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RESULTS
Table 4.1.Purchased Equipment Cost of each equipment
Equipment Name
Tanks
T101-104
T105
T106
Drums
D101
D102
D103
D104
Pumps
P101A/B
P102A/B
P103A/B
P104A/B
P105A/B
Heat Exchangers
E101
E102
E103
E104
Distillation Columns
C102
C103
C104
Reactor
R101
PEC(TL)
Workers pay (%50 PEC)
Total PEC with Workers Pay
PEC(TL)
4,858,857
28,791
28,791
28,395
10,670
4,263
2,645
4,500
720
560
600
2,060
16,912
16,912
7,904
6,282
289,735
183,587
254,702
17,283
5,764,168
2,882,084
8,646,252
Electricity (kW)
Pumps
Heat Exchangers
Catalyst (kg)
15,299
1,15
2197
Range
100%
TL
8,646,252
47% PEC
36% PEC
68% PEC
11% PEC
70% PEC
18% PEC
4% PEC
4,063,738
31,12,650
5,879,451
951,087
6,052,376
1,556,325
345,850
30,607,733
33% PEC
3% PEC
40% PEC
22% PEC
2,853,263
259,387
3,458,500
1,902,175
Indirect Cost
Engineering & Supervision
Legal Expenses
Construction Expenses
Contractor's Fee & Construction Expenses
Contingency
Total Indirect Cost
44% PEC
0.1*TCI
3,804,351
12,277,678
42,885,412
4,765,045
47,650,457
Range
Cost, TL/yr.
56,349,526
Operating Labor
2,766,000
Operating Supervision
Utilities
276,600
Components
Cooling Water
65,129
Catalyst
123,936
Steam
1,446,768
Electricity
22,370
%2 FCI
857,708
Operating Supplies
%15 Maintenance
128,656
Laboratory Charges
290,520
Operating Cost
63,985,419
B. Fixed Charges
Depreciation
FCI/20
2,144,271
Local Taxes
% 1 FCI
428,854
Insurance
%0,05 FCI
214,427
Financing
% 5 FCI
2,382,523
Fixed Cost
C. Plant Overhead Cost
5,170,075
%50 A-expenses
1,950,154
%50 A-expenses
780,061
2. General Expenses
Administrative
3. Total Annual Cost
69,936,985
Note: A-expenses means that sum of the Operating labor, operating supervision and
maintenance and repair expenses.
70
2,144,270
0,874
0,993
Return
22,2
Payout Period
19,298,435
% Taxes
0,2
Taxes (TL/yr)
3,859,687
15,438,748
SHUTDOWN POINT
Capacity (lt/yr)
77,576,750
% Capacity
100
2,144,270
0,612
0,695
Return
22,2
Payout Period
19,298,435
% Taxes
0,2
Taxes (TL/yr)
3,859,687
15,438,748
SHUTDOWN POINT
Capacity (lt/yr)
110823928
5. DISCUSSION
First revision was to determine heat entegration in the heat exchangers. The heated streams
must be used for heat another streams while restrictions suitable and requirements were
sufficient. The stream at the reactor outlet has been sent to third exchanger which was Shell
and tube heat exchanger. This stream will be heat the feed, also this idea was improved by
generating steam at 9 bar spontaneously. This steam at 9 bar also will be generated in
calandria which were last exchanger.
Furthermore, this steam was expected to use in distillation columns. Unfortunately, the
amounts of steam that must be used to heat columns have been determined but it was
insufficient. So specific steam generator has been used to provide steam at 9 bar to heat the
distillation columns.
Second Revision was to determine storage tanks and its properties. Storage tanks have been
placed with high strong material as stainless steel 304 type. Stainless steel 304 type has a
corrosion resistance to high corrosive organic compounds. It has been searched in literature
that all construction materials in an order to stock the raw materials. Since the methanol was
high corrosive organic compounds the sufficient construction material has been selected as
stainless steel 304 type. This type has five stars to stock this organic compound. Also storage
tank design has been made so it has 23,43 m diameter and 7,73 m height been found.
Optimum aspect ratio has been found as 0.3. It has been selected as four storage tanks as
slight change from five tanks according to our graph. Also increase in tank quantity causes
much land conquered. So four tanks selected has been selected due to this issues. Size of the
profiles has been selected as 1,5x6 type for storage, intermediate tanks and the feed drum.
This type of profile leads to less welding also it cannot cause the leakage in the tanks. Also the
cost of nitrogen gas to provide no ignition has been found 441 TL.
Heat exchanger purchased cost has been determined according to price of stainless steel per
kilogram. The tubes and Shell of the exchanger cost has been calculated according to total
weight of this system.
Also specifications in heat exchangers have been determined. The pressure drop at the Shell
side and tube side has been discovered as low due to the less length of the tubes. So the
electricity of these equipments has been calculated as low cost. As a comparison with the
electricity in pumps to heat exchanger, power of pump calculated bigger than the exchanger
requirement so its neglected to add the electricity cost.
The electricity requirement of the reflux pumps has been calculated according to common
height of the platform and height of top of the column. Also pressure drop in this section has
been assumed.
So another revision was to reassemble the reactor specifications. Required profile cost of the
reactor has been calculated to determine to purchased equipment cost. Construction material
was also selected as stainless steel due to corrosive compounds and reaction occurring in this
system.
The amount of construction material volume has been calculated and passed to its mass by
using density of it. Then profile cost has been calculated with respect to profile cost per
kilogram. Head of the reactor was assumed as one profile thickness height and top and bottom
head has been calculated. This head and profile cost has been calculated as 16816 TL.
The serpentine system has 32 tubes. Also cost of the tubes has been calculated. Construction
material of the tubes was stainless steel also. Cost of the tubes has been calculated in the same
manner. It has been found 466 TL. All this data has been sum and it has been found as
purchased equipment cost as 17,283 TL.
After this manner, operating cost calculation has been done for this equipment. Firstly,
catalyst and cooling water cost has been determined in this section. The price of the catalyst
Gama-alumina has been searched from the literature per kilogram. Service life has been taken
as 2 years. The void fraction has been used for calculating the volume of catalyst. The mass of
catalyst has been determined with respect to its density. The cost of catalyst has been found as
123,936 TL/year. Catalyst cost cannot be add into purchased equipment cost. It can be said
that the provider has no responsibility to add the catalyst in it. Catalyst must be add in after
purchased. To protect the temperature constant cooling water has been used. Reactor cooling
water cost has been found 6923 TL/year.
The fixed capital investment and total capital investment of the DME plant that has been
constructed was estimated according to some specific properties of cost estimation pen. The
all percentages have been taken from global determinations except for raw materials,
engineering supervision and maintenance and repairs. These values estimated according to our
country.
For cost estimation, updated data has been used. Moreover, utility estimation has been done
due kilowatts per hour price, cubic meter of the water price and the steam generator prices.
This datas has been determined by doing market survey in our country.
Other revision was to determine the distillation column properties. First and third column
Rd/Rdmin ratio was estimated again from the graph. This reason can be said that; there must
be real estimation for columns not for total annual cost. The optimum Rd/Rdmin value has
been selected from number of stage graph. First column ratio was determined as 1.46, third
column selection was 1.41.
Another important issue was determination of the operating labor. For the laboratory
experiments, one chemistry technique personnel and three labor ants have been hired for this
duty. For field agents, three chemical engineer, six technical personnel and thirty employers
have been hired. The cost of the employees to the employer has been calculated according to
social insurance datas in our country. We found the cost factor of an engineer as 2.0 and
technical personnel and workers factor as 1.8 from the social insurance community.
107,330 tons methanol has been processed to produce 75000 tons DME per year. Plant was
processed firstly seventy percent capacity. This statement can be mentioned as; the demand of
the product could not be predicted and control of the machines must be checked whether its
stable or not. The production of the DME has been investigated in Turkey that was less
amount percentage with respect to the global production. The abetment of the production of
DME must be provided by the government. The money that we have been invested for plant
assumed to be return in two years. Then average profit has been calculated per year. This
value was 19.298.435 TL/year. This value has been calculated after taxes as 15.438.748 TL/yr
with the tax ratio has been searched for markets as twenty percent of profit. The price of the
DME has been calculated as 0,993 TL/lt. for seventy percent capacity plant. If capacity of the
plant processed with hundred percentages so the price of the DME has been calculated as
0,695 TL/lt. Furthermore, there will be more production with less worth. Full capacity work
must be selected when the mechanical equipments on the stable as maximum.
Finally, fixed capital investment has been found as 42.885.411TL. So total capital investment
has been calculated with this data as 47.650.457 TL. At last, total annual cost has been
calculated the biggest due to the raw material prices so the total annual cost was 69.936.985
TL/year.
6. CONCLUSION
Past to present, there must be some issues to understand. Firstly, in equipment design we
learned the fundamentals of these equipments.
First the heat entegration in the system has been done. The stream at reactor outlet has been
sent to third heat exchanger (E103) to heat the feed stream.
After all these revision to the equipments there must be some considerations for the cost of
the system.
Fixed and Total capital investments of the DME plant has been calculated according to some
specific datas in literature. Also there must be some corrections to the percentages due to plant
location in which country. Operating labor pen has been calculated according to social
insurance community datas to provide the legal working conditions.
Gross earnings also has been calculated according to total income and total production cost.
Gross earnings have to be assembled according to some taxes in the country for your legal
considerations. Payout period has been calculated for to discuss whether its a reasonable study
or not.
It was the most important value as fixed capital investment. This value means that you must
put these values to the table at first to start the production. These values can be arranged with
some specific options which have been discussed.
After all, total capital investment, fixed capital investment and total annual cost of the system
has been determined and checked whether its reasonable or not according to payout period.
7. RECOMMENDATION
The purchased equipment cost of the heat exchangers have been calculated from the
price per kilograms. Also the purchased equipment cost can be calculated from the
tanks.
Ignition and flammable digital indicators can be put into tanks system due to engage
8. SYMBOLS
A
b
C
Cb
C bR
CK
C PM
CT
FM
FNR
FRM
FRT
NR
n
X
x
y
z
AT
: Baffle (m)
: Clearance (m)
Di
Do
Ds
dc
: Length (m)
SC
Area (m2)
: Void fraction
9. REFERENCES
1. Uysal, B., KTLE TRANSFER, Alp Yaynevi, 2003.
2. Perry J.H., Chemical Engineers Handbook, 4th ed., McGraw-Hill Co., 1963.
3. Coulson J.M., Richardson J.F., Sinnott R.K., Chemical Engineering Volume &
Design, Pergamon Press, Oxford, 1983
4. Peters M.S., Timmerhaus K.D., Plant Design and Economics for Chemical
Engineers, McGraw-Hill, International Student Ed., Singapore, 1981.
5. Ulrich G.D., A Guide Chemical Engineering Process Design and Economics, John
Wiley & Sons, 1984.
6. Safety Data Sheet, www.rawchem.co.uk/
APPENDIXES
APPENDIX A.AREA VERSUS COST GRAPHS FOR CONDENSER AND REBOILER
Descrip.
TOP
BOTTOM
0,982
0,638
Tray space
0.45
0.45
10
24
205,37
314,62
Height of Column(m)
15,87
Rdmin
0,51
Nmin
Bottom
360
155,51
VAPOUR TO TRAY
Rate (kmol/h)
6,93
Density (kg/m3)
18,3
Pressure(atm)
10.43
10.63
Temperature(K)
320,1
434,4
470
Rate (kmol/h)
155
Temperature (K)
320,1
434,4
Density(kg/m3)
617,58
835
Viscosity (Pa.sec)
3.93*10-4
1.49*10-4
mwater/msteam (kg/s)
27,05
0,8
114,15
109,34
Area
Condenser/Reboiler
(m2)
of
1698,9
1640,2
4279
Technical/Mechanical Data
Column Material
Tray Material
Corrosion
allowance
(mm)
Pressure of Steam for
Reboiler (bar)
Descrip.
TOP
BOTTOM
0,89
0,76
Tray space
0.45
0.45
14
4,25
310,36
Height of Column(m)
8,66
Rdmin
15,37
Nmin
(m)
Bottom
VAPOUR TO TRAY
Rate (kmol/h)
204,24
200
Density (kg/m3)
9.73
4.035
Pressure(atm)
5.76
5.96
Temperature(K)
336,6
413
200
510
Density (kg/m3)
668
860
Temperature(K)
336.6
413
Viscosity (Pa.sec)
3.23*10-4
1.7*10-4
mwater/msteam (kg/s)
2,66
0,146
8,25
8,49
167,5
297,27
Area
of
Condenser/Reboiler
(m2)
3574
Technical/Mechanical Data
Column Material
Tray material
Corrosion
allowance
(mm)
Pressure of Steam for
Reboiler (bar)
3
9
Descrip.
TOP
BOTTOM
1,3
0,92
Tray space
0.45
0.45
15
12
100,63
209,73
Height of Column
13,15
Rdmin
1,52
Nmin
Bottom
VAPOUR TO TRAY
Rate (kmol/h)
317
Density (kg/m3)
1,17
Pressure(atm)
216
0,713
1,2
Temperature(K)
338
378
216
426
Rate (kmol/h)
Density (kg/m3)
751
970
Temperature(K)
338
378
Viscosity (Pa.sec)
3.18*10-4
2,18*10-4
mwater/msteam (kg/s)
49,85
1,21
105,78
35,29
3130,86
2470,65
Area
Condenser/Reboiler
of
(m2)
7576
Technical/Mechanical Data
Column Material
Tray Material
Corrosion
(mm)
allowance
Table ..
Descrip.: Heater
Operating Data
Size
0.883.5
Type
608
Flow Allocation
Shell Side
Fluid Name
Tube Side
Steam
Feed mixture
1.4
2.32
1.4
2.32
1.4
2.32
Vaporized or condensed
condensed
vaporized
448
448
306
428
6.12
945,5
13.55
722
0.0001523
0.000018
0.0003
18
18
32
32
1.76
3.06
0.679
0.0215
0.18
2029,50
3636.36
0.01
1463,64
508,78
No.of passes
Heat transfer coefficient (W/m .K)
12.5
10000
Velocity (m/s)
2
882
Qsafety
1.16
317,19
OD: 0.0254
Shell (m)
ID: 0.88
Baffles
ID: 0.02329
Length: 3.5
Corrosion allowance
3
(mm)
Table .... E102 Data Sheet
Equipment No: E102
Descrip.: Heater
Operating Data
Size
0.883.5
Type
608
Flow Allocation
Shell Side
Fluid Name
Tube Side
Steam
Feed mixture
1.4
2.32
1.4
2.32
1.4
2.32
Vaporized or condensed
condensed
vaporized
448
448
306
428
6.12
945,5
13.55
722
0.0001523
0.000018
0.0003
18
18
32
32
1.76
3.06
0.679
0.0215
0.18
2029,50
9
2
882
9
12.5
10000
3636.36
0.01
1463,64
508,78
Qsafety
1.16
317,19
Tubes
OD: 0.0254
ID: 0.02329
Shell (m)
ID: 0.88
Baffles
Length: 3.5
Corrosion allowance
3
(mm)
Table .... E103 Data Sheet
Equipment No: E103
Descrip.: Heater
Operating Data
Size
0.542.44
Shell and
No. of Tubes
tube
Type
316
Flow Allocation
Shell Side
Fluid Name
Tube Side
Hot stream
Feed mixture
4.64
4.64
4.64
4.64
4.64
4.64
Vaporized or condensed
628
494
428
523
8.75
10.31
0.000018
0.0000156
32
32
32
32
1.88
0.046
0.035
11.83
11.82
12.5
12.47
0.092
2.45
10000
3636.36
Velocity (m/s)
18.22
8.25
No.of passes
1535
424
261.69
OD: 0.01954
ID: 0.01483
Shell (m)
ID: 0.54
Baffles
Length: 2.44
Corrosion allowance 3 mm
Table .... E104 Data Sheet
-TEMA Heat Exchanger Specification Sheet
Operating Data
Size
0.682.5
Type
349
Shell Side
Tube Side
Cooling water
Feed mixture
1.41
4.64
1.41
4.64
2.63
1.41
2.01
Vaporized or condensed
evaporated
condensed
298
452
494
350
5.78
972.8
10.56
526.53
0.0000152
0.000282
0.0000148
0.000131
18
18
32
14
34.77
75.79
0.547
0.271
0.03
0.68
0.324
0.3086
2029.5
11.83
11.83
10000
3636.36
0.07
1356
752.02
Qsafety
1.19
388.19
OD: 0.0254
Shell (m)
ID: 0.68
Baffles
Corrosion allowance 3 mm
ID: 0.02329
Length: 2.5