C1

APPENDIX C

EQUIPMENT SIZING AND COSTING

C.1

INTRODUCTION

Sizing and costing for a plant is important factor that should be done in good manner
because its determined the whole plant profitability besides ensure that the plant run
smoothly without any problem during the operation.

In acrylonitrile production plant, it involves many important units in the set up of the
plant operation. Generally, the units comprise of reactor, flush drum, distillation
column, heat exchnager and compressor. In this plant design, equipments sizing and
costing will be refered to Product and Process design Principles.

C2

C.2

HEAT EXCHANGERS

Example HX-08

a) Equipment sizing
shell
298.00
278.00

tube
268.00
278.00

(T1R = T2)/(t2-t1)
R=
2

( eqn.
12.6 )

Tin (K)
Tout (K)

(t2-t1)/(T1S= t1)
S=
0.3333

( eqn.
12.7 )

Ft can be obtained from fig. 12.19 ( vol. 6 ),

Ft =
lm

0.8200

can be calculated from the equation,

( eqn.
12.4 )

=12/[ln (1/2)]

lm

14.4270

The usual practice in the design of shell and tube

exchangers is to estimate the
'true temperature difference' from the DTlm byapplying a
correction factor to allow for the departure from the true
counter-current flow,
Therefore, the actual temperature difference is
Ft

lm

11.8301

Assumption: (Table 12.1, 'Chem. Eng', Vol. 6)

U
Provisional area of heat exchanger, A can be obtained

W/(K.m2
1500 )

C3

trough the formulae,

Q = UAFTTLM
Provisional area, A

65.3581 m2
703.5092 ft2

Costing For Heat Exchanger

Example HX-08
Purchased cost, CP = FP FM FL CB
Base cost, CB = exp {11.147 0.1986[ln(A)] + 0.09790[ln(A)2]}
Substitute A = 65.3581 m2,
CB = $18449.80187
Take tube length = 20 ft and FL = 1.00
FP only applicable when the design pressure is in between 100 to 2000 psig.
Therefore, FP is ignored.
FM = a + (A/100)b
Where,
Carbon steel/carbon steel: a = 0, b = 0
FM = 1
Therefore,
Purchased cost, CP = 1.00 X 1.00 X 18449.80187 = $ 18449.80187
Cbm = CP X Fbm X UF
Fbm = 3.17 , UF = 1.587
Therefore, Cbm = RM 352 771.93

C4

C.3

REACTOR

Reactor Design for R-001 (Plug Flow Reactor)

Operating Conditions for Plug Flow Reactor

120oC (393.15K)

Temperature
Pressure

1.1 bar (1 atm)

Feed Ratio: H2Oto EO

12:1

Rate of Reaction
The reactions involve:
C2H4O + H2O C2H6O2 (monoethylene glycol)
C2H4O + C2H6O2 C4H10O3 (diethylene glycol)
C2H4O + C4H10O3 C6H14O4(triethylene glycol)

The value of specific reaction rate, E/R = 9525 K, A = 338 (m3)3kmol-3s-1. This
value is obtained from the equation proposed in Melhem et al. (2001).The value of k for
all reactions, can be well expressed as below:

(3 )

= exp() = 1.0071 108 3 .(E.3.1)

= [][2 ][]2

(E.3.2)

C5

Where,
-rEO: rate of reaction for ethylene oxide, kmol/m3.s
k : specific reaction rate
[EO]: concentration of ethylene oxide, kmol/ m3
[H2O]: concentration of water, kmol/m3
[ROH]: concentration of hydroxyl groups, kmol/m3

= 1019.24

To calculate concentrations of each substance from outlet stream, S6 based on

mass balance calculated in APPENDIX A:

= 230.727

= 0.0641

3600

= 60168.06

1 3
3

= 59.0323
1019.24

[] = 25.001

= 0.4235
3

59.0323
3

The calculations of each substance will follow the above example and the following
results are obtained.

C6

Substance

Concentrations, kmol/m3

H2O

43.4169

MEG

3.4487

DEG

0.0254

TEG

0.0109

Hence,
[] = [2 ] + 2[] + 2[] + 2[] = 50.3869

= 4.7013 104

3
.

To calculate design volume of reactor, based on Biegler et al. (1997)

0.9

1
1
=
= 0.0641 =
= 122.712 3

4.7013 104
0

Separate into 10 units hence Vi = 12.2712 m3. Assuming L/D = 4 and =

(

2
4

). We would get D = 1.5749 m and L = 6.2995 m. For design purpose, 2 in

stainless steel pipe with schedule 40 is chosen also based on Biegler et al., (1997) with
outside diameter of 60.325 mm. Thus using the same formula, cross-sectional area is
0.002859 m2 and the volume of each pipe is 0.018 m3. To calculate the amount of tubes
required,
=

12.2712

=
= 681.29 682

0.018

C7

Tube Length Suitability

59.0323
3
=
=
= 0.0086558
(682 10)

0.0086558
3
=
=
= 3.0275

0.002859

122.712
10
, =
= 2.0787
59.0323
10
Distance passed by fluid,
= = 6.29 6.3
Hence it is proven here that the calculation for tube length is correct based on above
formula.

Costing of Reactor
Based on Biegler et al., (1997) Table 4.2, 4.11 while Seider et al., (2010) based
cost is at 100 for year 1957 while the present cost index of year 2006 is 500 (from
Chemical Engineering Index).

Operating pressure = 1 atm = 14.7 psig

Safety pressure = Design pressure 1.5 = (14.7)(1.5) = 22.05 psig

From Table 4.2 of Biegler, our safety pressure is lower than recommended 50
psig hence pressure factor, FP is 1. Considering the operating pressure and taking into
account corrosion and other factors, we decided to use solid stainless steel 316 with
material factor, FM = 3.67. Hence MPF = FP FM = 3.67.

C8

From Table 4.11, and using the formula provided, diameter of reactor, D is
5.16699 ft and L = 20.43799 ft. Other values provided are Co = US$ 690, Lo = 4 ft, Do =
3 ft, = 0.78 and = 0.98. Hence base cost is:

= ( ) ( ) = $ 4, 197.76

Update factor, =

@2006
@ 1957

500

= 100 = 5, and MF is 3.58 since C value is

lower than US$ 200, 000. Thus bare module cost per reactor is:
= ()( + 1) = $ 122, 784.48

Total cost for all reactor is as following and based on an exchange rate of RM3.61 per
US$.
= 10 $ 122, 784.48 = $ 1, 227, 844.80 4, 432, 519.73

C9

C.4

COMPRESSOR

Sizing

The compressor work is:

W = ( / (-1) ) R Tinlet( (Poutlet / Pinlet)( (-1) / ) - 1

With :

Compressor work (kJ/ s)

Molar gas flowrate (kmol/ s)

Cp/ Cv

Gas constant

8.314 kJ/ kmol K

Inlet temperature (K)

Poutlet =

Outlet pressure (atm)

Pinlet

Inlet pressure (atm)

Tinlet

1.237

The actual compressor work is :

Wactual = W / (c x m)

With:
Wactual =

Actual compressor work (hp)

Compressor work (kW)

Compressor efficiency

Motor efficiency

844.9831 kmol/ hr

= 0.2347kmol/s

C10

1.237

8.314 kJ/ kmol K

Tinlet

45.81 C

318.96 K

Poutlet =

1 atm

= 1.01325 bar

Pinlet

0.0987 atm

= 0.10001 bar

For compressor work

W
1.237 )

( / (-1) ) R Tinlet( (Poutlet / Pinlet)( (-1) / ) - 1 )

0.2347 ( 1.237 / (1.237-1) ) 8.314 x 318.96 ((1.01325 / 0.10001)( (1.237-1) /

- 1)
=

3248.48 x 0.5584

1813.95 kW

For actual work

c

0.8

( for compressor efficiency )

0.9

( for motor efficiency )

Wactual

1813.95 kW / ( 0.8 x 0.9 )

2519.38 kW

(2519.38 kW x 1.34102 hp )/1 kW

3378.54hp

With FD

1.25

(for gas turbine device)

With FM

2.5

( stainless steel)

Costing

Cp = FDFMCB

Base cost, CB =
=

exp { 7.9661 + 0.8 (lnPC)}

exp { 7.9661 + 0.8 (ln 3378.54) }

C11

exp { 7.9661 + 6.500 }

$ 497836.43

Thus,
Purchase cost, CP

CBM

$497836.43x 1.25 x 2.5

$ 1555738.85
550

= 1555738.85(500)(3.5)
= $5989594.57
= RM22435224.38

C12

C.5

FLASH DRUM

C.5.1 Flash Drum (V-001)

Sizing

S8
V-001
S8

S8

3
v(lb/ft )

= 0.057588

3
l(lb/ft )

= 63.91390284

K drum

l v
v

Kdrum = exp [A + BlnFlv +C(lnFlv) + D(lnFlv) + E(lnFlv)4]

Where A = -1.87748, B = -0.81458, C = -0.18707, D = -0.01452, E = -0.00101

= = 0.436105

C13

lnFlv = -0.82987
Kdrum= 0.266469

Column Diameter
AC =

3600

= 4.643559 2

Assuming vertical drum,

For Vertical Column

4
=
= 2.431535 = 0.741141

= + 0.152 = 0.893141

For a typical flash drum

L/D = 4

Therefore height of Drum

L = 3.572564 m

C14

Vapor Height to centerline of the feed

= 36

1
1
+ = 1.3609
39.37 2

Height of the centerline of the feed to liquid surface

= 12

1
1
+ = 0.7514
39.37 2

The depth of liquid pool

=

= = 1.4603
2
4
=

2
= 0.9149 3
4

2
= 2.2383 3
4

Dimensional Design of Column

hv =

1.3609

hf = 0.7514
L = 3.5726
hl = 1.4603

D = 0.8931

C15

Costing
Operating pressure = 1 atm = 14.7 psig
Design pressure = 14.7 1.5 = 22.05 psig
From Biegler et al (1997), Table 4.2, pressure factor, FP = 1.00 since safety pressure
22.05 psig is in the range of 0-50 psig.
Taking into consideration of other factors such as corrosion, erosion etc. material
factor, Fm = 3.67 for solid stainless steel 316.
MPF = (1.00)(3.67) = 3.67
Assumptions,

Vertical vessel
L/D ratio is 4
Cylindrical pressure vessel

To calculate base cost,

= ( ) ( )

Where from Table 4.11,

Co = $ 1000
Lo = 4 ft
Do = 3 ft
= 0.81
= 1.05

And from previous calculation, D = 2.9301 ft, L = 11.721 ft.

Hence C = $ 2330.462
In reference to Table 22.6 in Seider et al (2010), the base cost index is taken from
Chemical Engineering Plant Cost Index, year 195-1959 at 100 while 2006 = 500 to
calculate update factor. Thus update factor, UF = 500/100 = 5.
To calculate bare cost module CBM, the following formula is used with MF taken
from Table 4.11 of Biegler et al. (1997) at 4.23.

C16

= ()( + 1) = $ 80 400.94 = 289 443.38

The exchange rate as of June 2015 is RM3.60 for every US$.

C.5.2. Flash Drum (V-002)

Sizing

S21
V-002
S20

S22
3
v(lb/ft )

= 0.068437

3
l(lb/ft )

= 69.49754

Kdrum = exp [A + B lnFlv + C(lnFlv) + D(lnFlv) + E(lnFlv)4]

K drum

l v
v

Where A = -1.87748, B = -0.81458, C = -0.18707, D = -0.01452, E = -0.00101

C17

= = 0.395674

lnFlv = -0.92716
Kdrum= 0.280209

Column Diameter
AC =

3600

= 0.999595 2

Assuming vertical drum,

For Vertical Column

4
=
= 1.128151 = 0.343864

= + 0.152 = 0.495864

For a typical flash drum

L/D = 4

Therefore height of Drum

L = 1.983458 m

C18

Vapor Height to centerline of the feed

= 36

1
1
+ = 1.1623
39.37 2

Height of the centerline of the feed to liquid surface

= 12

1
1
+ = 0.5527
39.37 2

The depth of liquid pool

=

= = 0.2685
2
4

2
=
= 0.1067 3
4

2
= 0.3830 3
4

Dimensional Design of Column

hv = 1.1623

hf = 0.5527
L=

hl = 0.2685

D = 0.4959

Costing
Operating pressure = 1 atm = 14.7 psig

1.9835

C19

Design pressure = 14.7 1.5 = 22.05 psig

From Biegler et al (1997), Table 4.2, pressure factor, FP = 1.00 since safety pressure
22.05 psig is in the range of 0-50 psig.
Taking into consideration of other factors such as corrosion, erosion etc. material
factor, Fm = 3.67 for solid stainless steel 316.
MPF = (1.00)(3.67) = 3.67
Assumptions,

Vertical vessel

L/D ratio is 4

Cylindrical pressure vessel

To calculate base cost,

= ( ) ( )

Where from Table 4.11,

Co = $ 1000

Lo = 4 ft

Do = 3 ft

= 0.81

= 1.05

And from previous calculation, D = 1.6269ft, L = 6.5075 ft.

Hence C = $ 780.097
In reference to Table 22.6 in Seider et al (2010), the base cost index is taken from
Chemical Engineering Plant Cost Index, year 195-1959 at 100 while 2006 = 500 to
calculate update factor. Thus update factor, UF = 500/100 = 5.

C20

To calculate bare cost module CBM, the following formula is used with MF taken
from Table 4.11 of Biegler et al. (1997) at 4.23.
= ()( + 1) = $ 26 913.35 = 96 888.05
The exchange rate as of June 2015 is RM3.60 for every US$.

C21

C.6

PUMP

Sizing
Heuristic 39: Estimate theoretical horsepower (THp) for pumping a liquid form:
THp = (gpm) (pressure increase, psi)/ 1714
1

FX= x mass flowrate

FEO

882 3

x 1.63174 x 264.17 3 x 60

= 8.145103
Fwater =

= 2.995
FMEG =

999.9 3

1115 3

x 680.11 x 264.17 3 x 60

x 12583.41 x 264.17 3 x 60

= 49.688
FDEG

1118 3

x 197.4 x 264.17 3 x 60

= 0.777
FTEG

1125 3

x 84.41 x 264.17 3 x 60

= 0.330
Q = Ftotal = 8.145103 + 2.995 + 49.688 + 0.777 + 0.330

= 53.798
THp

= 53.798 x
= 0.416 Hp

13.246
1714

C22

Costing for pump

S = QH0.5

H=
=

100
0.012 5.02
92.89
1.46
0.6231
882 + 999.9 + 1115 + 1118 + 1125

= 1108.61 3
Inlet Pressure, Pi

= 0.0987 atm =10000.78kg/ms2

Outlet Pressure, Po

= 1 atm

= 101325kg/ms2

= (101325 10000.78) 2

13
1108.61

2
9.81

= 8.397 m
= 27.55 ft
S

= 53.798(27.55)0.5
= 282.38

CB

= exp {9.7171-0.6019[ln(S)] + 0.0519[ln(S)]2}

= exp {9.7171-0.6019[ln(282.38)] + 0.0519[ln(282.38)]2}
= $ 2902.27

CP

= CBFTFM
= 1.00(2.00)(2902.27)
= $ 5804.54

Costing for motor

PC

= -0.316 + 0.24015(ln53.798) 0.01199(ln53.798)2

C23

= 0.5953
0.416

PB

= 0.5953 = 0.6988

= 0.8 + 0.0319(ln0.6988) 0.00182(ln0.6988)2

= 0.7883
0.416

PC

= 0.5953(0.7883) = 0.8865

CB

= exp{5.8259 + 0.13141[ln(0.8865)] + 0.053255[ln(0.8865)]2 +

0.0028625[ln(0.8865)]3 0.0035549[ln(0.8865)]4}
= $ 333.88

CP

= FTCB
= 1.3(333.88)
= $ 434.04

Total cost

= 434.04 + 5804.54
= $ 6238.58

CBM

= CP (I/IB)(FBM)
= 6238.58 (500/381)(3.4)
= $ 2738.58
= RM 100226.95

C24

C.7

DISTILLATION COLUMN

Sizing

Assumptions:
-

tray spacing

= 0.3m

extra feed space

= 1.5 m

disengagement space = 3.0 m

skirt height

= 1.5 m

= 5D

density of carbon steel = 0.284Ib/in3

From Chapter 2,
Number of stages is 3 stages

Seider et al. (2010) presented a sample of calculation on columns sizing and costing.

Tray stack

= (NA 1) x tray spacing

= (3 1) x 0.3 m
= 0.6 m

Column Height, L

= tray stack + extra feed space + disengagement space + skirt

height
= 0.6 + 1.5 + 3.0 + 1.5
= 6.6 m
= 21.65 ft = 259.84 in
L

Column Diameter, D = 5 =

6.6
5

= 1.32 m

= 4.33 ft = 51.97 in

C25

Costing

T (C)

P (psi)

Top

223

14.7

Bottom

217

14.7

Operating

197.3

14.7

Operating pressure of distillation column is greater than 10 psi. So need to calculate

value of Pd.

Design Pressure, Pd
= exp(0.60608 + 0.91615 ln(Popr) + 0.0015655(ln Popr)2 )
= exp(0.60608 + 0.91615 ln(14.7) + 0.0015655(ln14.7)2 )
= 21.76 psi
The design temperature is chosen from the highest temperature in table above which is
223 C = 433.4F. By adding 50F, Td = 483.4 F.

For carbon steel at this temperature, the maximum allowable stress, S, is 15,000 psi
(Seider et al., 2010). Assume that the wall thickness will be less than 1.25 in, giving
weld efficiency, E, of 0.85 (Seider et al., 2010). From the pressure-vessel code formula,
Wall thickness, tp

P D

d i
= 2SE1.2P

21.7651.97

= 2150000.851.221.76
= 0.044 in

Therefore, specify a steel plate thickness, ts, of 1.25 in,

C26

Vessel Weight, W

= (Di + t s )(L + 0.8Di )t s

= (51.97 + 1.25)(259.84 + (0.8 51.97))(1.25 0.284)
= 17890.37 Ib

Purchase Cost, Cv

= exp(7.2756 + 0.18255(ln W) + 0.02297(lnW)2 )

= exp(7.2756 + 0.18255(ln 17890.37 ) +

0.02297(ln 17890.37 )2 )
= $ 78087.05

The material factor, Fm, is 1.0 (Seider et al., 2010). Thus, FmCv = $ 78087.05. To this is
added the cost of the platforms and ladders, CPL.

CPL

= 361.8(Di )0.73960 (L)0.70684

= 361.8(4.33 )0.73960 (21.65)0.70684
= $ 9400.91

Purchase cost at CE index of 550 for just the tower, platforms and ladders is,
Cp

550

= (500) (78087.05 + 9400.91)

= $ 96236.76

To this must be added cost of 2 bubble cap trays, CBT.

CBT

= 468 exp(0.1739Di )
= 468 exp(0.1739 4.33)
= $ 993.72 per tray

Upgrading cost index to 550,

Cost of trays, CT

= NTFNTFTTFTMCBT
2.25

2.25

where NT = Total no of tray =2, FNT = 1.0414NT = 1.04142 = 2.07, FTT = 1.87,
FTM = 1.0 (Seider et al., 2010)
So, CT

550

= (2 2.07 1.87 1 993.72 )(500)

C27

= $ 8462.50
Total Cost, CTotal

= $ 96236.76+ $ 8462.50
= $104699.26
= RM 377126.73

Bare Module Cost, CBM = CTotal FBM (Seider et al., 2010)

where FBM = 4.16 (Seider et al., 2010).

So, CBM

= 377126.73 4.16
= RM 1568847.21

C28

C.8

MIXER

Density:

Flow rate:

Ethylene Oxide, EO = 882.00 kg/m3

Water, H2O

= 1000 kg/m3

Mix, mix

= 977.76 kg/m3

Ethylene Oxide, FEO = 10151.988 kg/hr

Water, FH2O

= 49837.32 kg/hr

Therefore,
Actual flow rate:
Ethylene Oxide, FactEO

Water, FactH2O

Total Fact

(10151.988 / 882) 3600

0.003197 m3/s

(49837.32/ 1000) 3600

0.013844 m3/s

0.01704 m3/s

Assume space time, = 180 s

Therefore,
Volume, V

Fact

0.01704180 s

3.0672 m3

From Chemical Engineering Volume 6, 2nd Edition,

Mixer with propeller is selected, therefore;

C29

= 1150 rpm
= 19.1667 rps

= 3.0672 m3

( Dt Dt Dt)/6 = 3.0672 m3

Dt

= 1.8027 m

Where, assume;
H

= 1.5Dt
= 2.704 m

Vessel diameter, Dt = 1.8027m

Vessel Height, H = 2.704 m

Based on figure 10.58, Chemical Engineering Volume 6, 2nd Edition,

D/ Dt = 0.4
p/ D = 1.0

Therefore,
Impeller diameter, D = 0.33Dt
= 0.33 (1.8027)
= 0.595 m
Blade pitch, p = 1.0 Dt
= 1.8027m

Using Gambill method to calculate viscosity mixture

mix1/3 = XEOEO1/3 + XH2OH2O1/3

C30

Viscosity, : Ethylene Oxide

= 14 10-4 Pa.s

Water

= 3.5 10-4 Pa.s

Mixture, mix

= 5.0061 10-4 Pa.s

Reynolds Number, NRe

= (D2N )/
= [(0.595)2 (19.1667977.76)] 0.00050061
= 13252994.64

From figure 10.58, Chemical Engineering Volume 6, 2nd Edition,

At

NRe

= 13252994.64and curve 4,

Np

= 0.3

Therefore,
Np= P / D5N3p

Rearrange,
P

= Np D5N3p
= (0.3) (0.595)5(19.1667)3(977.76)
= 147660watt
= 147.66kW
= 198hp

Costing for mixer

Since mixture sizing,

Volume, V

= 3.0672 m3

Diameter, D

= 1.8027 m

Height, H

= 2.704 m

C31

Mixer is sized as vertical fabrication.

From Systematic Methods of Chemical Process Design Biegler et al (1997), pp. 134.

Co = $ 690
Ho= 4.0 ft
Do = 3.0 ft
= 0.78
= 0.95
From the results calculated,
D = 1.8027 m or 5.9144 ft
H= 2.704 m or 8.871 ft

Therefore,
Base cost, BC = Co (H/ Ho)(D/ Do)
= 690 (8.871/4.0)0.81(5.9144/3.0)0.98
= $ 2497.78

Based on BC calculated, the module factor, MF for this mixer is:

MF = 3.18

The material and pressure factor, MPF for mixer is:

MPF = Fd= 2.0 (stainless steel)

Here the bare module cost is modified by the following factors:

Uninstalled cost, $ = (BC) (MPF) = $ 4995.56
Installation, $ = BC (MF-1) = $ 5445.16
Total installed cost, $ = BC (MPF + MF 1) = $ 10440.72
Total cost, RM = 3.25 (BMC) = RM 33932.34

C32

C.8

EVAPORATOR

Sizing For Multiple Effect Evaporator

1st Effect
1

A1 = 11
=10870611.62/(3123)(11.1745)
= 311.50 m2
=3352.96ft2

2nd Effect
2

A2 = 22
=8457361.453/(1987)(11.85)
= 359.19 m2
=3866.29 ft2

3rd Effect
3

A3 = 33
=9322113.434/(1136)(20.117)
= 400.88 m2
=4315.04 ft2

C33

Costing for Multiple Effect Evaporator

By using formula for Long Tube Vertical (rising film) with material stainless steel.
Cp = 5700(A)0.55
1st Effect
Cp = 5700(3352.96)0.55
Cp = 495290.87$
CBM = 495290.87 x 2.45 x 3.7
= RM 4489811.76
2nd Effect
Cp = 5700(3866.29)0.55
Cp = 535656.93$
CBM = 535656.93 x 2.45 x 3.7
= RM 4855730.02

3rd Effect
Cp = 5700(4315.04)0.55
Cp = 569005.30$
CBM = 569005.30 x 2.45 x 3.7
= RM 5158033.05