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6.
0 APPENDIX
VAPORIZER PURCHASED COST ESTIMATION

Specifications; D=1.8 m, L=3 m, P=30 bar

Purchased cost of vaporizer, C
p
, is read from the Figure A.13 [Ref1] as 20000 $. Since P=
30 bar=29 barg pressure factor F
P
is read from the Table A.19 as F
p
=2.492.5 [Ref1].
Carbon-steel can be selected as construction material. From Table A.20 bare module
factor for vaporizer is found as FBM=2.8 [Ref1].
Then, purchased cost for the vaporizer is calculated:
based on mid-1996.

Hence, the purchased cost of the vaporizer is estimated to be 97219 $.

REACTOR PURCHASED COST ESTIMATION
For the reactor used in cumene plant of 3 m length and 1 m diameter, volume is 2.36 m
3
.
Selecting carbon steel as manufacturing material.
Ce=CS
n
where Ce is purchased equipment cost and C is cost constant from [Ref.2] in $.
2004 Chemical engineering cost index is taken as 457.4 [Ref2]
Ce= CS
n
=9300$ (2.36)
0.4
=13111 $ based on mid-2004.

Reactor includes cooler section so cooler economic design is required for all cost analysis
of reactor. For the cooler used in cumene plant of 18.84 m
2
heat transfer area:
Purchased Cost= (bare cost from figure)* Type factor*Pressure factor
Bare cost is taken from figure A.1, pressure factor is taken from Table A.19 type factor is taken
from Table A.2 [Ref1].
Purchased Cost=8000*1.0*1.0=27000 based on mid-1996

Hence, the purchased cost of the reactor is estimated to be 33236 $.
COOLER-CONDENSER PURCHASED COST ESTIMATION
For the cooler-condenser used in cumene plant of 367.31 m
2
heat transfer area, totally:
Purchased Cost= (bare cost from figure)* Type factor*Pressure factor
Bare cost is taken from figure A.1, pressure type factor is taken from Table A.19 [Ref1].
Purchased Cost=25000*1.0*1.0=25000 based on mid-1996
Cost index in year A 539
Cost in year A= Cost in year B* 25000* 35275
Cost index in year B 382
= =
Hence, the purchased cost of the cooler-condenser is estimated to be 35275$.
FURNACE COST ESTIMATION

The heat duty of furnace is 41376 kW and area of furnace is 181.7 m
2
.
From Table A12;

BENZENE DISTILLATION COLUMN
Assuming the column is a vertical pressure vessel including plates, for the column
designed of 2.18 m diameter and 3 m height, working at 1.75 atm, plate cost can be
estimated as:
Sieve trays cost is read 580 $ from Figure A.7. Pressure factor (F
q
) is selected as 2.33
respected to number of trays [Ref.1]. Material of construction (F
BM
) is selected as 1.2.
Number of trays is 5.

For the condenser used in cumene plant of 249 kW driver power,
C
P
is read as 60000$ from Figure A.12. F
p
is read as 1 from Table A.17. Bare module
factor (F
BM
) is read as 2.1 from Table A.17 [Ref.1].
* * 2.1*60000*1 126000
BM BM P P
C F C F = = = $ based on mid-1996
= = $

For the boiler used in cumene plant of 1469 kW driver power,
C
P
p
factor (F
BM
* * 2.1*100000*1 210000
BM BM P P
= = $
Total HCL tower purchased cost is found as 482560$.

PROPYLENE TOWER PURCHASED COST ESTIMATION
estimated as:
Sieve trays cost is read 270$ from Figure A.7. Pressure factor (F
q
) is selected as 2
BM
* * * 1.2*270*2*7 4536
BM BM P q
C F C F N = = = $
= = $

Vertical vessel cost is read 8000$ from Figure A.4. Pressure factor (F
P
) is selected as 1 in
range of -0.5<P<3.7barg [Ref.1], material of construction (F
M
) is selected as CS.
* * 1*8000*1 8000
BM M P P
C F C F = = =
= = $
For the condenser used in allyl-chloride plant of 8.6 kW driver power,
C
P
p
factor (F
BM
* * 2.1*5000*1 10500
BM BM P P
= = $
For the boiler used in allyl-chloride plant of 150 kW driver power,
C
P
p
factor (F
BM
* * 2.1*7000*1 14700
BM BM P P
= = $
Total propylene tower purchased cost is found as 46845$.

2-CHLORO- PROPENE TOWER PURCHASED COST ESTIMATION
estimated as:
q
) is selected as 1.67
BM
* * * 1.2*265*1.67*9 4780
BM BM P q
C F C F N = = = $
= = $

P
) is selected as 1 in
range of -0.5<P<3.7barg [Ref.1], material of construction (F
M
* * 1*9000*1 9000
BM M P P
C F C F = = =
= = $
For the condenser used in allyl-chloride plant of 210 kW driver power,
C
P
p
factor (F
BM
* * 2.1*9000*1 18900
BM BM P P
= = $
C
P
p
factor (F
BM
* * 2.1*5000*1 10500
BM BM P P
= = $

Total 2-chloro- propene tower purchased cost is found as 60926$.

ALLYL CHLORIDE TOWER PURCHASED COST ESTIMATION

designed of 0.5 m diameter and 5.5 m height, working at 1.5 atm, plate cost can be
estimated as:
q
) is selected as 2
BM
* * * 1.2*265*2*7 4452
BM BM P q
C F C F N = = = $
= = $
P
) is selected as 1
in range of -0.5<P<3.7barg [Ref.1], material of construction (F
M
* * 1*11500*1 11500
BM M P P
C F C F = = =
= = $
For the condenser used in allyl-chloride plant of 403 kW driver power,
C
P
p
factor (F
BM
* * 2.1*10500*1 22050
BM BM P P
= = $
C
P
p
factor (F
BM
* * 2.1*7000*1 14700
BM BM P P
= = $
Total allyl-chloride tower purchased cost is found as 74361$.

WASTE HEAT BOILER PURCHASED COST ESTIMATION
For the waste heat boiler used in allyl chloride plant of 22.6 m
2
heat transfer area:
Purchased Cost of boiler is read as 6000$ from FigureA.1. Type of heater is selected as Non-
Reactive Process Heater and F
P
is read as 1 from TableA.17. Bare Module Factor (F
BM
) is
selected as 2.1[Ref1].
BM P P BM
C C * F *F 6000*1*2.1 12600 = = = $
= = $
Hence, the purchased cost of the boiler is estimated to be 17779$.

MIXER I PURCHASED COST ESTIMATION
( )
3
3
3
0.0257
(24 )
3600
0.0257 50 24 *
1
704
157.7
mix
mix
kmol
F
s
F MW h
V
kmol kg s
h
s m h
V
kg
m
V m
=

=
=

Select; D
T
=
2
H
T

V =
T T
H D
2
4
t

3
T
D
2
V
t
=
3
2
10 1 2 10 3 10
157.7
2
4.64
9.3
log *log *(log )
T
T
T
p
D
D
H
C K K A K A
t
=
=
=
= + +

Mixer is selected as vertical orientation process vessel.

Cost in year A= Cost in year B* 293000* 413421$
= =

MIXER II PURCHASED COST ESTIMATION
1 2 3 1 2
1 2
2
10 10 10
4.3919; 0.2859; 0.1842; 2.5; 1.72; 1; .3& .4 [Re 1] 9.3
1 0.5 3.7 arg
*( * * )
log 4.3919 0.2859*log 9.3 0.1842*(log 9.3)
69432$
M T
P
BM P P M
p
p
BM
K K K B B F TableA TableA f A H
F is selected in range of P b
C C B B F F
C
C
C
= = = = = = = =
= < <
= +
= + +
=
= 69432*(2.5 1.72*1*1) 293000$ + =
( )
3
3
3
0.0308
(24 )
3600
0.0308 46.7 24 *
1
672
185
mix
mix
kmol
F
s
F MW h
V
kmol kg s
h
s m h
V
kg
m
V m
=

=
=

Select; D
T
=
2
H
T

V =
T T
H D
2
4
t

3
T
D
2
V
t
=
3
2
10 1 2 10 3 10
185
2
4.9
9.8
log *log *(log )
T
T
T
p
D
D
H
C K K A K A
t
=
=
=
= + +

1 2 3 1 2
1 2
2
10 10 10
4.3919; 0.2859; 0.1842; 2.5; 1.72; 1; .3& .4 [Re 1] 9.8
1 0.5 3.7 arg
*( * * )
log 4.3919 0.2859*log 9.8 0.1842*(log 9.8)
71824$
M T
P
BM P P M
p
p
BM
C C B B F F
C
C
C
= = = = = = = =
= < <
= +
= + +
=
= 71824*(2.5 1.72*1*1) 303100$ + =

= =

MIXER III PURCHASED COST ESTIMATION
( )
3
3
3
0.026
(24 )
3600
0.026 41 24 *
1
583
158
mix
mix
kmol
F
s
F MW h
V
kmol kg s
h
s m h
V
kg
m
V m
=

=
=

Select; D
T
=
2
H
T

V =
T T
H D
2
4
t

3
T
D
2
V
t
=
3
2
10 1 2 10 3 10
185
2
4.65
9.3
log *log *(log )
T
T
T
p
D
D
H
C K K A K A
t
=
=
=
= + +

1 2 3 1 2
1 2
2
10 10 10
4.3919; 0.2859; 0.1842; 2.5; 1.72; 1; .3& .4 [Re 1] 9.3
1 0.5 3.7 arg
*( * * )
log 4.3919 0.2859*log 9.3 0.1842*(log 9.3)
69432$
M T
P
BM P P M
p
p
BM
C C B B F F
C
C
C
= = = = = = = =
= < <
= +
= + +
=
= 69432*(2.5 1.72*1*1) 293000$ + =

= =

MIXER IV PURCHASED COST ESTIMATION
( )
3
3
3
0.02118
(24 )
3600
0.02118 42 24 *
1
522
147
mix
mix
kmol
F
s
F MW h
V
kmol kg s
h
s m h
V
kg
m
V m
=

=
=

Select; D
T
=
2
H
T

V =
T T
H D
2
4
t

3
T
D
2
V
t
=
3
2
10 1 2 10 3 10
185
2
4.5
9.0
log *log *(log )
T
T
T
p
D
D
H
C K K A K A
t
=
=
=
= + +

1 2 3 1 2
1 2
2
10 10 10
4.3919; 0.2859; 0.1842; 2.5; 1.72; 1; .3& .4 [Re 1] 9.0
1 0.5 3.7 arg
*( * * )
log 4.3919 0.2859*log 9.0 0.1842*(log 9.0)
67990$
M T
P
BM P P M
p
p
BM
C C B B F F
C
C
C
= = = = = = = =
= < <
= +
= + +
=
= 67990*(2.5 1.72*1*1) 286918$ + =

= =

TOTAL CAPITAL INVESTMENT (TCI)
Since purchase cost of all of the major equipments are estimated, using values given in
PPC can be calculated:
Purchase Cost of Major Equipment Items:
PCE=3117515$
Total Physical Plant Cost:
PPC=PCE*Lang Factor= (3117515)* 4.74 =1.48*10
7
$
Estimating the working capital as 12% of the fixed capital total investment required can
be calculated to be:
TCI=1.48*10
7
$ +0.12*(1.48*10
7
$) =1.66*10
7
$

OPERATING COSTS
Operating time is assumed to be 7200 h/year and following the route described above:
1. RAW MATERIALS:
Chloride, propylene, water:
6
6
3
$ $
cost of chlorine 0.18 *0.005063 *3600 *71 *7200 1.677*10
kg
$ $
cost of propylene 0.47 *0.004599 *3600 *42 *7200 2.353*10
kg
$
cost of water=0.3*10 *0.012 *36
kg
kmol s kg h
s h kmol year year
kmol s kg h
s h kmol year year
kmol
s
= =
= =
$
00 *18 *7200 1680
s kg h
h kmol year year
=
Total=4.03*10
6
$
2. MAINTANANCE:
Assume to be 6% of fixed capital cost=0.06*1.66*10
7
$ = 0.99*10
6
$/year
3. OPERATING LABOUR:
Assume to be 28000 $/year
4. LABORATORY COSTS:
Assume to be 15% of operating labour cost = 28000 $/year*0.15 = 4.2*10
3
$/year
5. SUPERVISION:
Assume to be 12% of operating labour cost=28000$/year*0.12=3.4*10
3
$/year
6. PLANT OVERHEADS:
Assume to be 40% of operating labour cost=28000$/year*0.4=11.2*10
3
$/year

7. CAPITAL CHARGES:
7
$=0.99*10
6
$/year
8. INSURANCE:
7
$=1.66*10
5
$/year
9. LOCAL TAXES:
7
$=3.32*10
5
$/year
10. ROYALTIES:
7
$=1.66*10
5
$/year
Direct Production CostsTotal=6.7*10
6
$/year

Sales expense
General overheads %25 of Direct Production Costs=0.25*6.7*10
6
$=1.68*10
6
$
Research and development

ANNUAL PRODUCTION COST=6.7*10
6
$+1.68*10
6
$=8.38*10
6
$/year
Selling price of 32wt% hydrochloric acid = $0.075/kg [Ref.4]
Selling price of 99.5 wt% pure allyl-chloride = $1.72/kg [Ref.4]
Waste disposal costs of 2 chloro propene = $0.20/kg [Ref.4]
Waste disposal costs of di chloro propene = $0.20/kg [Ref.4]
6 5
6 5 5
6 5 5
$ kg $
Selling Pr ice of HCL 0.075 *4.8*10 3.6*10
kg year year
$ kg $ kg $
Waste disposal cos t 0.075 *1.32*10 0.075 *2.55*10 1.18*10
kg year kg year year
$ $ $
8.38*10 1.18*10 3.6*10
year year ye
Pr oduction Cost of allyl chloride
= =
= + =
+
=
6
6 6
7
6
$ ar
0.9
kg
kg
9*10
year
$
Selling Pr ice of allyl chloride 1.7
kg
$ kg $
Annual Income 1.7 *9*10 15.3*10
kg year year
1.66*10 $
RATE OF RETURN 1.1 year
$
15.3*10
year
=
=
= =
= =

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