SCHOOL OF CHEMICAL ENGINEERING

School of Chemical Engineering Universiti Sains Malaysia Engineering Campus Nibong Tebal, Penang

ZA/II Semester 2011-2012 Weightage : 300 marks

EKC 453 : Chemical Plant Design and Economics Due date : 12nd March 2012

Design Task #1 [Each member in the group should contribute equally in the of task] PLANT AND EQUIPMENT COST ESTIMATION In PFD, you have identified all the equipment needed for your project. In the economic evaluation, the first task is to obtain a capital cost estimate for the plant.
PFD Marks

Update the PFD based on the suggestion and comments from the oral and viva presentation.
A. Equipment Cost Estimation [a] List down all the equipment, with their proper specification sheets showing equipment No., capacity/size, materials of construction and operating conditions (pressure and temperature). [b] Estimate purchase cost of each equipment using correlations, Aspen IPE and graphs/equations. Compare your values of the equipment cost using different methods. Tabulate all the purchase equipment cost calculated from graphs, equations and software using EXCEL and make the comparison, analyze and make final recommendation. Select the correct value of equipment cost in the calculation of total cost estimation [c] Identify the supplier and manufacturer of the equipment identified in your plant from the internet. Give full details of the supplier, type of equipment (capacity/size), country and other details. Please write which of the equipment are available in Malaysia. Obtain the quotation from equipment supplier for major equipment and compare the cost given in the quotation with the calculated purchased equipment cost. 50 Marks 50

50

[d] Show the summary of utility requirements for the equipment identified in PFD and obtains total yearly utility costs for the process in a Tabular

50

EKC 453 Chemical Plant Design & Economics - 1 -

SCHOOL OF CHEMICAL ENGINEERING

form using EXCEL. Does your plant needs separate utility services? List down the utility services with their design capacity and cost.

200 B. Total Cost Estimation [a] Use a suitable method to obtain a total capital cost estimate for the plant (Study Estimate) based on the purchase equipment cost. Compare total capital cost estimation using different methods such as the Ratio method and Factorial (Lang Factor) method and Method of Guthrie. Write down which method gives the reliable value. Marks 50

[b] Calculate the cost of manufacture (COM) for the product using the plant process. Include the cost of operating labor, utilities, waste treatment and raw materials. Represent different components of COM by pie diagram/chart with the total investment (ie. the whole pie). Calculate the total production costs.

50

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EKC 453 Chemical Plant Design & Economics - 2 -