2

V

3

2

10 1 2 10 3 10

1852

4.65

9.3

log *log *(log )

T

T

T

p

D

D

H

C K K A K A


1 2 3 1 2

1 2

2

10 10 10

4.3919; 0.2859; 0.1842; 2.5; 1.72; 1; .3& .4 [Re 1] 9.3

1 0.5 3.7 arg

*( * * )

log 4.3919 0.2859*log 9.3 0.1842*(log 9.3)

69432$

M T

P

BM P P M

p

p

BM



C C B B F F

C

C

C

69432* (2.5 1.72*1*1) 293000$



MIXER IV PURCHASED COST ESTIMATION

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3

3

3

0.02118

(24 )

36000.02118 42 24 *1

522

147

mix

mix

kmolF

s

F MW hV

kmol kg shs m hV

kg

m

V m

Select; DT =2

H T

V = TT HD 2

4

3

TD2

V

3

2

10 1 2 10 3 10

1852

4.5

9.0

log *log *(log )

T

T

T

p

D

D

H

C K K A K A


1 2 3 1 2

1 2

2

10 10 10

4.3919; 0.2859; 0.1842; 2.5; 1.72; 1; .3 & .4 [Re 1] 9.0

1 0.5 3.7 arg

*( * * )

log 4.3919 0.2859*log 9.0 0.1842*(log 9.0)

67990$

M T

P

BM P P M

p

p

BM



C C B B F F

C

C

C

67990* (2.5 1.72*1*1) 286918$



TOTAL CAPITAL INVESTMENT (TCI)

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Since purchase cost of all of the major equipments are estimated, using values given in

PPC can be calculated:

Purchase Cost of Major Equipment Items:

PCE=3117515$

Total Physical Plant Cost:

PPC=PCE*Lang Factor= (3117515)* 4.74 =1.48*107$

Estimating the working capital as 12% of the fixed capital total investment required can

be calculated to be:

TCI=1.48*107$ +0.12*(1.48*107$) =1.66*107$

OPERATING COSTS

Operating time is assumed to be 7200 h/year and following the route described above:

1. RAW MATERIALS:Chloride, propylene, water:

6

6

3

$ $cost of chlorine 0.18 *0.005063 *3600 *71 *7200 1.677*10

kg

$ $cost of propylene 0.47 *0.004599 *3600 *42 *7200 2.353*10

kg

$cost of water=0.3*10 *0.012 *36kg

kmol s kg h

s h kmol year year

kmol s kg h

s h kmol year year

kmol

s

$00 *18 *7200 1680

s kg h

h kmol year year

Total=4.03*106$

2. MAINTANANCE:Assume to be 6% of fixed capital cost=0.06*1.66*107$ = 0.99*106$/year

3. OPERATING LABOUR:Assume to be 28000 $/year

4. LABORATORY COSTS:Assume to be 15% of operating labour cost = 28000 $/year*0.15 = 4.2*103$/year

5. SUPERVISION:Assume to be 12% of operating labour cost=28000$/year*0.12=3.4*103$/year

6. PLANT OVERHEADS:Assume to be 40% of operating labour cost=28000$/year*0.4=11.2*103$/year

7. CAPITAL CHARGES:Assume to be 6% of fixed capital cost=0.06*1.66*107$=0.99*106$/year

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8. INSURANCE:Assume to be 1% of fixed capital cost=0.01*1.66*107$=1.66*105$/year

9. LOCAL TAXES:Assume to be 2% of fixed capital cost=0.02*1.66*107$=3.32*105$/year

10.ROYALTIES:Assume to be 1% of fixed capital cost=0.01*1.66*107$=1.66*105$/year

Direct Production CostsTotal=6.7*106$/year

Sales expense

General overheads %25 of Direct Production Costs=0.25*6.7*106$=1.68*106$

Research and development

ANNUAL PRODUCTION COST=6.7*106$+1.68*106$=8.38*106$/year

Selling price of 32wt% hydrochloric acid = $0.075/kg [Ref.4]

Selling price of 99.5 wt% pure allyl-chloride = $1.72/kg [Ref.4]

Waste disposal costs of 2 chloro propene = $0.20/kg [Ref.4]

Waste disposal costs of di chloro propene = $0.20/kg [Ref.4]

6 5

6 5 5

6 5 5

$ kg $Selling Pr ice of HCL 0.075 *4.8*10 3.6*10

kg year year

$ kg $ kg $Waste disposal cos t 0.075 *1.32*10 0.075 *2.55*10 1.18*10

kg year kg year year

$ $ $8.38*10 1.18*10 3.6*10

year year yeProduction Cost of allyl chloride

6

6 6

7

6

$ar0.9

kg kg9*10

year

$Selling Price of allyl chloride 1.7kg

$ kg $Annual Income 1.7 *9*10 15.3*10

kg year year

1.66*10 $RATE OF RETURN 1.1 year

$15.3*10

year

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