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

Financial Analysis of Cyclohexane Plant Assignment 3 Financial Analysis of Cyclohexane Plant

Purchased Equipment Cost  

Fixed Capital Investment

Fixed Capital Investment

Total Product Cost

Total Product Cost

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

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

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

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

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

Strauss Plot for FCI

Strauss Plot for Product Costs

Strauss Plot for Product Price

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

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

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

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

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

Simulation and Fluid Transport Assignment 5 Simulation and Fluid Transport

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

Heat and Material Balances

Heat and Material Balances

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)

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 248.413 Head FT 760.313 Work HP 12.5526

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

NPSHA and System Head vs. Flow Rate 1066.00 1067.00 1068.00 1069.00 1070.00 1071.00 1072.00 1073.00 1074.00 100 200 300 400 500 600 700 800 900 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

Fixed Capital Investment

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

Cyclohexane Production Unit

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

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

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 = 0.750 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 = 0.750 in Number = 179 Cost = $20,000

T-Q Diagram for E1

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

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 = 0.750 in Number = 19 Cost of Exchanger E1 = $ 21,715

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

Fixed Capital Investment

Distillation Column Design Pro/II software used Specified: Reflux ratio = 24 Bottom stream = 0.985 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

THANK YOU! Questions?