Cost
Cost
Cost
C BM (2015)
($)
Heat exchanger
E-100
E-101
E-102
E-103
E-104
E-105
E-106
99,494.697
108 158.14
10 606.7
165 502.44
136 740.20
146 252.41
102 867.35
Reactor
R-100
Fired Heater
111 324
F-100
Compressor
1 581 725
C-100
C-101
C-102
C-103
104 075.44
61 230.83
97930.78
59.30
Tower
T-100
Pumps
796,528.00
P-100
P-101
22 175.50
V-100
V-101
V-102
28 834.96
21 291.81
Vessel
50 532.27
21 976.62
Mixer
18,420.85
MX-100
MX-101
MX-102
18,420.85
18,420.85
Hollow fiber
35 800
M-100
Sample calculation
Bare module cost
R-100
Equipmen
Equipment
K1
K2
K3
Capacity
Min
Max
t type
Reactor
Description
Jacketed
3.3496
0.7235
0.0025
Units
Volume,m3
size
10
Size
100
nonagitate
d
C BM =C po ( B1 + B2 F P F M )
logA 2
log C p o ( 2001 )=K 1+K 2 logA + K 3
2
log 20 =4.29513
3.3496+ ( 0.7235 ) log 20+0.0025
C p o ( 2001 )=$ 19730.13
C p o ( 2015 ) =$ 19730.13
=$ 27831
( 560
394 )
C BM =C P F BM
4
(
C BM = 27831 ) ) = $111,324
E-100
Equipmen
Equipment
t type
Descriptio
Heat
n
Floating
exchanger
head
K1
K2
K3
Capacity
Min size
Units
4.8306
-0.8509
0.3187
Area, m2
Size
10
C BM =C po ( B1 + B2 F P F M )
logA 2
log C p ( 2001 )=K 1+ K 2 logA + K 3
o
=$ 26,265.76
( 560
394 )
P=7500kPa, P=75bar
log75 2
2
logP =0.03881+ (0.11272 ) log75+(0.08183)
log F P =C1 +C 2 logP+ C3
0.115
Fp=1.30
Form table A.18 for the carbon steel heat exchanger, Fm=1
Max
100
From table A. B1 and B2 for floating head heat exchangers is 1.63 and 1.66
1.63
Thus, C BM =( 26,265.76 ) +1.66(1.30)(1)) = $99,494.697
E-101
Area = 19.5402 m2
Purchased Equipment Cost,
From Table A.1,
Equipmen
Equipment
t type
Descriptio
Heat
n
Floating
exchanger
head
K1
K2
K3
Capacity
Min size
Units
4.8306
log 10 C 0p
-0.8509
0.3187
Area, m2
Max
Size
10
100
0.01
1 kPa
17.9982
From table A.2, C1 = 0.03881, C2 = -0.11272, C3 = 0.08183
log 10 F p
C p F BM =C p ( B1 + B2 F M F P )
18565.74[1.63+1.66 ( 1.4 ) ( 1.0623 ) ]
$ 76096.98
,C BM =C 1=$ 76096.98
CEPCI (2001) = 394
CEPCI (2015) = 560
C2 =C1
I2
)
I1
560
394
)
$ 76096.98
$ 108158.1446
E-102
Area = 21.9380 m2
Purchased Equipment Cost,
From Table A.1,
Equipmen
Equipment
K1
K2
K3
Capacity
Min
Max
t type
Descriptio
Heat
n
Floating
exchanger
head
log 10 C 0p
4.8306
-0.8509
0.3187
Units
size
Size
Area, m2
10
100
Pinlet =
1619.838 kPa
0.01
1 kPa
16.19838
From table A.2, C1 = 0.03881, C2 = -0.11272, C3 = 0.08183
log 10 F p
CBM =
C0p F BM =C 0p ( B1 + B2 F M F P )
18300[1.63+ 1.66 (1.4 ) ( 1.0524 ) ]
$ 74621.96
,C BM =C 1=$ 74621.96
CEPCI (2001) = 394
CEPCI (2015) = 560
C2 =C1
I2
)
I1
$ 74621.96
560
394 )
$ 10606.7
E-103
Area = 22.899m2
CBM = Cp[B1 + B2FpFM]
From table A.1 Heat Exchanger (air cooler)
K1 = 4.0336 K2 = 0.2341 K3 = 0.0497
2
P = 12.07 bar
From table A.2, Heat Exchanger (air cooler)
10 < P < 100 : C1,= -0.125, C2 = 0.15361, C3 = -0.02861
Fp = 1
Find FM using table A.3
Identification number = 10 (CS-air cooler)
From Figure A.18, FM = 2.67
Table A.4
Heat Exchanger (air cooler)
B1 = 0.96
B2 = 1.21
C BM ( 2015 )
= $165 502.44
E-104
Area = 10.8063 m2
CBM = Cp[B1 + B2FpFM]
From table A.1 Heat Exchanger (air cooler)
K1 = 4.0336 K2 = 0.2341 K3 = 0.0497
2
C p =$ 21314
P = 12.07 bar
From table A.2, Heat Exchanger (air cooler)
10 < P < 100 : C1,= -0.125, C2 = 0.15361, C3 = -0.02861
Fp = 1.1
Find FM using table A.3
Identification number = 10 (CS-air cooler)
From Figure A.18, FM = 2.67
Table A.4
Heat Exchanger (air cooler)
B1 = 0.96
B2 = 1.21
C BM ( 2015 )
= $136 740.20
E-105
Area = 4.172 m2
Purchased Equipment cost,
Equipment
type
description
Heat
Floating
exchanger
head
K1
K2
K3
Capacity
Min size
Max size
10
100
units
4.8306
-0.8509
0.3187
Area,m2
0.01bar
1kPa
Pinlet
= 6488.1kPa x
= 64.881 bar
From table A.2, C1= 0.03881, C2 = -0.11272, C3 = 0.08183
log10Fp
= C1 + C2log10P +C3(log10P)2
= 0.03881 - 0.11272 (log10 64.881) + 0.08183(log10 64.881)
= - 0.0172
= 0.9612
CBM = C1 = 102899.02
CEPCI (2001) = 394
CEPCI (2015) = 560
C2
= C1
I
I
2
1
560
394
= 102899.02(
= 146252.41
E-106
Area = 6.7422 m2
Purchased Equipment Cost,
From Table A.1,
Equipmen
Equipment
t type
Descriptio
Heat
n
Floating
exchanger
head
K1
K2
Capacity
Min size
Units
4.8306
log 10 C p
K3
-0.8509
Area, m2
0.3187
Size
10
K 1+ K 2 log 10 A+ K 3 ( log 10 A)
Max
100
0.01
1 kPa
47.2983
From table A.2, C1 = 0.03881, C2 = -0.11272, C3 = 0.08183
2
log 10 F p
0.7081
C0p F BM =C 0p ( B1 + B2 F M F P )
$ 22094.88[1.63+1.66 ( 1.4 )( 0.7081 ) ]
$ 72374.53
,C BM =C 1=$ 72374.53
CEPCI (2001) = 394
CEPCI (2015) = 560
C2 =C1
I2
)
I1
$ 72374.53
560
394 )
Vessels
Orientation
Length/
Diameter
Material
Pressure
Height
(meters)
of
(barg)
Volume
( m
Purch
Equip
V-100
Vertical
(meters)
2.813
0.938
construction
Carbon Steel
8.56
1.9425 m
Co
28 8
V-101
Vertical
2.307
0.769
Carbon Steel
46.29
1.0725 m3
50 5
V-102
Horizontal
3.51
1.17
Stainless steel
0.01
3.8 m3
21 9
$ 102867.35
Vessel
log 10 C
O
p
K1 +
K 2 log 10 ( A ) + K 3 [ log10 ( A ) ]
( P+1 ) D
+ 0.00315
2 [8500.6 ( P+1 ) ]
F P , vessel=
0.0063
C BM
CO p F BM = CO p ( B 1 + B 2 F P Fm )
V-100
2
log 10 C O p = 3.4974 + 0.4485 log 10 ( 1.9425 ) +0.1074 [log 10 ( 1.9425 )]
=3.63566
O
p
= 4321.758
560
CO p ( 2015 ) = 4321.758(
394 )
= 6142.60
Fm =1
( 8.56+1 ) 0.769
+0.00315
2 [8500.6 ( 8.56+1 ) ]
F P , vessel=
0.0063
F P , vessel= 1.343
C BM
=6142.60 ( 2.25 +
1.82 X 1 X 1.343 )
= 28 834.96
V-101
log 10 C
O
p
=3.51113
O
p
= 3244.385
560
O
C p (2015) = 3244.385(
394 )
= 4611.309
Fm =1
( 46.29+1 ) 0.938
+0.00315
2 [8500.6 ( 46.29+1 )]
F P , vessel=
0.0063
F P , vessel= 4.7848
C BM
2.25
= 4611.309 +
1.82 X 1 X 4.7848 )
= 50 532.27
V-102
log 10 C
O
p
=3.8058
O
p
= 6395.10
560
O
C p (2015) = 6395.10(
394 )
= 9089.48
From the table A.3, identification number for stainless steel horizontal vessel is
20; from the figure A.8, Fm=3.11
( 0.01+1 ) 1.17
+0.00315
2 [8500.6 ( 0.01+1 ) ]
F P , vessel=
0.0063
F P , vessel= 0.6104
C BM
1.49
= 9089.48 +
0.6104 X 1 X 1.52 )
= 21 976.62
Compressor
Compressor
Power (kW)
C-100
53.379
C-101
C-102
31.85
50.2137
Material of
Purchased
construction
Carbon steel
Equipment Cost
S104 075.44
Carbon steel
Carbon steel
S61230.43
$497930.78
C-103
3.636
Nickel alloy
$59.295
= 4.333
= 21 536.62
560
CO p (2015) = 21 536.62(
394 )
= 30 610.42
From the table A.6, identification number for carbon steel reciprocating
compressor is 10; from the figure A.19, Fbm=3.4
3.4
C BM
= 30 610.42 )
= 104 075.44
Make-up compressor second compressor (C-101)
log C o
Co
Co
= 12 670.5857
p (2015) = 12 670.5857
(560)
(394)
= 18 008.95
From the table A.6 , identification number for carbon steel reciprocating
compressor is 10;
log C o
Co
= 20 265.09
p (2015) = 20 265.09
(560)
(394)
= 28 803.17
From the table A.6 , identification number for carbon steel reciprocating
compressor is 10;
From figure A.19, FBm = 3.4
CBm = 28 803.17(3.4)
= 97 930.78 $
Natural gas recovery turbine( C-103)
log C
Co
p=
o
p
= 3.0202
p (2015) = 3.0202
(560)
(394)
= 4.2967
From the table A.6 , identification number for nickel alloy reciprocating
compressor is 12;
From figure A.19, FBm = 13.8
CBm = 4.2967(13.8)
= 59.2945 $
T-100
Material design
Stainless steel
Diameter
2.44m
Length
7m
C op
log
o
log 10 C p=2.9949+ 0.4465 log 10 32.73+0.3961
C op =$ 38,053.39
For
Fm
Design Pressure
1 bar
A3=61,
For
Fm =3.13
Fp
2
log 10
log 10 F p=C 1 +C2 log 10 P+ C3
C1 =0
C2 =0
C3 =0
F P=1
C BM =C oP F BM
C BM =C oP (B1 +B 2 F P F M )
C BM (2001)=$ 38,053.39 ( 2.25+1.82 ( 1 )( 3.13 ) ) = $302395.51
C BM (2015)=$
2,736,411.15
560
=$ 428,075.64
394
For
D / 4 = 4.676
C op
log
o
log 10 C p=K 1+ K 2 log 10 A + K 3
log
0.3961
2.9949+0.4465 log 10 4.676+
log 10 C op=
C op =$ 2963.08
C BM =C oP N F BM f q
N=48
Total
Total
C BM (2015) = $796,528.00
Power = 1.5 kW
For
Cp
log
o
log 10 C p=K 1+ K 2 log 10 A + K 3
lo g10 1.5 2
log 10 C op=3.8511+0.7009 log 10 1.5+ (0.0003 )
C op = $9429.42
For
F BM
F BM =1.38 ( Table A .7 )
C BM =C oP F BM
C BM = $9429.42 1.38
C BM (2001)=$ 13012.60
C BM (2015)=$ 13012.60
560
394
C BM (2015)=$ 18,420.85
Pump
P-100
P=0.122kW
Pump use is reciprocating pump
C BM =C po ( B1 + B2 F P F M )
logA 2
o
log C p ( 2001 )=K 1+ K 2 logA + K 3
log0.122 =3.683
3.8696+ ( 0.3161 ) log 0.122+ 0.1220
560
( 394
)=$ 6844.29
To ensure that the equipment does mot damage, thus the operating condition
chooses is 4bar. From Figure Fp=1 since C1, C2 and C3=0
Form table A.18 for the carbon steel pump, Fm=1
From table A. B1 and B2 for reciprocating pump is 1.89 and 1.35
1.89
Thus, C BM =( 6844.29 ) +1.35 (1)(1)) = $22175.50
P-101
P=0.047kW
Pump use is reciprocating pump
C BM =C po ( B1 + B2 F P F M )
logA 2
log C p o ( 2001 )=K 1+ K 2 logA + K 3
2
log0.047 =3.665
3.8696+ ( 0.3161 ) log 0.047+0.1220
=$ 6571.54
( 560
394 )
To ensure that the equipment does mot damage, thus the operating condition
chooses is 4bar. From Figure Fp=1 since C1, C2 and C3=0
Thus,
1.89
C BM =( 6571.54 ) +1.35 (1)(1)) = $21291.81
COL
Quantity
N np
Reactor
Heat
1
7
1
7
exchanger
Compress
2
3
1
3
1
Total
1
1
14
or
Pump
Vessel
Tower
Mixer
Furnace
per shift . A single operator works on the average 49 weeks( 3 weeks time off
for vacation and sick leave) a year, five 8-hour shift a week.
5 shift 49 week
shift per operator
x
=245
week
year
year
=365
days
year
shift
day = 1095
x3
shift
year
1095
shift
week
245
= 4.5 operators
N OL
Type
Low-Pressure Steam
CUT
Equipment
E-100
Price
$14.05/GJ
E-106
2.
3.
Electricity
Cooling Water
C-100
Price $/ year
41 274.207
610.344
$0.06/kWh
29 947.22
C-101
18 071.99
C-102
25 674.98
C-103
2 269.41
P-100
41.11
P-101
70.83
E-103
$0.354/GJ
196 202.8
E-104
220 595.58
E-105
2 174.73
F-100
186 634.20
Sample calculation
Utilities cost
E-100
Duty is
98.124 1 0 GJ / s
steam=$14.05/GJ
6
E-103
Duty is 1.85 X 104 J/s. From table above, cooling water = $ 0.354/GJ
Yearly cost = Q x Csteam x t
= (5.83 x 105 GJ/y) ($ 0.354/GJ) (0.96) (RM 4.30 / $ )
= RM 843 672.04 / year
E-104
Duty is 2.08 X 104 J/s. From table above, cooling water = $ 0.354/GJ
Yearly cost = Q x Csteam x t
= 2174.73 / year
E-106
Duty is 5.22
10-3 GJ/h = (
= $ 610.344/yr
Compressor
C-100
Electric power =
dr
P-100
P=0.122kW
CWT
Cost ($)
56/1000m
Yearly cost =
$ 56
m
118137.6 kg
x
x
1000 m 1000 kg
year
= $6.616
When convert to RM, the yearly cost for water treatment is RM28.85.
C RM
$ 29.59 759450.54 kg
x
1000 kg
y
= $2247.23
=RM 9 797.92/year
=4418795.216 sen/year
= RM 44 187.95
10 sen 620234.015 kg
x
x 0.1
kg
y
= 620234.015sen/year
= RM 6 202.34
TOTAL
C RM = RM 50 390.29/year
COM d
COM d
is:
C RM )