This action might not be possible to undo. Are you sure you want to continue?
22S.1 EQUIPMENT SIZING AND CAPITAL COST ESTIMATION USING THE ASPEN ICARUS PROCESS EVALUATOR (IPE)
The Aspen Icarus Process Evaluator (IPE) is a software system provided by Aspen Technology, Inc., for evaluation of capital expenditures, operating costs, and profitability of a process design. Aspen IPE has an automatic, electronic expert system which links to process simulation programs. It is used to: (1) extend the results of process simulations, (2) generate rigorous size and cost estimates for processing equipment, (3) perform preliminary mechanical designs, and (4) estimate purchase and installation costs, indirect costs, the total capital investment, the engineeringprocurement-construction planning schedule, and profitability analyses. This section concentrates on capital cost estimation, with profitability analysis covered in Chapter 23.
Aspen IPE uses five key steps in the evaluation of process designs:
1. Simulation results are loaded into Aspen IPE
2. Process simulation units (that is, blocks, modules, or subroutines) are mapped into more descriptive models of process equipment (e.g., mapping a HEATX simulation unit into a floating-head, shell-and-tube heat exchanger; mapping a RADFRAC simulation unit into a tray tower, complete with reboiler, condenser, reflux accumulator, etc.) and associated plant bulks, which include installation items, such as piping, instrumentation, insulation, paint, etc.
3. Equipment items are sized and re-sized when modified.
4. Capital costs, operating costs, and the total investment are evaluated for a project.
Results are presented to be reviewed. it is necessary to prepare simulation results for loading into Aspen IPE. Aspen IPE usually requires estimates of mixture properties not needed for the material and energy balances. and (2) the monochlorobenzene (MCB) separation process introduced in 22S-2 . it is necessary to augment the simulation report files with estimates by the simulator of mixture properties. and phase equilibria calculations performed by the process simulators. when the approximate DISTL and RSTOIC subroutines are used in ASPEN PLUS. rather than approximate. After the simulation file is augmented. and Seider. 2008). For this reason. and surface tension for each of the streams in the simulation flowsheet. This section presents estimates of equipment sizes and purchase and installation costs using Aspen IPE for two examples involving: (1) the depropanizer distillation tower presented in the multimedia modules which can be downloaded from the Wiley web site associated with this book (either HYSYS Separations Distillation or ASPEN PLUS Separations Distillation). Note that the ASPEN PLUS and ASPEN HYSYS simulators contain menu entries to direct the results to Aspen IPE. For details. these must be replaced by more rigorous subroutines. First. which are provided in the file. and other simulators. such as viscosity. This replacement can be viewed as the first step in computing equipment sizes and costs. the revised simulation is run and the results are sent to Aspen IPE. PRO/II. in the PDF Files folder on the Wiley web site associated with this book. to estimate equipment sizes. with modifications as necessary and reevaluation. ASPEN HYSYS. UNISIM. Second. This is normally accomplished by augmenting the simulation file in two ways. simulation subroutines. such as the RADFRAC and RPLUG subroutines. The program accepts results from ASPEN PLUS. Aspen IPE begins with the results of a simulation using one of the major process simulators. To estimate equipment sizes and costs.pdf. Aspen IPE Course Notes.5. Aspen IPE estimates equipment sizes using the simulation results computed by the more rigorous. CHEMCAD. the reader is referred to course notes prepared at the University of Pennsylvania (Nathanson. Consequently. thermal conductivity. Adams II.
using Aspen IPE. reboiler. the RADFRAC subroutine adjusts the reflux ratio to 8.1 Depropanizer The depropanizer distillation tower in Figure 22S. with simulation results using ASPEN PLUS provided in the multimedia module (ASPEN Principles of Flowsheet Simulation Interpretation of Input and Output Sample Problem). the reflux ratio. The material of construction is A515 Carbon Steel for the tower and A285C Steel for the condenser. The details of using Aspen IPE for these two examples are presented in the file. reflux accumulator. to achieve the desired distillate purity. Just the key specifications and results are presented here.1 Specifications for design of the depropanizer distillation tower 22S-3 . Example 22S. Figure 22S. using the DSTWU subroutine for the specification R = 1. number of equilibrium stages.88. When the tower is simulated with these specifications and D/F = 0.1 is designed and simulated using the procedures described in the multimedia modules (either HYSYS Separations Distillation or ASPEN Separations Distillation). it is desired to estimate the total permanent investment.Section 5. for the pressures shown. CTPI. N = 14. In this example. and pumps.4. and the feed stage are estimated to be: R = 6.06.pdf.226. In summary. and NFeed = 7. Aspen IPE Course Notes.75Rmin.
(2) a shell-and-tube heat exchanger with a fixed tube sheet for the condenser. such as the design pressure and temperature. and others. and assure nucleate boiling. and (5) a kettle reboiler with U tubes.SOLUTION For the depropanizer system. The designer can add a reboiler pump (to pump liquid from the sump to the reboiler).1 of the book. and 400 psia. Aspen IPE uses many parameters to estimate equipment sizes and to specify the characteristics of utilities. Aspen IPE Course Notes. Aspen IPE has three built-in utilities for steam at 100. To reduce the approach temperature difference. bottom sump height. However. and associated installation materials and labor costs for the distillation tower. the residence times in the process vessels. when 100 psia steam is used in the reboiler.8F and the bubble point temperature of the bottoms product at 252 psia is 260. The default parameters are listed in Appendix II of the file. or subroutines) are mapped into Aspen IPE. and estimates sizes. After the parameters for estimating equipment sizes and the utility parameters are adjusted. at 50 psia. reflux accumulator. there is only one distillation unit. Also.8F. and the tower specifications. modules. Aspen IPE performs mechanical designs. the simulation units (blocks. (4) a centrifugal reflux pump. T = 117F. For the condenser. and a new steam utility is defined.pdf (in the PDF Files folder on the Wiley web site associated with this book). Particular attention should be paid to the IPE Design Basis parameters. reflux pump. Changes can be made to the default parameters. purchase costs. and reboiler. condenser. In this case. is defined. which often results in undesirable film boiling as discussed in Section 18. (3) a horizontal drum for the reflux accumulator. as was done in obtaining this solution. including the tray efficiency. its default inlet and outlet temperatures were changed from 75 and 95F to 90 and 120F. the overdesign allowances. with default values built in that can be replaced by user-specified values. to be mapped. a low pressure steam utility. Because 100 psia steam condenses at 377. The default mapping results in: (1) a tray tower. Aspen IPE uses the cooling water utility. D1. 22S-4 . 165. vapor disengagement height.
and (2) adjust the standard basis. Aspen IPE evaluates all of the equipment items in the project. can be replaced with a shell-and-tube heat exchanger having a floating head. When the mapping for the simulation unit. rigorous methods are used to estimate the costs of 22S-5 .pdf . and cost models that have been developed and updated annually. Note also that the equipment sizes can be adjusted by the designer before Aspen IPE estimates equipment costs. Given the broad spectrum of Aspen IPE users worldwide. the Plant Engineer or Local Contractor profiles are preferable. which is added to a large plant complex. or one of the other built-in reboilers. since the mid-1970s. though preliminary. For this distillation system. it is important to replace the default project type (grass roots/clear field) with plant addition – suppressed infrastructure. the default mapping for the condenser. Aspen IPE does not use bare module factors as discussed in Section 22. the default values may correspond to inappropriate costs for the following reasons. Aspen IPE purchase cost estimates are based upon an extensive data base of material and construction labor costs and detailed. For this purpose. is completed. the default mapping is deleted and replaced with the preferred mapping. D1. This was done for the distillation tower in the course notes. a shell-and-tube heat exchanger with a fixed tube sheet. For installation costs. which defines the nature of the site and workforce. Aspen IPE Course Notes. The latter instructs Aspen IPE to omit items involving electrical switchgear and transformers. After the standard basis has been adjusted. During the evaluation. In the next step. in accordance with industry design codes and costs for numerous process plants. Before proceeding. work-item.To use a kettle reboiler with a floating head. purchase and installation costs are estimated. see the file. sizes have been estimated by Aspen IPE for all of the equipment items. Aspen IPE estimates the purchase and installation costs. Similarly. Aspen IPE utilizes design. which determine the engineering execution procedure. Note that for this distillation complex a reboiler pump is added by the designer and mapped separately by Aspen IPE. which are not needed when adding this distillation system to an existing process facility. Rather.3 of the book. When designing small plants. design methods. Here. the designer can (1) apply one of six engineering contractor profiles.
these results can be reproduced by accessing the DEC3RP folder (in the ASPEN folder on the Wiley web site associated with this book) from within Aspen IPE. with associated material costs and installation hours. and sizes. labor. Note that the DEC3 folder does not include the reboiler pump. Also. each having two tube passes and a correction factor. platforms. Version 2006.pdf.2 shows more details for the tray tower from the Capital Estimate Report.64. mechanical design methods. 22S-6 . These methods are based upon detailed design calculations for foundations. and construction equipment. piping. to develop lists of materials for piping and instruments. including the added reboiler pump. and painting. among other items involved in the installation. instrumentation.materials. For example. The calculations were carried out using Aspen IPE. quantities. the installation cost estimates by Aspen IPE are more accurate than those obtained using bare-module or factored-cost methods. the key equipment sizes and cost estimates are shown in Table 22S. FT = 0. Aspen IPE Course Notes. For the six equipment items in the depropanizer distillation system. the dimensions of the foundation and the amount of concrete are estimated based upon the height and weight of the tower. see Appendix III of the file. and equipment and stream information. Aspen IPE uses its library of piping and instrumentation models. and seismic zone. For details of the other equipment items. with the design and cost basis date being the First Quarter 2006. Figure 22S. It should be possible to improve this design by re-sizing the unit to obtain a correction factor close to unity. electrical connections. For piping and instrumentation types.1. wind velocity. user-adjustable. insulation. soil conditions. Consequently. eliminating one of the parallel units. Note that Aspen IPE designed the condenser to be a shell-and-tube heat exchanger with two parallel units. P&ID templates that are unique to each type of equipment. Aspen IPE uses self-contained. for concrete foundations.
8.Total Permanent Investment Aspen IPE also computes the total permanent investment. see the file. 22S-7 . which is discussed in Section 23. $983. the total permanent investment is computed by the spreadsheet. Profitability Analysis-2.800 Note that the total direct materials and labor costs. here.pdf (in the PDF Files folder on the Wiley web site associated with this book).000 Contractor Engineering Costs 451.200 Material and Labor G&A Overhead and Contractor Fees 77.9 of the book. which are obtained from Aspen IPE: Total Direct Materials and Labor Costs $983.xls. Aspen IPE Course Notes. However. CTPI.200. includes items not chargeable to the individual equipment items in Table 22S.1. as defined in Table 22.0. For the details of obtaining these values from Aspen IPE.000 Indirect Costs 423. When using the Aspen IPE option in the spreadsheet. the user enters the following values.
100 ft2 (5.550 ft2/shell) Reflux accumulator Volume = 2. of trays = 14 Tangent-to-tangent height = 42 ft Diameter = 5 ft Vessel weight = 31.100 134. $ 86.800 326.200 7.600 Equipment Sizes Tray tower No.580 ft2 Reboiler pump Fluid head = 20 ft Driver power = 3 Hp TOTAL Purchase Cost.700 94.200 22S-8 .400 $375. and direct materials and labor costs for installation of the depropanizer distillation complex Direct Materials and Labor Cost. $ 250.350 gal Diameter = 5 ft Length =16 ft Vessel weight = 9.100 $895.700 68.600 lb Reflux pump Fluid head = 225 ft Driver power = 20 Hp Reboiler Heat-transfer area = 3.1 Aspen IPE estimates of equipment sizes. purchase costs.300 179.100 25. C P.100 8.200 49. CDML.700 lb Condenser Heat-transfer area =11.Table 22S.100 40.
2106 : 59818.0280 126 : 1.314 : TOTAL MATERIAL AND MANPOWER COST =USD 250600. 0. 0.904 ===================================================================================================================== Figure 22S. 0.1364 : 9654. 0. 0.0000 : 2208.2330 760 : 0.0108 : 1948.5090 : 20107.1118 : 4427.0120 45 : 0.543 : INSULATION : 11769.00 INCHES Tray material A285C Tray thickness 0. 0. 0. 0.1119 455 : 0.091 : ------------------------------------------------------------------------SUBTOTAL : 190778.026 : PIPING : 34421. 0.820 : PAINT : 931. 0. 0.0226 106 : 2.M A T E R I A L ---:********* M A N P O W E R *********:--.459 : INSTRUMENTATION : 43929.0221 : 1034.458 : ELECTRICAL : 1903.00 FEET Design temperature 310. 22S-9 . 2. 0. INST'L COST/PE RATIO = 2.D E S I G N D A T A ------------------: EQUIPMENT: : : : D E S C R I P T I O N : : COST USD : ====================================================================================================================== Equipment mapped from 'D1'. 0. TW 1 TRAYED D1-tower Shell material A 515 86300 CODE OF ACCOUNT: 111 Number of trays 15 TAG NO.625 INCHES Total weight 31700 LBS I T E M :--.291 : STRUCTURAL STEEL : 9649.80 DEG F Design gauge pressure 262.6931 2539 : 0.C O M P O N E N T L I S T ======================================================================================================================= : : : : : PURCHASED: :ORIGIN : ITEM TYPE : I T E M :-----------------.524 : CIVIL : 1875.3989 : 18020.000 FEET Vessel tangent to tangent height 42.2088 737 : 0.188 INCHES Base material thickness 0. 1. 0.0513 218 : 0.2 Estimates of equipment sizes and purchase and installation costs for the depropanizer tray tower. 0.0256 92 : 0.L/M ---: : FRACTION : FRACTION : RATIO : : USD OF PE : USD OF PE MANHOURS : USD/USD : EQUIPMENT&SETTING: 86300.30 PSIG Application DISTIL Tray type SIEVE Tray spacing 24.: D1-tower Vessel diameter 5.0217 : 2421. 0.
3 Process flowsheet for the MCB separation process.3 is designed and simulated using the procedures described in Section 5. it is desired to estimate the total permanent investment. Figure 22S.2 Monochlorobenzene (MCB) Separation Process The monochlorobenzene (MCB) separation process in Figure 22S. 22S-10 . using Aspen IPE.Example 22S. In this example.4 and in the multimedia module which can be downloaded from the Wiley web site associated with this book (ASPEN PLUS Principles of Flowsheet Simulation Interpretation of Input and Output Sample Problem). CTPI.
the key equipment sizes and cost estimates are shown in Table 22S. M1. the standard basis profile is selected to be Local Contractor and the project type is selected as plant addition – suppressed infrastructure. these results can be reproduced by accessing the MCB folder (in the ASPEN folder on the Wiley web site associated with this book) from within Aspen IPE. After the standard basis has been adjusted.1.2. The calculations were carried out using Aspen IPE. the units. are mapped as Quoted Items having zero cost by Aspen IPE. this mapping is replaced by a double-pipe heat exchanger. purchase and installation costs are estimated.e. Version 2006. Because the absorber has a tray efficiency of 20%. with details of the equipment items provided in Appendix IV of the file. When this is replaced by the RADFRAC subroutine. the MCB separation process can be viewed as representing an addition to an existing plant. with the design and cost basis date being the First Quarter 2006.SOLUTION The simulation results were computed initially using the DISTL subroutine in ASPEN PLUS. which typically would be supported as a neighboring facility and not built as a separate entity. Consequently. H1. After the mapping and sizing are completed (i. During the evaluation. the two towers must be mapped separately. the equipment sizes are computed). while the tray efficiency of the distillation column is 60%. and T1.pdf. For 10 equipment items. Aspen IPE Course Notes. Aspen IPE evaluates all of the equipment items in the mapping.29 to 3. 22S-11 . the heat exchanger. Also. is too small to be mapped as a floating-head. prior to using Aspen IPE. shell-and-tube heat exchanger. Consequently. S1.. as for the depropanizer in Example 22S.35 and the stream flow rates differ slightly (< 1%). Finally. the reflux ratio is adjusted from 4. This is because a full grass roots/clear field installation would provide an unnecessary supporting power distribution substation and control system equipment for this small separation plant. Also.
References Nathanson. However. Philadelphia. Profitability Analysis-2. which is discussed in Section 23. in this textbook. the user enters the following values. Adams II. Aspen IPE Course Notes. University of Pennsylvania.100 Contractor Engineering Costs 654. see the file.. B.xls. For the details of obtaining these values from Aspen IPE. R. 22S-12 . Aspen Icarus Process Evaluator Course Notes. A.Total Permanent Investment Aspen IPE also computes the total permanent investment. When using the Aspen IPE option in the spreadsheet. Seider.0.400 Note that the total direct materials and labor costs. the total permanent investment is computed by the spreadsheet. T.800 Material and Labor G&A Overhead and Contractor Fees 84. includes items not chargeable to the individual equipment items in Table 22. and W. 2008.800. D. $828.34.8. which are obtained from Aspen IPE: Total Direct Materials and Labor Costs $828.100 Indirect Costs 546.pdf.
100 85.500 3.800 22S-13 .1 ft Driver power = 1.500 lb Reflux pump.400 26.400 140.000 25. CDML. P1 Fluid head = 62. D1 Heat-transfer area =154 ft2 Reflux accumulator. H1 Heat-transfer area = 58 ft2 Heat Exchanger.2 Equipment sizes and purchase costs for the MCB separation process.300 20.000 4.600 29.400 73. A1 No.700 lb Condenser.700 57.400 Equipment Sizes Tray Tower. H2 Heat-transfer area = 196 ft2 Pump. D1 Liquid volume = 238 gal Diameter = 3 ft Length = 4.500 14.700 86. D1 Heat-transfer area = 918 ft2 Absorber. of trays = 30 Tangent-to-tangent height = 72 ft Diameter = 3 ft Vessel weight = 23.600 lb Heat Exchanger.100 lb Flash Vessel.300 13.300 25.100 $828. C P.300 $200. $ 225.5 ft Vessel weight = 6. D1 Fluid head = 225 ft Driver power = 3.300 61.700 7.5 Hp TOTAL Purchase Cost.300 47. F1 Liquid volume = 635 gal Diameter = 3 ft Length = 12 ft Vessel weight = 2. $ 72. of trays = 15 Tangent-to-tangent height = 42 ft Diameter = 1.5 ft Vessel weight = 1.0 Hp Reboiler.700 9. Direct Materials and Labor Cost.Table 22S. D1 No.
This action might not be possible to undo. Are you sure you want to continue?
We've moved you to where you read on your other device.
Get the full title to continue listening from where you left off, or restart the preview.