Tabel 2.1 Typical equipment capacity delivered capital cost correlations.

Equipment Material of construction

Agitated reactor CS
Pressure vessel SS
Distillation column (Empty shell) CS
Sieve trays (10 trays) CS
Valve trays (10 trays) CS
Structured packing (5 m height) SS (low grade)
Scrubber (including random packing) SS (low grade)
Cyclone CS
Vacuum filter CS
Dryer SS (low grade)
Shell-and-tube heat exchanger CS
Air-cooled heat exchanger CS
Centrifugal pump (Small, including motor) CS
Centrifugal pump (Large, including motor SS (high grade)
Compressor (Including motor)
Fan (Including motor) CS
Vacuum pump (Including motor) CS
Electric motor (Small atmospheric)
Storage tank (Small atmospheric) SS (low grade)
Storage tank (Large atmospheric) CS
Silo CS
Package steam boiler (Fire-tube boiler) CS
Field erected steam boiler (Water-tube boiler) CS
Cooling tower (Forced draft)
CS = carbon steel; SS (low grade) = low-grade stainless steel, for example, type 304; SS (high grad
orrelations.

Capacity measure Base size QB Base Cost CB ($) Size range Cost exponent M

Volume (m3) 1 1.15E+04 1-5 0.45

Mass (t) 6 9.84E+04 4 - 100 0.82
Mass (t) 8 6.56E+04 8 - 300 0.89
Column diameter (m) 0.5 6.56E+03 0.5 - 4.0 0.91
Column diameter (m) 0.5 1.80E+04 0.5 - 4.0 0.97
Column diameter (m) 0.5 1.80E+04 0.5 - 4.0 1.7
Volume (m3) 0.1 4.92E+03 0.1 - 20 0.53
Diameter (m) 0.4 1.64E+03 0.4 - 3.0 1.2
Filter area (m2) 10 8.36E+03 10 - 25 0.49
Evaporation rate (kg H2O.h-1) 700 2.30E+05 700 - 3000 0.65
Heat transfer area (m2) 80 3.28E+04 80 - 4000 0.68
Plain tube heat transfer area (m2) 200 1.56E+05 200 - 2000 0.89
Power (kW) 1 1.97E+03 1 - 10 0.35
Power (kW) 4 9.84E+03 4 - 700 0.55
Power (kW) 250 9.84E+04 250 - 10000 0.46
Power (kW) 50 1.23E+04 50 - 200 0.76
Power (kW) 10 1.10E+04 10 - 45 0.44
Power (kW) 10 1.48E+03 10 - 150 0.85
Volume (m3) 0.1 3.28E+03 0.1 - 20 0.57
Volume (m3) 5 1.15E+04 5 - 200 0.53
Volume (m3) 60 1.72E+04 60 - 150 0.7
Steam generation (kg.h-1) 50000 4.64E+05 50000 - 350000 0.96
Steam generation (kg.h-1) 20000 3.28E+05 10000 - 800000 0.81
Water flowrate (m3.h-1) 10 4.43E+03 10 - 40 0.63
stainless steel, for example, type 304; SS (high grade) = high stainless steel, for example, type 316
Tabel 2.2 Typical average equipment materials of construction capital cost factors.
Material Correction factor fM
Carbon steel 1
Aluminum 1.3
Stanless steel (low grades) 2.4
Stanless steel (high grades) 3.4
Hastelloy C 3.6
Monel 4.1
Nickel an inconel 4.4
Titanium 5.8

Tabel 2.3 Typical material of construction capital cost factors for pressure vessels and distillation columns9,10.
Material Correction factor fM
Carbon steel 1
Aluminum 2.1
Stanless steel (low grades) 3.2
Stanless steel (high grades) 3.6
Hastelloy C 3.9
Monel 5.4
Nickel an inconel 7.7
Titanium 5.8

Tabel 2.4 Typical material of construction capital cost factors for shell-and-tube heat exchangers2.
Material Correction factor fM
CS shell and tube 1
CS shell, aluminum tubes 1.3
CS shell, monel tubes 2.1
CS shell, SS (low grade) tubes 1.7
SS (low grade) shell and tubes 2.9

Tabel 2.5 Typical equipment pressure capital cost factors.

Design pressure (bar absolute) Correction factor fp
0.01 2
0.1 1.3
0.5 to 7 1
50 1.5
100 1.9
Table 2.6 Typical equipment temperature capital cost factors.
Design temperature (oC) Correction factor fT
0 - 100 1
300 1.6
500 2.1
illation columns9,10.
 Tabel 2.7 Typical factors for capital cost based on delivered equipment costs.
Type of process
Item
Fluid processing Solid processing
Direct costs
Equipment delivered cost 1 1
Equipment erection, fER 0.4 0.5
Piping (installed), fPIP 0.7 0.2
Instrumentation & controls (installed), fINST 0.2 0.1
Electrical (installed), fELEC 0.1 0.1
Utilities, fUTIL 0.5 0.2
Off-sites, fOS 0.2 0.2
Buildings (including services), fBUILD 0.2 0.3
Site preparation, fSP 0.1 0.1
Total capital cost of installed equipment 3.4 2.7
Indirect costs
Design, engineering and construction, fDEC 1 0.8
Contingency (about 10% of fixed capital costs), fCONT 0.4 0.3
Total fixed capital cost 4.8 3.8
Working capital
Working capital (15% of total capital cost), fWC 0.7 0.6
Total capital cost, fI 5.5 4.4
 Tabel 2.8 Modification costs for distillation column retrofit17.
Column modification
Removal of trays to install new trays
Removal of trays to install packing
Removal of packing to install new trays
installation of new trays

installation of new structured packing

Tabel 2.9 Steam mains pressure settings.

Mains
HP
MP
LP

Tabel 2.10 Predicted annual cash flows.

Year

0
1
2
3
4
5
8 Modification costs for distillation column retrofit17.
Cost of modification (multiply factor by cost of new hardware)
0.1 for the same tray spacing
0.2 for different tray spacing
0.1
1.0 - 1.4 for the same tray spacing
1.2 - 1.5 for different tray spacing
1.3 - 1.6 when replacing packing
0.5 - 0.8

Tabel 2.9 Steam mains pressure settings.

Pressure (barg)
41
10
3

Tabel 2.10 Predicted annual cash flows.

Cash flows ($106)
Project A Project B
-10 -10
1.6 6.5
2.8 5.2
4 4
5.2 2.8
6.4 1.6
Tabel 2.10 Predicted annual cash flows.
Cash flows ($106)
Year
Project A Project B
0 -10.00 -10.00
1 1.60 6.50
2 2.80 5.20
3 4.00 4.00
4 5.20 2.80
5 6.40 1.60

Tabel 2.11 Calculation of DCFRR for Project A.

DCF 20% DCF 30% DCF 25%
Year ACF
ADCF Sigma ADCF ADCF Sigma ADCF ADCF Sigma ADCF
0 -10.00 -10.00 -10.0000 -10.00 -10.0000 -10.00 -10.0000
1 1.60 1.33 -8.6667 1.23 -8.7692 1.28 -8.7200
2 2.80 1.94 -6.7222 1.66 -7.1124 1.79 -6.9280
3 4.00 2.31 -4.4074 1.82 -5.2918 2.05 -4.8800
4 5.20 2.51 -1.8997 1.82 -3.4711 2.13 -2.7501
5 6.40 2.57 0.6723 1.72 -1.7474 2.10 -0.6529

Tabel 2.12 Calculation of DCFRR for Project B.

DCF 20% DCF 40% DCF 35%
Year ACF
ADCF Sigma ADCF ADCF Sigma ADCF ADCF Sigma ADCF
0 -10.00 -10.00 -10.0000 -10.00 -10.0000 -10.00 -10.0000
1 6.50 5.42 -4.5833 4.64 -5.3571 4.81 -5.1852
2 5.20 3.61 -0.9722 2.65 -2.7041 2.85 -2.3320
3 4.00 2.31 1.3426 1.46 -1.2464 1.63 -0.7062
4 2.80 1.35 2.6929 0.73 -0.5175 0.84 0.1368
5 1.60 0.64 3.3359 0.30 -0.2200 0.36 0.4936