report he
TRANSCRIPT
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HEAT EXCHANGER
Sample calculation for exchanger E-101
From the calculation;
Area, A = 55.371 m2
Pressure, P = 240 bar
MOC tube = SS ; MOC=Material of construction, SS= Stainless steel
MOC shell = SS
Estimation of Cp and Fp:
1. From table A-4 (multiple pipe):
B1 = 1.74
B2 = 1.55
2. From table A-2 (for P=240 barg):
C1 = 13.1467
C2
= -12.6574
C3 = 3.0705
3. Calculate value Fp using equation below:
log Fp = C1 + C2 log(P) + C3 [log(P)]2
log Fp = 13.1467
12.6574 log (240) + 3.0705 [log (240)]2
Fp = 2.61
4. Estimation of purchased cost, Cp0:
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From figure A.5;
Cp0/A =
Cp0(2001) = $ 19379.85
5. Estimation of material factor, FM:
Since material of construction for both shell and tube is SS and multiple type, therefore:
From Table A.3: Identification number = 5
Thus, from figure A-18: Material factor, FM = 2.75
Therefore,
CBM = Cp0 (B1 + (B2 x Fp x FM))
CBM = 19379.85 x (1.74 + (1.55 x 2.6 x 2.75)) = 249324.19
Bare Module Cost,
CBM (2012) = CBM (2001) [ I2 (2012) / I1 (2001) ]
Where:
I1 = cost index for year 2001 = 397
I2 = cost index for year 2011 = 643.11
For $1 = RM 3.1645 (average currency for year 2012)
So, Bare Module Cost,
CBM
(2012) = $249324.19 (643.11/ 397) = $ 403886.35
Bare Module Cost, CBM (2012) in Malaysia currency = RM1278098.36
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Table: Total price for all heat echanger:
Equipment Area, m2 Purchase cost,
Cp0(2001) ($)
Bare module cost,
CBM (2012) ($)
Bare module cost,
CBM (2012) (RM)
E-101 55.37 19,379.85 403,886.35 1,278,098.36
E-102 66.79 22,707.92 473,245.10 1,497,584.11
E-103 46.26 15,726.70 327,752.77 1,037,173.64
Total 1,204,884.22 3,812,856.11
Reactor
From the chemical and mechanical design calculation;
Volume, VTotal = 3.534 m3
Pressure, P = 240 bar
Materials of Construction = stainless steel
Estimation of Cp:
The value for K1 and K2 and K3 are referred to the table A.1 in the Turton (2009) page 910 and
the value are:
K1 = 4.7116
K2 = 0.5521
K3 = 0.0004
For V=3.534m3
log10Cpo = 4.7116 + 0.5521log10(3.5534) + 0.0004[log10(3.534)]
2
= 4.7116 + 0.3027 + 0.0004
= 5.0147
Cpo = 103,442.7
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Cpo (2011) = 103,442.7(622/397) = $ 162,067.8
log Fp = C1 + C2 log(P) + C3 [log(P)]2
For conversion vessel, the operating pressure is 2.2 barg. From Table A.2, C1=C2=C3=0 and
from equation A.3 (Turton, 2009), then Fp= 1
Bare Module Cost:
CBM = 162,067.8 (2.25+ (1.82) (3.1)(1))
CBM = $ 1,279,039.10
The currency $ 1 = RM 3.02
So, the value from Bare Module Cost is in US dollar ($) must be converted into Ringgit Malaysia
(RM)
$ 1,279,039.10 = RM 3,862,698.00
As conclusion, the price for the reactor is RM 3,862,698.00.
Vessel
From the chemical and mechanical design calculation;
Volume, D = 1.5 m
Height = 3.0 m
Pressure, P = 240 bar
Materials of Construction = stainless steel
By Using CAPCOST software:
Cpo (2011) = RM 11,800
CBM (2011) = 1,530,000
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Compressor
1) Fluid power = 4850.7 kW
MOC = SS
Compressor type = Centrifugal
Cpo (2011) = RM 1,630,000
CBM (2011) = 9,390,00
2) Fluid power = 5393.1 kW
MOC = SS
Compressor type = Centrifugal
Cpo (2011) = RM 1,630,000
CBM (2011) = 9,390,00
TOTAL CAPITAL INVESTMENT
Equipment Specification
Base Bare
Module Cost
(RM)
Heat Exchanger 1 E -100 712,342
Heat Exchanger 2 E -101 1,804,200
Heat Exchanger 3 E -102 58,227
Heat Exchanger 4 E -103 1,854,825
Component Splitter 1 X - 100 123,040
Component Splitter 2 X 101 123,040
Component Splitter 3 X 102 123,040
Reactor CRV-100 2,612,383Separator V-100 53,202
Pump 1 P-101 94,008
Pump 2 P-102 68,948
Pump 3 P-103 68,948
Compressor 1 K-100 154,060
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Contingency and Fee (8%)
Contingency = Total Bare Module Cost 0.15
= RM 1,199,439.75
Fees = Total Bare Module Cost 0.08
= RM 639,701.2
Total Module Cost, TMC = Total Bare Module Cost + Contingency + Fees
= RM 9,835,405.95
Auxiliary Facilities (10%)
Site Development = Total Bare Module Cost 0.05
= RM 399,813.25
Auxiliary Buildings = Total Module Cost 0.04
= RM 319,850.6
Offsite Facilities = Total Module Cost 0.21
= RM 1,679,215.65
Auxiliary Facilities = Site Development + Auxiliary Buildings +
Offsite Facilities
= RM 2,398,879.5
Grass-roots capital (GRC) = Total Module Cost + Auxiliary Cost
= RM 10,395,144.5
Compressor 2 K-101 146,002
Total Bare Module Cost (RM) 7,996,265
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Labor Cost
The operating labor requirement for chemical processing plants is given by:
NOL = (6.29 + 3.17P2 + 0.23 Nnp)
0.5
The value of Nnp is given by:
Nnp= Equipment
Where:
NOL The number of operators per shift
P The number of processing steps involving the handling of particulate solids.
Nnp The number of non particulate processing steps handling steps.
Type of Equipment No. Of Equipment NNP
Heat Exchanger 4 4
Reactor 1 1
Splitter 3 3
Vessel 1 -
Pump 3 -
Compressor 2 2
Total 10
NOL = (6.29 + 3.17P2 + 0.23 Nnp)
0.5
= 2.93
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Event Cost
onsite
Purchased Equipment Installation
Instrumentation and Control
(installed)
Piping (installed)
Electrical and Material (installed)
30 % GRC
15 % GRC
30 % GRC
8 % GRC
RM 3,118,543.75
RM 1,559,271.70
RM 3,118,543.75
RM 831,611.60
offsite
Building
Yard Improvements
Service Facilities
Land
10 % GRC
1 % GRC
5 % GRC
2% GRC
RM 1,039,514.50
RM 103,951.40
RM 519,757.20
RM 207,902.90
Total RM 10,499,096.80
Event Cost
Engineering and supervision
Construction Expenses
Contractors
Fee
Contingency
5 % GRC
8 % GRC
1.5 % GRC
10 % GRC
RM 519,757.2
RM 831,611.60
RM 155,927.20
RM 1,039,514.50
Total RM 2,546,810.50
Cost (RM)
1) 1 operator per month = 1,800
2) 1 operator per year = 21600
(including bonus + allowance)
Direct Cost
Indirect Cost
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Fixed Capital Investment (FCI)
Working Capital
Start Up Cost
(FCI = GRC + Total)
12 % FCI
8 % FCI
RM 23, 441, 051.80
RM 2,812,926.20
RM 1,875,284.10
Total Capital Investment (TCI) RM 28,129,262.10Total = Direct+Indirect = RM 13,045,907.30
Assumption
1) Plant performed: 3 shifts per day
2) Plant is tunning 24hours per day: 1 day
3) Maintainace day per year: 30 days
4) Operation day per year: 335 days
5) Minimum day for operator rest: 14 days
6) Week for 1 operator work: 48 weeks
7) Shift needed for a plant in year: 1005 shift/year
8) 1 operator can obtained shift: 230 shift/year.operator
NON :
Operating labor cost, COL:
COL = NOL x NON x PO
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Manufacturing Expenses Cost (RM/yr)
Cost PerProduction(RM/kg)
Direct Production
Cost
Raw Materials
Utilities & Land
Water, Electric & Land
Miscellaneous
Maintenance andRepairs
Operating Supplies
Operating Labor
Direct Supervision &
Clerical Labor
Laboratory Charges
Patents and Royalties
Indirect Production
Cost
Local Taxes
Insurance
Plant Overhead
2 % FCI
0.5% of Maintenance
and Repairs
0.2% of maintenance
and repair
10 % of Operating
Labour
15 % of Operating
Labour
0.01% FCI
1 % FCI
1% FCI
50 % of Operating
labor
259, 290. 000
32,590,000.00
468,821.03
2,344.1
937.60
93.76
140.60
2344.10
234,410.5
234,410.5
468.8
3.11
3,342.60
48.08
0.2404
0.0962
0.0096
0.0144
0.2404
25.3825
25.3825
0.0508
Total Manufacturing Expenses, AME 292,823,971 30,033.22
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Total Manufacturing Expenses, AME Cost (RM/yr)
Cost perproduction(RM/kg)
Administration Cost
Distribution & Selling
Expenses
Research &
Development
25 % of PlantOverhead
10% of FCI
3% of FCI
1,049,310.60
3,497,702.00
1,049,310.60
76.1474
253.8245
76.1474
Total General Expenses, AGE 5,596,323.19 406.1192
Total ProductionCost, APC
Depreciation, ABD
APC = AME + AGE
(excludingdepreciation)
10 % FCI
2,141,397,014.99
3,497,702.00
155398.9126
253.8245281
Total Expenses, ATE ATE = APC + ABD 2,144,894,716.99 155652.7371
price for product
Urea RM 21 /kg
Raw material usage
Urea 9750 kg/hr
Annual sales for product RM 204,750 /yr
Total revenue from
sales
Net annual profit,
ANP
Product
Total Revenue
535,125,100.00
45,248,845.50
54,884.62
4,640.90
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Income taxes
Net annual Profit,
ANNP
Rate of Return
30% ANP
ANPIncome Taxes
(ANNP-ABD)/TCI x
100%
13,574,653.65
31,674,191.85
125..03%
1,392.27
3,248.64
Cash flow
Year of construction 3 years
Plant Life 22 years
Working Capital RM 2,812,926.20
TCI
Total Annual RM 28,129,262.10
Sales RM 535,125,100.00
Total Expenses, ATE RM 2,144,894,716.99
Bank Loans
1st year = 10% of TCI
2nd year = 45% of TCI
3rd year = 45% of TCI