Instructions

Utilities

The following utilities are available.

Utility Code Name

Steam: Low Pressure (5 barg, 160C) SteamLow
Steam: Medium Pressure (10 barg, 184C) SteamMed
Steam: High Pressure (41 barg, 254C) SteamHigh
Dowtherm (300C) Dowtherm
Fuel Oil FuelOil
Natural Gas Gas
Custom Heating CustomHeat
Electricity (GJ/hr) ElectGJ
Electricity (KW) ElectKWH
Cooling Water CoolWater
Refrigeration: Water (5=>15C) RefWater
Refrigeration: Low T (-20C) RefLow
Refrigeration: Very Low (-50C) RefVeryLow
Refrigeration: Custom RefCustom

Note that electricity can be costed on the basis or either KWH or GJ.
The others are all in GJ (GigaJoules = 109 Joules = MKJ)
Quotation and Factor
Name Cost Factor Labour Utility Utility Utility
K$ Units Type Rate Units

Custom Equipment
Name Labour BM Cost Utility Utility Utility
Units K$ Type Rate Units

Black Box Available Materials: CS,SS,Cu,Ni,Ti,Cu Alloy,Ni Alloy,

Ti clad,SS clad,Cu Alloy clad

Black Box Parameters

Type Size Size Base Cost power n Pressure MOC
Units K$ Factor Sensitivity

Equipment Parameters
Name Size Pressure Pressure Material Spares Labour Utility Utility Utility
kPa barg Units Type Rate Units

Compressor/Expander Available Types: Compressor - Centrifugal,Axial,Rotary,Reciprocating

Expander - Axial,Radial
 Avaiable Materials: CS,SS,Ni

Name Type Material Power Power Spares

HP KW

Drive Available types: Gas Turbine, Internal Combustion Engine,

Steam Turbine, Electric (Explosion Proof, Totally Enclosed, Drip Proof)

Name Type Power - HP Power Power Spares

HP KW

Evaporator Available Types: Forced Circulation,Falling Film, Scraped wall

Short Tube, Long Tube
Available Materials: CS,Cu Alloy,SS,Ni Alloy,Ti

Name Type Material Pressure Pressure Area Utility Type Util. Rate Labour
kPa barg m2 GJ/hr Units

Furnace or Heater Available Types: Reformer Furnace,Pyrolosis Furnace, Fired Heater,Hot Water Heater,
Molten Salt,Mineral Oil,Diphenyl Oils,Packaged Steam Boiler
Available Materials: CS, Alloy Steel, SS

Name Type Material Duty Duty Pressure Pressure Superheat Utility Type Labour
KW GJ/hr kPa barg C Units

Heat Exchanger 1S Available Types: Air Cooler, Flat Plate, Scraped Wall
Spiral Plate, Teflon Tube
 Available Materials: CS,Cu,SS,Ni,Ti,Al

Name Type Material Pressure Pressure Area No. Shells Utility Type Util. Rate Labour
kPa barg m2 GJ/hr Units

Heat Exchanger 2S Available Types: Double Pipe, Multiple Pipe,

Fixed Tube Sheet or U, Floating Head, Bayonet,
Kettle Reboiler, Spiral Tube
Available Materials: CS/CS, CS/Cu, Cu/Cu, CS/SS,
SS/SS, CS/Ni, Ni/Ni, CS/Ti, Ti/Ti

Name Type Tube MOC Tube Press Tube Press Shell MOC Shell Press Shell Press Area No. Shells Utility Type Util. Rate Labour
kPa barg kPa barg m2 GJ/hr Units

Packed Tower Shell Materials: CS, SS clad, SS, Ni clad, Ni, Ti clad, Ti
Packing Materials: Ceramic, 304 SS, Plastic Saddles
Demister Options: none, SS, Fluorocarbon, Ni

Name Pack Type Shell MOC Diameter Diameter Height Height Pressure Pressure Demister Pack Height Pack Height Labour
ft m ft m kPa barg Type ft m Units

Pump Available Types: Centrifugal, Positive Displacement, Reciprocating

Available Materials: Cast Iron, CS, Cu Alloy, SS, Ni Alloy, Ti

Name Type Material Pressure Pressure Power Power Spares

kPa Barg HP KW
Storage Tank Available Types: Fixed Roof, Floating Roof

Name Type Volume

m3

Trayed Tower Tray Type: Sieve, Valve Tray MOC: CS,SS,Ni

Available Materials: CS, SS clad, SS, Ni clad, Ni, Ti clad, Ti
Demister Options: none, SS, Fluorocarbon, Ni

Name Tray Type Tray MOC Shell MOC Diameter Diameter Height Height Presure Presure Demister No. of Labour
ft m ft m kPa barg Type Trays Units

Vaporizer Available Types: Jacketed Vessel,Internal Coil Vaporizer,Jacket & Coil

Available Materials: CS,Cu,Glass Lined - SS,Glass Lined - Ni,
SS,SS Clad,Ni Alloy,,Ni Alloy Clad,Ti,Ti Clad

Name Type Material Pressure Pressure Volume Utility Type Util. Rate Util. Rate Labour
kPa barg m3 KW GJ/hr Units

Vessel Available Types: Vertical, Horizontal

Available Materials: CS, SS clad, SS, Ni clad, Ni, Ti clad, Ti
Demister Options: none, SS, Fluorocarbon, Ni

Name Type Material Diameter Diameter Height Height Presure Presure Demister Labour
ft ft ft m kPa barg Type Units
 Total Cost of Capital (Bare Module), Labour and Utilities for the Plant
Capital (K$) Labour Units Utilities (K$/yr)
0 0 0

Equipment Utilities
Name Module Cost Labour Utility Type Annual Cost
Raw Material Costs, Product Revenue, Additional Operating Costs and Revenue

Raw Materials
Material Rate - kg/hr Price - $/kg Cost - $K/yr
1 A 1000 2 16000
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 0
Total 16000

Products
Product Rate - kg/hr Price - $/kg Revenue - $K/yr
1 b 1000 6 48000
2 0
3 0
4 0
5 0
Total 48000

Waste Disposal and Other Operating Costs

Cost Cost - $K/yr
1
2
3
4
5
Total 0

Additional Revenue
Revenue Revenue - $K/yr
1
2
3
4
5
Total 0
Parameters that can be changed at any time

CEPCI 397
Hours/year 8000 Hours
Labour rate 80 K$/man-year
Taxation Rate 30 %
Discount Rate 15 %
Working Capital / Fixed Capital 17.5 %
Capital Cost/Bare Module Cost 118 %
Startup Year Costs 25 %
Startup Year Revenue 12.5 %
Capital in Year 1 10 %
Capital in Year 2 60 %
Capital in Year 3 30 %

Utility Costs

Steam: Low Pressure (5 barg, 160C) 6.08 $/GJ SteamLow

Steam: Medium Pressure (10 barg, 184C) 6.87 $/GJ SteamMed
Steam: High Pressure (41 barg, 254C) 9.83 $/GJ SteamHigh
Dowtherm (300C) 8.85 $/GJ Dowtherm
Fuel Oil 6 $/GJ FuelOil
Natural Gas 6 $/GJ Gas
Custom Heating 6 $/GJ CustomHeat
Electricity (GJ) 16.8 $/GJ ElectGJ
Electricity (KW) 0.06 $/KWH ElectKWH
Cooling Water 0.354 $/GJ CoolWater
Refrigeration: Water (5=>15C) 4.43 $/GJ RefWater
Refrigeration: Low T (-20C) 7.89 $/GJ RefLow
Refrigeration: Very Low (-50C) 13.11 $/GJ RefVeryLow
Refrigeration: Custom 6 $/GJ RefCustom
 22222

Net Present Value 68713 K$

Payback Period 0.00 Years (from year 2)

Year 1 2 3 4 5 6
Revenue
Sales 6000 48000 48000 48000
Additional Revenue 0 0 0 0
Total Revenue 6000 48000 48000 48000

Direct Manufacturing Costs

Raw Materials 16000 16000 16000
Utilities 0 0 0
Additional Costs 0 0 0
Operating Labour 903 903 903
Other labour 163 163 163
Maintenance and Repairs 0 0 0
Operating Supplies 0 0 0
Laboratory Charges 135 135 135
Patents and Royalties 667 667 667
Total Direct Manufacturing Costs 4467 17867 17867 17867

Fixed Manufacturing Costs

Local Taxes and Insurance 0 0 0
Plant Overhead Costs 639 639 639
Total Fixed Manufacturing Costs 160 639 639 639

General Mfg. Expenses

Administration 160 160 160
Distribution and Selling 2444 2444 2444
Research and Development 1111 1111 1111
Total General Mfg. Expenses 929 3715 3715 3715

Total Manufacturing Costs 5556 22222 22222 22222

Operating Income Before Tax 0 0 444 25778 25778 25778

Capital Total Capital Cost = 0

Fixed Capital Investment - K$ 0 0 0
Working Capital 0
Unused CCA 0 0 0 0
Capital Cost Allowance 0 0 0 0

Taxes 0 0 133 7733 7733 7733

Operating Income After Tax 0 0 311 18045 18045 18045

Cash Flow 0 0 311 18045 18045 18045

Discount Factor 1.0000 0.8696 0.7561 0.6575 0.5718 0.4972
Discounted Cash Flow 0 0 235 11865 10317 8971
Accumulated Disc. Cash Flow 0 0 235 12100 22417 31388

Cumulative Discounted Cash Flow

80000
70000
60000
50000
40000
30000
20000
10000
0
1 2 3 4 5 6 7 8 9 10 11 12 13
 Sensitivity Analysis
Uncertainties -% +% Min NPV 33032.97 Max NPV Range

1 Sales Revenue 20 15 -5167 20970 40573 45740

8 Capital Cost of Plant 5 40 9753 20970 22372 12619

3 Raw Materials 20 20 19074 20970 22867 3793

4 Utilities 20 20 20394 20970 21547 1153

7 Working Capital 10 10 20735 20970 21205 470

6 Operating Labour 15 15 20777 20970 21164 387

2 Additional Revenue 10 10 20970 20970 20970 0

5 Additional Costs 10 10 20970 20970 20970 0

Pe rc e n t Pro b a b ility

Cumulative Probability Distribution

100
90
80
70
60
50
40
30
20
10
0
-20000 -10000 0 10000 20000 30000 40000 50000 60000
NPV
Years (from year 2)

7 8 9 10 11 12 13

48000 48000 48000 48000 48000 48000 48000

0 0 0 0 0 0 0
48000 48000 48000 48000 48000 48000 48000

16000 16000 16000 16000 16000 16000 16000

0 0 0 0 0 0 0
0 0 0 0 0 0 0
903 903 903 903 903 903 903
163 163 163 163 163 163 163
0 0 0 0 0 0 0
0 0 0 0 0 0 0
135 135 135 135 135 135 135
667 667 667 667 667 667 667
17867 17867 17867 17867 17867 17867 17867

0 0 0 0 0 0 0
639 639 639 639 639 639 639
639 639 639 639 639 639 639

160 160 160 160 160 160 160

2444 2444 2444 2444 2444 2444 2444
1111 1111 1111 1111 1111 1111 1111
3715 3715 3715 3715 3715 3715 3715

22222 22222 22222 22222 22222 22222 22222

25778 25778 25778 25778 25778 25778 25778

0
0 0 0 0 0 0 0
0 0 0 0 0 0 0

7733 7733 7733 7733 7733 7733 7733

18045 18045 18045 18045 18045 18045 18045

18045 18045 18045 18045 18045 18045 18045

0.4323 0.3759 0.3269 0.2843 0.2472 0.2149 0.1869
7801 6784 5899 5129 4460 3879 3373
39189 45973 51872 57001 61462 65340 68713
-5166.7178 Tornado Diagram

26137 0

26137 0

25944 387

25902 470

25560 1153

24241 3793

14920 12619

0 45740

0.198012
0 0 0 18775.76
-14196.236 0.2 2 20063.15
-13547.792 0.3 1 35328.38
-12899.348 0.3 0 17398.69
-12250.904 0.6 3 22789.88
-11602.46 0.7 1 39800.68
-10954.016 0.7 0 34307.18
-10305.572 0.9 2 36355.14