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PROBLEMS

Chapter 6 Plant Design and Economics for Chemical Engineers Fifth Edition 6-1 The purchased cost of a shell-and-tube heat exchanger (floating-head and carbonsteel tubes) with 100 m2 of heating surface was $4200 in 1990 !hat will be the 1990 purchased cost of a similar heat exchanger with 20 m2 of heating surface if the purchased cost capacit" exponent is 0 #0 for surface areas ranging from $ 0 to 40 m2% &f the purchased cost capacit" exponent for this t"pe of exchanger is 0 '1 for surface areas ranging from 40 to 200 m2( what will be the purchased cost of a heat exchanger with 100 m2 of heating surface in 2000% 6)lot the 2000 purchased cost of the shell-and-tube heat exchanger outlined in )rob #-1 as a function of the surface area from 10 to 200 m2 *ote that the purchased cost capacit" exponent is not constant o+er the range of surface area re,uested

6-! The purchased and installation costs of some pieces of e,uipment are gi+en as a function of weight rather than capacit" -n example of this is the installed costs of large tan.s The 1990 cost for an installed aluminum tan. weighing 4/(000 .g was $#40(000 0or a si1e range from 90(000 to 4/0(000 .g( the installed cost weight exponent for aluminum tan.s is 0 92 &f an aluminum tan. weighing 200(000 .g is re,uired( what capital in+estment is needed in the "ear 2000% 6-" The 1990 cost for an installed 204 stainless steel tan. weighing 12/(000 .g was $1(100(000 The installed cost weight exponent for stainless steel tan.s is 0 '' for a si1e range from 100(000 to 200(000 .g !hat weight of installed stainless steel tan. could ha+e been obtained for the same capital in+estment as in )rob #-2% 6-# The purchased cost of a /-m2 stainless steel tan. in 199/ was $10(900 The 2-mdiameter tan. is c"lindrical with a flat top and bottom &f the entire outer surface of the tan. is to be co+ered with 0 0/-m-thic.ness of magnesia bloc.( estimate the current total cost for the installed and insulated tan. The 199/ cost for the 0 0/-m-thic. magnesia bloc. was $40 per s,uare meter while the labor for installing the insulation was $9/ per s,uare meter 6-6 - one-stor" warehouse 2# m b" 1' m is to be added to an existing plant -n asphalt pa+ement ser+ice area 1' m b" 9 m will be added ad3acent to the warehouse &t will also be necessar" to put in 1/0 linear m of railroad siding to ser+ice the warehouse 4tilit" ser+ice lines are alread" a+ailable at the warehouse site The proposed warehouse has a concrete floor and steel frame( walls( and roof *o heat is necessar"( but lighting and sprin.lers must be installed 5stimate the total cost of the proposed addition 6onsult -pp 7 of the 4th ed for necessar" cost data 6-$ The purchased cost of e,uipment for a solid processing plant is $/00(000 The plant is to be constructed as an addition to an existing plant 5stimate the total capital in+estment and the fixed-capital in+estment for the plant !hat percentage and amount of the fixed-capital in+estment are due to cost for engineering and super+ision( and what percentage and amount for the contractor8s fee%

6-% The purchased-e,uipment cost for a plant which produces pentaer"thritol (solid-fluid processing plant) is $200(000 The plant is to be an addition to an existing formaldeh"de plant The ma3or part of the building cost will be for indoor construction The contractor8s fee will be 9 percent of the direct plant cost -ll other costs are close to the a+erage +alues found for t"pical chemical plants :n the basis of this information( estimate the total direct plant cost( the fixed-capital in+estment( and the total capital in+estment 6-& 5stimate b" the turno+er ratio method the fixed-capital in+estment re,uired in 2000 for a proposed sulfuric acid plant (batter"-limit) which has an annual capacit" of 1 2 x 10' .g;"r of 100 percent sulfuric acid (contact-catal"tic process)( using the data from Table #-11( when the selling price for the sulfuric acid is $'# per metric ton The plant will operate 22/ da"s;"ear <epeat the calculation( using the cost capacit" exponent method with data from Table #-11 6-1' The total capital in+estment for a chemical plant is $1 million( and the wor.ing capital is $100(000 &f the plant can produce an a+erage of '000 .g of final product per da" during a 2#/-da" "ear( what selling price in dollars per .ilogram of product would be necessar" to gi+e a turno+er ratio of 1 0% 6-11 - process plant was constructed in the )hiladelphia area (=id--tlantic) at a labor cost of $42/(000 in 1990 !hat would be the labor cost for the same plant located in the =iami( 0lorida( area (south -tlantic) if it were constructed in late 199'% -ssume( for simplicit"( that the relati+e labor rate and relati+e producti+it" factor ha+e remained constant 6-1 - compan" has been selling a soap containing 20 percent b" weight water at a price of $20 per > : .g f o b (i e ( the customer pa"s the freight charges) The compan" offers an e,uall" effecti+e soap containing onl" / percent water The water content is of no importance to the laundr"( and it is willing to accept the soap containing / percent water if the deli+ered costs are e,ui+alent &f the freight rate is $l /0 per /0 .g( how much should the compan" charge the laundr" per /0 .g f o b for the soap containing / percent water% 6-1! The total capital in+estment for a con+entional chemical plant is $1(/00(000( and the plant produces 2 million .g of product annuall" The selling price of the product is $0 '2;.g !or.ing capital amounts to 1/ percent of the total capital in+estment The in+estment is from compan" funds( and no interest is charged ?eli+ered raw materials costs for the product are $0 09;.g@ labor( $0 0';.g@ utilities( $0 0/;.g@ and pac.aging( $0 00';.g ?istribution costs are / percent of the total product cost 5stimate the followingA

a. b. c. d.

=anufacturing cost per .ilogram of product Total product cost per "ear )rofit per .ilogram of product before taxes )rofit per .ilogram of product after income taxes at 2/ percent of gross profit

6-1" 5stimate the manufacturing cost per 100 .g of product under the following conditionsA 0ixed-capital in+estment B $4 million -nnual production output B 9 million .g of product <aw materials cost B $0 2/;.g of product 4tilitiesA '00-.)a steam B /0 .g;.g of product )urchased electric power B 0 9 .!h;.g of product 0iltered and softened water B 0 0'2 m2;.g of product :perating labor B 12 persons per shift at $2/ 00 per emplo"ee-hour )lant operates three hundred 24-h da"s per "ear 6orrosi+e li,uids are in+ol+ed >hipments are in bul. carload lots - large amount of direct super+ision is re,uired There are no patent( ro"alt"( interest( or rent charges )lant o+erhead costs amount to /0 percent of the cost for operating labor( super+ision( and maintenance 6-1# - compan" has direct production costs e,ual to /0 percent of total annual sales( and fixed charges( o+erhead( and general expenses e,ual to $200(000 &f management proposes to increase present annual sales of $'00(000 b" 20 percent with a 20 percent increase in fixed charges( o+erhead( and general expenses( what annual sales amount is re,uired to pro+ide the same gross earnings as the present plant operation% !hat would be the net profit if the expanded plant were operated at full capacit" with an income tax on gross earnings of 2/ percent% !hat would be the net profit for the enlarged plant if total annual sales remained at $'00(000% !hat would be the net profit for the enlarged plant if the total annual sales actuall" decreased to $900(000% 6-16 - process plant ma.ing /000 .g;da" of a product selling for $1 9/;.g has annual +ariable production costs of $2 million at 100 percent capacit" and fixed costs of $900(000 !hat is the fixed cost per .ilogram at the brea.e+en point% &f the selling price of the product is increased b" 10 percent( what is the dollar increase in net profit at full capacit" if the income tax rate is 2/ percent of gross earnings% 6-1$ - rough rule of thumb for the chemical industr" is that $1 of annual sales re,uires $2 of fixed capital in+estment &n a chemical processing plant where this rule applies( the total capital in+estment is $2(/00(000( and the wor.ing capital is 20 percent of the total capital in+estment The annual total product cost amounts to $1(/00(000 &f the income tax rates on gross earnings total 2/ percent( determine the followingA

a. )ercent of total capital in+estment returned annuall" as gross earnings b. )ercent of total capital in+estment returned annuall" as net profit
6-1% The total capital in+estment for a proposed chemical plant( which will produce $1(/00(000 worth of goods per "ear( is estimated to be $1 million &t will be necessar" to do a considerable amount of research and de+elopment (<C?) wor. on the pro3ect before the final plant can be constructed( and management wishes to estimate the permissible research and de+elopment costs &t has been decided that the after tax

return from the plant should be sufficient to pa" off the total capital in+estment plus all research and de+elopment costs in 9 "ears - return after taxes of at least 12 percent of sales must be obtained 7ecause <C? is an expense and the compan"8s income tax rate is 2/ percent of gross earnings( onl" #/ percent of the funds spent on <C? must be reco+ered after taxes are paid 4nder these conditions( what is the total amount the compan" can afford to pa" for research and de+elopment% 6-1& - chemical processing unit has a capacit" for producing & million .g of a product per "ear -fter the unit has been put into operation( it is found that onl" /00(000 .g of the product can be sold per "ear -n anal"sis of the existing situation shows that all fixed and other in+ariant charges( which must be paid whether or not the unit is operating( amount to 2/ percent of the total product cost when operating at full capacit" <aw material costs and other production costs that are directl" proportional to the ,uantit" of production (i e ( constant per .ilogram of product at an" production rate) amount to 40 percent of the total product cost at full capacit" The remaining 2/ percent of the total product cost is for +ariable o+erhead and miscellaneous expenses( and the anal"sis indicates that these costs are directl" proportional to the production rate during operation raised to the 1 / power !hat will be the percent change in total cost per .ilogram of product if the unit is switched from the original design rate of & 0#.g;"r of product to a time and rate schedule which will produce 0 /x 10# .g or Dhalf that amountD of product per "ear at the least total cost%

Pro(ectos para )ngenier*a +,*mica Fac,ltad de )ngenier*a Departamento de )ngenier*a +,*mica -ni.ersidad /acional 0,t1noma de 2ond,ras

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