(a) Malaysia Chemicals Group Bhd (MCG) has approved an investment for a polystyrene

plant within the Pengerang Integrated Complex in Pengerang, Johor. The estimated

capital cost using the study estimate method (Class 4) was calculated to be $158 million.

If the plant were to be built, over what range would you expect the actual capital estimate

to vary?

(b) Ir Shaiful Azuar ordered a set of Floating Head Heat Exchangers (Heat exchange area

= 120 m2), which cost $188,000 for his employer, Asia Chemical Sdn. Bhd. Based on

this information, a junior process engineer, Nurul Dayana estimated a cost for a heat

exchanger for similar service with heat exchange area of 60 m2 is half of the price. By

taking cost exponent of heat exchanger, n = 0.55, calculate and show Nurul Dayana that

her estimation was wrong.

(c) The capital cost of a 40,000 tonne/year benzene plant in 2012 was estimated to be $110

million. Estimate the capital cost of a new plant with a production rate of 60,000

tonne/year in 2022. CEPCI index: 2012 (586), 2022 (708).

(d) Table 2 shows the equipment details for construction of a new chemical plant. Certain

values for capital cost estimate are given in the Table 3. CEPCI index: 2012 (586), 2022

(708).

(i) Calculate bare module factor; FBM for X, Y and Z in Table 2.

(ii) Calculate purchased cost; Co

p(2012) and bare module cost; CBM(2012) ($) for

a. E-101, E-102, E-103

b. P-101A/B

(iii) Calculate the total module cost (CTM) for this expansion in 2022.

Table 2. Information on Equipment Required for the Plant Expansion Equipment No. Capacity/Size Material of Operating Construction Pressure (barg) E-101 Area=190 m Tube -CS Tube=5 Overhead Shell and tube (floating Shell-CS Shell-5 condenser head) E-102 Area-225 m Tube-SS Tube 18.0 Reboiler Shell and tube (floating Shell-CS Shell-6 head) E-103 Area-15 m All CS Inners Product cooler (double pipe) consctruction Outer = 5 CS P-101A/B Reflux pumps T-101 Aromatic column Discharge=5 Columns Vessel-CS Power shaft=5kW Centrifugal Diameter 21 m Height = 23 m 32 sieve trays Diameter = 1.8 m Length - 6m Horizontal Tray -CS Trays-SS Vessel-CS V-101 Reflux drum Vessel - 5 Equipment E-101 Table 3: Capital Cost Estimate F F. FNM C (2011) (5) 1.0 1.0 CRM(2011) (S) ? E-102 1.029 1.81 Y ? ? E-103 1.0 1.0 3.29 ? 2 P-101A/B 1.0 1.55 Z ? ? 1.681 1.513 1.0 1.0 5.31 3.79 57,000 13,500 290,700 51,200 T-101 V-101 Reflux drum 32 trays Totals 1.83 1.83 (32)(2200) ? 131,200 ? Table 2. Information on Equipment Required for the Plant Expansion Equipment No. Capacity/Size Material of Operating Construction Pressure (barg) E-101 Area=190 m Tube -CS Tube=5 Overhead Shell and tube (floating Shell-CS Shell-5 condenser head) E-102 Area-225 m Tube-SS Tube 18.0 Reboiler Shell and tube (floating Shell-CS Shell-6 head) E-103 Area-15 m All CS Inners Product cooler (double pipe) consctruction Outer = 5 CS P-101A/B Reflux pumps T-101 Aromatic column Discharge=5 Columns Vessel-CS Power shaft=5kW Centrifugal Diameter 21 m Height = 23 m 32 sieve trays Diameter = 1.8 m Length - 6m Horizontal Tray -CS Trays-SS Vessel-CS V-101 Reflux drum Vessel - 5 Equipment E-101 Table 3: Capital Cost Estimate F F. FNM C (2011) (5) 1.0 1.0 CRM(2011) (S) ? E-102 1.029 1.81 Y ? ? E-103 1.0 1.0 3.29 ? 2 P-101A/B 1.0 1.55 Z ? ? 1.681 1.513 1.0 1.0 5.31 3.79 57,000 13,500 290,700 51,200 T-101 V-101 Reflux drum 32 trays Totals 1.83 1.83 (32)(2200) ? 131,200