(A) Data for Sizing of Equipments: (1) Vessel Sizing: For the desired temperature range, consider the required materials of construction for vessels as shown in table below: Table 1: Materials of Construction
Tmax
High Temperature service ( F) Steel
Low Temperature service T min ( F) Steel
o
950 1150 1300 1500
2000
o
Carbon Steel (CS) 502 Stainless Steels 410 Stainless Steels 330 Stainless Steels 430, 446 Stainless Steels Stainless Steels (SS) (304, 321, 347, 316) Hastelloy C, X Inconel 446 Stainless Steels Cast Stainless, HC
-50 -75 -320
Carbon Steel (CS) Nickel Steel (A203) Nickel Steel (A353)
-425
Stainless Steels (SS) (302, 304, 310, 347)
Table 2: Guthrie Material and Pressure Factors for Pressure Vessels
Shell Material Carbon Steel (CS) Stainless Steel 316 (SS) Monel Titanium Up to Fp
50 1.00
100 1.05
200 1.15
MPF = Fm Fp Clad, F m 1.00 2.25 3.89 4.23 Vessel Pressure (psig) 300 400 500 600 1.20 1.35 1.45 1.60
Solid, Fm 1.00 3.67 6.34 7.89 700 1.80
800 1.90
900 2.30
1000 2.50
(2) Heat Transfer Equipment: Table 3: Typical Overall Heat Transfer Coefficients Shell Side
Tube Side
Design U (Btu/ft2-hr-oF)
Liquid – liquid Media
Cutback asphalt Demineralized water Fuel oil Fuel oil
Water Water Water Oil
10-20 300-500 15-25 10-15 Compiled By Prof. Prasad Parulekar
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Gasolene Heavy oils Heavy oils Hydrogen- rich reformer stream Kerosene or gas oil Kerosene or gas oil Kerosene or jet fuels Jacket water Lube oil (Low viscosity) Lube oil (High viscosity) Lube oil Naptha Naptha Organic solvents Organic solvents Organic solvents Tall oil derivatives, vegetable oil, etc. Water Water Wax distillate Wax distillate
Water Heavy oils Water Hydrogen- rich reformer stream Water Oil Trichlorethylene Water Water Water Oil Water Oil Water Brine Organic solvents Water
60-100 10-40 15-50 90-120 25-50 20-35 40-50 230-300 25-50 40-80 11-20 50-70 25-35 50-150 35-90 20-60 20-50
Caustic soda solutions (10-30%) Water Water Oil
100-250 200-250 15-25 13-23
Condensing vapour-liquid Media
Alcohol vapour Asphalt (450 oF) Dowtherm vapour Dowtherm vapour Gas-plant tar High-boiling hydrocarbons V Low-boiling hydrocarbons hydrocarbons A Hydrocarbon vapours (partial condenser) Organic solvents A Organic solvents high NC, A Organic solvents low NC, V Kerosene Kerosene Naptha Naptha Stabilizer reflux vapours Steam
Water Dowtherm vapour Tall oil and derivatives Dowtherm liquid Steam Water Water Oil
100-200 40-60 60-80 80-120 40-50 20-50 80-200 25-40
Water Water or brine Water or brine Water Oil Water Oil Water Feed water
100-200 20-60 50-120 30-65 20-30 50-75 20-30 80-120 400-1000
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Gas-liquid Media
Air, N2, etc. (compressed) Air, N2, etc., A Water or brine Water or brine Water
Water or brine Water or brine Air, N2 (compressed) Air, N2, etc., A Hydrogen containing natural-gas mixtures
40-80 10-50 20-40 5-20 80-125
Vaporizers
Anhydrous ammonia Steam condensing 150-300 Chlorine Steam condensing 150-300 Chlorine Light heat-transfer oil 40-60 Propane, butane, etc. Steam condensing 200-300 Water Steam condensing 250-400 Note: NC = noncondensable noncondensable gas present, V = vacuum, A = atmospheric pressure Table 4: Guthrie Material and Pressure Factors for Heat Exchangers MPF = Fm (Fp + Fd) Design Type
Fd 1.35 1.00 0.85 0.80
Kettle Reboiler Floating Head U Tube Fixed tube sheet Up to Fp Surface Area (ft2) Up to 100 100 to 500 500 to 1000 1000 to 5000
150 0.00 CS / CS 1.00 1.00 1.00 1.00
Cs / Brass 1.05 1.10 1.15 1.30
Vessel Pressure (psig) 300 400 0.10 0.25 Shell / Tube Materials, F m CS / SS / CS / SS SS Monel 1.54 2.50 2.00 1.78 3.10 2.30 2.25 3.26 2.50 2.81 3.75 3.10
800 0.52 Monel / Monel 3.20 3.50 3.65 4.25
(3) Furnaces and Direct Fired Heaters: Table 5: Guthrie Material and Pressure Factors for f or Furnaces MPF = Fm + Fp + Fd Design Type
Fd
1000 0.55 CS / Ti 4.10 5.20 6.15 8.95
Ti / Ti 10.28 10.60 10.75 13.05
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Fp
0.00
0.10 0.15 0.25 Radiant Tube Material, F m
Carbon Steel Chrome / Moly Stainless Steel
0.40
0.60
0.00 0.35 0.75
Table 6: Guthrie Material and Pressure Factors for f or Direct Fired Heaters MPF = Fm + Fp + Fd Design Type
Fd 1.00 1.33
Cylindrical Dowtherm Up to Fp
500 0.00
Vessel Pressre (psig) 1000 0.15 Radiant Tube Material, F m
Carbon Steel Chrome / Moly Stainless Steel
1500 0.20 0.00 0.45 0.50
(4) Distillation Columns: Table 7: Guthrie Material and Pressure Factors for Tray Stacks MPF = Fm + Fs + Ft Tray Type Grid (no downcomer) Plate Sieve Valve or trough Bubble cap Koch Kascade
Ft 0.0 0.0 0.0 0.4 1.8 3.9 Tray Spacing, Fs
(inch) Fs Carbon Steel Stainless Steel Monel
24”
18”
12”
1.0
1.4 Tray Material, F m
2.2 0.0 1.7 8.9
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MPF = Fm Fo Material Type
Fm 1.00 1.28 1.93 2.89 3.23 3.48 8.98
Cast iron Bronze Stainless Hastelloy C Monel Nickel Titanium Max Suction Pressure (psig) Max Temperature ( oF) Fo
Operating Limits, F o 150 250 1.0
500
1000
550 1.5
850 2.9
(6) Compressors: Table 9: Guthrie Material and Pressure Factors for f or Compressors MPF = Fd Design Type Centrifugal / motor Reciprocating / steam Centrifugal / turbine Reciprocating / motor Reciprocating / gas engine
Fd 1.00 1.07 1.15 1.29 1.82
(7) Refrigerators: Table 10: Guthrie Equipment Factors for Mechanical Refrigeration Refrigeration MPF = Ft Evaporator Temperature 40 F / 278 K 20 oF / 266 K 0 oF / 255 K -20 oF / 244 K -40 oF / 233 K o
Ft 1.00 1.95 2.25 3.95 4.54
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(B) Data for Cost Estimation of Equipments: Equipments: Table 11: Chemical Engineering Plant Index (cost indices, CI) for updating cost of equipments Year
CI 100 115 126 316 359 381
1957 – 59 1968 ½ 1970 ½ 1983 1993 1995
Table 12: Base Costs for Process Vessels Equipment Type
Co ($)
Lo (ft)
Do (ft)
α
β
Vertical Fabrication 1 ≤ D ≤10 ft , 4 ≤ L ≤ 100 ft Horizontal Fabrication
1000
4.0
3.0
0.81
1.05
MF2/MF4/MF6/MF8/MF 10 4.23/4.12/4.07/4.06/4.02
690
4.0
3.0
0.78
0.98
3.18/3.06/3.01/2.99/2.96
180
10.0
2.0
0.97
1.45
1.0/1.0/1.0/1.0/1.0
1 ≤ D ≤10 ft , 4 ≤ L ≤ 100 ft
Tray Stacks 2 ≤ D ≤10 ft , 1 ≤ L ≤ 500 ft
Note: Lo = Base length; Do = Base diameter; Co = Base cost; α and β = Exponents in power law expression; MF = Module factor with respect to base cost.
Table 13: Base Costs for Process Equipments Equipment Type Process Furnaces S = Absorbed duty (10
Co ($103)
So
Range (S)
100
30
10 - 300
0.83
2.27/2.19/2.16/2.15/2.13
20
5
1 - 40
0.77
2.23/2.15/2.13/2.12/2.10
5
400
100 - 104
0.65
3.29/3.18/3.14/3.12/3.09
α
MF2/MF4/MF6/MF8/MF 10
6
Btu/hr) Direct fired Heaters S = Absorbed duty (10 6 Btu/hr) Heat Exchangers Shell and Tube, S = Area (ft2)
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S = [Calculated area (ft2)/15.5] Centrifugal Pumps
0.39
S = C/H factor (gpm × psi)
0.65 1.5
10
10 - 2× 103
0.17
3.38/3.28/3.24/3.23/3.20
2 × 103 2 × 103 - 2 ×
0.36
3.38/3.28/3.24/3.23/3.20
2 × 104 104
0.64
3.38/3.28/3.24/3.23/3.20
2 × 104 - 2 × 105 Compressors
23
100
30 - 104
0.77
3.11/3.01/2.97/2.96/2.93
60
200
50 - 3000
0.70
1.42
S = Break horsepower Refrigeration S = ton refrigeration (12,000 Btu/hr removed) Note: Co = Base cost; So = Base capacity; α = Exponent in power law expression; MF = Module factor with respect to base cost. Table 14: Module Factors for Particular range of Base Costs Module Factor (MF) to be used
Range of Base Cost for which MF to be used
MF2
Up to $ 200,000
MF4
$ 200,000 to $ 400,000
MF6
$ 400,000 to $ 600,000
MF8
$ 600,000 to $ 800,000
MF10
$ 800,000 to $ 1,000,000
