Thursday 10 March 2011

ESTIMATION OF PURCHASED EQUIPMENT COST (Hot section)


 Different components of purchased equipment cost are

 Cracking Furnace And Transfer Line Exchanger Cost


The furnace and TLX contributes 21%of the ISBL cost, it is also reported
that the total cost investment for    450000 metric ton/year olefins plant is
$325000000 out of which 50 % is the cost of OSBL, therefore 450000
metric ton olefins plant,
ISBL cost                                 =325000000/1.5          =$216670000
Applying the method of power factor applied to plant capacity ratio, for a
thirty thousand metric ton/year olefins plant, investment required is
Capacity ratio, R=30000/450000=0.066
   Power exponent=0.083
Hence cost for 30000 metric ton/year olefins plant is
Cost  = 216670000[0.055]             = $22.7*106
Cost  = $22.7*106(924/774)         =27*106
Therefore, the furnace & TLX cost     = 0.21*27*106   = $5.67*106
                                                                                                         =3.40*108Rs

Cost Of Heat Exchangers

Cost of H.Ex           = 89475$           = 5.37*106Rs
                                               


Cost Of Inter Coolers


The purchased cost of a 344 ft2 heat transfer area finned shell and
tube exchanger is                       =$8650        = 5.2*105Rs
Since all the intercoolers and after coolers have the same design specification,
The cost of five finned shell and tube exchangers          =$43250 = 5.6*106Rs

Cost Of Air Coolers


The purchased cost of 1725 ft2 (E4) air cooler          =$15525 = 9.3*105Rs
The purchased cost of 500 ft2 air cooler                    =$ 8100 = 4.86*105Rs
Cost of all heat exchangers=$89475                            = 5.37*106Rs

Cost Of Compression System


The purchased cost of 220 h.p. compressor                        = $90000
The purchased cost of 120 h.p. compressor                         =$80000
The purchased cost of 65 h.p. compressor                         =$50000
The purchased cost of 35 h.p. compressor                         =$50000
The purchased cost of 20 h.p. compressor                         =$50000
The purchased cost of the compression system = $320000       = 1.92*107Rs

Cost Of Towers


The purchased cost of oil quench tower          =$48000      = 2.88*106Rs
The purchased cost of water quench tower          =$43200      = 2.6*106Rs

Cost Of Knock Out Drums


The purchased cost of 4.3 ft dia drums                              =$6300
The purchased cost of 3.6ft dia drums                                   =$5600
The purchased cost of 3 ft dia drums                                  =$4800
The purchased cost of 2.7 ft dia drums                              =$4800
The purchased cost of 2.45 ft dia drums                       =$4000
The purchased cost of all knock out drums          =$25500= 1.53*106Rs

 

Total Purchased Equipment Cost

 

Cost of furnace and TLX=$5.67*106                                         = 3.40*108Rs
Heat exchangers=$89475                                              = 5.37*106Rs
Compressors=$320000                                          = 1.92*107Rs
Oil quench tower=$48000                                       = 2.88*106Rs
Water quench tower=$43200                                    = 2.6*106Rs
Knockout drums=$25500                                                = 1.53*106Rs
Total purchased cost=$6.2*106                                                            = 3.72*108Rs


ESTIMATION OF PURCHASED EQUIPMENT COST (Cold Section)

*(Cost is given in Pound Sterling)

Distillation column(De-Methanizer)


a)          Purchased cost                                       =51440
b)          Reboiler purchased cost                        =9600
c)          Condenser purchased cost             =88400
d)          Reflux drum purchased cost             =4025

Distillation column(De-Ethanizer)

 

a)          Purchased cost                                       =58176
b)          Reboiler purchased cost                        =3250
c)          Condenser purchased cost             =11232
d)          Reflux drum purchased cost             =5151

Distillation column (For Ethylene)

 

a)          Purchased cost                                        =90720
b)          Reboiler purchased cost                       =13625
c)          Condenser purchased cost             =80000
d)          Reflux drum purchased cost             =17760


Distillation column (Propane)

 

a)          Purchased cost                                        =51440
b)          Reboiler purchased cost                       =9600
c)          Condenser purchased cost             =88400
d)          Reflux drum purchased cost             =4025

 Distillation column (For Ethane)

 

a)       Purchased cost                                       =61352
b)          Reboiler purchased cost                       =14740
c)          Condenser purchased cost             =10560
d)          Reflux drum purchased cost             =26048

Acetylene Converter


Purchased Cost                                         =5280
Total purchased cost                                 =687035


Estimation of capital investment based on purchased equipment cost.

Item                                                   %age                        Costs (Rs)                                                         
Direct cost
Purchased equipment cost                   100                         51340169
Purchased equipment installation cost 47                          24129879
Instrumentation and controls
(Installed)                                             18                          9241231
Piping (installed)                                  66                         33884512
Buildings (including services)             18                          9241231
Yard improvements                             10                          5134016
Service facilities (installed)                 70                          35938118
Land (If purchase is required)             6                            3080410
Total direct plant cost                         346                         178536990
Indirect cost
Engg and supervision                         33                          16942256
Construction expenses                        41                          21049469
Total direct and indirect costs            420                        21652872
Contractor’s fee (about 5% of direct
And indirect cost)                               21                          10781435
Contingency fee (about 10% of direct  
and indirect plant costs)                      42                         21562871
Fixed capital investment                     483                       248873020
 Working capital (about 15% of total
Capital investment)                             86                         44152545
 Total capital investment                    569                        293025570

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