Home

aspen icarus process evaluator (ipe)

1. i ALL ad AMOUNT OF PROCUREMENT MATERIAL MANHOURS MANPOWER INDIRECTS SUBCONTRACTS CONTRACT K USD K USD 5 K USD K USD E K USD s K USD TOTAL 1 PURCHASED EQUIPMENT 378 6 378 6 19 6 2 EQUIPMENT SETTING 212 6 5 6 5 0 3 3 PIPING 158 0 2893 70 7 228 7 11 8 4 CIVIL 18 8 717 13 9 32 7 5 STEEL 9 6 218 4 4 14 1 0 7 6 INSTRUMENTATION 104 9 1496 39 3 144 2 Pho 7 ELECTRICAL 19 9 380 9 0 28 9 1 29 8 INSULATION E 35 3 1346 28 5 63 9 353 9 PAINT 3 6 398 ES 10 9 0 6 10 OTHER 413 0 74 7 0 0 372 4 860 1 44 4 11 SUBTOTAL 413 0 803 5 7720 179 9 000 B oe 1768 6 91 4 12 SUBCONTRACTS 0 0 0 0 0 0 13 G AND A OVERHEADS 0 0 24 1 5 4 11 2 0 0 40 7 2 1 14 CONTRACT FEE 38 0 28 1 19 4 40 3 0 0 125 8 6 5 15 BASE TOTAL 451000 855 7 2204 5 1935 1 100 0 16 ESCALATION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 17 CONTINGENCIES 81 2 154 0 36 8 76 3 0 0 348 3 18 0 18 TOL 53222000 1009 7 24 4 500 2 2283 4 118 0 NO SUBCONTRACTS COMPONENT LIST IPE 66 PURCHASED ORIGIN ITEM TYPE ITEM EQUIPMENT DESCRIPTION COST USD Equipment mapped from 1 HE 3 HORIZ DRUM 1 acc Shell material A 515 25700 CODE OF ACCOUNT 114 Liquid volume 2350 23 GALLONS TAG NO 1 acc Vessel diameter 5 000 FEET Vessel tangent to tangent length 16 00 FEET Design tem
2. e MCB_IPE Scenario Process View Main Project 4 Miscellaneous Flowsheet Area E Hi E Hz bri il 51 LI a 8 E 3 EM Proje Proce MCB_IPE S When the mapping and sizing are completed it is prudent to check the equipment sizes computed by Aspen IPE especially for major equipment items such as towers large heat exchangers compressors and chemical reactors For the MCB separation process the two towers are of particular interest To view the Aspen IPE result for an equipment item double click on the item of interest in the IPE Main window For the absorber this produces the following results IPE 46 J MCB_IPE Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE A1 tower E Run view Tools Window Help All components Ed EF J Main Project OK Cancel Apply Options Size Evaluate P amp ID Add Delete Pon Trayed tower pert Flowsheet Aree Units E Di tower Component WBS E D1 cond Quoted cost per item USD E D1 cond Currency unit for matl cost D1 reflux pump Number of identical items 1 E D1 overhead split Tr M E D1 bottoms spli
3. Contract structure 0201 Miscellaneous Flowsheet Miscellaneous Flowsheet COMPONENT LIST PROJECT SUMMARY PROJECT DATA SHEET PROJECT SCHEDULE CONTRACT NO 1 PRIME SUMMARIES BY REPORT GRC amp 1 Main Area Equipment mapped from Dl amp Equipment List RB 7 KETTLE Dl reb Tube material CODE OF ACCOUNT Heat transfer area amp Report group cost summary 2 Miscellaneous Flowsheet NO Dl reb Shell material amp Equipment List ype Sn Shell design gauge pressure eport group cost summary Shell design temperature 3 New Item Shell diameter Equipment List Shell length amp Report group cost summary Tube port diameter amp Design data sheets Tube design gauge pressure amp Detailed bulks Tube design temperature Bulk summary groups Tube outside diameter group Tube length extended 20 00 Bulk summary total Total weight 13400 2 Major account summary Units of measure data MATERIAL MAN POW E R L Input stats FRACTION FRACTION Barcharts USD OF PE USD EQUIPMENT amp SETTING 35400 0000 1011 PIPING 14884 4204 10029 CIVIL z 1117 1572 STRUCTURAL STEEL 0 0 INSTRUMENTATION 15974 ELECTRICAL 0 INSULATION 5740 5682 0 5006 oooooooo SUBTOTAL H A TOTAL MATERIAL AND MANPOWER COST 08 97400 INST L For Help press F1 I
4. Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE List Ei Run View Tools Window Help z z 275 All components 27 MCB 5 1 Process View mem User Tag Number Item Description J C Program Files AspenTe Project 2 A1 tower A1 tower TW TRAYED J Additional Project Con fiy Miscellaneous Flowsheet Area Batch DMD Process Al gp Batch Ethyl Lactate Pr Continuous DMD Proc 9 Continuous EtOH Proc H1 H H2 Qo Homework 16 4 Qo IPE PDO RE RD Process 51 PDO SC Process RADFRACQ Bip RADFRACX Bip RADFRACY RADFRACZ amp p Sample Projects Semicontinous EtOH P Semicnntinnienis MMM E Libraries Compo ES Pmje Proce Ready IPE 42 Before mapping the distillation unit D1 the tray efficiency is changed to 0 6 in the Design Criteria Subsequently each of the remaining equipment items is mapped and sized one at a time as described above Note that the unit H1 is too small to be mapped as a floating head heat exchanger Consequently it is necessary to change the default equipment type to a Double pipe heat exchanger which is more appropriate for this application To change the mapping select HE FLOAT HEAD the Current Map List and press the Delete One Mapping button Project
5. Ln3427ofi0029 5 26 PM These steps are repeated when it is desired to change the default utilities for other equipment items in the process Furthermore for most equipment items other specifications can be adjusted using interactive sizing This can be accomplished for condensers reboilers flash drums reflux accumulators storage vessels pumps and compressors Note however that interactive sizing is not possible for reactor vessels For a complete listing of equipment items that can be sized interactively refer to the chapter on Sizing Project Components in the Aspen IPE User s Guide Aspen Icarus Process Evaluator User s Manual Sizing Project Components IPE 39 MONOCHLOROBENZENE SEPARATION PROCESS In this section equipment sizes and costs are estimated for the monochlorobenzene MCB separation process which is discussed in Section 5 4 of the textbook and in the multimedia module on the Wiley web site for this book ASPEN Principles of Flowsheet Simulation Interpretation of Input and Output Sample Problem Beginning with the file MCB bkp which is available in the ASPEN folder on the Wiley web site additional mixture properties are added and the DISTL subroutine used to model the D1 distillation column is replaced with the RADFRAC subroutine The reflux ratio computed using the RADFRAC subroutine is 3 35 as compared with 4 29 computed using the approximate DISTL subroutine Also the stream flow rates
6. PURCHASED ITEM DESIGN DEAN EQUIPMENT ORIGIN ITEM TYPE D 9 CR I P T 0 N COST USD Equipment mapped from DIS GE s 5 CENTRIF Dl reflux pump Casing material cS 4400 CODE OF ACCOUNT 161 Liquid flow rate 37 32 GPM TAG NO Dl reflux pu Fluid head 225 00 FEET Design temperature 254 98 DEG F Speed 3600 00 RPM Driver power 3 000 HP Fluid viscosity 0 267 CPOISE Design gauge pressure 35 30 PSIG Driver type MOTOR Seal type SNGL Total weight 270 LBS ITEM MATERIAL MANPOWE R xxx L M FRACTION FRACTION RATIO USD OF PE USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 4400 1 0000 240 0 0544 10 8 0 054 PIPING 27079 0546176 3 5344 1 2146 2170 0 1 967 CIVIL 190 0 0432 574 0 1305 30 4 3 019 STRUCTURAL STEEL 0 0 0000 0 0 0000 0 000 INSTRUMENTATION 5475 1 2443 2081 0 4729 80 0 380 ELECTRICAL 674 0 1532 1013 0 2302 42 14503 INSULATION 1663 0 3779 1854 0 4213 87 14226 PAINT 87 0 0198 243 0 0553 13 2 244591 SUBTOTAL 15206 3 4560 11349 2 5793 479 0 746 TOTAL MATERIAL AND MANPOWER COST USD 26600 INST L COST PE RATIO 6 045 Equipment mapped from D1 QUOTE EQP T 1 split Number of identical items 0 CODE OF ACCOUNT 100 TAG NO Dl overhead PURCHASED EQUIPMENT COST USD ITEM QUOTE
7. Projects Libraries Compo Eg Pumps Eg Compressors xl Es Heat Exchangers Towers Towers Trayed IP Eg Packed E Trayed Name Tray Efficiency s Configuration Data Type gt S vessels Min s Agitated Max B Storage Eg Horizontal sg Vertical Eg Miscellaneous Eg Configurations Fle a FA Utility Snecifiratinns 7 lt g Ez List Towers Tray Ready To size the absorber column A1 block a tray efficiency of 0 2 or 20 is entered No other changes to the default values are necessary Changes to the Utility Specifications such as the cooling water temperatures are made at this point IPE 41 Mapping Process Simulation Units to Aspen IPE To map a single process unit right click on the selected item on the Aspen IPE Main window and choose Map In the Map dialog box select Map Selected Item s and use Default and Simulator Data as the basis 2 Source Basis Map Selected Item s Last Mapping MapAllItems ptions Size ICARUS Project Component s Review Sizing Selection Auto Map Streams to Lines Cancel Help Press OK to produce the Project Component Map Preview dialog box not shown here Since the Current Map List does not need to be altered select OK to map the unit When the mapping and equipment sizing has been completed the A1 unit has been added to the list of Project Components as shown below 7
8. EQP 8 Di bottoms split Number of identical items 1 0 CODE OF ACCOUNT 100 TAG NO Dl bottoms s Equipment mapped from 1 RB 8 U TUBE Di reb Tube material A 214 29300 CODE OF ACCOUNT 262 Heat transfer area 918 29 SF TAG NO 1 Shell material A285C TEMA type BKU Shell design gauge pressure 68 64 PSIG Shell design temperature 353 02 DEG F Shell diameter 39 00 INCHES Shell length 13 00 FEET Tube port diameter 26 00 INCHES Tube design gauge pressure 110 30 PSIG Tube design temperature 377 80 DEG F Tube outside diameter 1 000 INCHES Tube length extended 20 00 FEET Total weight 9100 LBS ITEM MATERIAL i R x xx x L M FRACTION FRACTION 2 RATIO USD OF PE USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 29300 1 0000 784 0 0267 92 0 027 PIPING 11066 053777904 10526 0 3592 429 0 951 CIVIL 1270 0 0434 1718 0 0586 89 15 352 STRUCTURAL STEEL 0 0 0000 0 0 0000 Qs 0 000 INSTRUMENTATION 15161 0 521234 4 5612 0 1915 2157 3 0 370 ELECTRICAL 0 0 0000 0 0 0000 EC 0 000 INSULATION 5203 0 272767 4 4892 0 1670 231 0 940 PAINT 269 0 0090 649 0 0222 35 2 465 SUBTOTAL 62264 212500 3 24180 0 8253 1031 0 388 TOTAL MATERIAL AND MANPOWER COST USD 86400 INST L COST PE RATIO 2 949 COMPONENT LIST IPE 78 ITEM Lingus Fl flash vessel CODE OF ACCOUNT TAG NO Fl flash Equipment MAE 2 9 CYLINDER mapped from ITEM
9. EQUIPMENT amp SETTING PIPING CIVIL STRUCTURAL STEEL INSTRUMENTATION ELECTRICAL INSULATION PAINT SUBTOTAL 113 ves USD 13100 13120 936 4260 25289 675 4336 399 62115 PURCHASED EQUIPMENT COST USD Shell material A 515 13100 Liquid volume 634 56 GALLONS Vessel diameter 3 000 FEET Vessel tangent to tangent height 12 00 FEET Design temperature 320 00 DEG F Design gauge pressure 35 30 PSIG Application CONT Base material thickness 0 313 INCHES Total weight 2600 LBS eee ee N P O W E Rote eee SSS y FRACTION FRACTION RATIO OF PE USD OF PE MANHOURS USD USD 1 0000 599 0 0457 25 0 046 1 0015 9627 0 7349 394 0 734 0 0714 1401 0 1069 Ta 1 497 0 3252 2133 0 1628 105 0 501 1 9305 4465 0 3408 169 0 0516 455 0 0347 20 0 674 0 3310 4076 0 3111 192 0 940 0 0305 847 0 0646 46 2 120 4 7416 23602 1 8017 1024 0 380 USD 85700 INST L COST PE RATIO 6 542 TOTAL MATERIAL AND MANPOWER COST ITEM ORIGIN ITEM TYPE bog p tE ION PURCHASED EQUIPMENT COST USD Equipment mapped from H1 CODE OF ACCOUNT TAG NO H1 HE 10 JACKETED ITEM EQUIPMENT amp SETTING PIPING CIVIL STRUCTURAL STEEL INSTRUMENTATION ELECTRICAL INSULATION PAINT SUBTOTAL 263 USD 7300 11265 767 0 6429 0 4273 261 30296 Material cS 7300 Heat transf
10. Inch Pound Main Area D1 cond Di cond E Default Miscellaneous Flowsheet Aree D1 cond acc D1 cond B 0 Plant Engineer EJ D1 tower Di reflux pump _ Di reflux pump B 1 PLANT OWNER EJ Di cond Di overhead s D1 overhead split E 2 OWNER HEAD E D1 cond acc Di bottoms split D1 bottoms split E 3 Locat corR EY Di reflux pump Di reb Di reb E 4 NATIONAL COI EJ D1 overhead split B 5 INTERNATIONE EJ D1 bottoms split Tr 3 E D1 reb Projects Libraries ETE Miscellaneous Flowsheet Area Then highlight Main Project right click and press Add Area to produce the Area Information dialog box in which an Area Name e g New Item is entered with its dimensions Here a 50 x 50 area is reserved and used to estimate piping lengths etc This is adequate for most applications Note that the original area for the plant which was named Miscellaneous Flowsheet Area by Aspen IPE is also 50 x 50 by default LZ RADFRACX Scenario Aspen Icarus Process Evaluator 2006 aspenONE List Run View Tools Window Help Da lt lw Z 2 758 gt R U components E RADFRACX Scenario1 Project View Item Description Basis For Capital Costs Main Project Di tower D1 tower Inch Pound QA Main Area 9 Default 3 5 Miscellaneous Flowsheet Aree Q Plant Engineer EJ D1 tower 4 E 1 PLANT OWNER EJ D1 cond d Area Name New Item E
11. 0 0256 92r 0 026 PIPING 34421 0 3989 18020 0 2088 737 0 524 CIVIL 1875 0 02 24 2421 0 0280 126 1 291 STRUCTURAL STEEL 9649 0 1118 4427 0 0513 218 0 459 INSTRUMENTATION 43929 0 5090 20107 0 2330 760 0 458 ELECTRICAL 1903 0 0221 1034 0 0120 45 0 543 INSULATION z 11769 0 1364 9654 0 1119 455 0 820 PAINT 931 0 0108 1948 0 0226 106 2 091 SUBTOTAL 190778 2 2106 59818 0 6931 2539 0 314 TOTAL MATERIAL AND MANPOWER COST USD 250600 INST L COST PE RATIO 2 904 COMPONENT LIST IPE 68 ORIGIN ITEM TYPE TOTSOESM DESCRIPT Equipment mapped from 1 HE 2 FLOAT HEAD 1 CODE OF ACCOUNT TAG NO Dl cond ITEM EQUIPMENT amp SETTING PIPING CIVIL STRUCTURAL STEEL INSTRUMENTATION ELECTRICAL INSULATION PAINT SUBTOTAL TOTAL MATERIAL AND Tube material A 214 261 Number of shells 2 Area per shell 5551 00 SF Shell material A285C TEMA type BES Shell design gauge pressure 258 61 PSIG Shell design temperature 250 00 DEG F Shell diameter 46 00 INCHES Shell length 23 00 FEET Tube design gauge pressure 167 51 PSIG Tube design temperature 250 00 DEG F Tube outside diameter 1 000 INCHES Tube length extended 20 00 FEET Total weight 89400 LBS MA TERIAL MANPOWE R xxxxx L M FRACTION FRACTION RATIO USD OF PE USD OF PE MANHOURS USD USD 179800 1 0000 1760 0 0098 73 0 010 76345 0 4246 21423 0 1191 881 0 281 1474
12. 2_OWNER_HEAD_ EJ D1 cond acc d 3 LOCAL CONTR E D1 reflux pump Area GRADE 7 E 4 NATIONAL COI D1 overhead split B 5 INTERNATIONE E D1 bottoms split Area Dimensions E lt E Di reb Length 50 FEET Projects Libraries Width 50 FEET Height FEET Cancel Help T Pr Pr Ready Press OK and the new area which is named New Item appears on the Project View left window of the IPE Main window IPE 26 RADFRACX Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE List E File Run Tools Window Help PET Sk 2 Al components m n RADFRACX Scenario1 Project View User Tag Number Description Basis for Capital Costs Main Project gt fi D1 tower Di tower Inch Pound 1 QA Area 22 D1 cond D1 cond Default Miscellaneous Flowsheet Aree Di cond acc Di cond acc B 0 Plant Engineer Di tower Di reflux pump Di reflux pump E 1 PLANT OWNER E D1 cond Gs Di overhead s Di overhead split E 2 OWNER HEAD 52 D1 cond Ble Di bottoms split D1 bottoms split 3 LOCAL CONTR D1 reflux pump Di reb Di reb E 4 NATIONAL EJ D1 overhead split B 5 INTERNATIONE D1 bottoms split 4 EJ Di reb QA New Item Projects Libraries Next highlight the New Item area right click and click on Add Project Component to produce the
13. AREA INSTR RUNS TRAYS JBOX 2200 49 1150 3350 AREA EQUIPMENT GROUNDING 209 11 259 468 AREA PILED FOUNDATION 10802 83 1638 12440 Number of piles 14 AREA ELECTRICAL TESTING 0 16 389 389 AREA ROTATING EQP SPARE PARTS 500 0 s 500 IPE 24 These non chargeable items add to 39 743 Together with the Other item on line 10 of the Contract Summary 74 700 and Code of Accounts item 105 for equipment contingencies to allow for design changes 11 100 these sum to approximately 125 543 which is sufficiently close to 137 400 the difference reported above Returning to the Capital Estimate Report material and manpower costs associated with G and A General and Administrative Overheads 24 100 and 5 400 are obtained from line 13 and material and manpower charges associated with Contract Fees 28 100 and 19 400 from line 14 These sum to 77 000 The contractor engineering and indirect costs are in row 15 BASE TOTAL in the first column under DESIGN ENG G AND PROCUREMENT K USD and in the fifth column under CONSTRUCTION INDIRECTS K USD These are Contractor Engineering Costs 451 000 Indirect Costs 423 800 Together with the fees for materials and manpower G and A Overheads and Contract Fees these are added to the total direct installed equipment costs Cpr to give the ZBL Total Bare Module Cost Finally all of the Aspen IPE results can be reproduced using the DEC3 folder in the ASPEN folder on the W
14. Main Area Equipment L Report grou 2 Miscellaneou 8 Equipment L amp Report grouy Design data she Detailed bulks O0RIGIN ITEM Equipment mapped from Dl RB 7 KETTLE Dl reb HII Ill Hl RE I NI fil li CODE OF ACCOUNT TAG NO Dl reb s 7 v e gt el 2 PES CO RX T 2 08 Tube material Heat transfer area Shell material TEMA type Shell design gauge pressure Shell design temperature Shell diameter Shell length Tube port diameter Tube design gauge pressure Tube design tenperature Tube outside diameter Tube length extended Total weight 3579 55 SF A285C BRT 262 00 PSIG 310 80 DEG F 54 00 INCHES 25 00 FEET 36 00 INCHES 169 77 PSIG 331 00 DEG F 1 000 INCHES 20 00 FEET 34300 LBS Bulk summary g Bulk summary tc Major account s Units of measure Input stats Barcharts ITEM DRC MATERIAL FRACTION OF PE 1 0000 0 2239 0 0251 0 0000 0 2346 0 0000 0 0980 HANHPOWEJA T ttree9xe 1 FRACTION RATIO OF PE MANHOURS USD USD 0 0186 52 0 019 0 1517 422 0 677 0 0310 110 1 235 0 0000 0 000 0 0834 219 0 356 0 0000 0 000 0 0890 0 908 H Hl IRE USD 68100 15248 1711 USD 1266 10330 EQUIPMENT amp SETTING PIPING CIVIL gt STRUCTURAL STEEL 0 iE Ti INSTRUMENTATION 15974 ELECTRICAL t 0 INSULATION 6674 PAINT SUBTOTA
15. Towers etc DP OP 1 A 100 B Common Design Pressure Table 1 Design Temperature Table 2 Pumps Design Pressure Table 1 Design Temperature Table 3 Pump Overdesign Factor 1 1 Compressors Design Pressure Table 1 Design Temperature Table 4 Driver Type Motor Heat Exchangers Design Pressure Table 1 Design Temperature Table 3 Apply 2 3 Rule for Design Pressure YES Heat Ex Area Min Overdesign Factor 1 15 Air Cooler Inlet Temperature F 77 Air Cooler Exit Temperature F 120 Plate Fin Launch MUSE No Furnace Fractional Efficiency 0 9 Furnace Fuel Heating Value Btu lb 840 Towers Design Pressure Table 1 Design Temperature Table 3 Vapor Disengagement Height ft 6 Bottom Sump Height ft 8 R R Minimum 1 35 Towers Packed Design Pressure Table 1 Design Temperature Table 3 Packing Type Random Packing Factor for Packings 55 Packed Tower Derating Factor 1 Packed Tower Flooding Factor 0 6 HETP ft 3 Packed Section Height ft 10 Surface Area Per Unit Volume fefe 75 Towers Trayed Design Pressure Table 1 Design Temperature Table 3 Tray Spacing in 24 Trayed Tower Flooding Factor 0 8 Foaming Tendency Moderate Trayed Tower Derating Factor 1 Relative Vol of Key Components 1 5 Tray Efficiency 1 IPE 62 Operating From To A B Pressures psia psia Range 1 0 15 100 15 Range 2 15 50 100 50 Range 3 50 265 0 25 Range 4 265 1015 0 50 Range 5 1015 5 0 Table 2 Design Temp DT Common Items DT OT 1 A 100
16. differ slightly 196 Both of the files MCB IPE bkp and MCB IPE rep are in the ASPEN folder on the Wiley web site Initial Setup After sending the file MCB IPE rep to Aspen Icarus the user is ready to use Aspen IPE Aspen IPE is opened automatically and the Create New Project dialog box appears After the Project Name MCB is entered the Inch Pound IP unit set is selected in the Project Properties dialog box After OK is pressed Aspen IPE loads the information associated with each process model in ASPEN PLUS When completed the IPE Main window appears QP Aspen Icarus Process Evaluator 11 1 MCB Scenario1 List ni x E Run View Tools Window Help 81 xl Dac eje EF MCB Scenario Process View 7 Main Project 2 Miscellaneous Flowsheet 01 8 F1 E 2 R 51 R Ti The project contains 0 Project Components IPE 40 The MCB separation process has two types of columns an absorber and distillation column each having a distinct tray efficiency Absorber efficiencies are normally low at roughly 20 while efficiencies for distillation columns are considerably higher in this case at about 60 This difference must be taken into account when proceeding with Aspen IPE Because Aspen IPE allows only one specification for the tray efficiency it is necessary to map and size each of the column
17. lt gt ER DP p pro EJ Radio El Reboler Pum Note that the design capacity of the Reboiler pump has been adjusted to 756 5 gpm which is 10 percent higher than the flow rate leaving the sump a default specification in the Design Criteria At this point 20 ft is entered to replace the default fluid head of 225 IPE 32 ft 20 ft should be sufficient to convey the bottoms liquid to the reboiler Before leaving this form click OK To obtain the variables for the CP BE stream double click on it Develop Stream Cancel Update Mixture Print Reset To SIM Description Primary Fluid Component Temperature DEG F Pressure PSIA Molecular Weight Total Mass Flow LBH LIQUID INFORMATION Liquid Mass Flow LBH Liquid Mass Density PCF Liquid Specific Heat Capacity BTU LB DEG F 0 630514 Liquid Conductivity BTUHFTDEG F 0 049712 Liquid Viscosity CPOISE 0 000002 Surface Tension DYNES CM 8 216044 VAPOR INFORMATION Vapor Mass Flow LBH Vapor Mass Density PCF Vapor Specific Heat Capacity BTULBIDEGF Conductivitv BTUHFT DEG F Observe that 756 5 gpm is 10 percent higher than 687 74 gpm which is equivalent to the mass flow rate 160 645 Ib hr When the effluent stream 2 is clicked on the stream report does not display the stream properties because the stream has been referenced to the ICP BE stream This procedure is repeated to add other equipment
18. to be included in the design and cost estimates Typically these include a new control system and electrical substation components Under Project Type click on the Value field to produce a pulldown menu that displays the options Grass Roots Clear field Plant addition adjacent to existing plant Plant additions inside existing plant Plant addition suppressed infrastructure Plant modification Revamp While guidelines are not provided concerning the selection of Project Type costs can be computed for each option if desired Through examination of the results the default values and items included or omitted can be observed When selecting Plant addition suppressed infrastructure items involving the new control system electrical switchgear and transformers are not provided These are not needed for the addition of the depropanizer column to an existing process Note that in some older versions of Aspen IPE the Estimated Start Day of Engineering or Month or Year may have a null default value in the General Specs form Unless a finite value is entered an error message results when the process units are evaluated that is when purchase and installation costs are estimated IPE 18 Equipment Costing Aspen IPE estimates the purchase and installed cost of each equipment item individually or provides estimates for all of the equipment items 1 the entire project using a single command For an individual unit
19. 0 0082 1904 0 0106 99 1 292 0 0 0000 0 0 0000 0 0 000 11546 0 0642 3342 0 0186 129 0 289 0 0 0000 0 0 0000 0 0 000 14567 0 0810 10748 0 0598 506 0 738 984 0 0055 2238 0 0124 121 2 274 284716 1525835 41415 0 2303 1809 0 145 MANPOWER COST USD 326100 INST L COST PE RATIO 1 814 PURCHASED EQUIPMENT COST USD 179800 IPE 69 AREA BULK ORT TOTAL AREA AREA AREA AREA AREA AREA MISC CONCRETE ITEMS PIPE TESTING UNPAVED AREA Area length Area width INSTRUMENT TESTING INSTR RUNS TRAYS JBOX EQUIPMENT GROUNDING PILED FOUNDATION Number of piles ELECTRICAL TESTING ROTATING EQP SPARE PARTS IPE 70 743 8552 50 000 FEET 50 000 FEET 2200 209 10802 14 500 95 49 11 83 16 2718 5112 2997 2474 1150 259 1638 389 2474 3350 468 12440 389 500 Depropanizer With the Reboiler Pump see DEC3RP Folder G OCN OT Ry T T S UM M AR Y PRIME CONTRACTOR CONTRACT NO 1 DESIGN CONSTRUCTION MISC AND PERCENT NO ITEM ENG G AND ALL AMOUNT OF PROCUREMENT MATERIAL MANHOURS MANPOWER INDIRECTS SUBCONTRACTS CONTRACT K USD K USD K USD K USD E K USD K USD TOTAL 1 PURCHASED EQUIPMENT 353 8 353 8 17 6 2 EQUIPMENT SETTING d 284 6 8 6 8 0 3 3 PIPING 174
20. 6 EJ D1 reflux pump 225 F 250 PSI 2 494283 15723 D1 overhead split 249 DEG F 252 PSI 0 000000 0 00001 EJ D1 bottoms split 115 DEG F 248 PSI 0 000000 PCF 0 00001 E Di reb 115 DEG F 248 PSI 0 000000 0 00001 115 DEG F 248 PSI 1 137118 PCF 9615 6 281 DEG F 50 PSIA 281 DEG F 50 PSIA 0 117141 PCF 12023 95 DEG F 50 PSIA 75 DEG F 50 PSIA l v ES Proje Proce Proje E List PADFRACY E Process Ste Ready Finally the PE Block Flow Diagram shows the simulation flowsheet It is displayed using the View pulldown menu and clicking on Block Flow Diagram to give IPE 13 compressors and chemical reactors Flow Diagram 3 Run View Tools Window Help amp P lt 9 2 iQ e mu IT components RADFRACY Scenario1 Project View Bp Main Project 04 Area Miscellaneous Flowsheet Area E D1 tower E D1 cond Dy D1 cond acc E D1 reflux pump EJ D1 overhead split D1 bottoms split E D1 reb Ee Proje Proce Proje 83 RADFRACY Process Str E RADFRACY Mapping Results After Aspen IPE has mapped and sized the equipment items it is prudent to check the results especially for major equipment items such as towers These items are usually very expensive and consequently it is a good practice to estimate equipment sizes independently
21. 6195 2408 3 1 967 CIVIL 176 O 0533201 547 0 1659 28 31115 STRUCTURAL STEEL 0 0 0000 0 0 0000 0 0 000 INSTRUMENTATION 5475 1 6591 2081 0 6305 80 0 380 ELECTRICAL 674 0 2042 1013 0 3069 42 1 503 INSULATION 1621 0 4912 1817 0 5507 86 allen PAINT 87 0 0264 243 0 0738 13 222192 SUBTOTAL 14050 4 2576 11286 3 4199 476 0 803 TOTAL MATERIAL AND MANPOWER COST USD 25300 INST L COST PE RATIO 7 667 IPE 80 PURCHASED EQUIPMENT COST USD ORIGIN ITEM TYPE E S C R I P T I O AN aa QUOTE EQP 19 Number of identical items 1 0 CODE OF ACCOUNT 100 TAG NO 1 IPE 81 ORIGIN AREA AREA AREA AREA AREA AREA ITEM SYMBOL MISC CONCRETE ITEMS PIPE TESTING UNPAVED AREA Area length Area width INSTRUMENT TESTING INSTR RUNS TRAYS JBOX EQUIPMENT GROUNDING PILED FOUNDATION Number of piles ELECTRICAL TESTING ROTATING EQP SPARE PARTS BULK IPE 82 REPORT MATERIAL COST USD 918 8552 50 000 FEET 50 000 FEET 4132 419 16974 22 540 127 179 81 23 131 22 4672 1943 519 2575 548 4672 6075 938 19549 548 540
22. B Operating From To A B Temps CB CF Range 1 0 15 100 15 Range 2 15 50 100 50 Range 3 50 265 0 25 Range 4 265 1015 0 50 Range 5 1015 3 0 Table 3 Design Temp DT Pumps Heat Exch s Towers etc DT OT 1 A 100 B Operating From To A B Temps CE CCP CF Range 1 459 7 32 0 50 Range 2 32 70 100 70 Range 3 70 200 100 250 Range 4 200 600 0 50 Range 5 600 0 50 Table 4 Design Temp DT Compressors DT OT 1 A 100 B Operating From To A B Temps F F F Range 1 459 7 32 0 0 Range 2 32 70 0 0 Range 3 70 200 0 0 Range 4 200 600 0 0 Range 5 600 0 0 OT Operating Temperature OP Operating Pressure IPE 63 Name Unit Item Towers Configurations Precooler Outlet Fluid Temperature Process Fluid Condensation Temperature F Ratio of Recycle to Ovhdliqprod Reflux 10 SC Trim Splitter Flow Split Ratio 0 2 Ratio of SC Trim Duty to Overall Duty 0 1 Ratio of Precooler Duty to Overall Duty 0 5 Vessels Design Pressure Table 1 Design Temperature Table 3 Residence Time min 5 Process Vessel Height to Diameter Ratio 3 Minimum Vessel Diameter ft 3 Vapor Liquid Separator Sizing Method Liquid Entrainment Model Average Liquid Particle Diameter in 0 15 Design Factor Multiplier for Disengagement Velocity 0 5 Separation Factor Vessels Agitated Design Pressure Table 1 Design Temperature Table 3 Minimum Disengagement Height ft 4 Residence Time min 5 Agitator Type Mech Seal Vessels Storage Design Pressure Tabl
23. Evaluator 2006 aspenONE Global DESIGN E File Run View Tools Window Help m x lt All components six 8 Project Basis e J C Program Files AspenTech B Project Properties OK Cancel Additional Project Compor Eg General Project Data DEC3 C Basis for Capital Costs DEC3 B Name 1 Eg Output Reports Unit ij DEC3B s General Specs EONNTIONS RADFRAC ff Currency Design Pressure Click 9 4 Sample Projects Construction Design Temperature Click Here gt Toms New Test tg General Rates Eg Craft Rates 20 Indexing Eg Material 5 Man hour Es Location J Process Design Eg Simulator 29 Simulator File Name cg Simulator Units of Eg Project Component M sJ Design Criteria Common lt lv Projects Libraries Compo Pumps Compressors Heat Exchangers Towers Packed Eg Trayed Es Configuration Vessels Eg Agitated Eg Storage Eg Horizontal Eg vertical Miscellaneous Configurations Fle F gt lt 7 PPro E Lit Global De Ready D B WE lt Default values are provided for many of the entries in the forms under Design Criteria These can be modified as necessary and missing entries
24. FEET Vessel tangent to tangent height 42 00 FEET Design temperature 301 04 DEG F Design gauge pressure 35 30 PSIG Application DISTIL Tray type SIEVE Tray spacing 24 00 INCHES Tray material A285C Tray thickness 0 188 INCHES Base material thickness 0 438 INCHES Total weight 6100 LBS MATERIAL i MANPOWE xxxx L M FRACTION FRACTION RATIO USD OF PE USD OF MANHOURS USD USD 25700 1 0000 599 0 0233 25 i 0 023 11368 0 4423 16244 0 6321 660 1 429 1082 0 0421 1626 0 0633 84 1 503 6200 0 2413 2436 0 0948 120 3 0 393 39952 1 5546 20107 0 7824 760 0 503 1307 0 0509 791 0 0308 34 0 605 5684 0 2212 5573 0 2169 262 0 980 511 0 0199 1149 0 0447 62 2 250 91806 3451722 48525 1 8881 2007 0 529 MANPOWER COST USD 140300 INST L COST PE RATIO 5 459 RIAL AND ORIGIN ITEM TYPE ITEM DESCRIPTION PURCHASED EQUIPMENT COST USD Equipment mapped from 1 TW 2 TRAYED 1 Shell material A 515 72500 CODE OF ACCOUNT 111 Number of trays 30 TAG NO Dl tower Vessel diameter 3 000 FEET Vessel tangent to tangent height 72 00 FEET Design temperature 353 02 DEG F Design gauge pressure 35 30 PSIG Application DISTIL Tray type SIEVE Tray spacing 24 00 INCHES Tray material A285C Tray thickness 0 188 INCHES Base material thickness 0 500 INCHES Total weight 23700 LBS ITEM MATERIAL i oo x x L M FRACTION FRACTION RATIO USD OF PE
25. Heat exchangers heaters RB FU Heat exchanger Air cooler free standing or rack mounted Fixed tube sheet shell and tube exchanger Floating head shell and tube exchanger U Tube shell and tube exchanger TEMA shell and tube exchanger Pre engineered standard U tube exchanger Electric immersion tank heater Bare pipe immersion coil heating cooling Double pipe heat exchanger Finned double pipe heat exchanger Cross bore all graphite heat exchanger Thermascrew Reitz single screw conveyor Tec lente 31 k errele mse Cancel Select Help After these steps are completed the Current Map List is modified in the Project Component Map Preview dialog box Project Component Map Preview Simulator Information Component Map Information Simulator Items Configuration Component Name OO umawa Current Map List New Mapping Delete One Mapping Delete ll Mappings ICARUS Project Component Description Process equipment Heat exchangers heaters RB FU Heat exchanger Double pipe heat exchanger r Instructions Select desired simulator information Press New Mapping to create new ICARUS project components corresponding to the simulator selection To remove mappings use a Delete OK Cancel Help Note that when the sizing calculations are being carried out for the flash vessel F1 two Message dialog boxes appear The first indicates that the diameter is calculated to be 2 007 ft but that the
26. IRADFRACX Scenario1 Project View Main Project Stage temperature F 04 Main Area units Miscellaneous Flowsheet Aree E D1 tower Stage vapor flow D1 STAGE VAPOR Di cond rates FLOW RATES EJ D1 cond Di reflux pump Top stage liquid flow 2006 29291 LBMOL HR D1 overhead split Top stage vapor flow 226 LBMOL HR b li 277 Tray duty Di TRAY DUTY Sizing Data Duty 11585411 BTUH Raw surface area 9652 31544 SF 5 0 0003 DEG Shell side fouling resistance F BIU Shell side heat transfer 264 550265 BTU H SF DEG coefficient F Side for hot stream Shell Temperature correction factor 0 635071607 0 001 DEG Tube side fouling resistance EBTU Tube side heat transfer 1052 63158 BTU H SF DEG coefficient F Ua 143548447 BTU H DEG F lt gt Pr 7 Pr Sp Pro Ready El L 4 IPP Note that only a small portion of the Report is shown above The raw surface area 9 652 ft is quite large because the log mean temperature difference 12 7 F not shown above is relatively small This is related to the condenser pressure which was set at 248 psia At this pressure the distillate enters the condenser at 125 F and leaves as a saturated vapor at 115 F Using cooling water heated from 90 to 120 F the small log mean temperature difference is obtained It might be preferable to increase the column pressure to increase the log
27. PROCUREMENT MATERIAL MANHOURS MANPOWER INDIRECTS SUBCONTRACTS CONTRACT K USD K USD K USD K USD K USD K USD TOTAL 1 PURCHASED EQUIPMENT R 206 7 Ed 206 7 9 2 2 EQUIPMENT SETTING gt 339 8 1 gt 8 1 0 4 3 PIPING 112 8 4432 108 6 221 4 9 8 4 CIVIL 26 5 987 19 1 45 6 2 0 5 STEEL 21 3 438 8 9 30 2 13 6 INSTRUMENTATION 182 8 2815 74 0 256 8 11 4 7 ELECTRICAL 23 4 507 12 0 35 4 1 6 8 INSULATION 45 9 2011 42 7 k 88 6 3 9 9 PAINT 3 2 397 223 10 6 0 5 10 OTHER 602 9 63 8 0 0 482 3 1149 0 51 0 11 SUBTOTAL 666 3 11926 280 9 48 3 E rM 2052 4 914 12 SUBCONTRACTS s 0 0 0 0 0 0 13 G AND A OVERHEADS 0 0 20 6 8 4 14 5 0 0 43 5 19 14 CONTRACT FEE 51 2 26 2 28 9 49 7 0 0 156 0 6 9 15 BASE TOTAL 733 1 32 54654 2251 9 100 0 16 ESCALATION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 17 CONTINGENCIES 117 7 132 0 57 3 98 4 0 0 405 3 18 0 18 65 0 x 355 2657 3 118 0 NO SUBCONTRACTS IPE 75 ORIGIN ITEM TYPE Equipment mapped from 1 TW 1 TRAYED Al tower ITEM DE S C R IP TION CODE OF ACCOUNT TAG NO ITEM EQUIPMENT amp PIPING CIVIL STRUCTURAL INSTRUMENT ELECTRICAL INSULATION PAINT SUBTOTAL TOTAL MATE Al tower SETTING STEEL ATION PURCHASED EQUIPMENT Shell material A 515 25700 111 Number of trays 15 1 diameter 1 500
28. SUBCONTRACTS K USD K USD PURCHASED EQUIPMENT EQUIPMENT SETTING PIPING CIVIL STEEL INSTRUMENTATION ELECTRICAL INSULATION PAINT SUBTOTAL SUBCONTRACTS G AND OVERHEADS CONTRACT FEE BASE TOTAL ESCALATION CONTINGENCIES DESIGN ENG G AND PROCUREMENT MATERIAL K USD K USD s 378 6 158 0 18 8 9 6 104 9 19 9 35 3 3 6 413 0 74 7 413 0 0 0 24 1 38 0 28 1 855 7 0 0 0 0 81 2 154 0 92 2 1009 7 2893 717 1496 380 1346 398 NO SUBCONTRACTS INS NUM 1094 of 9126 Note that the entry for the purchased equipment 378 600 from line 1 is approximately the sum of the entries for the pieces of equipment provided above 367 000 The difference is due to the Misc Item Allowance 11 100 and the Warehouse Spares 500 These additional items are in Code of Accounts 105 and 107 and appear in the Code of Accounts Summary section of the Capital Estimate Report just below the Contract Summary The total direct material and manpower costs for construction of the plant are 803 500 and 179 700 as shown in line 11 These sum to 983 200 and include items that cannot be charged to the individual equipment items e g charges for instrument testing pipe testing and equipment grounding equipment items are displayed on the List View IPE 23 Note that the installed costs of the 5 10 PM 7 DEC3 Scenario
29. The blank fields for Capacity Head and Pump Efficiency indicate that the pump has not been previously sized When OK is pressed Aspen IPE sizes the pump When finished double click on the pump icon to display the component specification form P RadFrac New Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE Reboiler Pump il Run View Tools Window Help cT uk 9 A U All components zx RadFrac New Scenariol Project V B 4 gG j Main Project OK Cancel Options Size Evaluate Main Area Reboller Pump Centrifugal single or mult stage pump ili Miscellaneous Flowsheet Arez ener T D1 tower Bora E D1 cond D1 reflux pump EJ D1 overhead split component T 7 gt Quoted costpertem USD Reboiler Pump Currency unit for matl cost QA Number of identical items Casing material cs m Fludhead 0 FEET Speed RPM Fluid specific gravity 0486474453 Driver power W Driver type MOTOR Seal type SNGL Design gauge pressure PSIG 261 996308 Design temperature 298 989543 Fluid viscosity CPOISE 0 000002 Pump efficiency PERCENT 70 Steam gauge pressure PSIG 400 Primary seal pipe plan Secondary seal pipe plan Cooling water pipe plan Pipe plan pipe type ELD zl Pipe plan material type zi lt y
30. USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 7100 1 0000 618 0 0870 26 3 0 087 PIPING 10899 125351 i 5131 0 7227 21007 0 471 CIVIL BLD 0 0444 796 0 1121 41 2 528 STRUCTURAL STEEL 0 0 0000 0 0 0000 0 0 000 INSTRUMENTATION 7051 0 9931 2081 0 2931 80 0 295 ELECTRICAL 679 0 0957 4 1102955 0 1430 42 1 494 INSULATION 2310 023253 2089 0 2942 98 0 904 PAINT 176 0 0248 411 0 0579 22 2 936 SUBTOTAL 28530 4 0184 12141 1 7100 519 3 0 426 TOTAL MATERIAL AND MANPOWER COST USD 40700 INST L COST PE RATIO 5 732 Equipment mapped from 1 QUOTE EQP 5 Dl overhead split Number of identical items 1 0 CODE OF ACCOUNT 100 TAG NO Dl overhead COMPONENT L IST IPE 67 PURCHASED ORIGIN ITEM TYPE EQUIPMENT DESCRIPTION COST USD Equipment mapped from 1 QUOTE EQP 6 Dl bottoms split Number of identical items js 0 CODE OF ACCOUNT 100 TAG NO Dl bottoms 5 Equipment mapped from 1 RB 7 KETTLE Di reb Tube material A 214 68100 CODE OF ACCOUNT 262 Heat transfer area 3579 55 SF TAG NO 1 Shell material A285C TEMA type BKT Shell design gauge pressure 262 00 PSIG Shell design temperature 310 80 DEG F Shell diameter 54 00 INCHES Shell length 25 00 FEET Tube port diameter 36 00 INCHES Tube design gauge pressure 169 77 PSIG Tube design temperature 331 00 DEG F Tube outside diameter 1 000 INCHES Tube length extended 20 00 F
31. can be entered Particular attention should be paid to the design pressure and temperature to the overdesign factors to the residence times in the process vessels as well as to other tower information The user must be careful to check all of the relevant specifications that apply to the equipment under study Note that the design criteria are defined in the Aspen IPE User s Guide which can be accessed from the Documents entry in the Help menu in Aspen IPE with the values specified for the depropanizer process shown in Appendix II Defining the Project Basis Process Design Design Criteria Note also that design criteria files can be created for use with other design projects For implementation details see the Aspen IPE User s Guide Also it is usually important to examine the default values associated with the utilities For this purpose the Utility Specifications entry under the Process Design heading is selected to produce the Develop Utility Specifications dialog box IPE 5 Cooling Water V High Temp Heating 01 Low Temp Heating Dil Refrigerant Ethane Low Temp Hot il Refrigerant Ethylene Refrigerant Ethane Refrigerant Freon12 Refrigerant Ethylene 7 Pron Refrigerant Freon 12 efriaerant Pro Refrigerant Propane sient dean Dreate Note that all existing utilities to be used by Aspen IPE are listed Default values should be examined and modified and missing u
32. for comparison with the Aspen IPE results To view the Aspen IPE results for an equipment item double click on the item on the IPE Workbook window or on its icon in the Process For example the following component specification form which contains some of the sizing results is obtained for the depropanizer tower J DEC3 5 1 Aspen Icarus Process Evaluator 2006 aspenONE D1 tower Ed File Run Tools Window Help Deh uk ose All components DEC3 Scenario1 Project View Bg B o d A E CJ C Program FileslAspenTechl Main Project Cancel Apply Options Size Evaluate P amp ID Add Delete Additional Project Compor Main Area D1 tower Trayed tower DECS i BB Miscellaneous Flowsheet Aree ame Uni 1 G Sample Projects D1 tower E _ D1 cond Item Reference Humber 1 By D1 cond acc Remarks 1 Equipment mapped from D1 EJ D1 reflux pump Remarks 2 m 4 EJ D1 overhead split Item description User tag number Di ower Stucturetag 3 E Component WES Quoted cost per item USD Number of identical items Tray type SIEVE Shell material Vessel diameter mr 221 D1 tower Trayed tower Vesseltangenttotangentheignt Feet Design gauge pressure PSIG 262 304 meme Vacuum desig
33. low and intermediate strength Material codes alloy types and maximum service temperatures are tabulated in the chapter on Material Selections in the ICARUS Reference Manual choose the Documentation option in the Help menu in Aspen IPE and follow the link for carus Reference Furthermore the effect of material on size and cost can be determined easily In some cases a high strength alloy that is more expensive per pound may have thinner walls and be less expensive than a low strength material that is less expensive per pound Changes can be made to any of the equipment sizes computed by Aspen IPE or to the default values used by Aspen IPE Note that the default values are displayed in blue As changes are made dependent results are adjusted by Aspen IPE A more detailed report can be obtained in two ways First right click on the equipment item in the Process Flow Diagram and select Report in the menu that appears Alternatively right click on the equipment item in the Project View of the Project Explorer in the Main window or in the List View and select Report in the menu that appears These steps produce the Report a portion of which is illustrated here for the condenser IPE 15 RADFRACX Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE TEMP IRP HTM Eile Run View Tools Window Help Deb amp a lt f uk amp gt AU components x
34. mean temperature difference and reduce the condenser area However at a higher pressure the separation would become somewhat more difficult resulting in more trays Note that Aspen IPE can easily compare the capital costs at various pressures Note also that Aspen IPE used two floating head shell and tube heat exchanger in parallel for condensing the overhead vapor Each condenser has two tube passes with a temperature correction factor Fr in Eq 18 7 of 0 635 The number of tube and shell passes for each exchanger can be seen on the report produced by double clicking on the condenser in the IPE Workbook window or on the condenser icon in the Process Flow Diagram It might be possible to improve the condenser design by re sizing the unit with different numbers of shell and tube passes to give a correction factor close to unity IPE 16 Standard Basis Six standard basis profiles are available within Aspen IPE for estimating the capital cost These model the nature of the contractor to execute the project depending on the size of the project as shown below Three of the profiles are for projects to be executed by an Owner company 0 1 and 2 and the other three are for projects to be executed by Engineering and Construction firms 3 4 and 5 For the small depropanizer project of this example the LOCAL CONTRACTOR is appropriate J Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE List E amp B lt
35. right click on the unit in the List View and select Evaluate Item Aspen IPE produces a detailed item report for the unit For the depropanizer tower by scrolling about a third of the way down the report the following summary of the cost estimates appears 8 Run View Tools Window Help De amp ET ui gt All components M RADFRACX Scenario1 Process Vie Shop labor cost 17190 USD Main Project fg Miscellaneous Flowsheet Aree Shop overhead cost 17753 USD Bo Office overhead cost 10910 USD Profit 11218 USD Total cost 86300 USD Cost per unit weight 2 7224 USD LBS Cost per tray 5753 USD Cost per unit height or length 2054 USD FT Summary Costs Equipment amp Setting 86300 2208 Piping 34421 18020 737 Civil 1875 2421 126 Structural Steel 9649 4427 218 Instrumentation 43929 20107 760 Electrical 1903 1034 45 Insulation 11769 9654 455 Paint 931 1948 106 Subtotal 190777 59819 2539 Total material and manpower cost USD 250600 lt EJ Lit TEMP IRP Observe that the tower designed by Aspen IPE has a Purchased Equipment and Setting Cost of 86 300 and an Installed Direct Cost of 250 600 which includes the cost of the tower and setting it in place on its foundation civil At this point the designer can observe the effects of modifications in the design specifications on these costs for the unit Be aware that the Total Material and Manpower Cost is the co
36. shown in Appendix I and in the multimedia tutorial on the Wiley web site associated with this book ASPEN Tutorials Separation Principles Flash and Distillation Initial Setup Having sent the ASPEN PLUS simulation file to Aspen IPE it is opened automatically and the Create New Project dialog box appears IPE 3 Create New Project 21 C Program Files AspenTech 4spe 6 Additional Project Components Batch DMD Process DK 4p Batch Ethyl Lactate Process Continuous DMD Process Cancel Qo Continuous EtOH Process Qo foot 4p Homework_16_4 Import PDO RE RD Process PDO SC Process Help 4p RADFRACX 4p Sample Projects J 4p Semicontinous EtOH Process 3 Cl V lt Project Name RADFRAC IPE Scenario Name Scenariol The user can either select an existing project in which to start a new scenario or enter a new Project Name The Project Name RADFRAC IPE is assigned automatically from the ASPEN PLUS file name however punctuation marks are not allowed so enter the Project Name DEC3 instead Note that the underscore and space characters are permitted After pressing the OK button the first of four dialog boxes not shown here appear The first is the Project Properties dialog box in which a Project Description and further remarks may be entered A units of measure set is also chosen which for this example is the Inch Pound IP units set Seco
37. turbine impeller Low consistency stock pump Pb mre deed AMICI oo mo abio odose s soom Cancel Select Help After the OK button is pressed the pump specification form is displayed J RadFrac New Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE Reboiler Pump DEAR Ej Run view Tools Window Help Da 8 21898 e U All components SSF RadFrac New Scenario1 Project V amp g ae E Main Project OK Cancel Apply Options Size Evaluate P amp ID QA Main Area Pune ae B Miscellaneous Flowsheet Arez E D1 tower E D1 cond E D1 cond EJ D1 reflux pump EJ D1 overhead split E D1 bottoms split E Di reb newitem IE Reboiler Pump 29 Note that the specifications are incomplete because the Reboiler pump has not been connected into the main process which resides in the Miscellaneous Flowsheet Area as shown in the IPE Process Flow Diagram 9 DEC3 REBOILERPUMP Scenario Aspen Icarus Process Evaluator 2006 aspenONE DEC3_REBOILERPUMP Scenario1 Process Flow Diagram File Run View Tools Window Help ae x 5 lt 15 v amp components zixl DEC3_REBOILERPUMP Scenario1 F Main Project Qi Main Area E B Miscellaneous Flowsheet Arez D1 tower EJ D1 cond EJ D1 cond EJ D1 reflux pump EJ D1 ov
38. user specified minimum value of 3 ft is used instead The second indicates that the L D ratio is 1 67 rather than 3 0 from the Design Criteria Also for the heat exchanger a l degree difference between the inlet and outlet IPE 44 temperatures of the hot stream is assumed The unit 1 is a mixing junction between two pipes and the unit S1 is a simple pipeline splitter Size and cost estimates are not needed for these units The unit 1 represents a treater which is not being considered at this point in the design of the MCB separation process Aspen IPE maps the mixer 1 and splitter S1 as Quoted Items with zero cost The default mapping for the treater T1 is a VT CYLINDER with size and cost estimates computed This default mapping is replaced with a Quoted Item having zero cost To accomplish this delete the mapping for In the Project View right click on then on Map On the Map dialog box click on OK to produce the Project Component Map Preview dialog box Delete the VT CYLINDER mapping and click on New Mapping to produce the CARUS Project Component Selection dialog box Click on Project Components select Quoted equipment and click OK This places the unit T1 into the List View with a C to indicate that it is a Quoted Item having zero cost After all of the equipment items have been mapped and sized successfully the IPE Main window is displayed Scenario1 Aspen Icarus Process Evaluator 200
39. 04 DEG F Report grc Design gauge pressure 35 30 PSIG Design data st rp renon a ray type Detailed bulks Tray spacing 24 00 INCHES Bulk summary Tray material 285 Bulk summary Tray thickness 0 188 INCHES Major account Base material thickness 0 438 INCHES Total weight 6100 LBS Input stats Barcharts ITEM 1 MATERIAL M A N P O V E tttttexII FRACTION FRACTION RATIO USD OF PE USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 25700 1 0000 599 0 0233 25 0 023 PIPING 11368 0 4423 16244 0 6321 660 1 429 CIVIL 1082 0 0421 1626 0 0633 84 1 503 STRUCTURAL STEEL 6200 0 2413 2436 0 0948 120 0 393 INSTRUMENTATION 39952 1 5546 20107 0 7824 760 0 503 ELECTRICAL E 1307 0 0509 791 0 0308 34 0 605 INSULATION 2 5684 0 2212 5573 0 2169 262 0 980 PAINT 511 0 0199 1149 0 0447 62 2 250 SUBTOTAL 91806 3 5722 48525 1 8881 2007 0 529 TOTAL MATERIAL AND MANPOWER COST USD 140300 INST L COST PE RATIO 5 459 lt For Help press F1 INS NUM 1 of 12161 4 29 PM In summary the equipment sizes purchase costs and total material and manpower cost for the MCB separation process are tabulated below 1 Note that changing to a 6 or 7 point font is more suitable for printing IPE 49 Simulation Unit Equipment Item Size Pl Pump 1 5 Hp Al Tower 1 5 ft diam 42 ft height D1 Tower 3 0 ft diam 72 ft height 3 0 Hp 9
40. 1 Aspen Icarus Process Evaluator 2006 aspenONE List DEAR Ez File Run View Tools Window Help X ep 6 lt mix 21785 A U fan components iz xd DEC3 5 1 Project View Main Project D1 tower D1 tower TW TRAYED 86300 250600 Main Area D1 cond D1 cond HE FLOAT HEAD 179800 326100 Miscellaneous Flowsheet Arez D1 cond acc D1 cond acc HT HORIZ DRUM 25700 94200 D1 tower D1 reflux pump D1 reflux pump CP CENTRIF EY D1 cond Di overheads Di overhead split D1 cond acc Di bottoms split Di bottomssplit EJ D1 reflux pump D1 reb D1 reb RB KETTLE D1 overhead split D1 bottoms split EJ D1 reb EP 7 Pr Pro Ready The installed costs shown in the Direct Cost column sum to 845 800 that is 137 400 less than the total direct cost of materials and manpower for installation of the plant 983 200 This Installed Direct Cost is referred to in Chapter 22 of the textbook as the Total Direct Materials and Labor Cost Finally the materials and manpower items that are not chargeable to the individual equipment items are displayed in the Area Bulk Report within the Capital Estimate Report AREA BULK REPORT MATERIAL COST USD DIRECT AREA MISC CONCRETE ITEMS AREA PIPE TESTING 0 204 5112 5112 GRADE UNPAVED AREA 8552 127 2997 11549 Area length 50 000 FEET Area width 50 000 FEET AREA INSTRUMENT TESTING 95 2474 2474
41. 1 3154 714 251 2 12 5 4 CIVIL 18 4 712 13 8 32 1 1 6 5 STEEL 9 6 218 4 4 14 1 0 7 6 INSTRUMENTATION 112 0 1581 41 5 153 5 7 6 7 ELECTRICAL 29 2 565 13 4 42 5 2 1 8 INSULATION 37 6 1409 29 9 67 5 3 4 9 PAINT 3 8 428 7 9 T1331 0 6 10 OTHER 445 3 75 7 0 0 385 4 906 4 45 0 11 SUBTOTAL 44532000 842 194 8 22 7 1839 0 91 4 12 SUBCONTRACTS c 0 0 0 0 0 0 13 G AND A OVERHEADS 0 0 24 4 5 8 Td 56 0 0 41 8 2 1 14 CONTRACT FEE 40 1 28 5 20 9 41 3 0 0 130 7 6 5 15 BASE TOTAL 4854 4 00 867 1 2215 438 2 00000 2012 3 100 0 16 ESCALATION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 17 CONTINGENCIES 87 4 156 1 39 9 78 9 0 0 362 2 18 0 18 TOL 8270000 1023 2 Cms 2374 5 118 0 NO SUBCONTRACTS IPE 71 ORIGIN ITEM TYPE 8 CENTRIF ITEM morc DESIGN DAT A EQUIPMENT DE S CRIT TI ON COST USD Reboiler Pump Casing material CS 8100 CODE OF ACCOUNT 161 Liquid flow rate 756 52 GPM Fluid head 20 00 FEET Design temperature 298 99 DEG F Speed 3600 00 RPM Driver power 3 000 HP Fluid viscosity 0 00000200 CPOISE Design gauge pressure 262 00 PSIG Driver type MOTOR Seal type SNGL Total weight 630 LBS ITEM MATERIAL MANPOWE R xxxx L M FRACTION FRACTION RATIO 2 USD OF PE USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 8100 1 0000 542 0 0669 28 22 0 067 PIPING 16439 2 0295 6255 0 7722
42. 100 The contractor engineering and indirect costs are in row 15 BASE TOTAL in the first column under DESIGN AND PROCUREMENT K USD and in the fifth COLUMN under CONSTRUCTION INDIRECTS K USD These are Contractor Engineering Costs 654 100 Indirect Costs 546 400 Together with the fees for materials and manpower G and A Overheads and Contract Fees these are added to the total direct installed equipment costs to give the JBL Total Bare Module Cost Finally all of the Aspen IPE results can be reproduced using the MCB folder in the ASPEN folder on the Wiley web site for this book from within Aspen IPE Total Permanent Investment The total permanent investment is computed by the spreadsheet Profitability Analysis 2 0 xls discussed in Section 23 8 of the textbook When using the Aspen IPE option the user enters IPE 52 Total Direct Materials and Labor Costs 828 800 Material and Labor G amp A Overhead and Contractor Fees 84 100 Contractor Engineering Costs 654 100 Indirect Costs 546 400 IPE 53 ASPEN IPE FOLDERS AND FILES When a new project is created within Aspen IPE a folder having the project name e g DEC3 is created in the Wrogram FilesVAspenTechMAspen Icarus 2006 ic_cache Projects YourProjectName folder As work with Aspen IPE proceeds various files are created and stored in this project folder for example the DEC3 ccp file which contains the Capital Estimate Report for the depropan
43. 12 0 summary total br account summary 8 INSULATION 45 9 2011 42 7 5 of measure data i stats 9 PAINT 3 2 397 7 8 harts 10 OTHER 602 9 63 8 0 0 11 SUBTOTAL 602 9 686 3 11926 280 9 12 SUBCONTRACTS 13 G AND OVERHEADS 0 0 20 6 8 4 14 CONTRACT FEE 51 2 26 2 28 9 15 BASE TOTAL 654 1 733 1 318 2 16 ESCALATION 0 0 17 CONTINGENCIES 117 7 NO SUBCONTRACTS y le For Help press F1 IPE 50 INDIRECTS SUBCONTRACTS K USD K USD NUM Ln 1097 of 12161 Note that the entry for the purchased equipment 206 700 from line 1 is approximately the sum of the entries for the pieces of equipment provided above 200 100 The difference is due to the Misc Item Allowance 6 100 and the Warehouse Spares 540 These additional items are in Code of Accounts 105 and 107 and appear in the Code of Accounts Summary section of the Capital Estimate Report just below the Contract Summary The total direct material and manpower costs for construction of the plant are 686 300 and 280 900 as shown in row 11 These sum to 967 200 and include items that cannot be charged to the individual equipment items e g charges for instrument testing pipe testing and equipment grounding Note that the installed costs of the equipment items are displayed on the List View MCB IPE Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE List Eg File Run View Tools Window Help m x s B lt ul AU compon
44. 18 ft 154 ft 238 gal Reflux pump Reboiler Condenser Reflux accumulator 58 ft Heat exchanger H2 Heat exchanger 196 fc Fl Flash vessel 635 gal TOTAL The Contract Summary section of the Capital Esti Total Material Purchase Cost Manpower Cost 3 300 25 300 25 700 140 300 72 500 225 400 4 400 29 300 14 700 9 300 26 600 86 400 57 700 61 000 7 300 47 400 20 500 73 000 13 100 85 700 200 100 828 800 mate Report is displayed when the CONTRACT NO 1 PRIME CONTRACTOR is accessed The entries shown below are totals for all of the equipment items in the project Note that portions of the complete printed output are provided in Appendix IV of these notes 17 ICARUS Editor df Fie Edit View Options Window Help oela e gt 218316 ele s OSIM el page Lac oti DESIGN structure GG AND zin tents PROCUREMENT MATERIAL MANHOURS MANPOWER JECT SUMMARY K USD K USD K USD DATA SHEET MECT SCHEDULE ITRACT NO 1 PRIME Ci 1 PURCHASED EQUIPMENT 206 7 IMARIES BY REPORT GF 2 2 EQUIPMENT SETTING 339 8 1 jain Area Equipment List 3 PIPING 112 8 4432 108 6 Report group cost summar iscellaneous Flowsheet 4 CIVIL 26 5 987 19 1 Equipment List Report group cost summar 8 STEEL 21 3 438 8 9 ign data sheets 6 INSTRUMENTATION 182 8 2815 74 0 piled bulks Summary groups 7 ELECTRICAL 23 4 507
45. 2567 2 0 380 CIVIL 190 0 0235 574 0 0709 30 3 019 STRUCTURAL STEEL 0 0 0000 0 0 0000 0 73 0 000 INSTRUMENTATION 7067 0 8725 1 2081 0 2569 80 0 294 ELECTRICAL 674 0 0832 1013 0 1250 42 1 503 INSULATION 3205 0 3957 2404 0 2967 113 0 750 PAINT 247 0 0304 572 0 0706 31 2 320 SUBTOTAL 35922 4 4349 13440 1 6592 575 5 0 374 TOTAL MATERIAL AND MANPOWER COST USD 49400 INST L COST PE RATIO 6 099 PURCHASED IPE 72 ORIGIN AREA AREA AREA AREA AREA AREA ITEM SYMBOL D E MISC CONCRETE ITEMS PIPE TESTING UNPAVED AREA Area length Area width INSTRUMENT TESTING INSTR RUNS TRAYS JBOX EQUIPMENT GROUNDING PILED FOUNDATION Number of piles ELECTRICAL TESTING ROTATING EQP SPARE PARTS BULK IPE 73 REPORT MATERIAL COST USD 8552 50 000 FEET 50 000 FEET 2200 251 10802 14 1100 100 49 14 83 17 2611 1150 311 1638 425 TOTAL DIRECT COST USD 2611 3350 562 12440 425 1100 APPENDIX IV ASPEN IPE CAPITAL ESTIMATE REPORT FOR THE MONOCHLOROBENZENE SEPARATION PROCESS Selected portions of the List of Equipment and Bulk Material by Area and the Contract Summary IPE 74 C O N T R A C T S U MM AR Y PRIME CONTRACTOR CONTRACT NO 1 3 DESIGN CONSTRUCTION MISC AND PERCENT NO ITEM ENG G AND I ALL AMOUNT OF i i
46. 4000000 BPVAL CAH10 1 C6H14 1 0111000000 BPVAL C4H10 1 C2H6 6 70000000E 3 BPVAL C5H12 1 C3H8 0233000000 BPVAL C5H12 1 CAH10 1 0204000000 BPVAL C5H12 1 C2H6 5 60000000E 3 STREAM FEED SUBSTREAM MIXED TEMP 225 PRES 250 MOLE FLOW C2H6 30 C3H8 200 C4H10 1 370 C5H12 1 amp 350 C6H14 1 50 IPE 56 BLOCK D1 RADFRAC PARAM NSTAGE 14 COL CONFIG CONDENSER PARTIAL V FEEDS FEED 7 PRODUCTS BOT 14 L DIS 1 V P SPEC 1 248 COL SPECS D F 226 DP COL 4 MOLE RR 6 06 SPEC 1 MOLE FLOW 191 PHASE V STAGE 1 COMPS C3H8 VARY 1 MOLE RR 3 9 STREAM REPOR MOLEFLOW Stream Variables BOT DIS FEED STREAM ID BOT DIS FEED FROM D1 D1 TO 5 1 SUBSTREAM MIXED PHASE LIQUID VAPOR MIXED COMPONENTS LBMOL HR C2H6 3 5935 03 29 9964 30 0000 C3H8 9 0000 191 0000 200 0000 C4H10 1 365 0282 4 9718 370 0000 C5H12 1 349 9682 3 1817 02 350 0000 C6H14 1 50 0000 5 6799 06 50 0000 TOTAL FLOW LBMOL HR 774 0000 226 0000 1000 0000 LB HR 5 1173 04 9615 6886 6 0789 04 CUFT HR 1757 1876 4228 0955 7798 4407 STATE VARIABLES TEMP F 260 8017 115 0748 225 0000 PRES PSI 252 0000 248 0000 250 0000 VFRAC 0 0 1 0000 0 2831 LFRAC 1 0000 0 0 0 7169 SFRAC 0 0 0 0 0 0 ENTHALPY BTU LBMOL 6 1678 04 4 4212 04 5 7856 04 BTU LB 932 8868 1039 1178 951 7619 BTU HR 4 7738 0
47. 579 55271 BTUH 111711177 BTUHDEG F 457 962 274 Overall Heat transfer Coeffici BTU H SF DEG F 147129169 Shell Side Heat Transfer Coe BTU H SF DEG F 275 027503 Shell Side Fouling Resistanc SF DEG FBTU 0 00115 Tube Side Heat Transfer Coe BTU H SF DEG F 1000 Tube Side Fouling Resistanc H SF DEG F BTU 00003 Temperature Correction Fac 0 996868137 lt In the 1 column that contains the values the items for Hot Inlet Stream and Hot Outlet Stream are ICUST IN and ICUST EX respectively which correspond to the default utility in this case steam at 50 psi To change to steam at 100 psi new user streams for the inlet and outlet must replace the default utility streams created by Icarus To accomplish this go to the Process Flow Diagram accessible from the View menu right click on the CUST IN stream which is green leading into the D1 reboiler and choose Delete Then click on the Add Stream button in the toolbar 4 This gives the Develop Streams dialog box Develop Streams Create Base Stream 1 Simulator Premap User Basis ICP BE 2 Absolute Utility ICUCw EX C Relative ICUCW IN Close First select a basis stream by highlighting CUST EX in the Utility subsection Its properties such as molecular weight etc are copied into the new stream Leave the radio button set to Absolute Then click on the Create button and type IPE 35 a name for the new stream
48. 6 aspenONE List Ei File Run View Tools Window SB lt TF 2 A U All components xl 27 Scenario1 Process View J C Program Files AspenTe Main Project A1 tower Al tower TW TRAYED Additional Project Con Miscellaneous Flowsheet Area D1 tower D1 tower TW TRAYED Batch DMD Process D1 cond D1 cond HEFIXEDT S Qp Batch Ethyl Lactate Pr D1 cond acc 01 acc HT HORIZ DRUM Continuous DMD Proc Fi Di reflux pump Di reflux pump CP CENTRIF Gp Continuous EtOH Proc Di overhead Di overheadsplit Gp 2 Di bottoms split Di bottomssplt C 5 Homework 16 4 D1 reb D1 reb RB U TUBE MCB_IPE Fi flash vessel 1 vessel VT CYLINDER Gp PDO Process z Hi H1 HE JACKETED H2 H2 HE FLOAT HEAD RADFRACX c J RADFRACY 1 1 CP CENTRIF RADFRACZ 51 51 c Sample Projects 1 1 c Semicontinous EtOH P Semicentiniienie NMN r T Libraries Compo ES Proje 27 Proce Ready Note that the five C entries represent Quoted Items having zero cost The associated Process Flow Diagram after some reorganizing 1s IPE 45 7 MCB_IPE Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE MCB_IPE Scenario1 Process Flow Diagram File Run View Tools Window Help amp B lt ak diiwse gt AY Al components
49. 7 9 9918 06 5 7856 07 ENTROPY BTU LBMOL R 105 9894 66 3064 96 4772 BTU LB R 2176031 1 5584 5125871 DENSITY BMOL CUFT 0 4405 5 3452 02 0 1282 LB CUFT 29 1220 2 2742 7 7950 W AVG 66 1148 42 5473 60 7885 Process Unit Output BLOCK D1 ODEL RADFRAC INLETS FEED STAGE 7 OUTLETS DIS STAGE STAGE 14 PROPERTY OPTION SET RK SOAVE STANDARD RKS EQUATION OF STAT IPE 57 MASS AND ENERGY BALANCE IN OUT RELATIVE DIFF TOTAL BALANCE OLE LBMOL HR 1000 00 1000 00 0 113687E 15 ASS LB HR 60788 5 60788 5 0 263325E 14 ENTHALPY BTU HR 0 578562E 08 0 577303E 08 0 217615E 02 KERK INPUT DATA x NUMBER OF STAGES 14 ALGORITHM OPTION STANDARD ABSORBER OPTION NO INITIALIZATION OPTION STANDARD HYDRAULIC PARAMETER CALCULATIONS NO INSIDE LOOP CONVERGENCE METHOD BROYDEN DESIGN SPECIFICATION METHOD NESTED MAXIMUM NO OF OUTSIDE LOOP ITERATIONS 25 MAXIMUM NO OF INSIDE LOOP ITERATIONS 10 MAXIMUM NUMBER OF FLASH ITERATIONS 50 FLASH TOLERANCE 0 000100000 OUTSIDE LOO
50. 8 PRODUCT RATI Fl LBMOL HR LIQUID VAPOR 226 774 0000 PRODUCT RATE LB HR 0000 LIQUID VAPOR 9615 51173 05 C5H12 71663 29316 10340 75943 15547 23898 24609 28601 31913 37366 45216 1 C6H14 E 03 36784 E 02 41399 E 01 39505 E 01 18785 88845 25864 25942 27216 29880 38453 64599 6886 I E 06 E 05 E 04 E 02 E 02 E 01 E 01 E 01 E 01 E 01 E 01 STAGE ho 2 12 13 14 C2H6 259273 64894 01 37438 01 23512 01 22436 01 14670 01 61322 02 38744 03 14792 03 54526 04 18479 04 MOLI C3H8 84513 88165 84931 62700 48332 37152 29788 11540 76709 01 478301 267501 01 01 0 0 0 0 0 0 0 0 0 0 0 E Y PROFILE C4H10 1 21999E 01 52798E 01 11061 32189 42565 48748 555617 69553 70375 68040 61003 IPE 60 C5H12 1 14078 03 65833E 03 26424E 02 27326 01 66941 01 12031 13318 18013 20941 25783 33697 C6H14 1 25132E 07 33314E 06 37136E 05 27279 03 16554 02 60259 02 66399 02 85532 02 99812 02 13882 01 26231 01 APPENDIX II DESIGN CRITERIA SPECIFICATIONS IPE 61 Name Unit Item Table 1 Design Pressure DP Pumps Heat Exch s
51. 928 3 136 57 248 62 52692 45507 5 170 39 249 23 55843 47215 6 190 65 249 54 57560 48372 7 209 38 249 85 59032 49521 8 217 28 250 15 259293 50212 11 235 62 251 08 59970 51780 12 241 42 251 38 60295 52207 13 248 99 251 69 60816 52686 14 260 80 252 00 61678 53340 STAGE FLOW RATE FEED RATE LBMOL HR LBMOL HR LIQUID VAPOR LIQUID VAPOR MIXED 1 2006 226 0 2 2955 2232 3 1864 2181 5 22677 1989 6 1600 1903 283 3846 7 2334 1542 716 6153 8 22312 1560 11 2453 1661 12 2454 1679 13 2430 1680 14 774 0 1656 MASS FLOW PROFILES STAGE FLOW RATE FEED RATE LB HR LB HR LIQUID VAPOR LIQUID VAPOR MIXED 1 0 8848E 05 9616 2 0 8897 05 0 9810E 05 3 0 8829 05 0 9859E 05 5 0 8877 405 0 9759E 05 6 0 8996E 05 0 9838 05 15740 05 7 0 1382 406 0 8384E 05 45048 05 8 0 1425 06 0 8706 05 11 0 1523 06 0 9845 05 12 0 1544 06 0 1012 06 13 0 1558 06 0 1032 06 14 0 5117 05 0 1047 06 KAAN MOLE X PROFILE ERAK STAGE C2H6 C3H8 C4H10 1 1 0 57253E 01 0 88576 0 56268E 01 0 2 0 26424E 01 0 84979 0 12085 0 3 0 14274E 01 0 74938 022597 0 5 0 75715E 02 0 43455 0 48005 0 6 0 66748E 02 0 29446 0 53451 0 7 0 40998E 02 0 20293 0 52813 0 8 0 16827E 02 0 15681 0 56948 0 11 0 10271E 03 0 56172 01 0 63050 0 12 0 38791 04 0 36411 01 0 61454 0 13 0 14072E 04 0 21933E 01 0 56594 0 14 0 46428E 05 0 11628 01 0 47161 0 59 HEAT DUTY BTU HR 11585 08 11711 0
52. AL STEEL 0 0 0000 0 0 0000 0 0 000 INSTRUMENTATION 8666 0 5895 3925 0 2262 128 0 384 ELECTRICAL z 0 0 0000 0 0 0000 0 0 000 INSULATION 3507 0 2386 3234 0 2200 152 0 922 PAINT 261 0 0178 606 0 0412 33 2 319 SUBTOTAL 39670 2 6987 18063 1 2288 775 0 455 TOTAL MATERIAL AND MANPOWER COST USD 57700 INST L COST PE RATIO 3 925 PURCHASED EQUIPMENT ITEM ORIGIN ITEM TYPE P A DE SACRE PET EQN Equipment mapped from D1 BT 4 HORIZ DRUM 1 acc Shell material A 515 9300 CODE OF ACCOUNT 114 Liquid volume 237 96 GALLONS TAG NO Dl cond Vessel diameter 3 000 FEET Vessel tangent to tangent length 4 500 FEET Design temperature 254 98 DEG F Design gauge pressure 35 30 PSIG Application CONT Base material thickness 0 313 INCHES Total weight 1500 LBS ITEM Ay AA D MANPOWER L M FRACTION FRACTION RATIO USD OF PE USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 9300 1 0000 598 0 0643 25 2 0 064 PIPING 8758 0 9417 9217 0 9911 376 1 052 CIVIL 1185 0 1274 1637 0 1760 85 1 382 STRUCTURAL STEEL 0 0 0000 0 0 0000 0 0 000 INSTRUMENTATION 19355 2450812 5 4218 0 4536 159 0 218 ELECTRICAL 0 0 0000 0 0 0000 0 0 000 INSULATION 2844 0 3058 3140 02 33 771 147 1 104 PAINT 210 0 0226 525 0 0564 28 2 496 SUBTOTAL 41652 4 4788 19335 2 0790 820 0 464 TOTAL MATERIAL AND MANPOWER COST USD 61000 INST L COST PE RATIO 6 559 IPE 77
53. ASPEN ICARUS PROCESS EVALUATOR IPE Equipment Sizing and Costing Using ASPEN PLUS to Initiate Evaluation Notes prepared by Robyn B Nathanson Thomas A Adams II Warren D Seider University of Pennsylvania May 2008 Previous versions were coauthored with Holger Nickisch Maizatul Zain University of Pennsylvania Robert Nedwick Pennsylvania State University CONTENTS INTRODUCTION PREPARING AN ASPEN PLUS SIMULATION FOR ASPEN IPE Additional Mixture Properties INVESTMENT ANALYSIS USING ASPEN IPE DEPROPANIZER Initial Setup Mapping Process Simulation Units into Aspen IPE Standard Basis Equipment Costing Total Permanent Investment Adding Equipment Applying Alternative Utilities MONOCHLOROBENZENE SEPARATION PROCESS Initial Setup Mapping Process Simulation Units to Aspen IPE Standard Basis Equipment Costing Total Permanent Investment ASPEN IPE FOLDERS AND FILES REFERENCES APPENDIXI DEPROPANIZER ASPEN PLUS REPORT APPENDIX II DESIGN CRITERIA SPECIFICATIONS APPENDIX III ASPEN IPE CAPITAL ESTIMATE REPORT FOR THE DEPROPANIZER APPENDIX IV ASPEN IPE CAPITAL ESTIMATE REPORT FOR THE MONOCHLOROBENZENE SEPARATION PROCESS 17 19 25 25 34 40 40 42 48 48 52 54 54 55 61 65 74 INTRODUCTION These notes are prepared to provide a step by step procedure for estimation of the total capital investment using the Aspen Icarus Process Evaluator Aspen IPE Aspen IPE is a software system provided by Aspen Techno
54. CARUS Project Component Selection dialog box For the addition of a reboiler pump enter Reboiler Pump as the Project Component Name highlight Process equipment and press the OK button ICARUS Project Component Selection Project Component Name Reboiler Pump LI Project Components Plant bulks Site development Buildings Quoted equipment Unit cost library Equipment model library Cancel Selec Help Continue through the appropriate menus until the desired equipment type is obtained which in this example is a centrifugal pump IPE 27 ICARUS Project Component Selection Reboiler Pump Agitators mix react knead Compressors and blowers Drivers P heaters Towers columns trayed packed Vacuum system equipment Vessels pressure storage Crushers flakers mills stock Evaporators dryers cryst Solids conveying ICARUS Project Component Selection Reboiler Pump Pump Centrifugal Pump Gear Pump Pos displacement IPE 28 ICARUS Project Component Selection Project Component Name Reboiler Pump Project Components Process equipment Pumps E Pump Centrifugal Standard ANSI single stage pump Plastic ANSI single stage pump 610 pump 610 in line pump Axial flow vertical pump Canned motor pump Centrifugal single or multi stage pump General service pump General service in line pump High speed vertical in line 610 pump Vertical sump pump
55. Component Map Preview Simulator Information Component Map Information Simulator Items Configuration Component Name de Current Map List HE FLOAT HEAD New Mapping Delete One Mapping Delete All Mappings ICARUS Project Component Description Process equipment Heat exchangers heaters HE RB FU Heat exchanger Floating head shell and tube exchanger Instructions Select desired simulator information Press New Mapping to create new ICARUS project components corresponding to the simulator selection To remove mappings use a Delete Then select New Mapping Heat exchangers and then heaters to give ICARUS Project Component Selection Component Name Suffix m Project Components 11 Process equipment Agitators mix react knead AG AT BL K MX Compressors and blowers GC FN Drivers MOT TUR Heat exchangers heaters Packings linings LIN Pumps CP GP P Towers columns trayed packed DDT Tw Vacuum system equipment C EJ VP Vessels pressure storage HT VT Crushers flakers mills stock CR FL M ST Evaporators dryers cryst CRY E WFE AD D DD RD TDS Solids conveying CO CE EL FE HO 5 oT Ne rer Cancel Select Help IPE 43 From the next dialog box select Heat exchanger and finally choose the Double pipe heat exchanger ICARUS Project Component Selection Component Name Suffix H1 Project Components LI Process equipment
56. EET Total weight 34300 LBS ITEM MATERIAL MANPOWE R xxxx L M FRACTION FRACTION H RATIO USD OF PE 2 USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 68100 1 0000 1266 0 0186 52 3 0 019 PIPING 15248 0 2239 10330 0 1517 422 0 677 CIVIL 1711 070251 2 2113 0 0310 110 1 2395 STRUCTURAL STEEL 0 0 0000 0 0 0000 2 0 000 INSTRUMENTATION 15974 0 2346 5682 0 0834 217 0 356 ELECTRICAL 0 0 0000 0 0 0000 Qus 0 000 INSULATION 6674 0 0980 6058 0 0890 286 0 908 PAINT 314 0 0046 746 0 0109 40 233973 SUBTOTAL 108021 1 5862 26195 0 3847 275 0 243 TOTAL MATERIAL AND MANPOWER COST USD 134200 INST L COST PE RATIO 1 971 PURCHASED EQUIPMENT COST USD DE N Equipment mapped from D1 TW 1 TRAYED 1 Shell material A 515 86300 CODE OF ACCOUNT 111 Number of trays 15 TAG NO Dl tower Vessel diameter 5 000 FEET Vessel tangent to tangent height 42 00 FEET Design temperature 310 80 DEG F Design gauge pressure 262 30 PSIG Application DISTIL Tray type SIEVE Tray spacing 24 00 INCHES Tray material A285C Tray thickness 0 188 INCHES Base material thickness 0 625 INCHES Total weight 31700 LBS ITEM MATERIAL i R xxxx L M B FRACTION FRACTION RATIO 5 gt USD OF PE USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 86300 1 0000 2208
57. Horizontal Eg Vertical s Miscellaneous Eg Configurations Flash s Utility Specifications Eg Sizing Selection B Investment Analysis 2 Investment Parameters Es Operating Unit Costs Eg Raw Material Specifications Eg Product Specifications Streams IPE 37 Next the reboiler is sized using the new utility specifications Right click on the reboiler and choose Size ltem Delete the values for the Raw Surface Area Surface Area with Overdesign Uncorrected as shown below Final Surface Area UA and LMTD When OK is pressed these variables are recalculated using the properties of the new steam streams Interactive Sizing DRB KETTLE Cancel Apply Reset Print Name Units 1 Raw Surface Area ISF Surface Area with Overdesig SF Final Surface Area SF Duty BTUH 11 714 177 UA BTUHDEG F Overall Heat transfer Coeffici BTU H SF DEG F 147 129169 Shell Side Heat Transfer Coe BTUH SF DEG F 275 027503 Shell Side Fouling Resistanc H SF DEG 000115 Tube Side Heat Transfer Coe BTU H SF DEG F Tube Side Fouling Resistanc H SF DEG FBTU Temperature Correction Fac 4 000 t 0 0003 10 995868137 Side For Hot Stream LMTD Uncorrected DEGF Overdesign Factor I MECHANICAL DESIGH INFORM TEMA Type Shell Diameter After the reboiler is re sized right click on the reboiler and again select Size Item to view the
58. IES BY REF CODE OF ACCOUNT 161 Liquid flow rate 756 52 GPM Fluid head 20 00 FEET 1 Main Ama Design temperature 298 99 DEG F Equipment List Speed 3600 00 RPM _ Report group cost Driver power 3 000 HP 2 Miscellaneous Flow Fluid viscosity 0 00000200 CPOISE Equipment List Design gauge pressure 262 00 PSIG Report group cost Driver type MOTOR E 3 Seal type SNGL Equipment List Total weight 630 LBS 2 Report group cost ITEM DCC MATERIAL ltttx HANPOWER e L M Design data sheets FRACTION FRACTION PATIO Detailed bulks USD OF PE USD OF MANHOURS USD USD Bulk summary groups EQUIPMENT amp SETTING 8100 1 0000 542 0 0669 23 0 067 Bulk summary total PIPING 16439 2 0298 6255 0 7722 256 0 380 Major account summa CIVIL 190 0 0235 574 0 0709 3 019 amp Units of measure data STRUCTURAL STEEL 0 0 0000 0 0 0000 0 000 INSTRUMENTATION 7067 0 8725 2081 0 2569 0 294 Input stats ELECTRICAL 674 0 0832 1013 0 1250 42 1 803 E Barcharts INSULATION 3205 0 3957 2404 0 2967 0 750 PAINT 247 0 0304 572 0 0706 81 2 320 SUBTOTAL 35922 4 4349 13440 1 6592 575 0 374 TOTAL MATERIAL AND MANPOWER COST USD 49400 INST L COST PE RATIO 6 099 lt gt lt gt For Help press F1 INS NUM Ln 3000 of 10029 4 50 PM Note that no equipment items remain in the New
59. ING 16426 0 8013 3 9826 0 4793 404 0 598 CIVIL 805 0 0393 1275 0 0622 67 1 563 STRUCTURAL STEEL 0 0 0000 0 0 0000 0 0 000 INSTRUMENTATION 8667 0 4228 3833 0 1626 128 s 0 385 ELECTRICAL 0 0 0000 0 0 0000 0 0 000 INSULATION 5858 0 2858 4202 0 2050 197 0 717 PAINT 359 0 0175 826 0 0403 45 2 305 SUBTOTAL 52615 2 5666 20423 0 9962 881 0 388 TOTAL MATERIAL AND MANPOWER COST USD 73000 INST L COST PE RATIO 3 561 PURCHASED ORIGIN ITEM TYPE ITEM DESIGN DATA EQUIPMENT DESCRIPTION COST USD Equipment mapped from 1 QUOTE EQP 14 1 Number of identical items 1 0 CODE OF ACCOUNT 100 TAG NO M1 Equipment mapped from 51 QUOTE EQP 15 S1 Number of identical items 1 0 CODE OF ACCOUNT 100 TAG NO S1 Equipment mapped from 1 CP 13 CENTRIF Pl Casing material cs 3300 CODE OF ACCOUNT 161 Liquid flow rate 22 73 GPM TAG NO Pl Fluid head 62 10 FEET Design temperature 250 00 DEG F Speed 3600 00 RPM Driver power 1 500 HP Fluid viscosity 0 583 CPOISE Design gauge pressure 60 30 PSIG Driver type MOTOR Seal type SNGL Total weight 210 LBS ITEM MATERIAL MAN R x xxxx L M FRACTION FRACTION H RATIO 2 USD OF PE 2 USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 3300 1 0000 240 0 0726 d10 3 0 073 PIPING 2 O A 0 8235 5344 1
60. L 108021 TOTAL MATERIAL AND MANPOWER COST USD 134200 INST L COST PE RATIO 1 971 For Help press F1 Ln 1 of 9126 4 18PM In summary the equipment sizes purchase costs and total material and manpower cost for the depropanizer system without the reboiler pump are as follows Total Material Simulation Size Purchase Cost and Manpower Cost Unit DI Equipment Item 5 0 ft diam 42 ft height 20 Hp 3 580 ft 11 100 ft 5 550 ft shell 2 350 gal Tower 86 300 250 600 7 100 68 100 179 800 40 700 134 200 326 100 Reflux pump Reboiler Condenser Reflux accumulator 25 700 94 200 TOTAL 367 000 845 800 The Contract Summary section of the Capital Estimate Report is displayed when the CONTRACT NO 1 PRIME CONTRACTOR is accessed The entries shown below are totals for all of the equipment items i e the entire project Note that selected portions of the complete printed output are provided in Appendix III of these notes 1 Note that changing to a 6 or 7 point font is more suitable for printing IPE 22 Gi File Edit View Options Window Help pe s a gt page tract structure JECT SCHEDULE TRACT NO 1 PRIME CONTRACTOR MARIES BY REPORT GROUP iscellaneous Flowsheet summary groups summary total account summary s of measure data For Help press F1 D amp B e gt 810815 MANHOURS MANPOWER K USD INDIRECTS
61. P CONVERGENCE TOLERANCE 0 000100000 KEEK COL SPECS KEER MOLAR VAPOR DIST TOTAL DIST 1 00000 MOLAR REFLUX RATIO 6 06000 DISTILLATE TO FEED RATIO 0 22600 KKKK RESULTS x xxx COMPONENT SPLIT FRACTIONS KKE OUTLET STREAMS DIS BOT COMPONENT C2H6 99988 11978 03 C3H8 95500 45000 01 4 10 1 13437 01 98656 C5H12 1 90906 04 99991 C6H14 1 11360 06 1 0000 SUMMARY OF KEY RESULTS do TOP STAGE TEMPERATURE F 115 075 BOTTOM STAGE TEMPERATURE F 260 802 TOP STAGE LIQUID FLOW BMOL HR 2 006 29 BOTTOM STAGE LIQUID FLOW BMOL HR 774 000 TOP STAGE VAPOR FLOW BMOL HR 226 000 BOTTOM STAGE VAPOR FLOW BMOL HR 15 6554 79 MOLAR REFLUX RATIO 8 87737 MOLAR BOILUP RATIO 2 13927 CONDENSER DUTY W O SUBCOOL BTU HR 0 115854 08 REBOILER DUTY BTU HR 0 117112 08 ERRE PROFILES KERK NOTE REPORTED VALUES FOR STAGE LIQUID AND VAPOR RATES ARE THE FLOWS FROM THE STAGE EXCLUDING ANY SIDE PRODUCT FOR THE FIRST STAGE THE REPORTED VAPOR FLOW IS THE VAPOR DISTILLATE FLOW FOR THE LAST STAGE THE REPORTED LIQUID FLOW IS THE LIQUID BOTTOMS FLOW IPE 58 ENTHALPY STAGE TEMPERATURE PRESSURE BTU LBMOL F PSI LIQUID VAPOR 1 115 07 248 00 50783 44212 2 125 28 248 31 51581 44
62. USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 72500 1 0000 2237 0 0308 0 031 PIPING 8 23610 0 3257 16724 0 2307 687 0 708 CIVIL 1357 0 0187 1911 0 0264 99 1 408 STRUCTURAL STEEL 10818 0 1492 4345 0 0599 214 0 402 INSTRUMENTATION 44164 0 6092 20308 0 2801 768 0 460 ELECTRICAL 2530 0 0349 1357 0 0187 ei 0 536 INSULATION 10890 OS OZ 22 10184 0 1405 481 0 935 PAINT 807 0 0111 1631 0 0225 88 2 020 SUBTOTAL 166677 2 2990 58695 0 8096 2489 0 352 TOTAL MATERIAL AND MANPOWER COST USD 225400 INST L COST PE RATIO 3 109 IPE 76 COMPONENT PURCHASED EQUIPMENT COST USD ITEM DESCRIPTION ORIGIN ITEM TYPE Equipment mapped from D1 HE 3 FIXED T 5 1 Tube material A 214 14700 CODE OF ACCOUNT 261 Heat transfer area 154 20 SF TAG NO 1 Shell material A285C TEMA type BEM Shell design gauge pressure 35 30 PSIG Shell design temperature 255 39 DEG F Shell diameter 8 000 INCHES Shell length 20 00 FEET Tube design gauge pressure 60 30 PSIG Tube design temperature 255 39 DEG F Tube outside diameter 1 000 INCHES Tube length extended 20 00 FEET Total weight 1800 LBS ITEM MATERIAL i MANPOWE R xxxxx L M FRACTION FRACTION RATIO x USD OF PE 5 USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 14700 1 0000 924 0 0629 38 0 063 PIPING 11741 0 7987 8714 0 5928 358 0 742 CIVIL 795 0 0540 1261 0 0858 66 1 587 STRUCTUR
63. be printed This is accomplished by highlighting the desired section and pressing the Print button on the toolbar It is often preferable to print in landscape format When the appropriate specifications are made Aspen IPE computes annual operating costs as well as a complete profitability analysis the results of which appear in this Investment Analysis spreadsheet These notes discuss capital cost estimation only because the spreadsheet Profitability Analysis 2 0 xls which is discussed in Section 23 8 of the textbook is used to compute operating costs working capital and profitability measures As shown below the List of Equipment and Bulk Material by Area portion of the report is displayed when the Equipment List is accessed This provides the Purchased Equipment amp Setting and Installed Direct Costs 1 Total Material and Manpower Cost or Total Direct Materials and Labor Cost for each piece of equipment e g the reboiler as shown next Note that the right hand window below is displayed using a 7 IPE 21 point font This is achieved by pressing the Select Font button on the toolbar Furthermore portions of the complete printed output are provided in Appendix III of these notes Ef ICARUS Editor CAP REP ccp d File Edit View Options Window Help osal gt 2 55 1 e Title page Contract structur Contents PROJECT SUM PROJECT DAT PROJECT SCHE CONTRACT NO SUMMARIES B 1
64. calculated results Interactive Sizing DRB KETTLE Cancel Unit Apply Reset Print s Item 1 Hot Outlet Stream ST100 EX Cold Inlet Stream Cold Outlet Stream PROCESS INFORMATION ICP BSPLR ICP BR Raw Surface Area 1 097 5485 Surface Area with Overdesig SF 1 262 28578 1 262 29578 Final Surface Area ISF BTUH 11 711 177 BTUHDEG F 181 496 12 Overall Heat transfer Coeffici BTUH SF DEG F 147 129169 Shell Side Heat Transfer Coe BTU H SF DEG F nc SF DEG FBTU Temperature Correction Fac Side For Hot Stream 275 027503 0 00115 1000 0 0003 0 995868137 LMTD Uncorrected 72 7446 lt Using steam at 100 psi the final surface area is 1 262 ft reduced from 3 580 i while the log mean temperature difference is 72 7 F increased from 25 7 F IPE 38 Finally the capital cost of the entire process is re evaluated since the cost of the smaller reboiler is lower This is accomplished by pressing the Evaluate Project button on the toolbar and selecting Evaluate All Items The results appear in the Capital Estimate Report in the List of Equipment and Bulk Material by Area section They are accessed by selecting Equipment List under Miscellaneous Flowsheet in the left hand window Ef ICARUS Editor REP ccp d File Edit View Options Window Help 01518 o 8158106 e B z u a maam
65. carus Process Evaluator 2006 aspenONE RADFRACY Scenario1 Process Flow Diagram 9 File Run View Tools Window Help Demen lt T A BARS gt RO U All components E zixi RADFRACY 5 1 Project View Main Project QA Main Area f Miscellaneous Flowsheet Area E D1 tower D1 cond E D1 cond EJ D1 reflux pump EJ D1 overhead split EJ D1 bottoms split E Di reb waman Proje E Lit Proje Proce Note that the unit icons and streams have been repositioned using drag and drop facilities It is also possible to view a list of the process streams utilized by Aspen IPE that is a list of all streams and their physical properties in the Process Flow Diagram Using the View pulldown menu click on Streams List to produce Run view Tools Window mug Dua lt 21454 gt ALU AN components zixl RADFRACY Scenario1 Project View reme mnes Rho Vap mfr Main Project 249 252 PSIA 0 000000 PCF 0 00001 QA Main Area 261 DEG F 252 PSIA 2 274236 109472 Miscellaneous Flowsheet Area 115 DEG F 248 PSIA 0 000000 0 0000 EJ D1 tower 125 DEG F 248 PSIA 2 274236 PCF 94978 1 EJ D1 cond 261 F 252 PSI 0 000000 0 00001 E D1 cond 115 F 248 PSI 2 274236 PCF 9615
66. e 1 Design Temperature Table 3 Number of Holding Days 1 Holding Hours in a Day 24 Storage Vessel Height to Diameter Ratio 0 4 Vapor Free Space of Total Storage Vessel Vol 5 Vessels Horizontal Design Pressure Table 1 Design Temperature Table 3 Residence Time min 5 Vapor Area Cross Sectional Area 0 2 Separation Factor Multiplier 1 25 Minimum Boot Length ft 3 Minimum Boot Diameter ft 2 Boot Leg Liquid Velocity ft min 0 5 Name Unit Item Vessels Vertical Design Pressure Table 1 Design Temperature Table 3 Residence Time min 5 Minimum Disengagement Height ft 4 Minimum Height above Mist Eliminator ft 1 Height of Mist Eliminator ft 0 5 Minimum Ht Btw Low and High Liq Lev Taps ft 4 Ht Btw Inlet Nozzle and High Liq Level Tap ft 2 Ht Btw Low Level Liquid Tap and Tang Line ft 0 5 Miscellaneous Vibrating Screen Feed Material Wood Cyclone Inlet Linear Velocity ft sec 150 Flash Configurations Delta T across Recirculation HX F 10 Delta P across Recirculation Pump psi 5 IPE 64 APPENDIX III ASPEN IPE CAPITAL ESTIMATE REPORT FOR THE DEPROPANIZER Selected portions of the List of Equipment and Bulk Material by Area and the Contract Summary IPE 65 Depropanizer Without the Reboiler Pump see Folder C O N T R A C T S U M M A R Y PRIME CONTRACTOR CONTRACT NO 1 PERCENT DESIGN CONSTRUCTION MISC AND NO ITEM 2 ENG G AND
67. e simulation results for use with Aspen IPE While this is accomplished in a similar manner for most of the major process simulators these notes focus on the steps to prepare ASPEN PLUS simulations For the steps when using the other process simulators the reader should refer to the Aspen IPE User s Guide click on Documentation in the Help menu of Aspen IPE It is normally necessary to adapt the simulation file in two ways First to estimate equipment sizes Aspen IPE usually requires estimates of mixture properties not needed for the material and energy balance and phase equilibria calculations performed by the process simulators For this reason it is necessary to augment the simulation report files with estimates of mixture properties such as viscosity thermal conductivity IPE 2 and surface tension for the streams in the simulation flowsheet Second Aspen IPE requires specifications to estimate equipment sizes that are not computed by some of the approximate simulation models This is the case for example when the DISTL and RSTOIC models are used in ASPEN PLUS circumvent this these are replaced by more rigorous models such as the RADFRAC and RPLUG models This replacement can be viewed as the first step in computing equipment sizes and costs Note that it is also possible to provide specifications for computing equipment sizes without using ASPEN PLUS Additional Mixture Properties Estimates for the additional stream prop
68. ents M xi MCB IPE Scenariol Project View Tt User Tag Number Item Description Equipment Cost USD Direct Cost USD Installation Bulks Main Project E31 A1 tower A1 tower TW TRAYED 25700 140300 Main Area 22 D1 tower D1 tower TW TRAYED 72500 225400 Ej Miscellaneous Flowsheet Arez D1 cond D1 cond HE FIXED T 5 14700 57700 A1 tower E34 Di cond acc Di cond acc HT HORIZ DRUM 9300 61000 EJ D1 tower Os Di reflux pump Di reflux pump CP CENTRIF 4400 26600 E D1 cond 126 Di overhead s D1 overhead split 0 0 D1 cond acc 127 Di bottoms split D1 bottoms split 0 0 Di refiux pump Es Di reb Di reb RB U TUBE 29300 86400 iesus e 21 H2 H2 HE FLOAT HEAD 20500 73000 m re mE 212 0 0 2213 P1 P1 CP CENTRIF 3300 25300 Bw E314 51 51 0 0 PL 217 n re 0 0 Bis H1 H1 HE JACKETED 7300 47400 2219 F1 flash vessel F1 flash vessel VT CYLINDER 13100 85700 EJ F1 flash vessel Pr Pro F1 flash ve Ready These direct installed costs sum to 828 800 that is 138 400 less than the total direct cost of materials and manpower for installation of the plant 967 200 This Installed Direct Cost is referred to in Chapter 22 of the textbook as the Total Direct Materials and Labor Cost Finally the materials and manpower items that cannot be charged to the individual equipment
69. er E D1 cond EJ D1 cond D1 reflux pump E D1 overhead split EJ D1 bottoms split E D1 reb Bil New Reboiler Pump 1 Project Component Note that a new stream which appears in white has been created and named CP BE 2 by Aspen IPE Although the Reboiler pump has been inserted into the process it remains in the New Item area To move it into the Miscellaneous Flowsheet area in the Project View drag and drop the Reboiler pump from the New Item Area to the Miscellaneous Flowsheet area This results in 7 RADFRACX Scenario1 Aspen Icar File Run View Tools Window Help Duk amp mf ux RADFRACX Scenario1 Project View Main Project Main Area Miscellaneous Flowsheet Area EJ D1 tower D1 cond EJ 01 acc Di reflux pump EJ D1 overhead split D1 bottoms split Dy D1 reb Reboiler Pump bay New Item m IPE 31 Next right click on the Reboiler pump and select Size on the menu that appears note that the Spec Sheet for the reboiler pump may have to be closed first when it is open in another tab The interactive sizing form appears lil Interactive Sizing DCP CENTRIF Item 1 Inlet Stream ICP BE Outlet Stream 71 ICP BE 2 PROCESS INFORMATION Capacity Overdesign Factor SIZE INFORMATION GPM Head FEET Liquid Specific Gravity Viscosity cP Pump Efficiency
70. er area 58 23 SF Tube length 20 00 FEET Number of tubes per shell ak Design gauge pressure 110 30 PSIG Temperature 377 80 DEG F Number of sections 3 Total weight 2670 LBS ERIAL MAN P OWE R x xxxx L M FRACTION FRACTION RATIO OF PE USD OF PE MANHOURS USD USD 1 0000 965 0 1322 40 0 132 1 5431 8688 1 1901 357 0 771 0 1051 1226 0 1680 64 1 598 0 0000 0 0 0000 0 0 000 0 8807 1895 0 2596 69 0 295 0 0000 0 0 0000 0 0 000 0 5854 3767 0 5160 LEA 0 881 0 0358 606 0 0830 33 2 319 4 1501 17146 2 3488 740 0 566 USD 47400 INST L COST PE RATIO 6 493 TOTAL MATERIAL AND MANPOWER COST COMPONENT Th So IPE 79 t PURCHASED ORIGIN ITEM TYPE I T EM EQUIPMENT DESCRIPTION COST USD Equipment mapped from H2 HE 11 FLOAT HEAD H2 Tube material A 214 20500 CODE OF ACCOUNT 261 Heat transfer area 195 80 SF TAG NO H2 Shell material A285C TEMA type BES Shell design gauge pressure 35 30 PSIG Shell design temperature 353 02 DEG F Shell diameter 10 00 INCHES Shell length 22 00 FEET Tube design gauge pressure 60 30 PSIG Tube design temperature 353 02 DEG F Tube outside diameter 1 000 INCHES Tube length extended 20 00 FEET Total weight 2300 LBS ITEM MATERIAL c i R x xxxx L M FRACTION FRACTION 5 RATIO USD OF PE USD OF PE MANHOURS USD USD EQUIPMENT amp SETTING 20500 1 0000 960 0 0468 40 0 047 PIP
71. er with floating head Instructions Select desired simulator information Press New Mapping to create new ICARUS project components corresponding to the simulator selection To remove mappings use a Delete DK Cancel Help Other mappings be altered in a similar fashion For example for the condenser the mapping is altered from a shell and tube heat exchanger with a fixed tube sheet to one with a floating head When the desired changes are completed press OK to continue and wait for the equipment mapping and sizing to be completed IPE 11 At this point the equipment items have been sized by Aspen IPE because the Size ICARUS Project Components button was checked in the Map dialog box whose calculations are based upon the simulator data as well as the default values specified earlier As each equipment item is sized it appears in the Aspen IPE Main window as a list that is the List window Note that the Project Explorer window displays the Process View Ez File Run View Tools Window Help Deh E lt x RADFRACY Scenario1 Project View User Tag Number Item Description All components M 4p Main Project E31 D1 tower D1 tower TW TRAYED oa Main E32 D1 cond D1 cond HE FLOAT HEAD f Miscellaneous Flowsheet Area D1 cond acc D1 cond acc HT HORIZ DRUM EJ D1 tower E234 Di reflux pump 01 pump CP CENTRIF D1 cond E35 Di ov
72. erhead s D1 overhead split D1 cond EJs D1 bottoms split D1 bottoms split C 2 D1 reflux pump 227 1 D1 reb RB KETTLE D1 overhead split D1 bottoms split Di reb lt gt Proje Proce b Proje Ez List The blue boxes to the left of each item in the list Indicate the Project Components The yellow arrows inside the boxes indicate that the equipment item was obtained from the mapping of a process simulation unit whose name appears after its box Note that by default Aspen IPE lists all of the equipment items in the Workbook Mode as shown above The List tab at the bottom of the Main window denotes that the equipment items are listed in the Workbook Mode Also note that user inputted equipment items such as a reboiler pump not included in the above frame are represented in the Workbook by blue boxes without the yellow arrow To add these equipment items see the section Adding Equipment The OK in the Status column of the Workbook indicates that the minimum required information for costing the equipment is available When one or more items are missing a question mark appears instead alerting the user to provide a specification s so that the equipment sizing step can proceed In addition it is possible to view the PE Process Flow Diagram This is accomplished using the View pulldown menu and clicking on Process Flow Diagram to produce IPE 12 RADFRACY Scenario1 Aspen I
73. erhead split EJ D1 bottoms split EJ Di reb B New Item Reboiler Pump The Reboiler pump is positioned in the upper left hand corner of the Process Flow Diagram in the New Item area independent of the Miscellaneous Flowsheet Area Observe that the Reboiler pump appears in the New Item area on the Project View Before proceeding after completing this example it was brought to our attention that reboiler pumps are used normally with vertical reboilers not with kettle reboilers When appropriate to add a reboiler pump or any other equipment item to the mapping the procedures in this section should be followed To insert the Reboiler pump into the liquid stream from the sump CP BE press the Edit Connectivity button and place the cursor over the Reboiler pump after which the cursor becomes a hand Keeping the left mouse button depressed drag the Reboiler pump over the CP BE stream Release the mouse and click with the left mouse button to insert the Reboiler pump After the streams are realigned the Process Flow Diagram appears as follows IPE 30 DEC3_REBOILERPUMP Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE DEC3 REBOILERPUMP Scenario1 Process Flow Diagram DEX 2g Fie Run View Tools Window DH X s Z g j fA componens zj xi DEC3_REBOILERPUMP Scenario f Main Project QA Main Area B Miscellaneous Flowsheet Arez D1 tow
74. erties are added using the PROPSETS apt file in the ASPEN folder on the Wiley web site associated with this book To accomplish this the ASPEN PLUS simulation file is opened first e g RADFRAC bkp in the ASPEN folder on the Wiley web site Under the File pull down menu the Import entry and the PROPSETS apt file are selected Aspen IPE automatically adds three new property sets after which the file can be saved as RADFRAC IPE bkp a copy of which is in the ASPEN folder on the Wiley web site To check that this has been accomplished using the Data pull down menu select Setup and then Report Options Then display the Streams page by selecting the appropriate tab and click the Property Sets button Observe that all three Aspen IPE property sets have been entered into the Selected Property Sets box Now that the Aspen IPE property sets have been added it is necessary to re run the simulation It remains to transfer the ASPEN PLUS simulation results into Aspen IPE This is accomplished by selecting Send To Aspen Icarus from the File pull down menu in ASPEN PLUS The simulation results are loaded automatically into Aspen IPE INVESTMENT ANALYSIS USING ASPEN IPE In this section the use of Aspen IPE for equipment sizing and costing is illustrated for a depropanizer and for the monochlorobenzene separation process DEPROPANIZER This example involves the single distillation column shown in Figure 1 with its simulation flowsheet and selected results
75. ey 2003 Seider W D J D Seader and D R Lewin Process Design Principles Synthesis Analysis and Evaluation Wiley 1999 Seider W D J D Seader and D R Lewin Product and Process Design Principles Synthesis Analysis and Evaluation Second Edition Wiley 2004 Smith J M C Van Ness and M M Abbott Introduction to Chemical Engineering Thermodynamics Sixth Edition McGraw Hill 2001 IPE 54 APPENDIX I DEPROPANIZER ASPEN PLUS Report IPE 55 ASPEN PLUS Flowsheet simulation results be reproduced using the file RADFRAC bkp in the ASPEN folder on the Wiley web site D1 ASPEN PLUS Program IN UNITS ENG DEF STREAMS CONVEN ALL DATABANKS PURE93 AQUEOUS SOLIDS INORGANIC amp Eh ps SOLIDS INORGANIC NOASPENPCD PROP SOURCES PURE93 AQUEOUS COMPONENTS C2H6 C2H6 C3H8 C3H8 4 10 1 C4H10 1 C5H12 1 C5H12 1 C6H14 1 C6H14 1 FLOWSHEET BLOCK D1 IN FEED OUT DIS BOT PROPERTIES RK SOAVE USER PROPS DRUSR2 1 2 3 PROP DATA RKSKIJ 1 IN UNITS ENG PROP LIST RKSKIJ BPVAL C2H6 C3H8 2 2000000E 3 BPVAL C2H6 C4H10 1 6 70000000E 3 BPVAL C2H6 C5H12 1 5 60000000E 3 BPVAL C2H6 C6H14 1 0156000000 BPVAL C3H8 C4H10 1 0 0 BPVAL C3H8 C5H12 1 0233000000 BPVAL C3H8 C6H14 1 2 2000000E 3 BPVAL C3H8 C2H6 2 2000000E 3 BPVAL C4H10 1 C3H8 0 0 BPVAL CAH10 1 C5H12 1 020
76. iley web site for this book from within Aspen IPE Total Permanent Investment The total permanent investment is computed by the spreadsheet Profitability Analysis 2 0 xls discussed in Section 23 8 of the textbook When using the Aspen IPE option the user enters Total Direct Materials and Labor Costs 983 200 Material and Labor G amp A Overhead and Contractor Fees 77 000 Contractor Engineering Costs 451 000 Indirect Costs 423 800 Adding Equipment Thus far all of the equipment items have originated with the simulation units from an ASPEN PLUS simulation After the mappings have been completed yellow arrows are placed in the blue boxes associated with each equipment item in the Aspen IPE Main window Also in the Process Flow Diagram all of the streams are yellow with the exception of the IPE generated utility streams which are green When it is desirable to add a piece of equipment that is not in a simulation or has not been created during the mapping of simulation units by Aspen IPE the following steps are taken From the IPE Main window press the Project View tab at the bottom of the left hand window 1 the Project Explorer window to give IPE 25 RADFRACX Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE List Ed File Run View Tools Window Help De S B 5 RADFRACX Scenario1 Project View m User Tag Number Item Description J Basis for Capital Costs Main Project Di tower D1 tower
77. is a distillation tower to recover propane and lighter species from a normal paraffins stream as shown in Figure 1 The simulation flowsheet and selected results are shown in Appendix I and in the multimedia tutorial on the Wiley web site associated with this book ASPEN Tutorials Separation Principles Flash and Distillation Also a copy of the file RADFRAC bkp is provided in the ASPEN folder on the Wiley web site 3 Additional features of Aspen IPE are introduced for a more complete process the monochlorobenzene MCB separation process which is discussed in Sections 5 4 of the textbook Seider et al 2009 A copy of the simulation file MCB bkp is provided in the ASPEN folder on the Wiley web site After completing these notes to practice estimating capital costs using Aspen IPE you may wish to solve Exercises 22 4 and 23 21 in the textbook In these notes all of the calculations were carried out using Aspen IPE Version 2006 0 with the design and cost basis date being the First Quarter 2006 IPE 1 d Ibmole hr Py 248 psia 191 nCjH o 5 Ibmole hr C H 30 LK 200 nC Hio 370 350 4 50 1000 P 250 psia b Ibmole hr Tp 225 F z C H 9 nC H o 365 252 psia Figure 1 Depropanizer PREPARING AN ASPEN PLUS SIMULATION FOR ASPEN IPE To estimate equipment sizes and costs using Aspen IPE for a process simulated with ASPEN PLUS it is necessary to prepare th
78. items which may be added to the New Item area or to other new areas To estimate the installed cost of the Reboiler pump either right click on Reboiler pump in the Project View or on its icon in the Process Flow Diagram Then select Evaluate Item brief report that contains the installed cost 49 400 can be accessed by highlighting Reboiler pump in the Project View and pressing the List tab to obtain the Workbook complete report is obtained by re evaluating the capital estimates for the process This is accomplished by pressing the Evaluate Project button and requesting that all equipment items be re evaluated The detailed report appears in the Capital Estimate Report in the List of Equipment and Bulk Material by Area section It can be accessed by selecting Equipment List under Miscellaneous Flowsheet in the left hand window IPE 33 ET ICARUS Editor REP ccp fh File Edi View Options Window Help osu e 3 erm ej el 0201 Miscellaneous Flowsheet Miscellaneous Flowsheet a amp Title page COMPONENT LIST Contract structure Contents R PROJECT SUMMARY onrcrw ITEM TYPE ITEM DESIGN DATA PROJECT DATA SHE DESCRIPTION 2 PROJECT SCHEDULI amp CONTRACT NO 1 F CP 8 CENTRIF Reboiler Pump Casing material cs SUMMAR
79. items are displayed in the Area Bulk Report within the Capital Estimate Report IPE 51 AREA BULK REPORT MANPOWER TOTAL 2 ITEM DESCRIPTION MATERIAL DIRECT ORIGIN SYMBOL 5 N D A T COST USD MANHOURS COST USD COST USD AREA MISC CONCRETE ITEMS 918 173 3354 4272 AREA PIPE TESTING 0 335 8381 8381 GRADE UNPAVED AREA 8552 E23 2997 11549 Area length 50 000 FEET Area width 50 000 FEET AREA INSTRUMENT TESTING 0 179 4672 4672 AREA INSTR RUNS TRAYS JBOX 4132 81 1943 6075 AREA EQUIPMENT GROUNDING 419 23 519 938 AREA PILED FOUNDATION 16974 131 2575 19549 Number of piles 22 AREA ELECTRICAL TESTING 0 22 548 548 AREA ROTATING EQP SPARE PARTS 540 0 0 540 These additional costs sum to approximately 56 500 Together with the Other item on line 10 of the Contract Summary 63 800 and Code of Accounts item 105 for equipment contingencies to allow for design changes 6 100 these sum to approximately 126 400 which for profitability analysis in the conceptual design stage is sufficiently close to 138 400 the difference reported above Returning to the Contract Summary material and manpower costs associated with G and A General and Administrative Overheads 20 600 and 8 400 are obtained from line 13 and material and manpower charges associated with Contract Fees 26 200 and 28 900 from line 14 These sum to 84
80. izer Note that these files are deleted when the project is closed When closed projects are stored in compact backup files izp and szp in the Program Files AspenTech Aspen Icarus 2006 Data Archives_IPE YourProjectName folder When returning to work with Aspen IPE using the File pulldown menu open the folder having the appropriate project name This produces the Open an IPE Project dialog box Select the Project Name and press the OK button This produces the Process Project View window that is the IPE Main window When working in the Process Project View window to examine any portion of the Capital Estimate Report which is automatically stored in your Projects folder after it has been generated press the Capital costs button on the toolbar This produces the Select Report Type To View dialog box Select one of the two options to have Aspen IPE display the capital cost report as an HTML file or in the ICARUS Editor Then press OK Note that when more than one report file exists the Select Capital Cost Report File dialog box is produced from which the appropriate report file is selected This produces the Capital Estimate Report REFERENCES Aspen Technology Inc Aspen IPE 2006 User Guide 2006 Lewin D R W D Seider J D Seader E Dassau J Golbert D N Goldberg M J Fucci and R B Nathanson CD ROM Using Process Simulators in Chemical Engineering A Multimedia Guide for the Core Curriculum Version 2 0 Wil
81. lation items equipment sizes are computed Note that the mapping and equipment sizing steps are accomplished in sequence with sizes and costs of the installation items estimated during the Equipment Costing step To begin the mapping step in the IPE Main window the Map Simulator Items button on the toolbar is pressed to produce the Map dialog box xm Map Source Basis 5 Last Mapping Map All C mi ei ptions Size ICARUS Project Components Review Sizing Selection Auto Map Streams to Lines Cancel For the depropanizer all items are mapped and sized in sequence since the Size ICARUS Project Components button is checked When this button is not checked only the mapping step is completed Also when there are multiple process units of a certain type it may be preferable to map each process unit independently For example if two distillation towers differ in tray efficiency it is necessary to map them separately and change the tray efficiency under Design Criteria before each tower is mapped In this case with just one tower it is simplest to press the Map all Items button under Source Under Basis the Default and Simulator Data button should be selected as shown After pressing OK the Project Component Map Preview dialog box is produced IPE 8 Project Component Map Preview Simulator Information Component Map Information Simulator Items Configuration Component Name Standard Total 1
82. logy Inc for economic evaluation of process designs It determines the capital expenditure operating costs and the profitability of proposed designs Aspen IPE has an automatic electronic expert system which links to process simulation programs It is used to 1 extend the results of process simulation 2 generate rigorous size and cost estimates for processing equipment 3 perform preliminary mechanical designs and 4 estimate purchase and installation costs indirect costs the total capital investment the engineering procurement construction planning schedule and profitability analyses Aspen IPE usually begins with the results of a simulation from one of the major process simulators e g ASPEN PLUS HYSYS CHEMCAD and PRO ID it being noted that users can alternatively provide equipment specifications and request investment analysis without using the process simulators In these notes only results from ASPEN PLUS are used to initiate Aspen IPE evaluations and only capital cost estimation is emphasized Readers should refer to the Aspen IPE User s Guide Click on Documentation in the Help menu of Aspen IPE for detailed instructions explanations and for improvements in new versions of the software system These notes are organized as follows 1 Instructions are provided to prepare an ASPEN PLUS simulation for use with Aspen IPE 2 A depropanizer example is provided to illustrate the use of Aspen IPE The depropanizer
83. m equipment C EJ VP Vessels pressure storage HT Crushers flakers mills stock CR FL M ST Evaporators dryers cryst CRY E wFE AD D DD RD TDS Solids conveying CO CE EL FE HO 5 me rer Cancel Select Help Reboiler is chosen from the dialog box that appears and finally a Kettle type reboiler with floating head is selected as the last step of the replacement procedure IPE 10 ICARUS Project Component Selection 4 ICARUS Project Component Selection Component Name Suffix D1 reb Component Name Suffix m Project Components Project Components Process equipment Process equipment Heat exchangers heaters RB FU Heat exchangers heaters RB FU Reboiler Heat exchanger Kettle type reboiler with floating head Thermosiphon type reboiler U tube kettle type reboiler Cancel Select Help After these steps are completed the modified mapping should appear on the Project Component Map Preview dialog box Project Component Map Preview Simulator Information Component Map Information Simulator Items Configuration Component Name Standard Total D1 reb Current Map List HT HORIZ DAUM CP CENTRIF E Delete One Mapping Delete All Mappings m ICARUS Project Component Description Process equipment Heat exchangers heaters RB FU Reboiler Kettle type reboil
84. n Component Name Standard Total Di eb Current Map List HT HORIZ DRUM New Mapping CP CENTRIF Delete One Mapping Delete All Mappings ICARUS Project Component Description Process equipment Heat exchangers heaters RB FU Reboiler U tube kettle type reboiler Instructions Select desired simulator information Press New Mapping to create new ICARUS project components corresponding to the simulator selection To remove mappings use a Delete Cancel Help When the configuration is switched from Standard Total to Full Single a reboiler pump is automatically added during the mapping as well as a distillation pump and two product heat exchangers In this chapter the reboiler pump is added manually for illustrative purposes IPE 9 New Mapping is pressed and reb is highlighted on the screen that appears Then OK is pressed Select a Suffix Select one item from the following list other Cancel Help Next Heat Exchangers heaters is highlighted on the CARUS Project Component Selection dialog box that appears and OK is pressed ICARUS Project Component Selection Component Name Suffix pi eb LI Project Components LI Process equipment Agitators mix react knead AG AT BL K Compressors and blowers GC FN Drivers MOT TUR Heat exchangers heaters Packings linings PAK LIN Pumps CP GP P Towers columns trayed packed DDT Tw Vacuum syste
85. n gauge pressure PSIG tangent height Design temperature DEGF 310801723 Real Operating temperature DEGF 260801723 Tray material Default CTI E scription 4 5 M plus tray Tray spacing WICHES 24 stack height Demister thickness INCHES Cladding material zi Skirt height FEET ind or seismic desian l v lt E DEC3 Sce 7 D1 tower IPE 14 Observe that the depropanizer tower was designed by Aspen IPE to have a 5 ft diameter and a 36 ft tangent to tangent height using sieve trays Note that the number of trays is the number of equilibrium stages 12 14 2 excluding the condenser and reboiler divided by the tray efficiency 0 8 which is 12 0 8 15 With a 2 ft tray spacing a 4 ft high disengagement region at the top and a 10 ft high sump at the bottom the nominal vessel tangent to tangent height is 2 x 14 4 10 42 ft Consequently the number of trays and the vessel tangent to tangent height must be adjusted manually to 15 and 42 ft respectively Be sure to click the OK button at the top of the form to save any sizing changes Also Aspen IPE calculated a design temperature and pressure in accordance with the Design Criteria specifications used the default shell material A515 which is carbon steel for pressure vessels at intermediate and higher temperatures and used the default tray material A285C which is for carbon steel plates in pressure vessels that have
86. nd For the MCB separation process it is convenient to have Aspen IPE estimate the costs for the entire project at once After pressing the Evaluate Project button on the IPE Main window the Evaluate Project dialog box appears Evaluate Project x sf C Evaluate Gre Evaluate All Items Report File MCB ECE Cancel Help As discussed for the depropanizer Aspen IPE prepares the Capital Estimate Report MCB ccp which contains detailed listings of the items to be procured to install the equipment classified in the areas of piping instrumentation electrical structural steel and insulation estimates of the man hours required for installation estimates of the costs and an installation schedule Estimates for contractor engineering and indirect costs are listed as well The CARUS Editor displays the report in two adjacent windows with a listing of the major subject headings listed in the left hand window Most of this information though necessary for obtaining accurate cost estimates is far too detailed for most estimates made in the conceptual design stage and hence is normally not printed by process engineers for whom these notes are intended Of greatest interest to process engineers is the information in the following two sections IPE 48 1 Equipment List 2 CONTRACTOR NO 1 PRIME CONTRACTOR which are accessed by double clicking on these titles in the left hand window It is recommended that jus
87. nd the Input Units of Measure Specifications dialog box is displayed This form allows the user to customize the units of measure that will appear on input specification forms Click the C ose button to accept the default settings Third the General Project Data dialog box appears Since no adjustments are needed in this example press the OK button Fourth the Load Simulator Data dialog box is displayed Enter Yes to do so Aspen IPE now opens two windows shown below The narrow Project Explorer on the left is in Project View mode and a wider Main window initially blank is on the right When they are not opened by default two additional windows Palette and Property can be opened using the View pulldown menu Aspen IPE allows the user to specify many parameters for equipment sizing or to accept default values These are the bases for sizing the equipment and for specifying its utilities The first step in completing this simulation is to examine the project Design Criteria This can be done by selecting the Project Basis View tab in the Project Explorer Note that the Design Criteria and Utility Specifications entries under the Process Design heading are the most relevant when estimating equipment sizes and costs When it is not already open double click on IPE 4 Design Criteria to expand its folder Then double click on Common to cause the Global IP form to appear in the Main window RADFRAC Scenario1 Aspen Icarus Process
88. nt item and its associated installation items and costs materials and manpower items not typically charged to the tower e g charges for instrument testing pipe testing and equipment grounding are excluded These costs are accumulated for each area that contains project components and are summed for the entire project as discussed later in this section To have Aspen IPE estimate the capital costs of all the units at once i e the entire project press the Evaluate Project button on the IPE Main window The Evaluate Project dialog box appears The dialog box shows the default report file name CAP REP CCP The contents of this report are viewed in the CARUS Editor If you prefer a different name e g DEC3 as shown below enter it in the Report File field Evaluate Project ge C Evaluate Evaluate All Items Report File DEC3 DK Cancel Help FERENT When finished with its evaluation Aspen IPE displays a window that contains an executive summary of its results This window is not shown here Note that when the user presses the Tools pulldown menu selects Options and then View Spreadsheet in Excel Aspen IPE is activated to prepare several spreadsheets including the Equipment Summary Utility Summary available in Version 12 1 ProjSum Executive Summary and Run Summary spreadsheets available in older versions For the details of these spreadsheets see the Aspen IPE User s Guide choo
89. perature 250 00 DEG F Design gauge pressure 258 30 PSIG Application CONT Base material thickness 0 625 INCHES Total weight 9600 LBS ITEM MATERIAL i MANPOWE R xxxxx L M FRACTION FRACTION H RATIO USD OF PE USD OF MANHOURS USD USD EQUIPMENT amp SETTING 25700 1 0000 693 0 0270 293 0 027 PIPING 21078 0 8202 10716 0 4170 439 0 508 CIVIL 1892 07077362 2280 0 0887 118 1 205 STRUCTURAL STEEL 0 0 0000 0 0 0000 0 000 INSTRUMENTATION 24219 0 9424 4428 0 1723 168 0 183 ELECTRICAL 0 0 0000 0 0 0000 Oye 0 000 INSULATION 0 0 0000 0 0 0000 0 0 000 PAINT 2 1781 0 0460 2004 0 0780 108 1 696 SUBTOTAL 74071 2 882 20122 0 7830 862 0 272 TOTAL MATERIAL AND MANPOWER COST USD 94200 INST L COST PE RATIO 3 665 PURCHASED ORIGIN ITEM TYPE ITEM DESIGN DATA EQUIPMENT DESCRIPTION COST USD Equipment mapped from 1 GB 4 CENTRIF Dl reflux pump Casing material cS 7100 CODE OF ACCOUNT 161 Liquid flow rate 401 99 GPM TAG NO Dl reflux pu Fluid head 225 00 FEET Design temperature 250 00 DEG F Speed 3600 00 RPM Driver power 20 00 HP Fluid viscosity 0 0775 CPOISE Design gauge pressure 258 30 PSIG Driver type MOTOR Seal type SNGL Total weight 710 LBS ITEM MATERIAL MANPOWE R xxxx 1 FRACTION FRACTION RATIO USD OF PE
90. rom D1 EJ D1 cond acc Remarks 2 Boe em dessin User tag number D1 tower EJ D1 reb Structure tag Component WBS EJ F1 flash vessel Quoted cost per item 050 Ei Currency unit for cost 2 Humber of identical items 1 Bs Bray ome z Application d Shell material 5 Vesse ameter Vessel tangent to tangent height FEET 72 Design gauge pressure PSIG 35 304 Vacuum design gauge pressure PSIG Design temperature DEGF 353 017692 Operating temperature DEGF 303 017692 Tray material A Humber of rays Tray spacing INCHES 24 Demister thickness INCHES Cladding material NONE Skirt height FEET Wind or seismic desian l lt lt lt EP E MCB E Ready IPE 47 Similarly the distillation column is designed to have a 3 ft diameter a 72 ft tangent to tangent height and 30 trays also in accordance with Figure 5 23 in the textbook Seider et al 2009 Standard Basis As for the depropanizer discussed earlier the MCB separation process can be viewed as representing an addition to an existing plant Consequently the standard basis profile is selected to be LOCAL CONTRACTOR and the Project Type is selected as Plant addition suppressed infrastructure Equipment Costing Aspen IPE estimates purchase and installed costs for the equipment units individually or for the entire project using a single comma
91. s heading to produce the Standard Basis IP dialog box IPE 17 Project Basis 5 Project Properties Eg General Project Data gt J Basis For Capital Costs s Output Reports Unit General Specs Currency 4 OK Cancel Standard Basis IP Hame Process Description Process Complexity Item 1 Proven process Typical 4 Construction WorkFor Process Control Digital Eg General Rates PROJECT IHFORMATION t3 craft kates Project Location ndexing 3l n B Material Project Type ZEE Plant addition suppressed infra 5 Man hour Contingency Percent 18 B Location Estimated Start Day of Basic Engineering 01 5 6 Process Design Estimated Start Month of Basic Engineering JAN B m 5 Estimated Start Year of Basic Engineering 06 M rae Hae gt Soil Condition Around Site SOFT CLAY Eg Simulator Units of E Project Component M EQUIPMENT SPECIFICATION Design Criteria Pressure Vessel Design Code ASME Eg Common Vessel Diameter Specification ID Eg Pumps P and I Design Level FULL E Camnrescnre For the depropanizer column most of the default values are acceptable Because a single distillation system would be installed normally on an existing plant site using utilities provided by the site the Project Type would not be selected as Grass Roots Clear field This Project Type would cause new items already provided at the site
92. s separately with the appropriate efficiency specified in the Design Criteria prior to each mapping Note that to locate the tray efficiency open the Design Criteria folder then the Towers folder and finally the Trayed entry to give J MCB_IPE Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE Towers Trayed DESIGN E File Run View Tools Window Help B x a i gt AW All components r Eh Project Basis 4 Process equipment Eg Project Properties OK Cancel Apply J Plant bulks Eg General Project Data Towers Trayed IP J Site development Basis for Capital Costs Hama Unis 4 E Buildings Eg Output Reports Unit I E Quoted equipment Eg General Specs segnrresswe ____ E Unit cost library Eg Currency Design Temperature E Equipment model library Construction Workfor Tray Spacing INCHES 24 Recent Items Eg General Rates Trayed Tower Flooding Factor B Craft Rates Po 20 Trayed Tower Derating Factor B Man hour Relative Volatility of Key Components Eg Location Tray Efficiency Equipment Item J Process Design 2 Simulator Type Stack without flare tip Eg Simulator File Name Eg Simulator Units of A Derrick supported Flare st 4 B Project Component M lt gt GQ Design Criteria Eg
93. se Documentation from the Help IPE 20 Menu and follow the path Aspen Icarus Process Evaluator User s Manual Evaluating the Project Reviewing Investment Analysis To view a detailed report of the capital costs access the CARUS Editor by pressing the Capital Costs button on the IPE Main window On the Select Report Type to View dialog box mark the Evaluation Reports checkbox and press the OK button Note that when the nteractive Reports checkbox is pressed the Aspen ICARUS Reporter dialog box is produced This permits the user to select individual items to be examined rather than entire reports as discussed below Select Report Type To View X C Interactive Reports On Screen html xls Evaluation Reports ccp prp irp cci srp scn Cancel Help The CARUS Editor displays the report in two adjacent windows with the major subject headings listed in the left hand window Most of this information though necessary for obtaining accurate cost estimates is far too detailed for most estimates during the conceptual design stage and hence is normally not printed by process engineers for whom these course notes are intended Of greatest interest to process engineers is the information in the following two sections 1 Equipment List 2 CONTRACTOR NO 1 PRIME CONTRACTOR which are accessed by double clicking on these titles in the left hand window It is recommended that just small portions of the report
94. section of the report Having added the Reboiler pump the total permanent investment can be re estimated as discussed in the prior section This discussion is not repeated here Finally all of the Aspen IPE results can be reproduced using the DEC3RP folder in the ASPEN folder on the Wiley web site from within Aspen IPE Applying Alternative Utilities When desired the default utility applied by Aspen IPE can be altered interactively for a particular equipment item such as a condenser or reboiler after it has been mapped For example when the resulting surface area of a reboiler is too large due to a small log mean temperature difference the steam utility can be replaced with steam at a higher pressure to reduce the area being careful to stay in the nucleate boiling region This is illustrated for the reboiler of the depropanizer as an example For this reboiler Aspen IPE uses steam at 50 psi as the default utility To change to higher pressure steam say at 100 psi the following steps are taken In the Process View or Process Flow Diagram right click on the reboiler and select Size Item from the menu that appears This produces the Interactive Sizing dialog box as shown below IPE 34 Interactive Sizing DRB KETTLE Item 1 ICUST IN ICUST EX ICP BSPLR ICP BR 4141414 PROCESS INFORMATION Raw Surface Area SF 3 112 65453 Surface Area with Overdesig SF 3 578 55271 Final Surface Area SF 13
95. st of the equipment item and the direct cost of installation materials and labor directly related to the equipment item These include the piping and field instruments that bring the process streams to and from the tower the foundation to support the tower structural steel e g ladders and platforms attached to the tower electrical lighting heat tracing cable and local components insulation piping and fireproofing It does not include 1 the fractional cost of buildings pipe racks the project control system or electrical substations fire control systems chemical and storm sewers and drains treatment IPE 19 systems fences guard houses etc 2 the work required to perform basic and detail engineering to procure all project components and to manage the engineering process and 3 taxes freight to the site permits royalties etc Note that the cost basis date is 2006Q1 with the costs updated in each new version of Aspen IPE You can check the cost basis for your version by selecting Show Cost Basis in the Help menu Consequently the total material and manpower cost is not the total bare module cost discussed in Section 22 3 of the textbook The estimate reported by Aspen IPE does not include contractor engineering costs indirect costs cost of pipe racks and intra plant piping and the cost of sumps and sewers which can be added to the project as additional items Furthermore because the report focuses on an equipme
96. steam tables of Smith et al 2001 Units Design Temperature DEGF 331 Design Pressure PSIA 175 Inlet Temperature DEG F 281 Exit Temperature DEG F 281 Pressure B PSIA 50 Energy Transfer per Unit Mass BTULB 824 Unit Cost 275 Unit Cost Units CostiKLB T T When complete the OK button is pressed to return to the Develop Utility Specification dialog box Then the Close button is pressed to return to the IPE Main window Note that utility files can be created for use on other design projects For implementation details see the Aspen IPE User s Guide IPE 7 Other specifications can be changed in a manner similar to those described for the utilities and design criteria More information and definitions are provided in the Aspen IPE User s Guide Defining the Project Basis Process Design Mapping Process Simulation Units into Aspen IPE Having completed the initial setup the next step is to map the process simulation units that is blocks modules or subroutines into more descriptive models of process equipment e g mapping a HEATX simulation unit into a floating head shell and tube heat exchanger mapping a RADFRAC simulation unit into a tray tower condenser reflux accumulator etc and associated plant bulks which include installation items such as piping instrumentation insulation paint etc After Aspen IPE completes the mapping and reserves storage for the instal
97. such as 87100 In the next dialogue box enter Steam 100PSI as the description and change the temperature and pressure to that of saturated steam at 100 psia 327 8 F Delete the entry for the total mass flow as it is recalculated by Aspen IPE as shown below L Develop Stream 57100 Cancel Update Mixture Print Item 1 SICUST EX Steam 100 5 Water 3278 PSIA 100 Molecular Weight 18 015 Total Mass Flow LBH 10 LIQUID INFORMATION Liquid Mass Flow LBH Liquid Mass Density PCF 51 784484 Liquid Specific Heat Capacity BTULB DEG F Liquid Conductivity BTUHFT DEG F Liquid Viscosity CPOISE Surface Tension DYNES CM VAPOR INFORMATION LBH Click the OK button to accept these changes Now the new stream must be attached to the reboiler With the Ports Visible button depressed click on Draw Disconnected Stream 4 Select the new stream from the list and add it to the flowsheet by left clicking on the reboiler Then left click again on the steam entry port Not that the port is highlighted in green as the cursor hovers over it The new stream now appears in white as shown below IPE 36 QP RADFRACX 5 1 Aspen Icarus Process Evaluator 200 File Run View Tools Window Help S talg t Q ae gt ALU components aspenONE RADFRACX Scenario1 Process Flow Diagram General Rates Eg Craf
98. t Rates Indexing Ej Material Eg Man hour Eg Location Process Design 9 Simulator Simulator File Name s Simulator Units of Measure B Project Component Map Specif 5 29 Design Criteria Eg Common 5 Pumps Eg Compressors Eg Heat Exchangers Towers Packed s Trayed Es Configurations Towers 5 vessels Agitated Eg Storage s Horizontal Eg Vertical Miscellaneous Eg Configurations Flash Utility Specifications Sizing Selection B Investment Analysis Investment Parameters s Operating Unit Costs s Raw Material Specifications Product Specifications Streams Now repeat this procedure for the exit stream replacing it with a new user stream named ST100 EX using ST100 IN as the basis stream The result is shown below J RADFRACX 5 1 Aspen Icarus Process Evaluator 2006 aspenONE RADFRACX Scenario1 Process Flow Diagram File Run View Tools Window Help fT w a e gt A U All components E 5 General Rates Eg Craft Rates B Indexing Eg Material Es Man hour ad split Eg Location Process Design Eg Simulator Es Simulator File Name s Simulator Units of Measure Eg Project Component gt J Design Criteria Eg Common s Pumps Trayed Es Configurations Towers Eg vessels Eg Agitated Eg Storage Es
99. t sad EJ D1 reb Application u PU Shell material F1 flash vessel Vessel diameter FEET E Hz Vessel tangent to tangent height FEET 42 E Design gauge pressure PSIG 35 304 Vacuum design gauge pressure PSIG EN Ti Design temperature DEGF 301 035439 Operating temperature DEGF 251 035439 Tray material Humber of trays Tray spacing INCHES Demister thickness INCHES Cladding material NONE gt Skirt height FEET Wind or seismic design 21 Fluid volume PERCENT 20 Manhole diameter INCHES Humber of manholes Base material thickness INCHES Corrosion allowance INCHES Humber of body flange sets PAIR lt gt E Li MCB_IPE At tower Note that the column is designed to have a 1 5 ft diameter a 42 ft tangent to tangent height and 15 trays in accordance with the specifications in Figure 5 23 of the textbook Seider et al 2009 Because of the small diameter a packed column would be preferred but is not considered here F MCB_IPE Scenario1 Aspen Icarus Process Evaluator 2006 aspenONE D1 tower Run View Tools Window Help Duis d 6 D lt l xl MCB_IPE Scenario1 Project View Main Project d Options Size Evaluate P amp D Add Delete 04 Main Area B Miscellaneous Flowsheet Arez E A1 tower EJ D1 tower E D1 cond Remarks 1 Equipment mapped f
100. t small portions of the report be printed This is accomplished by highlighting the desired section and pressing the Print button on the toolbar It is often preferable to print in landscape format As shown below for the absorber the List of Equipment and Bulk Material by Area portion of the report is displayed when the Equipment List is accessed This provides the Purchased Equipment amp Setting and Installed Direct Costs 1 Total Material and Manpower Cost or Total Direct Materials and Labor Cost for each piece of equipment Furthermore portions of the complete printed output are provided in Appendix IV of these notes EZ ICARUS Editor d File Edit View Options Window Help Dag art e gt maB e amp LICENSED FOR USE BY 9 0201 Miscellaneous Flowsheet Miscellaneous Flowsheet COMPONENT LIST 2 5 PURCHASED ORIGIN ITEM ITEM id DESIGN EQUIPMENT CONTRACT N DESCRIPTION COST USD amp SUMMARIES o uno x mV ramo RR So eee wr maed eS Te ee ee oe eS ae ey amp 1 Main Area Equipment mapped from 1 TW 1 TRAYED Al tower Shell material 515 25700 Equipment CODE OF ACCOUNT 111 Number of trays 1s _ Report arc TAG NO Al tower Vessel diameter 1 500 FEET 2 Miscellanec Vessel tangent to tangent height 42 00 FEET Equipment Design temperature 301
101. tilities should be added For example because the textbook recommends that process designs accept cooling water at 90 F and heat it to 120 F it is necessary to replace the temperatures associated with the cooling water utility To modify these temperatures double click on the Cooling Water entry which produces the Utility Specifications dialog box Utility Specifications C Program Files AspenTech Aspen Icarus 2006 ic_cache Pr E3 Cooling Water Water 7 sss 19 98 Then the inlet and exit temperatures are changed to 90 and 120 F as shown above Other default values can be changed similarly Click OK when finished IPE 6 add a utility not in the existing utility list click on the Create option on the Develop Utility Specifications dialog box As shown below low pressure steam is added as a utility which is named Steam 9 50PSI and has the Steam Fluid Class Develop Utility Specifications C Program Files AspenTech ption C Modify Create Modify Existing Utility Stream Create New Utility Stream Name Cooling Water Steam 5 PSI High Temp Healing Dil Fluid Class Sos esteso Refrigerant Freon 12 Refrigerant Ethane Refrigerant Propane Refrigerant Ethylene Refrigerant Propylene Refrigerant Freon 12 Refrigerant 50 Utilit Refrinerant Pronane V After the Create button is pressed the new utility is displayed as shown below where the entries have already been made from the
102. tower Current Map List New Mapping HE FIXED T 5 E HT HORIZ DRUM Delete One Mapping CP CENTRIF Ss Delete All Mappings ICARUS Project Component Description Process equipment Towers columns trayed packed DDT Tw Tower single diameter Trayed tower Instructions Select desired simulator information Press New Mapping to create new ICARUS project components corresponding to the simulator selection To remove mappings use Delete Cancel For each Simulator unit or block the Current Map List shows all corresponding equipment items in Aspen IPE Observe that for the default configuration Standard Total five equipment items are included TW TRAYED tower HE FIXED T S condenser HT HORIZ DRUM reflux accumulator CP CENTRIF reflux pump and RB U TUBE reboiler Note that the two C entries denote stream splitters For this example a reboiler pump will be added as discussed in the section on Adding Equipment Furthermore each equipment item has a specific type assigned by Aspen IPE that can be modified To modify the equipment type highlight the item to be modified In this example the kettle reboiler with U tubes is replaced by a kettle reboiler with a floating head To begin the RB U TUBE reboiler is deleted by highlighting it and pressing Delete One Mapping Project Component Map Preview Simulator Information Component Map Information Simulator Items Configuratio
103. ux A U All components Select a Standard Basis File Project Basis Eg Project Properties Eg General Project Data Basis For Capital Costs s Output Reports Unit 1 PLANT OWNER Standard Basis Name Standard Basis Description 5 General Specs 2 QwNER HEAD OFFICE E Currency 3 LOCAL CONTRACTOR Cancel 4 NATIONAL CONTRACT J Construction Workfon _ Ey General Rates 5 INTERNATIONAL CON Help Eg Craft Rates CJ Indexing Eg Material Eg Man hour Eg Location J Process Design Eg Simulator Type Eg Simulator File Name Similar Inite To select a standard basis profile for a project in the Project Basis view right click on the Basis for Capital Costs Click Select to choose the most appropriate profile You may be asked to confirm your selection since your choice may alter costs that have been previously determined The Basis for Capital Costs includes specifications for process controls plant location currency wage rates units of measure and contractor profiles Default values are provided for all entries most of which need not be adjusted When modifying the Basis for Capital Costs changes can be made to the General Standard Basis Specifications or to the Construction Workforce and Indexing To view the General Standard Basis Specifications the Project Basis tab is selected in the Project Explorer Double click the General Specs entry under the Basis for Capital Cost

aspen icarus process evaluator (ipe)

Contents

Download Pdf Manuals

Related Search

Related Contents