CHAPTER 8 Sizing and Costing

CHAPTER 8
EQUIPMENT SIZING AND COSTING

8.1 INTRODUCTION

Among the most important parts for the success of production of 100,000
MTA of MMA are the sizing of the chosen equipment followed by preliminary
costing for every one of them. Equipment sizing will affects the profitability of a
plant where the choice of material used and the size of the units determine the
feasibility of a plant. For this purpose, the calculations are based on the throughput
into the equipment and its corresponding operating parameters. The results will be
needed for the cost correlations to estimate the equipment cost. Sizing and costing
for a plant is important factor that should be done in good manner because its
determined the whole plant profitability besides ensure that the plant run smoothly
without any problem during the operation.

Generally, the units including main units comprises of Reactor, Distillation
Column, Flash Column and some side units of Mixer, Compressor, Heat
Exchanger,Heater, Cooler, Pump and Storage Tank. For the preliminary calculation
of sizing and costing, parameters that important such as flow rate, temperature,
pressure and density. And generally, determination of volume, diameter and length
has been carried out using the parameters simulated from results of simulation and
manual mass balance results.

The exchange rate used for the calculation is from US dollar ($) to Ringgit
Malaysia: $ 1 US dollar = RM 3.20. The costing index is based on the Chemical
Engineering Plant Cost Index (CE Plant cost Index). When using Product and
Process Design Principle, the base cost index (2006) is CE500 and for present cost
index (2010) is CE532.9. When using the reference of Chemical Engineering Volume
6, the base cost index (mid of 2004) of CE444.2 is used for the costing calculation.

In this plant design, most of the equipment sizing and costing will be referred
to Chemical Engineering Volume 6, Product and Process Design Principle, A Guide
to Chemical Engineering Process Design and Economics and Systematic Methods of
Chemical Engineering Process Design.

The sizing and costing calculation for each unit operation will be enclosed in
Appendix A. Only the summary will be considered here. The equipment and the unit
operation used in the process plant are listed in Table 8.1 below. However, the sizing
for divider is not calculated since it involves in gas phase, which needs only pipeline.
Due to the low cost of valves compared to other equipment, the sizing and costing of
3 main valves also neglected.

Table 8.1: The Equipment List
EQUIPMENT QUANTITY
Pump 2
Mixer 3
Compressor 2
Heat Exchanger 4
Reactor 2
Flash Column 4
Distillation Column 1
Storage Tank 3
Cooled 3
Heater 1
Pervaporation membrane 1

In this chapter, the summary result of all equipment will be shown and the detailed
calculation can be found in Appendix A. The result of this chapter will be used in the
calculation of mechanical design in Chapter 10. The base cost all equipment is based
on the methods in Chemical Engineering Volume 6 (Sinnott, 1983), Product and
Process Design Principle (Seider, 2010), Systematic Methods of Chemical Process
Design (Biegler, 1997) and A Guide to Chemical Engineering Design & Economics
(Ulrich, 1984)

8.2 PUMP

The pump used in the plant is centrifuge pump with electric motor. The
calculation was done based on the Product and Process Design Principle (Seider,
2010). The summary of pump sizing is shown in Table 8.2.

Table 8.2: Summary on Sizing and Costing for Pump
Identification Pump 1 Pump 2
Item no. P-1 P-2
Liquid Flow rate, kg/hr 9926.85 4382.84
Liquid Density, kg/m
3
810 790
Pressure inlet, bar 3.03975 1.01325
Pressure outlet, bar 5.06625 5.06625
Power, kW 406.82 368.48
Equipment cost, RM 44314.51 53758.45

8.3 MIXER

The function of mixer is to mix the different components from different
stream into one stream. Turbulent flow is important to make sure that the component
mixes well. In theory, turbulent flow can be achieve when the Reynolds Number
>2000. Therefore, a space-time assumption of 5 second (M-1) and 30 second (M-2
and M-3) is made in the calculation in order to achieve a Reynolds Number >2000.

Detailed calculations of mixer as shown in Appendix A and for MMA plant three
mixers are used. Mixer-1 is used to well mix the raw material, isobutylene with the
air and steam. Mixer-2 is used to mix the air, methanol and intermediate product
(methacrolein) stream from second stage separation while for Mixer-3 is used to well
mix the raw material, pure methanol with the methanol in recycle stream.

Table 8.3: Summary on Sizing and Costing For Mixer
Identification Mixer 1 Mixer 2 Mixer 3
Item no M-1 M-2 M-3
Type of mixer Agitators with
propeller
Agitators with
propeller
Agitators with
propeller
Material of construction Carbon steel Carbon steel Carbon steel
Flow rates, kg/ hr. 50323.26 41010.47 4254.82
Volume, m
3
100.191 47.13847 0.04469
Tank Diameter, m 5.762 4.482 0.440
Agitator Diameter, m 1.729 1.345 0.132
Blast Pitch, m 3.112 2.420 0.238
Tank Height, m 5.762 4.482 0.440
Power, kW 3.140 9.287 0.673
Equipment Cost, RM 28,741.14 41,039.50 22,118.57

8.4 COMPRESSOR

Compressor is used to compress gases from one low pressure to high
pressure. Three type of compressor widely use in the process industries namely,
centrifugal, reciprocating and axial flow compressor. Each compressor is generally a
function of the gas capacity, action and discharge head.

In this MMA plant, there are 2 compressors used to increase the pressure for
the next separation system. The methods used to calculate the sizing and costing is
show in Appendix A

Table 8.4: Summary on Sizing and Costing For Compressor
Identification Compressor 1 Compressor 2
Item no C-1 C-2
Flow rate, kgmol/h 1935.56 924.88
Inlet Temperature, K 623.15 383.15
Pressure inlet, atm 3 3
Pressure outlet, atm 3 3
Actual work, kW 546464.9 1085929
Equipment cost, RM 552094.7

544265.1

8.5 HEAT EXCHANGER

Type of heat exchanger used in this plant is shell and tube exchanger with
one shell pass and two tube passes. The reasons for using this type of heat exchanger
is because the surface area per volume is larger compared to other heat exchanger
and the easier cleaning procedure. Besides, it can be constructed from a wide range
of materials with well-established fabrication techniques and design procedures.

There are many kinds of shell and tube heat exchangers such as fixed-tube
plate, U-tube type, internal floating head and external floating head. Split-ring
internal floating head type is chosen as the model of the heat exchangers in this plant
because of the following features.

Its suitable for high temperature differentials between shell and tubes
Its easier to be cleaned as the tubes can be nodded from end to end and the
bundle removed
It can be used for fouling liquids

The way to allocate the fluid in the shell and tubes plays a very important role
in the heat exchanger design. Where no phase change occurs, the following factors
provide the basic guidelines in the allocation of the fluid stream to the shell or tubes.

Corrosive fluid should be allocated to the tube-side
Higher fouling tendency fluid should be placed in the tube because tubes
are easier to be cleaned than shell
Higher temperature fluid should be allocated in the tube to reduce the
overall cost
The higher-pressure stream should be allocated to the tube-side
For the same pressure drop, higher heat-transfer coefficients will be
obtained on the tube-side than the shell-side
More viscous fluid should be placed in the shell-side
Locating the fluids with the lowest flow-rate to the shell side will give the
most economical design

The general specification of shell and tubes heat exchanger is as follow:

Tube length between 2.44m and 8.88m
Tube with outer diameter between 15.88 to 19.05 mm and inner
diameter
of 10.33 to 16.56 mm
One shell pass and two tube passes

The designing procedures are based on the Kerns and Bells method (Sinnott,
1991). The design produce is as below:

i. Define the duty: heat transfer rate, fluids flow rate and temperature
ii. Collect the fluid physical required: density, viscosity and thermal
conductivity

iii. Decide the type of exchanger to be used
iv. Select the trial value for the exchanger to be used
v. Calculate the mean temperature different, T
lm

vi. Calculate the area required
vii. Decide the exchanger layout
viii. Calculate the individual coefficients
ix. Calculate the overall coefficient and compare with the trial value. If the
calculated value differ from the estimate value, substitute the calculated
value and return to step (vi)
x. Calculate the heat exchanger pressure drop: if unsatisfactory return to step
(vii) or (iv) or (iii) in that order of procedure

Table 8.5: Sizing Specification Sheet of Heat Exchanger, X-1
Sizing Specification Sheet Heat Exchanger, X-1
Identificatio
n
: Item Heating Heat Exchanger Date: 03-5-2014
Item No. X-1 No required 1
Function
: Heat-exchange
Operation
: Continuous
Type
: Horizontal Shell and Tube Heat Exchanger -Split-ring floating head type
Duty: 13278.584 kW
Tube Side
: Tube:
Outer diameter 19.05
mm
Inner diameter 15.75
mm

Flowrate 53.063 kg/s Number of tube 1968
Cross Flow
Area
194.85 mm
2
Length 2.44 m
Temperature 110.00
o
C to 340.00
o
C
1 Passes
Head Material Carbon steel Tube Material Carbon
steel
Shell Side
: Shell:
Flowrate 5.08E+04 kg/h 1.1964 m diameter
Cross Flow
Area
0.2863 m
2

Temperature 350.00 C to
347.42 C
Shell Material:
Carbon steel

Identificatio
n
Function
: Heat-exchange
Operation
: Continuous
Type
Duty: 2896.40 kW
Tube Side
: Tube:
mm
mm

Cross Flow
Area
194.85
mm
2
Length 2.44 m
Temperature 40.00
o
C to 110.00
o
C 1 Passes
steel
Shell Side
: Shell:
Cross Flow
Area
0.0244 m
2

347.08 C
Shell Material:
Carbon steel

Identificatio
n
Function
: Heat-exchange
Operation
: Continuous
Type
Duty: 1555.405 kW
Tube Side
: Tube:
mm

mm
Cross Flow
Area
83.8198 mm
2
Length 8.88 m
Temperature 40.00
o
C to 79.99
o
C 1 Passes
steel
Shell Side
: Shell:
Cross Flow
Area
0.3354 m
2

64.23 C
Shell Material:
Carbon steel

Identificatio
n
Function
: Heat-exchange
Operation
: Continuous
Type
Duty: 96.919 kW
Tube Side
: Tube:
Outer diameter 25.4 mm
Inner diameter 22.1
mm

Cross Flow
Area
383.65
mm
2

Length 2.44 m
Temperature 30.00
o
C to 43.29
o
C 1 Passes
steel
Shell Side
: Shell:
Cross Flow
Area
0.0080 m
2

87.58 C
Shell Material:
Carbon steel

Table 8.9: Sizing Specification Sheet of Cooler, C-1

Sizing Specification Sheet Cooler, C-1
Identificatio
n
Item No. C-1 No required 1
Function
: Cooler
Operation
: Continuous
Type
Duty: 15275.138 kW
Tube Side
: Tube:
Inner diameter 15.75 mm

Cross Flow
Area
194.85 mm
2
Length 4.88 m
Temperature 25.00
o
C to 35.00
o
C 1 Passes
Head Material Carbon steel Tube Material: Carbon
steel
Shell Side
: Shell:
Cross Flow
Area
0.0578 m
2

Temperature 347.08 C to 344.11
C
Shell Material:
Carbon steel

Identificatio
n
Function
: Cooler
Operation
: Continuous
Type
Duty: 1571.832 kW
Tube Side
: Tube:

Cross Flow
Area
194.8531 mm
2
Length 4.88 m
Temperature 25.00
o
C to 40.00
o
C 1 Passes

steel
Shell Side
: Shell:
Cross Flow
Area
0.0793 m
2

Temperature 64.33 C to 48.95 C Shell Material:
Carbon steel

Identificatio
n
Function
: Cooler
Operation
: Continuous
Type
Duty: 702.875 kW
Tube Side
: Tube:

Cross Flow
Area
140.8339 mm
2
Length 4.88 m
Temperature 25.00
o
C to 48.00
o
C 1 Passes
steel
Shell Side
: Shell:
Cross Flow
Area
0.0422 m
2

Temperature 87.58 C to 40.19 C Shell Material:
Carbon steel

Table 8.12: Sizing Specification Sheet of Heater, H-1
Sizing Specification Sheet Cooler, H-1
Identificatio
n
Item No. H-1 No required 1

Function
: Heater
Operation
: Continuous
Type
Duty: 295.446 kW
Tube Side
: Tube:

Cross Flow
Area
194.8531 mm
2
Length 4.88 m
Temperature 340.00
o
C to 350.00
o
C
1 Passes
steel
Shell Side
: Shell:
Cross Flow
Area
0.0253 m
2

Temperature 360.00 C to 355.00
C
Shell Material:
Carbon steel

Table 8.13: Summary on Sizing and Costing for Heat Exchanger
Type Item
No.
Material of
Construction
Utility Cost
(RM/ year)
Equipment
Cost (RM)
Shell
Side
Tube
Side
Heat Exchanger X-1 Carbon
steel
Carbon
steel
0 128580.98
steel
Carbon
steel
0 20167.57
steel
Carbon
steel
0 382860.36
steel
Carbon
steel
0 6317.11
Cooler C-1 Carbon
steel
Carbon
steel
433,430,077.90

64227.37

Cooler C-2 Carbon
steel
Carbon
steel
418,855,584.97

80579.81
Cooler C-3 Carbon
steel
Carbon
steel
387,228,424.36

56804.23
Heater H-1 Carbon
steel
Carbon
steel
9,730,650,837.29

32552.08

8.6 REACTOR

There are two main reactors in the MMA plant. The first reactor is used to
synthesis isobutylene to methacrolein and gases. Meanwhile, the second reactor is
used to convert the intermediate product from first reactor to MMA by adding
methanol, air and catalyst.

As the reactor is a type of continuous stirred tank reactor, method in
Systematic Methods of Chemical Process Design (for vessel pressure) is used for
sizing and costing. The reactor-sizing summary is shown in Table 5.6 below.

Table 8.14: Summary on Sizing and Costing for Reactor
Identification Reactor 1 Reactor 2
Item no R-1 R-2
Material construction Carbon steel Carbon steel
Type of vessel Horizontal pressure vessel Vertical pressure vessel
Catalyst palladium 5% palladium-lead
containing on alumina
Temperature (C) 350 80
Pressure (atm) 3 5
Flowrate (kg/h) 50332.42 3013.73
Density (kg/m3) 847.0 813.65
Molecular weight (kg/kmol) 70.078 18.02
Residence time (hour) 5 10

Reactor volume (m
3
) 356.58 1011.66
Diameter (m) 6.714 6.85
Height (m) 396.46 27.42
Volume of catalyst (m
3
) 178.29
Equipment Cost (RM) 1,859,929.71 1,713,345.3

8.7 VAPOR- LIQUID SEPARATOR COLUMN

The separator column is simply a pressure vessel to phase-split between
liquid and vapor phase. The chemical engineering design of the separator column is
calculate as similar as flash drum based on the method found in Chemical
Engineering Volume 6 (Sinnott, 1983) and Product and Process Design Principle
(Seider, 2010). Detailed calculation is shown in Appendix A.

Table 8.15: Summary on Sizing and Costing for Separator
Identification Separator 1 Separator 2 Separator 3 Separator 4
Item no. F-1 F-2 F-3 F-4
Material Carbon Steel Carbon Steel Carbon Steel Carbon Steel
Type of vessel Vertical Vertical Vertical Vertical
Temperature,
0
C 110 40 40 30
Pressure, atm 3 3 5 1
Flowrate of vapor, kg/hr 32147.340 22225.250 24909.130 227.530
Density of vapor, kg/m
3
3.330 3.320 5.720 1.630
Flowrate of liquid, kg/hr 18185.080 9922.100 13100.670 214.970
Density of liquid, kg/m
3
907.620 813.630 917.470 802.540
Residence time, min 10 10 10 10
Volume, m
3
3.339 2.032 2.380 0.04464
Diameter, m 4.666 2.079 1.864 0.252
Length, m 2.431 4.017 3.968 1.572
Equipment cost, RM 203,553.93 168,468.32 156,134.31 131,274

8.8 DISTILLATION COLUMN

Distillation is the most common method of separating homogenous mixtures.
The separation of liquid mixtures by distillation depends of the differences in
volatility between the components. The greater the volatility of a component
compared to other component, the easier it is to be separated. Vapour flows up to the
top column and the liquid flows counter currently down to the bottom of the column.
The vapour is brought into intimate contact with the liquid on every plate. The design
of distillation columns in this production of 100 000 MTA of MMA is based on the
typical design procedures as stated in the Product and Process Design Principle
(Seider, 2010). This is for the convenient of costing calculation. However, the more
detail mechanical design of the plate is calculated in chapter 8 when designing the
mechanical drawing.

For the column sizing and costing, it included the column vessel, tray stack,
column condenser and column reboiler. The detail calculation for each of the
columns is shown in Appendix A

8.8.1 Choosing a Plate or Packed Column

There are two common types of distillation column used in the industries that
are plate or packed column. It is important to choose the right type of distillation
column in order to obtain the most efficient and cost effective for separation process.
The most suitable type of column must be determined for the desired separation
process because each of the columns has its own function. In this project, a sieve
plate has been selected because:

1. Its modernization compared to bubble cap and other related plates as well as
the economic value.

2. It is more effective than other plate in bringing the vapour and liquid flows to
be in intimate contact for achieving the desired separation.
3. It satisfactory for most application.
4. It can be designed to give a satisfactory operating range typically from 50%
to 100%.
5. It gives the lowest pressure drop.
6. It gives the best capacity among the valve plate and bubble cap.

8.8.2 Plate Spacing

Plate spacing is the most important part for determining the overall height of
the column. Plates spacing ranges from 0.15 m to 1 m are normally used. The
spacing chosen depends on the column diameter and operating conditions. For
columns above 1 m diameter, plate spacing 0.3 to 0.6 m will normally be used and
0.45 m can be taken as initial. This will be revised as necessary.

8.8.3 Column Diameter

The principle factor in determining the column diameter is the vapour flow
rate. The column diameter can be calculated by calculating the top and the bottom
net area at its maximum volumetric flow rate. The velocity is normally between 70 to
90% of what which could cause flooding.

8.8.4 Height of Column

The height of column in the distillation column is calculated by knowing the
number of actual stages. The height of the column can be calculated by multiplying
the number of the actual stages with tray spacing value.

Table 5.8 shows the calculation summary of three distillation columns. For
further information, please refer to Appendix A.

Table 8.16: Summary on Sizing and Costing for Distillation Column
Identification Distillation Column
Item no. DC-1
Material of construction ? Steel
Type of plate Sieve tray
Temperature,
0
C
Pressure, atm 1
Number of Tray
Reflux Ratio, R
Q condenser, kW
Q reboiler, kW
Column Height, m
Diameter, m
Tray Stack Cost, RM
Column Vessel Cost, RM
Column Condenser Cost, RM
Column Reboiler Cost, RM
Total Equipment cost, RM
Utility cost, RM / year

8.9 STORAGE TANK

Storage tank is needed for storing the product (MMA) and raw material
(isobutylene and methanol) before entering to mixer. These components are in liquid
form at the atmospheric pressure. The type of storage tank that has been chosen is
fixed-cone roof, atmospheric pressure storage tank. Table 8.17 shows the summary
of the storage tank.

H
R

Stored liquid
H
s

H
L

Diameter, D

Figure 5.1: Storage Tank Design.

Table 8.17: Summary on Sizing and Costing for Storage Tank
Identification Storage tank 1 Storage tank 2 Storage tank 3
Stored Isobutylene Methanol MMA
Type of roof Fixed-cone roof Fixed-cone roof Fixed-cone roof
Storage Classification Horizontal Horizontal Horizontal
Material of construction Stainless Steel Carbon Steel Carbon Steel
Day of Inventory 3 days 7 days 7 days
Liq flowrate, m
3
/hr 13.6475 5.09 14.91
Storage volume, m
3
1080.882 844.12 2504.88
Diameter, m 14.014 12.900 18.54
Height of tank (Hs), m 7.007 6.450 9.270
Liquid space (H
L
), m 5.991 5.371 7.649

Vapor space (H
R
), m 1.234 1.140 1.630
Wall thickness, m 0.202 0.1856 0.267
Equipment cost, RM 699,638.59 527,309.54 1,306,350.74

8.10 PERVAPORATION MEMBRANE

By referring to Product and Process Design Principles book by Seider etc
(2010), the cost for pervaporation membrane is typically $38/ft
2
. Therefore, the
cost had been calculated together with the cost for the second reactor (R-2).

Table 8.19: Summary on Sizing and Costing for pervaporation membrane
Identification Membrane
Area (ft
2
) 397.25

8.11 Summary of Equipment Total Costing

The total costing including the equipment cost and the utility cost for all the
equipment used is listed in the Table 8.18 below.

Table 8.18: Summary of Equipment Total Costing
Equipment Equipment Cost (RM) Utility Cost (RM/yr)
P-1
48289.43 0
P-2
52672.23 0
M-1
28,741.14 0
M-2
41,039.50 0
M-3
22,118.57 0
COMP-1
472198.7 0
COMP-2
465502.1 0
X-1
128580.98 0

X-2
20167.57 0
X-3
382860.36 0
X-4
6317.11 0
C-1
64227.37 433,430,077.90
C-2
80579.81 418,855,584.97
C-3
56804.23 387,228,424.36
H-1
32552.08 9,730,650,837.29
R-1
1,859,929.71 0
R-2
0
F-1
203,553.93 0
F-2
168,468.32 0
F-3
156,134.31
F-4
131,274 0
DC-1

Pervaporation membrane

Isobutylene Storage Tank
699,638.59 0
Methanol Storage Tank
527,309.54 0
MMA Storage Tank
1,306,350.74 0
Total

CHAPTER 8 Sizing and Costing

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EQUIPMENT SIZING AND COSTING

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