1. Kathryn Knopinski Kara Shelden Kim Fink Justin Sneed Mark Shreve
Green Group
Kathryn Knopinski
Kara Shelden
Kim Fink
Justin Sneed
Mark Shreve

2. Financial Analysis of Cyclohexane Plant
Assignment 3
Financial Analysis of Cyclohexane Plant

3. Purchased Equipment Cost

4. Fixed Capital Investment

5. Fixed Capital Investment

6. Total Product Cost

7. Total Product Cost

8. 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

9. 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

10. Analysis of Profits Based on current prices Return on investment
489%
Pay-out time
57 days
Discounted cash flow rate of return
430%

11. Risk Analysis and Piping Analysis of Cyclohexane Plant
Assignment 4
Risk Analysis and Piping Analysis of Cyclohexane Plant

12. Sensitivity Analysis Strauss plots determined NPW sensitivity
NPW vs. FCI
NPW vs. Product Costs
NPW vs. Product Price

13. Strauss Plot for FCI

14. Strauss Plot for Product Costs

15. Strauss Plot for Product Price

16. 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

17. 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

18. 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

19. Piping Insulation Thickness
Varies from 1 – 1.5 inches
Material: mineral wool
Low thermal conductivity
Standard metal finish to reduce maintenance and heat loss

20. Fixed Capital Investment
New Piping Design System
$3,670,000
Optimized Piping System
$2,890,000

21. Simulation and Fluid Transport
Assignment 5
Simulation and Fluid Transport

22. 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

23. Heat and Material Balances

24. Heat and Material Balances

25. 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)

26. 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

27. 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

28. 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

29. Fixed Capital Investment

30. Design of the Heat Exchanger Network
Assignment 6
Design of the Heat Exchanger Network

31. Cyclohexane Production Unit

32. 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

33. Hand Design Exchanger E1 designed for two cases:
Single-Pass Tubes
Double-Pass Tubes
Equipment cost determined for each design
T-Q Diagram compared

34. 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

35. T-Q Diagram for E1

36. 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

37. 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

38. 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

39. Fixed Capital Investment

40. 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

41. THANK YOU!
Questions?