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Column1

Utility

Column2
Conditions

Column3
Equipment

MP- Steam1

31bar, 234,8C

DC2

MP- Steam2

9,92bar, 180C

DC1
RWDC1
RWDC2
RWDC TOTAL

Cooling Water

1 bar, 20C

DC1
DC2
RWDC1
RWDC2
RWDC TOTAL
HE5
HE6

3
Electricity

Pump1
Pump2
Pump3
Compressor
B1

4
Process water
MP Steam1 produced
MPSteam2 produced

873.74
1837.559

Column4
Requirement

Column5

816.69 kg/hr

Column6
Column7
Utility to be purchased

kg/hr
kg/hr
kg/hr
kg/hr
kg/hr

246.58
815.2
251.71
254.83
506.54
1039.68
94.63
2702.63

kg/hr
kg/hr
kg/hr
kg/hr
kg/hr
kg/hr
kg/hr
kg/hr

2702.63

(kW)
kW
kW
kW

kW
kg/hr

Column9
Euros per hour

534.84
237.84
290.63
528.47
1063.31

3.08
1.55
0.000935
132.58
0.19147
137.402405
2423

Column8
Price

1099.21924 MWh

0.03531

95.4298653

774.249

Process Economics for 135,000 T/yr MEK


SBA Technology New Technology
Capital
Fixed capital
Working capital
Start-up costs
450
Variable Operating Costs
Raw Materials
n butane
Catalysts and Chemical
Utilities
By-product Credit
NET Variable Costs
Fixed Operating Costs
Capital Charges at 15% DCF/ROI
Required Selling Price

MM$
MM$
MM$
MM$

9
1
13
23

MM$
MM$
MM$
MM$

2
0
0
0
2
2
3

MM$
MM$
MM$
MM$
MM$
MM$
MM$

TUE
Ethylene Oxide
with Oxygen

Process Economics Worksheet


Product
DME
Capacity
Start-up year

Case Indirect Process


Operating Factor

3.712 kT/year
2016

CAPITAL
Fixed Capital
Working Capital
Start-up Costs
Total Capital

9.30
0.73
12.59
22.6

MM$
MM$
MM$
MM$

Cost/Unit
Raw Materials
Methanol

8000 hr/year

( ISBL
7.8 OSBL
Note : WC includes 0,116 MM$ for initial catalyst)

1.5 )

Annual Cost
k$

Annual Consumption

$381.000 $/T

1.3917

T/T

Total Raw Materials

Unit Cost
$/T

1,968

530.2

1,968

530.2

11

2.99
0.0

11

2.989

19
398

5.1
107.1

0.3

27.4

Catalysts and Chemicals

Catalyst for RWDC

$332,880.00

0.033333333

Total Catalysts and Chemicals

Usage
kg/year
324304.8
0.2
0.249102

Utilities
Electricity
Steam
Cooling water

71
26.00

$/MWh
$/T

72.44 MWh/year
4119.16 T/year

0.06

$/T

4787.24 T/year

Usage
kg/year
324304.8
1570980
2223878
4119.164

Total Utilities

418

112.5

5.8
Cost
$/year

Fixed Costs
Operators
Supervision
Maintenance
Plant Overhead
Taxes & Insurance
Total Fixed Costs

Capital Charges @
S,G&A

1
1
5
80
2

15
5

shift positions, each &


shift positions, each &
% ISBL +
3
% operating labor +
% of fixed capital

400
600
% OSBL
20

New Plant
Fully depreciated

8607.05007
41693.8233
59021.739
109322.6124

Total Fixed costs

400
600
0
800
0
1,801

107.8
161.6
0.1
215.5
0.1
485.1

OPERATING COSTS

4,198

1130.8

(See Sheet 2)

2,974
359

801.2
96.6

41.5
5.0

REQUIRED SELLING PRICE (without byproduct credit)

7,172

1932.0

100.0

REQUIRED SELLING PRICE (without byproduct credit)

4,571

1231.5

0
0
0
0

0.0
0.0
0.0
0.0

7,172

1932.0
1231.5

% DCF-ROI
% of RSP

k$/YR
k$/YR
% maint.

25.1

Usage
kg/year
28576.41
313131.3
2210227
2235301
4787.235

Usage
kW
0.008893
0.000163
72.44312

Byproducts
Steam

Fully depreciated

$/T
$/T
$/T

1.67 T/T
T/T
T/T

Required selling price (with byproduct credit)


Required selling price (with byproduct credit)

4,571

4.671642

2.835821

1932.0
1.932009611
2.883596434

$/T
$/l

TUE
Ethlene Oxide
with Oxygen

Inputs from first sheet

Calculation of Capital Charges

ISBL
OSBL
Netto Oper. Costs
Fixed costs
Required inventory

7.80
1.50
4.20
1.80
1

MM$
MM$
MM$/YR
MM$/YR
months

equals

0.35 MM$/months

Years of
construction

Innitial
cat.load

0.029

MM$

Capital charges
Fixed Cap. (FCI)
WC (WC)
Start-up (SU)

9.30 MM$
0.73 MM$
1.05 MM$

a=
b=
c=

0.259
0.305
0.174

2.4 MM$/yr
0.2 MM$/yr
0.2 MM$/yr

Ann.Fix.Cost (FIX)

1.8 MM$

d=

0.089

0.2 MM$/yr

FOR A NEW PLANT

ISBL
OSBL
Netto Oper. Costs
Fixed costs
Required inventory

0.0
0.0
4.2
1.8
1

MM$
MM$
MM$/YR
MM$/YR
months

equals

Total

3.0 MM$/yr

$/Ton
801.2

$/Ton
100.66

0.3 MM$/months

Years of
construction

Innitial
cat.load

MM$

Capital charges
Fixed Cap. (FCI)
WC (WC)
Start-up (SU)

0.0 MM$
0.7 MM$
0.0 MM$

a=
b=
c=

0.259
0.305
0.174

0.0 MM$/yr
0.2 MM$/yr
0.0 MM$/yr

Ann.Fix.Cost (FIX)

1.8 MM$

d=

0.089

0.2 MM$/yr

FOR FULLY DEPRECIATED PLANT

Total

0.4 MM$/yr

Costs for Equipments (Include Labors and installation)

Profitability Analysis
New Plant
MM$/y
$/T

Sales from products


Price
MEK

Yield
2442 $/T

136.3 kT/year
Total

332.7

89638.2

332.7

89638.2

2.0

530.2

330.8

89108.0

Raw Materials
Upgrading Value
Other Operating Costs
(Total Operating cost - Raw
Materials - byproducts)
Gross Margin
Capital Charges
Profit (before tax)

Required Selling Price

2.2

600.6227

328.5

88507.4

3.0

801.2

325.6

87706.2

7.2

1932.0

325.6

87706.2

4.674627 per liter

Fully Depreciated Plant


MM$/y
$/T
332.7

89638.2

332.7

89638.2

2.0

530.2

330.8

89108.0

0.0

0.0

330.8

89108.0

0.4

100.7

330.4

89007.4

4.6

1231.5

328.2

88406.7

Component Name

Component Type

B1
CMPRSR1
DC1-bottoms split
DC1-cond
DC1-cond acc
DC1-overhead split
DC1-reb
DC1-reflux pump
DC1-tower
DC2-bottoms split
DC2-cond
DC2-cond acc
DC2-overhead split
DC2-reb
DC2-reflux pump
DC2-tower
FLASH-flash vessel
FURNACE
HE1
HE3
HE4
HE5
HE6
LPMRCT1
LPMRCT2
LPMRCT3
MIXER1
MIXER2
PRE-RFM1
PRE-RFM2
PUMP1
PUMP2
PUMP3
PUMP4
RFRMR1
RFRMR2
RWDC1-bottoms split
RWDC1-cond
RWDC1-cond acc
RWDC1-overhead split

DGC CENTRIF
DGC CENTRIF
C
DHE FIXED T S
DHT HORIZ DRUM
C
DRB U TUBE
DCP CENTRIF
DTW TRAYED
C
DHE FIXED T S
DHT HORIZ DRUM
C
DRB U TUBE
DCP CENTRIF
DTW TRAYED
DVT CYLINDER
DAT REACTOR
DHE FLOAT HEAD
DHE FLOAT HEAD
DHE FLOAT HEAD
DHE FLOAT HEAD
DHE FLOAT HEAD
DAT REACTOR
DAT REACTOR
DAT REACTOR
C
C
DAT REACTOR
DAT REACTOR
DCP CENTRIF
DCP CENTRIF
DCP CENTRIF
DCP CENTRIF
DAT REACTOR
DAT REACTOR
C
DHE FIXED T S
DHT HORIZ DRUM
C

Total Direct Cost


(EUR)

Equipment Cost
(EUR)

477,200.00
1,138,500.00
0
59,600.00
95,100.00
0
89,900.00
26,000.00
199,100.00
0
61,200.00
95,100.00
0
78,900.00
30,500.00
333,300.00
100,300.00
232,900.00
132,800.00
84,800.00
84,800.00
63,100.00
61,400.00
214,700.00
203,400.00
199,000.00
0
0
203,400.00
216,300.00
74,300.00
35,900.00
25,200.00
24,300.00

464,760.00
1,124,460.00
0
8,400.00
15,700.00
0
26,700.00
4,560.00
60,300.00
0
9,800.00
15,700.00
0
15,900.00
4,780.00
172,900.00
19,600.00
90,400.00
18,600.00
14,000.00
14,000.00
12,300.00
9,700.00
74,800.00
64,700.00
60,500.00
0
0
64,700.00
76,000.00
50,300.00
15,600.00
3,670.00
3,670.00

203,400.00
0
67,900.00
87,100.00
0

164,700.00
0
12,000.00
15,700.00
0

RWDC1-reb
RWDC1-reflux pump
RWDC1-tower
RWDC2-bottoms split
RWDC2-cond
RWDC2-cond acc
RWDC2-overhead split
RWDC2-reb
RWDC2-reflux pump
RWDC2-tower
SPLITTER
TURBINE
V1

DRB U TUBE
DCP CENTRIF
DTW TRAYED
C
DHE FIXED T S
DHT HORIZ DRUM
C
DRB U TUBE
DCP CENTRIF
DTW TRAYED
C
DGC CENTRIF
C

59,200.00
26,500.00
343,800.00
0
68,200.00
86,700.00
0
64,000.00
26,500.00
354,100.00
0

11,600.00
4,780.00
188,900.00
0
12,300.00
15,300.00
0
13,900.00
4,780.00
191,200.00
0

Piping
Civil
Steel

Paint
Other

CMPRSR2
CMPRSR1
DC1
DC2
Flash
Furnace
HE1
HE3
HE4
HE5
HE6
LPMRCT1
LPMRCT2
LPMRCT3

464,760.00
1,124,460.00
115660
219080
19,600.00
90,400.00
18,600.00
53,000.00
42,500.00
12,300.00
9,700.00
74,800.00
64,700.00
60,500.00

PRE-RFM1

64,700.00

PUMP1
PUMP2
PUMP3
PUMP4
RFRMR1
RFRMR2
RWDC1
RWDC2

50,300.00
15,600.00
3,670.00
3,670.00
132,000.00
164,700.00
232,980.00
46280
3,083,960.00

EQUIP.ICS (Equipment)
Area Name
505,680.00

Miscellaneous Flowsheet Area


Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area
Miscellaneous Flowsheet Area

PROJECT CAPITAL SUMMARY


Total Cost

Design, Eng, Procurement


Construction
Construction
Material Manhours

Purchased
Cost
Equipment
Equipment
Cost
Setting
Piping Cost
Civil
Cost
Steel
Cost
Instrumentation
Cost
ElectricalCost
InsulationCost
Paint
Cost
Other Cost
Subcontracts
Cost
G and A Overheads
Cost
Contract Cost
Fee
Escalation
Cost
Contingencies
Cost

731,860.10
########
27,374.30
357,969.80
########
99,861.30
56,513.40
49,299.20
42,347.80
893,967.60
########
508,750.60
########
119,094.70
59,547.30
35,029.00
10,238.50
2,144,800.00 1,345,700.10 23,400.00
0
108,669.20
0 70,883.10
274,191.80 102,273.20 48,673.10
-0.1
-0.1
0
963,156.20 260,635.20 ########
0

Total Project
CostCost
AdjustedCost
Total Project Cost

6,314,023.70
6,237,700.34

1,226.00
7,718.00
2,005.00
301
4,144.00
2,443.00
2,629.00
1,195.00

Equipment calculation
Column1
Equipment Setting
Piping
Civil
Steel
Instrumentation
Electrical
Insulation
Paint
Miscellaneous
Subtotal
Contract Fee
Base total
Contingencies
Total ISBL
Total OSBL
Total ISBL
Total OSBL

Column2
505680
357,969.80
99,861.30
49,299.20
893,967.60
508,750.60
119,094.70
35,029.00
2,253,469.20
4,823,121.40
274,191.80
5,097,313.20
963,156.20

6,060,469.40 Euros

EQUIP.ICS (Equipment)
Component Name

Component Type

Total Direct Cost


(EUR)

B1
DC2-bottoms split
DC2-cond
DC2-cond acc
DC2-overhead split
DC2-reb
DC2-reflux pump
DC2-tower
HE6
PUMP3
PUMP4
RWDC1-bottoms split
RWDC1-cond
RWDC1-cond acc
RWDC1-overhead split
RWDC1-reb
RWDC1-reflux pump
RWDC1-tower
RWDC2-bottoms split
RWDC2-cond
RWDC2-cond acc
RWDC2-overhead split
RWDC2-reb
RWDC2-reflux pump
RWDC2-tower

DCP CENTRIF
C
DHE FIXED T S
DHT HORIZ DRUM
C
DRB U TUBE
DCP CENTRIF
DTW TRAYED
DHE FLOAT HEAD
DCP CENTRIF
DCP CENTRIF
C
DHE FIXED T S
DHT HORIZ DRUM
C
DRB U TUBE
DCP CENTRIF
DTW TRAYED
C
DHE FIXED T S
DHT HORIZ DRUM
C
DRB U TUBE
DCP CENTRIF
DTW TRAYED

Construction Manpower

Construction Indirects

27,374.30
175,550.20
43,348.00
6,951.40
91,883.40
54,389.40
59,547.40
24,790.60
775,700.00
14,515.00
47,343.20
0
98,224.70

23,271.00
75,902.20
0
157,477.20

35,200.00
0
95,900.00
0
55,500.00
26,000.00
333,300.00
25,200.00
24,300.00
0
67,900.00
87,100.00
0
67,600.00
26,500.00
354,100.00
0
68,200.00
86,700.00
0
67,700.00
26,500.00
354,100.00

12.582

Purchased Equipment
Equipment Setting
Piping
Civil
Steel
Instrumentation
Electrical
Insulation
Paint
Other
Subcontracts
G and A Overheads
Contract Fee
Escalation
Contingencies

Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost

7818005.526 USD
1563601.105

Equipment Cost
(EUR)

731,860.10
27,374.30
357,969.80
99,861.30
49,299.20
893,967.60
508,750.60
119,094.70
35,029.00
2,144,800.00
0
108,669.20
274,191.80
-0.1
963,156.20

11.50743

14,800.00
0
15,700.00
0
11,900.00
4,560.00
172,900.00
3,670.00
3,670.00
0
12,000.00
15,700.00
0
16,700.00
4,780.00
191,200.00
0
12,300.00
15,300.00
0
16,800.00
4,780.00
516,760.00

Column1
Raw Materials

Column2
Natural Gas
Oxygen

Total Raw Materials


Catalysts and Chemicals
Catalyst for Reactor LPMEOH1
Catalyst for LPMEOH2
Catalyst for LPMEOH3
Catalyst for Reformer1
Catalyst for Reformer 2
Catalyst for pre-reformer
Catalyst for RWDC
Total Catalysts and Chemicals
Utilities
Electricity
Boiler water
Cooling water
Total Utilities
Total Fixed Costs

OPERATING COSTS

Column3
314
1,705
2,019
6
3
2
2
14
5
11
42
290
144
5
438
2,522
5,022

WC (WC)

Column1 Column2
Fixed Cap. (FCI)
22.85
0.85
Start-up (SU)
1.23
Ann.Fix.Cost (FIX)

Column3
MM$
MM$
MM$

2.5 MM$

Column4

Column5 Column6
Column7
a=
0.259
b=
0.305
c=
0.174
d=
FOR A NEW PLANT

Column8

0.089

Column9

Column10
5.9 MM$/yr
0.3 MM$/yr
0.2 MM$/yr
0.2 MM$/yr

Total

6.6 MM$/yr

EQUIP.ICS (Equipment)
Area Name ComponentComponent
Name
Total
TypeDirectEquipment
Cost
Cost
(EUR)
(EUR)

Miscellaneous
B1 Flowsheet
DCP
Area
CENTRIF35,200.00
Miscellaneous
DC2-bottoms
Flowsheet
C split
Area
0
Miscellaneous
DC2-cond
Flowsheet
DHE
Area
FIXED T S
Miscellaneous
DC2-cond
Flowsheet
acc
DHT
Area
HORIZ DRUM
95,900.00
Miscellaneous
DC2-overhead
Flowsheet
C Area
split
0
Miscellaneous
DC2-reb
Flowsheet
DRB
Area
U TUBE55,500.00
Miscellaneous
DC2-reflux
Flowsheet
pump
DCP
Area
CENTRIF26,000.00
Miscellaneous
DC2-tower
Flowsheet
DTW
Area
TRAYED
########
Miscellaneous
HE6Flowsheet
DHE
Area
FLOAT HEAD
Miscellaneous
PUMP3
Flowsheet
DCP
Area
CENTRIF25,200.00
Miscellaneous
PUMP4
Flowsheet
DCP
Area
CENTRIF24,300.00
Miscellaneous
RWDC1-bottoms
Flowsheet
C Area
split
0
Miscellaneous
RWDC1-cond
Flowsheet
DHE
Area
FIXED T67,900.00
S
Miscellaneous
RWDC1-cond
Flowsheet
DHT
acc
Area
HORIZ DRUM
87,100.00
Miscellaneous
RWDC1-overhead
Flowsheet
C Areasplit
0
Miscellaneous
RWDC1-rebDRB
Flowsheet Area
U TUBE67,600.00
Miscellaneous
RWDC1-reflux
Flowsheet
DCP
Area
pump
CENTRIF26,500.00
Miscellaneous
RWDC1-tower
Flowsheet
DTW
Area
TRAYED
########
Miscellaneous
RWDC2-bottoms
Flowsheet
C Area
split
0
Miscellaneous
RWDC2-cond
Flowsheet
DHE
Area
FIXED T68,200.00
S
Miscellaneous
RWDC2-cond
Flowsheet
DHT
acc
Area
HORIZ DRUM
86,700.00
Miscellaneous
RWDC2-overhead
Flowsheet
C Areasplit
0
Miscellaneous
RWDC2-rebDRB
Flowsheet Area
U TUBE67,700.00
Miscellaneous
RWDC2-reflux
Flowsheet
DCP
Area
pump
CENTRIF26,500.00
Miscellaneous
RWDC2-tower
Flowsheet
DTW
Area
TRAYED
########

14,800.00
0
15,700.00
0
11,900.00
4,560.00
########
3,670.00
3,670.00
0
12,000.00
15,700.00
0
16,700.00
4,780.00
########
0
12,300.00
15,300.00
0
16,800.00
4,780.00
########

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