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Basics in Process Design
Project cost estimation
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Chemical Engineering Design,
Towler, Sinnott, 2013
Block flow diagrams
Calculate flows from mass and
energy balances
Rough sizing of equipment for
– storage
– preprocessing
– reaction
– separation,
– heat exchange
– transport
Instrumentation
Cost estimates
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Cost
Capital cost = cost of building the process
plant (planning, equipment, construction ...)
Operating cost = cost of running the
process plant (raw materials, energy, waste
handling, salaries ...)
Profit = Income from sales – capital costs –
operating costs
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Reading
The methods and data described are taken
from chapter 6 in Chemical Engineering
Design by R. K. Sinnott (vol. 6 in
Coulson&Richardsons Chemical engineering).
http://site.ebrary.com/lib/abo/docDetail.action?
docID=10186190
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Time value of money
Changes in cost
– Measured as inflation
Interest on loans
Cost indexes
– Cost index as a function of time
– Cost of equipment of same type but
different size
– Cost estimates
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Plant cost index
Chemical Engineering,
http://www.che.com/Assets/File/CEPCI_1_01-2002.pdf
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Plant cost index
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Plant size
Estimate of capital cost related to plant
capacity
C2 cost of plant with capacity S2
C1 cost of plant with capacity S1
n = 0.6
n
S
SCC
1
212
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Factorial method
– Estimate total cost of major equipment (PCE or Ce)
– Estimate total fixed capital cost using Lang factor
(value depends on type of process)
Cf = total fixed capital cost
Ce = total cost of major equipment cost
fL = Lang factor
Cost estimation
CefCf L
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Equipment cost
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Ancilliary equipment
nSCCe
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Example
Estimate the cost of the following equipment 2014 using data from 2004:
1. A shell and tube heat exchanger, heat transfer area 50 m2, floating head type, carbon steel shell, stainless steel tubes, operating pressure 25 bar.
2. A horizontal, cylindrical storage tank, 3 m diameter, 12 m long, used for liquid chlorine at 10 bar, material carbon steel.
3. Turbine agitator, 20 kW drive.
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Heat exchanger
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Pressure vessel
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Turbine agitator
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Total
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Questions?