using rules

Present cost

old cost *

Equipment used
Heat exchangers *8
Vessels*3
Reactors*1
Distillation towers*2
Pumps*3

Note:

ipment used
t exchangers *8

illation towers*2

Pumps calculations are neglected

Heat exchangers

Area

Pressure delta Pressure

E-201

99.4

14.2

4.2

E-202

171

14.1

1.2

E-203

101.8

12.8

8.8

E-204

22

10

0.5

E-205

100.6

9.3

5.3

E-206

83

10

3.4

E-207

22.7

6.3

2.3

E-208

22.8

6.6

2.6

Heat exchangers
Heat exchangers

Equipment cost @1979(BP)

P factor

Type Factor

9100

1.1

15000

1.1

9900

1.1

3400

1.1

9500

0.8

8500

1.1

3450

3500

1
Sum

Heat exchangers cost @1979(BP)=

51860

Heat exchangers cost @2016(BP)= Err:509

Heat exchangers cost(EGP)

2855885

Purchased cost(BP)
10010
16500
10890
3740
7600
9350
3450
3500
65040

assum ptions

unit

Cost index @1979=

238.7

Cost index @2016=

550

1 dollar=

18.5

EGP

1 British pound

23.9

EGP

Vessels

Type

V-201

Horizontal

V-202

Horizontal

V-203

Horizontal

Reactor vessel

Type

R-201

Vertical

Catalyst type
Silicon-aluminium oxide zeolite

Area (m2)
0.4071

Diameter

Length

Material factor

Pressure

0.96

2.89

10.3

0.85

2.53

7.3

Diameter

Height

Pressure

Equipment cost

0.72

3.5

14.7

13500

Reactor vessel @2016(BP)=

Err:509

Reactor vessel @2016(EGP)=

Err:509

Volume(m3) Mass (Kg) Selling price dollar /kg

2.93112

2139.7176

1.34

Catalyst cost (EGP)

Bulk density
730

53043.599304

Total Reactor cost (EGP 945163.4149722

P factor

Equipment cost(BP)

Purchased cost @1979(BP)

10000

Err:509

1.2

9000

Err:509

1.1

6000

Err:509

Sum

27400

Vessels cost@ 2016(BP)=

63133.6405529954

Vessels cost (EGP)=

1508894.00921659

P factor

Material factor

Purchased cost(BP)

1.2

Err:509
Cost index @1979=
Cost index @2016=

cost (dollar)

Cost (EGP)

2867.2216

53043.599304

1979(BP)

assum ptions

unit

Cost index @1979=

238.7

Cost index @2016=

550

1 dollar=

18.5

EGP

1 British pound

23.9

EGP

Distillation towers

Diameter

Height

T-201

0.79

5.2

Trays number=

21

T-202

0.87

Trays number=

26

Colonne1

Colonne2

Towers cost @1979(BP)

10445.5

Towers cost @2016(BP) 24067.9724

Towers cost (EGP)

575224.539

4.6

Bare cost (BP)

Pressure

P factor

Type

Material factor

2500

9.6

1.1

sieve

1.7

sieve

1.7

55
2800
60

6.3

1.1

Sum

Purchased/ Installed cost(BP)

2750
1963.5
3080
2652
10445.5

assum

ptions

Cost index @1979=

238.7

Cost index @2016=

550

1 dollar=

18.5

1 British pound

23.9

unit

EGP
EGP

Total equipment cost

Heat exchangers
Vessels
Reactor vessel
Distillation column
sum=

EGP
2855885
1508894
945163
575225
5885167

Items of PPC (Fluid)

Colonne1

Equipment

Installation

0.4

Piping

0.7

Instrumentation

0.2

Electrical

0.1

Buildings

0.15

Storages

0.15

Utilities

0.5

Site development

0.1

Auxilary Buildings

0.15

PPC

3.45

Physical Plant Cost=

20303826.15

Total investment required(EGP)=

29440548

FCI=

29440548

WCI=
Total Capital Investment(EGP)=

4416082
33856630

Items of IPC (Fluid)

Design and Engineering

0.3

Contractor's fee

0.05

Contingency

0.1

IPC

0.45

Inderect Plant Cost=

9136722

Total euqipment cost=

5885167

#
1
2
3
4
5
6
7

Equipment
E-201
E-203
E-204
E-205
E-206
E-207
E-208

pump costs

Utility
mps
cw
mps
cw
mps
cw
cw

Flow rate (ton/hr)

7.22
297.1
1.37
78.47
3.29
160.1
28.7

flow rate (kg/hr)

7220
297100
1370
78470
3290
160100
28700

8797408 EGP

Utility

mps

cw

mps

Equipment

E-201

E-203

E-204

Temperature In (C)

184

30

184

Temperature Out (C)

184

40

184

Flow (tonne/h)

7.22

297.1

1.37

total utilities annual cost

448667800 EGP

Kg/year
51984000
2139120000
9864000
564984000
23688000
1152720000
206640000

Unit Cost (L.E./kg)

5
0.003
5
0.003
5
0.003
0.003

sum=

Cost (L.E./year)
259920000
6417360
49320000
1694952
118440000
3458160
619920
439870392

cw

mps

cw

cw

E-205

E-206

E-207

E-208

30

184

30

30

40

184

40

40

78.47

3.29

160.1

28.7

Raw material cost

methanol
stream (1)
process water
stream (15)

product cost

Product,tonne/h
5.97

Q Metric Tonne/h

costEGP/hr
8.37

131618.25
Cost EGP/hr

2.39

4.78
total cost of raw material

V (m^3/hr)

cost of DME ($) /metric ton

cost of DME EGP/hr

2500

276112.5

Annual cost( EGP)

947651400
Annual cost EGP
34416
947685816

Cost of DME (EGP)/year

1,988,010,000.00

Assumptions
1 US dollar = 18.5 EGP
Cost of methanol= 850 $/metric ton
Cost of di methyl ether = 12500 $/metric ton

Labor calculations

Product(DME)

Using curve 6-8 in peters intersecting line C

Operating labor,employee-hours/(day)(process step)
Considering we have three basic process steps( reaction distillation and heat transfer
and the plant operates 300 days per year
we get the total number of employee hours per year
We will assume that an average worker charges 3000 EGP per month( one month is 22 day
so now we can calculate the charge of one hour for the employee
The total cost of labor

5.97
143.28

ton/hr
ton/day

31.5

employee hr/day.process step

28350

hr/year

17.04545455
483,238.64

EGP/hr
EGP/year

FCI=

29440548 EGP

Indirect
Sales and Distribution
Research and Development
General Overheads
Indirect =

Manufacturing Cost
TPC (EGP)

Direct
0.25*Manufacturing Cost

371,834,087.30

EGP

1,487,336,349.20 EGP
1,859,170,436.50

Variable
Raw Materials
Utilities
Shipping and packaging
Miscellaneous
VC =

Direct
Variable

Fixed
947,685,816.00
Labor
48,323,864.00
448,667,800.00 Supervision 9,664,772.80
0
Plant overhead24,161,932.00
294,405.48
Depreciation 4,416,082.20
###
Interest
588,810.96
Insurance
294,405.48
Rent
294,405.48
Maintenance 2,944,054.80
FC =
###
EGP

TPC (EGP)

Annual sales
Gross Profit
Taxes (25%)
Net Profit

1859170436.5

1988010000
128839563.5

96629672.625

FCI
90688327.72
Turn Over Ratio 21.9213436831
Pay Back Time
%Return

1.0655138876
93.8514280928

Annual sale

Variable cost

1988010000

1396648021

Capacity

12

10

Fixed cost
0

Err:509

10

Err:509

20

Err:509

30

Err:509

40

Err:509

50

Err:509

60

Err:509

70

Err:509

80

Err:509

90

Err:509

100

Err:509

0
0

10

20

30

40

50

fixed cost

TPC

Colonne1

90688327.72 1487336349.2

Variable cost

Annual sales

Colonne1

TPC

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Err:509

Fixed cost
Variable cost
Annual sales
Colonne1
TPC

Fixed cost
Variable cost
Annual sales
Colonne1
TPC

30

40

50

60

70

80

90

100

Fixed cost
Variable cost
Annual sales
Colonne1
TPC

100

Fixed cost
Variable cost
Annual sales
Colonne1
TPC

BEP=

15% Capacity