TA Session 9

Chemical & Petroleum
Engineering Department
Process Design Preliminary
Subject: Analysis of Cost Estimation(3)

Cost of Distillation Columns & pumps
Presented by: Mehdi Heidary Doost

Supervisor: Dr. Saied Eini 14011-Nov-2022
Chemical & Petroleum Plant Design Preliminaries
Engineering Department 14011 – Jul - 2022
Previous Topics
❖ The method of Mulet, Corripio, and Evans (1981)

The f.o.b. purchase cost of the shell and two 2:1 elliptical heads which is for
carbon-steel construction and includes an allowance for platforms, ladders,
and a nominal number of nozzles and manholes, is given by
CV=The base f.o.b. purchase cost of the vessel including nozzles, manholes, and supports(CEPCI=567)
FM=The material-of-construction factor for pressure vessels and towers
CPL=The added cost for platforms and ladders
1
Ref. PRODUCT AND PROCESS DESIGN PRINCIPLES., seider,seader,Lewin,Forth edition, pp 467.
Copyright © Mehdi Heidary Doost, Dept. of Chemical & Petroleum Engineering, Sharif Univ. of Tech.
Previous Topics
❖ CV & CPL calculations for Towers

CV Calculation
CPL Calculation
2
Plates Costs
❑ Vertical towers for absorption, distillation, and stripping utilize trays (plates) or packing.
❑ Mulet et al. (1981b) present a method for estimating the purchase cost of trays installed
in a vertical tower.
❑ This cost is added to Eq. (16.52) to obtain the total purchase cost.
❑ The cost for the installed trays, CT, all with downcomers, is given by
• CT=The cost for the installed trays all with downcomers (CEPCI=567)
• CBT=The base cost for a sieve tray at a CE cost index of 567
• NT= Number Of Trays
• FNT= Number Of Trays Factor
• FTT=Type Of Tray factor
• FTM=Tray Material factor
3
Plates Costs
❖ CBT=The base cost for a sieve tray at a CE cost index of 567
Di=Inside diameter of column in feet
➢ Note: This equation is valid for inside diameter in range 2 to 16ft.

❖ FNT=Number of trays factor
If that number is greater than 20, the factor FNT = 1. If NT < 20, the factor is
greater than 1, as given by:
4
Plates Costs
❖ FTT =Type of tray factor

The factor FTT accounts for the type of tray:
❖ FTM =Tray Material Factor

The factor FTM, which depends on column diameter(ft) ,corrects for the material of construction:
5
EXAMPLE!
A distillation column is to be used to separate isobutane from n-butane.

The column, which is equipped with 100 sieve trays, has an inside
diameter of 10 ft (120 in.) and a tangent-to-tangent length of 212 ft
(2,544 in.). Operating conditions are 110 psia and 150∘F at the bottom
of the tower and 100 psia and 120∘F at the top. The material of
construction is carbon steel. The barometric pressure at the plant
location is 14.5 psia. Estimate the purchase cost of the distillation
column at a CE index of 600.
6
Solution
STEP1: Calculating Design Pressure
PO=(110-14.5)=95.5Psig
Pd = exp{0.60608 + 0.91615[ln(95.5)] + 0.0015655 [ln(95.5)]2} = 123 psig
STEP2: Obtaining Design Temperature

Td=150+50=200˚F
STEP3: Material based properties

The Column material is carbon steel.
S(Max Allowable Stress)=15000psi
𝑙𝑏
Density=0.284𝑖𝑛3
7
Solution
STEP4: Calculating Column Thickness
By assuming joint efficiency of 0.85:

(123)(120)
tP = = 0.582 in.
2(15,000)(0.85) − 1.2(123)
which is greater than the minimum value of 0.4375 in. required for rigidity. Because orientation of the
vessel is vertical and because it is quite tall, the tower may be subject to wind load or earthquake.
From below equation, assuming a wall thickness of 1.25 in., which gives an outside diameter, Do, of 122.5
in., the additional tower wall thickness at the bottom of the tower is
0.22(122.5 + 18)[(212)(12)]2
tW = 2 = 0.889 in.
15,000 ×122.5
8
Solution
❑ Required thickness(top of the column): 0.582inch.
❑ Required thickness(bottom of the column): 0.582+0.889=1.471inch.
0.582+1.471
❑ Average thickness(tV): =1.027inch.
2
❑ Average thickness(with corrosion allowance): 1.027+0.125=1.152inch
❑ Final thickness(including steel plate thickness):1.152+0.125=1.277≅ 1.25𝑖𝑛𝑐ℎ.
9
Solution
STEP5: Column shell weight
W = (3.14)(120 + 1.250)[2,544 + 0.8(120)](1.250)(0.284)=356,800 lb
STEP6: Column shell base cost(CV)
CV = exp{10.5449 − 0.4672[ln(356,800)] + 0.05482 [ln(356,800)]2} = $753,400

STEP7: Cost of platform and ladders(CPL)
CPL = 341(10)0.63316(212)0.80161 = $107,300

10
Solution
STEP8: Final updated cost of shell(CP)
600
CP= (753,400+ 107,300) (567 )= 910,800$
STEP9: Calculating the base cost of each tray(CBT):
CBT = 468 exp[0.1482(10)] = $2060 per tray
STEP10: Obtaining FTT & FTM & FNT

Trays are in sieve type, so FTT=1. Material is CS, so FTM=1. The number of trays
is more than 20, so FNT=1
11
Solution
STEP11: Final updated cost of Trays(CT)
600
CT = NT FNTFTTCBT = 100(1.0)(1.0)(2060) (567 )= $218,000
STEP12: Final updated cost of Distillation Column
The total purchase cost of the distillation column is
$910,800 + $218,000 = $1,130,000
12
Pumps
❑ Pumps are used widely in chemical processing plants to move liquids through
piping systems from one piece of equipment to another.
❑ The three most commonly used pumps are radial centrifugal, piston or plunger
reciprocating, and external rotary gear
❑ Of these three, the radial centrifugal pump (referred to here as just the centrifugal
pump) is selected for industrial service approximately 90% of the time because it is:
1) Relatively inexpensive to purchase and install.

2) Operated at high speed so that it can be driven directly with an electric motor.
3) Relatively simple in construction with no closely fitting parts that might wear, resulting in a low
maintenance cost.
4) Available in a wide range of materials of construction.
13
PUMPS
14
Pumps
➢ When we use a centrifugal pump?!...
Volumetric flow rate from 10 gpm (0.000631 m3∕s) to 5,000 gpm (0.3155 m3∕s).
Head from 50 ft (15.24 m) to 3,200 ft (975.4 m).
Kinematic viscosity less than 100 centistokes (0.0001m2∕s).
Available NPSH greater than 5 ft (1.52 m).
❑ when one or more of the other three requirements cannot be met, one of the
Reciprocating pumps & External rotary gear pumps should be considered for the
service.
15
centrifugal pumps Cost
❑ Much purchase-cost data for centrifugal pumps of the most common radial type have been
published.
❑ The cost most often includes the pump, a base plate, and a direct-drive coupling.
❑ Here, the cost correlation method used is that of the Monsanto Company in their
FLOWTRAN simulation program, which was subsequently adopted by Corripio et al. (1982a)
❑ Their size factor, S, which recognizes the fact that a given centrifugal pump can operate
over a range of flow rate and head combinations, is :
Q : the flow rate through the pump in gallons per minute

H : the pump head in feet of fluid flowing
16
❑ In addition to the size factor, the purchase cost of a centrifugal pump depends on other
parameters like:
✓ rate of rotation (usually in the range of 1,800 to 3,600 rpm)

✓ the number of impellers (usually in the range of 1 to 4) in series to reach the desired head.
✓ the orientation of the splitting of the bolted-together pump case (HSC, horizontal split
case, or VSC, vertical split case)
✓ Material of construction
17
❑ The f.o.b. purchase cost of a centrifugal pump is given by:
CB: the f.o.b. purchase cost of a single-stage centrifugal pump with VSC construction of cast iron and
operating at 3,600 rpm The cost includes the base plate and driver coupling but not the electric motor.
FM: Material Factor
FT: Type Of Pump Factor
❖ CB(base cost)
❑ The base cost of a centrifugal pump can be obtained from the below equation:
For: 400 < S < 100,000
18
Base f.o.b. purchase cost for radial centrifugal pumps.

19
❖ FT: Type Of Pump Factor

❑ Typical Types of Radial Centrifugal Pumps and FT Factors are in the below table:
20
❖ FM: Pump Material Factor
21
Electric Motors
❑ A centrifugal pump is usually driven by an electric motor whose cost is added to the pump cost
❑ The size parameter for the motor is its power consumption, PC, which is determined from
the theoretical horsepower of the pump, PT
Q : the flow rate through the pump in gallons per minute

H : the pump head in feet of fluid flowing
𝜌 : equal to the liquid density in pounds per gallon
𝜂P : fractional efficiency of the pump

𝜂M :fractional efficiency of the motor
22
Electric Motors Cost
Corripio et al. (1982a) give the following equations for estimating 𝜂P as a function of the
volumetric flow rate, and 𝜂M as a function of pump brake horsepower:
50gpm < Q < 5,000gpm
1hp < PB < 1,500hp
From the electric motor cost correlations of Corripio et al. (1982a), indexed to 2013 (CE = 567),
the f.o.b. purchase cost of an electric motor operating at 3,600 rpm with an open, drip-proof
enclosure (as a function of the horsepower consumption PC),.
1hp < PC < 700hp
23
Electric Motors Cost
❑ The final cost of an electric motor is given by:
CB: The base cost of electric motor

FT : motor-type factor given in bellow table, applicable within a range of electric motor power
consumption, PC, from 1 to 1,500 Hp:
24
EXAMPLE!
In a vinyl-chloride process(VCM), a Reactor Pump takes a stream of of

1, 2-dichloroethane(263,800 lb∕hr) at 90∘C and 1.5 atm and delivers it
to an evaporator operating at a much higher pressure of 26 atm.
Select a suitable pump and electric motor and estimate the f.o.b.
purchase cost at a CE index of 600.(choose a cast steel material)
The feed characteristics are :
𝑙𝑏 𝑙𝑏 𝑔𝑟
Density: 9.54 𝑔𝑎𝑙 (71.4 𝑓𝑡 3 , 1.14 𝑐𝑚3)
Viscosity: 0.37 cP
vapor pressure : 1.212 atm.
25
Solution!...
STEP1: Obtaining feed volumetric flow(Q)
𝑙𝑏 1ℎ𝑟 1𝑔𝑎𝑙𝑙𝑜𝑛
𝑄 = 263,800 × × = 461𝑔𝑝𝑚
ℎ𝑟 60𝑚𝑖𝑛 9.54𝑙𝑏
STEP2: Obtaining Pump Head(H)
14.696𝑝𝑠𝑖 144𝑖𝑛2
26−1.5 𝑎𝑡𝑚× ×
∆𝑃 1𝑎𝑡𝑚 1𝑓𝑡2
𝐻= →ℎ= 𝑙𝑏 =726ft
𝜌 71.4 3
𝑓𝑡
𝐷𝑦𝑛𝑎𝑚𝑖𝑐 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 0.37
kinematic viscosity = → kinematic viscosity = 1.14 = 0.32 centistokes
𝐷𝑒𝑛𝑠𝑖𝑡𝑦
26
Solution!...
STEP3: Obtaining available NPSH
Suction pressure − Vapor pressure (1.5 − 1.212)(14.696)(144)

NPSHA = = = 8.54 ft
Liquid density 71.4
So we can purchase a radial centrifugal pump with a required NPSH > 5.
STEP4: Obtaining the centrifugal pump size parameter
S = Q(H)0.5 = 461 (726)0.5 = 12,420
STEP5: Obtaining the base purchase cost of pump
CB = exp{12.1656 − 1.1448[ln(12,420)] +0.0862 [ln(12,420)]2} = $8,380
27
Solution!...
STEP6: Obtaining FT & FM for pump
for the given flow rate and relatively high head, choose a 2-stage, 3600-rpm, HSC
centrifugal pump, with FT = 2.70.
We choose cast steel material with FM = 1.35 because of the relatively high discharge pressure.
STEP7: Obtaining Final updated cost of pump
CP = (2.70)(1.35 (8,380$) )(600∕567) = 32,300 $
28
Solution!...
STEP8: Obtaining pump efficiency
Q=461gpm→ln(Q)=6.13
𝜂P = −0.316 + 0.24015(6.13) − 0.01199 (6.13)2 = 0.706
STEP9: Obtaining pump brake horsepower
QH𝜌 (461)(726)(9.54)
PB = = = 137 BHp
33,000𝜂P 33,000(0.706)
STEP10: Obtaining Motor efficiency
PB = 137 →ln(PB)=4.92
𝜂M = 0.80 + 0.0319(4.92) − 0.00182(4.92)2 = 0.913

29
Solution!...
STEP11: Obtaining Power Consumption of motor
PB 137
PC = = = 150 Hp
𝜂M 0.913
STEP12: Obtaining the base cost of motor
PC=150Hp→ln(PC)=5.01
CB = exp{5.9332 + 0.16829(5.01) − 0.110056 (5.01)2 +0.071413 (5.01)3 − 0.0063788 (5.01)4} = 7,910 $
STEP13: Obtaining FT for motor

Because of the possible flammability hazard of 1,2-dichloroethane, specify an
explosion-proof electric motor to drive the pump. for 3,600 rpm, FT is 1.8
30
Solution!...
STEP14: Obtaining Final updated cost of motor
600
CP = FTCB = (1.80) (7,910$) ( ) = 15,070 $
567
STEP15: Obtaining Final updated cost Pump(included motor)
Total Cost = Pump Cost + Motor Cost

Total Cost = 32,300 + 15,070 = 47,370 $
31
Thanks For Your
Attention
THE END!.

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Chemical & Petroleum

Process Design Preliminary

Subject: Analysis of Cost Estimation(3)

Presented by: Mehdi Heidary Doost

❖ The method of Mulet, Corripio, and Evans (1981)

FM=The material-of-construction factor for pressure vessels and towers

CPL=The added cost for platforms and ladders

❖ CV & CPL calculations for Towers

❖ CBT=The base cost for a sieve tray at a CE cost index of 567

Di=Inside diameter of column in feet

➢ Note: This equation is valid for inside diameter in range 2 to 16ft.

❖ FTT =Type of tray factor

❖ FTM =Tray Material Factor

A distillation column is to be used to separate isobutane from n-butane.

STEP1: Calculating Design Pressure

STEP2: Obtaining Design Temperature

STEP3: Material based properties

STEP4: Calculating Column Thickness

By assuming joint efficiency of 0.85:

❑ Required thickness(top of the column): 0.582inch.

❑ Required thickness(bottom of the column): 0.582+0.889=1.471inch.

❑ Average thickness(with corrosion allowance): 1.027+0.125=1.152inch

❑ Final thickness(including steel plate thickness):1.152+0.125=1.277≅ 1.25𝑖𝑛𝑐ℎ.

STEP5: Column shell weight

W = (3.14)(120 + 1.250)[2,544 + 0.8(120)](1.250)(0.284)=356,800 lb

STEP6: Column shell base cost(CV)

CV = exp{10.5449 − 0.4672[ln(356,800)] + 0.05482 [ln(356,800)]2} = $753,400

CPL = 341(10)0.63316(212)0.80161 = $107,300

STEP8: Final updated cost of shell(CP)

STEP9: Calculating the base cost of each tray(CBT):

CBT = 468 exp[0.1482(10)] = $2060 per tray

STEP10: Obtaining FTT & FTM & FNT

STEP11: Final updated cost of Trays(CT)

STEP12: Final updated cost of Distillation Column

The total purchase cost of the distillation column is

$910,800 + $218,000 = $1,130,000

1) Relatively inexpensive to purchase and install.

➢ When we use a centrifugal pump?!...

Head from 50 ft (15.24 m) to 3,200 ft (975.4 m).

Kinematic viscosity less than 100 centistokes (0.0001m2∕s).

Available NPSH greater than 5 ft (1.52 m).

centrifugal pumps Cost

Q : the flow rate through the pump in gallons per minute

centrifugal pumps Cost

✓ rate of rotation (usually in the range of 1,800 to 3,600 rpm)

centrifugal pumps Cost

❑ The f.o.b. purchase cost of a centrifugal pump is given by:

FT: Type Of Pump Factor

For: 400 < S < 100,000

centrifugal pumps Cost

Base f.o.b. purchase cost for radial centrifugal pumps.

centrifugal pumps Cost

❖ FT: Type Of Pump Factor

centrifugal pumps Cost

❖ FM: Pump Material Factor

Q : the flow rate through the pump in gallons per minute

𝜂P : fractional efficiency of the pump

Electric Motors Cost

50gpm < Q < 5,000gpm

1hp < PB < 1,500hp

1hp < PC < 700hp

Electric Motors Cost

❑ The final cost of an electric motor is given by:

CB: The base cost of electric motor