The University of Jordan

School of Engineering
Department of Chemical Engineering

Chemical Plant Design (0935582)

Fixed Capital Cost Estimation
Homework Number: 04
Group Number: 07
Date of submission: 23.12.2020
Registration # Student name Task
0157614 Abdalla Barjous Power point formatting
0161416 Bana Alazab CAPCOST
0137309 Eman Alomari Microsoft word formatting
0161141 Lana Salaymeh Manual calculations
0161319 Ronza sbeih Manual calculations

Supervised by: Prof. Menwer Attarakih

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Summary
The objective of this assignment is to estimate the fixed capital cost by using the equations and
tables of appendix A in Turton and by using the CAPCOST program.

1.1Introduction

The planning, engineering and construction of a chemical process plant finds its justification in economic
life. One of the essential phases in the evaluation of the economic soundness of a plant is Cost
Estimation. The scope of cost estimating activities is to calculate the fixed capital costs, which is “the
sum of all direct and indirect costs, plus additional amounts for contingency and auxiliary costs, incurred
in planning and building a plant ready for start up”.
Chemical plants are built to make a profit, and an estimate of the investment required, and the cost of
production is needed before the profitability of a project can be measured.

1.2Theory
The following steps were followed to estimate the bare module cost for equipment’s:
1-Estimate base cost Cp0 using equation (1) for the desired piece of equipment by referring to
the figures in Appendix A(figures A.1-A.17) or the data in Table A.1. from Turton book.

…(1)

2- For exchangers ,pumps, and vessels, find the pressure factor Fp by referring to table A.2 and
using equation (2) or equation (3). And for the material of construction factor FM, use Table A.3
and figure A.18. from Turton book.

…(2)

…(3)

 Prof. Menwer Attarakih Chemical PlantDesign

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3-Use equation (4) to estimate the bare module factor, FBM, or find FBM by using table A.6 and
figure A.19 from Turton book.
F BM =B 1+ B 2∗Fm∗Fp …(4)

4-Calculate the bare module cost of equipment CBM from equation (5)

C BM =C P∗F BM …(5)

1.3Results and discussion

 Detailed calculations in the Appendix

Table.1 Results of Hand Calculations for capital costs

Equipment Purchased Costs Bare Module Costs Base Bare Module

CP C BM Costs C ° BM
E-101 32977 108494.33 108494.33

E-102 36874.5 171236.2013 121317

E-103 3730 12271.7 12271.7
T-101 54742 290701.8 222802.8

Sieve tray 2241(32) 131232 71712

V-101 13500 51165 40635

 Using the CAPCOST program to generate the same data of Table E.7.14 (b), Capcost
values of the equipment summarized in table (2).

 Prof. Menwer Attarakih Chemical PlantDesign

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Table.2 Capcost values of the equipment’s.

Table3: Comparison between CAPCOST values and Hand calculations

CAPCOST Program Hand calculations

Cp CBM Cp CBM
E-101 32,800 108,000 32,977 108,494
E-102 36,600 177,000 36,874 171,336
E-103 3700 12,200 3730 12,271
T-101 54,721 290,640 54,742 290,701
32 trays 71,808 126,200 32(2241) 131,232
V101 13,400 47,300 13,500 51,165

 Prof. Menwer Attarakih Chemical PlantDesign

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1.4conclusion
In conclusions it was noticed that using Capcost or manually calculating the costs both give
the same answers with small difference.

1.5References
1. Prof .Menwer Attarakih’s handouts

2. R. Turton, R. C. Bailie, W. B. Whiting & J. A. Shaeiwitz, (2012). Analysis, synthesis

and design of chemical processes, 4th Ed., Prentice Hall, PTR, New Jersey.

 Prof. Menwer Attarakih Chemical PlantDesign

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APPENDIX:
Using the equations and tables of Appendix A in Turton book.
For the heat exchanger (E-101):
Constants K1, K2 and K3 for floating head shell and tube heat exchangers from table A.1:
Table 4 Constants K1, K2 and K3 for floating head shell and tube heat exchangers from table A.1

Value

K1 4.8306
K2 -0.8509
K3 0.3187
A m2 170

By using equation (1)

2
log(Cp)=4.8306−0.8509∗log ( 170 ) +0.3187∗[ log ( 170 ) ]
Cp=32977

If P<5, then C1=C2=C3=0

Fp=1
Table 5 Constants values from table A.4, A.3 and graph A.18 in Appendix A

Value
B1 1.63
B2 1.66
Fm 1
Fp 1

F BM =B 1+ B 2∗Fm∗Fp

F BM =1.63+1.66∗1∗1=3.29

C BM =C P∗F BM =32977∗3.29=108494.33

CBM at base conditions of Fm=1, Fp=1

C BM =C P∗F BM =¿ ¿32977*3.29=108494.33

 Prof. Menwer Attarakih Chemical PlantDesign

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For the heat exchanger (E-102):

Using the equation in appendix A:
Table 6 Constants K1, K2 and K3 for floating head shell and tube heat exchangers from table A.1

Value

K1 4.8306

K2 -0.8509

K3 0.3187

A m2 205

Applying the constants from Table 6 in equation 1

2
log (Cp)=4.8306−0.8509∗log ( 205 ) +0.3187∗[ log ( 205 ) ]
Cp=36874.5

From table A.2, 5<p<140 , since P(shell)=6barg , P(tube)=18barg

P taken in the equation =8 barg
Fp= 1.00862

Table7 constants C1, C2 and C3 from table A.2

Value

C1 0.03881

C2 -0.11272

C3 0.0818
Table 8 Values from table A.4, A.3 and graph A.18

Value

B1 1.63
B2 1.66
Fm 1.8
Fp 1.00862

 Prof. Menwer Attarakih Chemical PlantDesign

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F BM =B 1+ B 2∗Fm∗Fp

F BM =1.63+1.66∗1.8∗1.00862=4.64376

C BM =C P∗F BM =36874.5∗4.64376=171236.2013

CBM at base conditions of Fm=1, Fp=1

C BM =C P∗F BM =36874.5*3.29=121317

For the heat exchanger (E-103):

Using the equation in appendix A:
Table 9 Constants K1, K2 and K3 for double pipe heat exchanger from table A.1

Value
K1 3.3444
K2 0.2745
K3 -0.0472
A 10
m
2

Using equation (1)

Cp=3730

If P<5, then C1=C2=C3=0

Fp=1

Table10 Values from table A.4, A.3 and graph A.18 in Appendix A

Value

B1 1.74
B2 1.55

Fm 1

Fp 1

F BM =B 1+ B 2∗Fm∗Fp

F BM =1.74+ 1.55∗1∗1=3.29

 Prof. Menwer Attarakih Chemical PlantDesign

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C BM =C P∗F BM =3730∗3.29=12271 .7

CBM at base conditions of Fm=1, Fp=1

C BM =C P∗F BM =3730*3.29=12271.7

For (T-101):
Table 11 Constants K1, K2 and K3 for towers from table A.1

Value
K1 3.4974
K2 0.4485
K3 0.1074
D 2.1
L 23
P 5

π D2
V= (L)= 79.66m3
4
Cp=54742.
Table.12 Values from table A.4, A.3 and graph A.18 in Appendix A

Value

B1 2.25
B2 1.82
Fm 1
Fp 1.6815

Fp for the tower:

Fp=1

F BM =B 1+ B 2∗Fm∗Fp

F BM =2.25+1.82∗1∗1.6815=5.31

C BM =C P∗F BM =54742.7∗5.31=290701.8

CBM at base conditions of Fm=1, Fp=1

 Prof. Menwer Attarakih Chemical PlantDesign

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C BM =C P∗F BM =54742.7*4.04=222802.8

For 32 trays:
Using the equation in appendix A:
Table.13 Constants K1, K2 and K3 for trays from table A.1

Value

K1 2.9948
K2 0.4465
K3 0.3961
D 2.1
Trays 32

π D2
Area ¿ =3.46m2
4
Cp=2241 for 32tray

If P<5, then C1=C2=C3=0

FP=1

Using table A.6 & fig.A.9 to find Fm for sieve tray MOC SS
Fm≈ 1.83
Table.14 Values from table A.4, A.3 and graph A.18 in Appendix A

Value

Fm 1.83
Fp 1

F BM =1.83

C BM =C P∗N∗F BM =2241∗32∗1.83=131232.

CBM at base conditions of Fm=1, Fp=1

 Prof. Menwer Attarakih Chemical PlantDesign

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C BM =C P∗N∗F BM =2241*32*1=71712

For (V-101):

Table 15 Constants K1, K2 and K3 for Process Vessels from A.1

Value
K1 3.5565
K2 0.3776
K3 0.0905
D 1.8
L 6

π D2
V= ∗( L)= 15.26m3
4
Cp=13500

Table 16 Values from table A.4, A.3 and graph A.18 in Appendix A

Value

B1 1.49
B2 1.52
Fm 1
Fp 1.6815

Fp for tower:

F BM =B 1+ B 2∗Fm∗Fp

 Prof. Menwer Attarakih Chemical PlantDesign

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F BM =1.49+1.52∗1∗1.5126=3.789

C BM =C P∗F BM =13500∗3.789=51165

CBM at base conditions of Fm=1, Fp=1

C BM =C P∗F BM =13500*3.01=40635

 Prof. Menwer Attarakih Chemical PlantDesign