HEAT EXCHANGER

Sample calculation for exchanger E-101

From the calculation; Area, A = 55.371 m2 Pressure, P = 240 bar MOC tube = SS ; MOC=Material of construction, SS= Stainless steel MOC shell = SS

Estimation of Cp and Fp: 1. From table A-4 (multiple pipe): B1 = 1.74 B2 = 1.55 2. From table A-2 (for P=240 barg): C1 = 13.1467 C2 = -12.6574 C3 = 3.0705 3. Calculate value Fp using equation below: log Fp = C1 + C2 log(P) + C3 [log(P)]2

log Fp = 13.1467 12.6574 log (240) + 3.0705 [log (240)]2 Fp = 2.61 4. Estimation of purchased cost, Cp0:

From figure A.5; Cp0/A =

Cp0(2001) = $ 19379.85 5. Estimation of material factor, FM: Since material of construction for both shell and tube is SS and multiple type, therefore: From Table A.3: Identification number = 5 Thus, from figure A-18: Material factor, FM = 2.75 Therefore, CBM = Cp0 (B1 + (B2 x Fp x FM)) CBM = 19379.85 x (1.74 + (1.55 x 2.6 x 2.75)) = 249324.19 Bare Module Cost,

CBM (2012) = CBM (2001) [ I2 (2012) / I1 (2001) ] Where: I1 = cost index for year 2001 = 397 I2 = cost index for year 2011 = 643.11 For $1 = RM 3.1645 (average currency for year 2012) So, Bare Module Cost,

CBM (2012) = $249324.19 (643.11/ 397) = $ 403886.35 Bare Module Cost, CBM (2012) in Malaysia currency = RM1278098.36

Table: Total price for all heat echanger: Equipment Area, m2 Purchase cost,
Cp0(2001) ($)

Bare module cost,

Bare module cost,

E-101 E-102 E-103 Total

55.37 66.79 46.26

19,379.85 22,707.92 15,726.70

403,886.35 473,245.10 327,752.77 1,204,884.22

1,278,098.36 1,497,584.11 1,037,173.64 3,812,856.11

Reactor

From the chemical and mechanical design calculation; Volume, VTotal = 3.534 m3 Pressure, P = 240 bar Materials of Construction = stainless steel Estimation of Cp:

The value for K1 and K2 and K3 are referred to the table A.1 in the Turton (2009) page 910 and the value are: K1 = 4.7116 K2 = 0.5521 K3 = 0.0004 For V=3.534m3 log10Cpo = 4.7116 + 0.5521log10(3.5534) + 0.0004[log10(3.534)]2 = 4.7116 + 0.3027 + 0.0004 = 5.0147 Cpo = 103,442.7

Cpo (2011) = 103,442.7(622/397) = $ 162,067.8

log Fp = C1 + C2 log(P) + C3 [log(P)]2 For conversion vessel, the operating pressure is 2.2 barg. From Table A.2, C1=C2=C3=0 and from equation A.3 (Turton, 2009), then Fp= 1

Bare Module Cost: CBM = 162,067.8 (2.25+ (1.82) (3.1)(1)) CBM = $ 1,279,039.10 The currency $ 1 = RM 3.02 So, the value from Bare Module Cost is in US dollar ($) must be converted into Ringgit Malaysia (RM) $ 1,279,039.10 = RM 3,862,698.00 As conclusion, the price for the reactor is RM 3,862,698.00.

Vessel From the chemical and mechanical design calculation; Volume, D = 1.5 m Height = 3.0 m Pressure, P = 240 bar Materials of Construction = stainless steel By Using CAPCOST software: Cpo (2011) = RM 11,800 CBM (2011) = 1,530,000

Compressor 1) Fluid power = 4850.7 kW MOC = SS Compressor type = Centrifugal Cpo (2011) = RM 1,630,000 CBM (2011) = 9,390,00 2) Fluid power = 5393.1 kW MOC = SS Compressor type = Centrifugal Cpo (2011) = RM 1,630,000 CBM (2011) = 9,390,00

TOTAL CAPITAL INVESTMENT

Base Bare Equipment Specification Module Cost (RM) Heat Exchanger 1 Heat Exchanger 2 Heat Exchanger 3 Heat Exchanger 4 Component Splitter 1 Component Splitter 2 Component Splitter 3 Reactor Separator Pump 1 Pump 2 Pump 3 Compressor 1 E -100 E -101 E -102 E -103 X - 100 X 101 X 102 CRV-100 V-100 P-101 P-102 P-103 K-100 712,342 1,804,200 58,227 1,854,825 123,040 123,040 123,040 2,612,383 53,202 94,008 68,948 68,948 154,060

Compressor 2

K-101

146,002 7,996,265

Total Bare Module Cost (RM)

Contingency and Fee (8%) Contingency = = Fees = = Total Module Cost, TMC = = Total Bare Module Cost 0.15 RM 1,199,439.75 Total Bare Module Cost 0.08 RM 639,701.2 Total Bare Module Cost + Contingency + Fees RM 9,835,405.95

Auxiliary Facilities (10%) Site Development = = Auxiliary Buildings = = Offsite Facilities = = Total Bare Module Cost 0.05 RM 399,813.25 Total Module Cost 0.04 RM 319,850.6 Total Module Cost 0.21 RM 1,679,215.65

Auxiliary Facilities

Site Development + Auxiliary Buildings + Offsite Facilities

= Grass-roots capital (GRC) = =

RM 2,398,879.5 Total Module Cost + Auxiliary Cost RM 10,395,144.5

Labor Cost
The operating labor requirement for chemical processing plants is given by: NOL = (6.29 + 3.17P2 + 0.23 Nnp)0.5 The value of Nnp is given by: Nnp = Equipment Where: NOL P Nnp The number of operators per shift The number of processing steps involving the handling of particulate solids. The number of non particulate processing steps handling steps.

Type of Equipment Heat Exchanger Reactor Splitter Vessel Pump Compressor Total

No. Of Equipment 4 1 3 1 3 2

NNP 4 1 3 2 10

NOL = (6.29 + 3.17P2 + 0.23 Nnp)0.5 = 2.93

Cost (RM) 1) 1 operator per month = 1,800 2) 1 operator per year = 21600 (including bonus + allowance)
Purchased Direct Cost Equipment Installation Instrumentation and Control (installed) Piping (installed) Electrical and Material (installed) onsite Event Cost

30 % GRC 15 % GRC 30 % GRC 8 % GRC offsite

RM 3,118,543.75 RM 1,559,271.70 RM 3,118,543.75 RM 831,611.60

Building Yard Improvements Service Facilities Land Total

10 % GRC 1 % GRC 5 % GRC 2% GRC

RM 1,039,514.50 RM 103,951.40 RM 519,757.20 RM 207,902.90 RM 10,499,096.80

Event Engineering and supervision Construction Indirect Cost Expenses Contractors Fee Contingency Total 1.5 % GRC 10 % GRC 5 % GRC 8 % GRC

Cost RM 519,757.2 RM 831,611.60

RM 155,927.20 RM 1,039,514.50 RM 2,546,810.50

Fixed Capital Investment (FCI) Working Capital Start Up Cost

(FCI = GRC + Total) 12 % FCI 8 % FCI

RM 23, 441, 051.80 RM 2,812,926.20 RM 1,875,284.10 RM 28,129,262.10

Total Capital Investment (TCI)

Total = Direct+Indirect = RM 13,045,907.30

Assumption 1) Plant performed: 2) Plant is tunning 24hours per day: 3) Maintainace day per year: 4) Operation day per year: 5) Minimum day for operator rest: 6) Week for 1 operator work: 7) Shift needed for a plant in year: 8) 1 operator can obtained shift: 3 shifts per day 1 day 30 days 335 days 14 days 48 weeks 1005 shift/year 230 shift/year.operator

NON : Operating labor cost, COL: COL = NOL x NON x PO

Manufacturing Expenses Direct Production Cost Raw Materials

Cost (RM/yr)

Cost Per Production (RM/kg)

259, 290. 000

3.11

Utilities & Land Water, Electric & Land Miscellaneous Maintenance and Repairs Operating Supplies 2 % FCI 468,821.03 48.08 0.5% of Maintenance and Repairs 0.2% of maintenance and repair 10 % of Operating Labour 15 % of Operating Labour 0.01% FCI 0.2404 Indirect Production Cost Local Taxes Insurance Plant Overhead 1 % FCI 25.3825 1% FCI 50 % of Operating labor 25.3825 0.0508 468.8 Total Manufacturing Expenses, AME 292,823,971 30,033.22 234,410.5 2,344.1 0.2404 32,590,000.00 3,342.60

937.60

Operating Labor Direct Supervision & Clerical Labor Laboratory Charges Patents and Royalties

93.76

0.0962

140.60 2344.10

0.0096

0.0144

234,410.5

Total Manufacturing Expenses, AME Administration Cost Distribution & Selling Expenses Research & Development 10% of FCI 25 % of Plant Overhead

Cost (RM/yr) 1,049,310.60

Cost per production (RM/kg) 76.1474

3,497,702.00

253.8245

3% of FCI

1,049,310.60 5,596,323.19

76.1474 406.1192

Total General Expenses, AGE

Total Production Cost, APC

APC = AME + AGE (excluding depreciation) 10 % FCI ATE = APC + ABD

2,141,397,014.99

155398.9126

Depreciation, ABD Total Expenses, ATE

3,497,702.00 2,144,894,716.99

253.8245281 155652.7371

price for product Urea Raw material usage Urea Annual sales for product

RM

21 /kg 9750 kg/hr

RM 204,750 /yr

Total revenue from Product sales Net annual profit, Total Revenue ANP

535,125,100.00

54,884.62

45,248,845.50

4,640.90

Income taxes

30% ANP

13,574,653.65 31,674,191.85

1,392.27 3,248.64

Net annual Profit, ANP Income Taxes ANNP Rate of Return (ANNP-ABD)/TCI 100% Cash flow Year of construction Plant Life Working Capital TCI Total Annual Sales Total Expenses, ATE Bank Loans 1st year = 10% of TCI 2nd year = 45% of TCI 3rd year = 45% of TCI

x 125..03%

3 years 22 years RM 2,812,926.20

RM 28,129,262.10 RM 535,125,100.00 RM 2,144,894,716.99