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Published byMilo Douglas Modified over 9 years ago
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Kathryn Knopinski Kara Shelden Kim Fink Justin Sneed Mark Shreve
Green Group Kathryn Knopinski Kara Shelden Kim Fink Justin Sneed Mark Shreve
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Financial Analysis of Cyclohexane Plant
Assignment 3 Financial Analysis of Cyclohexane Plant
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Purchased Equipment Cost
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Fixed Capital Investment
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Fixed Capital Investment
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Total Product Cost
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Total Product Cost
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Sales Income Gross Product Income
Current prices: $160 million 3x current prices: $480 million ½ current prices $80 million Majority of profits come from the sale of cyclohexane Benzene, hydrogen, and methane were also sold
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Profits after 10 years Cash Flow Net Present Worth
Current prices: $108 million 3x current prices: $2,491 million ½ current prices $-487 million Net Present Worth Current prices: $63 million 3x current prices: $1,490 million ½ current prices $-461 million
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Analysis of Profits Based on current prices Return on investment
489% Pay-out time 57 days Discounted cash flow rate of return 430%
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Risk Analysis and Piping Analysis of Cyclohexane Plant
Assignment 4 Risk Analysis and Piping Analysis of Cyclohexane Plant
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Sensitivity Analysis Strauss plots determined NPW sensitivity
NPW vs. FCI NPW vs. Product Costs NPW vs. Product Price
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Strauss Plot for FCI
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Strauss Plot for Product Costs
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Strauss Plot for Product Price
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Risk Evaluation Conclusion
Minimum sale price of cyclohexane: $3.39/gal NPW: $63 ± 130 million using propagation of error $63 ± 289 million using Monte-Carlo
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Pipe Material Pressure Drop
Piping for all streams was high-alloy stainless steel Ability to resist corrosion at higher temperatures Pressure Drop Ranged from 0.84 – 2700 psi 2 pumps and 5 compressors required
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Bursting Strength 2,480 kPa for all pipes Operating Pressures
4% - 143% of safe working pressure 3 sections under safe pressure Error with unit conversion: all pipes should be safe
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Piping Insulation Thickness
Varies from 1 – 1.5 inches Material: mineral wool Low thermal conductivity Standard metal finish to reduce maintenance and heat loss
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Fixed Capital Investment
New Piping Design System $3,670,000 Optimized Piping System $2,890,000
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Simulation and Fluid Transport
Assignment 5 Simulation and Fluid Transport
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Heat and Material Balances
Simulated using SIMSCI PRO/II using the Saove-Redelich-Kwong thermodynamic package Stream summaries, material balances, and heat balances obtained Table 1. Heat Balances on Heat Exchangers Hx Name E1 E2 E3 Hx Description Duty MM BTU/HR 7.129 7.6808 3.9265
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Heat and Material Balances
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Heat and Material Balances
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Reactor Material Selection
High-alloy stainless-steel should be used Hydrogen not compatible with carbon-steel Cast-iron not durable at reactor operating conditions (375 psia and 435oF)
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Pump Work Requirements
Equivalent pipe lengths were found PRO/II used to find pump work requirements Pump work found to be 12.6HP, or 9.4 kW Table 5. Pump Properties Pump Name P1 Pump Description Pressure Gain PSI Head FT Work HP
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Pump Selection Gear pump chosen Positive displacement pump
Stainless-steel case, gears, and shaft Can process liquids containing small amounts of vapor Handles 83 gal/min flow rate Handles 1.7 MPa pressure gain
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NPSHA and System Head vs. Flow Rate
100 200 300 400 500 600 700 800 900 1000 Cyclohexane Flow Rate (ft3/h) NPSHA (ft) 0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 System Head (ft) NPSHA Hs
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Fixed Capital Investment
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Design of the Heat Exchanger Network
Assignment 6 Design of the Heat Exchanger Network
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Cyclohexane Production Unit
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Selection of Material Shell-and-Tube Heat Exchangers
Different stream composition in each side CAUTION! Hydrogen causes damage to carbon steel and low alloy metals; stainless steel must be used
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Hand Design Exchanger E1 designed for two cases:
Single-Pass Tubes Double-Pass Tubes Equipment cost determined for each design T-Q Diagram compared
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Single-Pass Double-Pass
Overall Heat Transfer Coefficient U = 52 Btu/hr·ft2·˚F Heat Transfer Area A = 1288 ft2 Tubes Length = 16 ft OD = in Number = 411 Cost = $22,000 Overall Heat Transfer Coefficient U = 63 Btu/hr·ft2·˚F Heat Transfer Area A = 1119 ft2 Tubes Length = 16 ft OD = in Number = 179 Cost = $20,000
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T-Q Diagram for E1
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Pro/II Design Rigorous heat exchanger model used for exchanger E1
Tube length and diameter and shell diameter were varied to produce the smallest heat transfer area Minimize heat transfer area Minimize cost
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Pro/II Design Shell-and-Tube double-pass heat exchanger
Overall heat transfer coefficient, U = 129 Btu/hr·ft2·˚F Heat transfer area, A = 964 ft2 Tubes: Length = 16 ft OD = in Number = 19 Cost of Exchanger E1 = $ 21,715
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Fixed Capital Investment
Fixed Capital Investment = Direct Costs + Indirect Costs Based on purchased equipment delivered cost E1: Stainless steel shell and tubes E2: Carbon steel shell, stainless steel tubes E3: Carbon steel shell, stainless steel tubes Assuming the same heat transfer area for each exchanger as E1 found from Pro/II, the costs are E1 = $ 21,715 E2 = E3 = $ 20,370 Total purchased equipment cost = $ 62,500
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Fixed Capital Investment
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Distillation Column Design
Pro/II software used Specified: Reflux ratio = 24 Bottom stream = mole fraction cyclohexane Resulted in design specifications of Pressure = 14.7 psia Number of stages = 30 Feed tray = 16 Tray Spacing = 24 in Tray type: Valve, 15 in minimum diameter Column diameter = 78 in Column height = 60 ft
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THANK YOU! Questions?
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