Costs of Individual Equipment

21 C O S T S OF I N D I V I D U A L E Q U I P M E N T The choice of appropriate equipment often is influenced by considerations of price. A lower efficiency or a shorter life may be compensated for by a lower price. Funds may be low at the time of purchase and expected to be more abundant later, or the economic life of the process is expected to be limited. Alternate kinds of equipment for the same service may need to be considered: watercooled exchangers vs. air coolers, concrete cooling towers vs. redwood, filters vs. centrifuges, pneumatic conveyors vs. screw or bucket elevators, and so on. In this chapter, the prices of classes of the most frequently used equipment are collected in the form of correlating equations. The prices are given in terms of appropriate key characteristics of the equipment, such as sqft, gpm, lb/hr, etc. Factors for materials of construction and performance characteristics other than the basic ones also are provided. Although graphs are easily read and can

bring out clearly desirable comparisons between related types of equipment, algebraic representation has been adopted here. Equations are capable of consistent reading, particularly in comparison with interpolation on logarithmic scales, and are amenable to incorporation in computer programs. Unless otherwise indicated, the unit price is $1000, $K. Except where indicated, notably for fired heaters, refrigeration systems, and cooling towers (which are installed prices), the prices are purchase prices, FOB, with delivery charges extra. In the United States delivery charges are of the order of 5% of the purchase price, but, of course, dependent on the unit value, as cost per lb or per cuft. Multipliers have been developed whereby the installed cost o f various kinds of equipment may be found. Such multipliers range from 1.2 to 3.0, but details are shown in Table 21.3.

TABLE 21.1. Index of Equipment 1. Agitators 2. Compressors, turbines, fans Centrifugal compressors Reciprocating compressors Screw compressors Turbines Pressure discharge Vacuum discharge Fans 3. Conveyors Troughed belt Flat belt Screw, steel Screw, stainless Bucket elevator Pneumatic 4. Cooling towers Concrete Wooden 5. Crushers and grinders Cone crusher Gyratory crusher Jaw crusher Hammer mill Ball mill Pulverizer 6. Crystallizers External forced circulation Internal draft tube Batch vacu u m 7. Distillation and absorption towers Distillation tray towers Absorption tray towers Packed towers 8. Dryers Rotary, combustion gas heated Rotary, hot air heated Rotary, steam tube heated Cabinet dryers Spray dryers Multiple hearth furnace 9. Evaporators Forced circulation Long tube

Falling film 10. Fired heaters Box types Cylindrical types 11. Heat exchangers Shell-and-tube Double pipe Air coolers 12. Mechanical separators Centrifuges Cyclone separators Heavy duty Standard duty Multiclone Disk separators Filters Rotary vacuum belt discharge Rotary vacuum scraper discharge Rotary vacuum disk Horizontal vacuum belt Pressure leaf Plate-and-frame Vibrating screens 13. Motors and couplings Motors Belt drive coupling Chain drive coupling Variable speed drive coupling 14. Pumps Centrifugal Vertical mixed flow Vertical axial flow Gear pumps Reciprocating pumps 15. Refrigeration 16. Steam ejectors and vacuum pumps Ejectors Vacuum pumps 17. Vessels Horizontal pressure vessels Vertical pressure vessels Storage tanks, shop fabricated Storage tanks, field erected

719

720

COSTS OF INDIVIDUAL EQUIPMENT

always as great as they are for vessels that are made entirely on special materials. Thus, when the tube side of an exchanger is special and the shell is carbon steel, the multiplier will vary with the amount of tube surface, as shown in that section. For multipliers see information under each type equipment in Table 21.2. As with most collections of data, the price data correlated here exhibit a certain amount of scatter. This is due in part to the incomplete characterizations in terms of which the correlations are made, but also to variations among manufacturers, qualities of construction, design differences, market situations, and other factors. Accordingly, the accuracy of the correlations cannot be claimed to be better than + 25% or so.

Cost data were obtained from a number of different sources and are referred to for each algorithm in Table 21.2. All algorithms have been updated to the first quarter of 2003 and the cost data were checked with equipment manufacturers' data. Any cost index may be used but the Chemical Engineering Index found in the magazine Chemical Engineering is satisfactory for costing equipment. Material of construction is a major factor in the price of equipment so that multipliers for prices relative to carbon steel on other standard materials are given for many of the items covered here. Usually only the parts in contact with process substances need be of special construction, so that, in general, the multipliers are not

m

TABLE 21.2. Purchase Prices of Process Equipment Costs 1st Q 2003 1. Agitators C = 1 . 2 1 8 e x p [ a + b l n H P + c(InHP) 2] KS, 1 < HP < 400

Single Impeller

Carbon steel Type 316

Dual Impeller

Speed 1

2

3

1

2

3

8.57 0.1195 0.0819 8.82 0.2474 0.0654

8.43 -0.0880 0.1123 8.55 0.0308 0.0943

8.31 -0.1368 0.1015 8.52 -0.1802 O.1158

8.80 0.1603 0.0659 9.25 0.2801 0.0542

8.50 0.0257 0.0878 8.82 0.1235 0.0818

8.43 -0.1981 0.1239 8.72 -0.1225 0.1075

a b c a b c

Speeds 1: 30, 37, and 45 rpm 2: 56, 68, 84, and 100 rpm 3: 125, 155, 190, and 230 rpm

2. Compressors, turbines, and fans (KS) Centrifugal compressors, w i t h o u t drivers C - 7.90(HP) ~

KS,

200
Reciprocating compressors w i t h o u t drivers C = 7.19(HP) ~

KS,

100
Screw compressors with drivers C = 1.81(HP) ~

KS,

10
Turbines: Pressure discharge, Vacuum discharge,

C = 0.378(HP) ~ C = 1.10(HP) ~

KS, KS,

20
Fans with motors C = 1.218fmfpexp[a + b l n Q + c(InQ) 2] installed cost, KS, Q in KSCFM

Radial blades Backward curved Propeller Propeller, with guide vanes

a

b

c

Q

0.4692 0.0400 -0.4456 -1.0181

0.1203 0.1821 0.2211 0.3332

0.0931 0.0786 0.0820 0.0647

2-500 2-900 2-300 2-500

Installation factor, fm Carbon steel Fibreglass Stainless steel Nickel alloy

2.2 4.0 5.5 11.0

COSTS OF INDIVIDUAL E Q U I P M E N T TABLE 21.2.--(continued)

Pressure Factors, F p Axial

Centrifugal Pressure (kPa[gage])

Radial

Backward Curved

Prop.

Vane

1 2 4 8 16

1.0 1.15 1.30 1.45 1.60

1.0 1.15 1.30 1.45 m

1.0 m

1.00 1.15 1.30

3. Conveyors K$ Troughed belt: C = 1.71L~ < L < 1300ft Flat belt: C = 1.10L~ < L < 1300ft Screw (steel): C = 0.49L~ < L < 100ft Screw (stainless steel): C = 0.85L~ < L < 100ft Bucket elevator: C = 5.14L~ < L < 100ft Pneumatic conveyor 600ft length C = 1.218 exp[3.5612 - 0.0048 I n W + 0.0913(In W)2],10 < W < 1 0 0 k l b / h r

4. Cooling towers, installed K$ Concrete C = 164fQ~ At(~ f

10 1.0

< Q < 60Kgal/min: 12 1.5

15 2.0

Redwood, w i t h o u t basin: C = 44.3Q~

< Q < 20 Kgal/min

5. Crushers and grinders KS Cone crusher: C = 1.89W 1~ 20 < W < 3 0 0 t o n s / h r Gyratory crusher: C = 9.7W ~176 25 < W < 2 0 0 t o n s / h r J a w crusher: C = 7.7W ~ 10 < W < 2 0 0 t o n s / h r H a m m e r mill: C = 2.97W ~ 2 < W < 200tons/hr Ball mill: C = 61.0W ~ 1 < W < 30tons/hr Pulverizer: C = 27.5W ~ 1 < W < 5tons/hr

6. Crystallizers External forced circulation: C = 1.218 f exp {4.868 + 0.3092 In W + 0.0548( In W)2}, 10 < W < 100 k l b / h r of crystals

Internal draft tube: C = 217f W ~ 15 < W < 1 0 0 k l b / h r of crystals Batch vacuum: C = 9.94fV ~ 50 < V < 1000 cuft of vessel

Type

Material

Forced circulation

Mild steel Stainless type 304 Mild steel Rubber-lined Stainless type 304

Vacuum batch

f 1.0 2.5 1.0 1.3 2.0

7. Distillation and absorption towers, tray and packed prices in $ Tray towers: Ct = 1.218[ fl Cb + Nf2 f3 f4 Ct + Cpt ] Purchased and installed costs are in 1,000.

Distillation: Cb = 1.218 exp [7.123 + 0.1478(In W ) + 0.02488( In W) 2 +O.01580(L/D)In(Tb/TD)], 9020 < W < 2,470,000 Ibs of shell exclusive of nozzles and skirt

Ct = 457.7exp (0.1739 D),2 < D < 16ft tray diameter N - n u m b e r of trays

Cpl = 249.6 00-6332L08016, 2 < D < 24, 57 < L < 170 ft (platforms and ladders) (continued)

721

722

COSTS OF INDIVIDUAL EQUIPMENT

T A B L E 21.2.---(continued)

Material

fl

f2

Stainless steel, 304 Stainless steel, 316 Carpenter 20CB-3 Nickel-200 Monel-400 Inconel-600 Incoloy-825 Titanium

1.7 2.1 3.2 5.4 3.6 3.9 3.7 7.7

1.189 + 0.0577 D 1.401 + 0.0724 D 1.525 + 0.0788 D

Tray Types

2.306 + 0.1120 D

f3

Valve Grid Bubble cap Sieve (with downcorner)

1.00 0.80 1.59 0.95

f4 = 2.25/(1.0414) N, when the number of trays N i s less than 20

Tb is the thickness of the shell at the bottom, Tp is thickness required for the operating pressure, D is the diameter of the shell and tray, L is tangent-to-tangent length of the shell Absorption: Cb = 1.218exp [6.629 + 0.1826( In W) + 0.02297( In W)2], 4250 < W < 980,000 Ib shell Cpl = 300D~ ~176 3 < D < 21, 27 < L < 40ft (platforms and ladders), fl,f2,f3, and f4 as for distillation Packed towers:

C = 1.218[flCb + VpCp Jr- Cpl] Vp is volume of packing, Cp is cost of packing $/cuft

Cp ($/cuft)

Packing Type Ceramic Raschig rings, 1 in. Metal Raschig rings, 1 in. Intalox saddles, 1 in. Ceramic Raschig rings, 2 in. Metal Raschig rings, 2 in. Metal Pall rings, 1 in. Intalox saddles, 2 in. Metal Pall rings, 2 in.

23.9 39.3 23.9 76.6 28.0 39.3 17.4 28.0

8. Dryers Rotary combustion gas heated: C = 1.218(1 + fg + fro)exp [4.9504-0.5827(InA) + 0.0925( In A)2], 200 < A < 30,000 sqft lateral surface Rotary hot air heated" C = 2.90(1 + fg + fm)A~ 200 < A < 4000 sqft lateral surface Rotary steam tube: C = 2.23FAt~176500 < At < 18,000 sqft tube surface, F = 1 for carbon steel, F = 1.75 for 304 stainless Cabinet dryer: C = 1.40fpA ~ 10 < A < 50sqft tray surface

Pressure

fp

Atmospheric pressure Vacuum

1.0 2.0

Material

fm

Mild steel Stainless type 304

1.0 1.4

Drying Gas Hot air Combustion gas (direct contact) Combustion gas (indirect contact)

fg 0.00 0.12 0.35

COSTS OF INDIVIDUAL EQUIPMENT

723

TABLE 2 1 . 2 . - - ( c o n t i n u e d )

fm

Materials Mild steel Lined with stainless 304-20% Lined with stainless 316-20%

0.00 0.25 0.50

Spray dryers: C = 1.218 F exp (0.8403 + 0.8526( In x) - 0.0229( In X) 2, 30 < x < 3000 Ib/hr evaporation

Material

F

Carbon steel 304, 321 316 Monel Inconel

0.33 1.00 1.13 3.0 3.67

Multiple hearth furnaces (Hall, 1984) C = 1 . 2 1 8 e x p ( a + 0.88N), 4 < N < 14 number of hearths Diameter (ft) Sqft/hearth, approx a

6.0 12 5.071

10.0 36 5.295

14.25 89 5.521

16.75 119 5.719

18.75 172 5.853

22.25 244 6.014

26.75 342 6.094

9. Evaporators (IFP) Forced circulation: C - 1.218 frn exp [5.9785-0.6056( In A) + 0.08514( In A) 2], 150 < A < 8000 sqft heat transfer surface Long tube: C = 0.44fmA ~ 300 < A < 20,000 sqft Falling film (316 internals, carbon steel shell) C = 1.218exp [3.2362 - 0.0126(InA) + 0.0244( In A)2], 150 < A < 4000 sqft C is in K$

Forced-Circulation Evaporators Construction Material: Shell/Tube

fm

Steel/copper M o nel/cu pron ickel Nickel/nickel

1.00 1.35 1.80

Long-Tube Evaporators Construction Material: Shell/Tube

fm

Steel/copper Steel/steel Steel/aluminum Nickel/nickel

1.0 0.6 0.7 3.3

10. Fired heaters, installed Box type: C - 1.218k(1 +

fd + fp)QO.S6, 20 < Q < 200M B t u / h r Tube Material Carbon steel CrMo steel Stainless

Design Type Process heater Pyrolysis Reformer (without catalyst)

Design Pressure, (psi) Up to 500 1,000 1,500 2,000 2,500 3,000

k 25.5 33.8 45.0

fd 0 0.10 0.35

fp 0 0.10 0.15 0.25 0.40 0.60

Cylindrical type: C = 1.218k(1 + f~ + fn)Q ~

2 < Q < 30MBtu/hr

(continued)

724

COSTS OF I N D I V I D U A L E Q U I P M E N T

TABLE 21.2.re(continued)

Tube Material

k

Carbon steel CrMo steel Stainless

27.3 40.2 42.0

fd

Design Type Cylindrical Dowtherm

0 0.33

fp

Design Pressure (psi) Up to 500 1,000 1,500

0 0.15 0.20

11. Heat exchangers Shell-and-tube: C = 1.218 fdfmfpCb, price in $ Cb = exp[8.821 - 0.30863(In A) + 0.0681(INA)2], 150 < A < 1 2 , 0 0 0 s q f t

fd

Type Fixed-head Kettle reboiler U-tube

exp [ - 1.1156 + 0.0906( In A)] 1.35 exp [ - 0.9816 + 0.0830( In A)]

fp

Pressure Range (psig) 100-300 300-600 600-900

0.7771 + 0.04981( In A) 1.0305 + 0.07140( In A) 1.1400 + 0.12088( In A) fm -- gl + g2( In A)

gl

g2

0.8603 0.8193 0.6116 1.5092 1.2989 1.2040 1.1854 1.5420 0.1549

0.23296 0.15984 0.22186 0.60859 0.43377 0.50764 0.49706 0.42913 0.51774

Material Stainless steel 316 Stain less steel 304 Stainless steel 347 N ickel 200 M o n e l 400 Inconel 600 I ncoloy 825 Titan i u m H astel Ioy C = 1096fmfpA ~

Double pipe:

2 < A < 60sqft, price in $

Material: Shell/Tube

fm

cs/cs cs/304L stainless cs/316 stainless

1.0 1.9 2.2

fp

Pressure (bar) _<4 4-6 6-7

1.00 1.10 1.25

Air coolers: C - 30.0A ~ 4o, 0.05 < A < 200 Ksqft, price in K$

12. Mechanical separators Centrifuges: solid bowl, screen b o w l or pusher types C = 1 . 2 1 8 [ a + bW], K$

Organic Process

Inorganic Process Material Carbon steel 316 Monel Nickel Hastelloy

a

b

42 65 70 84.4 --

1.63 3.50 5.50 6.56 m 10 < W < 90

m 98 114 143 300

5.06 7.14 9.43 10.0

5 < W < 40tons/hr

COSTS OF INDIVIDUAL EQUIPMENT

TABLE 21.2.--(continued) Disk separators, 316 stainless: C = 9.74 0 ~ 15 < Q < 150gpm, K$ Cyclone separators: K$ Heavy duty: C = 1.69 Q0.96, 2 < Q < 40 K SCFM standard duty: C = 0.79 0 TM, 2 < Q < 40 K SCFM Multiclone: C = 1.90 Q0.68, 9 < Q < 180 K SCFM Filters, prices in $/sqft: rotary vacuum belt discharge: C = 1.218 exp [11.20-1.2252( In A) + 0.0587( In A)2], 1 0 < A < 8 0 0 s q f t rotary vacuum drum scraper discharge: C = 1.218 exp[11.27 - 1.3408( In A) + 0.0709( In A)2]$/sqft, 10 < A < 1500 sqft rotary vacuum disk: C = 1.218 exp [10.50 - 1.008( In A) + 0.0344( In A)2]$/sqft, 100 < A < 4000 sqft horizontal vacuum belt: C = 34469/A~ 10 < A < 1200sqft pressure leaf: C = 847/A~ 30 < A < 2500sqft Plate-and-frame: C = 560/A~ 10 < A < 1000sqft vibrating screen: C = 3.8/A ~ KS, 0.5 < A < 35sqft

13. Motors and couplings, prices in $ Motors: C = 1.46 exp[al + a2(In HP) + a3(In HP) 2] Belt drive coupling" C = 1.46 exp [3.689 + 0.8917(In HP)] Chain drive coupling" C = 1.46 exp[5.329 + 0.5048(In HP)] Variable speed drive coupling: C = 14616/(1.562 + 7.877/HP), HP < 75

Coefficients Type Open, drip-proof 3600 rpm

1800 rpm

1200 rpm

Totally enclosed, fan-cooled 3600 rpm

1800rpm 1200 rpm Explosion-proof 3600rpm 1800rpm 1200 rpm

a7

a2

a2

HP limit

4.8314 4.1514 4.2432 4.7075 4.5212 7.4044 4.9298 5.0999 4.6163

0.09666 0.53470 1.03251 -0.01511 0.47242 -0.06464 0.30118 0.35861 0.88531

0.10960 0.05252 -0.03595 0.22888 0.04820 0.05448 0.12630 0.06052 -0.02188

1-7.5 7.5-250 250-700 1-7.5 7.5-250 250-600 1-7.5 7.5-250 250-500

5.1058 3.8544 5.3182 4.9687 4.5347 5.1532 5.3858

0.03316 0.83311 1.08470 -0.00930 0.57065 0.28931 0.31004

0.15374 0.02399 -0.05695 0.22616 0.04609 0.14357 0.07406

1-7.5 7.5-250 250-400 7.5-250 250-400 1-7.5 7.5-350

5.3934 4.4442 5.2851 4.8178 5.4166 5.5655

-0.00333 0.60820 0.00048 0.51086 0.31216 0.31284

0.15475 0.05202 0.19949 0.05293 0.10573 0.07212

1-7.5 7.5-200 1-7.5 7.5-250 1-7.5 7.5-200

14. Pumps Centrifugal prices in $: C = FMFTCb,base cast-iron, 3550 rJ~m_VSC 2 Q in gpm, H in ft head Cb = 1.39 exp[8.833-0.6019( In Qv/-H) + 0.0519( In Qv//-/)2],

Material Cast steel 304 or 316 fittings Stainless steel, 304 or 316 Cast Gould's alloy no. 20 Nickel Monel ISO B ISO C Titanium Hastelloy C Ductile Iron Bronze

Cost Factor FM 1.35 1.15 2.00 2.00 3.50 3.30 4.95 4.60 9.70 2.95 1.15 1.90

(continued)

725

726

COSTS OF INDIVIDUAL EQUIPMENT

TABLE 21.2.i(continued)

FT = e x p [ b l -I- b2( In Qv/-H) + b3( In Q ~ - ~ ]

Type One-stage, One-stage, One-stage, Two-stage, Multistage,

1750 rpm, VSC 3550 rpm, HSC 1750 rpm, HSC 3550 rpm, HSC 3550 rpm, HSC

Type

bl

bz

b3

5.1029 0.0632 2.0290 13.7321 9.8849

-1.2217 0.2744 -0.2371 -2.8304 -1.6164

0.0771 -0.0253 0.0102 0.1542 0.0834

Flow Range(gpm)

One-stage, One-stage, One-stage, One-stage, Two-stage, Two-stage,

3550 rpm, 1750 rpm, 3550 rpm, 1750 rpm, 3550 rpm, 3550 rpm,

VSC VSC HSC HSC HSC HSC

Head Range(~)

50-900 50-3500 100-1500 250-5000 50-1100 100-1500

HP(max)

50-400 50-200 100-450 50-500 300-1100 650-3200

75 200 150 250 250 1450

Vertical mixed flow: C = 0.044(gpm)~ 500 < gpm < 130,000 Vertical axial flow: C = 0.024(gpm)~ 1000 < gpm < 130,000 Gearpumps: C = 1.218 e x p [ - 0 . 0 8 8 1 + 0 . 1 9 8 6 ( I n Q) + 0.0291( In Q)2]K$, 1 0 < Q < 9 0 0 g p m Reciprocating: Cast iron: C = 76.9Q~ Others: C - 795FQ~ 316 stainless AI bronze Nickel Monel

15 < Q < 400gpm 1 < Q < 400gpm F = 1.00 1.40 1.86 2.20

15. Refrigeration" C = 178FQ~ Temperature Level (~ 0 -10 -20 -30 -40 -50

0.5 < Q < 400 M B t u / h r , i n s t a l l e d p r i c e s

F 1.00 1.55 2.10 2.65 3.20 4.00

16. Steam ejectors and vaccum pumps Ejectors: C = 13.3flf2f3X~ 0.1 < X < 100 X = (fb air/hr)/(suction pressure in Torr)

Type

fl

No. Stages

fz

Material

f3

No condenser 1 surface condenser 1 barometric condenser 2 surface condensers 2 barometric condensers

1.0 1.6 1.7 2.3 1.9

1 2 3 4 5

1.0 1.8 2.1 2.6 4.0

carbon steel stainless steel astelloy

1.0 2.0 3.0

Vacuum pumps: C = 9.93Xl,~ 0.3 < X < 15 (Ibs air/hr)/(suction Tort).

17. Vessels prices in $ Horizontal pressure vessels: C = FMCb + Ca Cb = 1.218exp[8.571 -0.2330( In W) + 0.04333( In W)2], 800 < W < 914,000 Ib shell weight Ca = 1669D ~176 3 < D < 12ft diameter (platforms and ladders) Vertical vessels: C = FMCb+ Ca

Cb = 1.218exp [9.100 - 0.2889( In W) + 0.04576( In W)2], 5000 < W < 226,000 Ib Ca - 300D~ ~176 6 < D < 10,12 < L < 20ft tangent-to-tangent

Material Stainless steel, 304 Stainless steel, 316 Carpenter 20CB-3 Nickel-200 Monel-400 Inconel-600 Incoloy-825 Titanium

Cost Factor FM 1.7 2.1 3.2 5.4 3.6 3.9 3.7 7.7

COSTS OF INDIVIDUAL E Q U I P M E N T

TABLE

727

21.2.--(continued)

Storage tanks, shop fabricated: C = 1.218FM exp [2.631 + 1.3673( In V) - 0.06309( In V)2], 1300 < V < 21,000 gal Storage tanks, field erected: C - 1.218FM exp [11.662 - 0.6104( In V) + 0.04536( In V)2], 21,000 < V < 11,000,000 gal

Cost Factor FM

Material of Construction Stainless steel 316 Stainless steel 304 Stainless steel 347 Nickel Monel Inconel Zirconium Titanium Brick-and-rubber-or brick-and-polyester-lined steel Rubber- or lead-lined steel Polyster, fiberglass-reinforced Aluminium Copper Concrete

2.7 2.4 3.0 3.5 3.3 3.8 11.0 11.0 2.75 1.9 0.32 2.7 2.3 0.55

EXAMPLE 21.1

Installed Cost of a Distillation Tower Shell and trays are made of AISI 304 stainless steel. Dimensional data are: D = 4ft, L = 120ft, N = 58 sieve trays, wall thickness tp : 0.50 in. for pressure, tb = 0.75 in. at the bottom, flanged and dished heads weigh 325 lb each, weight W = (rc/4)(16)(120(0.5/12)(501) + 2(325) = 32,129 lb Cb = 1.218 exp[7.123 + 0.1478(10.38) + 0.02488(10.38) 2 +0.158(120/4) In (0.75/0.50)] = 697,532,

f3 = 0 . 8 5 , f4=l, Ct = 457.7 exp [0.1739(4)] = 917.6, Cpl = 249.6(4)~ ~176 = 27,923 purchase price C = 1.7(697,532) + 58(1.42)(0.85)(917.6) +27,867 = $1,266,414 $1,266,470 F r o m Table 3, the installation factor is 2.1 so that the installed price is Cinstalled =

2.1 ($1,266,470) = $2,659,587.

A tower packed with 2 in. pall rings instead of trays: packing volume Vp = 02/4)(4)2(120) - 1508 cuft, Cinstalled - - 2.111.7(697,532)+ 1508(28.0)+ 27,923] = 2,637,436

fl = 1.7, f2 = 1.189 + 0.0577(4)= 1.420,

EXAMPLE 21.2

Purchased and Installed Prices of Some Equipment a. A box type fired heater with C r M o tubes for pyrolysis at 1500 psig with a duty of 40 million Btu/hr. F r o m Item No. 10 (Table 21.2), the installed price is $1,228,000 Cinstallcd - -

(1218)33.8(1.0 + 0.10 + 0.15)(40) 0.86 = 1,219,602

b. A 225 H P reciprocating compressor with m o t o r drive and belt drive coupling. Items Nos. 2 and 13 (Table 21.2). The installation factor is 1.3. Compressor C = 7190(225) ~ = 197,572, motor,1800 r p m , T E F C , C = 1.46 x exp [4.5347 + 0.57065(5.42) + 0.04069(5.42) 2] = $11,858

belt drive coupling, C = 1.46 exp [3.689 + 0.8917(5.42)] = $8,772, total installed cost, Ctotal --- 1.3(197,572 + 11,858 + 8772) = $283,663. c. A two-stage steam ejector with one surface condenser to handle 200 lb/hr of air at 25 Torr, in carbon steel construction. F r o m Table 21.3 the installation factor is 1.7. X = 200/25 = 8, fl = 1.6, f 2 = 1 . 8 , J~ = 1.0 purchase Cp = 13.3(1.6)(1.8(1.0)(8))~ $90,510, installed C = 1.7Cp = $153,866. _

_

728

COSTS OF INDIVIDUAL EQUIPMENT

TABLE 21.3. Multipliers for Installed Costs of Process Equipment a Equipment Agitators, carbon steel stainless steel Air heaters, all types Beaters Blenders Blowers Boilers Centrifuges, carbon steel stainless steel Chimneys and stacks Columns, distillation, carbon steel distillation, stainless steel Compressors, motor driven steam on gas driven Conveyors and elevators Cooling tower, concrete Crushers, classifiers and mills Crystallizers Cyclones Dryers, spray and air other Ejectors Evaporators, calandria thin film, carbon steel thin film, stainless steel Extruders, compounding Fans Filters, all types Furnaces, direct fired Gas holders Granulators for plastic Heat exchangers, air cooled, carbon steel coil in shell, stainless steel Glass Graphite plate, stainless steel plate, carbon steel shell and tube, stainless/stainless steel

Multiplier 1.3 1.2 1.5 1.4 1.3 1.4 1.5 1.3 1.2 1.2 3.0 2.1 1.3 1.5 1.4 1.2 1.3 1.9 1.4 1.6 1.4 1.7 1.5 2.5 1.9 1.5 1.4 1.4 1.3 1.3 1.5 2.5 1.7 2.2 2.0 1.5 1.7 1.9

Equipment Heat exchangers, shell and tube, carbon/steel/aluminum shell and tube, carbon steel/copper shell and tube, carbon steel/Monal shell and tube, Monel/Monel shell and tube, carbon steel/Hastelloy Instruments, all types Miscellaneous, carbon steel stainless steel Pumps, centrifugal, carbon steel centrifugal, stainless steel centrifugal, Hastelloy trim centrifugal, nickel trim centrifugal, Monel trim centrifugal, titanium trim all others, stainless steel all others, carbon steel Reactor kettles, carbon steel kettles, glass lined kettles, carbon steel Reactors, multitubular, stainless steel multitubular, copper multitubular, carbon steel Refrigeration plant Steam drums Sum of equipment costs, stainless steel Sum of equipment costs, carbon steel Tanks, process, stainless steel Tanks, process, copper process, aluminum storage, stainless steel storage, aluminum storage, carbon steel field erected, stainless steel field erected, carbon steel Turbines Vessels, pressure, stainless steel pressure, carbon steel

Multiplier 2.2 2.0 1.8 1.6 1.4 2.5 2.0 1.5 2.8 2.0 1.4 1.7 1.7 1.4 1.4 1.6 1.9 2.1 1.9 1.6 1.8 2.2 1.5 2.0 1.8 2.0 1.8 1.9 2.0 1.5 1.7 2.3 1.2 1.4 1.5 1.7 2.8

a[j. Gran, Chem. Eng., (6 Apr. 1981)]. Installed Cost = (purchase price) (multiplier). Note: The multipliers have remained essentially the same through late 2002.

Example 21.1 and 21.2 illustrate the use of the algorithms to obtain equipment cost data.

REFERENCES Chemical Engineering Magazine, Modern Cost Engineering, McGraw-Hill, New York, 1979. Chemical Engineering Magazine, Modern Cost Engineering H, McGraw-Hill, New York, 1984. J. Cran, Improved factor method give better preliminary cost estimates, Chemical Engineering Magazine, Modern Cost Engineering H, McGrawHill, New York, 1984, pp. 76-90. L.B. Evans, A. Mulet, A.B. Corripio, and K.S. Chretien, Costs of pressure vessels, storage tanks, centrifugal pumps, motors, distillation and absorption towers, in Chemical Engineering Magazine, Modern Cost Engineering II, McGraw-Hill, New York, 1984, pp. 140-146, 177-183. D.W. Green, and J. O. Maloney (Eds.), Perry's Chemical Engineers' Handbook, 6th ed., McGraw-Hill, New York, 1984, cost data on pp. 6.7, 6.22, 6.112, 6.113, 6.121, 7.19, 11.19, 11.20, 11.21, 11.29, 11.42, 17.27, 17.33,

18.45, 18.46, 18.47, 19.13, 19.40, 19.45, 19.65, 19.89, 19.101, 19.102, 20.37, 20.38, 21.22, 21.45, 22.134, 22.135, 25.69, 25.73-25.75. R.S. Hall, J. Matley, and K.J. McNaughton, Chemical Engineering Magazine, Modern Cost Engineering H, McGraw-Hill, New York, 1984, pp. 102-137. Institut Francaise du Petrole (IFP), Manual of Economic Analysis of Chemical Processes, Technip 1976, McGraw-Hill, New York, 1981. B.G. Liptak, Costs of process instruments, in Chemical Engineering Magazine, Modern Cost Engineering, McGraw-Hill, New York, pp. 1979, 343-375. C. Meyers and J. Kime, Chemical Engineering, (McGraw-Hill, New York) pp. 109-112 (September 1976). A. Pikulik and H.E. Diaz, Costs of process equipment and other items, in Chemical Engineering Magazine, Modern Cost Engineering, 1979, pp. 302-317. G.P. Purohit, Costs of shell-and-tube heat exchangers, Chemical Engineering, 22 (August 1983, 4 March 1985, 18 March 1985). G.D. Ulrich, A Guide to Chemical Engineering Process Design and Economics, Wiley, New York, 1984. W.M. Vatavuk, Coasts of baghouses, electrostatic precipitators, venturi scrubbers, carbon adsorbers, flares and incinerators, in Estimating Costs of Air Pollution Control, Lewis Publishers, Chelsea, MI, 1990.