exerpy 0.0.3__py3-none-any.whl → 0.0.4__py3-none-any.whl

exerpy/data/cost_correlations/material_factors.json

@@ -0,0 +1,428 @@
+{
+    "_metadata": {
+        "reference": "Turton et al., Analysis, Synthesis, and Design of Chemical Processes, 3rd Edition, 2008",
+        "description": "Material factors (Fm) for different materials of construction",
+        "notes": [
+            "Material factors are used in: CBM = Cp * (B1 + B2*Fp*Fm)",
+            "Base case (carbon steel) has Fm = 1.0",
+            "Some equipment has fixed FBM values in turton2008.json instead of separate Fm"
+        ]
+    },
+    "material_abbreviations": {
+        "CS": "Carbon Steel",
+        "SS304": "Stainless Steel 304",
+        "SS316": "Stainless Steel 316",
+        "SS": "Stainless Steel (generic 304/316)",
+        "Ni200": "Nickel 200",
+        "Monel400": "Monel 400 (Ni-Cu alloy)",
+        "Inconel600": "Inconel 600 (Ni-Cr alloy)",
+        "Incoloy825": "Incoloy 825 (Ni-Fe-Cr alloy)",
+        "Hastelloy": "Hastelloy (Ni-Mo alloy)",
+        "Ti": "Titanium",
+        "Cu": "Copper",
+        "CuNi": "Copper-Nickel alloy (90/10 or 70/30)",
+        "Al": "Aluminum",
+        "Brass": "Brass",
+        "Bronze": "Bronze",
+        "CS_clad": "Carbon Steel with SS clad",
+        "Ni_clad": "Carbon Steel with Ni clad",
+        "Ti_clad": "Carbon Steel with Ti clad"
+    },
+    "heat_exchangers": {
+        "_description": "Shell/Tube material combinations for shell-and-tube heat exchangers",
+        "_format": "shell_material/tube_material",
+        "CS/CS": {
+            "Fm": 1.00,
+            "description": "Carbon steel shell and tubes",
+            "identification_number": 1
+        },
+        "CS/Cu": {
+            "Fm": 1.27,
+            "description": "Carbon steel shell, copper tubes",
+            "identification_number": 2
+        },
+        "CS/SS": {
+            "Fm": 1.81,
+            "description": "Carbon steel shell, stainless steel tubes",
+            "identification_number": 3
+        },
+        "CS/Monel": {
+            "Fm": 2.30,
+            "description": "Carbon steel shell, Monel tubes",
+            "identification_number": 4
+        },
+        "CS/Ti": {
+            "Fm": 5.20,
+            "description": "Carbon steel shell, titanium tubes",
+            "identification_number": 5
+        },
+        "CS/CS_clad": {
+            "Fm": 1.55,
+            "description": "Carbon steel shell, SS-clad tubes",
+            "identification_number": 6
+        },
+        "Cu/Cu": {
+            "Fm": 1.69,
+            "description": "Copper shell and tubes",
+            "identification_number": 7
+        },
+        "Cu/CuNi": {
+            "Fm": 1.91,
+            "description": "Copper shell, copper-nickel tubes",
+            "identification_number": 8
+        },
+        "SS/SS": {
+            "Fm": 2.73,
+            "description": "Stainless steel shell and tubes",
+            "identification_number": 9
+        },
+        "SS/Monel": {
+            "Fm": 3.29,
+            "description": "Stainless steel shell, Monel tubes",
+            "identification_number": 10
+        },
+        "SS/Ti": {
+            "Fm": 6.64,
+            "description": "Stainless steel shell, titanium tubes",
+            "identification_number": 11
+        },
+        "Monel/Monel": {
+            "Fm": 4.12,
+            "description": "Monel shell and tubes",
+            "identification_number": 12
+        },
+        "Ti/Ti": {
+            "Fm": 9.60,
+            "description": "Titanium shell and tubes",
+            "identification_number": 13
+        },
+        "Ni200/Ni200": {
+            "Fm": 4.71,
+            "description": "Nickel 200 shell and tubes",
+            "identification_number": 14
+        },
+        "Hastelloy/Hastelloy": {
+            "Fm": 6.00,
+            "description": "Hastelloy shell and tubes",
+            "identification_number": 15
+        },
+        "Inconel/Inconel": {
+            "Fm": 5.52,
+            "description": "Inconel shell and tubes",
+            "identification_number": 16
+        }
+    },
+    "process_vessels": {
+        "_description": "Material factors for vertical and horizontal process vessels",
+        "CS": {
+            "Fm": 1.00,
+            "description": "Carbon steel"
+        },
+        "CS_clad": {
+            "Fm": 1.75,
+            "description": "Carbon steel with stainless clad"
+        },
+        "SS304": {
+            "Fm": 3.11,
+            "description": "Stainless steel 304"
+        },
+        "SS316": {
+            "Fm": 3.40,
+            "description": "Stainless steel 316"
+        },
+        "SS": {
+            "Fm": 3.11,
+            "description": "Stainless steel (generic, use 304 value)"
+        },
+        "Ni200": {
+            "Fm": 8.89,
+            "description": "Nickel 200"
+        },
+        "Monel400": {
+            "Fm": 6.20,
+            "description": "Monel 400"
+        },
+        "Inconel600": {
+            "Fm": 8.28,
+            "description": "Inconel 600"
+        },
+        "Incoloy825": {
+            "Fm": 7.84,
+            "description": "Incoloy 825"
+        },
+        "Hastelloy": {
+            "Fm": 10.38,
+            "description": "Hastelloy C"
+        },
+        "Ti": {
+            "Fm": 7.89,
+            "description": "Titanium"
+        },
+        "Ti_clad": {
+            "Fm": 4.71,
+            "description": "Carbon steel with titanium clad"
+        }
+    },
+    "pumps": {
+        "_description": "Material factors for pumps (centrifugal and positive displacement)",
+        "CI": {
+            "Fm": 1.00,
+            "description": "Cast iron"
+        },
+        "CS": {
+            "Fm": 1.00,
+            "description": "Carbon steel (use cast iron value)"
+        },
+        "Ductile_iron": {
+            "Fm": 1.15,
+            "description": "Ductile iron"
+        },
+        "Bronze": {
+            "Fm": 1.30,
+            "description": "Bronze"
+        },
+        "SS304": {
+            "Fm": 1.95,
+            "description": "Stainless steel 304"
+        },
+        "SS316": {
+            "Fm": 2.40,
+            "description": "Stainless steel 316"
+        },
+        "SS": {
+            "Fm": 2.00,
+            "description": "Stainless steel (generic)"
+        },
+        "Hastelloy": {
+            "Fm": 3.50,
+            "description": "Hastelloy C"
+        },
+        "Monel": {
+            "Fm": 3.30,
+            "description": "Monel"
+        },
+        "Ni200": {
+            "Fm": 4.00,
+            "description": "Nickel 200"
+        },
+        "Ti": {
+            "Fm": 6.00,
+            "description": "Titanium"
+        }
+    },
+    "compressors": {
+        "_description": "Material factors for compressors - typically not used (FBM is fixed)",
+        "_notes": "Compressor costs typically use fixed FBM values; material changes affect only a portion of equipment",
+        "CS": {
+            "Fm": 1.00,
+            "description": "Carbon steel"
+        },
+        "SS": {
+            "Fm": 1.30,
+            "description": "Stainless steel"
+        },
+        "Ni_alloy": {
+            "Fm": 1.80,
+            "description": "Nickel alloy"
+        }
+    },
+    "trays": {
+        "_description": "Material factors for distillation trays (sieve, valve, bubble cap)",
+        "CS": {
+            "Fm": 1.00,
+            "description": "Carbon steel"
+        },
+        "SS304": {
+            "Fm": 1.70,
+            "description": "Stainless steel 304"
+        },
+        "SS316": {
+            "Fm": 1.83,
+            "description": "Stainless steel 316"
+        },
+        "SS": {
+            "Fm": 1.83,
+            "description": "Stainless steel (generic, use 316 value)"
+        },
+        "Monel": {
+            "Fm": 4.03,
+            "description": "Monel"
+        },
+        "Ni_alloy": {
+            "Fm": 4.68,
+            "description": "Nickel alloy"
+        }
+    },
+    "packing": {
+        "_description": "Material factors for tower packing (random and structured)",
+        "ceramic": {
+            "Fm": 1.00,
+            "description": "Ceramic (Raschig rings, saddles)"
+        },
+        "CS": {
+            "Fm": 1.00,
+            "description": "Carbon steel (metal packing)"
+        },
+        "SS304": {
+            "Fm": 4.81,
+            "description": "Stainless steel 304"
+        },
+        "SS316": {
+            "Fm": 5.12,
+            "description": "Stainless steel 316"
+        },
+        "SS": {
+            "Fm": 5.12,
+            "description": "Stainless steel (generic)"
+        },
+        "Monel": {
+            "Fm": 14.51,
+            "description": "Monel"
+        },
+        "Ni_alloy": {
+            "Fm": 27.39,
+            "description": "Nickel alloy"
+        },
+        "Ti": {
+            "Fm": 35.00,
+            "description": "Titanium"
+        }
+    },
+    "plate_heat_exchangers": {
+        "_description": "Material factors for plate-and-frame heat exchangers",
+        "SS304": {
+            "Fm": 1.00,
+            "description": "Stainless steel 304 (base case for plate HX)"
+        },
+        "SS316": {
+            "Fm": 1.15,
+            "description": "Stainless steel 316"
+        },
+        "Ti": {
+            "Fm": 3.00,
+            "description": "Titanium"
+        },
+        "Hastelloy": {
+            "Fm": 3.50,
+            "description": "Hastelloy"
+        }
+    },
+    "reactors": {
+        "_description": "Material factors for stirred tank reactors",
+        "CS": {
+            "Fm": 1.00,
+            "description": "Carbon steel"
+        },
+        "SS304": {
+            "Fm": 3.11,
+            "description": "Stainless steel 304"
+        },
+        "SS316": {
+            "Fm": 3.40,
+            "description": "Stainless steel 316"
+        },
+        "SS": {
+            "Fm": 3.11,
+            "description": "Stainless steel (generic)"
+        },
+        "glass_lined": {
+            "Fm": 4.00,
+            "description": "Glass-lined carbon steel"
+        },
+        "Hastelloy": {
+            "Fm": 10.38,
+            "description": "Hastelloy"
+        },
+        "Ti": {
+            "Fm": 7.89,
+            "description": "Titanium"
+        }
+    },
+    "fired_heaters": {
+        "_description": "Material factors for fired heaters (radiant section tubes)",
+        "CS": {
+            "Fm": 1.00,
+            "description": "Carbon steel tubes"
+        },
+        "Cr-Mo": {
+            "Fm": 1.40,
+            "description": "Chrome-moly steel"
+        },
+        "SS304": {
+            "Fm": 1.70,
+            "description": "Stainless steel 304"
+        },
+        "SS316": {
+            "Fm": 1.85,
+            "description": "Stainless steel 316"
+        },
+        "SS": {
+            "Fm": 1.70,
+            "description": "Stainless steel (generic)"
+        },
+        "HK40": {
+            "Fm": 2.10,
+            "description": "HK40 (25Cr-20Ni)"
+        },
+        "Incoloy800": {
+            "Fm": 2.50,
+            "description": "Incoloy 800"
+        },
+        "Inconel600": {
+            "Fm": 3.00,
+            "description": "Inconel 600"
+        }
+    },
+    "corrosion_resistance_guide": {
+        "_description": "General guide for material selection based on process fluids",
+        "_warning": "This is a simplified guide. Always consult corrosion data for specific conditions.",
+        "water_steam": {
+            "recommended": ["CS", "SS304"],
+            "notes": "Carbon steel suitable for most water/steam applications"
+        },
+        "seawater": {
+            "recommended": ["CuNi", "Ti", "SS316"],
+            "avoid": ["CS", "SS304"],
+            "notes": "Chloride ions cause pitting in carbon steel and 304SS"
+        },
+        "dilute_acids": {
+            "recommended": ["SS316", "Hastelloy", "Ti"],
+            "avoid": ["CS", "Cu"],
+            "notes": "Depends heavily on acid type and concentration"
+        },
+        "concentrated_acids": {
+            "recommended": ["Hastelloy", "Ti", "glass_lined"],
+            "avoid": ["CS", "SS304", "SS316"],
+            "notes": "Highly dependent on specific acid"
+        },
+        "caustic_solutions": {
+            "recommended": ["CS", "Ni200", "Monel"],
+            "avoid": ["Al", "Cu"],
+            "notes": "Carbon steel often suitable for NaOH service"
+        },
+        "chlorinated_solvents": {
+            "recommended": ["Hastelloy", "Ti"],
+            "avoid": ["CS", "Cu", "Al"],
+            "notes": "Chlorine compounds very aggressive"
+        },
+        "ammonia": {
+            "recommended": ["CS", "SS304"],
+            "avoid": ["Cu", "Bronze", "Brass"],
+            "notes": "Copper alloys susceptible to stress corrosion cracking"
+        },
+        "hydrogen": {
+            "recommended": ["Cr-Mo", "SS304", "SS316"],
+            "avoid": ["CS at high temperature"],
+            "notes": "High-temperature hydrogen attack concern"
+        },
+        "sulfur_compounds": {
+            "recommended": ["SS316", "SS304", "Hastelloy"],
+            "avoid": ["CS"],
+            "notes": "H2S causes sulfide stress cracking"
+        },
+        "refrigerants": {
+            "recommended": ["CS", "SS304", "Cu"],
+            "notes": "Material depends on specific refrigerant"
+        }
+    }
+}

exerpy/data/cost_correlations/pressure_factors.json

@@ -0,0 +1,206 @@
+{
+    "_metadata": {
+        "reference": "Turton et al., Analysis, Synthesis, and Design of Chemical Processes, 3rd Edition, 2008",
+        "description": "Pressure factor coefficients for equipment cost correction",
+        "equations": {
+            "general": "log10(Fp) = C1 + C2*log10(P) + C3*(log10(P))^2",
+            "vessel": "Fp = [(P+1)*D / (2*S*E - 1.2*(P+1)) + CA] / t_min"
+        },
+        "units": {
+            "P": "barg (gauge pressure in bar)",
+            "D": "m (vessel diameter)",
+            "S": "bar (maximum allowable stress)",
+            "E": "dimensionless (weld efficiency)",
+            "CA": "m (corrosion allowance)",
+            "t_min": "m (minimum wall thickness)"
+        },
+        "notes": [
+            "For equipment with no pressure factor, Fp = 1.0",
+            "Vessel pressure factors depend on diameter - use vessel equation",
+            "Vacuum operation (P < -0.5 barg): use Fp = 1.25 for vessels"
+        ]
+    },
+    "heat_exchanger": {
+        "_description": "Pressure factors for shell-and-tube heat exchangers",
+        "_notes": "Based on maximum of shell-side or tube-side pressure",
+        "ranges": [
+            {
+                "P_min": -0.5,
+                "P_max": 5.0,
+                "C1": 0.0,
+                "C2": 0.0,
+                "C3": 0.0,
+                "description": "Low pressure / atmospheric"
+            },
+            {
+                "P_min": 5.0,
+                "P_max": 140.0,
+                "C1": 0.03881,
+                "C2": -0.11272,
+                "C3": 0.08183,
+                "description": "Moderate to high pressure"
+            }
+        ],
+        "max_pressure": 140.0,
+        "notes": "For pressures above 140 barg, consult manufacturer"
+    },
+    "pump": {
+        "_description": "Pressure factors for pumps (based on discharge pressure)",
+        "ranges": [
+            {
+                "P_min": -0.5,
+                "P_max": 10.0,
+                "C1": 0.0,
+                "C2": 0.0,
+                "C3": 0.0,
+                "description": "Low pressure"
+            },
+            {
+                "P_min": 10.0,
+                "P_max": 100.0,
+                "C1": -0.3935,
+                "C2": 0.3957,
+                "C3": -0.00226,
+                "description": "Moderate pressure"
+            },
+            {
+                "P_min": 100.0,
+                "P_max": 200.0,
+                "C1": 0.0,
+                "C2": 0.0,
+                "C3": 0.0,
+                "Fp_fixed": 1.55,
+                "description": "High pressure (fixed factor)"
+            }
+        ],
+        "max_pressure": 200.0,
+        "notes": "Based on discharge pressure"
+    },
+    "vessel": {
+        "_description": "Pressure factors for process vessels (vertical and horizontal)",
+        "_equation": "Fp = [(P+1)*D / (2*S*E - 1.2*(P+1)) + CA] / t_min",
+        "parameters": {
+            "S_carbon_steel": {
+                "value": 944,
+                "unit": "bar",
+                "description": "Maximum allowable stress for carbon steel at ambient temperature"
+            },
+            "E": {
+                "value": 0.9,
+                "description": "Weld efficiency (radiographed welds)"
+            },
+            "CA": {
+                "value": 0.00315,
+                "unit": "m",
+                "description": "Corrosion allowance (1/8 inch)"
+            },
+            "t_min": {
+                "value": 0.0063,
+                "unit": "m",
+                "description": "Minimum wall thickness (1/4 inch)"
+            }
+        },
+        "vacuum_factor": {
+            "P_threshold": -0.5,
+            "Fp": 1.25,
+            "description": "For vacuum operation (P < -0.5 barg), use fixed Fp = 1.25"
+        },
+        "notes": [
+            "Vessel pressure factor depends on both pressure and diameter",
+            "For t < t_min, Fp = 1.0",
+            "Maximum allowable stress decreases with temperature - see material data"
+        ],
+        "stress_vs_temperature": {
+            "_description": "Approximate S values for carbon steel at elevated temperatures",
+            "_reference": "ASME SA515-Grade 55",
+            "temperatures_C": [0, 100, 200, 300, 350, 400, 450, 500],
+            "S_values_bar": [944, 944, 944, 896, 821, 620, 413, 206]
+        }
+    },
+    "fired_heater": {
+        "_description": "Pressure factors for fired heaters (process side pressure)",
+        "ranges": [
+            {
+                "P_min": -0.5,
+                "P_max": 10.0,
+                "C1": 0.0,
+                "C2": 0.0,
+                "C3": 0.0,
+                "description": "Low pressure"
+            },
+            {
+                "P_min": 10.0,
+                "P_max": 200.0,
+                "C1": 0.1405,
+                "C2": -0.0665,
+                "C3": 0.0302,
+                "description": "Elevated pressure"
+            }
+        ],
+        "max_pressure": 200.0,
+        "notes": "For reformer and pyrolysis furnaces operating at high pressure"
+    },
+    "air_cooler": {
+        "_description": "Pressure factors for air-cooled heat exchangers",
+        "ranges": [
+            {
+                "P_min": -0.5,
+                "P_max": 10.0,
+                "C1": 0.0,
+                "C2": 0.0,
+                "C3": 0.0,
+                "description": "Low pressure"
+            },
+            {
+                "P_min": 10.0,
+                "P_max": 100.0,
+                "C1": 0.03881,
+                "C2": -0.11272,
+                "C3": 0.08183,
+                "description": "Elevated pressure"
+            }
+        ],
+        "max_pressure": 100.0,
+        "notes": "Uses same correlation as shell-and-tube heat exchangers"
+    },
+    "none": {
+        "_description": "Equipment with no pressure factor correction",
+        "Fp": 1.0,
+        "equipment_types": [
+            "compressors",
+            "turbines",
+            "electric_motors",
+            "generators",
+            "trays",
+            "packing",
+            "blowers",
+            "fans",
+            "storage_tanks"
+        ],
+        "notes": "These equipment types have pressure effects included in base cost or are not significantly affected by operating pressure"
+    },
+    "calculation_examples": {
+        "_description": "Example calculations for verification",
+        "heat_exchanger_100barg": {
+            "P": 100,
+            "calculation": "log10(Fp) = 0.03881 - 0.11272*log10(100) + 0.08183*(log10(100))^2 = 0.1407",
+            "Fp": 1.383
+        },
+        "heat_exchanger_50barg": {
+            "P": 50,
+            "calculation": "log10(Fp) = 0.03881 - 0.11272*log10(50) + 0.08183*(log10(50))^2 = 0.0704",
+            "Fp": 1.176
+        },
+        "vessel_2m_20barg": {
+            "P": 20,
+            "D": 2.0,
+            "S": 944,
+            "E": 0.9,
+            "CA": 0.00315,
+            "t_min": 0.0063,
+            "calculation": "t = (20+1)*2.0/(2*944*0.9-1.2*(20+1)) + 0.00315 = 0.0280 m",
+            "Fp": 4.44,
+            "notes": "Fp = t / t_min = 0.0280 / 0.0063"
+        }
+    }
+}