CONFIDENTIAL 22231/KUK2142 QUESTION 1 [40 MARKS] a) East Coast Engineering Consulting firm has undertaken an assignment to conduct a feasibility study on a newly proposed chemical plant in Gebeng, Kuantan, The estimated capital cost using the study estimate method (Class 4) was calculated to be $108 million. If the plant were to be built, over what range would you expect the actual capital estimate to vary? [8 Marks] [CO1, PO1, C3] A senior engineer of Chemical Plant Sdn. Bhd, Ir Danial Haqeem has purchased a heat exchanger of $150,000 (400 m? area) in 2012. Based on this information, you are requested to estimate the cost of the same heat exchanger in 2022. CEPCI index: 2012 (586), 2022 (708). [4 Marks] [CO1, POL, C3] PetChem Sdn. Bhd, a fluid processing plant has planned for a major plant expansion in 2022. Determine the capital cost for the expansion if the plant that has a total purchased cost of $70,000,000. [4 Marks] [CO1, PO1, C3] Figure 1 shows the process flow diagram (PFD) of a chemical process after an expension. The equipment details for the expansion are listed in Table 1 and the capital cost estimates are given in Table 2. With the CEPCI indexes: 2012 (586), 2022 (708); (Calculate purchased cost; C%(2012) ($) and bare module cost; Cum(2012) (S) for a, E-101,E-102, E-103 b. P-LO1AB Calculate the total module cost (Crs) for this expansion in 2022. (24 Marks| [CO1, POL, C3]22231/KUK2142 E103 Figure 1 Table 1 Equipment No. Capacity/Size Material of ‘Operating Construction _| Pressure (barg) E101 ‘Area=190 m? Tube -CS Tube=5 Overhead Shell and tube (floating Shell-CS Shell: condenser head) E-102 Area=225 m? Tube-SS Tube=18.0 Reboiler Shell and tube (floating Shell-CS Shel head) F103 ‘Area=15m* AICS Taner = 5 Product cooler (double pipe) consctruction Outer = 5 P-101A/B Power shaft -5kW cs Discharge5 Reflux pumps Centrifugal T-101 Diameter = 21m Vessel -CS Column = 5 Aromatic column Height = 23 m 32 sieve trays Tray -CS V-101 Diameter = 1.8m Trays-SS Vessel = 5 Reflux drum Length = 6 m Vessel- HorizontalCONFIDENTIAL 2223V/KUK2142 Table 2 Equipment Fp] Fm | Fem | C%p(2012)(S) ‘Cam(2012) (S) E-101 10 | 10 | 3.29 E-102 1.029 | 181 | 4.70 E103 To | 10 | 3.29 P-101A/B 10 | 155 | 3.98 T101 16st | 10 | 531 57,000 290,700 V-101 1513) 1.0 | 3.79 13,500 51,200 Reflux drum 32 trays 1337183 (G2)2200) 131,200 TotalsCONFIDENTIAL 22231/KUK2142 QUESTION 2 [40 MARKS] The production of 70,000 tonnes/year of acrylic acid involves the reaction between of propylene and oxygen supplied by air under the presence of steam. Figure 2 shows the process flow diagram (PFD) of the acrylic acid plant while Table 3 gives the stream data of the plant. The utility summary for acrylic acid production is given in Table 4 and Table 5 provides the information of some equipment of the plant, The plant is operated by 350 days in a year with the total module cost estimated to be $120,000,000. Given the recent market prices (2022) for raw materials, product and wage of operator: Price of propylene: $ 520/tonne Price of steam: § 0.5/kg Price of acrylic acid: $ 1,685/tonne Price of air: $ 0 (atmospheric air) Wage of operator: $ 30/hr Determine the recent yearly costs for the raw materials and product and decide whether the plant is economical. [5 Marks} [CO1, PO1, C3] ‘Using the price data available from the PEE Handbook (Turton et al., 2012), determine the recent yearly costs for utilities involved in the acrylic acid production plant. Given the CEPCI indexes: 2012 (586), 2022 (708), (Steam (ii) Cooling water (iii) Electricity (iv) Total utilities [28 Marks} [CO1, POL, C3] Determine the total cost of manufacturing (COM) for the production of acrylic acid in year 2022, [7 Marks] [CO1, PO1, C3]CONFIDENTIAL 22231/KUK2142 (©1001 E-1001 inet At Blower Cooler Proms R001 TION Fro0e PONG E1002 T1009 E4009 TOOK E1009 E1004 Moten Set Motlen Sat Reaztor Quench OMGas Quench ‘Solent Sohent Sohent SoWent aractor Exchgt Towar Rabasor Condst Quench Acid Gre. Pumps Tower Absorber Pups Cooler C21 oxen Eas\ (P0088 P-1OG4A'B V-10C1 T1005 E-1006 E-1006 P-100SN/B V-1002T-1006 E1007 E:1008 P-1ON6ABV.1008 P-1007A 1010 ‘AcHl Solvent Solvent Acd Add Ace ASA Waste Waste Wate Wants Wante Protict Product Fees Rehan Rex Tower Rebollr CorderRefux Ruhax Tower Raboter Conder thc fet Pumps Cover Pompe One Pumge Drum Seen Temperanse,"C & Pres, bat P1007 AB. E1010 ‘eye ed Figure 2CONFIDENTIAL 22231/KUK2142 Table 3 Stream Number a a a a Temperature) «ss * = os =« « « & @ Preset ism &¢& S Bk tek we Bw Vapor ation 0 1 w 1 oo Ww o © of o Mesflow tome/hy «SAS OND a7 HAG OTS Moiefow Gmol/h) 2923-7 MRAZ_— MD MARS SIMO. RNG LDS Component flowrates tec (Genet). Men Sat pyle om 00 70 pam om oom ten 070m” 0M 567 ONO Om 7 Oxygen mis ow om) samy am Samak Carbon dose om om 0m = om gots amos Wee 23 m3 om wis = amma Aes cid a0 000 om) oma) Aenlcacd a0 0m 00mm) Som) Solvent (dincprytetic) om 0m oma madam mma vt KS ge o 0 09 Bb Bb © Oo @ ww o « © mu om uot uu a a 09 a 0 «00a 0 oo 0 00 27 100661553 36K 6h SR MM STA 6K 11569 15912 S019 1757 HRD 86K DM TIGA a7 om =o amo oma mom om =o om om mmm mmm cm = 0 oma mmm mmm am =o) om) am momma] 1is6 ims 0D) TISAI RT a0 608 6a) am ss Sesto) am 15am)? Table 4 Utility cw cw tps—sips_ cw sips, cw ps cw Equipment — E-1001 E-1002 E-1003 E-1005 E-1006 E-1007 E-1008 E1009 E-1010 Flow 1995.0 1682.0 48.5 107-545 10.19 378.0 3.85 16.7 (tonne /h)CONFIDENTIAL 22231/KUK2142 Table $ Equipment E001 E1002 £1003 E1006 E1005 E1006 E1007 lonting- Floating Floating Posed Floating: Floating head head head 1s head Type head Fixed TS reboiler condenser’ reboler’ condenser ebiler aay (M/A) 3400 70:00 11,000 103300 230 zs0 21200 Area) 10, 2550 so mo 197 733 "7 Shell Max temp °C) 0 eT 10 0 160 ” 160 Pressure (hang) 40 40 50 0 50 40 50 Phase b L Cond. steam L Cond. steam L Cond. steam Moc CCarbonsteel Carbon steel Carbon steel Carbonistel Carbon steel Carbonstee! Carbon steel Tube side Maxtemp(C) 280 5 %0 0 a aa Pressure (bang) 2.0 20 ost ns 099 a Moc Carbonstee! Stanies sce! Stainless steel Sta Carbonstee!_ Carbon steel Stainless steel Phase t L Boiling lig, Cond. vapor Boling, Cond vapor Boiling lig Equipment £-1008 E1009 £-1010 Fixed TS Type condenser Floating head Floating head Duty (Mh) 15,800 ‘3000 eon Area (om?) 210 197 103 Shell side Max temp (°C) 40 160 40 Pressure (barg) 40 50 40 Phase L Cond. steam L Moc Carbon steel Carbon steet Carbon stee! Tube side Max temp (°C) oo 40 89 Pressure (bars) oo 20 14 Moc Carbon steel Carbon steel Stainless steel Phase Cond. vapor L 7 (continuedCONFIDENTIAL 22231/KUK2142 Table S-cont. J Equipment P-1001.A/B P-1002 A/B P-1003 A/B P-1004A/B P-1005A/B P-1006A/8 P-1007 A/8 Caton Stainless Sines Stain Carbon Carbon ‘Stainless moc steel sted stl steel sel steel stel Power(shaft} 323 1062 ww 13 12 a0 1 «wy fiency 7% 7% 4% 7% 40% ae 4% ‘Type/drive Centiiugal/ Centrifugal’ Centifugal/ Centiugal/ Centiugal/ Cenrfugal/ Centifugal/ electric electric =—=—eletic «=e lec «= electrc electric Temperature 250 #0 0 B a @ ® oO) Pressure in 20 u ow an ow uw a6 {bar} Pressueout 36 29 208 4a 331 4a 26 (bar) Equipment 1001 a/B v-1001 v-1002 v-1003 Moc Carbon steel Stainlesssteel_ Carbon steel Carbon steel Power (shaft) (kW) 2260 - - = Efficiency 7% es os — Centrifugal ‘Type/arive Centrifugal -2 = = = stage/electric ‘Temperature °C) 3 - - - Pressure in (bat) 10 - - - Pressure out (bar) 50 — — = Pressure (barg) - -088 093 00 Diameter (m) ~ 24 10 15 Height/ength (mm) = 72 28 45 Orientation = Horizontal Horizontal Horizontal Internals = = = = END OF QUESTION PAPER