Professional Documents
Culture Documents
Costs of Equipment Data and Esti
Costs of Equipment Data and Esti
46058
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Current costs
•
of
processequlpnnent
Capital costs for key process equipment are represented in
over 50 graphs. Among the equipment included are tanks,
heat exchangers, columns, pumps, compressors,
centrifuges and filters. These are mostly
f.o.b. costs, up to date as of January 1982.
:: ~
"
." oil
D Estimates of the capital costs of projects are made The purpose of this report is simply to provide esti-
for a variety of purposes, including: gauging the eco- mators with up-to-date purchase costs of process equip-
nomic viability of projects, evaluating alternative in- ment, suitable for making study or order-of-magnitude
vestment opportunities, selecting from alternative de- estimates of total plant costs, without having to extend
signs the process likely to be the most profitable, available plant-construction-cost indexes beyond ac-
planning capital appropriations, budgeting and con- ceptable extrapolation ranges (generally set at a maxi-
trolling capital expenditures, and tendering competi- mum of five years).
tive bids for building new plants or remodeling existing Fabricated equipment (tanks, heat exchangers, etc.) con-
ones. stitutes the largest category of capital expenditure in most
The accuracy required of estimates generally follows the process plants - a representative figure being 37%. Next
foregoing listing in the presented order-that is, the least largest is process machinery (including pumps and com-
accuracy for the first, the greatest for the last. Of course, pressors) at about 21 %. Thus, equipment costs for the two
the purpose of the estimate determines the accuracy re- largest categories are presented in this article. (Cost data on
quired and in turn how much time and money is spent on it. the third largest category, piping at 20%, are furnished
Estimates have long been given a variety of names and elsewhere in this book.)
classified in different ways. To standardize the names and All the graphs are based on January 1982 data, un-
numerical designations, the American Assn. of Cost En- less otherwise stated. All the cost curves yield shop-
gineers has drawn up the following list of estimate types fabricated f.o.b. costs, except in the cases of fired heaters
and probable accuracies: (Fig. 46 and 47) and butterfly valves (Fig. 54), for which
Type Accuracy, ±% installed costs are provided.
Order-of- magni tude 40
Estimating total plant cost
(ratio estimate)
25 The equipment covered in this report is that which is
Study
(factored estimate)
most critical to making plant cost estimates, that which
12 generally accounts for at least 50% of total plant cost.
Preliminary
(budget authorization The estimator is assumed to already have a method
estimate) for estimating total plant costs from such information
Definitive 6 as is presented. If this is not the case, study or order-
(project control of-magnitude estimates of total plant costs may be pre-
estimate) pared via the module method of Guthrie [3], the sim-
Detailed 3 pler, less accurate factoring methods of Lang [6] and
(firm estimate) Hand [4], or the more complex, and likely more accu-
rate, variant of the Lang and Hand methods developed
Most of the capital cost estimates of equipment that by Viola [9].
may be derived from the cost curves in this report In the Lang method, the total investment cost of a
should range in accuracy between -+-10%and -+-25%.In plant is estimated by multiplying the total delivered
some instances, however, the error probability may cost of equipment by a factor that varies according to
range up to -+-35%.In this report, the probable accu- the type of process-3.1 for solids processing units, 3.63
racy of each equipment cost curve will be noted when it for solids and fluids processing units, and 4.74 for fluids
is discussed. processing units. (Pikulik and· Diaz suggest that the de-
CURRENT COSTS OF PROCESS EQUIPMENT 103
~yered cost of equipment may be approximated by in- correlated against estimated capital costs. This correla-
creasing the purchased cost of equipment, f.o.b. manu- tion depends on a base curve that is prepared by deter-
;acturer's shop, by 3% [8].) mining the costs of individual pieces of equipment for
In the Hand method, installation factors (multi- several plants. The complexity factor is a function of:
?liers) for each type of major equipment relate total the number of major operating steps in the process, a
~ttery-limit costs to equipment costs. The factors are correction factor for pressure level and materials of con-
::i.fferentfor each type of equipment. Some typical fac- struction, the ratio of raw material to product, an aver-
cors are 4 for distillation columns and pressure vessels, age-throughput correction factor, and the fraction of
32 for heat exchangers, 2Yzfor compressors and 2 for major operating steps handling solid-fluid mixtures.
::ired heaters [2]. Estimated equipment costs are multi- Both the Lang and Hand methods are only suitable
?lied by the factors to arrive at total installed costs, and for order-of-magnitude and, at .best, study estimates.
::hesum of these products represents the estimated total The accuracy of the Viola method should be higher,
. ide-battery-limit cost of the complete installed plant. and that of the Guthrie method still higher. However,
In the Viola method, plant complexity factors are the latter two methods require more work.
f--- t----
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.--
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000 68
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....:
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o 2 3 4 5 6 7 8 " I,
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,
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Storage tanks-vertical, atmospheric, capacities to 8,000 gal, fiberglass-reinforced plastic, flat bottom.' Fig. 1
u - ~/ - - -
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....: V> 16
10
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26
14 ~
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202
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22
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2 4 6 8 10 12 14
Capacity, 1,000 gal
Storage tanks-vertical, atmospheric, capacities to 10,000 gal, stainless steel, flat top and cone bottom Fig. 3
106 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
12~--+--+---+---4--+--+---4--+--+---4--+--+-----4----1
101---+--+---+---4---+--+-----+---+--+----+---+---+-----4----1
u(;;;0_
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"
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;',
Capacity, 1,000
gal
"
, I Storage tanks-vertical, atmospheric, capacities to 3,000 gal, stainless steel, f1an!led-and-dished heads Fig. 2
0 u 0
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68
•... 0_0
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21---t:~o::::.-+---+--+---t---+---I--+--+---+-
o 2 4 6 8 10 12 14
Capacity, 1,000
gal
I
Storage tanks-vertical, atmospheric, capacities to 10,000 gal, stainless steel, flat top and bottom Fig. 4
CURRENT COSTS OF PROCESS EQUIPMENT 107
u
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....:
.ci
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38
28
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36
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o 5 10 15 20 25 30 35
Capacity, 1,000 gal
Storage tanks-vertical, atmospheric, capacities to 30,000 gal, stainless steel, flat top and bottom Fig. 5
,S "l'\eS
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Capacity, 1,000 gal
108 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
;,,"
- /" V
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0_ 51
0'" 36
33
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" 48
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45
39
18
42
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15
~-
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Capacity, 1,000 gal
Storage tanks-vertical, atmospheric, capacities to 30,000 gal, stainless steel, API 650 Appendix J Fig. 7
-,' I .J'
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fill'"
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Capacity, 1,000 gal
Storage tanks-horizontal, atmospheric, capacities to 3,500 gal, stainless steel, flanged-and-dished heads Fig.8
CURRENT COSTS OF PROCESS EQUIPMENT 109
90 .....--..,...---.---,--.- -,---,---,---,--,---,---,----,--,--,--:::;;r--,
.....•
80I--+---+--+--I---+---+---+----j---t---+---t---=f'''''--t--+---t----j
//
701---+---+--j---+---+--j---+---+- ""*"e...--j---t---t----j---t---t----j
oo
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W 601---+---jf--+---f--_f_--+-7'-+----+--j---t----l:::7''''''''""+----t--+--_+-___1
.0
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8 501---+---jf--+---f7~:..-_f_-_+--+_.l'~+--t---t----:---l--+--_+--+--_+-___1
401---+---A:....--j-
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30I--..,..."-+--~--+----+--+_-_+--+_-_+_--I__-
6 8 10 12 14 16 18 20
Capacity, 1,000
gal
Storage tanks-horizontal. 50 psi to full vacuum. capacities to 20.000 gal. stainless steel. ASME stamped Fig. 9
61--4---t--t---t----+--t---+----+--t---+----t--t---+----t--t----t
51--_+--1__--+--~--+_--+--+_-_+--+_-_+_-____i--+_-_+--+_-_+-___t
° u0o~.. 3
ci 0
4
.,..:
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.0 2
Receivers-vertical. 25 psi to full vacuum. capacities to 350 gal. stainless steel. ASME stamped Fig. 10
110 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
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Capacity, 1,000 gal
Receivers-vertical, 50 psi to full vacuum, capacities to 12,000 gal, stainless steel, ASME stamped Fig. 12
CURRENT COSTS OF PROCESS EQUIPMENT 111
4.-----.---....,....--~---.---"'""T""--,__-___r--"""T""--,._-__.,--__,._--,._-__.,r__-_.
000,
W ...: u0
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21-----j---+-_"'+--2I'--+---+-----ji----+-
Heat transfer
160
su rface, ft2
180 200 220 240 260 280
.
:;
Heat exchangers-fixed tubesheet, tubes of carbon steel, area 0-240 ft2, carbon steel shell Fig. 13
151---+--+_---1--+_---I---+---f----+--+---+--+_---I---+---f---__+---------I
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10
.ci
51--__+--+--~~'--+_-__1--+_---I--__+-
Heat exchangers-fixed tubesheet, tubes of carbon steel, area 300-1,500 ft2, carbon steel shell Fig. 14
112 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
u 0
o0W~.
00. 4
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Heat exchangers-fixed tubesheet, tubes of stainless steel, area 0-240 tt2, carbon steel shell Fig. 15
,~'/~~~.:/ //'/'
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6
o 300 600 900 1,200 1,500
Heat transfer surface, ft2
Heat exchangers-fixed tubesheet, tubes of stainless steel, area 300-1,500 ft2, carbon steel shell Fig. 16
CURRENT COSTS OF PROCESS EQUIPMENT 113
uW0ot'-0.
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2
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o 300 600 900 1,200 1,500
Heat transfer surface, ft2
. .. .. •• I ••• II II . ..
114 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
,~yV~g-
.'"~~,,,,'I." - " ~
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io'''- tJ'.Istainless Isteel
I I
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~'0 -3045.5..- tUb.!. use mUI!;Plier of 11.1
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Heat exchangers-U-tube, tubes of stainless steel, area 0-240 ft2, carbon steel shell Fig. 19
I I I I I I
For 316 stainless steel tubes, use multiplier of 1.1
18
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W 12
.0
o
....:
tf
o
u
-
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o 300 600 900 1,200 1,500
Heat transfer surface, ft2
Heat exchangers-U-tube, tubes of stainless steel. area 300-1,500 ft2, carbon steel shell Fig. 20
CURRENT COSTS OF PROCESS EQUIPMENT 115
4.------r--~---r--_,_-___,--__,_--.__-_r_-___".,.._-__._...."...-_.____,O'""""T--...,_-___.
0 U~ 3
00, ....:
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Heat transfer su rface, ft2
280
·
"
••
f
Heat exchangers-floating head, tubes of carbon steel, area 0-240 ft2, carbon steel shell Fig. 21 ..
15I---t----+--I-----!---+--I-----!----+--I-----!---+--I------t----+--I------I
ci u0W00,
....:
,<;;'
10
.ci
Heat exchangers-floating head, tubes of carbon steel, area 300-1,500 ft2, carbon steel shell Fig. 22
116 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
304 S.S.
oo
0_
~6f---!------l---+---+----+---+---+-~+---r+-
..a
c:i
....:
~-
a
U
'Ill!
o 20 40 60 80 100 120 140 160 180 200 220 240 260 280
Heat transfer su rface, ft2
Heat exchangers-floating head, tubes of stainless steel, area 0-240 ft2, carbon steel shell Fig. 23
U q
a0'" -
•..
....:
+hc:i
18
..a
12
0
Heat exchangers-floating head, tubes of stainless steel, area 300-1,500 ft2, carbon steel shell Fig. 24
CURRENT COSTS OF PROCESS EQUIPMENT 117
18
15
12
oo
0,
W
1\=
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9
ci
'+-'
t;'
uo 6 = o 0
1-
,.
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Tank vent condensers-stainless-steel finned-tube and housing, area 0-2,000 ft2 Fig. 25
..
...
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ess~ \e:;'
:::::::
--------- --- ----
12
...-"'-
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=
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u0, 68
0ci
'+-'
W
t;' ..ci
4
Tank vent condensers-aluminum-finned copper coil, various housings, 0-2,000 ft2 Fig. 26
118 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
70 .-------r---,---.--------r---,---.-------r--__r_--~-__r--__r_--~-___r--...,
60I----+--+---I----+--+---I-----+----+-::.~-+_-__+--_+_--+_-_+--___j
40
u00,
0
....:
W
50
30
0 ci .0
<;;;'
20f-------+.,:---/---j---f-----+----j---f-----+---+---t--_+_
101-----+--_+_--+-----+-~_+_--+_-__+--_+_-_+_-__+-
o 2 4 6 8 10 14
Capacity, 1,000 gal
Dimple-jacketed reactors-stainless steel, 0-10,000 gal; reactor 75 psi, jacket 125 psi Fig. 27
32 f---+--+---t---+--+---t---+---+---t----t---+------:::r----t---j
u0, 28
30
26
0
r>~
....: ci
W
.0
<;;;-
24
22t---+--F---j---f---+----j---f----
20 '--_--'- __ ....1-__ "--_--'- __ ....1-__ "'--_--'- __ -'- __ -'--_---' __ -'- __ -'--_---' __ -'
o 100 200 300
Capacity, gal/min
Reactor heating system-predicated on heating 50% ethylene glycol. 30 to 300 gpm Fig. 28
CURRENT COSTS OF PROCESS EQUIPMENT 119
15
--
_ ..... -
.------
----- -----
uaao00. 10
..ci
~
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1;;'
-
-
-
-
5 -
-
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o 2 3
Capacity, 1,000 gal
Blending tanks-liquid and slurry, atmospheric, jacketed for heating and cooling, agitated Fig. 29
100
/
.....
..•..
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-"'"' ",.
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..., ./' ioo'
,I
aa
10
~
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.;:"C
()
o0 .
CL
0.
E -0
:-0
0 ~
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1;;-
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./
Centrifugal pumps and drivers-ANSI pump, TEFC driver, coupling and base, 30-300,000 gpm Fig. 30
120 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
oo
o
W
~.
ou
.0
ci
....:
Q;
>
';:
"'0
"'0
C
co
~
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E
uo
} Compressors and drivers-reciprocal compressors with gas, electric or steam driver, 100-4,000 bhp Fig. 32
CURRENT COSTS OF PROCESS EQUIPMENT 121
100
120
0, u
00 140
80
9313
12
14
8
240 10567
11
4 2
00 W+.;
'+-'
V>
..0
60
220
40
180
20
160
200
0
Distillation columns-25-tray, 2-12 ft dia., 57% and 68 ft shell heights tot; 0,100 and 300 psig Fig. 33
0, 0 220 ~ .f
r\ I
0
280
240
260
W
..0'
o
200 ~_-_+--_+_----1~-_+--_+_-~I_-_+--~C---I_-_+--_+_--1_
180 I---+--+---I---+--+--'--I---+_c--+---+---+--+-----:!-
'+-'
tf
o
H i ht ~ 95
u 160
t
Distillation columns-50-tray, 2-12 ft dia., 95 and 118 ft shell heights tot; 0, 100 and 300 psig Fig. 34
122 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
°u 0.
....: '"
0 640
440
0 320
,......Q
~ ,..,... m
400 ._----~•.•.... I--- ---
--' t--..
,/./ //
~
°- -./
:::=:::::0 o psig
..0 360
•... \~ ~~
~~ ~
"""'--
;;;;
~ ~ .~
600
560280
520
480
160
240
200
c_-___
-_':.:
120
o 2 4 6 8 10 12 14
Column dia., ft
Distillation columns-100-tray, 4-12 ft dia., 170 ft shell height tot; 0,100 and 300 psig Fig. 35
°u 0.0t;~
....:
0
360
260
200
220
240
°
.0 ;;;;
160
340
300
280
140
320
0
100 180
120
P'O<luCl
99"t.melhll'lol
Distillation, packaged system-separation of methanol from water, ready for installation Fig. 36
CURRENT COSTS OF PROCESS EQUIPMENT 123
39
I
36 I I I I I 1
I
3.00
QuantiL
8 1.80
factor I
15 1.25
-
2 2.80 9 1.65 16 1.20
3 2.65 10 1.50 17 1.15-
4 2.50 11 1.45 18 1.10
30
27 -
- •• ~.·-·.·-·~V 5
6
7
2.30
2.15
2.00
12
13
14
1.40
1.35
1.30
19 1.05 -
20·29 1.00
30·39
0.98_
40+ 097
33 -~~::::::::~/"
24
u ~00ci
.,..: 15
21
18
0
.ri ..,-
369 12
0
----
2 4 6 8 10 12 14
Tray dia., ft
Sieve trays-1-12 ft dia., carbon, 304 and 316 steel; quantity factors also apply to valve trays Fig. 37
-
Q V
eO\/
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39
S'l.i\':'
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36
33 c-
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II •••• Icat
~ ••••••.
:::::::
Qua~tity factor~ un':"
CJ~Q~Q~GQQ~
if"'''''''''' "'''
VI
./ as in Fig. 37
~is same I
J /
30
27
o
o 24
~ 21
.ri
ci
.,..: 18
•...
~
u 15
12
o 2 4 6 8 10 12 14
Tray dia., ft
Valve trays-1-12 ft dia., carbon, 304 and 316 steel; cost date is November 1981 Fig. 38
124 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
/:/ ."
-' ~/.
~/
- V""
./ ......
12
~ •.. / -.'
-
••••• ."r
~
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70,......
------ •..•...••••..•.
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f=
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10 I =
oo
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fJ} 6
.0
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....:
o
5 10 15 20 25 30 35 40
Column dia., in.
Packed tower, single bed-25 psi to full vacuum, 4-ft section, carbon, 304 and '316 steel Fig. 39
//
/\V
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17
•.•.J.
. ,,\esC;,
•.•. ~ ~
...•••.•.......
'O0~ /1
15
13
>7 '~~ s~ e'/
4
5 15 20 25 30 35 40
Column dia., in.
Packed tower, double bed-25 psi to full vacuum, 5-ft sections, carbon, 304 and 316 steel Fig. 40
CURRENT COSTS OF PROCESS EQUIPMENT 125
60
u0~. 30
....:ci
.n W
20
50
~ 40
Tower packing-saddle-type packing made of porcelain; f.o.b. costs on ft3 basis Fig. 41
2001---+--1-+-I-++-Hf--+--+-++++
0 0
u0o.
W ~.
....:
ci
..ci
10
1'---_-'---'-.J.....J.--'-'..J...U'---_'---'--J.......L....L..L..L..U._---'_-'--L-l-.L-L.J...U-_--'-_'--'-'-J....Wu..L._--'----'--'--'-L...I-L..LJ
0.01 0.1 1 10 100 1,000
Heat transfer surface, 1,000ft2
('--
- -f--
-f-
I I
I
I
./
,/ ;;/ / / )~
o
o
0, 10
~
-0
Q)
tl
e
Q)
5
uo
t;"
~o
10
1 /,J 5 10 Ie .J 50 100
Capacity, 1,000 gpm
Cooling towers-erected, capacities to 20,000 gpm water throughput, basin not included Fig. 43
~t~ ,J-
-
/
100 ~ ~
/
/' !J ~-
Cooler
W
Cooting Tank
Cooling
II -B III I:
///
supply
waler """I 1 waler
I"""
0-
Gtycolsupply
./
(
- Glycol rtlurn
//1
u 00,
:3
80
70
90
..c:i ~0
•..
....: 60
0
50
40
o 3 6 9 12
Capacity, million Btu/h
Heat exchanger system-based on cooling 50% ethylene glycol, 1 million to 10 million Btu/h Fig. 44
CURRENT COSTS OF PROCESS EQUIPMENT 127
185
221
437
890
389
145110
353
121
375
9-3
10-9
14-3
16-9
621
305
269
449
964
286605
868
63
122
958
99
506
717
516-0feed
22-3
26-9
18-9
831
87
732
75
1,740
4,078
2,642
1,185
231 3,417
1,719
718
1,385
200
176
547
2552,755
1,969
1,202
1,705
4,386
1,051
792
3,063
2,173
1,536
1,236
2,053
2,907
1,284
3,725
1,870
2,438
1,057
1,032
1,432
2,402
4,740
2,094
1,501 Lime
and/or
carbon473
1.9-3.8
1.5-2.5
3-5
15-25
6-12 sludge
decolorize
5-10
2--4
Ib/h/ft2
applProcess
rates tertiary
ications recalcination-sludge
wastewater
useddescription
for
oils decolorization
and
1,411waxes
adsorbant
kaolin
Bauxite
Calcined
Charcoal
Lime
Product treatment
adsorbant
Bone
Active
Foundry char
carbon3,111
3,376
sand Regeneration of bone char ofused
Reclamation for
foundry Typical
sand product rates,
Regeneration
Regeneration
and other
Calcination
Manufacture of
cellulosic
ofof granular
ofkaolin
bauxite
0.0., wastes
ft-in.
for
charcoal activated
used
Biological to
pigment
from sludge
wood
Feed 4 plants
plant sludges
Typical
u00o.'"..,'0
600
1,000
500
°
.,..:
W
.D
800
900
700
400
300
200
4 5 6 7 8 9 10 11 12 13 14 15 16
Number of hearths
700
.--------,----,----,--,-...,r--.--.--,.-,-...,------.-----.-------r--.----,-r--,...-"
100
1------+----b6"=-t--+-:,~'-+-+-H-----+---+-
501------+-7flC---+---+--+-j-+-+-H-----+---+_
I' Fired heaters-cylindrical, various steel tubes, absorbed duty 2 million-30 million Btu/h Fig. 46
, !
r-----,----,---.---r-.---.-.-,-.,-----,..----,..---,--.,-,----r---r--r-l
6,000
5,000
1-----+---+--+--1-+--+--+--+-+-----+---+--+-+-+-+-++-1
Cost ~ Base (1 + Fd + Fp) Design pressure, psi Fp
Design type Fd - Up to 500
Process heater o 1,000
Pyrolysis 0.10 1,500
Reformer (without 2,000
catalyst) 0.35 2,500
oo 3,000
0,
;:;}
1;;'
a
ou 00
00
-0 00
'" 000
u
+"
~=""t.jOOOO
~ ••••••••••••
'"
-0 1,000
I------+---+----I~-+~I_+-,JL+-il_----+_- ••
~
u.. ••
:
• 0
500
1------+----;~-+_'4--+-jI--+-+-H-----+_-
:
•• 0
Fired heaters-box type, various steel tubes, absorbed duty 20 million-200 million Btu/h Fig. 47
CURRENT COSTS OF PROCESS EQUIPMENT 129
-.
- ----
1,000
- ...•.
r--- I
I "'-
1"--
..•..•.
....
1"0- "'- --...
-
I 500
N ....•.•..•
100
ci u~<8.ci.~-
~ A 50
10
10 50 100 500 1,000 5,000 10,000
Total filter area, ft2
Filters, pressure-leaf or tubular-carbon steel with stainless steel filtering elements Fig. 48
8,000
I I I I
~
c===J
c==::J
N II I I I
~
<A
Continuous-vacuum tilting pan,
100
10 50 100 500 1,000 5,000 10,000
Total filter area, ft2
1,000
..••••
~~
la/
"ra/.
911)0',
~
-
•.......
""i~a/s
vstr" Or
...•.•.••.
.••.•......
...••••
~ "'~ati
~s I'--r-
....•••..•••.••
er'lJ
~!JI·
- ~O' -:::'/Ur(J."
e,.v
r--..
?
""" ~ ~°'ea!J
...•....••...
500 I I I I I IIII
f-
f- ~~
ci u---N0
<17
.t=
....:
100
);;-
..ci 50
10
10 50 100 500 1,000 5,000 10,000
Total filter area, ft2
Filters, rotary vacuum disk-two designs, general heavy-duty and pulp-paper services Fig. 50
10,000 .. ~ ~"
•.•.•
I'o...~,,/ I
u.=- -'(1..--
Scrah: ~ ~ ar{;" b
- ~ I
\
.......••... ....•.•..
..•...•
=~
, {;"
•...... .I Paper-pul p ...•.•..•.
....• ....•.•.. ........ ..••....
.....•.
,j -I ~
......•.......eel
C!}ar.
'"
",.tal,,;
..•...•
drums
-
......•
~~
..•...
..•..•
•.••...
..•.•.....•
"~~61 ~
....~ I) Ste"
5,000
ci uWN0
.t=
....:
);;"
1,000
500
..ci
100
10 50 100 500 1,000 5,000 10,000
Total fi Iter area, ft2
- ~ --
700 V~--
l--/--
V
~~/
~ --
----~/?
~
~---
IIII -- - ~I----
- .//"------- ~ tee' ____ <gl
V- V ./ ./ .,-
I--- ,,/
~ ~
~oe\~ ~6sta\1
600
u0'"
o...,-
_
500
300
W 400
..ci .,..:
ci
0
200
100
10 20 30 40 50 60 70 80 90
Solids product capacity, ton!h
-- ~o~
700
~~
~-
-----h-
----
---
V"
V"
...",
~~......
....- @ I~ ~
........-
............ ~
~
~ ~c-~ M ~~~ss
..,.,.
.-'"
--- ~ ~\C~
.-'"
.,.,..,
~/""
y.,'O,'IC
./""
600
u 0o.
'"
ci .,..:
...,-
400
500
300
W
..ci
0
200
100
o 5 10 15 20 25 30 35 40
Solids product capacity, ton!h
-"L'
[]
- -
-- 6
,,/
/---
",...-
"" - (,'9 /// .// / /:r /
/--[:rr:]
.--'...--0
o0 'v~ ~ \,,:>'0
l..--"
I r ro
'"
,:,';:,'0
·011P
.\ 0
/ ()-",
1/ /' ~
J
go 4
o
2 4 6 8 10 12 14 16
Size, in.
Butterfly valves-high-performance, installed costs for ANSI classes 150,300 and 600 Fig. 54
-V
o.
:;;-
u00
...:
0ci ;;}.0
3627
36
33
30
12 9
21
39
24
18
15 -
----- --L-----./L--- -- ---
/',,/ -----
---
I
~ ~~ ......"---@".~..••.
I ~~ I ~ I I
rl
:--.....
3'0'0~
,,~
V/,/ ./V /
tc;~:
o
8 10 12 14 16 18 20 22 24
Pipe size, in.
Pipeline strainers-shell of carbon steel, slope-top and flat-top baskets of stainless steel Fig. 55
CURRENT COSTS OF PROCESS EQUIPMENT 133
cooling water, reconnect piping if required, and provide Example: A centrifugal pump is required to deliver
utilities to the unit. 1,430 gpm of a heavy organic mixture (specific
Example: How much would it cost to purchase a com- gravity = 0.952) with a differential head of 77 ft. Suc-
plete skid-mounted assembly as shown in Fig. 28 for tion pressure is below 275 psig at 100°F. The casing
heating a 180-gpm 50% ethylene glycol feed from 100 material is to be Alloy 20.
to 135oF? Fig. 28 indicates that this cost would be The head, in psi, is (77 X 0.952)/2.31 = 31.7 PSi,
about $29,000. where 2.31 ft/psi is a conversion factor.
Cost estimates derived from Fig. 28 should be accu-
rate to about +-10% as of January 1982. Capacity/head factor = 1,430X 31.7
= 4.5 X 104
Centrifugal pumps From Fig. 30, base cost = $3,500
When specifying pumps for any service, it is necessary Fm = 1.2
to know the liquid to be handled, total dynamic head, Fo = 1.0
suction and discharge pressures, and the properties of Cost = $3,500X 1.2
the fluid-temperature at operation, viscosity, specific = $4,200
gravity and vapor pressure.
Pumps are specified at the early stages of a project Cost estimates derived from Fig. 30 should be accu-
when a plant layout is not completely defined and most rate to about +-25-35% as of January 1982.
of the equipment dimensions and elevations are
sketchy. The easiest way to estimate the price of pumps Liquid and slurry blenders
is by using a current price-data book from one of the Fig. 29 gives f.o.b. costs of light-gage atmospheric-
leading pump manufacturers, unless the pumping re- pressure liquid and slurry blending tanks constructed of
quirements are unique, and a special design or even a Type 304 and 316 stainless steel. The tanks are jacketed
first-of-a-kind pump has to be created. In this case, the for heating or cooling, with transfer surfaces approxi-
usual procedure is to send detailed specifications to sev- mating 0.03 ft2 per gallon of capacity. Dimpled or
eral pump manufacturers for their bids. panelcoiljackets are designed for 125 psi at 350°F. The
Fig. 30 provides costs for centrifugal pumps designed agitator is turbine type, with motor requirements of
in accordance with American National Standards Insti-
approximately 1 hp/l,OOO gal of liquid. Electricals are
tute's (ANSI) B73.1-1977, which specifies horizontal, explosionproof, Class I, Group D. Costs include a man-
end-suction, single-stage centrifugal pumps with center- way and drain nozzle, and should be accurate to +-10%
line discharge for chemical processes. as of January 1982.
Temperatures are limited to 300°F by the standard,
but in practice, temperatures between 500 and 900°F Compressors
are not uncommon. The motors used are T-frame, Na- Process gases are required in a wide range of capaci-
tional Electrical Manufacturers Assn. (NEMA) motors ties, pressures and temperatures; process gas compres-
with a 1.0 service factor. sion is a complex operation involving either centrifugal
The input required to make a cost estimate is: capac- or reciprocating machines.
ity (gpm), differential pressure (psi), suction pressure Commercial equipment has the following general
(psi), system temperature CF), and casing material. characteristics: centrifugal-high-capacity, low-dis-
The items included in the estimate are: ANSI pump- charge pressures; reciprocating-lower capacity, high-dis-
ing unit, TEFC T-frame NEMA motor, coupling, and charge pressures.
base plate. Custom-designed equipment is usually necessary for
Centrifugal pump cost, $ = Base cost X Fm X Fo applications exceeding the above capacities and pres-
where the adjustment factors are: sures. Motor, turbine or gas engine drives can also be
Material used.
Fm
Cast iron 1.00. For cost-estimating purposes, consider the many vari-
Bronze 1.35 ables, such as volume or weight capacity (ft3/min or
Cast steel 1.41 Ib/h), molecular weight, k-values (ratio of specific heat
Stainlesssteel 1.94 at constant pressure to that at constant volume), and
Alloy 20 2.27 compression ratios, as represented by the bhp parame-
Monel 3.31 ter. These calculations are required before Fig. 31 and
Nickel 3.47 32 can be used. Carbon steel construction is assumed.
Hastelloy C 3.78 Example: A turbine centrifugal compressor rated at
Hastelloy B 3.93 400 bhp may be priced from Fig. 31 at $143,000.
Titanium 5.71 A reciprocating air compressor is required at 800 bhp
and could be driven by steam or a gas engine. What
Operating limits Fa would be the approximate capital investment for each
Suction pressure: type of compressor?
-below 275 psig at 100°F 1.0 From Fig. 32, it may be seen that the steam-driven
-below 350 psig at lOO°F 1.5 compressor would cost $252,000 and the gas-engine ver-
SystemTemperature: sion would cost $412,000.
0-500°F (at ANSI allowable pressures) 1.0 Cost estimates derived from Fig. 31 and 32 should be
above 500°F (at ANSI allowable pressures) 1.5 accurate to about +-25-35% as of January 1982.
134 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
purchaser's foundation, install plpmg for glycol and tures to the fluid being heated. It must be able to do so
cooling water, reconnect piping if required, and provide without localized overheating of the fluid or of the
utilities to the unit. structural components.
Example: Find the price of a skid-mounted assembly Fired-heater size is defined in terms of the eqUIp-
as shown in Fig. 44, to be used for cooling a 50% ethyl- ment's heat-absorption capability, or duty. Duties
ene glycol solution from 120 to 105°F. The duty of the range from about a half-million Btu/h for small, spe-
heat exchanger has been calculated at 7.5 million cialty units to about 1 billion Btu/h for super-project
Btu/h. facilities such as the mammoth steam hydrocarbon-
Fig. 44 indicates that the price would be about reformer heaters. By and large, the vast majority of
$80,000. fired-heater installations fall within the 10 to 350-mil-
Cost estimates based on Fig. 44 should be accurate to lion-Btu/h range.
about +10% as of January 1982. There are many variations in the layout, design, and
detailed construction of fired heaters. Thus, virtually
Multiple-hearth furnaces every fired heater is custom-engineered for its particular
The Nichols/Herreshoff furnace consists of a series of application.
circular hearths, placed one above the other and en- The input required to use Fig. 46 and 47 is: absorbed
closed in a refractory-lined steel shell. A vertical rotat- heat duty (Btu/h), furnace type, design pressure (psig),
ing shaft through the center of the furnace carries arms and radiant-tube materia!.
with rabble teeth that stir the charge and move it in a The cost includes complete field erection and subcon-
spiral path across each hearth. The material is then fed tractor indirects. Fig. 46 applies to cylindrical designs
to the hearth below. and Fig. 47 applies to the "box" or A-frame type of
Discharge takes place through one or more ports at construction.
the bottom. Hot gases flow countercurrently, heating Example: Two fired heaters are required in a plant.
the charge to reaction temperature and carrying on the One is to be a simple cylindrical type with chrome-
desired reaction. molybdenum steel tubes, to be used at a pressure of
In many operations, combustion of the volatiles in 1,500 psi and a duty of 1.5 million Btu/h. Fig. 46
the charge provides the necessary heat. In other in- shows:
stances, heat is furnished by combustion of various fuels Base cost = $340,000
introduced through burners into certain hearths (direct Fp = 0.2
firing), or in separate combustion chambers (external Cost = 1.2 X $340,000
firing). = $408,000
Some applications with process descriptions are given
in the tables in Fig. 45. The other unit is a reformer (without a catalyst) to be
Example: The decolorization of an organic acid solu- designed for service at 2,000 psi and 66 million Btu/h.
tion produces 24,000 lb/ d of spent granular activated- Radiant tubes should be of stainless steel.
carbon. From Fig. 45, a typical product rate of 2 to Fig. 47 shows:
4 Ib/(h)(ft2) is obtained. Base cost = $1.95 million
The required furnace effective-area is calculated as Fa = 0.35
follows:
Fp = 0.25
Cost = 1.60 X $1.95 million
24000 lb X _d_ X h-ft2
, d 24 h 3 lb
= 333 ft2
= $3.12 million
From Fig. 45, a suitable furnace size is obtained-in Cost estimates based on Fig. 46 and 47 should be
this case, a 10-ft, 9-in.-O.D. by 8-hearth unit, and the accurate to about +25% as of January 1982.
f.o.b. price of such a unit is estimated at $410,000.
Cost estimates based on Fig. 45 should be accurate to Major types of filters
about +10% as of January 1982. Operations involving the separation of solids from
liquids are so prevalent in process plants that many esti-
Fired heaters mates of plant capital cost would be less reliable if they
A fired heater, for our purposes, will include a num- did not include costs of the equipment that perform this
ber of devices in which heat liberated by the combus- function, chiefly filters and centrifuges.
tion of fuel within an internally insulated enclosure is Fig. 48 through 51 shows costs per square foot of most
transferred to fluid contained in tubular coils. Typi- of the filter types that represent major capital-cost ex-
cally, the tubular heating elements are installed along penditures in process plants.
the walls and roof of the combustion chamber, where Fig. 48 gives f.o.b. costs of batch pressure-leaf or tu-
heat transfer occurs primarily by radiation, and, if eco- bular filters of carbon steel construction but with
nomically justifiable, in a separate tube bank, where filtering elements of stainless steel, the most common
heat transfer is accomplished mainly by convection. material of construction. Costs are for filters only, of
Industry identifies these heaters with such names as accuracies of about +10% as of January 1982. Installa-
process heater, furnace, process furnace and direct-fired tions would involve feed pumps, compressed air, and
heater, which are all interchangeable. usually feed storage and precoat tanks.
The fundamental function of a fired heater is to sup- These filters can be arranged vertically or horizon-
ply a specified quantity of heat at elevated tempera- tally. Slurry is introduced under pressure and forced
136 COSTS OF EQUIPMENT-DATA AND ESTIMATING METHODS
through the filter elements. Suspended solids are re- Costs for the general filter cover only carbon-steel
tained on the media. The clarified liquid flows to the construction. Multipliers for converting costs from car-
interior of the leaf. The solids are removed from the bon to 316 stainless steel are 1.15.for small units, 1.4 for
elements and the unit is ready for another cycle. These medium-sized units, and 1.7 for larger units. Probable
filters are described in the "Kirk-Othmer Encyclopedia accuracies are -+-10%.This type of filter is described in
of Chemical Technology," pp. 298 and 303-309 [5]. "Kirk-Othmer," pp. 300-305 and 314-317.
Fig. 49 presents costs of four types of vacuum filters: The pulp and paper filters are totally different be-
the horizontal table filter in both carbon and 316 stain- cause of the high hydraulic capacities required (tens of
less steel, a corrosion-resistant horizontal belt filter, a thousands of gal/min) and the discharge of pulp sheets.
316 stainless-steel tilting pan filter, and a 316 stainless- Brownstock and bleach washing represent major appli-
steel single-compartment drum filter. These filters com- cations, with deckering (pulp thickening) important
pete with each other in handling fast-filtering granular also.
and crystalline materials. The belt unit also competes The curves give costs only for carbon-steel and 304
with drum filters in washing applications. Vacuum sys- stainless-steel construction. To convert costs from 304 to
tems for these filters are similar to those for disk and 316 stainless, multiply by 1.08 for small units, 1.11 for
drum filters, often with the addition of extra receivers medium-sized units, and 1.16 for large units. To convert
and pumps for handling wash filtrates. Vacuum pumps from 304 to 317 stainless, multiply by 1.23 for small
often become a dominant cost consideration. Probable units, by 1.31 for medium-sized units, and 1.40 for large
cost accuracies run about -+-10%.These filters are de- units. Included in costs are normal accessories-feed-
scribed in "Kirk-Othmer," pp. 300-305 and 318-321. box, wash showers and repulper. As with pulp and
Fig. 50 indicates costs of continuous rotary vacuum paper disk filters, barometric legs are used to generate
disk filters of two basic designs: a heavy-duty unit for vacuum. Cost accuracies are about -+-10%,as of Janu-
general industrial applications (especially metallurgi- ary 1982.
cal, such as taconite, coal and flue dust), and a unit This filter's rotating cylindrical drum is made up of
specifically designed for fiber recovery and concentra- longitudinal sections, which form a drainage grid on
tion in the pulp and paper industry. which the filter medium is placed. Vacuum applied to
The curve for the general industrial filter yields costs the cylinder causes the formation of the sheet as the
only for carbon steel construction, because corrosion- cylinder rotates and submerges into the vat containing
resistant designs are not common. Costs cover only the pulp stock. The sheet, after passing through a spray
filter with agitator. A typical filter station would in- washing, is continually discharged. The filtrate goes
clude a vacuum system consisting of a vacuum receiver through the medium and out through an automatic
(to separate liquid from air), a filtrate pump, a vacuum valve to the barometric leg.
pump, and possibly a moisture trap, perhaps with a Not presented are two major types of filters-filter
scrubber or condenser, to protect the vacuum pump. presses and filter-belt presses. The first are manufac-
Vacuum-system costs can vary so widely that they can- tured in so many materials of construction and with
not· be lumped into the filter cost. such varied features that their costs could not be repre-
The curve for the pulp and paper unit represents sented via graphs. The second also come in so many
costs for 304 stainless-steel construction. To upgrade different configurations as to preclude graphical repre-
from 304 to 316 stainless-steel construction, use a cost sentation of costs.
multiplier of 1.19 for smaller units and 1.24 for larger
units. Costs do not include an agitator but do include a Continuous centrifuges
feedbox, hood and repulper, which are normally pro- Fig. 52 and 53 give costs of centrifuges of two basic
vided. The vacuum system consists of a barometric leg categories, the first for inorganic chemical applications,
rather than a pump (taking advantage of the very high the second for organic chemical applications. Both cate-
liquid flows) and a vacuum receiver. gories are represented in single groups of curves by the
Probable cost accuracies are about -+-10%. These solid-bowl, screen-bowl and pusher types of centrifuges.
types of filters are discussed in "Kirk-Othmer," pp. In the inorganic chemicals applications, solids are
300-301 and 313-314. suspended in a mother liquor of water, caustic soda,
Fig. 51 shows costs of two basic types of continuous brine, or some other nonflammable liquid. Therefore,
multicompartment rotary vacuum drum filters: one for housings can be unsealed. Materials of construction can
chemical, metallurgical and general industrial services be as basic as carbon steel, sometimes as exotic as nickel,
(the lower pair of curves), the other for pulp and paper but rarely of Hastelloy.
applications (the upper pair). (One other type of drum In the organic chemicals applications, it is assumed
filter is included in Fig. 49, with horizontal filters, with that the unit must be sealed against oxygen inflow.
which it competes.) Such sealings add from 10 to 20% to costs. Materials of
The general filter has five major types of discharge construction usually involve nothing less costly than
device: scraper, belt, string, roll and precoat (two oth- stainless steel and sometimes require H;;J.stelloyC-276.
ers, coils and wire, are more specialized). The two Costs represented by Fig. 52 and 53 are for the com-
curves plot costs only for filters with belt and scraper plete but basic centrifuge, f.o.b. point of shipment, Jan-
discharge, because these bracket the costs for all types of uary 1982. Not included are drive motor and special
dischargers. The costs of filters with roll and string dis- structures, as well as shipping and installation. As aver-
charge are intermediate between the belt and scraper, age costs of the three basic centrifuges are presented,
and the precoat is comparable to the belt. probable accuracies are -+-25%.
CURRENT COSTS OF PROCESS EQUIPMENT 137
pushes the cake off the second basket and into a cake
chute.
Fig. 55 gives f.o.b. costs of pipeline strainers. Outer supervision) process engineering and
process development.
cases are of carbon steel, the baskets of stainless steel. A graduate of Kansas State
Baskets may be slope-top for inline flow, or flat-top for University, with a B.S. degree in
offset flow. Probable accuracies of costs are + 10%as of chemical engineering, and State
University of Iowa, with a B.A. in
January 1982. liberal arts, he is a member of AIChE,
American Assn. of Cost Engineers and
The Fil tralion Soc.
References
1. Corripio, A. B., Mulet, A., and Evans, L. B., Estimate Costs of Distillation Kenneth J. McNaughton is an associate
and Absorption Towers via Correlations, Chern. Eng., Dec. 29, 198!. editor at Chemical Engineering and editor
2. Desai, M. B., Preliminary Cost Estimating of Process Plants, Chern. Eng.,July of the "You and Your Job" department.
27, 198!. He received his B.Eng. (Chern.) at
3. Guthrie, K. M., Capital Cost Estimating, Chern. Eng., Mar. 24, 1969. Melbourne University and an M.Eng.
Sci. at Monash University in
4. Hand, W. E., From Flow Sheet to COStEstimate, Pelro/eurn Ref., Sept. 1938. Australia. Mr. McNaughton did research
5. "Kirk-Othmer Encyclopedia of Chemical Technology," Vol. 10, 3rd ed., at London University in biochemical
John Wiley & Sons, Inc., 1980. engineering, and has worked wi th sugar
6. Lang., H. ]., Simplified Approach to Preliminary Cost Estimates, Chern. and oil refineries in Australia and with
Eng., June 1948. Texaco Inc. in the Bahamas. He has
7. Miller,]. S., and Kapella, W. A., Installed Cost of a Distillation Column, published technical articles on fluid flow
and has edited three books for
Chern. Eng., Apr. 11, 1977. McGraw-Hill on materials.
8. Pikulik, A., and Diaz, H. E., Cost Estimating for Major Process Equipment,
Chern. Eng., Oct. 10, 1977.
9. Viola,]. L.,Jr., Estimate Capital Costs via a !)TewShortcut Method, Chern.
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