(A) Data for Sizing of Equipments:

(1) Vessel Sizing:

For the desired temperature range, consider the required materials of construction for vessels
as shown in table below:

Table 1: Materials of Construction

High Temperature service Low Temperature service

o o
Tmax ( F) Steel Tmin ( F) Steel
950 Carbon Steel (CS) -50 Carbon Steel (CS)
1150 502 Stainless Steels -75 Nickel Steel (A203)
1300 410 Stainless Steels -320 Nickel Steel (A353)
330 Stainless Steels
1500 430, 446 Stainless Steels -425 Stainless Steels (SS)
Stainless Steels (SS) (302, 304, 310, 347)
(304, 321, 347, 316)
Hastelloy C, X
Inconel
2000 446 Stainless Steels
Cast Stainless, HC

Table 2: Guthrie Material and Pressure Factors for Pressure Vessels

MPF = Fm Fp
Shell Material Clad, Fm Solid, Fm
Carbon Steel (CS) 1.00 1.00
Stainless Steel 316 (SS) 2.25 3.67
Monel 3.89 6.34
Titanium 4.23 7.89
Vessel Pressure (psig)
Up to 50 100 200 300 400 500 600 700 800 900 1000
Fp 1.00 1.05 1.15 1.20 1.35 1.45 1.60 1.80 1.90 2.30 2.50

(2) Heat Transfer Equipment:

Table 3: Typical Overall Heat Transfer Coefficients

Shell Side Tube Side Design U (Btu/ft2-hr-oF)

Liquid – liquid Media
Cutback asphalt Water 10-20
Demineralized water Water 300-500
Fuel oil Water 15-25
Fuel oil Oil 10-15
Compiled By Prof. Prasad Parulekar
Gasolene Water 60-100
Heavy oils Heavy oils 10-40
Heavy oils Water 15-50
Hydrogen- rich reformer stream Hydrogen- rich reformer stream 90-120
Kerosene or gas oil Water 25-50
Kerosene or gas oil Oil 20-35
Kerosene or jet fuels Trichlorethylene 40-50
Jacket water Water 230-300
Lube oil (Low viscosity) Water 25-50
Lube oil (High viscosity) Water 40-80
Lube oil Oil 11-20
Naptha Water 50-70
Naptha Oil 25-35
Organic solvents Water 50-150
Organic solvents Brine 35-90
Organic solvents Organic solvents 20-60
Tall oil derivatives, vegetable oil, Water 20-50
etc.
Water Caustic soda solutions (10-30%) 100-250
Water Water 200-250
Wax distillate Water 15-25
Wax distillate Oil 13-23
Condensing vapour-liquid Media
Alcohol vapour Water 100-200
o
Asphalt (450 F) Dowtherm vapour 40-60
Dowtherm vapour Tall oil and derivatives 60-80
Dowtherm vapour Dowtherm liquid 80-120
Gas-plant tar Steam 40-50
High-boiling hydrocarbons V Water 20-50
Low-boiling hydrocarbons A Water 80-200
Hydrocarbon vapours Oil 25-40
(partial condenser)
Organic solvents A Water 100-200
Organic solvents high NC, A Water or brine 20-60
Organic solvents low NC, V Water or brine 50-120
Kerosene Water 30-65
Kerosene Oil 20-30
Naptha Water 50-75
Naptha Oil 20-30
Stabilizer reflux vapours Water 80-120
Steam Feed water 400-1000
Steam No. 6 fuel oil 15-25
Steam No. 2 fuel oil 60-90
Sulphur di-oxide Water 150-200
Tall oil derivatives, Water 20-50
vegetable oils (vapour)
Compiled By Prof. Prasad Parulekar
 Gas-liquid Media
Air, N2, etc. (compressed) Water or brine 40-80
Air, N2, etc., A Water or brine 10-50
Water or brine Air, N2 (compressed) 20-40
Water or brine Air, N2, etc., A 5-20
Water Hydrogen containing natural-gas 80-125
mixtures
Vaporizers
Anhydrous ammonia Steam condensing 150-300
Chlorine Steam condensing 150-300
Chlorine Light heat-transfer oil 40-60
Propane, butane, etc. Steam condensing 200-300
Water Steam condensing 250-400
Note: NC = noncondensable gas present, V = vacuum, A = atmospheric pressure

Table 4: Guthrie Material and Pressure Factors for Heat Exchangers

MPF = Fm (Fp + Fd)

Design Type Fd
Kettle Reboiler 1.35
Floating Head 1.00
U Tube 0.85
Fixed tube sheet 0.80
Vessel Pressure (psig)
Up to 150 300 400 800 1000
Fp 0.00 0.10 0.25 0.52 0.55
Shell / Tube Materials, Fm
Surface CS / Cs / CS / SS / CS / Monel / CS / Ti /
Area (ft2) CS Brass SS SS Monel Monel Ti Ti
Up to 100 1.00 1.05 1.54 2.50 2.00 3.20 4.10 10.28
100 to 500 1.00 1.10 1.78 3.10 2.30 3.50 5.20 10.60
500 to 1000 1.00 1.15 2.25 3.26 2.50 3.65 6.15 10.75
1000 to 1.00 1.30 2.81 3.75 3.10 4.25 8.95 13.05
5000

(3) Furnaces and Direct Fired Heaters:

Table 5: Guthrie Material and Pressure Factors for Furnaces

MPF = Fm + Fp + Fd
Design Type Fd
Process Heater 1.00
Pyrolysis 1.10
Reformer (without catalyst) 1.35
Vessel Pressre (psig)
Up to 500 1000 1500 2000 2500 3000
Compiled By Prof. Prasad Parulekar
Fp 0.00 0.10 0.15 0.25 0.40 0.60
Radiant Tube Material, Fm
Carbon Steel 0.00
Chrome / Moly 0.35
Stainless Steel 0.75

Table 6: Guthrie Material and Pressure Factors for Direct Fired Heaters

MPF = Fm + Fp + Fd
Design Type Fd
Cylindrical 1.00
Dowtherm 1.33
Vessel Pressre (psig)
Up to 500 1000 1500
Fp 0.00 0.15 0.20
Radiant Tube Material, Fm
Carbon Steel 0.00
Chrome / Moly 0.45
Stainless Steel 0.50

(4) Distillation Columns:

Table 7: Guthrie Material and Pressure Factors for Tray Stacks

MPF = Fm + Fs + Ft
Tray Type Ft
Grid (no downcomer) 0.0
Plate 0.0
Sieve 0.0
Valve or trough 0.4
Bubble cap 1.8
Koch Kascade 3.9
Tray Spacing, Fs
(inch) 24” 18” 12”
Fs 1.0 1.4 2.2
Tray Material, Fm
Carbon Steel 0.0
Stainless Steel 1.7
Monel 8.9

(5) Pumps and Drivers:

Table 8: Guthrie Material and Pressure Factors for Centrifugal Pumps and Drivers

Compiled By Prof. Prasad Parulekar

 MPF = Fm Fo
Material Type Fm
Cast iron 1.00
Bronze 1.28
Stainless 1.93
Hastelloy C 2.89
Monel 3.23
Nickel 3.48
Titanium 8.98
Operating Limits, Fo
Max Suction Pressure 150 500 1000
(psig)
Max Temperature (oF) 250 550 850
Fo 1.0 1.5 2.9

(6) Compressors:

Table 9: Guthrie Material and Pressure Factors for Compressors

MPF = Fd
Design Type Fd
Centrifugal / motor 1.00
Reciprocating / steam 1.07
Centrifugal / turbine 1.15
Reciprocating / motor 1.29
Reciprocating / gas engine 1.82

(7) Refrigerators:

Table 10: Guthrie Equipment Factors for Mechanical Refrigeration

MPF = Ft
Evaporator Temperature Ft
o
40 F / 278 K 1.00
20 oF / 266 K 1.95
0 oF / 255 K 2.25
-20 oF / 244 K 3.95
-40 oF / 233 K 4.54

Compiled By Prof. Prasad Parulekar

(B) Data for Cost Estimation of Equipments:
Table 11: Chemical Engineering Plant Index (cost indices, CI) for updating cost of equipments

Year CI
1957 – 59 100
1968 ½ 115
1970 ½ 126
1983 316
1993 359
1995 381

Table 12: Base Costs for Process Vessels

Equipment Type Co ($) Lo (ft) Do (ft) α β MF2/MF4/MF6/MF8/MF

10
Vertical Fabrication 1000 4.0 3.0 0.81 1.05 4.23/4.12/4.07/4.06/4.02
1 ≤ D ≤10 ft , 4 ≤ L ≤ 100 ft
Horizontal Fabrication 690 4.0 3.0 0.78 0.98 3.18/3.06/3.01/2.99/2.96
1 ≤ D ≤10 ft , 4 ≤ L ≤ 100 ft
Tray Stacks 180 10.0 2.0 0.97 1.45 1.0/1.0/1.0/1.0/1.0
2 ≤ D ≤10 ft , 1 ≤ L ≤ 500 ft
Note: Lo = Base length; Do = Base diameter; Co = Base cost; α and β = Exponents in power law
expression; MF = Module factor with respect to base cost.

Table 13: Base Costs for Process Equipments

Equipment Type Co So Range (S) α MF2/MF4/MF6/MF8/MF

($103) 10
Process Furnaces 100 30 10 - 300 0.83 2.27/2.19/2.16/2.15/2.13
S = Absorbed duty (106
Btu/hr)
Direct fired Heaters 20 5 1 - 40 0.77 2.23/2.15/2.13/2.12/2.10
S = Absorbed duty (106
Btu/hr)
Heat Exchangers 5 400 100 - 104 0.65 3.29/3.18/3.14/3.12/3.09
Shell and Tube, S = Area
(ft2)
Heat Exchangers 0.3 5.5 2 - 100 0.02 1.83/1.83/1.83/1.83/1.83
Shell and Tube, S = Area 4
(ft2)
Air Coolers 3 200 100 - 104 0.82 2.31/2.21/2.18/2.16/2.15

Compiled By Prof. Prasad Parulekar

S = [Calculated area
(ft2)/15.5]
Centrifugal Pumps 0.39 10 10 - 2× 103 0.17 3.38/3.28/3.24/3.23/3.20
S = C/H factor (gpm × psi) 0.65 2 × 103 2 × 103 - 2 × 0.36 3.38/3.28/3.24/3.23/3.20
1.5 2 × 104 104 0.64 3.38/3.28/3.24/3.23/3.20
2 × 104 - 2 ×
105
Compressors 23 100 30 - 104 0.77 3.11/3.01/2.97/2.96/2.93
S = Break horsepower
Refrigeration 60 200 50 - 3000 0.70 1.42
S = ton refrigeration (12,000
Btu/hr removed)
Note: Co = Base cost; So = Base capacity; α = Exponent in power law expression; MF = Module
factor with respect to base cost.

Table 14: Module Factors for Particular range of Base Costs

Module Factor (MF) to be used Range of Base Cost for which MF to be used
MF2 Up to $ 200,000
MF4 $ 200,000 to $ 400,000
MF6 $ 400,000 to $ 600,000
MF8 $ 600,000 to $ 800,000
MF10 $ 800,000 to $ 1,000,000

Compiled By Prof. Prasad Parulekar