Cost Accounting and Capital Cost Purchasing Costs

Product and Process Design Principles
Synthesis, Analysis and Evaluation
Chapter 22
Cost Accounting
& Capital Cost
Purchase Costs of Most Widely
Used Process Equipments
Part 1
Introduction to
Purchasing Costs
Introduction to Purchasing Costs
Recap
ACCOUNTING
Asset Income
Liability
Cost
Equity
Cost Accounting
Cost Accounting and Capital Costs: Purchasing Costs Page 3

Recap (Cost Accounting)
TOTAL CAPITAL INVESTMENT (CTCI)
Total Permanent Investment (CTPI) Working Capital (CWC)
Total Depreciable Capital (CTDC) Total Non-Depreciable Capital
Direct Permanent Unexpected/ Land Cost Startup Cost

Investment (CDPI) Contingency Costs (Ccont) (Cland) (Croyal)
Total On-Site/ Bare Royalties

Module Costs (CTBM) Total Off-Site Costs
Cost (Croyal)
Equip & Machinery Bare Site

Purchase
Module Costs (CBM) Development
Costs (CP)
Costs (Csite)
Spares Bare Module
Costs (Cspare) Service
Direct Material &
Facilities
Storage & Surge Bare Labour Costs (CML)
Costs (Cfacilities)
Module Costs (Cstore)
Indirect Expenses Utility Plants
Initial Catalyst Charges
e.g. delivery (CIE) Costs (Calloc)
(Ccatalyst)
Comp. & Software Bare
Module Costs (Ccomp)

Why do We Need Purchase Costs, CP ?

• CP is needed to estimate CTCI.
– Lang’s Overall Factor Method aka Study Estimate

𝐼𝑖
𝐶𝑇𝐶𝐼 = 1.05 𝑓𝐿,𝑇𝐶𝐼 ෍( )(𝐶𝑃𝑖 )
𝐼𝑏𝑖
𝑖
– Guthrie’s Individual Factors Method aka Prelim Estimate

𝐶𝑇𝐶𝐼 = 𝐶𝑇𝑃𝐼 + 𝐶𝑊𝐶
= 1.18 𝐶𝑇𝐵𝑀 + 𝐶𝑠𝑖𝑡𝑒 + 𝐶𝑏𝑢𝑖𝑙𝑑𝑖𝑛𝑔 + 𝐶𝑓𝑎𝑐𝑖𝑙𝑖𝑡𝑖𝑒𝑠 + 𝐶𝑊𝐶
𝐼𝑖
where 𝐶𝑇𝐵𝑀 = σ 𝐶𝐵𝑀 = σ𝑖( )(𝐶𝑃𝑖 )(𝐹𝐵𝑀 + 𝐹𝑑 𝐹𝑃 𝐹𝑚 − 1)
𝐼𝑏𝑖

General Form of Purchase Costs, CP
Purchase Costs (CP) = Fa Fb Fc … x Base Costs (CB)

The purchase costs (CP) in this eqn., is free-on-board

(f.o.b.), i.e. delivery charges not included.
Delivery costs (indirect costs) are only included in

calculation of bare-module costs (CBM) [prev. lecture]

Equipment-Specific Correction Factors,

e.g. Material Factor (FM), Pressure Factor (FP),
Tube-Length Factor (FL, specific for heat ex.),
Motor Drive Factor (FD, specific for motors).

Dependent on size factor (S) of equipment.

Size factor is the representative size parameter of
equipment, e.g. size factor for heat ex. is area.
General Form of CB: CB = A(S)b

OR
General Form of CB:
CB = exp {A0 + A1ln(S) + A2[ln(S)]2 + …}
Remember, CP changes over the years !

• All CP calc. are based on factors and tables
given in textbook with a ref. year of 2006
(ICE=500) unless mentioned otherwise.
• If desired CP is not in 2006, we need to use

price index formula:
𝐼𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑦𝑒𝑎𝑟 CE index for
𝐶𝑃𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑦𝑒𝑎𝑟 = 𝐶𝑃 × 2006 = 500
𝐼2006 (Table 22.6,
Pg 544)

Overview of CP
Purchase Costs (CP)
Main Equipment Other Equipment
Pumps, Heat Vessels,

Motors Exchangers Towers
Covered
Fans, by Expert
Blowers, Fired Packings Team 3
Compressors Heaters
Plates

Part 2
Pumps and
Electric Motors
Pumps and Electric Motors
Pumps
• There are 3 main industrial pumps:
– CENTRIFUGAL Pumps
– EXTERNAL ROTARY GEAR Pumps

(or gear pumps in short)
– RECIPROCATING Pumps

Pumps
• About 90% of the time, CENTRIFUGAL pump
is used because
– Inexpensive among the 3 pumps
– High Speed
– Simple construction, little to no wear & tear
– Large no. of suppliers
– Wide range of materials flowrates & temperatures
– Smooth pumping flowrate
– Can handle slurries
– Easy operation

Pumps
• The other 2 pumps are preferred over
centrifugal pumps when
– Liquid is viscous (>100 centistokes)
– Narrow pump efficiency on pump curve
– Head greater than 3200 ft is required
– Flowrate greater than 1500 GPM
• Remember!! Pumps have limitations!
– Don’t pump liquid with large amount of air (will
cause air binding in pumps  priming is required)
– Don’t pump liquid near bubble pt  prevent
cavitation
Pumps: Centrifugal Pump
MUD HOGTM Centrifugal Pump (Source: Forum Energy Technologies)


• To use a CENTRIFUGAL Pump:
– Vol. Flow Rate :
10 GPM (.000631m3/s) – 5000 GPM (.3155m3/s)
– Head :
50ft (15.24m) – 3200 ft (975.4m)
– Kinematic Viscosity :
< 100 centistokes (.0001m2/s)
– Available NPSH:
> 5ft (1.52m)

Purchase Costs for Centrifugal Pumps:

CP = FT FM CB Eqn 22.15,
pg561
where:
FT is centrifugal pump type correction factor
FM is pump material correction factor
CB is base cost


CP = FT FM CB
• Base Cost (CB) Calculation
– Size Factor: Pump Flowrate (Q)
S = Q (H) 0.5
where: Q is in gallons per min (GPM) Eqn 22.13,
H is in ft pg560
– Base Cost:
Eqn 22.14,
CB = exp{9.7171 - 0.6019ln(S) + 0.0519[ln(S)]2} pg561
OR
Refer to Cost Curve @ Fig. 22.3 Pg. 561

Base Cost Curve (for Centrifugal Pump)

CP = FT FM CB
CB
CB = f(S)
In this case,
CB = exp{9.7171 - 0.6019ln(S) + 0.0519[ln(S)]2}
Size Factor, S


CP = FT FM CB
• Correction Factors – FT, FM
– Centrifugal Pump Type Factor, FT:
Refer to Radial Centrifugal Pump FT
@ Table 22.20 Pg. 561


CP = FT FM CB
• Correction Factors – FT, FM
– Pump Material Factor, FM
Refer to Construction Materials FM
@ Table 22.21 Pg. 562

Pumps: External Rotary Gear Pump

(A type of positive displacement pump)
External View Internal View
External Rotary Gear Pump (Source: Viking Pump Technologies)


• To use a EXTERNAL GEAR Pump:
> 1500 GPM (.252m3/s)
– Head :
> 3000ft (914.4m)
100 – 500,000 centistokes
However, external gear pumps are more pricey and has less
smooth pumping than centrifugal pumps…

Purchase Costs for Gear Pumps:

CP = FM CB
Eqn 22.22,
where:
pg563
CB is base cost


CP = FM CB
– Size Factor: Pump Flowrate (Q)
S=Q
where: Q is in gallons per min (GPM)
– Base Cost:
Eqn 22.21,
CB = exp{7.6964 + 0.1986ln(Q) + 0.0291 [ln(Q)]2} pg563
OR
Info for rotary gear pumps cost curve are very limited… the
above CB formulae are applicable to 300-3500rpm only…
Base Cost Curve (for External Rotary Gear Pump)

CP = FM CB


CP = FM CB
• Correction Factors – FM
– External Rotary Gear Pump Type Factor, FT:
Not available since info for gear pump
types are limited

Refer to Construction Materials FM
@ Table 22.21 Pg. 562

Pumps: Reciprocating Plunger Pump

(A type of positive displacement pump)
External View Internal View
TriplexTM Reciprocating Plunger Pumps (Source: Triplex Plunger Pumps)


• To use a RECIPROCATING PLUNGER Pump:
> 500 GPM (.031545m3/s)
– Head :
Maximum Horsepower:
> 20,000ft (6096m) 200 hp!
<100,000 centistokes
However, external gear pumps are even more expensive and

has even less smooth pumping than rotary gear pumps…

Purchase Costs for Reciprocating Pumps:

CP = FM CB
Eqn 22.22,
where:
pg563
CB is base cost


CP = FM CB
– Size Factor: Pump Brake Horsepower (PB)
S = PB = (PT/ηP) or (QHρ/33000 ηP)
where: PT is total pump horsepower in hp Eqn 22.16,
Q is pump flowrate in GPM rewritten,
H is pump head in ft pg561
ρ is density in lb/gallon
ηP is pump efficiency, usually by default 0.9
– Base Cost:
Eqn 22.23,
CB = exp{7.8103 + 0.26986ln(PB) + 0.06718 [ln(PB)] } pg563
2
OR
Base Cost Curve (for Reciprocating Plunger Pump)

CP = FM CB


CP = FM CB
– Centrifugal Pump Type Factor, FT:
Not available for Reciprocating Plunger Pumps
Refer to Pg. 564

Motors
• Pumps, especially centrifugal pumps, are driven
by electric motors.
• All pump CP calculated previously does not

include motors.
• We need to calculate the f.o.b. purchase costs

of motors separately.

Motors
Purchase Costs for Motors:

CP = FT CB
where: Eqn 22.20,
FT is motor type correction factor pg562
CB is base cost

Motors
CP = FT CB
– Size Factor: Motor Power Consumption (PC)
S = PC = PT/(ηP ηM )
= PB / ηM Eqn 22.16,
pg561
= QHρ/(33000 ηP ηM)
where: PT is total pump horsepower in hp
PB is pump brake horsepower in hp
Q is pump flowrate in GPM
H is pump head in ft
ρ is density in lb/gallon
**ηP is pump efficiency, calculable by Eqn 22.17
**ηM is motor efficiency, calculable by Eqn 22.18

Motors
CP = FT CB
• Base Cost (CB) Calculation (…Continued)
**Steps to calculate ηP and ηM ???
1. Identify Pump Flowrate, Q (GPM). (around 50-50000GPM)
2. Calculate Pump Efficiency, ηP :
Eqn 22.17,
ηP = -0.316 + 0.24015 lnQ – 0.01199 (lnQ)2
pg562
3. Calculate Pump Brake Horsepower, PB :
Eqn @ Slide #27
PB = QHρ/(33000 ηP) Follow units requirements
4. Finally, calculate Motor Efficiency, ηM :
Eqn 22.18,
ηM = 0.80 + 0.0319 lnPB – 0.00182 (lnPB)2 pg562

Motors
CP = FT CB
– Base Cost for Motors:
CB = exp{5.8259 + 0.13141 ln(PC) + 0.053255 [ln(PC)]2 Eqn 22.19,
+ 0.028628 [ln(PC)]3 – 0.0035549 [ln(PC)]4} pg562
OR

Base Cost Curve (for Motors)

CP = FT CB

Motors
CP = FT CB
• Correction Factors – FT
– Motor Type Factor, FT:
Refer to Motor Type (Enclosure and rpm) FM
@ Table 22.22 Pg. 563

General Steps in Calculating CP for Pump-Motor Combo

1. Change vol. flowrates (Q) to GPM, density (ρ) to lb/gal and
lb/ft3 and g/cm3, kinematic viscosity (i.e. viscosity in cP
divided by ρ (g/cm3)) to centistokes.
2. Determine increase in pressure (∆P) in lb/ft2 (Useful
conversions: 1atm = 14.7psi = 2116.8 lb/ft2 and 1psi = 144 lb/ft2)
3. Calculate Pump Head H in ft, where H = ∆P (lb/ft2) /ρ (lb/ft3)
4. Determine NPSH in ft, where NPSH = (Suction pressure-
Vapour Pressure)/ ρ
5. Select pump of choice
6. Calculate CP for selected pump:
a. Determine Size Factor, S, of pump
b. Determine Base Cost, CB, based on S
c. Find FT or FM where necessary
d. Determine CP

General Steps in Calculating CP for Pump-Motor Combo

7. Select electric motor of choice (open, drip-proof/
enclosed, fan-cooled/ explosion-proof)
8. Calculate CP for selected motor:
a. Determine Pump Efficiency, ηP, based on Q
b. Determine Pump Brake Horsepower, PB, based on slide #27
c. Determine Motor Efficiency, ηM, based on PB
d. Determine Size Factor, i.e. Motor Power Consumption, PC,
based on Q, H, ρ (lb/gal) , ηP and ηM (Eqn 22.16)
e. Determine CB based on PC
f. According to motor type and speed, find FT
g. Determine CP
9. Total CP of Pump-Motor Combo = CP, Pump + CP, Motor
10.Adjust CP with appropriate price index if necessary

Working Session 1: Example 22.6

• In chapter 4, a vinyl chloride process is synthesised, with a
detailed process flow diagram shown in figure 4.19. In that
process, Reactor pump P-100 takes stream 4 (a mixture of
streams 3 and 16) of 263800 lb/hr of 1,2 –dichloroethane at
900C and 1.5 atm (entering/suction pressure) and delivers it to
an evaporator operating at a much higher pressure of 26 atm.
Select a suitable pump and explosion -proof electric motor and
estimate f.o.b. CP at CE index of 550.
• Additional information:
– Density: 9.54 lb/gal (1lb=453.592g; 1 gallon= 0.133681ft3= 3785.41cm3)
– Viscosity: 0.37 cP (1 cP = g/s.cm)
– Vapour pressure: 1.212 atm
Answer: Choose centrifugal pump, total cost CP = $42,250

Part 3
Fans, Blowers
and Compressors
Fans, Blowers and Compressors
Overview of Fans, Blowers, Compressors

• Purpose
To move gas through various pipeline or ducts
with the presence of energy input
• Compression Ratio
= Tot. discharged pressure/Tot. suction pressure
• Total Head = Dynamic Head + Pressure Head

(Velocity) (Static)
HTotal = [v2/(2g)] + [P/(ρg)]
Overview of Fans, Blowers, Compressors

• General limitations of fans, blowers, compressors:
– Discharge temperature limit: 375 - 400 oF
Assuming 85 % isentropic efficiency (yes, all gas
pressure changers are isentropic!) and outlet gas temp.
reaches 400 oF (limit),
• Compression ratio limit of air  3.75
• Compression ratio limit of diatomic gases  3.75
• Compression ratio of monoatomic gases  2.50
• Others: compression ratio limit of methane  6.0
– Ultimate compression ration limit: 8.0

Classification
FANS BLOWERS COMPRESSORS
Almost all energy input Energy input increases Almost of all energy
increases the velocity both velocity head and input increases the
head (increase pressure head pressure head (increase
flowrate) (increase flow rate and pressure)
pressure)
Widely used for high- Used for the Widely used with a
flow, low pressure- applications (eg: fired variety of gases (gas
increase application (eg: heaters, fixed-bed mixtures) to increase
heating and ventilation absorbers) with more their pressure to
system) pressure drop than a required level for
fan chemical reaction and
separation
Compression Ratio ≤ 1.2 Compression Ratio ≤ 2 Compression Ratio ≥ 2

Fans
• There are 2 main industrial fans:
– CENTRIFUGAL Fans
• Backward-Curved Blade
• Straight-Radial Blade
– AXIAL-FLOW Fans
• Vane Axial
• Tube Axial

Fans
• CENTRIFUGAL Fans:
– Able to achieve high discharge pressure (relative
to axial fans)
1. Centrifugal Backward-Curved
• Cheapest compared to Straight-Radial
Centrifugal Fans
• Most efficient
• Discharge pressure decreases rapidly from its
maximum value as flow rate is increases
• Only suitable for air and clean gases

Fans
• CENTRIFUGAL Fans:
– Able to achieve high discharge pressure (relative
to axial fans)
2. Centrifugal Straight-Radial
• Suitable for dust-laden gases
• Maintain discharge pressure up to 1.2 over a
wider range of flow rate
• Less efficient

Fans
Centrifugal Fan
Backward-Curved Blade Straight-Radial Blade

Fans
• AXIAL-FLOW Fans:
– Able to achieve high flow rate (relative to
centrifugal fans)
1. Vane Axial Fans

• Compression Ratio – up to 1.04 (<1.04)
2. Tube Axial Fans

• Compression Ratio – up to 1.025 (<1.025)

Fans
Axial Flow Fan
Vane Axial Cross-Section Tube Axial Cross-Section

Fans
• Among 4 types of fans, which to choose???
– Refer to Table 22.23 Pg566 (Typical Operating
Range of Fans)
– Also consider the characteristics of each fan

(Slide #49, #50, #52)
Fans
Purchase Costs for Fans:

CP = FH FM CB
where: Eqn 22.24,
FH is fan head correction factor pg566
FM is fan material correction factor
CB is base cost

Fans
CP = FH FM CB
– Size Factor: Inlet Gas Flowrate (Q)
S=Q
where: Q is in Actual Cubic Feet per Minute (ACFM)
– Base Cost:
• Centrifugal Fans
Centrifugal backward-curved fan (valid from Q = 1000 to 100,000 ACFM)
Eqn 22.25,
CB = exp{11.0757 - 1.12906 lnQ + 0.08860 [lnQ]2} pg566
Centrifugal straight-radial fan (valid from Q = 1000 to 20,000 ACFM)
Eqn 22.26,
CB = exp{12.1678 - 1.31363lnQ + 0.09974 [lnQ]2} pg566

Fans
CP = FH FM CB
– Base Cost:
• Axial-Flow Fans
Vane-axial fan (valid from Q = 1000 to 800,000 ACFM)
Eqn 22.27,
CB = exp{9.5229 – 0.97566lnQ + 0.08532 [lnQ]2} pg567
Tube-axial fan (valid from Q = 2000 to 800,000 ACFM)
Eqn 22.28,
CB = exp{6.12905 - 0.40254lnQ + 0.05787[lnQ]2} pg567
OR
Refer to Overall Fan Cost Curve @ Fig. 22.7 Pg. 566

Base Cost Curve (for all 4 types of Fans)

CP = FH FM CB

Fans
CP = FH FM CB
• Correction Factors – FH, FM
– Fan Head Factor, FH:
Refer to Fan Head FH @ Table 22.24 Pg. 566
𝑷 𝒗𝟐
Recall: 𝑯𝒆𝒂𝒅 = +
𝝆𝒈 𝟐𝒈

Fans
CP = FH FM CB
• Correction Factors – FH, FM
– Fan Material Factor, FM:
Refer to Pg. 566

Fans: Additional Calculation

• Power Consumption of Fans
PC = PB / ηM = QHt/(6350 ηF ηM)
where: PC is total power consumption in hp
Eqn 22.29,
PB is fan brake horsepower in Bhp pg567
Q is inlet gas flowrate in ACFM
Ht is change in pump head in inches H2O
ηF is fan efficiency
• Mainly Dynamic/Velocity Change (ηF = 0.4)
• Mainly Static/Pressure Change (ηF = 0.6)
• Mixture of both (ηF = 0.7)
ηM is motor efficiency, usually 0.9
For more accuracy, use PB to estimate ηM (Eqn22.18

Pg562), where PB = QHt/(6350 ηF )
General Steps in Calculating CP for Fans

1. Change vol. flowrates (Q) to ACFM, pressure (P) to lb/ft2 or psia
if necessary, temperature to oR (shown in working session 2)
(Useful conversions: 1atm = 14.7psi = 2116.8 lb/ft2 and 1psi = 144 lb/ft2)
2. Calculate density (ρ) based on ideal gas assumption by using the
equation ρ = (P (psia) *MW)/(R*T). Convert your answer to lb/ft3.
Use ideal gas constant R = 10.73159 ft3psi/(oR lb-mol)
3. Determine total Head Change, Ht, where
H (ft lbf/lbm) = [∆P (lb/ft2) /ρ (lb/ft3)] + [v2 / (2gc)]
4. Change Ht to in. H2O (Conversion: 1 ft lbf/lbm = 0.01237 in. H2O)
5. Based on Q, Ht & dust conditions, select fan of choice
6. Calculate CP for selected fan:
a. Determine Size Factor, S, of fan
b. Determine Base Cost, CB, based on S
c. Find FH and FM
d. Determine CP
7. Adjust CP with appropriate price index if necessary

• A flue gas at 200°F and 740 torr, with an
average molecular weight of 313, is to
discharged at a rate of 12,000 standard cubic
feet per minute (SCFM) at 60°F and 1 atm to
a pressure of 768 torr in a duct where the
velocity , V will be 150 ft/s. Calculate the
actual inlet flow rate in cubic feet per minute
(ACFM) and the power consumption, Pc .
Select a suitable fan and estimate the
purchase cost, Cp for CE=550

Working Session 2 Solution

1. Calculate flowrate, Q in ACFM
• Note : Temperature must in °R unit and Pressure must in
psia.
𝑇𝑎 𝑃𝑎
Q (ACFM) = SCFM( )( )
𝑇𝑠 𝑃𝑠
𝑇𝑎 = 200°F + 460 = 660°R
𝑇𝑠 = 60°F + 460 = 520°R
14.7 𝑝𝑠𝑖𝑎
𝑃𝑎 = 740 torr x = 14.313 psia
760 𝑡𝑜𝑟𝑟
𝑃𝑎 = 760 torr x 760 𝑡𝑜𝑟𝑟 = 14.7 psia
660°R 14.313 psia

Q (ACFM) = 12,000( )( ) = 14830 ACFM
520°R 14.7 psia

2. Calculate dynamic head
Since we assume the inlet velocity equals to zero,
2 𝑓𝑡2
𝑉2 150 ( 2 )
Dynamic head = = 𝑠
𝑙𝑏𝑚.𝑓𝑡 = 349 ft.lbf/lbm
2𝑔𝑐 2 32.2 ( )
𝑙𝑏𝑓.𝑠2


3. Calculate pressure head
Density from ideal gas law = 0.0644 lbm/𝒇𝒕𝟑
∆𝑃
Pressure head =
𝜌
= 0.0644 𝑙𝑏𝑚/𝑓𝑡 3 ×
768−740 𝑡𝑜𝑟𝑟 1 𝑎𝑡𝑚
760 𝑡𝑜𝑟𝑟
×
1 𝑎𝑡𝑚
×
144 𝑖𝑛2
1 𝑓𝑡 2
×
1 𝑙𝑏𝑓/𝑖𝑛2
1 𝑝𝑠𝑖𝑎
= 1211 ft.lbf/lbm of gas


4. Total head = 1211 ft.lbf/lbm + 349 ft.lbf/lbm
= 1560 ft.lbf/lbm
= 19.3 in. H2O
5. Calculate power consumption, Pc

When ƞ𝐹 = 0.60 ( static head predominant) and
ƞ𝑀 = 0.90,
14,830 (19.3)
Pc = = 𝟖𝟑. 𝟓 𝑯𝒑
6,350 0.60 (0.90)


6. Selecting suitable fans
With Q = 14,830 ACFM, and Ht = 19.3 in H20
Also, flue gas is dust-laden gas


7. Calculate purchase cost
Correction factors  FH = 1.45, FM = 1.0,
CE = 550/500
550
CP = 1.45 ( )exp{12.1678 -1.31363[ln 14,830] +
500
0.09974 [ln (14,830)]2}
= $ 10,080

Blowers
• Blowers give compression ratios up to 2
• There are 2 main industrial blowers:
– Multistage CENTRIFUGAL Blowers

• Or known as ‘Centrifugal Blowers’
– ROTARY Positive Displacement Blowers

• Or known as ‘Straight-Lobe Blowers’

Blowers
Centrifugal Blowers Straight-Lobe Blowers

Blowers ICFM: Inlet ACFM
Multistage Centrifugal Rotary positive-displacement

(straight-lobe blower)
• Operate at higher speeds & o Most common rotary blower are
discharge pressure straight-two-lobe (Root) blower
• Operating ranges: 100 – 50000 ICFM o Operating ranges: 20 – 50000 ICFM
• Mechanical efficiency, ƞ𝐵 = 70 - 80% o Mechanical efficiency, ƞ𝐵 = 50 - 70%
(high efficiency only for
compression ratios 1.2 - 1.3, for 1.3 -
2.0 efficiency falls off rapidly)
• Deliver a smooth flow rate o Deliver a pulsing flow
• Varies volumetric flow rate with o Delivers a fixed volumetric flow rate
changes in inlet / discharge pressure with varying inlet & outlet pressures
• Application: Widely used to supply air o Application: useful for pneumatic
to stripper, dryers and combustion conveying and other applications
devices with fixed volumetric flow rates
• Blowers driven by motor /direct drive o Blowers driven by belt / chain drive

Blowers
Purchase Costs for Blowers:

CP = FM CB
where: Eqn 22.31,
FM is blower material correction factor pg568
CB is base cost

Blowers
CP = FM CB
– Size Factor: Blower Power Consumption (PC)
S = PC = PB / ηM
where: PC is blower power consumption in hp Eqn 22.29,
pg567
**PB is blower brake horsepower in hp,
calculable by Eqn 22.30
**ηM is motor efficiency, usually 0.9 or

Blowers
CP = FM CB
**Steps to calculate PB and ηM ???
1. Identify Inlet Flowrate, Q (ACFM); Inlet & Outlet
Pressures, PI & PO (psia).
2. Identify Blower Efficiency, ηB (Slide #73 / Pg567)
3. Identify heat capacity ratio, k (CP/CV)
• Air & diatomic gases  k = 1.4
• Monoatomic gases  k = 1.67
Continued……

Blowers
CP = FM CB
**Steps to calculate PB and ηM ???
4. Calculate Blower Brake Horsepower, PB :
Eqn 22.30,
pg567

Eqn 22.18,
ηM = 0.80 + 0.0319 lnPB – 0.00182 (lnPB)2 pg562
(Only valid for PB range of 1 – 1500 Bhp, else assume ηM as 0.90)

Blowers
CP = FM CB
– Base Cost for Blowers:
Centrifugal (Turbo) Blower (valid from PC = 5 to 1000 hp)
Eqn 22.32,
CB = exp{6.8929 + 0.7900 lnPC} pg568
Rotary Straight Lobe Blower (valid from PC = 1 to 1000 hp)
Eqn 22.33,
CB = exp{7.59176 + 0.79320lnPC - 0.0129 [lnPC]2} pg568
OR
Refer to Overall Blower Cost Curve @ Fig. 22.8 Pg. 568

Base Cost Curve (for all 2 types of blowers)

CP = FM CB

Blowers
CP = FM CB
– Blower Material Factor, FM, for materials other than
cast iron:
Refer to Pg. 566 (Same as Fans)
Aluminium FM = 0.60
(Additional material @ Pg. 568)

General Steps in Calculating CP for Blowers

1. Change flowrates (Q) to ACFM; inlet, outlet pressures (P) to
psia (Useful conversions: 1atm = 14.7psi = 2116.8 lb/ft2 and 1psi = 144 lb/ft2)
2. Based on Q, select blower of choice
3. Identify ηB according to selected blower
4. Calculate PB based on Q, PI, PO, k, ηB, then calculate ηM based
on PB
5. Calculate PC based on PB and ηM, and check whether the
calculated PC falls into the selected blower range. If not, try
another blower
6. Calculate CP for selected blower:
a. Determine Base Cost, CB, based on S, i.e. PC
b. Find FM
c. Determine CP

Compressors
• Compressors give compression ratios greater
than 2
• There are 3 main industrial compressors:
– Double-acting crosshead RECIPROCATING
compressor
• Or known as ‘Reciprocating Compressor’
– Multistage CENTRIFUGAL compressor
• Or known as ‘Centrifugal Compressor’
– Rotary twin-SCREW compressor
• Or known as ‘Screw Compressor’

Compressors
• Compressors may be driven by electric motor
(ƞ = 95% *), steam turbine (ƞ = 65% *) or gas
turbine (ƞ = 35% *)
*efficiency at 1,000 Hp
• Available up to 20,000 Hp
• For application below 200 Hp, electric motor
are used almost exclusively

Compressors
Centrifugal
Compressor
Reciprocating Screw
Compressor Compressor

Compressors
Reciprocating compressor Centrifugal compressor Screw compressor
• Widest range pressure: • Can deliver pressures • Have the smallest

vacuum to 100,000 psig up to 5,000 psig pressure range: up to
400 psig
• Narrowest range of • Largest range flow • Flow rate: 800 –
flow rate, from 5 – rate, from 1,000 – 20,000 ACFM
7,000 ACFM 150,000 ACFM
• Power: up to 20,000 Hp • Power: up to 2,000 Hp • Power: up to 6,000 per
per machine per machine machine
• Efficiency: 80 – 90% • Efficiency: 70 – 75% • Efficiency: 75 – 85%
• Positive-displacement • Delivers a smooth flow • Positive-displacement
type rate (dependent on the type
required discharge
pressure)

Reciprocating vs Screw Compressor

• More expensive
• Larger in size
• More flexible in operation
• Accompanied in operation by larger shaking
forces that require a larger foundation and more
maintenance
• Less noisy
• Does not deliver a smooth flow rate
• Cannot tolerate the presence of liquid or solid
particles in the feed gas and consequently, must
be protected by a knock-out drum

Compressors
Purchase Costs for Compressors:

CP = FD FM CB
where: Eqn 22.35,
FD is compressor drive correction factor pg569
FM is compressor material correction factor
CB is base cost

Compressors
CP = FD FM CB
– Size Factor: Compressor Power Consumption (PC)
S = PC = PB / ηM
where: PC is compressor power consumption in hp Eqn 22.29,
pg567
**PB is compressor brake horsepower in hp,
calculable by simulation software
**ηM is motor efficiency, usually 0.9 or
Note! Compressors usually involve high pressure gases, where ideal gas law do
not apply. Hence simulation software (with real gas equation of state) is
used to estimate PB.
Preliminary crude estimate of PB can be done by using Eqn22.30 Pg 567.

Compressors
CP = FD FM CB
**Steps to calculate PB (crude estimate) and ηM ???
1. Identify Inlet Flowrate, Q (ACFM); Inlet & Outlet
Pressures, PI & PO (psia).
2. Identify Compressor Efficiency, ηC (Slide #85 / Pg569)
3. Identify heat capacity ratio, k (CP/CV)
• Air & diatomic gases  k = 1.4
• Monoatomic gases  k = 1.67
Continued……

Compressors
CP = FD FM CB
**Steps to calculate PB (crude estimate) and ηM ???
4. Calculate Compressor Brake Horsepower, PB :
Eqn 22.30,
ηC pg567

Eqn 22.18,
ηM = 0.80 + 0.0319 lnPB – 0.00182 (lnPB)2 pg562
(Only valid for PB range of 1 – 1500 Bhp, else assume ηM as 0.90)

Compressors
CP = FD FM CB
**Steps to calculate PB (true value) and ηM ???
6. Accurate estimation of PB :
• Use Simulation Software (e.g. ASPEN PLUS) to obtain
REAL PB value of compressor, then use Eqn 22.18 Pg562
to estimate ηM.

Compressors
CP = FD FM CB
– Base Cost for Compressors:
Centrifugal Compressor (valid from PC = 200 to 30,000 hp)
Eqn 22.36,
CB = exp{ 7.5800 + 0.80 lnPC } pg569
Reciprocating Compressor (valid from PC = 100 to 20,000 hp)
Eqn 22.37,
CB = exp{ 7.9661 + 0.80 lnPC } pg569
Screw Compressor (valid from PC = 10 to 750 hp)
Eqn 22.38,
CB = exp{ 8.1238 + 0.7243 lnPC } pg569
OR
Refer to Overall Compressor Cost Curve @ Fig. 22.9 Pg. 570
Base Cost Curve (for all 3 types of compressors)

CP = FD FM CB

Compressors
CP = FD FM CB
• Correction Factors – FD, FM
– Compressor Drive Factor, FD, for compressor drive
other than electric motors:
Refer to Pg. 569
Electric Motor Drive  FD = 1.0

Steam Turbine Drive  FD = 1.15
Gas Turbine Drive  FD = 1.25

Compressors
CP = FD FM CB
• Correction Factors – FD, FM
– Compressor Material Factor, FM, for compressor
material other than carbon steel:
Refer to Pg. 569
Carbon Steel  FM = 1.0

Stainless Steel  FM = 2.5
Nickel Alloy  FM = 5.0

Compressors: Additional Calculation

• Compressors operate under isentropic, not
isothermal conditions  Tempout ≠ Tempin
• Isentropic Exit Temperature of Compressors:
Eqn 22.34,
pg569
where: TI, TO is inlet, outlet temperature in K respectively

PI, PO is inlet, outlet pressures in any units resp.
k is heat capacity ratio of gas (CP/CV)
ηC is compressor efficiency, from slide #85 / Pg569

General Steps in Calculating CP for Compressors

1. Change flowrates (Q) to ACFM; inlet, outlet pressures
(P) to psia
(Useful conversions: 1atm = 14.7psi = 2116.8 lb/ft2 and 1psi = 144 lb/ft2)
2. Based on Q and PO, select compressor of choice
3. Calculate outlet temp., TO, to determine whether the 400
oF temperature limit is exceeded, if yes, use multiple
stages
4. Repeat Steps 3 – 5 of Blower Calculation General Steps
5. Calculate CP for selected blower:
a. Determine Base Cost, CB, based on S, i.e. PC
b. Find FD and FM
c. Determine CP

Part 4
Heat Exchangers
Heat Exchangers
Heat Exchangers
Usage Heating, cooling, condensing, and
vaporizing process streams
Types • Shell-and-tube
Main Focus
• Double-pipe
• Air-cooled fin-fan
• Compact heat exchanger
• For A < 200 ft², choose double-pipe HE.

• For A > 200 ft², choose shell-and-tube HE.
• For non-demanding application, choose compact
HE.
Heat Exchangers
Shell-and-Tube Heat Exchanger

• Geometrical variables:
• Tube diameter, wall thickness, length, spacing &
arrangement
• Baffle type and spacing
• No. of tube and shell passes
• Fixed-head, floating-head, U-tube & kettle design
• HE surface area (A) – Refers to outside surface

area of the tubes in ft²
- Range: 150 – 12,000 ft²
• Correction factors – Pressure, materials,
tube-length
Heat Exchangers

• Type of heads:
• Floating head
• Fixed head
• U-tube
• Kettle vaporizer

Heat Exchangers
Purchase Costs for Shell-and-Tube HE:

CP = FP FM FL CB
where: Eqn 22.43,
FP is HE shell-side pressure correction factor pg571
FM is HE material correction factor
FL is HE tube length correction factor
CB is base cost

Heat Exchangers

CP = FP FM FL CB
– Size Factor: HE Surface Area (A)
S=A
where: A is in squared feet (ft2)
– Base Cost for Shell-and-Tube HE:

Floating Head
Eqn 22.39,
CB = exp{11.667 – 0.8709 lnA + 0.09005 [lnA]2} pg571
Fixed Head
Eqn 22.40,
CB = exp{11.0545 - 0.9228 lnA + 0.09861 [lnA]2} pg571

Heat Exchangers

CP = FP FM FL CB
– Base Cost for Shell-and-Tube HE (…Continued):
U-Tube
Eqn 22.41,
CB = exp{11.147 – 0.9186 lnA + 0.09790 [lnA]2} pg571
Kettle Vaporizer
Eqn 22.42,
CB = exp{11.967 – 0.8709 lnA + 0.09005 [lnA]2} pg571
OR
Refer to Overall Shell-and-Tube HE Cost Curve @
Fig. 22.10 Pg. 571

Heat Exchangers
Base Cost Curve (for all 4 types of Shell-and-Tube HE)
CP = FP FM FL CB
*CE index = 500

Heat Exchangers

CP = FP FM FL CB
• Correction Factors – FP, FM, FL
– HE Shell-side Pressure Factor, FP, for pressure
other than 100 psig:
FP = 0.9803 + 0.018 (P/100) + 0.0017 (P/100)2 Eqn 22.45,

where: P is shell-side pressure in psig (psia – 14.7) pg571
* Valid for range of 100psig < P < 2000psig

Heat Exchangers

CP = FP FM FL CB
– HE Material Factor, FM, for non-carbon steel:
Eqn 22.44,
pg571
FM = a + (A/100)b
where:
A is HE surface area in ft2
a, b are constants from
Table 22.25 Pg. 571

Heat Exchangers

CP = FP FM FL CB
– HE Tube Length Factor, FL, for tube lengths other
than 20 ft:
Refer to Pg. 571

Heat Exchangers
Double-Tube Heat Exchanger

• HE Surface Area, A, is based on outside
surface area of the inner pipe.
• For A < 200 ft²and as low as 2 ft²

Heat Exchangers
Purchase Costs for Double-Tube HE:

CP = FP FM CB
where: Eqn 22.47,
FP is HE shell-side pressure correction factor pg572
FM is HE material correction factor
CB is base cost

Heat Exchangers

CP = FP FM CB
– Size Factor: HE Surface Area (A)
S=A
where: A is in squared feet (ft2)
– Base Cost for Double-Tube HE:

Eqn 22.46,
CB = exp{ 7.1460 + 0.16 lnA } pg572
OR
Refer to Double-Tube HE Cost Curve @ Fig. 22.11
Pg. 572

Heat Exchangers
Base Cost Curve (for Double-Tube HE)

CP = FP FM CB
*CE index = 500

Heat Exchangers

CP = FP FM CB
• Correction Factors – FP, FM
– HE Tube Pressure Factor, FP, for pressure other
than 600 psig:
FP = 0.8510 + 0.1292 (P/600) + 0.0198 (P/600)2 Eqn 22.48,

where: P is tube pressure in psig (psia – 14.7) pg572

Heat Exchangers

CP = FP FM CB
– HE Material Factor, FM :
Refer to Pg. 572
Both Carbon Steel Pipes  FM = 1.0

Outer Pipe: Carbon Steel; Inner Pipe: Stainless Steel  FM = 2.5
Both Stainless Steel Pipes  FM = 3.0

Heat Exchangers
General Steps in Calculating CP for Heat Exchangers

1. Change heat duty (Q) to Btu/hr; inlet, outlet temperatures (TI,
TO) at both tubes / shell and tube to oF ; and pressures at both
tubes / shell and tube to psig
2. Calculate log mean temp. difference in oF, i.e.
∆TM = (∆Thot side - ∆Tcold side) / ln (∆Thot side / ∆Tcold side)
3. Estimate overall heat transfer coefficient U in units of Btu/hr
ft2 oF using simulation or transport phenomena knowledge
4. Calculate HE Area, A, in ft2 by using formula A = Q/(U ∆TM )
5. Select HE of choice and propose suitable design pressure P,
where P > current pressures at both tubes / shell and tube
6. Calculate CP for selected HE:
a. Determine Base Cost, CB, based on S, i.e. A
b. Calculate FP based on P and find FM & FL where necessary
c. Determine CP

Heat Exchangers

In Section 5.3, a toluene hydrodealkylation process is
synthesized. Material- and energy-balance calculations on that
process give a combined feed to the hydrodealkylation reactor
of 5,802 lbmol/hr, containing mainly 35 vol% hydrogen, 58 vol%
methane, and 7 vol% toluene, at 127.6 ˚F and 569 psia. This
stream is heated to 1,000 ˚F in a heat exchanger by 6,010
lbmol/hr of quenched reactor effluent (which also contains a
significant percentage of hydrogen), entering the exchanger at
1,150 ˚F and 494 psia, and exiting at 364.2 ˚F and 489 psia.
The calculated heat duty, Q, is 69,360,000 Btu/hr. Estimate
the area of the exchanger and the f.o.b. purchase cost at a CE
index of 550.

Heat Exchangers

Step 1:
∆𝑇1 −∆𝑇2
Calculate ∆𝑇𝑀 using formula ∆𝑇𝑀 = ∆𝑇1
𝑙𝑛
∆𝑇2
150℉ − 236.6℉
∆𝑇𝑀 = = 190.02℉
150℉
𝑙𝑛
236.6℉
Heat Exchangers

Step 2:
Determine A using Q=UA∆𝑇𝑀
𝐵𝑡𝑢
Assume 𝑈 = 50 ℎ𝑟.𝑓𝑡 2 .℉
𝑄 69,360,000 𝐵𝑡𝑢/ℎ𝑟
𝐴= =
𝑈(∆𝑇𝑀 ) 50 𝐵𝑡𝑢 (190.02℉)
ℎ𝑟. 𝑓𝑡 2 . ℉
𝐴 = 𝟕𝟑𝟎𝟎𝐟𝐭 𝟐

Heat Exchangers

Step 3:
Decide type of HE, design pressure, and material.
• 𝐴 = 7300𝑓𝑡 2 (> 200 ft²), choose shell-and-tube HE
with 20-ft long tube
• Pressure on both the shell and tube sides > 500 psig,
choose design pressure of 700 psig
• Temperature is as high as 1000 to 1150℉,

– Carbon steel cannot be used
– Choose stainless steel

Heat Exchangers

Step 4:
Calculate 𝐹𝑃 , 𝐹𝑀 , 𝐹𝐿 𝑎𝑛𝑑 𝐶𝐵
From Eqn 22.39:

2
𝐶𝐵 = exp{11.667 − 0.8709 ln 7300 + 0.09005 ln 7300 }
𝐶𝐵 = $𝟔𝟐𝟔𝟕𝟎. 𝟗𝟒
From Eqn 22.44 and Table 22.25, for stainless steel

0.07
7300
𝐹𝑀 = 2.70 + = 4.05
100

Heat Exchangers

Step 4:
Calculate 𝐹𝑃 , 𝐹𝑀 , 𝐹𝐿 𝑎𝑛𝑑 𝐶𝐵
From pg 571, for 20 ft long,

𝐹𝐿 = 1.00
For pressure of 700 psig, Eqn 22.45,

2
700 700
𝐹𝑃 = 0.9803 + 0.018 + 0.0017 = 1.19
100 100

Heat Exchangers

Step 5:
Calculate 𝐶𝑃
• From Eqn 22.43, 𝐶𝑃 = 𝐹𝑃 𝐹𝑀 𝐹𝐿 𝐶𝐵
At CE index of 550, the f.o.b. purchase cost is

550
𝐶𝑃 = 1.19 4.05 (1.00) 62670.94 = $𝟑𝟑𝟐, 𝟐𝟒𝟔. 𝟖𝟓
500

Part 5
Fired Heaters
Fired Heaters
Fired Heaters (also known as Furnace)
• Function: To heat and elevate temperature

beyond steam temperature
• Uses fuel oil or gas
• To use fired heaters, heat duty (Q) should be
in range :
– 10,000,000-340,000,000 Btu/hr
– 3000-100,000 kJ/s
– 3–100 MW
• Carbon steel tubing suitable for T=1100⁰C and
P=500psig
• Thermal Efficiency = 70% - 90%
Fired Heaters
Fired Heaters
Purchase Costs for Fired Heaters:

CP = FP FM CB
where: Eqn 22.50,
FP is fired heater pressure correction factor pg573
FM is fired heater material correction factor
CB is base cost

Fired Heaters
Fired Heaters
CP = FP FM CB
– Size Factor: Fired Heater Heat Duty (Q)
S=Q
where: Q is in Btu/hr
(valid range: 10-500 mil Btu/hr)
– Base Cost for Fired Heaters:
Eqn 22.49,
CB = exp{ 0.32325 + 0.766 lnQ } pg573
OR
Refer to Fired Heaters Cost Curve @ Fig. 22.12 Pg. 573

Fired Heaters
Base Cost Curve (for Fired Heaters)

CP = FP FM CB
*CE index = 500

Fired Heaters
Fired Heaters
CP = FP FM CB
– Fired Heater Pressure Factor, FP, for pressure
other than 500 psig:
FP = 0.986 + 0.0035 (P/500) + 0.0175 (P/500)2 Eqn 22.51,

where: P is fired heater pressure in psig (psia – 14.7) pg573

Fired Heaters
Fired Heaters
CP = FP FM CB
– Fired Heater Material Factor, FM :
Refer to Pg. 573
Carbon Steel  FM = 1.0

Cr-Mo (molybdenum) Alloy  FM = 1.4
Stainless Steel  FM = 1.7

Fired Heaters
General Steps in Calculating CP for Fired Heaters

1. Change heat duty (Q) to Btu/hr; temperature
(T) to oF ; and pressure (P) to psig
2. Determine whether Q falls within the range of
10 to 340 million Btu/hr; if yes, fired heaters
can be used
3. Calculate CP for fired heater:
a. Determine Base Cost, CB, based on S, i.e. Q
b. Calculate FP based on P and find FM
c. Determine CP
4. Adjust CP with appropriate price index if
necessary
Fired Heaters

Further heating combined feed from Example
22.10 (35 vol% hydrogen, 58 vol% methane, and
7 vol% toluene) from 1000˚F to 1200˚F in a
fired heater at a CE index of 550.
Q = 18,390,000 Btu/hr
Design pressure of tube = 700psig
Fm due to significant conc H₂ = 1.7(stainless
steel)

Fired Heaters

𝐶𝐵 = 𝑒 0.32325+0.766(𝑙𝑛18390000) = $507,100
2
700 700
𝐹𝑃 = 0.986 − 0.035 + 0.0175 = 1.015
500 500
550
𝐶𝑃 = 1.015 1.7 507,100 = $962,500
500

Part 6
Pressure Vessels,
Distillation Towers,
Absorption and Stripping
Pressure Vessels and Towers
Horizontal Pressure Vessel Vertical Pressure Vessel

a.k.a Towers

Pressure Vessels
Application:
• Reflux drum
• Flash drum
• Knock-out drum
Di
• Settlers
• Chemical reactors
L • Mixing vessels
• Vessels for fixed-
bed adsorption
• Storage drum

Towers
Application:
• Distillation
• Absorption
• Stripping

Purchase Costs for Vessels or Towers:

CP = FM CV + CPL
where: Eqn 22.52,
FM is vessel/tower material correction factor pg574
CV is base cost for vessel/tower
CPL is cost for platforms and ladders
CPL is an auxiliary/additional cost

(not in general form of CP)


CP = FM CV + CPL
• Base Cost (CV) Calculation
– Size Factor: Vessel/Tower Weight (W)
S = W = π (Di + ts) (L + 0.8Di) ts ρ
where: W is vessel/tower weight in lb Eqn 22.59,
pg575
Di is internal diameter of vessel
L is tangent-to-tangent length of vessel
ρ is density of carbon steel, i.e. 490 lb/ft3 or 0.284
lb/in3
**ts is shell thickness (assume thickness is uniform
throughout), calculable by many steps
**The calculation steps for ts will be very long and

tedious. Don’t get confused and stay focused!

CP = FM CV + CPL
• CV Calculation (…Continued)
** tS Calculation – Important Terminologies:
• tS : Final Shell/Wall Thickness
• tV : Average Wall Thickness
• tP : Required Thickness to Withstand Internal Pressure
• tW : Required Thickness to Withstand Wind / Earthquakes
• tC : Additional thickness for corrosion allowance
• Po, Pd : Vessel/Tower Operating, Design Pressure
• To, Td : Vessel/Tower Operating, Design Temperature


CP = FM CV + CPL
** tS Calculation – General Overall Relation:
tS = tV + tC
Not in
where: textbook
tS is final shell thickness in inch
tV is average thickness in inch
tC is thickness for corrosion allowance in inch


CP = FM CV + CPL
tS = tV + tC
** tS Calculation – Horizontal Vessel:
• For horizontal vessels, the walls only need to withstand
internal pressure, hence tV = tP
tP = Pd Di / (2SE – 1.2Pd)
where: Eqn 22.60,
tP is required thickness to withstand internal pressure in inch pg575
Pd is design pressure in psig (psia – 14.7)
Di is vessel internal diameter in inch
S is maximum allowable stress @ design temp. Td in psi
E is weld efficiency, either 0.85 or 1.0


CP = FM CV + CPL
tS = tV + tC
tV = tP = PdDi/
• tP  Design Pressure, Pd :
(2SE – 1.2Pd)
Refer to Pg. 575
For PO = 0 - 5psig For PO > 1000psig

 Pd = 10 psig  Pd = 1.1 PO
For PO = 10 - 1000 psig 

Eqn 22.61,
Pd = exp {0.60608 + 0.91615 pg575
lnPO +0.0015655 [lnPO]2}


CP = FM CV + CPL
tS = tV + tC
tV = tP = PdDi/
• tP  Design Temperature, Td :
(2SE – 1.2Pd)
Refer to Pg. 575
Td = TO + 50 oF
All temperature units are in oF
If -20˚F < Td < 650˚F If 650˚F < Td < 900˚F

Use Carbon Steel Use Low Alloy Steel


CP = FM CV + CPL
tS = tV + tC
tV = tP = PdDi/
• tP  Maximum Allowable Stress, S :
(2SE – 1.2Pd)
Design Refer to Pg. 575

Temp,
Td


CP = FM CV + CPL
tS = tV + tC
tV = tP = PdDi/
• tP  Weld Efficiency, E :
(2SE – 1.2Pd)
Refer to Pg. 575
For tP ≤ 1.25 inch, use E = 0.85

For tP > 1.25 inch, use E = 1.0
Note !!!
At this point, tP is not calculated yet. Make a guess of E=1.0.
After tP is calculated from equation 22.60, check back
whether tP > 1.25 inch; if yes, proceed; if no, use E = 0.85.


CP = FM CV + CPL
tS = tV + tC
• If tV = tP calculated is too small, i.e. less tV = tP = PdDi/
(2SE – 1.2Pd)
than min wall thickness at given Di, we
need to use the minimum wall thickness as tP :
Refer to
Pg. 575


CP = FM CV + CPL
tS = tV + tC
** tS Calculation – Vertical Tower:
• For vertical towers, the walls need to withstand both internal
pressure AND wind/earthquake, thus tV = 0.5 (2tP + tW)
• tP can be calculated by Eqn 22.60 pg 575 (Follow Slides 141-146)
• tW can be calculated as follows:
tW = 0.22 (Do +18) L2 / (SDo)2

Eqn 22.62,
where:
pg576
tW is required thickness to withstand wind/earthquake in inch
Do is vessel external diameter in inch, assume Do= Di
L is tangent-to-tangent length in inch
S is maximum allowable stress @ design temp. Td in psi


CP = FM CV + CPL
tS = tV + tC
** tS Calculation – Vertical Tower:
• tW  Outer Diameter, Do (may require iteration): tW = 0.22 (Do
+18) L2 /(SDo)2
Do = Di + 2ts
where:
Note !!! ts is final shell thickness in inch
At this point, tS is not calculated yet. Assume Do = Di.

Calculate tP (Eqn22.60), tW (Eqn22.62),tV (tV=tP+tW), tC (1/8
inch, discussed later) and get ts (ts=tV+tC) followed by real
Do (Do = Di + 2tS). Check whether error > 5%, if yes repeat
whole process (iterative). Usually error is small if Di is big

CP = FM CV + CPL
tS = tV + tC
** tS Calculation – Vacuum Vessel:
• For vertical towers, the walls need to withstand vacuum to
prevent implosion, thus tV = tE + tEC Completely different
from normal vessel !
• tE can be calculated as follows:
tE = 1.3 Do [(Pd L) / (EM Do)] 0.4 Eqn 22.63,

where:
pg576
tE is required thickness to withstand vacuum in inch
Do is vessel external diameter in inch, assume Do = Di
L is tangent-to-tangent length of vessel in inch
Pd is design pressure in psig
EM is modulus of elasticity of wall @ Td in psi


CP = FM CV + CPL
tS = tV + tC
• For vertical towers, the walls need to withstand vacuum to
prevent implosion, thus tV = tE + tEC Completely different
from normal vessel !
• tEC can be calculated as follows:
tEC = L (0.18 Di – 2.2) x 10-5 – 0.19 Eqn 22.64,

where: pg576
tEC is tE correction in inch
L is tangent-to-tangent length of vessel in inch


CP = FM CV + CPL
tS = tV + tC
• tE Elasticity Modulus, EM : tE = 1.3 Do [(Pd
L) / (EM Do)] 0.4
Refer to
Table @
Pg 576


CP = FM CV + CPL
tS = tV + tC
• tE  Outer Diameter, Do (may require iteration): tE = 1.3 Do [(Pd
L) / (EM Do)] 0.4
Do = Di + 2ts
where:
Note !!! ts is final shell thickness in inch
At this point, tS is not calculated yet. Assume Do = Di.

Calculate tP (Eqn22.60), tW (Eqn22.62),tV (tV=tP+tW), tC (1/8
inch, discussed later) and get ts (ts=tV+tC) followed by real
Do (Do = Di + 2tS). Check whether error > 5%, if yes repeat
whole process (iterative). Usually error is small if Di is big

CP = FM CV + CPL
tS = tV + tC
** tS Calculation – Final Correction:
• tC is allocated as a thickness correction for corrosion
allowance, usually under non-corrosive conditions,
Text,
tC = 1/8 inch pg576
• Under greater corrosion conditions, tC exceeds 1/8 inch


CP = FM CV + CPL
tS = tV + tC
** tS Calculation – Thickness Roundoff:
• Metal sheets are only available at specific standard
thickness values, hence we need to round off tS to the
nearest standard thickness
• tS Roundoff Guideline (always roundoff to higher value):
Refer to
Pg. 576

Working Session 5(a)

• What metal sheet thickness should be used
for a calculated ts value of:
– 0.50 inch  0.50 inch
– 0.5899 inch  5/8 or 0.625 inch
– 15/16 inch  1.0 inch
11
–1 inch  14/8 or 1.75 inch
16
– 2.13346 inch  2.25 inch
– 1.3117 inch  11/8 or 1.375 inch

Bonus: tS Roundoff Table e.g. if
tS Roundoff (inches) tS Roundoff (inches) ts=1.28 inch
3/16 or 0.1875 1 1/4 or 1.2500

1/4 or 0.2500 1 3/8 or 1.3750 ts, roundoff
=1.375 inch
5/16 or 0.3125 1 1/2 or 1.5000
3/8 or 0.3750 1 5/8 or 1.6250
Not
7/16 or 0.4375 1 3/4 or 1.7500 available in
1/2 or 0.5000 1 7/8 or 1.8750 textbook,
pls copy
5/8 or 0.6250 2.000 down for
3/4 or 0.7500 2 1/4 or 2.25 easy ref.
7/8 or 8750 2 1/2 or 2.50

1.0000 2 3/4 or 2.75
1 1/8 or 1.1250 3.0000
Working Session 5(b)


CP = FM CV + CPL
– After tS and W are calculated, Base Cost for
Vessels /Towers :
Horizontal Vessels (Valid from W = 1000 lb to 920,000 lb)
Eqn 22.53,
CV = exp{8.9552 – 0.2330 lnW + 0.04333 [lnW]2} pg574
Vertical Vessels (Valid from W = 4200 lb to 1,000,000 lb)
Eqn 22.54,
CV = exp{7.0132 + 0.18255 lnW + 0.02297 [lnW]2} pg574
Towers (Valid from W = 9000 lb to 2,500,000 lb)
Eqn 22.57,
CV = exp{7.2756 + 0.18255 lnW + 0.02297 [lnW]2} pg575
OR
Refer to Overall Vessel Cost Curve @ Fig. 22.13 Pg. 574
Base Cost Curve (for all vessels and towers)

CP = FM CV + CPL
*CE index = 500


CP = FM CV + CPL
– Vessel/Tower Material Factor, FM :
Refer to
Materials-of-
Construction FM
@ Table22.26
Pg576


CP = FM CV + CPL
• Auxiliary Cost – CPL
– Added platforms & ladders costs, CPL :
Horizontal Vessels (For Di = 3 ft to 12 ft)
Eqn 22.53,
CPL = 2005 (Di)0.20294 pg574
Vertical Vessels (For Di = 3 to 12 ft and L = 12 ft to 40 ft)
Eqn 22.54,
CPL = 361.8 (Di)0.73960 (L)0.70684 pg574
Towers (For Di = 3 ft to 24 ft and L = 27 ft to 170 ft)
Eqn 22.57,
CPL = 300.9 (Di)0.63316 (L)0.80161 pg575
where: Di and L are in ft

General Steps in Calculating CP for Horizontal Vessels

1. Change internal diameter (Di) and tan-to-tan length (L) to both ft & inch;
operating temperatures (To) to oF ; operating pressures (Po) to psig;
density of steel (ρsteel) to 490 lb/ft3
2. Calculate CP for horizontal vessels:
a. Get Design Pressure, Pd, from Po
b. Get Design Temperature, Td, from To (Td = To + 50oF)
c. Get maximum allowable stress, S, from Td (Pg575)
d. Assume Weld Efficiency, E, as 1.0 (Pg575)
e. Calculate tP and check back assumption (d)  if violated, use E=0.85
f. Since tV=tP, tS = tP + corrosion allowance, tC, of 1/8 inch (Pg576)
g. Roundoff ts (Pg 576)
h. Using tS, Di, L and ρsteel, get W (Eqn22.59 Pg575)
i. Get base cost, CV, based on W (Eqn22.53 Pg574)
j. Find FM (Table 22.6 Pg576) and calculate CPL (Eqn22.55 Pg574)
k. Get CP based on CV, FM and CPL (Eqn22.52 Pg574)

General Steps in Calculating CP for Vertical Towers

1. Change Di and L to both ft & inch; To to oF ; Po to psig; and ρsteel to 490 lb/ft3
2. Calculate CP for vertical towers:
a. Get Design Pressure, Pd, from Po
c. Get maximum allowable stress, S, from Td (Pg575)
d. Assume Weld Efficiency, E, as 1.0 (Pg575)
e. Calculate tP and check back assumption (d)  if violated, use E=0.85
f. Assume Do = Di, and calculate tW (Eqn22.62 Pg576) and tV (tV = 0.5 (2tP + tW))
g. Get tS, where, tS = tV + corrosion allowance, tC, of 1/8 inch (Pg576)
h. Roundoff tS (Pg 576)
i. Get real Do (Do = Di + 2ts) and check whether new Do = old Do, if error > 5%,
repeat (f) to (i) with new Do
j. Using tS, Di, L and ρsteel, get W (Eqn22.59 Pg575)
k. Get base cost, CV, based on W (Eqn22.54 Pg574/ Eqn22.57 Pg575)
l. Find FM (Table 22.6 Pg576) and calculate CPL (Eqn22.56 Pg574/ Eqn22.58
Pg575)
m. Get CP based on CV, FM and CPL (Eqn22.52 Pg574)

General Steps in Calculating CP for Vacuum Vessels

1. Change Di and L to both ft & inch; To to oF ; Po to psig; and ρsteel to 490 lb/ft3
2. Calculate CP for vacuum vessels:
a. Get Design Pressure, Pd (max pressure diff between inside & outside of vessel)
c. Get tEC based on Di and L (Eqn22.64 Pg576)
d. Get Elasticity Modulus, EM, based on Td (Pg576)
e. Assume Do = Di, and calculate tE (Eqn22.62 Pg575) and tV (tV = tE + tEC,
Eqn22.65 Pg576)
f. Get tS, where, tS = tV + corrosion allowance, tC, of 1/8 inch (Pg576)
g. Roundoff tS (Pg 576)
h. Get real Do (Do = Di + 2ts) and check whether new Do = old Do, if error > 5%,,
repeat (e) to (h) with new tS
i. Using tS, Di, L and ρsteel, get W (Eqn22.59 Pg575)
j. Get base cost, CV, based on W (Eqn22.53/ Eqn22.54 Pg574/ Eqn22.57 Pg575)
k. Find FM (Table 22.6 Pg576) and calculate CPL (Eqn22.55/ Eqn22.56 Pg574/
Eqn22.58 Pg575)
l. Get CP based on CV, FM and CPL (Eqn22.52 Pg574)


A distillation column is to be used to separate iso-butane
from n-butane. The column, which is equipped with 100
sieve trays, has an inside diameter of 10 ft (120 in.) and a
tangent-to-tangent length of 212 ft (2,544 in.). Operating
conditions are 110 psia and 150 ⁰F at the bottom of the
tower and 100 psia and 120 ⁰F at the top. The material of
construction is carbon steel. The barometric pressure at
the plant location is 14.5 psia. Estimate the purchase cost
of the distillation column at a CE index of 550.
*Let’s calculate the Cp excluding the cost for plates!
Answer: Cp = $804,500
Cost Accounting and Capital Costs: Purchasing Costs

Part 7
Plates
Plates
Plates (also known as Trays)
• Plates/Trays utilized in vertical towers for

– Absorption
– Distillation
– Stripping
• Costs of plates are regarded as auxiliary

costs for vertical towers, hence:
Total CP of tray tower = FM CV + CPL + CP of plates
Previous subtopic

Plates
Plates/Trays
Purchase Costs for Plates :

CP = NT FNT FTT FTM CBT
where: Eqn 22.66,
NT is number of plates/trays pg577
FNT is tray number correction factor
FTT is tray type correction factor
FTM is tray material correction factor
CBT is base cost for trays

Plates
Plates/Trays CP = NT FNT FTT FTM CBT
• Base Cost (CBT) Calculation

– Size Factor: Tower Internal Diameter (Di)
S = Di
where: Di is in feet
– Base Cost for Trays:

Eqn 22.67,
CBT = 468 exp { 0.1739 Di } pg577

Plates
• Correction Factors – NT, FNT, FTT, FTM

– NT : Number of plates/trays
– Tray Number Factor, FNT :
Refer to Pg577
For NT > 20 For NT < 20 Eqn 22.68,

FNT = 1.0 FNT = 2.25/(1.0414NT) pg577

Plates

– Tray Type Factor, FTT, for tray types other than
sieves:
Refer to Pg577

Plates

– Tray Material Factor, FTM, for tray materials other
than carbon steel:
Refer to Pg577
where Di is tower internal diameter in ft

Plates
General Steps in Calculating CP for Tray Tower
1. Calculate CP of vertical tower based on Slide #163

2. Change Di to ft
3. Calculate CP for plates/trays:
a. Determine base cost, CBT, based on Di (Eqn22.66 Pg577)
b. Find NT, FNT (Eqn22.68 Pg577), FTT (Pg577) and calculate FTM
(Pg577) based on Di
c. Determine CP (Eqn22.52 Pg574)
4. CP for Tray Tower = CP for Vertical Tower + CP for plates/trays
5. Adjust Tray Tower CP with appropriate price index if necessary

Plates
Working Session 6: Example 22.13 Cont.

A distillation column is to be used to separate isobutane
from n-butane. The column, which is equipped with 100
sieve trays, has an inside diameter of 10 ft (120 in.) and a
tangent-to-tangent length of 212 ft (2,544 in.). Operating
conditions are 110 psia and 150 ⁰F at the bottom of the
tower and 100 psia and 120 ⁰F at the top. The material of
construction is carbon steel. The barometric pressure at
the plant location is 14.5 psia. Estimate the purchase cost
of the distillation column at a CE index of 550.
*Let’s calculate the total purchase cost by adding the

cost for plates into the Cp calculated before!
Answer: Total purchase cost = $1,097,100
Cost Accounting and Capital Costs: Purchasing Costs

Part 8
Packings
Packings
Packings
• Apart from trays, packings are also utilized in
vertical towers for
– Absorption
– Distillation
– Stripping
• Costs of packings are also regarded as

auxiliary costs for vertical towers, hence:
Total CP of packed tower = FM CV + CPL + CP of packings
Previous subtopic

Packings
Types of Packings
Dumped Packings Structured Packings
▪ Random ▪ Layers of wire mesh or
corrugated sheet

Packings
Structured Packings
Advantages Disadvantages
▪ Reduce pressure drop ▪ More expensive in
dollars per cubic foot
▪ Higher stage of packing
efficiency in terms of
reduced HETS ▪ Not normally available
in carbon steel
▪ Offer capacity in
terms of reduced
diameter

Packings
Packings
Purchase Costs for Packings:

CP = VP CPK + CDR
where: Eqn 22.69,
VP is volume of packing in ft3 pg578
CPK is base installed cost of packings
CDR is installed cost of H.P.L. distributors &
redistributors (an auxiliary cost)

Packings
Packings CP = VP CPK + CDR
• Packing Base Installed Cost (CPK)

– Base Cost for Dumped Packings (Table 22.27 Pg578):

Packings
• Packing Base Installed Cost (CPK)

– Base Cost for Structured Packings :
• Not available, can be crudely estimated as:
CPK = $ 250 / ft3 stainless steel corrugated sheet pg579

Packings
• Correction Factors – VP
– VP : Volume of Packings in cubic feet (ft3)
• Auxiliary Cost - CDR

Pg579
– High Performance Liquid Distributor and Pls copy down
Redistributor Cost, CDR : for easy ref.
CDR = 125 AT NDR

where:
AT is cross-sectional area of tower/column in ft2
NDR is no. of dis/redistributors used, NDR= [No. of feed points +
(Tower height / 20ft) ]
[Distr. should be used @ feed points, Redistr. should be used every 20ft]

Packings
General Steps in Calculating CP for Packed Tower
1. Calculate CP of vertical tower based on Slide #163

2. Change Di to ft, and calculate VP & AT in units of ft3 & ft2
3. Calculate CP for packings:
a. Determine base packing installed cost, CBT, based on type, i.e.
dumped (Table22.27 Pg578) or structured (Slide #181)
b. Calculate NDR (Slide #182) and determine CDR
c. Determine CP (Eqn22.69 Pg578)
4. CP for Packed Tower = CP for Vertical Tower + CP for packings
5. Adjust Packed Tower CP with appropriate price index if necessary

Packings

A distillation column has two sections. The one above
the feed is 14ft in inside diameter with a 20ft height,
15ft of which is packed with structured packing of the
corrugated-sheet type. The bottom section is 16ft in
diameter with a 70ft height, 60ft of which is packed
with 4 inches cascade mini rings. The column is made of
carbon steel, but both packings are of stainless steel.
The column will operate under vacuum with conditions of
55kPa and 60C at the top and 60kPa and 125C at
bottom. A total of four liquid distributors or
redistributors will be used, Estimate the f.o.b purchase
cost of the column, including installed packings,
distributors and redistributors, for CE cost index of
550. The barometric pressure is 100kPa.
Packings

Given:
Carbon steel column, Stainless steel packing
Consist of 4 liquid distributors or redistributors
Barometric pressure=100kPa
CE cost index=550
Top of tower Bottom of tower
Di=14ft (168in) Di=16ft (192in)
L=20ft L=70ft
15ft is packed with structured 60ft is packed with 4in cascade
packing of corrugated sheet type mini rings
P=55kPa P=60kPa
T=60C (140F) T=125C (257F)
Packings
Solution (Wall thickness of top section,tE)

▪ Pd=100 – 55 = 45kPa (6.5 psig)
▪ L=20 + 70 = 90ft
▪ Design temperature= 257+50 = 307F
At 307F, EM=28.9E6
▪ Assume Do=Di=14ft (168in)
Apply Eq. 22.63 (pg 576), tE = 1.01 in

Apply Eq. 22.64 (pg 576) for correction, tEC = 0.11 in
Apply Eq. 22.65 (pg 576), tV = 1.12 in
Add 1/8 in corrosion allowance = 1.245 in

Packings
Solution (Wall thickness of bottom section,tE)
▪ Pd=100 – 55 = 45kPa (6.5 psig)

▪ L=20 + 70 = 90ft
▪ Design temperature= 257+50 = 307F
At 307F, EM=28.9E6
▪ Assume Do=Di=16ft (192in)
Apply Eq. 22.63 (pg 576), tE = 1.09 in

Apply Eq. 22.64 (pg 576) for correction, tEC = 0.16 in
Apply Eq. 22.65 (pg 576), tV = 1.25 in
Add 1/8 in corrosion allowance = 1.375 in

Packings
Solution (CV of vertical tower-Top)

▪ Di=14ft (168in)
▪ ts=1.25in
▪ L=20 + 70 = 90ft (1080 in)
▪  = 0.284Ib/in3 (carbon steel)
Apply Eq. 22.59 (pg 575), W = 229100Ib
Apply Eq. 22.57 (pg 575), CV = $454800

Packings
Solution (CV of vertical tower-Bottom)

▪ Di=16ft (192in)
▪ ts=1.25in
▪ L=20 + 70 = 90ft (1080 in)
▪  = 0.284Ib/in3 (carbon steel)
Apply Eq. 22.59 (pg 575), W = 319300Ib
Apply Eq. 22.57 (pg 575), CV = $584800
For CV of entire empty tower, apply Eq. 22.70, CV =$555900

Packings
Solution (CPL for platforms and ladders-Top)

▪ L=20 + 70 = 90ft
▪ Di=14ft (168in)
Apply Eq. 22.58 (pg 575), CPL = $59000
Solution (CPL for platforms and ladders-Bottom)

▪ L=20 + 70 = 90ft
▪ Di=16ft (192in)
Apply Eq. 22.58 (pg 575), CPL = $64200
For CPL of entire empty tower, apply Eq. 22.70, CPL =$63100

Packings
Solution (Volumn of packing, VP-Top)

▪ L=20 + 70 = 90ft
▪ Di=14ft (168in)
Apply cylinder volume D^2(L)/4, VP = 2310ft3
Solution (Volumn of packing, VP-Bottom)

▪ L=20 + 70 = 90ft
▪ Di=16ft (192in)
Apply cylinder volume D^2(L)/4, VP = 12060ft3

Packings
Solution (Installed cost, CPK-Top)

▪ Structured packing of corrugated sheet type
CPK approximate = $250/ft3
Solution (Installed cost, CPK-Bottom)

▪ From Table 22.27 (pg 578), find 4in stainless
steel cascade mini rings
CPK = $52/ft3

Packings
Solution (Installed cost of high performance

liquid distributors and redistributors, CDR)
▪ Assume one distributor at the feed (diameter = 14ft),
the other three are redistributor (diameter = 16ft)
▪ CDR approximate = $125/ft2
Apply circle surface area D^2/4,

A (Distributor) = 154 ft2
A (Redistributor) = 201 ft2
CDR total = 1 unit(154ft2)($125ft2) + 3 units(201ft2)($125ft2)

= $94600

Packings
Solution (Total purchase cost, CP)

Variable Value
FM of carbon steel column 1.0
(Table 22.26, pg576)
CV $ 555900
CPL $ 63100
VP Top – 2310 ft3
Bottom – 12060 ft3
CPK Top - $250/ft3
Bottom - $52/ft3
CDR $94600
Apply Eq. 22.69 (pg 578), CP = $ 1918220

Packings
But..
CE index (question) = 550
CPK given is indexed to CE = 500
So…
Cp = 550/500($1918220)
= $2110042
Final answer
= $ 2110042

Part 9
Bookmark/
Indexing Guide
Bookmark/ Indexing Guide
Pumps and Motors (1)

Eqn. / Tab./ Page
Item
Fig. / Text No.
Centrifugal Pump – Overall CP Eqn 22.15 561
Centrifugal Pump – Size Factor Eqn 22.13 560
Eqn 22.14
Centrifugal Pump – CB 561
Fig 22.3
Centrifugal Pump - FT Tab 22.20 561
Centrifugal, Rotary Gear Pump - FM Tab 22.21 562
Rotary Gear, Reciprocating Pump – Overall CP Eqn 22.22 563
Eqn 22.21
Rotary Gear Pump – CB 563
Fig 22.5
Reciprocating Pump – Size Factor (PB) Eqn 22.16 561
Eqn 22.23 563
Reciprocating Pump – CB
Fig 22.6 564

Pumps and Motors (2)

Eqn. / Tab./ Page
Item
Fig. / Text No.
Reciprocating Pump – FM Text 564
Motors – Overall CP Eqn 22.20 562
Motors – Size Factor (PC) Eqn 22.16 561
Motors – PC - ηP Eqn 22.17 562
Motors – PC - ηM Eqn 22.18 562
Eqn 22.19
Motors - CB 562
Fig 22.4
Motors - FT Tab 22.22 563

Fans, Blowers and Compressors (1)

Eqn. / Tab./ Page
Item
Fig. / Text No.
Total Head Slide #46 -
Fans – Operating Range Selection Tab 22.23 566
Fans – Overall CP Eqn 22.24 566
Eqn 22.25,
566,
Fans - CB 26, 27, 28,
567
Fig 22.7
Fans - FH Tab 22.24 566
Fans - FM Text 566
Fans, Blowers, Compressors - PC Eqn 22.29 567
Blowers – Overall CP Eqn 22.31 568
Blowers, Compressors – PC - PB Eqn 22.30 567
Blowers, Compressors – ηM Eqn 22.18 562

Fans, Blowers and Compressors (2)

Eqn. / Tab./ Page
Item
Fig. / Text No.
Eqn 22.32,
Blowers - CB 22.33, 568
Fig 22.8
566,
Blowers - FM Text
568
Compressors – Overall CP Eqn 22.35 569
Eqn 22.36,
569,
Compressors - CB 37, 38,
570
Fig 22.9
Compressors - FD Text 569
Compressors - FM Text 569
Compressors - TO Eqn 22.34 569

Heat Exchangers
Eqn. / Tab./ Page
Item
Fig. / Text No.
Shell & Tube HE – Overall CP Eqn 22.43 571
Eqn 22.39,
Shell & Tube HE – CB 40, 41, 42 571
Fig 22.10
Shell & Tube HE – FP Eqn 22.45 571
Eqn 22.44
Shell & Tube HE – FM 571
Tab 22.25
Shell & Tube HE – FL Text 571
Double Tube HE – Overall CP Eqn 22.47 572
Eqn 22.46
Double Tube HE – CB 572
Fig 22.11
Double Tube HE – FP, FM Text 572

Fired Heaters
Eqn. / Tab./ Page
Item
Fig. / Text No.
Fired Heaters – Overall CP Eqn 22.50 573
Eqn 22.49
Fired Heaters – CB 573
Fig 22.12
Fired Heaters – FP Eqn 22.51 573
Fired Heaters – FM Text 573

Pressure Vessels and Towers (1)

Eqn. / Tab./ Page
Item
Fig. / Text No.
Vessels & Towers – Overall CP Eqn 22.52 574
Vessels & Towers – Size Factor (W) Eqn 22.59 575
Horizontal Vessels – W – tS – tP Eqn 22.60 575
Text
Horizontal Vessels – W – tS – tP - Pd 575
Eqn 22.61
Horizontal Vessels – W – tS – tP - Td Text 575
Horizontal Vessels – W – tS – tP - S Text 575
Horizontal Vessels – W – tS – tP - E Text 575
Horizontal Vessels – W – tS – Min tP Text 575
Vertical Towers – W – tS – tV – tW Eqn 22.62 576
Vacuum Vessels – W – tS – tE Eqn 22.63 576
Vacuum Vessels – W – tS – tEC Eqn 22.64 576
Pressure Vessels and Towers (2)

Eqn. / Tab./ Page
Item
Fig. / Text No.
Vacuum Vessels – W – tS – tE – EM Text Table 576
Vessels and Towers – W – tS – tC Text 576
Vessels and Towers – W – tS Roundoff Text 576
Vessels and Towers – W – tS Roundoff Table Slide #156 -
Eqn 22.53,
574,
Vessels and Towers – CV 54, 57
575
Fig 22.13
Vessels and Towers – FM Tab 22.26 576
Eqn 22.55, 574,
Vessels and Towers – CPL
56, 58 575

Plates
Eqn. / Tab./ Page
Item
Fig. / Text No.
Plates – Overall CP Eqn 22.66 577
Plates - CBT Eqn 22.67 577
Text
Plates - FNT 577
Eqn 22.68
Plates - FTT Text 577
Plates - FTM Text 577

Packings
Eqn. / Tab./ Page
Item
Fig. / Text No.
Packings – Overall CP Eqn 22.69 578
Packings – Dumped CPK Tab 22.27 578
Packings – Structured CPK Text 579
Packings – CDR
Text 579
*Copy down CDR equation for easy reference

Part 10
Exercise 22.4
Page 207
Exercise 22.4
Analysis of Problem
• To find out the Purchased Cost of…
– Column (Tower)
– Condenser (HEX)
– Reboiler (HEX)
– Reboiler Pump
– Combined Reflux and Distillate Pump
– Reflux Accumulator (Vessel)
• To estimate total bare-module cost
• To estimate total permanent investment (CTPI)

Exercise 22.4
Purchased Cost of Column (Tower)

• Information Provided
– Column inside diameter = Di = 6 ft
– Column height = L = 47 ft
– 23 sieve trays
– Operating Temp: 227℉
– Operating Pressure: 0 psig
• Design Temp = 227 + 50 = 277 ℉ pg 575

• Design Pressure: 10 psig pg 575

Exercise 22.4

• Shell Materials: grade C carbon steel pg 575
– Maximum Allowable Stress, S = 13750 psi
– Density of Carbon Steel = 490lb/ft2
• Assume a weld efficiency = E = 0.85

• Corrosion allowance = 0.125 inch

Exercise 22.4

• Calculation of tp
• Equation 22.60 pg 575

– tP = Pd Di / (2SE – 1.2Pd)
– tP = 10 (6x12) / [2 (13,750) (0.85) – 1.2 (10)]
= 0.031 in
tP is too small… Then refer to pg 575
Take tP as 5/16 = 0.3125 in

Exercise 22.4

• Calculation of tw

– tw = 0.22 (Do +18) L2 / SDo2
– tw = 0.22 (6x12 +18)(47x12) 2 / (13750x(6x12) 2)
– tw = 0.08836 in

Exercise 22.4

• Calculation of ts
ts = tv + tc
ts = 0.5(2tp + tw) + tc
ts = 0.5(2x0.3125 + 0.08836) + 0.125
ts = 0.48168 in
ts (round-off) = 0.50 in

Exercise 22.4

• Calculation of W Eq 22.59 Pg 575
• W = π (Di + ts) (L + 0.8Di) ts ρ

• W = π [6ft+(0.5in)(1/12 ft/in)]
[47ft+0.8(6ft)] × (0.5in)(1/12 ft/in)
(490 lb/ft3)
• W = 20,073 lb

Exercise 22.4

• Calculation of Cv Eq 22.57 Pg 575
• CV = exp{7.2756 + 0.18255 lnW + 0.02297

[lnW]2}
• CV = exp{7.2756 + 0.18255[ln(20,073)] +
0.02297[ln(20,073)]2} = $ 84,009

Exercise 22.4

• Calculation of CPL Eq 22.58 Pg 575
• CPL = 300.9 (Di)0.63316 (L)0.80161
• CPL = 300.9 (6)0.63316 (47)0.80161 = $ 20,487

Exercise 22.4

• Calculation of CBT Eq 22.67 Pg 577
• CBT = 468 exp { 0.1739 Di }

• CBT = 468 exp [0.1739 (6.0ft)] = $ 1,329

Exercise 22.4

• Calculation of CT Eq 22.66 Pg 577
• CT = NT FNT FTT FTM CBT
• CT = 23 (1) (1) (1) ($1,329) = $ 30,567

Exercise 22.4

• Calculation of Bare-Module Cost of Column
with ladders, platforms, and trays
Table 22.11 Pg 549
• Bare-Module factor = 4.16
• Bare-Module Cost
= 4.16 (84,009 + 20,487 + 30,567)
= $561,862

Exercise 22.4
Purchase Cost of Reflux Pump

Step 1: Conversion flowrates and kinematics viscosity
• Volumetric Flowrate, Q from ASPEN= 1130.67 ft³/hr
• Distillate Density, ρL= 50.78 lb/ft³
1130.67 𝑓𝑡³ 1 ℎ𝑟 0.133680556 𝑓𝑡³

Q= x x = 140.97 GPM
ℎ𝑟 60 𝑚𝑖𝑛𝑠 𝑔𝑎𝑙
50.78 𝑙𝑏 0.133680556 𝑓𝑡³
• ρ= L x = 6.7883 lb/ gal
𝑓𝑡³ 𝑔𝑎𝑙
Step 2: Determine Increase in Pressure,ΔP

• As provided in Question: 100 psi (pound per square
inch)

Exercise 22.4

Step 3: Calculate Pump Head (in lb/ft²)
∆𝑃 100 𝑙𝑏 (12 𝑖𝑛)²
• H= =( x )/(50.78 lb/ ft³)= 283.6 ft
ρ 𝑖𝑛² (1 𝑓𝑡)²
Step 4: Determine theoretical power

requirement for 100 psi
1130.67 𝑓𝑡³ 1 ℎ𝑟 100 𝑙𝑏𝑓 (12𝑖𝑛)²
• Ws = x x x x
ℎ𝑟 60 𝑚𝑖𝑛𝑠 𝑖𝑛² 1 𝑓𝑡²
1𝑚𝑖𝑛 550.22 𝐻𝑝
x = 8.22 Hp
60 𝑠 (𝑙𝑏𝑓.𝑓𝑡)/𝑠

Exercise 22.4

Step 5: Pump Selection
• Type of Pump : Centrifugal pump
Pg 561
Previous Calculations
• Q= 140.97 GPM
• H= 283.6 ft
• Ws= 8.22 Hp

Exercise 22.4

Step 6: Calculate Cp
• S= 140.97GPM(283.6ft)^0.5= 2374 gpm-

ft^0.5
• CB= $3548

Exercise 22.4

CP= FTFMCB
• From Table 22.20, FT= 1.00

• Material of pump: Cast steel, FM= 1.35
• CP= (1.00)(1.35)($3548)= $4790

Exercise 22.4
Purchase Cost of Reflux Pump-Motor

Step 7: Selection of Electric Motor
• Explosion Proof Motor, FT=1.8
Step 8: Calculate Cp for Motor
• Pump efficiency, np= 0.87

Exercise 22.4
• PB= 8.22Hp/0.58 = 14.21 BHp
• nM= 0.87

Exercise 22.4
Power Consumption, PC = 14.21/0.87 = 16.30 Hp
CP = 1.8 x exp{5.8259 + 0.13141[ln(16.30)] + 0.053255[ln(16.30)]2

+ 0.028628[ln(16.30)]3 – 0.0035549[ln(16.30)]4} = $2,002
The total purchase cost of the pump and motor is: $4,790 + $2,002 =
$ 6,792
From Table 22.11, the bare-module factor = 3.30.
Therefore, the bare-module cost = 3.3(6,792) = $ 22,414

Exercise 22.4
Purchase Cost of Reboiler Pump

• From ASPEN: F= 96,589 lb/hr
ρ= 48.88 lb/ft³
Step 1: Conversion flowrates and kinematics viscosity
• Q = (96,589 lb/hr)(48.88 lb/ft3) = 1976.0 ft3/hr=
246.4 gpm
Step 2: Determine Increase in Pressure,ΔP
• As provided in Question: 100 psi (pound per square
inch)

Exercise 22.4

Step 3: Calculate Pump Head (in lb/ft²)
∆𝑃 100 𝑙𝑏 (12 𝑖𝑛)²
• H= =( x )/(48.88 lb/ ft³)= 294.6 ft
ρ 𝑖𝑛² (1 𝑓𝑡)²
Step 4: Determine theoretical power

requirement for 100 psi
1976.0 𝑓𝑡³ 1 ℎ𝑟 100 𝑙𝑏𝑓 (12𝑖𝑛)²
• Ws = x x x x
ℎ𝑟 60 𝑚𝑖𝑛𝑠 𝑖𝑛² 1 𝑓𝑡²
1𝑚𝑖𝑛 550.22 𝐻𝑝
x = 14.37 Hp
60 𝑠 (𝑙𝑏𝑓.𝑓𝑡)/𝑠

Exercise 22.4

Step 5: Pump Selection
• Type of Pump : Centrifugal pump
Pg 561
Previous Calculations
• Q= 246.4 GPM
• H= 294.6 ft
• Ws= 14.37 Hp

Exercise 22.4

• Step 6: Calculate Cp
• S= 246.4GPM(264.6ft)^0.5= 4228gpm-ft^0.5
• CB= $4063

Exercise 22.4

CP= FTFMCB
• From Table 22.20, FT= 1.00

• Material of pump: Cast steel, FM= 1.35
• CP= (1.00)(1.35)($4063)= $5485

Exercise 22.4
Purchase Cost of Reboiler Pump-Motor

Step 7: Selection of Electric Motor
• Explosion Proof Motor, FT=1.8
Step 8: Calculate Cp for Motor
• Pump efficiency, np= 0.64

Exercise 22.4
• PB= 14.37Hp/0.64 = 22.35 BHp
• nM= 0.88

Exercise 22.4
Power Consumption, PC = 22.35/0.88 = 25.36 Hp
CP = 1.8 x exp{5.8259 + 0.13141[ln(25.36)] + 0.053255[ln(25.36)]2

+ 0.028628[ln(25.36)]3 – 0.0035549[ln(25.36)]4} = $2,905
The total purchase cost of the pump and motor is: $5,485 + $2,905 =
$ 8,390
From Table 22.11, the bare-module factor = 3.30.
Therefore, the bare-module cost = 3.3(8,390) = $ 27,687

Exercise 22.4
Purchase Cost of Condenser

• Given information:
– Qc = 9.734 x 106 Btu/hr
– TH,in = TH,out = 179.36 ⁰F
– TC,in = 90 ⁰F
– TC,out = 120 ⁰F
– Overall U = 100 Btu/hr-ft2-⁰F
• Sizing of the condenser
∆𝑇1 −∆𝑇2
– ΔTLM = ∆𝑇1
𝑙𝑛
∆𝑇2
179.36−90 −(179.36−120)
= 179.36−90 = 73.34 ⁰F
ln( )
179.36−120

Exercise 22.4

𝑄 9.734 𝑥 106 𝐵𝑡𝑢/ℎ𝑟
𝐴𝑐 = =
𝑈(∆𝑇𝑀 ) 100 𝐵𝑡𝑢 (73.34℉)
ℎ𝑟. 𝑓𝑡 2 . ℉
𝐴𝑐 = 𝟏𝟑𝟐𝟕 𝐟𝐭 𝟐 > 200 ft2
(Use shell-and-tube exchanger)
*Assume fixed-head, carbon steel shell, 20

foot long brass tubes
At pressure 100 psig, Fp = 1
FL = 1
Exercise 22.4

1327 0.05
𝐹𝑀 = 1.08 + = 2.22
100
𝐶𝐵 = exp{11.0545 − 0.9228 ln 1327 +

0.09861 ln 1327 2 }
= $13,597.69
Cp = (1) (2.22) (1) (13,597.69) = $ 30,186.87

Bare-module factor = 3.17
Bare-module cost = 3.17(30,186.87) = $95,692.38

Exercise 22.4
Purchase Cost of Reboiler

• Heat reflux = 12,000 Btu/hr-ft2
• Heat duty = 9.917 x 106 Btu/hr
• AR = QR / Flux
= 9.917 x 106 / 12,000
= 826.42 ft2 > 200ft2
(Use shell-and-tube exchanger)

Exercise 22.4
Purchase Cost of Reboiler

• Using Kettle vaporizer
• Carbon steel
𝐶𝐵 = exp{11.967 − 0.8709 ln 826.42 +

0.09005 ln 826.42 2 }
= $26,372.67
Cp = (1) (1) (1) (26,372.67) = $ 26,372.67
Bare-module-factor = 3.17
Bare-module-cost = 3.17( 26,372.67)
= $83,601.36

Exercise 22.4
Purchased Cost of Reflux Accumulator

• Information Provided
– Reflux Ratio = 1.25
– Residence Time = 5 min at half full
• Volumetric Flow of Distillate (ASPEN) =

502.51 ft3/hr
• Vdrum,in = (1 + R) (Dvolumetric)
= (1+1.25)(502.51 ft3/hr)
= 1130.67 ft3/hr

Exercise 22.4

• For a residence time = 5 min at half full:
V = 1130.67 ft3/hr * (5 min / (60 min/hr) ) × 2
= 188.45 ft3
• For L/D = 2
V = π (D/2)2L = πD3/2
D = (2V/π)^(1/3) = (2x188.45/π)^(1/3)
D = 4.93 ft, L = 2D = 2(4.93) = 9.86 ft

Exercise 22.4

• Design Temp = 227 + 50 = 277 ℉ pg 575
• Design Pressure: 10 psig pg 575
• Shell Materials: grade C carbon steel pg 575

– Maximum Allowable Stress, S = 13750 psi
– Density of Carbon Steel = 490lb/ft2
• Assume a weld efficiency = E = 0.85

• Corrosion allowance = 0.125 inch

Exercise 22.4

• Calculation of tp

– tP = Pd Di / (2SE – 1.2Pd)
– tP = 10 (6x12) / [2 (13,750) (0.85) – 1.2 (10)]
= 0.031 in
tP is too small…

Exercise 22.4

• Calculation of ts
ts = tv + tc
ts = 0.3125 + 0.125 pg 575
ts = 0.4375 in (7/16in)

Exercise 22.4

• Calculation of W Eq 22.59 Pg 575
• W = π (Di + ts) (L + 0.8Di) ts ρ

• W = π [4.93ft+(0.4375in) (0.083in/ft)]
[9.86ft+0.8(4.93ft)] × (0.4375in)(0.083in/ft)
(490 lb/ft3)
• W = 3,851 lb

Exercise 22.4

• Calculation of Cv Eq 22.57 Pg 575
• CV = exp{7.2756 + 0.18255 lnW + 0.02297

[lnW]2}
• CV = exp{7.2756 + 0.18255[ln(3851)] +
0.02297[ln(3851)]2} = $ 31,209

Exercise 22.4

• Calculation of Bare-Module Cost of Horizontal
Vessel
Table 22.11 Pg 549
• Bare-Module factor = 3.05
• Bare-Module Cost = 3.05(31,209) = $95,187

Exercise 22.4
Total Bare-Module Cost

• Column – $ 561,862
• Reflux Pump – $ 22,414
• Reboiler Pump – $ 27,687
• Condenser – $ 95,693
• Reboiler – $ 83,602
• Reflux Accumulator – $ 95,187
Total : $ 886,445 (CE = 500 @ 2006 )

Exercise 22.4
Total Permanent Investment (Lang Factor)

• F.O.B Purchased Cost
– Column – $ 135,063
– Reflux Pump – $ 6,742
– Reboiler Pump – $ 8,390
– Condenser – $ 30,187
– Reboiler – $ 26,373
– Reflux Accumulator – $ 31,209
CTPI : 1.05(4.74)(237,964) = $ 1,184,347

Eq 22.9 Pg 555 (CE = 500 @ 2006 )
Exercise 22.4
Total Permanent Investment (Guthrie)

• Add 5% for site, 5% for buildings, and 5% for
offsite facilities.
• CTPI : 1.18(1.15)(886,445) = $ 1,202,906

Eq 22.11 Pg 557 (CE = 500 @ 2006 )

Cost Accounting and Capital Cost Purchasing Costs

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Cost Accounting and Capital Cost Purchasing Costs

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Product and Process Design Principles

Synthesis, Analysis and Evaluation

Cost Accounting and Capital Costs: Purchasing Costs Page 3

Total Permanent Investment (CTPI) Working Capital (CWC)

Total Depreciable Capital (CTDC) Total Non-Depreciable Capital

Direct Permanent Unexpected/ Land Cost Startup Cost

Total On-Site/ Bare Royalties

Equip & Machinery Bare Site

Cost Accounting and Capital Costs: Purchasing Costs Page 4

Why do We Need Purchase Costs, CP ?

– Lang’s Overall Factor Method aka Study Estimate

– Guthrie’s Individual Factors Method aka Prelim Estimate

Cost Accounting and Capital Costs: Purchasing Costs Page 5

General Form of Purchase Costs, CP

Purchase Costs (CP) = Fa Fb Fc … x Base Costs (CB)

Cost Accounting and Capital Costs: Purchasing Costs Page 6

General Form of Purchase Costs, CP

Purchase Costs (CP) = Fa Fb Fc … x Base Costs (CB)

The purchase costs (CP) in this eqn., is free-on-board

Delivery costs (indirect costs) are only included in

Cost Accounting and Capital Costs: Purchasing Costs Page 7

General Form of Purchase Costs, CP

Purchase Costs (CP) = Fa Fb Fc … x Base Costs (CB)

Equipment-Specific Correction Factors,

Cost Accounting and Capital Costs: Purchasing Costs Page 8

General Form of Purchase Costs, CP

Purchase Costs (CP) = Fa Fb Fc … x Base Costs (CB)

Dependent on size factor (S) of equipment.

General Form of CB: CB = A(S)b

Remember, CP changes over the years !

• If desired CP is not in 2006, we need to use

Cost Accounting and Capital Costs: Purchasing Costs Page 10

Main Equipment Other Equipment

Pumps, Heat Vessels,

Cost Accounting and Capital Costs: Purchasing Costs Page 11

– EXTERNAL ROTARY GEAR Pumps

Cost Accounting and Capital Costs: Purchasing Costs Page 13

Cost Accounting and Capital Costs: Purchasing Costs Page 14

Pumps: Centrifugal Pump

MUD HOGTM Centrifugal Pump (Source: Forum Energy Technologies)

Cost Accounting and Capital Costs: Purchasing Costs Page 16

Pumps: Centrifugal Pump

Cost Accounting and Capital Costs: Purchasing Costs Page 17

Pumps: Centrifugal Pump

Purchase Costs for Centrifugal Pumps:

Cost Accounting and Capital Costs: Purchasing Costs Page 18

Pumps: Centrifugal Pump

Cost Accounting and Capital Costs: Purchasing Costs Page 19

Base Cost Curve (for Centrifugal Pump)

Cost Accounting and Capital Costs: Purchasing Costs Page 20

Pumps: Centrifugal Pump

Cost Accounting and Capital Costs: Purchasing Costs Page 21

Pumps: Centrifugal Pump

Cost Accounting and Capital Costs: Purchasing Costs Page 22

Pumps: External Rotary Gear Pump

External View Internal View

External Rotary Gear Pump (Source: Viking Pump Technologies)

Cost Accounting and Capital Costs: Purchasing Costs Page 23

Pumps: External Rotary Gear Pump

Cost Accounting and Capital Costs: Purchasing Costs Page 24

Pumps: External Rotary Gear Pump

Purchase Costs for Gear Pumps:

Cost Accounting and Capital Costs: Purchasing Costs Page 25

Pumps: External Rotary Gear Pump