APPENDIX 1
EQUIPMENT COST ESTIMATES
The following section provides very rough cost estimates for a wide variety of process equipment. It must be remembered in using these charts that there is no such thing as an exact, definite, fixed price for any piece of equipment of a given size or capacity. As with buying merchandise, clothing or a car there are many styles, quality differences, optional features and designs to meet specific needs or services. Presumably charts could be made for each of these variations, but the nuinber would be large and confusing, and for many preliminary estimates the engineer would not know exactly what he wanted at that stage of the design, so only average, representative equipment should be more useful. Again, a range of prices could be shown, but usually a single line is more practical, keeping in mind that the price could quite normally vary considerably depending upon the exact design requirements and the company policy on quality, maintenance, and so on.
With these generalities in mind, the following charts have been taken from a number of sources. Most are from cost estimating articles or books, although some are from recent vendor quotations. In case only a single source was available, that reference has been noted. However, often many sources were available and a somewhat biased consensus of opinion curve was selected. In this case the sources were not noted except for inclusion in the reference list at the end of the appendix. In case different variables were used as the sizing parameter, the most logical one in the author's opinion was selected.
All costs were factored to an early 1987 basis, or a chemical engineering index number of 320. When equations were available for the cost relationship they were listed beneath the charts, and when straight line functions existed for the costs on log-log paper a sizing exponent was given:
(size 2)SiZe exponent
cost size 2 = cost size 1 -.--size 1
In a number of references various authors have estimated the fraction of the purchased equipment cost that it takes to install the equipment. This generally included freight and shipping costs, foundations, mounting, and simple electric and piping connections, such as switch gear, starters, flange connections, and so on. Unfortunately these numbers often varied widely, so the range and average are both listed when available:
255
256 APPENDIX 1
installed cost = purchase price x installation factor
A similar number that also includes all of the adjacent minor equipment and connec-tions is sometimes listed in the literature (principally by Guthrie 1975 and Ulrich 1984) covering the cost of purchase and installation of the major equipment as well as all of the supporting equipment around each major unit. This is called the module factor, and when available is also listed under the charts as the range given by different authors and the average value.
cost of the installed module = purchase price x module factor
As a final item under the equipment cost graphs, often a simple factor can be used to estimate the cost of some other material, pressure, size, or other variable for the equip-ment, than is shown on the graph. For instance, the cost of a stainless steel agitated tank is 1.7 times the cost of a mild steel tank (which is shown on the chart). These factors have also been listed when available, and again, sometimes as a consensus of different authors' estimates .
8 0 . ;;; Ii o u
10 I
Adsorb.rs. Activated Carbon
Mild steel construction, including instruments and controls
6 8 10 20
Weight of carbon. 1,000 lb.
Equations:
, , , 40 60 80 100
Cost = 15.200 + 1, 100WC O.4 81 for We > 250. < 10,000 lb. Cost ~ 76,200 + O.422Wc 1.2 for We > 1 0.000, < 200 ,000 lb . We == weight of activated carbon, Ib,
200
1000
800
600
400
200
100
80
60
0 40 a ;;; Ii 0 u 20
10
8
Size exponent :
Turbine : > 30 HP 0.68 4-30 HP 0.56
< 4 HP 0.23
Propeller: 3- 100 HP 0.51 1-3 HP 0.42
EQUIPMENT COST ESTIMATES 257
Agiwtors
Dual [urbine blades; mild steel; 30- 45 rpm, motor, gear reduction, shaft Propeller; mi ld .teel, single blade
6 8 10 20 40
Size, HP
Installation factor:
Turbine Propel ler
Range 1.20-40 1.12-32
Module factor 2.0
Average 1.32 1.22
60 80 100 200 400 600 BOO 1000
Factors for: ~ Average Turbine:
Single blade 0.75-0.85 0.82 56-100 rpm 0.57-0.70 0.66 125-230 rpm 0.37-0.51 0.47 316 stainless 1.23- 1.87 1.47
Propeller : Stainless steel 1.19 With seal Ifor closed tank) 1.32
258 APPENDIX 1
Agitated TankS'
Jacketed , ogitated, m i ld steel
lOOO~ ___ _ 800~
20 40 60 80 tOO 200 400 600 tOOO 2000 4000 6000 10000 20000
Size, gal
Size exponent 0.53 Instal lation factor : Material factors : Module factor 2.5 Range Avg . Stain Ie .. steel
Open tank 1.41 - 66 1.58 1.22.2, .",) . = 1.7 low pressure 1.30 57 1.44 GI ... l ined Autoclave 1.50 70 1.60 1.2 - 2.0, ."') . 1.6
See Reactors
1000
800
600
400
200
~ iii 100
B 80 0
60
40
20
10 1
EQUIPMENT COST ESTIMATES 259
1-- ' - 1-I-
I ~-- 1--
1-'-'-;"
1=-:-
::------c---._-' ,
,--
1- ./
Air Conditioning
Compressor, motor, controls, condenser. refrigerant
-8 10
Size exponent 0.73
Installalion. Module factor 1.38- 53 avg. 1.46
20 40
Refr igeration, tons
60 80 100 200
'One ton = 12,000 Btu
1---
I:
.. - .
-I-
1-
400 600 800 1000
o 8, iii
260 APPENDIX 1
20 40 60 60100
Size exponent.s: Ribbon, double arm, sigma, twin shell 0.60 Double cone 0.42
Material factor:
304 stain Ie" steel 1.6
Blenders
Mi ld steel construction
200 400 600 BOO 1000
Capacity, ftl (Approximately HP X 0.125)
Installation factor 1.30
Modu Ie factor:
H,DDon 2.0 Sigma 2.B Double arm, cone,
twin shell 2.2
2000
0
8~ in
is u
1000
800
600
400
200
100
SO
60
40
20
10
8
6
1 100 200
Si2e exponent :
30 psi 0,52 10 psi 0,79
262 APPENDIX 1
---100
80 ..
~
40 0" :: ..
20
g I :
1--
1000
800
600
400
200
0
8. ;;; 100
S 80
60
40
20
20
EQUIPMENT COST ESTIMATES 263
Boilers, Waste Heat
40 60 80 100 200
Flue gas flow rate, 1,000 sclm
Size exponent 0.75
I nstallation factor:
1.40-82 a.g . 1.67
Modu le factor 1.81
Factors:
High- temperature operation 1.2
Finned tubes 1.5 Alloy-clad tube. 3.0 M@chanical ash
removal 1.8 Radiation section 2.0
8 0. ;;; B u
264 APPENDIX 1
1000
800
600
400
200
100
80
60
40
20
10
6
100 200
Build ing'
Office type with air cond itioning. restrooms. plaster Or equivalent walls, insulation, modest architectural features
400 600 800 1000 2000 4000 6000 10000 40000 60000 100000
Floor space, ftl lincl. all floors)
Size exponent O.S Factors:
Warehouse 0.25 Laboratory 1.5 Manufacturing bldg. 0.5
400
200
100
o o 10 15 20
Installation factor:
Range 1.20-2.02
EQUIPMENT COST ESTIMATES 265
Centrifuges
Solid- bowl, screen-bowl, pusher types, 316 stainless steel
25 30 35 40 45
Capacity, t/hr
50 55
Material factors:
allY . 1.54 Carbon steel Monel Nickel
60 65
0.68 1.35 1.7
Module factor: 2.0 Hastalloy C 2.6
266 APPENDIX 1
Chimneys, Stacks
Carbon steel, lined, insulated, with foundations Itall); No lining Ishon)
7.0
6.5
6.0
5.5
5.0
4.5
~ 4.0
8 0 , 3.5 iii
3' 3.0 2.5
2.0
1.5
1.0
.5
300
20 40
Size exponent, Tall 1.63
Installation factor : 1.20-28 aV\j. 1.24
400 500 (T . 11) 600 Height, tt
60 60 (Soon) 100
Factors for: Brick lined 2.3 Concrete 3.8 O iameter(~'p.55
I shon) 54 i nJ
700
120
28
26
24
2.2
20
18
16
14
12
10
8
6
o IlOO
140
Material factor, Shon
Acid resistant. Fiberglass 1.3
~ 0 :
, '" tf 0
U
10000
8000 1:-:-: .-
6000 1- ' -
f- :-'" 4000
";:- :'.-'-"C
2000 :~ ~~
~:--= '-- _.
=~ . . ~ 1000
800 , .... .. , .. 600
8 c=.. 0 . 400
;;; _ .. -:;;' 0 :..; U
200
!=;::::-:::.
I==: 100
80 1--
60 r--~
40 I~':
20 F-.;.c
~ :::-:-1--- r-
10 ,-- I-I
, ... r-
,
,.:: .... '-- 1-:-
8 10
Size exponent 1.32
EQUIPMENT COST ESTIMATES 267
Classifier, Rake or Spiral
Mild steel construction
I ,
' .. '
I ~
. . :;' f. " ... ~.. 1-' "- 1'"
I:-=:::j-.... _+ . . : ~ _:" I ~ 1- 1--
20 40 60 80100 200 400 600 800 1000
Solids handling capacity, t/h r
Installation factor
1.63-2.61 avg.2. 12
Module faclor 2.3
268 APPENDIX 1
.c .8
"" ~ .6 c: E " '8 .4 '0
0 0 D . .2
Vl
is u
Size exponent
10' - 1as Ib 0.78
Instal lation cost:
1.29- 2.03 avg. 1.72
Modu le factor
Vertical 4.16 Horizontal 3.05
Columns, Dls1i llation. Absorption Towers, etc. Mild steel construction , 0- 50 psi , vert ical
10 o iam eter r ft 10' 10'
Weight,lb
Material factors
Carbon steel 1.0 Stainless 304 1.7 Stainle" 316 2.1 Monel 400 3.6 Titanium 7.7 Carpenter 20 CB- 3 3.2 Nic~el 200 5.4 Inconel600 3.6 Incolcy 825 3.7
Ot h er factors Horizontal vessel 0.6
p 0.44 Pressu re 50 or see chart
10' 20
10
Pr.ssure factors (vertical)
psi psi 50 1.00 800 3.80
100 1.25 900 4.00 200 1.55 1,000 4.20 300 2.00 1,500 5.40 400 2.40 2,000 6.50 500 2.80 3,000 8.75 600 3.00 4,000 11.25 700 3.25 5,000 13.75
100
80
60
40
20
8 '" ~ 10 t
8 Co
B 6 u
Instaliation factor 1.20 Number factor:
25 1 20 1.05 15 1.25 10 1.50 5 2.30
3.0
EQUIPMENT COST ESTIMATES 269
Column Trays
Mild steel
8 10
Column diameter, ft
rray type factor;
20 40
Turbo grid I,tamped) 0,8 Grid, plate, ",ive 1 ,0 Trough, valve 1 ,2
Material factor:
Ijrass 1.2 304 ,tainless 1.5 316 stainless 1.9 347 stainless 2.1 Incone l 3.3 Monel 7.7
'" .I:' U.
~ u
270 APPENDIX 1
90
80
70
60
50
40
30
Material Factors; size exponents
Material
Berl saddles Porcelain
Pall ring 55 Polypropylene
Size exponent
- 1.16 - 0.64 - 0.95
Column Packing
Ratio for other material
1.24 Stoneware
0.30 Carbon steel
Size, in.
Material Size exponent
I nterlox $Odd Ie. Porcelain - 0.4 Polypropylene ...{J.95
Rasch ig rings Porcelain - 0.5
Ratio for other material
0.94 Stoneware
6.11 Stainless steel 2.35 Carbon 1.5B Mild steel 0.78 Stoneware
800
600
400
EQUIPMENT COST ESTIMATES 271
Compressors, Medlum ~ Low Pressure
20 40 60 80 100
Size exponents:
Straight lobe SI id i ng van. Helical screw Reciprocating (air)
0.51 0.79 0.87 0.34
200 400 600 800 1000
Capacity. ",11m in
Installation factor:
1.3C>-87 ; OV9. 1.49
Modu le factor :
2.2- 3.1 ; avg. 2.6
2000 4000 6000 10000
Factors:
Straight lobe:
Pressure (fo ) 0'.
~ (fl
B u
272 APPENDIX 1
10000
8000 I c- -6000
f- -_ .... ,
F ';
4000 r~
1= i== . .. F==~
2000
" 1000 "'
,
800 1'-'
600
400
200
r----1===1-b I
100 "
80 " ..
60
40
20
1-'- I- . , 1--
Compressors, High-Capacity and/or Pressure
1,000 psi; electric mOt.or dri~e. gear reducer, steel
: , I " I I I I
" , ,
" ,
~~~ ~ .
, I
, ,
" . .- -- [._ . .. . I -:
. . . :. b:~
I--::: .~
:.:
~ . 1:-:"
~= t' I
"
, ,
1-
... ::.:: 1'::' 10
10 20 ~o 60 80 100 200 400 600 800 1000 2000 4000 6000 10000
Size exponent 0,80
Equation: (I sothermal compression)
HP ~ O.0044P,Q, In P,/P, P, ;; inlet pressure, psi P2 ..,.. outlet pressure, psi 0 1 inlet flow rate, cfm
HOrSepower
Installation factor :
1.30-87; avg, 1.49
Module factor :
2,15-3.1; avg. 2,6
Factors:
Turbin. drive 1.13 Gas engine 1.41
p ( P ) 0.1' ressure 1000
Stainless steel 2.5 Nick le alloy 5, 0
1000
800
600
400
200
100
80
60
8 40 0 .
iii
0 '-'
20
10
6 8 10
Sile exponent :
Screw conveyor Belt conveyor Bucket elevator. rol l Pneumat ic conveyor Vibrating
Installation factor :
0.7B 0.76 0.5 0.37 1.0
Range 1.40-2.15 avg . 1.72
Modu Ie factors:
Screw. pneumat ic. ro ll 2.2 Belt, bucket, vibrat ing 2.4
EQUIPMENT COST ESTIMATES 273
Conveyors Mild steel construction
20 40
Length, ft 60 80 100 200
Size faclors:
(dian:eter) 1.2 Screw conveyor 9 10 .
( width) D.6 Belt conveyor "i6Tr1."""
400 600 800 1000
( bucket wd . X hI. ) 0.37 Bucket elevator 6 X 4 24 in.2
. (diameter) 0 .55 Pneumatic conveyor --nn.-
Rol l (2~:~) 0 .55; 4 in. spacing X 0.B4
. . (width )0.51 Vibrating 36Tii":
(; c-
'iii c
~ ~
~ .J:J E
.:'1 " ~ 9; 0; '5 ~ ~ a 8, ;;; 1i 0
0
i "0 8 '" '0 j in
,3
274 APPENDIX 1
1000
800
600
400
200
100
80
60
40
20
10
6
1 1
Coolers, Quenchers
Mild steel construction; Cascade cooler . 2 in. diameter pipe
- ,--7"''- : ~~~~'
'=---'t:,= ;'; ~ ~~,
,,=-- ~:::c: , -
==--~ _. ,
c--- 1--
II I " ,
, -
~
~.:....,- '-' --
I nstallation factor:
1.40-1,85; o.g. 1.62
Module Factor:
- ~: ' F~ , ' I =.. ,~ ':: i -e I , ;
" ~
I I I I I
)faY cham_ber
I
:::Q~" .. I
':~
I
~~ I 1'-,
~-;;;':co;;;;= II
II I" 1:= "c. I- - = I~~.: ,:"-- 1-= f=
8 10 20 40 60 80 100 200 400 600 800 1000
Heat transfer surface, h ' Icascade cooler) In,et flow rate, 1,000 elm (quencher, spray chamber)
Duct diameter, in, (dilution air port)
Equations:
Spray chamber: 5(358 X M scI + 65,000) Quencher 51 335 X M scI + 12,200)
Factors:
Cascade cooler
(pipe d i~meter)O.6 2 In,
Spray chamber, quencher 2.7
EQUIPMENT COST ESTIMATES 275
Cooling Tower
15"F range, 10" F approach, 82" F weI bulb
1000
800
600
400
200
~ V> 100
1; 80 0
60
40
20
10 ., .2 .6 .8 1 4 6 8 10 20 40 60 80 100 Capacity, 1,000 gpm
Size exponent 0.79 Wet bulb temperature Ins-tallation factor 1.20 "F Factor Approach , .e.," F Factor Module lac tor 1.70 68 0.65 6 1.60 Factors; 70 0 .68 8 1.20
e "F t 57 72 0.72 10 1.00 Range: """'i"5""' 74 0.77 12 0.85 76 0.82 16 0.65 78 0 .87 20 0.50 80 0 .93 24 0.40 82 1.00
276 APPENDIX 1
800
600
8 400 0.
Vi 1i 0 u 200
100
80
60
40
20
10 1 8 10
Size exponent:
Cooling, evaporative 0.68 Growth, forced
circulation, OTB 0.63 Vapor recompression 0.75
Courtesv of Swenson,
Crystallizers
Mild steel construction
20 40 60
Capacity, tons per hour
Installation factor:
1.30-2.03, avg. 1.80
Modu le factor:
2.4- 2.9, avg. 2.6
80100
Material factors:
Stain less steel 2.1 Copper alloy 1.3 Nickel alloy 2.6 Titanium 6.0
1000
800
600
400
200
100
80
60
8 40 0 . y;
5 u
20
10
8
6
EQUIPMENT COST ESTIMATES 277
Dryers
Mild steel construction
200 400 600 800 1000 2000 4000 6000 10000
Size exponents:
Rotary dryer Fluid bed Spray dryer
Peripheral area, ft2 (rotary dryer) Volume, ft3 Wuid bed, spray dryer) + 10
0.45 0.48 0.29
Installat ion factor:
1.25-96; avg. 1.64
Module factor:
Rotary 2.3 Fluid, spray 2.7
20000 40000 60000 100000
Factors:
Rotary to: Roto- Louvre 1.25 Vacuum shelf 0.35
Ishelf area)
Materials:: Nickle alloy 3.7 8rick -lined.
stainless ;teel 2.2
0 0 C( ;; .; 0
U
278 APPENDIX 1
1000
800 i--== -= 600
r:= ~~'
400
10::-
~ 200
100
80 r-;c
60
40
20
1=
1-----. 10
6 ~
1.::.=::1--
Ducts
Wall thickness 1/8 in.
6 8 10 20 40 60 80 100
Duct Diameter. In.
:~: - ...
I :': 1-'--1 :
1-1--
-- f- f--I -. ~~
200 400 600 800 t 000
Size exponent : 1.08
Installat ion factor: 1.45
Equations: Si ft Factors: Mild 'S1eel (- 2.22 + 1.66D) Mild steel: Stainless (- 6.43 + 5.84D ) (wall thickness/ 1/8 in.)o . Water cooled (79 + 6.78D) Stai nless:
(wall thick ness/1 /8 in.) 1.0
1000
800
600
400
200
100
80
60
8 40 0_
v; --(; u
20
10
8
--1- I- I-1---
.~'" ,.' ~ ~
I~-~
.,-,.
I==-
1.,.-7'" I-
1=-:
1=-= f"---
F:':: I-
i=: ~ ---I--~-. ~--
F== ~. p;. I-
~
1= V-
~.: 1--:-... I-1-
I nstallation factor:
1.76- 2.00; ""9. 1.90
,
EQUIPMENT COST ESTIMATES 279
Oust Collectors Mild steel const f'" ' jC iOFl
- j--j-
- ;~ ~,~ I
~~::-1 ~ m
~o"~ ';" -(j~
8 10 20 40 60 80100
Ga, Flow Rate, 1,000 clm
Module factors;
Electrost.atic precipitators 2.3 Bag f ilters 2,2 Venturi scrubber 2.5 Cyclone. mul t iclone 3.0
1-- 1- >"
f. ::- Ic.:
! .~
I ~
0'..,. 1::"::
,"'---,.
:"~ ,~ . .::
--" -"- ----.c.C . . _
_ ... -200 400 600 800 1000
Material factors for venturi , cyclone scrubbers:
High temperature with membrane. bric~ lining 1.6
304 Stainless 1,8 316L Stainle.. 2,1 316L Slainiess, clad 1.9 Monel 3.0 Monel clad 2.7 Titanium 3.2
280 APPENDIX 1
40 60 60 100
Si~e exponents:
Forced circu lation 0.7 Falling film, long, s~on tube 0.53
Also, see Cyrstall izers
Evaporalors '
Single effect; sta in less steel
200 400 600 800 1000
Heat exchange area, ft2
Installation factor:
1.5-2.50; avg. 2.09
Module factor :
Forced circulation 2.9 Falling Film 2.3
2000
Material factors:
Mild steel Copper alloy Nickle alloy Titanium
0.44 0.57 1.22 2.93
1000
800 1----1 1-
600 1==
400
1'--
-:.:: . 200
1-
100
60 1---
60
8 1=',' 0:'" . 40 ;;; ,-.-: t;;' 0 u
20
1---
10
~
=,
-1
1
EQUIPMENT COST ESTIMATES 281
:._ ...
" - 1-
Fans Mi ld steel; motor, starter; 311 in. H, Oap
8 10
III
--
20 40 60 60 100
Flow Rate, 1,000 elm 200
Installation factor ; Factors:
Range : 1.30-2.05; a.g. 1.61
Module lactor: 2.2
( t.P) 0 .3 Pressu re: 3.5 Fiberglass: 1.8 Stainless steel : 2.5
400 800 800 1000
8. V>
o u
282 APPENDIX 1
1000
6
8 10
Size exponents:
Rotary vacuum drum, leaf Vacuum table. tilt ing pan, belt Pressure leaf, plate Be frame
0.39 0.5 0.61
20
Filters
Stainless steel
40 60 80 100
Fi lter area, ft '
Installation factor :
1.19-2.21 ; a"9. 1.69
Modu Ie factor:
200
Rotary table, belt , tilt ing pan 1.4 - 2.8; a"9 . 2.4
Others 2 .8
400 600 1000 2000 4000 6000 10000
Factors: Rotary drum; belt/ screw or string discharge 1.22
General/paper pu lp 2.' 7 -3 .38 Mild steel/stainle .. steel 0 .69 Vacuum table mild steel/55 0.48 Vacuum filter auxilliaries (vac . pump .
receivers. etc ." Often - 50% of filter cost
;;; t: o u
800
EQUIPMENT COST ESTIMATES 283
Flares Mi ld steel , High Btu , with accessories
2000 4000 6000 10000
Size exponents:
Elevatoo 0.59 Ground 0.39
I nstal lation factor 1.45
'H igh = 1,000; low = 60 Btul ft'
20000 40000 60000 100000 200000 400000 600000 1000000
Waste gas flaw rate, Ib/h r
Factors:
Ground : Low/ High Btu, 0.3 Elevatoo : Low/ High ' Btu, O.S Corrosive 2.0 Guyoo ( 100 ft .). selt- support ing
(xel .,tOO) 1.3- 1.B
8 q ;;;
8
284 APPENDIX 1
10000
8000
800
200
100
80
60
40
20
10 1
Size ex.ponents:
Hershott Box Cylindrical
6 8 10
0.48 0.70 0.78
Furnaces
Mild Sleel tubes
Type Bo)( Furnace Factor Pressure Factors
500 1000 2000 1.04 1.12 1.26 1.06 1.15 1 .32 1.08 1.22 1.42
--(psi I 100 1.0 1.0 1.09 1.0 1.34 1.0 1.24 1.34
20 40 60 80 100 200 400 600 800 1000
T-ansterred h.at, MM Btu/ hr
In,,", ll.tion f.ctor: Material factors:
1.30-71; a"9. 1.52 Cy, indric.', vertical tubes: Stainless Sleel 1.74
Module factor: 2.1 Chrome/ moly 1.44 with Dowtherm 1.33
Hershott diameter: 6-19 It 10/61 55 > 19 10/6165
8000
6000 ----
h = I'
4000 I-==--
- 1--"-r- '
800 ___ ..
---600
---1-, ---
100
80 1_,
60 1--
I-~ 40 F -'::- __ 1_
20 1=:=--I...c.... _-:
I-:r 10
100 200 400 600 800 1000
Size exponents:
Diesel driye 0.71 Turbine driye 0.76
EQUIPMENT COST ESTIMATES 285
GeneratOr, Electric Power
.. -
." :: . ...
2000 4000 6000 10000 20000 40000 60000 100000
Electric generat ing capacity. KW
Instal lation factor:
2.22- 2.39 ayg . 2.31
Modu le factor 2.5
Factors: Gas/diesel engine 1.81 Coal /oi l, gas (turbinel 1.29
286 APPENDIX 1
1000
800 == F 600
400
= 200
F r.:-
~ .; ,
100 I
80
60
g 40 0.
Vi of 0
0 20
f::--p:: ',oel 10
8 ,'A,,"
8 0.
;;; 1);' 0 0
100
60 : : :-:c:c 60
. ;:=. 40
["::
20 r--
1=-:.;-10
C-----_ .. -
-
-:c: .
.. --. 1 10
EQUIPMENT COST ESTIMATES 287
1-=
I'
I--
I
Heat Exchangers: Spiral. Plate and Frame
304 stainless steel; no insu lation
:: ... ' ,:"f~e: . :..'">. ' 0'
I I
20 40 60 60 100 200 400 6008001000
Size exponent :
Plate & frame 0.78
Equations:
Spira l plate : S 660Ao." Pla te & frame: S ~ l00AOJ8
Heat transfer area, ft2
Installation Factor:
Plate & frame : Mild steel 1. 70 Sta i nle.. 1. 53
:::'=1:"
I
I.::: .;::
2000 4000 6000 10000
Material Factor:
Mild steel 316 stainless Nickel Titanium
0.43 1.1 1.2 2.6
o 8. II>
~.
288 APPENDIX 1
10000
Size exponents: Rotary ki ln Hearth Catalyt ic Direct flame
0.48 0.64 0.75 0.39
8 10
Incinerators Mild steel construction
20 40 60 80 100 200 400 600 SOO 1000
Heal input, 1()" Btu/hr
Module factor 2.2 Factors:
Corfosive material 1.5 Toxic waste 2.0 316 stainless 2.7 Monel 3.3 Nickel 3.5
00
BO 1-- . f--
OIl
40
20
f-'--101-----
g 4 "
1-,-1-
.1 .2
EQUIPMENT COST ESTIMATES 289
Insulation
2 in. th ickness for pipe
' ,
, -teork iV~ls)
,
.4 ,6 .8 1 8 10
Pipe size. in.; InS(J lation th ickness. in. (ves.sels)
Insulation thickness factors for pipe:
3 in. 1.5 1% in. 0.7 1 in. 0.55 % in. 0.4
1+
I..:: 20 40 60 BO 100
290 APPENDIX 1
Ion Exchange'
Mild steel construction; 465 ppm removed
1000
aoo
aoo
400
200
100
80
60
8 40 0 .
;;; tf 0 u 20
10
8
6
10 20 40 60 80 100 200 400 600 800 1000 2000 4000 6000 10000
Water treated, gpm
Size exponent: 0.97 Installation factor; Factor
Module factor 2.0 , .58-65, a.g. 1.62 , A) Ions removed (_ 0.5 1
465
(-35 ppm typical for boi ler makeup)
.. See water treating. (-~20 ppm typical for cooling tower makeup)
1000
800 I-t-- 'r
600
~-400
1::-:: ..;:::--= ,- _.
200
[. 1---1--'
100
80
-, 60
.'c'. 8 40 0. 1:::::-: (I)
:;f 0
0 20
17:-:--
P= 10
1---
p =----
,"-
~::.-i, - -1--- - ' 1
,~- - l-I
,
, ':
EQUIPMENT COST ESTIMATES 291
Mills ; Hammer, Jaw, Gyratory, Roll Crushers
I
"
"
~ iii!
r~ I~~-~~;
, ,
"-II: --
,-I--
,,,:1-' :7 ~
r-
1--
1-
----1-" '--- I:::. 8 10 20 40 60 80 100 200 400 600 800 1000
Mill capacity, t/hr
Modu Ie factor: I nstallation factor :
1.30-2.15, avg, 1.83 Hammer 2,8 0 1hers 2,1
292 APPENDIX 1
Mil ls: Ball, Rod, Pebble (Wet), Jet, Rubbish
Reduct ion ratio 34 (i.e., - 1/ 2 in. - 65 mesh; 3/4 in. - 45 mesh)
Size exponent
Shredder Mills; installed
purchased
0.53 0.62 0.70
Grinding capacity, t/ hr
Installation factor:
1.30 - 2.15; avg. 1.83
Modu lar factor:
1.8 - 2.B; avg. 2.3
Factors:
Ball, etc. mill, Size reduction
( R ed~~t ion ) 1.3
Dry/ wet = 1.25
100
80
60
40
20
10
0 E
"lii
! 8 0 ,
u;
1l u
0.8
0.6
0.'
0 .2
0.1
EQUIPMENT COST ESTIMATES 293
Motors Drives
Electric : totally enclosed, fan cooled ITE FC)
c-'-f-
~
t::-:-:-:--
f---'-
f-.-
_\;;~ ;:;~~ ..
~-:0~ :\e' " .
=--=
...;..~~
- _.
== :=
/ - -7" ---
--
_._ ! :'. I::~ ll'
:A" h fPc I- :-rt l"-'_I __
:= 1-'':'' ::::;;
1-:
-- 1- .. ,--1- 1- -- f-
~ I~:
1000
100
10
-: :::.: .::: := ~- :Smal ~ motors, varable 'sp~ jrive, . -- - - I ,
1 8 10
100
Size exponent :
Electric motors, small 0.86 Gas turbine, engine 0 .76 Steam turbine 0.41
Module factor:
20
200'
' 0 60 80 100
400 600 800 1000
T urbines. engines, large motors. HP
Variable speed drives : Ratio 1.5 to 5/ 1
6/ 1
Factor 1.0 1.08
Electric 2.0 (1.5 on fans, pumps, compressors) Gasoline 2.0 Gas, steam turbines 3,5
2000 4000 6000 10000
Factors : Electric motors Speed, 1800 1.0 rpm 3600 1.04
1200 1.6 900 2.6
Construction : TE FC 1.0 Explosion proof 1.2 Drip proof 0.74
~ 0 E ., ~ 8 0. u;
0 U
" c.
294 APPENDIX 1
BOO
:'j;:~~-. 200 ~;~.::
--:-:-0
~ .. .:::... 100 -_.
ii: 10
-,
.. _. =:=' =, ...:.~, -:--~-
-= C.::: . '1 ' j -- f/'-
,._-
8 to
Si~e exponent :
Pipel ines 0.99
Pipe, Pipelines
Mild steel
20 40
--1- '-: .-.
1-"-
--- 1"-
=:b:
-'.~+' ' 1" -_. ,---- ::-..:I~:- I "
60 80 100 200 400 600 800 1000
Pipe size, in ,
Factors : 304 stain less, schedule lOS
Bar. pipe 2 .05 Traced, insulated 3.4
Fi ttings 18 Valves 94
EQUIPMENT COST ESTIMATES 295
'0
Presses: Roll, Screw
Mild steel construction
20 40 60 80 '00
Capacity, tlh r
I nstallation factor: 2.05 Material factors :
Module factor: 2.4 Stainless steel Nickle alloy
200
1.5 1.9
400 800 800'000
296 APPENDIX 1
:; u
Factors: Conven tiona l
Size exponent Installation 1.30 Module factor 1.5 Cast steel 1.4 316 sta in less 2.0 Copper alloy 1.3 Nickel alloy 3.6 Titanium 5.7
Pumps. Centrifugal
Cast iron, horizontal, includes mOlor, coupling, base
6 8 10 20 40 60 80 100
In-l ine
1.27 1.75 1.3 1.6
Flow X pressure , gpm X psi X 1,000 {approximatel '~ HPI
Pressure factor : Ax ial Mixed Flow Flow
0.79 0.79 In-line 1.58 1.32 Conventional 2.05 1.70
Factors:
Conventional :
200 400 600 800 1000
to 150 150- 500-psi 500 psi 1000 psi
1.00 1,48 1.92 1.0 1.62 2.12
APS/AVS = 1.6 In-l ine: vertical/ horizontal . 0.89 Mixed , ax ial flow : vertical / horizontal 1 .12
100
80
0 60
0 u; co 40 0
.~
:s '5 20 .~
.s= u ",'
Iii 10 > '" c: '0 ~
~ C)
a 4 ~ en Ii 8
1 1
Factors
Size eXpOnent Installation Module factor Cast iron Cast steel Stain less Nickel alloy 0-150 psi 150-500 500-1000
EQUIPMENT COST ESTIMATES 297
Pumps, Miscellaneous
Mild steel construction
20 40 60 80 100 200 400 600 800 1000
Flow X pressure, gpm X psi X 1,000 (approx imately HP)
Rec iprocating
0.59
3.3 1.0 1.8 2.4 5.0 1.0 1.32 1.53
Turbine
0.47 1.38 1.80
Chemical In jection
0.52 1.58 2.83 1.0 1.25 1.95
1.0 1.37 1.79
General installation factor:
1.25 - 2.40; avg, 1.74
Factors:
Other size e)(ponents:
Diaphragm .43 Rotary .52 Gear .75 Sump .15
Reciprocat ing: .:l.P 11,000 - 5,000)/(0 - 1,000) ~ 3.8 Sump: 3600/1800 rpm ~ 1.2
120011800 in . 1.5 Chemica l injection: Fixedl variable speed 1.67
298 APPENDIX 1
1000
800
600
400
200
100
80
60
:; 8
40
q ;;; :;;' 0 20 U
'0
8
6
6 8 10
1000 4000 6000 10000
Size exponent: 15 psi (gal) 0.64
Pressure Vessels' Mild steel construction
40 60 80 100 20
20000 40000 60000 100000
Vessel weight, Ib
See columns for pressure and material correction factors.
200
200000
10000
8000
6000
aOOO
2000
1000
800
600
~ 400 8
0 .
U;
200 g
100
80
60
40
20
10 400 600 800 1000
400000 1000000
EQUIPMENT COST ESTIMATES 299
Reactors-304 stain I ... steel; jacketed; no agitation
80
70
60
50
. '"
40
B u
30
20
10
0 0 6 9 10 11 12
Reactor volume. 1.000 gal
Module factors: I nstallation factor : Material factors:
Stainl... 1.8 1.40 - 2.10; ""9.1.70 316 stain Ie.. 1.2 Gla .. lined 2.1 Gla .. lined .8 Mild steel 2.3 Lead lined .7
Mild steel .6
OSee agitated tank~
300 APPENDIX 1
0
8. :i>
:s u 200
100
80
60
40
40 60 BO 100
Size exponent 0.69
'One ton 12,000 Btu
Refrigerat ion 40 00 F temperature
200 400 600 800 1000
Refrigeration, tons
Installation, Module factor
1.38- 53; avg. 1.46
2000 4000 6000 10000
Evaporat ive temperature factor's:
+20F o
- 20 - 40
1.5 1.9 2.4 3.5
100
80
60
40
ZO
'" 10 ;;; 0
U
6 8 10
Size exponent: 0.75
Module factor : 2.8
EQUIPMENT COST ESTIMATES 301
Screens, V ibrating
Mi ld steel, single deck
20 40
Screen area, ft2
I nstallation factor ;
1.45- 2.27; avg. 1.85
60 80 100 zoc 400 600 800 1000
Factors:
Double deck Stainless steel Nickel alloy
1.6 1.25 1.8
302 APPENDIX 1
100
BO
60
40
20
8 q ;;; 10 1;; 0
U
1 .1 .2 .4 .6 .B
Size exponent
Pug mill 0 .15 Pellet mill 0.12 Pellet izing rolls 0.58
Installation factor : 2.05
Size Enlargement Mild steel construction
6 Capacity , l/ hr
Factors
8 10
Module factor Stainle .. steel Nickel alloy
20
Pug mill extruder ---u-
1.2 1.4
Screw/pug mill extruder Disk/drum granu lator
40 60 80100
Disk, drum granulator Others
fa ~ 1.1 1.2 1.3 1.4
5.6 0.68
EQUIPMENT COST ESTIMATES 303
Tanks Mild steel construction unless otherwise noted
1000
800 1-' 1--
600
400
200
100 rT-
80
60
8. 40 (ii
B u 20
Small cone top large cone top
i_ -
8 10
Size Module exponent factor
0.51 1.6 0.51 1.9
Horizontal, pressure 0 .72 2.08
Spher. 0.62 1.87
Fiberglass 0.71 Small storage 0.71
-
,
, -20 40 60 80 100
Tank capacity. 1,000 gal
Pressure factor
200 250 psi 1.18 1.38 50 75 100 125 200 [ij8 1-:19 US f39" f53
Ii
.. - 1=
1- 1-
~ ~.
~ I~
:
~ __ .c Ie;' 1:-... - -.- ::::: .-... -=
200 400 600 800 1000
Factors:
Rubber lined 1.5 Lead lined 1.6 Stainless 2.0 Floating roof;
large, field eretted 1.8
Ins'tallation factor :
1.20 - 2.30. avg. 1.88
304 APPENDIX 1
Tanks, (Smal l) 304 sta inless steel
l00 _____ ~
o o O.
;;>
U
. 1 .2 .4 .6 ,8
Size exponent
Dished head. 50 psi Flanged. dished head Cone toP. bottom, legs FI.t toP. bottom
Capacity. 1,000 g.1
0.68 0.48 0.57 0.93
10 20 40 60 80 100
Factor
316/304 st.in less steel 1.39
o o o. ;;;; Ii 8
EQUIPMENT COST ESTIMATES 305
Thickeners, Clarifiers
Rake mechanism, concrete tank, drive
8000
40
20~_1I 10~
10 20 40 Size exponent : 1.03 Installation factor :
1.63-2.61; avg . 2.12
Module factor: 3.0
60 80100
Diameter. ft
200 400 600 800 1000
Tank factor : Concretel steel 0 .7 for units under 40 It diameter
8 q (I)
:;;' 0 u
306 APPENDIX 1
1000
800
600
400
200
100
80
60
., .4
Vacuum Equipment M ild steel or cast iron
8 '0
Ejector Factors
1 surface condenser 1 .6 2 surface condensers 2.3 1 barometric condenser 1.3 2 barometric condensers 1.7 1 stage 1.0 2 stages 1.8 3 stages 2.1 4 stages 2.5 5 stages 4.0 Cast iron 1.0 Caroon steel 1.3 Stainless steel 2.0 Hastelloy 3.0 Nick le alloy 2.2
20 40 60 80100 Capacity factor , equiv. air flow.lb/ hr/ vacuum, mm mercury;
Water throughput , 1,000 gpm (barometric condensers)
Size exponents: Installat ion factor 1.12
Module factor 2.2 Vacuum pumps 0.75 Steam iet ejectors 0.42 Barometric condensers 0.67
REFERENCES
Allen , D. H., and R. C. Page. 1975. Revised techniques for predesign cost estimating. Chemical Engineering (March).
Alonso, J. R. F . 1971. Estimating the costs of gas cleaning plants. Chemical Engineering. Axtell, Oliver, and James M. Robertson. 1986. Economic Evaluation in the Chemical Process
Industries. John Wiley & Sons, New York. Beckman, James, ed. 1986. Series Design of Equipment. Vol. 1, Plant Design and Cost Estimating.
American Institute of Chemical Engineers, New York.
EQUIPMENT COST ESTIMATES 307
Bennett, Richard D. 1987. Evaporator, crystallizer costs. Swenson Process Equipment Inc., 15700 Lathrop Ave., Harvey, IL 60426; 1988, Matching Crystallizer to Material, Chemical Engineering (May 23): 118-127.
Blecker, H. G., H. S. Epstein, and T. M. Nichols. 1974. Wastewater Equipment. Chemical Engineering (Oct.).
Chase, D. J. 1970. Plant costs vs. capacity. Chemical Engineering (April). Chemical Engineering, compo & ed. 1979 and 1984. Modern Cost Engineering: Methods and Data.
2 vols. McGraw-Hili, New York. Chemical Engineering, compo & ed. 1979. Process Technology and Flowsheets. McGraw-Hili,
New York. Clark F. D., and S. P. Terni. 1972. Thick wall pressure vessels. Chemical Engineering (April). Corripio, A. B., K. S. Chrien, and L. B. Evans. 1982. Estimate cost of heat exchangers and storage
tanks via correlations. Chemical Engineering (Feb.): 125-127. Desai, M. B. 1981. Preliminary cost estimating of process plants. Chemical Engineering (July 27). Epstein, L. D. 1971. Costs of standard vertical storage tanks and reactors. Chemical Engineering
(July 13):141-142. Fang, C. S. 1980. The cost of shredding municipal solid waste. Chemical Engineering (April
21):151-152. Guthrie, Kenneth M. 1974. Process Plant Estimating, Evaluation, and Control. Craftsman Book
Co., Solana Beach, CA. Hall, R. S., J. Mately, and K. J. McNaughton 1982. Current costs of process equipment. Chemical
Engineering (April 5). Happel, J., and D. G. Jordan. 1975. Chemical Process Economics. Marcel-Dekker, New York;
219-231. Herkimer, Herbert. 1958. Cost Manual for Piping and Mechanical Construction. Chemical
Publishing, New York. Hoerner, G. M. 1976. Nomograph updates process equipment costs. Chemical Engineering (May). Holland, F. A., F. A. Watson, and J. K. Wilkinson. 1974. How to estimate capital costs. Chemical
Engineering (April). Huff, G. A. 1976. Selecting a vacuum producer. Chemical Engineering (March). Kharbanda, O. P. 1979. Process Plant and Equipment Cost Estimation. Craftsman Book Co.,
Solana Beach, CA. Klumpar, L. V., and S. T. Stavsky. 1985. Updated cost factors: process equipment. Chemical
Engineering (July 22):73-77. -. 1985. Commodity materials. Chemical Engineering (Aug. 19):76-77. -. 1985. Installation labor. Chemical Engineering (Sept. 16):85-87. Koenig, A. R. 1980. Choosing economic insulation thickness. Chemical Engineering (Sept. 8). Kumana, Jimmy D. 1984. Cost update on specialty heat exchangers. Chemical Engineering (June
25): 169. Lindamood, D. M. 1985. Most economical thickness, hot-pipe insulation. Chemical Engineering
(April 1):96. Meyer, W. S. and D. L. Kime. 1976. Cost estimation for turbine agitators. Chemical Engineering
(Sept.). Miller, J. S. and W. A. Kapella. 1977. Installed cost of a distillation column. Chemical Engineering
(April). Moselle, Gary, ed. 1979. National Construction Estimator. Craftsman Book Co., Solana Beach,
CA. Mulet, A., A. B. Corripio, and L. B. Evans. 1981. Estimating costs of distillation and absorption
towers via correlations. Chemical Engineering (Dec. 28):77-82. -. 1984. Pressure vessels. Chemical Engineering (Oct. 5). Patrascu, Anghel. 1978. Construction Cost Engineering. Craftsman Book Co., Solana Beach, CA.
308 APPENDIX 1
Peters, M. S., and K. D. Timmerhaus. 1980. Plant Design and Economics/or Chemical Engineers. McGraw-Hili, New York.
Pikulik, A., and H. E. Diaz. 1977. Cost estimating for major process equipment. Chemical Engineering (Oct. 10): 107-122.
Purohit, G. P. 1985. Cost of double-pipe and multitube heat exchangers. Chemical Engineering (March 4):92-96. (April 1):85-86.
Sommerville, R. F. 1970. Estimating mill costs at low production rates. Chemical Engineering. -. 1972. New method gives accurate estimate of distillation cost. Chemical Engineering (May). Swearingen, Judson S., and John E. Ferguson. 1983. Optimized power recovery from waste heat.
Chemical Engineering Progress 79 (Aug):66-70. Ulrich, G. D. 1983. A Guide to Chemical Engineering Process Design and Economics. John Wiley
& Sons, New York. Valle-Riestra, F. J. 1983. Project Evaluation in the Chemical Process Industries. McGraw-Hili,
New York. Vatavuk, William M., and Robert B. Neveril. (1980-1983). Air pollution control systems (Parts
1-16). Chemical Engineering (Oct.-May). -.1980. Pollutant capture hoods. Chemical Engineering (Dec. 1):111-115. -. 1984. Practical emmissions control. Chemical Engineering (April 2):97-99. -. 1984. Gaseous emmissions control. Chemical Engineering (April 30):95-98. Vogel, G. A., and E. J. Martin 1983. Estimating capital costs of facility components. Chemical
Engineering 90 (24) (Nov. 28):87-90. -. 1984. Operating costs. Chemical Engineering (Jan. 9):97-100. -. 1984. Incinerator costs. Chemical Engineering (Feb. 6): 121-122.
APPENDIX 2
COMPLETE PLANT COST ESTIMATING CHARTS
The following charts indicate the complete cost of plants to produce various chemicals in differing tonnages. The information has been assembled primarily from four sources: (1) curves on 54 plants published by Guthrie (1974), (2) curves on 18 plants published by Chemical Engineering (1973/1974), (3) 33 nomographs, and about 140 single plant size-cost data notations by Kharbanda (1979), and (4) several hundred recent plant construction notices in Chemical Engineering's Construction Alert. The first three sources are quite old, with most of the information gathered from the mid-60s through the early 70s. The last source was data from 1980 through 1987. Each source was inftation-corrected to 1987 (CE Index of 320) by means of the Chemical Engineering (CE) Index.
The first two references were probably quite authoratative when published, and repre-sented contractor prices for that plant alone, plus the necessary raw material and product storage. The infrastructure for a "grass roots" plant, or even for minor utility and other required nonplant facilities was not included. The later two sources, on the other hand, are basically press-release information stating what the complete facility cost. This might include land, site development, and/or any of the infrastructure required to make the plant function. Costs would thus be higher, and the assembled data would be much more scattered because of each location's different requirements.
Both factors, the early data's age, and the most recent data's complete cost basis, tend to limit the accuracy of the plots. When considerable data were available, high, low and average lines were shown. Presumably the high values represent more infrastructure requirements. When only one data point (i.e., one plant cost at one size) was available, the capacity versus cost line was drawn with a slope of 0.64, the average size-cost exponent of Guthrie's 54 plants.
Normally it should be expected that the costs shown in these plots should be roughly correct, and perhaps on the high side. However, some of the data from the first three references appear to be very low, so caution should be used with all of the charts. They may be useful as a guide, but not too much confidence should be placed in their accuracy. The basis for the costs should be considered as a reasonably high value for the plant alone, plus storage, and the CE Index 320.
309
310 APPENDIX 2
60
20
8 o g 0,10
;;;; 8 :;;' o u
8 10
Size exponent
Acetic acid Acetone Acetylene Acetaldehyde
Plant Costs, A
20 40 60 60100
Capacity, tid
0.59 0.55 0.65 0.41
Raw material
Methanol Propylene Hydrocarbons Ethylene
200 400 600 600 1000
200
100
0 0
~f o.
'" ~~ 0 u
10
"Assumed
COMPLETE PLANT COST ESTIMATING CHARTS 311
6 8 10
Size exponent Acryl ic fi ber Acrylonitrile Alkyl benzene (linear) Aromatic,s Acryl ic acid
Plant Costs, A
20 60 60100 200
Plant capaci ty, tid
1.02 0.60 1.07 0.40 0.64"
Raw material
Acrylon itrile Acetylene, hydrogen cyanide
400 600 600 1000
312 APPENDIX 2
60
40
8 20
o ~ ~ 10 ~
8 c .. 0::
I 10 20
Size exponent"
Allyl chloride Acetic anhyd ride Adipic acid Aniline
40
Alylales, detergent
, All assumed
Planl COSIS, A
60 80100
Plant capacity, tid
200 400 600 800 1000
Raw material
0.64 0.64 0.64 0.64 0.64
Propylene, C12; Dich loropropane Acetic acid Cyclohexanol Benzene; nit ric, 5ulfu ric acids
1000
800
600
400
200
tOO
80
10
COMPLETE PLANT COST ESTIMATING CHARTS 313
Plant Costs, Aluminum Chemical.
20 40
Siz e exponen ts
Alumina Alumina, sintered Aluminum
60 80 100 200
Plant capacity, tid
400 600 800 1000
Assumed Aluminum sulfate
0.54 0.64' 1.0 0.64'
Raw materials
Bauxite Alumina Alumina Bauxite, H2 S04
314 APPENDIX 2
1000
800
600
400
200
100
80
0 60 0 0 g 40 '" a 0
" 20 iii 0::
10
20
Assumed
Pla nt Costs, Ammonium CompOunds
40 60 80 100
Size exponents
Ammonia Ammonium nitrate Ammonium sulfate Ammonium phosphale Ammonium perchlorate Ammonium bicarbonate
200 400 600 800 1000 2000 4000 6000 10000
Plant capacity, tId
0.58 0,65 0,67 0,64' 0,64' 0,64'
Raw material (process) Gas, air Ammonia; Iprilled) Ammonia. sulfuric acid, (crystalized ) Ammonia, phosphoric acid , (granulatedl Ammonia, CI2 Ammonia, CO,
80
60
40
8 20 o
~ ;;; t; 8 c ..
0::
I I
Size exponent
Butad iene Butanol Butanol Benzene Benzoic acid Bjsphenol A Butanol Butane, iso Benzene, toluene, xy lene
0.63 0.48 0.69 0.73 0.64' 0.64' 0.64' 0.64' 0.64'
COMPLETE PLANT COST ESTIMATING CHARTS 315
to
Planl COSIS, B
20 40
Planl capacity, tid
Raw malerial Iprocess)
Butane; butylene Propylene Butylene
60 80100
Toluene, H2 lDetol) Toluene Acelone; phenol Elhanol Butan e, pentane Reformate (extraction)
200 400 600 800 1000
Factors for benzene process:
DOIOI 1.0 Litol 1.42 Pyrotol 1.48
Assumed
316 APPENDIX 2
100
80
8 60 g 0 . 40 ;;;
10
t 1
Size exponent
Carbon black Chlorine Caprolactum Cyclohexane Carbon tetrachloride Carbon d isu lfide Cement Cyanoacetate Ch loroacet ic acid , mono
Assumed
0.S7 0.47 0.52 0 .49 0.48 0.64' 10 0.64' 0.64'
Plant Costs, C
10 20 40 60 80 100 200 400 600 800 1000
Plant capacity , tId lor cement, 10 bbl/d)
Raw material (process'
Aromatic oi ls; gas N.CI brine lelectrolysis)ICaust ic soda by product; 1.07 Ib/ lb C12) Cyc/ohex.ne, NH , IAmmonium sulfate by-product; 1.7E Ibllb caprolactum ) Benzene, H2 Prop.ne, CI 2 IPerchlorethylene by-product ; 1.33 Ib/lb CCI, )
1000
800 I-- 1-' . 1--1-
600 F==
400 I~=-
200
...
~.
100
80 - ~: 0 80
8 ci 0 40 O.
in
8 ~
20
0::
10
6
1=
--= .. -1
COMPLETE PLANT COST ESTIMATING CHARTS 317
Pla nt Costs, C
, , I
8 10 20 40 60 80 100 200
Pl ant capacity, tlhr
Siz e ex ponent-
Citr ic acid 0.64 Carboxymethyl cellula,. 0.64 Cellu lose ace late 0.64 Cumene 0.64 Cyclohexanone/clyclohexanol 0.64 Ch loroprene monomer 0.64
Raw mater ia l (process)
(Submerged fermentation) Cellulose Cellulose Benzene, propylene Benzene, H2 Butad iene, CI2
,-I-=-
1--
400 600 800 1000
.. All size exponents assumed Factor for chloroprene raw materiaL Acetylene 1.57
318 APPENDIX 2
Plant Costs, D
600
P!3nl capacity. lid
Size exponent
DMT 0.51 Diphenyl amine 0.64' Dichlorophenoxyacetic acid 0.64' DDT 0.64' Detergent alkalate 0.64' Detergent alkalate 0.64 Diethanol amine 0.64 Dimethyl terephthalate 0.64' Dioctyl phthalate 0.64' Dimersol 0.64' Dimersol, ethylene 0.64
' Assumed Oiphenyl methane d iisocyanate 0.64
Raw materia l
Grassroo ts plants
Pllenol Ch loral , Chlorobenzene Propylene tetramer. benzene n- paraffin Ethy lene oxide. ammonia p- xylene , methanol Phthalic anhydride
Dimerization
8 ~i o. ;;;
Size exponent
Ethane Ethylene E thy I ene ox ide Ethyl benzene Ethyl chloride Ethylene d ichloride Ethylene glycol
Assumed
40
0.65 0.85 0.80 0.64 0.64 0.64 0.59
COMPLETE PLANT COST ESTIMATING CHARTS 319
Plant Costs. E
60 eo 100 200
Plant capacity. t Id
Raw material
Petroleum Gas:, naptha, gas oil, etc. Ethylene Ethylene. benzene Ethylene. HCI Ethylene. CI, Ethylene ox ide
400 600 800 1000 2000
Raw material factors for Ethylene (1350 tid; SI68 MM)
Ethane 1.0 Propane 1.10 Naptha 1.48 Gas oil 2.76
(produces 0.59 t propylenel t ethylene)
~
320 APPENDIX 2
60
40
20
;;; 10
1;;'" 8 8 li 6 ~
Plant Costs. E
__ II I--
1 1
-Assumed
B 10 20 40 60 SO 100
Plant capacity. tid
Size exponent
Epichlorhydrin 0.64 Ethyl ether 0.64 Ethyl hexanol 0.64 Ethyl diamine 0.64
Raw material
Al lyl ch loride Propylene. synthesis gas Acetaldehyde Ethylene dichloride
c.:;:
-- [.::: 1::::
200 400 600 800 1000
~ u E .. n:
COMPLETE PLANT COST ESTIMATING CHARTS 321
Plant Costs, Ethanol l Fermentation), Methanol
6 10 20
Size exponents
Methanol Ethanol
Ethanol plant capacity, MM gallvr Methanol , 100,000 t/vr
0.78 0.90 > 10 MM gal/vr 1.0 to 10 MM gal/yr
Raw materials (process)
Methane, CO, H2 (Fermentat ion)
322 APPENDIX 2
100
SO
60
40
"
0 20
8 0" 8, , , , ;;; 10 :;;'
8 8 ~ 0::
1-:-..:::1::: 1 - .-.
I-- ,:.'-'..: I:::I-F -' i-+
Plant Co,ts, F
I ~
8 10 20 40 riO 80 100 200 400 600 800 1000
~Assumed
Plant capacity, tid
Si.~e eXpOnent
Formaldehyde
Fatty alcohol Fluorocarbon Ferric chloride Fructose, crystalline Fructose, syrup
0.55 0.66 0.64' 0.64' 0.64' 0.64 0.64
Raw materials
Hydrocarbons, aqueous Methanol Coconut oil Carbon tetrachloride, H F Ferrous chloride, CI2
COMPLETE PLANT COST ESTIMATING CHARTS 323
Size exponent
Glycol 0.79 Glycerine 0.64'
.. Assumed
Plant Costs, G
Plant capacity, tId
Raw materia I
Ethylene, CI , A l lyl alcohol, epichlomydrin
324 APPENDIX 2
100 V -f---
80 :;:; =
60 - I 8 40 D .
~~
~ 20 0:: 1-=0
I=-~ .-= o
8 f----I--
6
Si2e exponent
Argon Oxygen Hydrogen LNG SNG Garbon dioxide
Plant Costs, Gases
II
1- 1-
.-
r=:::::I--. I-I-:' -- I - 1- .. 1- 1- .
6 8 10 20 40 60 80 100 200 400 600 800 1000
Plant capacity : argOn 1,000 sefh; SNG, 1,000,000 sefd; hydrogen. oxygen, tid; LNG, 1,000 tid
0.89 0.59 0.65 0.68 0.75 0.72
Raw material, process
Air, liquified Air. liquified Methane; partial ox idation; reforming Tea I arc process Coal
Factors for SNG feedstock
Coal 1.0 Crude oil 0.6 Medium, heavy gas oil , 0.5 Naptha, kerosene, 0.3
light gas oil
8 o
g '"
COMPLETE PLANT COST ESTIMATING CHARTS 325
Plant Costs, Liquid Air, Hydrogen, Carbon Dioxide, Oxygen, Nitrogen
200 400 600 800 1 000
Plant capacity, tid
Size exponent
Carbon dioxide, liqu id Ox.ygen , liquid A ir. nitrogen, liqu id Argon , hydrogen, liquid
0.72 0.37 0.66 0.66 (esl.l
2000 4000 6000 10000
326 APPENDIX 2
o 60 o o 0' ~ 40 in
10
8
6 f-------
I ::::-1::--I
I
"Assumed
, , ,
Size exponent
8 10
Hydrochloric acid Hydrofluoric acid Hexamethylene tetramine Hydrogen peroxide Hydrogen cyanide
Planl Costs, H
20 40 60 80 100 200 400 600 800 1000
Plant capacily, tid
0.69 0.72 0_64' 0.73 0.70
Raw materials
Sail, H 2 SO, INa, SO, by- prod U cl I CaF" H,S0 4 Methanol, ammonia lsopropy lene alcohol, 0, Propane, ammonia
Assumed
COMPLETE PLANT COST ESTIMATING CHARTS 327
a 10
Size exponent
Isoprene I soprapano I I sobutvlene lsooctanol Impact modifiers Impact modifiers for
Methylmethacrylate-butadiene- sty rene
Plant Costs. I
III
20 40 60 80 100 200
Plant capacity. tId
0.49 0.73 0.64' 0.64' 0.64' 0.64'
Raw material (process)
Propylene. methanol. O2 Propylene I liquid extract ion) Heptane
1--
I--
.=~'- ..
c_:.:..;... .:~: .....
400 600 600 t 000
328 APPENDIX 2
tOOO
800
600
400
200
100
80
60
g q
40 ;;;
\3 [ij
20 ii:
10
6
"Assumed
Plant Costs, L, M
8 10 20 40 60 60100 200
Plant capacity, tId
Size exponent
Lithium carbonate Maleic anhydride Melamine Methyl chloride Methyl ethyl ketone Methyl isobutyl ketone M ercaptobe nl O th i azole Methyl methacrylate Monochloroacetic acid
0.64" 0.48 0.64" 0.64" 0.64" 0.64 0.64' 0.64 " 0.64'
Raw material
Spodumene are Benzene Urea, ammonia Methanol
An iline Acetone, HCN Acet ic acid. CI ,
400 600 800 1000
8 20 0 8-q
'" ::: 8 ~ n:
. Assumed
COMPLETE PLANT COST ESTIMATING CHARTS 329
Plant Costs, M
8 10 20 40 60 80 100 200 400 600 800 1000
Plant capacity, ti d
Size exponent ~
Monosodium methyl arsonate 0 .64 Magnesium oxide 0 .64 Magnesium hydrox ide 0 .64 Methyl tertiary butyl ether 0 .64 Methyl amine 0 .64
Methanol - see page for ethanol
Raw material
(coproduct sod ium cocodylate - herbicides) Seawater ; brine Seawater; brine (calcined)
(coproduct , O.67 t dimethyl formamide)
330 APPENDIX 2
800
600
400
200
100
80
8 60 o 8-o~ 40
VJ
6 8 iii 20 ii:
10
6
1 1
A .... med
Plant Costs. N
-DB
8 10 20 40
Plant capacity . tid
Size exponent
Ni'tric acid Naplhol B Nylon 616 r .. in Nylon fi lament N itrophosphale N itro compounds, organic
0.59 0.64' 0.64' 0.64' 0.64' 0.64'
- I .. -.
60 80 100 200
Raw material
Ammonia Napthalene Ad ipic acid Dimethyl formamide Phosphate ore. NH03
1--- , ... I .. 1- 1-
400 600 BOO 1000
COMPLETE PLANT COST ESTIMATING CHARTS 331
c .. 0::
800
600
400
200
40
Planl Costs, a
60 80,00 200 400 600 800' 000
Plant capacity, tid
Size exponent
Oxo alcohols Olelins, alpha Olefins, linear, higher
-Assumed
0.74 0.64' 0.64'
Raw materials Olelins, CO, H2 Hydrocarbons; wax
332 APPENDIX 2
8 0 6 8.
100
BO
40
8 20 a 8' q ;;;
10
8 ~ 6 i[
2
Assumed
COMPLETE PLANT COST ESTIMATING CHARTS 333
6 8 10
Size exponent
Protein. single cell Para xylene Phenol
Phosphoric acid Phosphorus Phtalic anhydride Potassium sulfate
Plant Costs, P
20 40 60 BO 100 200 400 BOO 800 1000
Plant capacity, tid
0.64' 0.61 0.68 0.72 0.56 1.06 0.72 0.64'
Raw material (process)
(Crystallizalioni Benzene; loluene Cumene Phosphate rock, H,SO. Phosphate rock, electricity, coke Napthalene; o-xylene Potassium chloride, H2 S0 4
334 APPENDIX 2
BO
0
8 0' 8. Vi ~.
::; u
~
800 ._
600 1--
400
200
100
80
60
:; 20 ii:
10
8
6
4
2
1
1-'
r--
1--,---
COMPLETE PLANT COST ESTIMATING CHARTS 335
Plant Costs, Polyme"
-8 10 20 40 60 60 100 200 400 6008001000
Plant capacity tid
All size exponents assumed at 0.64.
336 APPENDIX 2
1000
800
Pla nt Costs. Polymers
20
Plant capacity. tid
All size exponents assumed at 0 .64 . except Polycarbonate 0.79
200 400 GOO 800 1000
100 '
60 ' ,
g ;;;
10 I
8 10
'Assumed
COMPLETE PLANT COST ESTIMATING CHARTS 337
Plant Costs, S (Organic)
1--
1--
r:::::r::;-
i--';" I- I~ ~I~ 20
Size exponent
Styrene Sorbitol
40 60 60100
Plant capacity, tId
Sulfonated and sulfated surfactants and detergents
0.56 0.64' 0.64 '
200 400 600 800 1000
Raw materials Benzene, ethylene, steam Corn syrup
338 APPENDIX 2
,~
'"
, "
'tlr 10 13 ~
1000
600
400
200
100
80
60
g" 40 q
340 APPENDIX 2
Plant Costs, I J. V, X
8 o 8 0. CI)
1_-10 20
Size exponent
Urea
40
Uranium oxide Uranium hexa fluoride Vinyl acetate Vinyl chloride o-xylene p-xylene
Assu med
60 80100 200 400 600 8001000
Plant capacity, tid
0.64 0.64' 0.64' 0.65 0.88 0.64' 0.64'
Raw materials (process)
Ammon ia, CO2 Uranium ore Uranium ore. fluorine Ethylene Ethylene, CI2 .o,t HCI Mixed xylenes (fractionation ) Mixed xylenes !fractionation I
60 8 8 q ;;; ~'
13 " i Ii:
10
COMPLETE PLANT COST ESTIMATING CHARTS 341
PI.nt COS". Met.,s. C.rbon
8 to 20 40 60 80 100 Plant capacity. tid of metal produced
Size exponents 0.64-1 ,0 avg. 1.0 Carbon fibers 0 .85
200 400 600 BOO 1 000
8 8' o. ;;; ~~ u
~ ii:
342 APPENDIX 2
1000
800 --=- --600
400 i==-'
L-c
~::Z' 200
=-100
80
60
40
F
20
f-C-- -10
8
10
' ....
."
20
Plant Costs. Minerals
-..
40 60 80 100 200 400 600 800 1000
Plant capacity. t Id
Size exponents:
Assumed to be 0.64
1"'-1"-
, 1..- .. ,.
~:.:.:::
1-
1-- = :: 1-.. .. 2000 4000 6000 10000
1000
= = 800 600
400
1=
200
=-100
80
0 60
8 0 0 40 0. ;;; ~f u ;: 20 .. iL
10
8
=
l== 1
1
COMPLETE PLANT COST ESTIMATING CHARTS 343
Plant Costs. Natural Gas Purification
- . ,
- ~~ ~~~~'~
I :.G
, , ~~ .. ~
C .. ~~: :.G'
-8 10 20 40 60 80 100
Plant capacity, M scfd
Size exponents
Gas treat ing alone 0.75 Gas treating with liquids fract ionation 0.75 Sour gas treating with sulfur recovery 0.84
and liquids fractionation
:,~
,
200
i---- ... 1---
1--""
1-- 1' '''
I.:: I:::
400 600 800 1000
0
8 0" 8. Vi .: ::; u
~ 0:
344 APPENDIX 2
1000
800
600
400
200
100
80
60
40
20
10
6
, Assumed
Petroleum Plant Costs, Complete Plants
8 10 20 40 100
Plant capacity , 1,000 bbl /d o r 1,000.000 scfd gas
Size exponent
Complete ref inery Gas processing Wax plant Lube plant Grease plant Re-refined oil
0.86 0.52 0.64' 0.59 0.64' 0.64'
Raw materials
Recovery of " Iight.nd,"
Reclaimed motor oil
80
60
40
COMPLETE PLANT COST ESTIMATING CHARTS 345
I-==r= I-~
Petroleum Plant Costs, Cracking
I-;~ I:: =: _. H -I- 1._
4 8 '0 20 40
Plant capaci ty, 1,000 bbl /d
Size exponent Ortho flow; general ; air li ft TCC 0.49 Hydro cracking; flu id catalytic crack ing IFC;;) 0.~3 Vi,breaking 0.54 Thermal 0.65
60 80
346 APPENDIX 2
200
100
80
60
8' 40
0 .
;;;
~ i 20 a:
10
"Assumed
Pelroleum Plant Costs, Coking, Extraction, Etc.
8 10 20 40 60 80 100 200
Plant capacity, 1,000 bbl/d
Size exponent
Cok ing, delayed Cok ing, fluid bed Aromatics extract ion Residium supercritical extraction Naptha recovery Residium desu lfurization Absorption
0.42 0.64 0.64-0.64 -0.64" 0.64" 0.64-
Operation
Thermal cracking; coke production Thermal cracking; coke prOduction Uquid extraction of aromatics High pressure, temperation extraction Distillation, desu lfurization, etc. Hvdrogenation
COMPLETE PLANT COST ESTIMATING CHARTS 347
Petroleum Plant Costs, Sulfur Removal; Extraction
20
10
a 8 D
~. '" :;; 0
" i ii:
2
1 1
Size exponent
Desulfurizing Hydrotreating Sweetening Gas oil desulfurization
Extraction Propane deasphalting Propane dewaxing Solvent dewaxing
4 6 8 10 20 40 60 80
Plant capacity, 1,000 bbl/d
0.64 0.57 0.78
0.61 0.47 0.66
Operation
Hydrogen treating of lube oils, naptha Treatment of gasoline to remove mercaptans, sulfides Hydrogen treatment of gas oils
Propane liquid ext.raction of vacuum distilled crudes Propane addition, filtration, stripping of diesel, etc. oils Solvent extraction of lube oils
8 8' D ,
;;; :;;' 0
" ~ 0:
348 APPENDIX 2
Petroleum Plant Costs, Gasoline Production, Distllation
60
40
20
10
8 10
Size exponent
Alkylation, low A lkylation, high Distillation, vacuum Disti llation, atmospheric Isomerization Polymerization Reforming. Disti llation
0.63 0.49 0.73 0.87 0.64 0.61 0.63
20 40 60 80100 200 400 600 600 1000
Plant capacity, 1,000 bbl/d
Operation
Med ium weight unsat . hydrocarbons to gasoline
Crude oil fractionation
Hydrogenation to upgrade pentane, hexane, etc. Conversion of olefinic streams into higher octane Dehydrogenation of paraffins, etc. into cycle compounds Genera l dist illation
8 ~ .. ~.
8 c ..
0::
COMPLETE PLANT COST ESTIMATING CHARTS 349
Plant Costs, Power from Refuse, Co--generation
6 8 10 20 40 60 BO 100 200 400 600 800 1000
Plant capacity, MW
Size exponent 0.15
350 APPENDIX 2
8 o . U;
il u
Water (Drinkingl Preparat ion Plants
2000
1000
800
-600 400
200
. ..
1-100
80
80 1-
40
I~"-
20 1-'"
1-:' ._-10
1--' 1--1- '
.1 .2 .4 .6 .8 6 8 10 20
Water production, 1.000 gpm
Size exponents
Desalination 0.89 Standard treatment 0.65 Pumping. clarif ication 0.74
Standard treatment: floculation. clarification. fil tration. chlorination . 'See Desalination graph
1=
i-' 1--' ..
-~
Ie ::: .::::
1, ,- . .
40 60 80 100
COMPLETE PLANT COST ESTIMATING CHARTS 351
Plant costs, Desalination
tOO
80
8 60
0 8
40 q V>
ti 8 c 20 .,
0::
to
8
6
8 to
Plant capacity. million gal pure water/day
Size exponent Mult istage flash dist illation ,
electrodialysis, reverse osmosis 0 .89 Vert ical tube evaporators 0 .82
352 APPENDIX 2
Wastewater or Sewage Treatment
Secondary sewag
COMPLETE PLANT COST ESTIMATING CHARTS 353
Guthrie, Kenneth M. 1974. Process Plant Estimating, Evaluation, and Control. Craftsman Book Co., Solana Beach, CA: 125-180,334-353,369-371.
Guthrie, Kenneth M. 1970. Capital and operating costs for 54 chemical processes. Chemical Engineering (June 15): 140-156.
Kharbanda, O. P. 1979. Process Plant and Equipment Cost Estimation. Craftsman Book Co., Solana Beach, CA.
Process Economics International. 1979-1980. Vol. 1 (2).
APPENDIX 3
MANUFACTURING COST
DATA PRESENTED
There are far less data in the literature on manufacturing cost than on the other compo-nents of cost estimating, primarily because it is a more complex and site, process, or company-specific cost. Some data do exist, however, and they are presented in the following pages. Most of the data are quite old, and difficult to easily update, although an attempt has been made to convert data to early 1987, or CE Index 320 values.
Section 1 presents manufacturing cost versus plant capacity curves of Guthrie (1974), with the percent breakdown into major cost components when available by Kharbanda (1979). The original Guthrie data were probably quite accurate as a first, general approx-imation, but they are old, and may have suffered badly by attempts to extrapolate them to the present time. The percent breakdown tables were undoubtedly based upon one single plant or process and location, and may be far from typical. Both sets of data at best should only be used for order-of-magnitude or "ballpark" estimates.
Section 2 gives some detailed manufacturing raw material and utility estimates from Chemical Engineering (197311974), which also probably were quite accurate when published. The processes may have changed considerably since that time, but at least these values should still be useful for conservative first approximations.
Section 3 provides more of the percent breakdowns of Kharbanda (1979), but now with the single plant size operating cost also estimated. In Section 4 Kharbanda has tabulated (or calculated) the raw materials and utilities required for many processes. As noted previously, the accuracy is probably very poor, but in many cases provides initial rough estimates that are better than nothing, and in other cases it is useful to doublecheck the figures quoted by vendors or others.
METHODS OF USE
Since each of the four sections of data overlap each other, are from different authors, and present limited lists of chemicals, each must be separately examined to make a manufacturing cost estimate. For example, ammonia is found in three of the four section's figures and tables. In cases such as this the data may not be consistent and you will have to make your best guess as to which to use and not use. This will complicate your study, but often there is some component of the information you know or feel more confident of, and this will aid in your selection. For instance, you may have heard that the average U.S. ammonia plant now uses 32 million Btu of fuel per ton of ammonia, and that the
354
MANUFACTURING COST 355
newest plants consume less than 25 million. This can allow you to somewhat adjust and evaluate the data from the three sections.
In other cases, merely knowing the current competitive selling price can allow you to adjust this data somewhat, assuming that the present manufacturers must make at least some profit on the product. This concept can lead you to further examine various alter-native raw materials, processes, and producers, to see where the competitive advantages exist, which may influence and assist in your cost estimates and recommendations.
SECTION 1. MANUFACTURING COST VS. PLANT CAPACITY (1); PERCENT COST BREAKDOWN (3)
Manufacturing Cost, A
600 Acrylonitrile
400 Acetone Acetic acid
Acetylene
Ammonia
Ammonium nitrate
Ammonium SUlfate
40
6 8 10 20 40 60 80 100 400 600 800
Plant capacity, tid
Manu facturing cost, %
Plant Raw Utiliti .. , capacity, tid materials Depreciation ~ Raw materials
Acrylonitrile 85 37 46 17 Propy lene, NH3 Acetone 70 74 6 20 Isopropanol; vapor
70 84 6 10 ; liquid Acetic acid 70 51 24 25 Acetaldehyde, ethanol
140 32 46 22 Methanol Acetylene 50 15 45 40 Hydrocarbon, Ammonia 1000 36 50 14 [email protected]/MM btu Ammonium nitrate 700 77 15 8 Ammonia
356 APPENDIX 3
Manufacturing Cost, B, C, E
: Chlorine
1 I ,
8 10 20 40 60 80100 200 400 600 800 1000
Plant capacity, tid
Manufacturing cost, % Plant Raw Utilities. capacity, tid materials Depreciation labor Raw materials (processl
Butanol 70 68 9 23 Ethanol Ethylene ox ide 85 48 33 19 Ethylene. (SOl
85 68 18 20 Ethylene, IShe11) Carbon black 110 27 50 23 Oil Cyclohe"ane 140 92 5 3 Benzene, H:z Butene 140 32 54 14 Butane Ethylene 280 25 45 30 Ethane; naptha
825 13 44 43 Propane; naptha Ethanol 280 57 24 19 Ethylene
8000
IiOOO
4000
2000
1000
800
c c S
600
Ii 400 8 CI>
.~ .'l ~ 200 ~ c
:!E
100
80
60
40
20
10 6 a 10
Isoprene
Methanol Glycol Formaldehyde
MANUFACTURING COST 357
Manufacturing Cost, F, G, H, I, M
HYdrofluoric acid
Glycol
FormaldehYde f-
HydrOchloric acid
20 40
Plant capacity, tid
60 80100
HYdrogen perox ide
Isoprene
Methanol
200 400 600 6001000
Manulacturing cost, %
Plant Raw Utilitiesl ca~i!y, tid materials De2reciation labor Raw materials
140 42 44 14 Propylene 140 50 25 25 Methanol 200 22 44 34 Methane 110 90 4 6 Ethylene oxide 140 59 23 18 Methanol
358 APPENDIX 3
Manufacluring Com, N, 0, P
1000
800 ~ 0 .t: 600 '" >;;,' 0
" 400 co .!: :; ~ "5 200 ~ i
100 , Plant capacilY, lId
Manufacturing cost. %
Planl Raw Utili ties, capacily, lId materials Depreciation labor Raw maler ial, (process)
Polyvinyl chloride 70 59 24 17 Vinylchloride: (suspe nsion : emulsion)
Phenol 140 43 35 22 (Modified Rasch ig) 140 33 35 32 Cumene
Phlhalic anhydr ide 40 38 50 12 o- xylene 40 53 41 6 Fluid bed: naDhthalene
p-xylene 70 34 50 16 (Fractionation) Propylene 70 77 13 10 Propane Nitric acid 300 53 36 11 Ammon ia
600 _
400
c: 200 ~ ... ~ 100 o 80 11 "; 60 c: .
:::E 40
20
10 1 2 4
Styrene Sulfur Urea Vinyl acetate Vinyl acetate Vinyl chloride Vinyl chloride
6 8 10
Plant capacity, tid
140 150 300
70 70
140 140
MANUFACTURING COST 359
Manufacturing Costs, S, U, V
;u/furic"acid -20 40 60 80100 200 400 600 800 1000
Plant capacity, tid
Manufacturing cost, % Raw Utilities, materials Depreciation labor Raw materials
68 14 1S Ethyl benzene 0 59 41 H, S - rich gas
66 19 15 Ammonia, CO2 70 21 9 Acetic acid, acetylene 49 42 9 Ethylene 80 10 10 Acetylene, HCI 71 15 14 Ethylene, Clz
6
. 2
.1 1
.1 1
Manufacturing Costs, Petroleum Plants
Coking
8 10 20 40 60 80100
Plant capacity, 1000 bbl/day
Manufacturing Costs, Petroleum Plants
8 10 20 40 60 80 100
Plant capacity, 1000 bbl/day
200 400 600 800 1000
200 400 600 800 1000
i 2
~ ;;; Ii o u .8 go
.~ .6 .. c. o
.4
.2
.1 1
MANUFACTURING COST 361
Operating Cost, Wastewater Treatment
i I .--1
8 10 20 40 60 80 100 200 400 600 800 1000
Plant capacity, mill ion gallday
Curve: Primary . secondary treatment , sludge handl ing, chlorinat ion
Factors Sand filtration 0.27 Activated carbon 0.62 Electrodialysis 1.08
Manufacturing Costs
SECTION 2. DETAILED REQUIREMENTS PER TON OF PRODUCT
I. Acetaldehyde 225 tId (75,000 t/yr) (Hydrocarbon Process 1967)
Raw materials: Ethylene Oxygen (99 .5%), scf Air, scf HCl (as 20 0 Be acid), lb Catalyst, $
Utilities: Electricity , KW hr Steam (150 psig) , M lb
One Stage (Oxygen)
1,3401b 9,460
30 2.75
45 2.4
Two Stages (Air)
1,3401b
54 ,000 80 2.75
270 2.4
362 APPENDIX 3
Process Water, M gal Demineralized water, gal Cooling tower water, M gal
Labor, operators/ shift
2. Ammonia (2)
Raw materials: Gas, process and fuel, MMBtu Catalyst and chemicals, $
Utilities: Electricity, kW hr Makeup water, M gal
Labor, operators/shift
3. Benzene (Houdry Hydrodealkation Processes) Raw materials: Detol
Cyclohexane, napthenes Hydrogen, M scf 11.4 Catalyst, $ 0.47 Clay, Ib 0.54
Utilities: Electricity, kW hr 49 Fuel, MM Btu;
consumed 2.26 produced 10.0 net + 7.74
Steam, Ib; consumed produced net
Boiler feed water, gal Cooling water, M gal
4. Butadiene (Shell ACN Process) (2) Raw materials:
Butane Acetonitrile, Ib Other chemicals, $
Utilities: Electricity, kW hr Steam (600 psig, 600F), Ib Refrigeration (@ 40F), Btu Process water, gal. Cooling water (30F rise), M gal
Labor, operators/shift By-products, per ton Butadiene
Butylene, ton 1.335; Light ends, Ib 11 Heavy ends, Ib 89
88
88
4.05
(2)
One Stage (Oxygen)
1.7 120 48 3 t04
Natural Gas
32.6 1.13
15 2.9 5
Pyrotol Approx 98.5% yields
22.6 0.63 0.82
47.2
3.0 25.0
+ 21.8 1,940 1,810 -130
0.72 10.43
98.6% yield 0.296 0.44
72 6,460
71,160 11.8 31.4
1.5
Two Stages (Air)
7.2
48 3-4
Naphtha
32.7 1.23
26.6 3.0 5
Litol
4.9 0.32 0.36
41
3.36 4.9
+ 1.54 300
1,074 + 774
3.91 6.86
MANUFACTURING COST 363
5. Caprolactum (Stamicarbon Process); 38,500 tlyr plant (2)
Raw materials: Cyclohexane, Ib Hydrogen (>95%; 100% basis), Ib Ammonia,lb Aqua ammonia (20% on 100% NH3 basis), Ib Oleum (100% H2S04 basis), Ib Sodium hydroxide, Ib Benzene,lb Tolulene, Ib Phosphoric acid Catalysts, $
Utilities:
Electricity, kW hr Fuel (75 % furnance efficiency), MM Btu Steam, Ib; 440 psig
184 56
Refrigeration (6C), M Btu Boiler feedwater, gal (95C) Process water, gal Cooling water, gal
By-products:
Ammonium sulfate, tIt Hydrogen (40% H2), Ib/t Hydrogen (95% H2), Ib/t
6. Chlorine (Hooker Diaphragm Process) (2)
Raw materials:
Salt, tons Misc. chemicals, materials, $ Diaphragm asbestos, Ib HCI,lb H2S04 ,lb
Utilities:
Electricity, kW hr: to cells other
Steam, Ib: evaporation other
Labor/plant capacity, tId Supervision Operators, man hours Cell rebuilding, man hours Maintenance, man hours
By-products:
Caustic Soda, tIt Hydrogen, Ib/ton
2,120 192 632 962
2,720 200 28 16 10 15.10
376 1.7
14,380 3,340 7,260
126 295 760
42,400
1.75 12 28
3.52 0.12 0.2
10 12
2,980 250
5,460 700
200 One man per shift
500
0.52 0.22 0.03 0.016 0.32
2.14 56.32
0.17
900
0.18 0.016 0.12
364 APPENDIX 3
7. Cyclohexane (IFP Liquid Phase Hydrogenation Process) (2) Raw materials:
Benzene,lb Hydrogen, Ib Catalyst, $
Utilities: Electricity, kW hr Steam (300 psig), Ib Boiler feed water, gal Cooling water (lOC rise), gal
By-products: Fuel gas, Ib Steam (65 psig), Ib
8. Cyclohexanol (Stamicarbon Process) (2) Raw materials:
Cyclohexane, Ib Caustic soda, Ib Catalysts, $
Utilities: Electricity, kW hr Steam, Ibs: 454 psig
56 psig Refrigeration (OC), M Btu Process water, gal Cooling water, (8C rise), M gal
1,870 130
11
8 370 230
4,000
620 1,900
2,200 180
1.56
200 7,300
700 66
101 101
9. Ethylene (propylene) (Lummus Naphta Pyrolysis Process) (2) Raw materials: High Severity;
ethane recycle
Medium range naptha, tons (117-308 of; 73 API) Catalysts, chemicals, $ Utilities:
Electricity, kW hr Fuel, MM Btu Boiler feed water, gal Cooling water, M gal (25F rise)
Labor: Operators, foremen/shift
Maintenance material, % of capital
By-products, Ib/ton ethylene: Propylene Butadiene Buty lenes/butanes Hydrogen Methane rich gas (21,630
Btu/lb) Ethane Benzene
5.95 1.55
34 26 96 70
8 2
991 272 251
92 956
401
Moderate severity; no
recycle
8 1.55
34 26 96 70
8 2
1,454 356 669
77 1,014
400 358
MANUFACTURING COST 365
Toluene Cg aromatics Cs - 400F + gasoline 400F + fuel oil (17,100 Btu/lb)
10. Fonnaldehyde (Reichhold Fonnox Process) Raw Materials:
Methanol, gal NaOH,lb Catalyst, Ib Ion exchange resin, fe
Utilities: Electricity, kW hr Steam, startup (168 hr/yr),
M Ib (150 psig) Fuel, startup (168 hr/yr),
MBtu Process feedwaterj gal Boiler feedwater, gal Cooling water, M gal: 85F
Instrument air, scf Labor:
Operator/shift Supervisor/shift Laboratory, hr/wk
60F
Maintenance: % of capital By-product:
Steam Ib/ton 150 psig
(2)
High Severity; ethane recycle
199 105 404 280
(per ton at 35 % solution)
130 2.2 0.08 0.0002
78.5
300
26.88 238
94 22.2
3.72 300
1 3 3
820
11. Liquefied natural gas (TEALARC Process) 1 MMM scfd (2) Chemicals:
Monoethanol amine, lb Antifoamant, lb Caustic soda, lb Hydrazinc, lb Tri sodium phosphate, lb Morpholine, lb Chlorohydric acid, lb Chlorine, lb (assumes seawater cooling) Molecular sieves, lb
Utilities: Electricity, kW hr Fuel, lb (13% of feed) Steam, M lb Cooling Water, M gal
Labor: Operators, technicians, engineers/3 shifts Maintenance/3 shifts
0.154 0.0006 0.0112 0.0052 0.0020 0.0024 0.0084 0.56 0.016
29 260
4.1 36.4
40 50
Moderate severity; no
recycle
280 115
1,104 174
366 APPENDIX 3
12. Methanol (lCI/Kellogg Process) (2) Raw materials:
13.
Natural gas, MM Btu Catalyst, $
Utilities: Electricity, kW hr Fuel, net, MM Btu Boiler feed water, gal Cooling water circulation, M gal
Labor: operators/shift Maintenance: % of capital By-product: steam, Ib
Phenol (2) Hercules-BPCI Phenol-
Raw materials:
Cumene,lb Hydrogen, Ib NaOH, Na2C03, H2S04 , Ib Catalyst, $
Utilities: Electricity, k W hr Fuel, MM Btu Steam, M Ib (450 psig) Cooling water, M gal (30F
rise) Labor, operators/shift
others
Maintenance, % of capital By-products:
Acetone
2,700 0.80
24 0.84
228 0.38
10.6 65
4
2
Acetone, Ib/ton 630 Hydrocarbons, Ib (18,500 Btu/lb) 220
27 1.40
4.8 5.14
297 44
4 3.5
271
Benzene,lb HCI,lb NaOH,lb Catalyst, $ Scrubber oil, Ib
Hooker
1,855 60 40
5.81 16
182 6.6
19.5 74
5 2/day shift I supervisor/shift
14. Soda ash (Na2CO,; Diamond Shamrock Solvey Process) 550 tid (2) Raw materials:
Salt (NaCI; brine), Ib Limestone (CaCO,), Ib Ammonia,lb Sodium sulfide, Ibs of S Coke, Ib (2.2 MM Btu/ton Na2C03)
Utilities: Electricity, kW hr Fuel, MM Btu (oil or gas) Treated water, gal Cooling water, M gal Cooling water, makeup if recycled, Mgol
Labor, operating man hr/ton maintenance.
3,060-3,200 2,080-2,800
4-5 0.6-1.2 160-240
54-134 7.2
240 30 (once through) 4.4 0.6 0.6
MANUFACTURING COST 367
Supplies: operating, $ maintenance, $
15. Sodium bicarbonate 150 tid (2) Raw materials:
Caustic soda, Ib Natural gas, scf
Utilities: Electricity, kW hr Steam, Ib (15 psig) Process water, 85C, gal Cooling water, M gal (20 F rise) Compressed air, 100 psig, scf
Labor, operators/shift Maintenance, % of capital
0.21 1.05
965 5,360
42 69
290 12.9
590 2 3.5
16. Synthetic natural gas (CRG/Kellogg Naphtha Reforming Process) Material per MM scf of SNG (993 Btu/scf)
Raw materials: Naphtha, M Ib (20,263 Btu/lb; Dist. 365F 47.95 Chemicals, $ 8.44 Catalysts, $ 63.70
Utilities: Electricity, kW hr 850 Fuel, M Ib (20,263 Btu/lb) 4.22 Boiler feedwater make up, M gal 4.7 Cooling tower circulation, M gal (25F rise) 9.6 Cooling tower makeup, gal 380
17. Styrene (Monsanto/Lummus Process) 900 tid (2) Raw materials:
Ethylene, Ib 620 Benzene,lb 1,680 Catalysts, chemicals, $ 4.4
Utilities: Electricity, kW hr 76 Fuel, MM Btu 4.32 Steam, M Ib: 200 psig 4.8
75 psig 2.7 Cooling water, M gal 26.1
Labor, operators/shift 3 supervisors (total) 2
Maintenance, % of capital 2-3 By-products:
Toluene, Ib/ton 126 AICI) (22 % solution), Ib/ton 28 Steam condensate, gal 863
18. Sulfuric acid (Monsanto Contact Process) (2) Raw material:
Sulfur, Ib 674
(2)
368 APPENDIX 3
Utilities: Process water, gal 60 Boiler feedwater, gal 324 Cooling water, circulation (25 F rise), M gal 7 Power, Kwh (steam turbine) 9
Labor, operators/shift Maintenance, % of capital By-product:
5
Steam, M Ib (225 psig) 1.7
19. Urea (Stamicarbon CO2-Stripping Process; producing prills) (2) Raw Materials: Biuret 0.7-0.8%
Ammonia, Ib 1140 Carbon dioxide, Ib 1510
Utilities: Electricity, kW hr Steam, M Ib (368 psig) Cooling water, M gal (l5C rise)
Labor: operators, supervisors/shift Maintenance, % of capital By-product:
Steam, Ib (60 psig)
109 2
11.5 3 3
300
0.2-0.25% 1140 1510
127 2.2
11.5 4 3
700
SE
CT
ION
3.
SIN
GL
E P
LA
NT
SIZ
E:
PE
RC
EN
T C
OS
T B
RE
AK
DO
WN
(3
)
Mfg
%
as
Pla
nt C
apac
ity.
C
ost.
% a
s %
as
Uti
liti
es.
Pro
cess
or
Che
mic
al
tid
C
ilb
Raw
Mat
eria
l D
epre
ciat
ion
Lab
or
Raw
Mat
eria
l
Ace
tald
ehyd
e 70
25
55
29
16
E
thyl
ene
70
25
72
12
16
Eth
anol
A
ceti
c an
hydr
ide
70
29
78
9 13
A
ceti
c ac
id
Acy
rlic
sta
ple
30
175
28
26
46
Dim
ethy
l fo
nnam
ide
Adi
pic
acid
18
0 38
79
9
12
Cyc
lohe
xano
l A
llyl
chl
orid
e 40
43
47
34
19
P
ropy
lene
Ani
line
55
32
65
25
10
N
itro
benz
ene
Ben
zene
35
0 14
.5
44
38
18
Nap
htha
14
0 14
.5
72
17
II
Tol
uene
B
enzo
ic a
cid
7 37
22
39
39
T
olue
ne
Bis
phen
ol A
30
42
63
23
14
A
ceto
ne.
phen
ol
Cap
rola
ctam
11
0 62
51
31
18
C
yclo
hexa
ne
Car
bon
disu
lfid
e 14
0 14
42
40
18
M
etha
ne.
S C
arbo
n te
trac
hlor
ide
30
21
53
32
15
Pro
pane
. C
I 2
Car
boxy
met
hyl
7 83
45
33
22
C
ellu
lose
ce
llul
ose
3: >
Cel
lulo
se a
ceta
te
70
81
36
26
26
Cel
lulo
se.
acid
ic a
cid
Z c:
Chl
orop
rene
."
>
m
onom
er
65
60
34
53
13
But
adie
ne
0 65
80
28
62
10
A
cety
lene
-I
c:
C
umen
e 22
0 17
80
10
10
B
enze
ne.
prop
ylen
e J:I
Z
Cyc
lohe
xono
ne-
140
40
68
18
14
Cyc
lohe
xane
C
)
cycl
ohex
anol
0
Dic
hlor
ophe
noxy
15
78
62
24
14
P
heno
l 0 CJ
)
acet
ic a
cid
(2.
4)
-I
DD
T
30
57
53
33
14
Chl
oral
. ch
loro
C
o)
01
benz
ene
CD
% a
s w
Pla
nt C
apac
ity,
%
as
% a
s U
tili
ties
, P
rinc
ipal
~
Che
mic
al
tid
C
ilb
Raw
Mat
eria
l D
epre
ciat
ion
Lab
or
Raw
Mat
eria
l ,. "a "a
Det
erge
nt a
lky
late
70
25
80
12
8
Pro
pyle
ne,
benz
ene
m
175
32
83
14
3 n-
Par
affi
n Z
C
D
ieth
anol
amin
e 18
23
63
28
9
Eth
ylen
e ox
ide,
. NH
3 X
D
imet
hyl
70
56
48
32
20
p-xy
lene
, m
etha
nol
w
tere
phth
alat
e D
ioct
y I
phth
alat
e 55
27
84
7
9 P
htha
lic
anhy
drid
e E
pich
lorh
ydri
n 55
57
78
II
II
A
llyl
chl
orid
e, C
I 2