Chemical Engineering August 2011 - 37

Table 7. purchase cosT (CPCS
Vessel - horizontal
Dia.,
m
CS2-V-101
CS6-V-101
Length,
m
0.9 1.4
1.2 3.5
CS5-V-102/103 1.3 3.9
CS1-V-102
CS1-V-101
CS6-V-103
CS4-V-101
CS7-VS-105
CS7-VS-106
CS6-V-102
Vessel - vertical
CS2-V-102
CS3-V-101
CS5-V-101
CS5-V-104
CS7-V-102
CS7-VS-102
CS7-V-101
CS7-VS-104
CS7-VS-103
CS7-VS-101
Vessel - jacketed
CS7-VS-110
CS7-VS-109
CS7-VS-108
CS7-VS-107
0.9 3.7
1.8 3.7
2.5 7.4
1.6 4.7
2.7 8.0
1.3 3.9
1.7 6.9
2.0 3.2
2.5 6.1
4.4 13.2
Material
)
of vessels
all vessel pressures less than 10 barg except cs1-v-101 with pressure = 60 barg
CapCost DFP CCEP
CPCS
EconExpert
AspenPEA
Δ%
Δ% Δ% Δ%
CS 5,014 155%* 372%* 1% 21%*
CS 9,212 308%* 188%* 1% 89%
CS 10,603 52% 183% 2% 105%
CS 14,490 38% 87% 4% 78%
CS 38,640 -10% 93% -4% 14%
SS
SS
SS
SS
SS
10,787 552%* 180%* 2% 104%
9,718 173% 345% 5% 111%
15,295 44% 189% 27% 80%
29,670 19% 135% 30% 43%
136,850 260% -14% -45% -28%
CS 6,992 629% 441%* 102% 40%*
CS 15,985 12% 191% 58% 72%
CS 40,135 -14% 130% 35% 17%
4.0 34.5 CS 386,400 -56% -13% -31% -27%
0.4 6.0
0.5 1.0
0.5 5.0
1.2 1.8
1.5 2.0
3.5 10.5
SS
SS
SS
SS
SS
SS
2.0 3.8
2.3 4.5
3.0 4.8
3.2 8.5
SS
SS
SS
SS
59,300+ n/a+
75,600+ n/a+
124,500+ n/a+
199,100+ n/a+
n/a+
n/a+
n/a+
n/a+
*cost of minimum size as size is less than the minimum size
+not available in this program and so taken from another program
of a centrifugal pump in CCEP depends
on an additional factor: the stages and
split-case orientation. For lower-power
pumps (up to 55 kW and flowrates up
to 57 L/s), the pump is operating in
one stage and vertical split case, and
the cost is lower. For higher power and
flowrates, the pump operates in two or
more stages and horizontal split case,
and the cost is higher. Hence, a jump is
observed for the CCEP cost in Figure 4
due to the change of stages. The CCEP
program warns the user if the pump is
not operating in the appropriate stage.
When CTM for reciprocating pumps
is plotted against shaft power, EconExpert
gives the highest cost of the four
programs, followed by CapCost and
CCEP, while AspenPEA predicts the
lowest (reciprocating pumps are not
available in DFP). This result is similar
to what is observed in case studies.
Towers
Towers are vertical-pressure vessels
for separation operations, such as absorption,
distillation and stripping.
They contain trays or packing, plus
manholes and nozzles. For both towers
and vessels, shell thickness is required
for cost estimation in DFP. Since in
most cases, the designed pressure is
provided in the equipment data, the
following equation from Ref. 1 is used
to estimate the shell thickness.
t = [PD ÷ (2Smax E - 1.2P) + CA] (10)
Here, t is the shell thickness in meters,
P is the design pressure in bars, D is
the diameter of the vessel (meters),
Smax is the maximum allowable working
pressure of the material (bars), E
is the weld efficiency and CA is the
corrosion allowance (0.0035 m).
For tray towers, the purchase cost
given in EconExpert does not include
trays and packing, while those
are included in the total module cost.
Hence, EconExpert's purchase cost is
not compared with CapCost (Table
6). DFP gives a purchase cost similar
to CapCost, whereas CCEP is higher
when the diameter is small (or lower
when large). When the total module
cost of the tower is compared, for towers
of large diameter, all programs give
similar results (online table V). CCEP
shows a relatively higher total module
cost (+59%). For small-dia. towers,
CapCost predicts a much lower cost
than the others. A packed tower is also
evaluated (Table 6). CapCost predicts
a much lower cost than the rest. Both
CCEP and AspenPEA predict the cost
of this packed tower to be significantly
higher than that by CapCost.
n/a+
n/a+
n/a+
n/a+
n/a+
n/a+
n/a+
n/a+
4,025 291% 923%* 276% 151%
2,841 430%* 1301%* 71%* 127%
4,761 238% 765%* 194% 144%
6,348 141% 527% 11% 56%
8,591 93% 414% 17% 26%
97,405 -44% 85% -15% -54%
Vessels
Vessels are used in chemical processing
plants as reflux drums, flash
drums, knock-out drums, settlers,
chemical reactors, mixing vessels and
storage drums. In general, for horizontal
vessels with low design pressure
and small diameter, CapCost and
EconExpert predict similar purchase
and total module costs while the others
give much higher costs (Table 7).
For horizontal vessels of large diameter,
CapCost, DFP and EconExpert
give similar results, while CCEP predicts
a higher cost. The total module
cost in AspenPEA is exceptionally
high due to the high instrumentation
cost, which is three times CPCS. This
contributes to CTM as ten times CPCS
(online table VI).
For vertical vessels, CapCost gives
significantly lower costs than the other
four programs. However, when the design
pressure of the vessel is very high
(CS1-V-101), CapCost predicts a very
high pressure factor according to:
log10 FP = C1 + C2 log10P + C3(log10P)2
(11)
where C1, C2 and C3 are constants
that can be found in Ref. 1. Hence,
although the purchase cost from CapCost
is comparable or even lower than
in other programs, the total module
cost in CapCost is much higher than
that by the other four programs.
The plot of total module cost of horizontal
vessels against volume (Figure
5) shows that CapCost and EconExpert
predict similar total module costs
for horizontal vessels. DFP predicts a
slightly higher cost, whereas AspenPEA
and CCEP predict the highest
costs. Also, CCEP's cost of horizontal
vessels increases faster with increasing
volume than that by AspenPEA.
When volume is large, CCEP predicts a
much higher cost than AspenPEA, and
the deviation becomes more significant
as the volume and size increase. The
horizontal vessels evaluated in the case
studies are all below 100 m3 (Table 7),
and their costs follow these trends.
For vertical vessels of small diameter,
CapCost predicts lower purchase
and total module costs than the others
(Figure 6, Table 7 and online table VI).
However, for large-diameter vertical
vessels (CS7-VS-101), the cost given
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Chemical Engineering August 2011

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