Equipment purchase costs heat exchangers

The process system consists of two long-tube vertical evaporators, a draft-tube baffled crystallizer, a rotary-drum vacuum filter, and a direct-heat rotary dryer. Also, pumps are needed to move the solution from evaporator 1 to evaporator 2, to recycle the filtrate from the filter to the crystallizer, and to move the magma from the crystallizer to the filter and a heat exchanger is needed to heat the recycle filtrate. However, the purchase costs for the three pumps and the heat exchanger are not considered here because examples for these types of equipment are presented in Section 16.5. For the equipment considered here, assume fabrication from stainless steel, with a material factor of 2 for the ratio of stainless steel cost to carbon steel cost. For the process, using the following size factors and the equations in Table 16.32, the estimated f.o.b. equipment purchase costs at a CE index of 394 are included in the following table. 

The purchased cost of the equipment for the heat exchanger in Example 7.11 would be Cp(2006) =... 

Published Cost Correla.tions. Purchased cost of an equipment item, ie, fob at seller s site or other base point, is correlated as a function of one or more equipment—size parameters. A size parameter is some elementary measure of the size or capacity, such as the heat-transfer area for a heat exchanger (see HeaT-EXCHANGETECHNOLOGy). Historically the cost—size correlations were graphical log—log plots, but the use of arbitrary equation forms for correlation has become quite common. If cost—size equations are used in computer databases, some limit logic must be included so that the equation is not used outside of the appHcable size range. 

It should be noted that a resequence or repipe does not involve zero capital cost, even though no new heat exchanger equipment might be purchased. The pipework modifications for a resequence or repipe might be very expensive. Also, equipment might need to be relocated. Methods for capital cost estimation for retrofit were discussed in Chapter 2. 

Purchased equipment costs for various types of heat exchangers. 

The total fixed capital investment (FCI) for the entire system taking all costs for heat-exchanger equipment, pumps, piping, installation, etc., into account is equal to the initial cost of the catalyst solution plus 4.5 times the purchased cost of the reactor. Assume none of the unreacted materials can be recovered. 

In the factor methods for cost estimating, first calculate the purchased or delivered cost of all major equipment, for example, distillation columns, reactors, pumps, heat exchangers, etc. Then multiply the total equipment cost by factors to estimate the various other components of the depreciable capital cost given in Equation 2.2, such as piping and electrical wiring. Thus, we arrive at the cost of installing all the equipment and supplying all the services needed to produce an operational process. 

The purchased cost of a shell and tube heat exchanger, carbon shell, 316 stainless steel tubes, heat transfer area 500 m, was 64,000 in January 2003 estimate the cost in January 2008. Use the M S Equipment Cost Index. 

For the ammonia process, which operates at high pressure (200 atm), mostly in the gas phase, the total f.o.b. purchase cost of the on-site process equipment is 31,520,000. Installation costs boost this amount by a factor of 3.453 to a total bare-module cost of 108,830,000. As seen in Table 16.14, this cost is dominated by the gas compressors, with significant contributions from the heat exchangers and the membrane separators. Surprisingly, the reactor cost is a small fraction of the total cost. This is often the case for chemical plants. The reactor may not cost much, but it is the heart of the process and it better produce the desired results. 

Table 16.32 Purchase Costs (f.o.b.) of Other Chemical Processing Equipment, CE Index = 394. Equations for pumps, compressors, motors, heat exchangers, and pressure vessels are in Section 16.5 ... 

Please submit a report on the two designs and cost estimates (flxed capital and utility operating costs only). For the capital cost of each of the two alternative sequences, sum the purchase costs of the distillation columns, heat exchangers, and any vacuum equipment. Multiply that cost by the appropriate Lang factor. To annualize the capital cost, multiply by 0.333. Add to this annualized cost the annual utility cost for steam and cooling water. Call this the total annualized cost for the alternative. 

Part Three includes chapters that provide instruction and examples of the design of heat exchangers, multistage and packed towers, and pumps, compressors, and expanders. In addition, Chapter 16 provides guidelines for selecting processing equipment and equations for estimating the purchase costs of a broad array of equipment items. Furthermore, Section 16.7 shows how to use the Aspen Icarus Process Evaluator (IPE), with the process simulators, to estimate purchase costs and the total permanent investment for a chemical plant. 

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