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2003 Course Process Economics & Project Eng.

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Total No. of Questions : 12] [Total No. of Pages : 6 [3764]-400 P1394 B.E. (Petrochemical) PROCESS ECONOMICS AND PROJECT ENGINEERING (2003 Course) Time : 3 Hours] [Max. Marks : 100 Instructions to candidates : 1) Answer any 03 questions from each section. 2) Answers to the two sections should be written in separate books. 3) Neat diagrams must be drawn wherever necessary. 4) Figures to the right indicate full marks. 5) Use of electronic pocket calculator and steam tables is allowed. 6) Assume suitable data, if necessary. SECTION - I Q1) Answer Any Four from the following: [18] a) Discuss breakdown of Fixed Capital Investment (FCI) items for a chemical process. b) Define the following and give examples of each: i) Current assets. ii) Current liabilities. iii) Fixed assets. c) Draw a break-even chart and write the advantages of Break-even chart on managerial decision. d) A central air-conditioning unit is purchased for Rs. 2,50,000 and has an expected life of 10 years. The salvage value for the unit at that time is expected to be Rs. 40,000. What will be the book value at the end of 7 years. Use sum of year s digits method of depreciation. e) Often it is said, Depreciation and taxes are irrevocably tied to each other. Give your comment on this statement. f) Recently a cast iron leaf pressure filter with 9.29 m2 was purchased for clarifying an inorganic liquid stream for Rs. 7,50,000. In a similar application, the company will need a 41.80 m2 cast iron leaf pressure filter. The size exponent for this type filter is 0.6. Estimate the purchased price of the 41.80 m2 unit. P.T.O. OR Q2) a) A process plant has an initial investment of Rs. 50 lakhs. The estimated salvage value is Rs. 2 lakhs. It has a life of 8 years. Estimate the book value of the plant after 5 years by (i) Straight line depreciation method. (ii) Declining balance method and (iii) Sinking fund method with a sinking fund interest rate of 10%. [9] b) Discuss the tree diagram showing cash flow for industrial operations.[9] Q3) a) Discuss the types of cost indices available in the Chemical Engineering literature. Discuss the importance of these cost indices for cost estimation of chemical engineering equipment. [6] b) A furnace installation A costs Rs. 12 lakhs with operating cost at Rs. 1,20,000 per annum. It has a life of 10 years. The installation B guarantees same performance with an operating cost of Rs. 96,000 with an initial cost of Rs. 25 lakhs. Salvage value for both is Rs. 1,90,000. What increase in life would be required for plan B to warrant its selection if money is worth 10%. [10] OR Q4) a) Discuss in brief the various components of a balance sheet and Profit and Loss account statements. [8] b) Company X is considering the Projects that have the following costs: (All costs are in Rupees): Item Project A Project B First cost 1,50,000 1,80,000 Annual Operating Costs 35,000 31,000 Salvage Value 10,000 20,000 6 9 Life, years i) ii) [3764]-400 Using money worth 15% per year, determine which alternative should be selected on the basis of a present-worth analysis. Company X has a standard practice of evaluating all projects over a 5-year period. If a study period of 5 years is used and the salvage values are expected (to be Rs. 15,000 and Rs. 30,000 for A and B respectively, which project) should be selected? [8] 2 Q5) a) A company proposes to install a dryer and has received the following offers: Item Spray Dryer Fluidized bed Dryer Moving bed Dryer Installation Cost Rs. 15 lakhs Rs. 10 lakhs Rs. 8 lakhs Operational and maintenance costs Rs. 1 lakh Rs. 1.5 lakhs Rs. 2 lakhs Salvage Value Rs. 2 lakhs Rs. 1 lakh Nil 10 8 6 Service life in years Money is worth 10%. Which offer should be accepted, for minimum annual cost? [10] b) A project expected to have cash flow for five years as follows after all expenses and taxes. The initial fixed capital investment is Rs. 10,00,000 and the working capital investment is 15% of the fixed capital investment. Time (Years) Cash Flow (Rs.) 0-1 2,00,000 1-2 2,70,000 2-3 3,30,000 3-4 4,00,000 4-5 4,75,000 Determine the payout time required for given project. [6] OR Q6) a) The following data are available for two reactors from a petrochemical plant: Item Reactor (Mild Steel) Reactor (Stainless Steel) Installed cost Rs. 5,00,000/- Rs. 1,50,000/- Salvage value 0 0 Service life 3 ? 12% 12% Interest rate (i) If the capitalized cost is same for both the reactors, estimate service life for stainless steel reactor. [8] [3764]-400 3 b) A plant is designed to produce 1.2 108 kg/hr of an agrochemical. The estimated fixed capital investment is Rs. 1.5 109. The working capital is 2 108 and startup cost (only in the first year of commissioning and to be accounted for in the first year) is 1.5 10 8. The following cost data are available: [8] i) Raw material : Rs. 0.8 / kg product. ii) Labor and Utilities, etc. : Rs. 0.25 / kg product. iii) Selling price of product : Rs. 20 / kg. iv) Other costs (on year basis) including Maintenance, insurance, etc., @ 10% of fixed capital. Indirect cost of administration, R & D, marketing, etc. 20% of sale proceeds. The plant will be fully depreciated over a period of 5 years using the straight-line method. The rate of income tax is 40%. Calculate: 1) The net profit at the end of first year. 2) The payout period. SECTION - II Q7) a) Synthesis gas may be prepared by continuous, non-catalytic conversion of any hydrocarbon by means of controlled partial combustion in a fire - bride line reactor. The hydrocarbon and oxidant (oxygen or air) are separately pre heated and charged to the reactor. Before entering the reaction zone, two feedstocks are intimately mixed in a combustion chamber. The heat produced by combustion part of the hydrocarbon pyrolyzes remaining hydrocarbons into gas and a small amount of carbon in a reaction zone. The reactor effluent then passes through a waste heat boiler, a waste-wash carbon removal unit, and water cooler-scrubber. Carbon is recovered in equipment of simple design in a firm, which can be used as fuel, or in ordinary carbon products. [14] i) ii) b) [3764]-400 Prepare a simplified equipment flow sheet in the process, with temperature and pressure. Draw a typical P & ID for fire-bride line reactor. Explain in brief the plant-design project stages with suitable example.[4] 4 OR Q8) a) Discuss in brief the anatomy of Chemical manufacturing process. What are the standard references / resources are available for chemical engineers working in Projects? b) [8] Make a proforma for the specifications for shell and tube heat exchanger. [10] Q9) a) Explain the items that should be considered in making a feasibility survey of a typical refinery project. b) [8] Discuss in brief the following safety terms: [8] i) Flash and Smoke Point. ii) Fault tree analysis. iii) Trip and interlock system. iv) HAZOP and HAZAN. OR Q10)a) Explain Plant shutdown and emergency procedure with suitable example. [8] b) What are process utilities? Briefly discuss important utilities required in a typical petrochemical complex / refinery unit. Q11)a) [8] Discuss in brief the following (Any Two): [8] i) Piping Specifications. ii) Engineering flow diagram and Piping and Instrumentation Diagram. iii) Plot plan and equipment layout. b) Discuss in brief Bar Chart, Milestone chart and Gantt Chart for Petrochemical Engineering Project analysis. OR [3764]-400 5 [8] Q12)a) A project has the following activities, activity duration and predecessors. Activity Duration Predecessor (days) A - B 10 A C 12 A D 9 B, C E 8 C F i) 6 5 D, E Draw the CPM / PERT chart for this problem and determine the critical path. ii) b) Indicate the critical path on the CPM/PERT chart. [10] Any successful design project depends on effective project management. There is no single correct way to manage a project but there are four basic steps: i) Define the project. ii) Create a project plan. iii) Track and maintain the project plan. iv) Close the project. You are a Process Engineer Incharge of preparing the process design report for methanol from syngas unit. Give a description of how you would manage this project giving some detail of the various aspects of a modern environmentally acceptable design. [6] Y [3764]-400 6

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