Question 1 Your group is tasked with performing both an order of magnitude (Class 5) and study estimate (Class 4) for the capital cost of a styrene production plant. A process flow diagram (PFD) and major plant item summary is appended to this brief. The plant nominally produces 100,000 tonnes per year of styrene, at a purity of 99.95% (w/w) using ethylbenzene as the feedstock. Byproducts generated include hydrogen, benzene and toluene. The plant is located on the US Gulf Coast and was constructed in the year 2020. As part of your estimates, you are required to: 1. Use a plant correlation to estimate the cost of a 100,000 tpa styrene production plant and convert the cost to US$ (in 2020) (Class 5 estimate). 2. Use the reference cost correlations provided to estimate the purchase cost of each item of major equipment and convert the item cost to US$ (in 2020). You are not required to account for installation factors, however, must consider the relevant material of construction for each item (Class 4 estimate). You may use other correlations provided they are clearly presented and cited. 3. Using an appropriate Lang Factor, convert the total estimated equipment cost to an estimated plant cost in USS (year 2020) (Class 4 estimate). 4. Costs of each item should be clearly summarised in a table, together with the total equipment cost. Material used in calculations must be clearly cited. 5. Sample calculations for the cost estimate of each item should be clearly presented in an appendix to the submission 6. Any assumptions made should be clearly presented together with citations to any relevant material Table 1. Major Equipment Summary for the Styrene Production Process shown in Figure 1. D-401 A/B Electric/explosion proof w=136.7 kW 98% efficiency Compressors and Drives C-401 Carbon steel w=134 kW 60% adiabatic efficiency Heat Exchangers E-401 Carbon steel A = 260m Boiling in shell, condensing in tubes 1 shell-2 tube passes Q = 13,530 MJ/h E-402 316 stainless steel 4 = 226 m Boiling in shell, process fluid in tubes 1 shell-2 tube passes Q=8322 MJ/h E-403 316 stainless steel A=1457 m Boiling in shell, process fluid in tubes 1 shell --2 tube passes Q = 44,595 MJ/h E-404 Carbon steel A = 702 m Boiling in shell, process fluid in tubes 1 shell-2 tube passes Q=13,269 MJ/h E-405 316 stainless steel A-1446 m cw in shell, process fluid in tubes 1 shell-2 tube passes Q=136,609 MJ/h Fired Heater H-401 Fired heater-refractory-lined, stainless-steel tubes Design Q = 23.63 MW Maximum Q=25.00 MW E-406 Carbon steel A=173 m Process fluid in shell, cooling water in tubes 1 shell --2 tube passes Q=12,951 MJ/h E-407 Carbon steel A = 64 m Steam in shell, steam condensing in tubes Desuperheater-steam saturated at 150C 1 shell tube passes Q=15,742 MJ/h E-408 Carbon steel A = 385 m Process fluid in shell, cooling water in tubes 1 shell-2 tube passes Q = 46.274 MJ/h E-409 Carbon steel A = 176m Boiling in shell, steam condensing in tubes Desuperheater-steam saturated at 150C 1 shell 2 tube passes Q = 45,476 Ml/h (continued) Table 1. Major Equipment Summary for the Styrene Production Process shown in Figure 1. (continued) Pumps P-401 AB P-404 A/B Centrifugal/electric drive Centrifugal electric drive Stainless steel Carbon steel W = 2.59 kW (actual W-0775kW (actual 80% efficient 80% efficient P-402 A/B P-405 A/B Centrifugal electric drive Centrifugal electric drive Carbon steel Carbon steel W = 1.33 kW (actual W=0825 kW (actual 80% efficient 80% efficient P-403 A/B P-406 A/B Centrifugal electric drive Centrifugal electric drive Carbon steel Carbon steel W=0.574 kW (actual) W=0.019 kW (actual 80% efficient 80% efficient Reactors R-401 R-402 316 stainless steel, packed bed 316 stainless steel. packed bed Cylindrical catalyst pellet (diameter 1.6 mm. Cylindrical catalyst pellet diameter 1.5 mm length=3.2 mm length 32 mm) Void fraction-04 Void fraction04 V=25m V=25m 9.26 m tall, 1.85 m diameter 9.26 m tall, 1.85 m diameter Towers T-401 T-402 Carbon steel Carbon steel D-3.0m D69m 61 sieve trays 158 bubble cap trays 54% efficient 55% efficient Feed on tray 31 Feed on tray 78 12- in tray spacing 6-in tray spacing 1-in wens 1-in weis Column height=61 ft=18.6m Column height = 79 ft=24,1 m Vessels V-401 V-403 Carbon steel Horizontal V26.8m Carbon steel V-402 L/D=3 Horizontal V-5m Carbon steel L/D=3 V-5m See Figure 11 and Table for shell and tube de pressure R-401 R-402 E-403 E-404 E-405 V-401 C-401 P-401AB T-401 E-406 E-407 P.402AB V-402 T-402 E-408 E-409 Styrene Styrene Product Product Product Three Compressor Waste Benzene Reboiler Condenser Reflux Reflux Styrene Reboller Condenser Reactor Reactor Cooler Cooler Cooler Phase Water Toluene Pump Drum Column Separator Pump Column P-403A/B P-404A/B P-405A/BP-406A/B H-401 E-401 E-402 Steam Feed Inter Reflux Styrene Recycle Benzone Heater Heater Heater Pump Pump Pump Toluene Pump P-405 NB C-401 Hydrogen Ethylbenzene E-401 pod E-400 R-401 P-406AB Benzene Toluene H-4011 T-401 E-402 V-401 V-402 To Steam Plant P-402 AB hps E-408 Bow V-403 T-402 R-402 HO E-407 P-403AB E-403 btw hps btw P-404 AB Styrene pe E-404 E-400 E-405 p.401 MB Wastewater Figure 1. Styrene Production - Process Flow Diagram