EQUIPMENT SIZING AND COSTING

Approximations are used to perform the

calculations quickly and establish qualitative
trends for screening process alternatives.
In particular, direct, non-iterative correlations
will be applied for equipment sizing and a well
established method developed by Guthrie (1969)
will be used for costing the equipment.
 Vessel Sizing
vessels include flash drums, storage tanks, decanters and
some reactors. Unless specified otherwise by particular
unit requirements, these will be sized by the following
criteria.
1. Select vessel volume (V) based on a five-minute liquid
holdup time with an equal volume added for vapor
flows. Thus, the formula is given by:
V = 2 [FL τ IρL]

where FL is the liquid flow rate leaving the vessel (as in

a flash drum), ρL is the liquid density, and τ is a
residence time, typically set to five minutes.
Specification of this residence time is dictated by
maintaining a liquid buffer for on/off switching times
for pumps.
2. In addition, we make a few assumptions:
• For general costing purposes, the aspect ratio, L/D will be
assumed to be four.
• If diameter is greater than four feet (1.2 m) size unit as a
horizontal vessel. (This requires more space but less cost for
structural support)
• As a safety factor choose the vessel (gauge) pressure to be
50% higher than the actual process pressure from the mass
and energy balance. From this we also observe the
appropriate pressure factors in Guthrie's method when
costing the vessel.
• For the desired temperature range, consider the required
materials of construction as shown in Table. Observe the
appropriate material factors in Guthrie's method when
costing the vessel.
 Materials of Construction
High Temperature Service
Tmax(oF) Steel
950 Carbon steel (CS)
1150 502 stainless steels
1300 4 1 0 stainless steels ;330 stainless steel
1500 430, 446 stainless steels Stainless steels
(SS) (304,321,347,316)
Hastelloy C, X Inconel
2000 446 stainless steels
Cast stainless, HC

Low Temperature Service

T min (F) Steel

-50 Carbon steel (CS)

-75 Nickel steel (A203)
-320 Nickel steel (A353)
-425 Stainless steels (SS) (302,304,310,347)
 Guthrie Material and pressure
factors for pressure vessels
MPF = Fm Fp

Shell Material Clad, F m Solid,Fm

Carbon Steel (CS) 1.00 1.00
Stainless 316 (SS) 2.25 3.67
Monel 3.89 6.34
Titanium 4.23 7.89

Vessel Pressure (psig)

Up to 50 100 200 300 400 500 900 1000

Fp 1.00 1.05 1.15 1.20 1.35 1.45 2.30 2.50
 Heat Transfer Equipment
Heuristics for cost estimations
• Consider the counter current, shell and tube heat exchanger.
Sizing equations for these heat exchangers can be found
overall heat transfer coefficients can be estimated from Table.
• Again for sizing and costing, we need to observe the design
criteria for temperature and pressure (Prated = 1.5 Pactual) and
observe the appropriate pressure and material factors in
costing me exchanger
• Note that phase changes in heat exchangers lead to changes
in V and need to be considered more carefully. In this case, we
split the exchanger into serial units and calculate V and A for
vapor media and for condensing media separately. Thus, the
total area is given by: Atotal = Avap + Acon
• Finally, we choose 10,000 ft2 (or 1000 m2) as the maximum
exchanger area.
Furnaces and Direct Fired Guthrie Material and Pressure Factors for Direct
Heaters Fired Heaters
Here the basic configuration MPF=Fm+Fp+Fd
for furnaces is given by a Design Type Fd
process heater with a box Cylindrical 1.00
or A-frame construction, Dowtherm 1.33
carbon steel tubes, and a
500 psig design pressure. Vessel Pressure (psig)
This includes complete Up to 500 1000 1500
field erection. The material Fp 0.00 0.15 0.20
and pressure factors for
various types of furnaces. Radiant Tube Material F m
for direct fired heaters is Carbon Steel 0.00
given by a process heater Chrome/Moly 0.45
with cylindrical Stainless Steel 0.50
construction, carbon steel
tubes, and a 500 psig
design.
Similarly Guthrie’s factors for HEX and Furnaces are available in the
literature
 REACTORS
• For reactor sizing we assume a given space
velocity (s per hr) based on a liquid or gas molar
flowrate µ. Then we have:
s = 1/τ= µ (ρVcat)
where ρ is the molar density at standard
temperature and pressure (1 atm, 273 K) and Vcat
is the volume of catalyst. The total volume, V, is
then calculated based on the void fraction, f, of
the catalyst (assume 50%).
• Depending on reactor conditions, we can then
cost the reactor as a pressure vessel, heat
exchanger, or furnace.
• Also, for these units use the appropriate material
and pressure factors in Guthrie's method.
 Guthrie Material and Pressure Factors
Distillation Columns for Tray Stacks
• We will start with a 24” tray MPF = F m + Fs + Ft
spacing with carbon steel
Tray Type Ft
plate/sieve. Grid (no downcomer) 0.0
Plate 0.0
• However, in order to cost the Sieve 0.0
vessel, tray stack, and heat Valve or trough 0.4
exchangers, we first need to Bubble Cap 1.8
calculate the number of theoretical Koch cascade 3.9
trays and the reflux ratio.
Tray Spacing, Fs
(inch) 24” 18” 12"
• Shortcut calculations for these can Fs 1.4 2.2 1.0
be performed through the Fenske
equation (for minimum number of Tray Material F m
theoretical trays), the Underwood Carbon Steel 0.0
equation ( for minimum reflux Stainless Steel 1.7
Monel 8.9
ratio), and the Gilliland correlation
that allows us to obtain the actual
reflux ration abd tray.
1. Determining Tray Number and Reflux Ratio
The following direct procedure can be applied to determine the
desired quantities.
• From the mass and energy balance calculations we have the relative
volatilities and the top and bottom recoveries.
• Calculate tray number and reflux ratio from the following
correlation:
Ni = 12.3/ {(α lk/hk - 1 )2/3 (1 –βi)1/6} and
Ri = 1.38/ {(α lk/hk - 1)0.9 (1 - βi)o.1}
for both i = lk, hk.
Then the number of theoretical plates and the reflux ratio is:
NT= γN maxi (N) + (1 - γN) mini (Ni)
R = γR maxi (Ri) + (1 – γ R) mini (R)
where γR and γN are arbitrary weights (set to 0.8).
The number of actual trays is given by NT/ η
where the efficiency (η) is assumed to be 80%.
2. Calculate Column Diameter
From the reflux ratio and the state of the feed, we
can calculate flow rates in the distillation column.
Based on these flowrates and relationships for
flooding velocity we can then calculate the
diameters.
 For two-phase feed the flow rates can be
calculated in an analogous manner.
Flv= L/V (ρg/ρl)0.5
 The flooding condition fixes the upper limit of
vapor velocity. A high vapor velocity is needed for
high plate efficiencies, and the velocity will
normally be between 70 and 90% of that which
would cause flooding.
1. Hole size less than 6.5 mm. Entrainment may be greater with larger hole sizes.
2. Weir height less than 15% of the plate spacing.
3. Non foaming systems.
4. Hole active area ratio greater than 0.10hole
5. Liquid surface tension 0.02 N/m; for other surface tensions s, multiply the value
of Csb by [/0.02]0.2.
 Calculation of flooding velocity
Here we define Unf as the linear flooding velocity is given by:
Unf= Csb (l/g)0.5
For a typical 24" tray spacing, Csb is about 0.33 ft/s.

In this range the column diameter is then given by the cross

sectional area:
A = π D2/4 = V/(0.8 Unf ε ρg)
where ε is the fraction of the area available for vapor flow (about
0.6 for bubble cap trays, 0.75 for sieve trays).

In this text, we allow the maximum column diameter to be 20 ft

(6 m). Any larger calculated diameters require the column to
be split into two columns run in parallel.
3. Determine the Tray Stack Height
• Also, assuming a two-foot (0.6 m) tray spacing, the tray stack height is
easily calculated. Finally, we choose a maximum height of 200 feet (60
m). A larger calculated height will require that the column be split into
two with liquid and vapor flows running between them.
4. Calculate Heat Duties for Reboiler and Condenser
• For a total condenser, we know from the energy balance that Qcond = H v -
H L> where H v and H L are the total stream enthalpies for the vapor and
liquid streams around the condenser. The reboiler duty can then be
calculated either directly from the vapor flow or from a total energy
balance around the column.
5. Costing of distillation column: use Gutherie’s method for further
calculaions. We now need to group the capacities of the empty vessel, tray
stack and HEX

ABSORBERS:
Here the calculation procedure be same and NT will be calculated by
using Kremer’s rule.
•We use a very low efficiency 20%
•We will use Guthurie’s data available for the costing of packing etc
 Cost Estimation
Equipment cost increases non-linearly with the equipment size or capacity
For pressure vessels, for instance, the service capacity depends on volume (V), while
the cost depends on the weight (W) of the metal (proportional to surface area).
For example, for a spherical vessel, we have:
v = π/6 D3 and W = ρM t (π D2)
where t is the vessel thickness and ρM is the metal density. In terms of
volume, we have:
D = (6V/π)l/3 and W = ρM t (πl/3 (6V)2/3)
• with the vessel cost directly proportional to W = k V2/3.
• For cylindrical pressure vessels, we adopt a more general form used by Guthrie:
C= Co (L/Lo)α (D/Do)β
Correlations for pressure vessels are given in Table. Guthrie also considers separate
correlations for storage vessels of various geometries.
• For preliminary design, we will only use the median data. Data for the
correlations taken from Guthrie are given in Table. The cost data in Tables next
two tables are given in terms of mid-1968 prices. In order to update these costs,
we apply an update factor to account for inflation. The update factor is defined
by:
UF = present cost index
base cost index
Base Costs for Pressure Vessels
Equipment Type Co($) Lo(ft) Do(ft) α β MF2/MF4/MF6/MF8/MF10
Vertical fabrication 1000 4.0 3.0 0.8 1.05 4.23/4.12/4.07/4.06/4.02
1≤D ≤ 10 ft,4 ≤ L ≤ 100ft
Horizontal fabrication 690 4.0 3.0 0.78 0.98 3.18/3.06/3.01/2.99/2.96
1≤D ≤ 10 ft,4 ≤ L ≤ 100ft

Tray stacks 180 10.0 2.0 0.97 1.45 1.0/1.0/1.0/1.0/1.0

2≤D ≤ 10 ft,1 ≤ L ≤ 500ft

Guthrie's Modular Method

To account for numerous direct and indirect costs associated with the cost of equipment, Guthrie
proposed a simple factoring method for add-on costs. A typical cost module (with representative
numbers) is given below.
1. Free on board equipment (FOB) 100
(Base cost, BC, or equipment cost, E, from graph)
2. Installation
a. Piping instruments, etc. b 62.2
b. Labor (L) 58.0
3. Shipping, taxes, supervision 74.9
Total cost 295.1
As a result, we define the Bare Module Cost = BC x MF. Here the module factor (MF) is
2.95 (a typical value); that is, the equipment cost is almost three times the base
cost.
• MF2 Up to $200,000
• MF4 $200,000 to $400,000
• MF6 $400,000 to $600,000
• MF8 $600,000 to $800,000
• MFIO $800,000 to $1,000,000

Moreover, for special materials and high pressures, we have already defined materials
and pressure correction factors (MPF) for various types of equipment. Here the
bare module cost is modified by the following factors:
• Uninstalled cost = (BC) (MPF)
• Installation = (BC) (MF) - BC = BC (MF - 1)
(this is usually calculated on a carbon steel basis)
• Total installed cost = BC (MPF + MF - 1)
• Updated bare module cost = UF (BC) (MPF + MF - 1)

Finally, we do not treat contingency costs and indirect capital costs as Guthrie does.
Instead for preliminary designs we apply overall indirect cost factors and a flat 25%
contingency rate after all the equipment is costed.
 Calculation of costs for a distillation column with
condenser, reboiler and utility cost
• We have the following data:
Column diameter = 0.82 m (2.7 ft.)
Column height = 19.2 m (63 ft.)
Tray Stack Height = 13.2 m (24 in. spacing)
• First, we find the cost of the column vessel itself. From last
Table we have an FOB cost (BC) of about $8350. Assuming
carbon steel construction, we have F m and Fp as well as the
MPF equal to 1.0.
• The resulting module factor (MF) is 4.23 and the update
factor is UF = 359/115 = 3.12.
• The bare module cost (BMC) is then obtained from:
BM(vessel) = UF (MF + MPF - 1) (BC) = $110,000.
The tray stack is also calculated from table with
L = 43.3 ft. (13.2 m) and D = 2.7 ft. (0.82 m) we
have BC = $1150.
• Assuming bubble cap trays with 24" spacing,
we have
MPF (Fs + F m + Ft) = 2.8.
Note there is no module factor for tray stacks. As
a result we have the following cost:
BM(vessel) = UF (MPF) (BC) = $ 10,000
The condenser can be costed as follows.
The overall heat transfer coefficients can be estimated
from Guthurie’s data and Perry's Handbook.
For an acetonewater (shell) 1 water (tube) system, we
have U = 100 - 200 Btu/hr. ft2°F and we select U = (100)
(5.678) = 567.8 W/m2 K. Also we have:
• ΔTlm = [(329 - 300) - (329 - 319)]/ In(29/10) = 17.8 K
• A = Qc/ U ΔTlm = 122 m2 - 1300 ft2 < 10,000 ft2 (max.)
From data table, the base cost (BC) = $10,800 and for a
floating head, carbon steel heat exchanger MPF = 1.0
and the module factor (MF) = 3.29.
Hence, the bare module cost is:
• BMC = 3.12 (10800) (3.29) = $110700 - $111,000
Finally, the reboiler can be costed in a similar manner.

• Sizing the reboiler first requires an overall heat transfer

coefficient.
• For a water (shell) / steam (tube) system we have from
data table, U = 250 - 400 Btu/hr ft2°F and we select U =
250 = 1420 W/m2 K. Also, ΔTlm = (459 - 385) = 74 K and
so the area is:
Areb = Qreb/U ΔTlm = 15.8 m2 = 170 ft2
• From data table, we have BC = $2900, MPF = 1.45 (for a
slightly higher pres. sure and carbon steel kettle reboiler)
and MF = 3.29. The resulting bare module cost becomes:
BMC = (3.12) [(3.29 + 1.45 - 1) (2900)] = $33,840 - 34,000
 Costs $
Vessel (19.2m x 0.78m) $ 110,000

Tray stack (13.2m x 0.78m) $10,000

Condenser $111,000
Reboiler $34,000
• Total $265,000
 Equipment module Costing
• Factors Affecting : Equipment type, MOC, System Pressure
• Use BARE MODULE COST: Use direct and indirect costs
CoBM = CP FoBM
To calculate FBM we have to know the value of FM and FP , both can
be either calculated from the correlations or figures available

Where
FM is material factor account for MOC ( for CS FM =1) and
FP is pressure factor to account for high pressure ( for ambient
pressure FP =1)
Estimate of actual BC for equipment
Five step algorithm
1. Obtain the purchase cost, CP for the desired piece of
Equipment using suitable figure/table
2. Find the material of construction factor, FM and pressure
factor, FP from appropriate figures and tables
3. Find BARE MODULE FACTOR, FoBM
4. Calculate the BARE MODULE COST, CoBM
5. Update the cost from CEPCI, 1996 to the present
Direct Cost
 Equipment free on board cost CP = CP
 Materials required for installation CM = CP αM CDE = CP + CM + CL
 Labor to install equipment and material CL= αL (CP + CM) = (1.0 + αM )(1.0+ αL)

Indirect Cost
CIDE = CFIT + CO + CE
 Freight, insurance and taxes CFIT = αFIT (CP + CM)
= (1.0 + αM )( αFIT + αLαO + α E)
 Construction overhead CO = αO CL
 Contractor engineering expenses CE = αE (CP + CM)

Bare Module
CBM = CDE + CIDE
Contingency fee
 Contingency Ccont = αCont CBM Bare Module Cost Factor
 Contractor fee Cfee = αCont CBM FBM= (1.0 + αM )( 1+ αL + αFIT + αLαO + α E)

Total Module
CTM = CBM + Ccont + CFee
Auxiliary facilities
 Site development Csite
 Auxiliary building Caux
 Offsite and Utilities Coff
Cp = $10000
M =0.71
Calculate Bare module cost factor
Bare module cost
Material cost and labor cost to install the HEX
L= 0.37
FIT= 0.08 Bare Module Cost Factor
FBM= (1.0 + αM )( 1+ αL + αFIT + αLαO + α E)
O = 0.7 CoBM = CP FoBM
E= 0.15 CM = αM CP

CL = αL (CP + CM)=(1.0 + αM )(1.0+ αL)

 Bare module cost for non base
case conditions
• For equipment made of other MOC other or
work at non ambient temp/pressure have
values of Fm and Fp more than 1.
• The BMF used for base case FBM is replaced
with an actual FoBM
 Grass Root and total Module Cost
• Total Module Cost: cost of small to moderate
expansions or alterations to an existing facility
CTM = 1.18 1Σn CBM,i

• Grass root: completely new facility

CGR = CTM + 0.35 1Σn COBM,i
Estimate the bare module cost, total module cost and grass root
cost for the following distillation column and other equipments
E-101

V-101

T-101

P-101

E-103

E-102
Equipment no Capacity/size MOC Operating pressure

E-101 Area= 170 m2 Tube CS Tube 5 barg

Overhead condenser Floating head Shell CS Shell 5 barg
E102 Area= 205 m2 Tube SS Tube 18 barg
Reboiler Floating head Shell CS Shell 6 barg
E103 Area=10 m2 All CS Inner 5
Product cooler Double pipe Outer 5
P-101 Power (shaft) = 5 Cast steel Suction 5
Reflux pump kW, centrifugal
T-101 D= 2.1 m CS Column 5
Distillation column H= 23 m
Sieve tray = 32 SS
V-101 D= 1.8 m CS Vessel 5
Reflux drum L= 6 m
Horizontal
Fp Fm FBM Cp CBM C0BM
E-101 1 1 3.3 20000 66000 66000
E-102 1.02 1.7 4.3 22000 72600 94600
T-101 1.1 1 4.4 81000 340200 356400
 Cost Equations
log10Cp =K1 +K2 log10 A +K3(log10 A)2
log10Fp = C1 + C2 log10 P + C3 (log10P) 2

C0BM= CpF0BM =Cp (B1+B2FMFp)

Cp = 235 + 19.8 D + 75.07 D2

C0BM= Cp NFBMFq
 Estimation of Manufacturing
cost

Information on PFD,
Estimate of fixed capital investment
Estimate of the number of
Operators required to operate
the plant
Costs units are $ per unit time
 Direct Manufacturing Costs: represents
operating expenses that vary production rate
Direct Cost: factors Factors that vary with the rate of production
Raw material For feed stocks required by the process flow rates (CRM)
Waste treatment Waste treatment to protect environment (CWT)
Utilities Power, steam, CW, instrument air, inert gas, refrigeration
(CUT)
Operating labor Personnel required for plant operation (COL)
Direct supervisory Administrative and engineering (0.18COL)
Maintenance and repair Labor and materials for maintenance (0.06FCI)
Operating supplies Chart paper, lubricants, protective clothing (0.009 FCI)
Laboratory charges Cost of routine and special laboratory test for product
quality (0.15COL)
Patents and loyalties Using patented or licensed technology (0.03COM)

DMC = CRM + CWT+ CUT+ 1.33COL+ 0.069 FCI +0.03 COM

COM = 0.304 FCI + 2.73 COL +1.23 (CRM + CWT+ CUT)
COM = cost of manufacturing; FCI = Fixed capital investment
 Fixed cost: independent of changes in
production rate
Fixed costs Factors not affected

Depreciation Costs associated with the physical plant .

Legal operating expenses for tax purpose (0.1 FCI)

Local taxes and insurance Costs associated with property taxes and liability
insurance (0.032FCI)

Plant overhead cost Catch-all costs associated with operation of auxiliary

facilities supporting the manufacturing process. Cost
involve : payroll and accounting services, fire protection
and safety services, medical services, cafeteria, recreation
facility (0.708 COL + 0.036 FCI)

FMC = 0.708 COL + 0.168 FCI

General Expenses: Costs associated with mgmt
level and admn activities not directly realted to
the manufacturing process
Admn cost Salary, administration, building
(0.177 COL + 0.009 FCI)
Distribution and Also include salaries (0.11 COM)
selling costs
R&D also include salaries and funds
for research related equipment
and supplies (0.05 COM)
GMC = 0.177 COL + 0.009 FCI + 0.16 COM

Total costs = DMC +FMC +GMC

For design of 95,000 tonne/yearof XYZ productionGiven the following
costs, calculate:
(a) manufacturing cost/yr and $/tonne of XYZ
(b) percentage of manufacturing costs resulting from DMC, FMC, GMC

FCI 11,000,000
CRM 7,950,000/yr
CWT 1,000,000/yr
CUT 356,000/yr
COL 300,000/yr
 Cost of Operating Labor
Equipment Type Operators per equipment per shift
Auxiliary facilities
Boilers 1
Cooling towers 1
Waste treatment plant 2
Refrigeration unit 0.5
Chimney and stacks 0
Process Equipment
HEX 0.1
Towers 0.35
Reactors 0.50
pumps 0.0

Manufacturing costs are usually reported in terms of $/yr

Stream factor = number of days plant operates per year/365 ~0.9-0.96
 UTILITY COST
Utility Description Cost $/GJ Cost $/ common unit
Cooling tower Process cooling 0.16 $6.7/1000 m3
water (30 oC to 45 oC)

High purity water for

process use, $ 0.04/1000 Kg,
boiler feed water, 2.54/1000 Kg,
potable, 0.26/1000 Kg,
deionized water 1.00/1000 Kg
Fuels Fuel oil 4.0 $170 /m3
Natural gas 2.5 $0.085/m3
coal 1.2 $31/tonne
Waste water Primary $39 /1000m3
treatment
Secondary $41/1000m3
tertiary $53/1000m3