Table 6.1. Typical factors for estimation of project fixed capital cost Process type Item Fluids Solids 1. Major equipment, total purchase cost PCE PCE PCE f1 Equipment erection o4 045 0.50 fa Piping 0.70 0.45 0.20 3 Instrumentation 0.20 O15 0.10 f Electrical oo 0.10, 0.10 fs Buildings, process os 0.10 0.05 * fg Ulilities 0.50 045 0.25 ‘fy Slorages 0.15 0.20 0.25 “fa Site development 0.05 0.05 0.05 * fy Ancillary buildings O15 0.20 0.30 2. Total physical plant cast (PPC) PPC = PCE (1+ f1+---+ fo) = PCE x 3.15 2.80 fio Design and Engineering 0.25 0.20 fii Contractor's fee 0.05 0.05 fiz Contingency 0.10 0.10 Fixed capital = PPC (1+ fio + f11 + f12) a = PPC x LAs 140 1.35 “Omitted for minor extensions or additions to existing sites.‘Shell and tube heat exchangers Time base mid 2004 1000.0 100.0 ¥ 8 8 2 100 & a 10 0.0 100.0 10000 Heat transfer area, sqm a) Pounds sterling Materials Pressure facors Type factors — Stel Tubes tobar x 1.0 Poatinghead x 1.0 @ Carbon stool Carbon steel = 10-20 x 1.1 -Fixad tbo shoat x 0.8 @cs. Brass 20-30 x 1.25 Utube « 0.85 @cs Stainoss stool = 90-80 x13 Kettlo. x43 @ss. 38. 80-70 x45 Figure 63a, b, Shell ad tube heat exchangers, Time base mid-2004 Purcasel cost = (bare cust from figure) x Type factor x Pressure factorTime base mid 2004 1000.0 100.0 S 6 Equipment cost, £1000 1.0 10.0) 100.0 Vessel height, m (a) Pounds sterling Diameter, m Material factors x 1.0 «20 “34 «15 x24 ‘Temperature up to 300°C Figure 6.5a,. Vertical pressure vessels. Time base mid-2004.Time base mid 2004 100.0 % 8 = 100 E & 1.0 1.0 Diameter, m Material factors Pressure factors. @—05 @—-20 CS x10 1S bar x 1.0 B10 @—20 SS x20 S10 x 44 ‘ ‘ Monel x 3.4 10-20 x 12 SS.cad x15 20-30 x14 Monel x 2.4 30-40 x 1.6 clad 40-50 x 1.8 50-60 x 22 ‘Temperature up to 300°C Figure 6.62, b. Horizontal pressure vessels. Time base mid-2004, Purchase cast = (bare cost from figure) x Material factor x Pressure factorTime base mid 2004 10000.0 1000.0 Cost per plate, © 100.9 ot 1.0 10.0 Plate diameter, m (@) Pound sterling Type Material factors @) Sieve cS. x 1.0 @ valve SS.x 1.7 @) Bubble cap Figure 6.7a,4. Column plates. Time base mid-2004 (for column costs see Figure 6.4) Installed cost = (cost from figure) x Material factorTable 6.2. Purchase cost of miscellaneous equiptment, cost faciors or use in euuation 6.7. Cost basis mid 2008 Trex Comment Fauipment Centrrages oriotat basket, Nestea basket, Compressors Ceatifusal Reciprocating Conveyors fet 05 mwide om wide Crashers Cone’ Pulversers bres Rowry Pan Evaporator: ‘Yerteal ute Faling fe riers Plate ad frame Nacuum dram eee r Se wait, § iver power, KW gm steam, dam iver power, KW length, m kom sea, a? beat abs. kW ‘capacity. m? Se Constant finge ce cs a 12001900 10a (3-309) 10° Ce ao io as-19 35000 8900 35000 $3,000 20-500 90 1602700 2H 1201900 1800 am 2-200 20 3500 ion on sm 21000 35,900 0 0 7700 1290 20.000 ‘50010100 sum _ si00 2100 34,900 0 wo MO San =m s3c0 15,000, rss 31000 2400 2900 350 2300 05 03 os oR o7s ors oss ons ous 035 oss 082 on on 0 oas oss 03s il or gas fired carton ste! S17 for ss ceeatic, ima pes, Sotar carton ste! Soe ‘carton ste! ‘lass tinea amos. pos. ‘Garton ste! 32 forTable 6.3. Cost of column packing. Cost basis mid 2004 Cost £/m? ($/m>) Size, mm 25 38 30 Saddles, stoneware ‘840 (1400) 620 (1020) 580 (960) Pall rings, polypropylene 650 (1080) 400 (650) 250 (400) Pall rings, stainless steel 1500 (2500) 1500 (2500) 830 (1360) To use Table 6.2, substitute the values given for the particular type of equipment into the equation: (6.7) where Ce = purchased equipment cost, £, S = characteristic size parameter, in the units given in Table 6.2, cost constant from Table 6.2, index for that type of equipment.Table 6.4. Raw material and product costs. ‘Typical prices for bulk purchases, mid-1998. All deliveries by rail or road tanker, and all materials technicaV/industrial grade; unless otherwise stated ‘Chemical, and state Cost unit — Cost unit Cast $/un. Acetaldehyde, 99% kg 053 Acetic acid ke 0.60 ‘Acetic anhydride ke 0.70 Acetone ke 0.63, ‘Acrylonitrile ke 1.20 ‘Ally alcohol kg 140 Ammonia, anhydrous t 180 Ammonium nitrate, bulk t 100 Ammonium sulphate, bulk t 90 Amyl alcohol, mixed isomers kg 0.67 ‘Aniline ke 0.52 Benzaldehyde, drums ke 1.95 Benzene ke 020 Benzoic acid, drums ke 220 Butene-| ke 030 n-Butyl aleohol ke 075 ‘n-Butyl ether, drums ke 195, ‘Calcium carbide, bulk 1 300 ‘Calcium carbonate, bulk, coarse 105, ‘Calcium chloride, bulk 1 200 Caleium hydroxide (lime), bulk 1 35. ‘Carbon disulphide t 370 ‘Carbon tetrachloride, drums ke 0.50 ‘Chlorine t 140 Chloroform ke 0.45 ‘Cupric chloride, anhydrous: ke 3.30Formaldehyde, 37% wiw Fommic acid, 94% w/w, drums Glycerine, 99.79% Heplane Hyurochloric act, aya. Hydrochloric acid, 30% wiw ‘Hydrogen fluoride, anhydrous ‘Hydrogen peroxide, 50% wiw Isobutanol, alcohol Isopropanol alcohol ‘Maleic anhydride, drums ‘Methanol ‘Methy! ethyl ketone ‘Monoethanolamine Methylstyrene Nitric acid, 50% whw 98% ww ‘Nitrobenzene GO BRGRE GE SR REE EER REGEE RETable 6.4. (continued) ‘Cost unit Cost £/unit Cost S/unit ke 058 096 ke 0.90 153 ke 1.09 162 ke aT ons ke 05 075 ke 056 om t 70 io ke 0.80 1.30 ke 2.00 3.70 t 350 370 ke 0.43 O64 ke 1.00 1.60 ke 093 138 ke 035 0.58 ke 040 06s Sodium hydroxide, drums ke 160 260 Sadium sulphate, bulk t n 120 Sodium ke 038 037 ‘Sulphur, crude, 99.5%, sacks t 85 140, ‘Sulphuric acid, 98% wiw t 40 6 Titanium dioxide, sacks ke 1.50, 250 “Toluene ke 032 047 ‘Toluene diisocyanate kg 220 3.20 ‘Trichloroethane kg 0.56 0.04 ‘Trichloroethylene kg 084 1.40 ‘Urea, 46% nitrogen, bulk t 1 160 ‘Vinyl acetate kg 065 1.08 ‘Vinyl chloride kg 044 0.66 Xylenes ke 029 043 ‘Anhyd. = anhydrous, cyl. = cylinder, refin. = refined Caution: Use these prices only as a rough guide to the probable price range. Actual prices at a given time will vary considerably from these values, depending ‘on location, contract quantities, and the prevailing market forces.Table 6.5. Cost of utilities, typical figures mid-2004 Utility UK USA Mains water (process water) 60 pit 50 cit Natural gas 0.4 p/MI 0.7 CMI Electricity 1.0 p/My 1.5 cMJ Fuel oil 65 Bt 100 St Cooling water (cooling towers) 15 pt lest Chilled water Smt 8 cit Demineralised water 90 pit 90 cit Steam (from direct fired boilers) 7 Ht 12: Sit Compressed air (9 bar) 04 pin? (Stp) 0.6 cm? Instrument air (9 bar) (dry) 0.6 pin? (Stp) 1 om? Refrigeration 1.0 pM 1.5 c/MI Nitrogen 6 plm? (Stp) 8 cm Note: £1 = 100p, 1$ = 100c, 1 t = 1000 kg = 2200 ib, stp— 1 atm, 0°C ‘These prices should be used only as a rough guide to the likely cost of utilities. The cost of water will be very dependent on the plant location, and the price of all utilities will be determined by the current cost of energy.‘Table 6.6. Summary of production costs ‘Sub-total B Direct production costs A + B 13. Sales expense 14. General overheads 15. Research and development ‘Sub-total C Annual production cost = A + B4+C = ‘Typical values from flow-sheets 10 per cent of item (5) from flow-sheet usually negligible 510 per cent of fixed capital from manning estimates 20-23 per cent of 6 20 per cent of item (6) 30 per cent of item (6) 10 per cent of the fixed capital 1 per cent of the fixed capital 2 per cent of the fixed capital 1 per ceat of the fixed capital ‘Annual production cast Production cost kg = ‘Annual production rate