1. Team Yellow

2. Experiment 3 IRI Economics

3. FCI and Annual Costs FCI is $4.63 million Annual product cost is $104 million Annual cash flow is -$77 million

4. Profitability Profitability based on rate of return is -15000% Profitability based on discounted cash flow is 54 million Profitability based on Net present worth is -$814.5 million Profitability based on POT is -$0.05

5. Net Profits Total net profit for life of the project is $-799 million Total capital investment is $4.63 million If product sold 3 times of initial estimate, NPW is $194 million If product sold ½ of initial estimate, NPW is $- 1.06 billion

6. Recommendations Towelie Consulting recommends IRI postpone the building of the plant. The price of product must rise by at least 2.65 times the current price in order for this process to be profitable by IRI standard. The accuracy of this report is ±15%

7. Experiment 4 IRI Piping

8. Objectives Determine risk using the error propagation method. Compare the minimum price between the product and the raw materials. Calculate pressure drop based on the given data of Table 1 and Pro/II simulation. Calculate the installation cost for the pipe network.

9. Risk Risk - $800,000

10. FCI - Piping Carbon steel – Benzene, feed, top, bottom Stainless steel – all remaining streams Cost of pipes - $500,000 Cost of globe valves - $200,000 Cost insulation - $37,500, Rock Wool FCI - $1.03 million

11. Experiment 5 IRI Pump Analysis

12. Suggestion of the material type for the reactor Determine the worked needed at the pump Suggestion of a suitable pump type with the diagram of NPSHA vs. flow rate and the system head vs. flow rate. Calculate the installation cost for the pump section

13. Pump Results Pump work – 3600 Watts Flow rate – 4000 ft 3 /hr System Head – 500 ft Using Fig 12-13, regenerative (turbine) pump

14. FCI Pump cost (including motor) - $90,000 Stainless steel pipes - $500 Stainless steel valves, 9 - $10,000 Installation Costs - $150,000 FCI - $520,000

15. Experiment 6 IRI Heat Exchanger Analysis

16. Objectives Design and calculate the cost of a heat exchanger using the rigorous model in PRO/II Calculate the cost of the other two heat exchangers in the plant Design the distillation column

17. Heat Exchanger, E1 Using TEMA guidelines: Front end heat type - Channel and removable cover Shell type - Two pass shell with longitudinal baffle Rear end head type – U-tube bundle $9,000

18. Heat Exchanger, E1, Specifications

19. Fixed Capital Investment 304-Stainless steel heat exchangers Fixed tube heat exchangers for E2 and E3 O.D. – ¾” Length – 20’ Cost - $5000 each $94,000

20. Distillation Column Specifications Tray Spacing2 ft Type of TraysValve Flooding60% Velocity3.372 ft/s Column Area38.50 ft 2 Column Diameter7.0 ft Column Height70 ft Area for Downcomers4.598, 12% of Column Area Pressure Drop per Tray0 Condenser Duty-11.66 MMBTU/HR Reboiler Duty 12.80 MMBTU/HR