C6 Appendix Costing

APPENDIX A - 1
APPENDIX A
Costing for Flash Column, V-100 2
Costing for Compressor 8
Costing for Ammonia Reactor, R-01 9
Costing for Mixer, M-100 11
Costing for heat Exchanger, HX-1 17

APPENDIX A - 2
1. V-101
Costing
Operating pressure = 43.076 psig
Design pressure = 43.076 1.5 = 64.614 psig
From Biegler et al (1997), Table 4.2, pressure factor, FP = 1.0146
Taking into consideration of other factors such as corrosion, erosion etc. material
factor, Fm = 3.67 for solid stainless steel 316.
MPF = (1.0146)(3.67) = 3.724
Assumptions,
Vertical vessel
L/D ratio is 4
Cylindrical pressure vessel
To calculate base cost,
Where from Table 4.11,
Co = $ 1000
Lo = 4 ft
Do = 3 ft
= 0.81
= 1.05
And from previous calculation, D = 1.918 ft, L = 7.671 ft.
Hence C = $ 1,042.782
In reference to Table 22.6 in Seider et al (2010), the base cost index is taken from
Chemical Engineering Plant Cost Index, year 195-1959 at 100 while 2006 = 500 to
calculate update factor. Thus update factor, UF = 500/100 = 5.
APPENDIX A - 3
To calculate bare cost module CBM, the following formula is used with MF taken
from Table 4.11 of Biegler et al. (1997) at 4.23.
= ()( + 1) =
= 5 (1,042.782) (3.724 + 4.23 1)
= $ 36,260.66
$ 26,913.35 = 108,541.54
The exchange rate as of May 2016 is RM 4.033 for every US$.

APPENDIX A - 4
2. V-002 (Ammonia Separator)
Costing
MPF = (1.157)(3.67) = 4.246
Assumptions,
Vertical vessel
L/D ratio is 4
Co = $ 1000
Lo = 4 ft
Do = 3 ft
= 0.81
= 1.05
Hence C = $ 1,150.217
APPENDIX A - 5
= ()( + 1) =
= 5 (1,150.22) (4.246 + 4.23 1)
= $ 42,995.22
$ 26,913.35 = 173,399.72

APPENDIX A - 6
3. V-002 (purge)
Costing
MPF = (1.157)(3.67) = 4.246
Assumptions,
Vertical vessel
L/D ratio is 4
Co = $ 1000
Lo = 4 ft
Do = 3 ft
= 0.81
= 1.05
Hence C = $ 487.68
APPENDIX A - 7
= ()( + 1) =
= 5 (487.68) (4.246 + 4.23 1)
= $ 18,229.48
US$ 26,913.35 = RM 73,519.49

APPENDIX A - 8
4. Compressor
Cp = FD.FM.CB
With FD = 1.25 (for gas turbine device)
With FM = 2.5 ( stainless steel)
550
Base cost, CB = 500 exp {7.9661 + 0.8 (lnPC)}
550
= 500 exp {7.9661 + 0.8 (ln 4425)}
550
= 500 exp {7.9661 + 6.716}

= 550 $ 2,378,784.02 )

500
= $ 2,616,662.42
Thus,
Purchase cost, CP = $ 2,616,662.42 qx 1.25 x 2.5
= $ 8,177,070.07
USD $ 8,177,070.07 = RM 32,978,123.59

APPENDIX A - 9
5. Ammonia Reactor, R-01
Based on Biegler et al., (1997) Table 4.2, 4.11 while Seider et al., (2010) based cost
is at 100 for year 1957 while the present cost index of year 2006 is 500 (from
Chemical Engineering Index).
Operating pressure = 1 atm = 14.7 psig
Safety pressure = Design pressure 1.5 = (14.7)(1.5) = 22.05 psig
From Table 4.2 of Biegler, our safety pressure is lower than recommended 50 psig
hence pressure factor, FP is 1. Considering the operating pressure and taking into
account corrosion and other factors, we decided to use solid stainless steel 316 with
material factor, FM = 3.67.
MPF = FP FM = 3.67.
= 1.0 3.67 = 3.67
From Table 4.11, and using the formula provided, where from table;
Co = US$ 690
Lo = 4 ft,
Do = 3 ft
= 0.78
= 0.98
And from previous calculation;
D = 2.8 m = 9.186 ft
APPENDIX A - 10
L = 11.2 m = 36.745 ft
Hence base cost is:
C = 690 (36.745/4)0.78 (9.186/3)0.98
= $ 11,651.50
Update factor, , and MF is 3.58 since C value

is lower than US$ 200, 000.
Thus bare module cost per reactor is:
= ()( + 1)
= 5 ($ 11,651.50) (3.67 + 3.58 1)
= $ 364,109.375
Total cost for all reactor is as following and based on an exchange rate of RM 4.033
per US$.
$ 364,109.375 = 1,468,453.11
APPENDIX A - 11
6. Mixer - 100
Costing for mixer
Since mixture sizing,
Volume, V = 223.38 m3
Diameter, D = 7.528 m
Height, H = 11.292 m
Mixer is sized as vertical fabrication.
From Systematic Methods of Chemical Process Design Biegler et al (1997), pp. 134.
Co = $ 1,000
Ho= 4.0 ft Do = 3.0 ft = 0.81 = 1.05
From the results calculated,
D = 7.528 m or 24.698 ft
H= 11.292 m or 37.047 ft
Therefore,
Base cost, BC = Co (H/ Ho)(D/ Do)
= 1,000 (37.047/4.0)0.81(24.698/3.0)1.05
= $ 55,505.87
Based on BC calculated, the module factor, MF for this mixer is:
MF = 4.23
APPENDIX A - 12
The material and pressure factor, MPF for mixer is:
MPF = Fd= 2.0 (stainless steel)
Here, the bare module cost is modified by the following factors:
Uninstalled cost,
$ = (BC) (MPF)
= $ 55,505.87 2.0
= $ 111,011.74
Installation,
$ = BC (MF-1)
= $ 55,505.87 (4.23 1)
= $ 179,283.96
Total installed cost,
$ = BC (MPF + MF 1)
= $ 55,505.87 (2.0 + 4.23 1)
= $ 290,295.7
Total cost, RM = 4.033 (BMC) = RM 1,170762.56

APPENDIX A - 13
7. Mixer - 101
Costing for mixer
Volume, V = 669.096 m3
Co = $ 1,000
Ho= 4.0 ft Do = 3.0 ft = 0.81 = 1.05
D = 10.852 m or 35.6 ft
H= 16.278 m or 53.405 ft
Therefore,
= 1,000 (53.405/4.0)0.81(35.6/3.0)1.05
= $ 109,576.63
MF = 4.23
APPENDIX A - 14
Here the bare module cost is modified by the following factors:
Uninstalled cost,
$ = (BC) (MPF)
= $ 109,576.63 2.0
= $ 219,153.26
Installation,
$ = BC (MF-1)
= $ 109,576.63 (4.23 1)
= $ 353,932.51
$ = BC (MPF + MF 1)
= $ 109,576.63 (2.0 + 4.23 1)
= $ 573,085.77
Total cost, RM = 4.033 (BMC) = RM 2,311,254.91

APPENDIX A - 15
8. Mixer - 102
Costing for mixer
Volume, V = 764.694 m3
Co = $ 1,000
Ho= 4.0 ft Do = 3.0 ft = 0.81 = 1.05
D = 11.346 m or 37.224 ft
H= 17.019 m or 55.836 ft
Therefore,
= 1,000 (55.836/4.0)0.81(37.224/3.0)1.05
= $ 119,047.11

APPENDIX A - 16
MF = 4.23
Here the bare module cost is modified by the following factors:
Uninstalled cost,
$ = (BC) (MPF)
= $ 119,047.11 2.0
= $ 238,094.22
Installation,
$ = BC (MF-1)
= $ 119,047.11 (4.23 1)
= $ 384,552.17
$ = BC (MPF + MF 1)
= $ 119,047.11 (2.0 + 4.23 1)
= $ 622,616.39
Total cost, RM = 4.033 (BMC) = RM 2,511,011.9

APPENDIX A - 17
9. HX-01
Costing For Heat Exchanger
Purchased cost, CP = FP FM FL CB
Base cost, CB = exp {11.147 0.1986[ln(A)] + 0.09790[ln(A)2]}
Substitute A = 2332.30684 m2,
CB = $5345301
Take tube length = 16 ft and FL = 1.05
Operating P = 520 KPa = 75.4196 psig
FP only applicable when the design pressure is in between 100 to 2000 psig.
Therefore, FP is ignored.
FM = a + (A/100)b
Where,
Carbon steel/carbon steel: a = 0, b = 0
FM = 1
Therefore,
Purchased cost, CP = 1.05 X 1.00 X 5345301 = $ 5612566
Cbm = CP X Fbm X UF
Fbm = 4.033 , UF = 1.579
Therefore, Cbm = RM 35 741 423

APPENDIX A - 18
10. HX-02
CB = $326279.2
Operating P = 520 KPa = 75.4196 psig
FM = a + (A/100)b
Where,
FM = 1
Therefore,
Purchased cost, CP = 1.05 X 1.00 X 5345301 = $ 342593.2
Cbm = CP X Fbm X UF
Fbm = 4.033 , UF = 1.579

APPENDIX A - 19
11. HX-03
CB = $370380.4
Operating P = 297 KPa = 43.0762psig
FM = a + (A/100)b
Where,
FM = 1
Therefore,
Cbm = CP X Fbm X UF
Fbm = 4.033 , UF = 1.579

APPENDIX A - 20
12. HX-04
CB = $133661.5
Operating P = 101.3 KPa = 14.692323 psig
FM = a + (A/100)b
Where,
FM = 1
Therefore,
Cbm = CP X Fbm X UF
Fbm = 4.033 , UF = 1.579
Therefore, Cbm = RM 893 729

APPENDIX A - 21
13. HX-05
CB = $68177.6
Operating P = 101.3 KPa = 14.692323 psig
FM = a + (A/100)b
Where,
FM = 1
Therefore,
Cbm = CP X Fbm X UF
Fbm = 4.033 , UF = 1.579
Therefore, Cbm = RM 455 870.3

C6 Appendix Costing

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C6 Appendix Costing

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APPENDIX A - 1

Costing for Flash Column, V-100 2

Costing for Flash Column, V-101 4

Costing for Flash Column, V-102 6

Costing for Compressor 8

Costing for Ammonia Reactor, R-01 9

Costing for Mixer, M-100 11

Costing for Mixer, M-101 13

Costing for Mixer, M-102 15

Costing for heat Exchanger, HX-1 17

Costing for heat Exchanger, HX-2 18

Costing for heat Exchanger, HX-3 19

Costing for heat Exchanger, HX-4 20

Costing for heat Exchanger, HX-5 21

Operating pressure = 43.076 psig

Design pressure = 43.076 1.5 = 64.614 psig

From Biegler et al (1997), Table 4.2, pressure factor, FP = 1.0146

MPF = (1.0146)(3.67) = 3.724

Cylindrical pressure vessel

To calculate base cost,

Where from Table 4.11,

And from previous calculation, D = 1.918 ft, L = 7.671 ft.

= 5 (1,042.782) (3.724 + 4.23 1)

The exchange rate as of May 2016 is RM 4.033 for every US$.

2. V-002 (Ammonia Separator)

Operating pressure = 142.7 psig

Design pressure = 142.7 1.5 = 214.05 psig

From Biegler et al (1997), Table 4.2, pressure factor, FP = 1.157

MPF = (1.157)(3.67) = 4.246

Cylindrical pressure vessel

To calculate base cost,

Where from Table 4.11,

And from previous calculation, D = 2.014 ft, L = 8.058 ft.

= 5 (1,150.22) (4.246 + 4.23 1)

The exchange rate as of May 2016 is RM 4.033 for every US$.

Operating pressure = 142.7 psig

Design pressure = 142.7 1.5 = 214.05 psig

From Biegler et al (1997), Table 4.2, pressure factor, FP = 1.157

MPF = (1.157)(3.67) = 4.246

Cylindrical pressure vessel

To calculate base cost,

Where from Table 4.11,

And from previous calculation, D = 1.173 ft, L = 5.866 ft.

= 5 (487.68) (4.246 + 4.23 1)

US$ 26,913.35 = RM 73,519.49

The exchange rate as of May 2016 is RM 4.033 for every US$.

With FD = 1.25 (for gas turbine device)

With FM = 2.5 ( stainless steel)

Purchase cost, CP = $ 2,616,662.42 qx 1.25 x 2.5

USD $ 8,177,070.07 = RM 32,978,123.59

5. Ammonia Reactor, R-01

Operating pressure = 1 atm = 14.7 psig

Safety pressure = Design pressure 1.5 = (14.7)(1.5) = 22.05 psig

= 1.0 3.67 = 3.67

And from previous calculation;

Hence base cost is:

C = 690 (36.745/4)0.78 (9.186/3)0.98

Update factor, , and MF is 3.58 since C value

Thus bare module cost per reactor is:

= 5 ($ 11,651.50) (3.67 + 3.58 1)

Costing for mixer

Since mixture sizing,

Mixer is sized as vertical fabrication.

Ho= 4.0 ft Do = 3.0 ft = 0.81 = 1.05