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Techno-Economic
Modeling for New
Technology Development
Chris Burk, P.E. Spreadsheet software can be used to build
Burk Engineering LLC
integrated process and economic models
that provide new insights into profitability.
T
echno-economic modeling (TEM) connects research finally build a user interface. The process model gener-
and development (R&D), engineering, and business. ates a stream table, which is the foundation of the techno-
By linking process parameters to financial metrics, it economic model. Information from the stream table is
can help businesses better understand the factors that affect used in equipment sizing calculations to derive parameters
the profitability of their technology development projects. necessary for estimating capital and operating costs. The
TEM is useful throughout the technology development user interface consolidates important input and results on
lifecycle. When considering new ideas, innovators can use a single sheet, facilitating model operation and sensitiv-
the technique to assess economic feasibility and potential. ity analysis. Figure 1 shows how these components are
At the bench scale, scientists can use it to identify the pro- interconnected.
cess parameters that have the greatest effect on profitability. Software platform. The two most common platforms for
During process development, engineers can use TEM to TEM are spreadsheet software and process simulation soft-
compare the financial impact of different process conditions ware. While each has its own benefits, this article focuses on
and configurations. TEM incorporates information from all using spreadsheet software. Spreadsheet models are flexible
of these stages of development, and offers a basis for making and do not require specialized software, so they are ideal for
objective decisions. early-stage companies and technologies. Process simulation
The individual techniques used in TEM, which include
process modeling, equipment sizing, and economic calcula- Process
tions (1–3), are already familiar to chemical engineers. This Model
article demonstrates how to integrate and leverage them in
a single, holistic model by building a techno-economic
model for the fictional ABCD chemical process, which Equipment User Sensitivity
Sizing Interface Analysis
consists of four unit operations centered on a gas-phase
catalytic reaction.
Copyright © 2018 American Institute of Chemical Engineers (AIChE) CEP January 2018 www.aiche.org/cep 43
Process Design and Development
tends to be less accessible and to require a greater degree illustrates the chemical process being modeled. The new
of certainty in process parameters and configuration, so it is technology being evaluated might be the process itself, or
generally more appropriate for later-stage projects and more- it might be just one component of the process. Label all
complex systems. major equipment, process streams, and major utilities so
Model behavior. In a techno-economic model, financial they can be easily referenced. Also, include an image of the
metrics are connected to process and economic parameters process flow diagram with the model for clarity and conve-
through a network of correlations. Automating these nient viewing.
connections makes a model more usable and efficient. User input. Take extra time to identify the most appro-
Consider how tedious it would be to collect sensitivity priate user input parameters, including those that are
analysis data from a model that required you to manually important in other parts of your organization. For example,
enter values from equipment cost curves. In most cases, if business managers consider capacity in terms of product
by carefully choosing methods and assumptions, you can rate, do not base the model on feedstock rate. Clearly label
minimize or eliminate the need for that type of manual and consolidate all user input at the top of the sheet.
intervention. Stream table. Catalog the important characteristics of
Accuracy. Capital cost estimates are often divided into each process stream in a stream table. You can perform sim-
five classifications based on accuracy (1): ple material balance calculations directly within the stream
• order-of-magnitude estimate (accuracy > ±30%) table, but more complex calculations should be performed in
• study estimate (accuracy ±30%) the calculations section.
• preliminary estimate (accuracy ±20%) Calculations. A clearly separated calculations section
• definitive estimate (accuracy ±10%) reduces troubleshooting time and complexity. In general,
• detailed estimate (accuracy ±5%). calculations should be efficient, easy for others to under-
For TEM, capital cost estimates should be detailed stand, and fast to debug. As a first step, always convert user
enough to respond to changes in process parameters. How- input to a coherent system of measurement. This section
ever, if your estimation method is too detailed, you will could include calculations related to chemical reactions,
have difficulty automating it. Order-of-magnitude esti- pressure drop, electrochemistry, and density.
mates are generally not detailed enough, since they do not
consider individual equipment characteristics. Preliminary, Equipment sizing
definitive, and detailed estimates are typically too detailed. To estimate equipment and utility costs, you first need
Study estimates are best suited for TEM, since they account to perform some equipment-sizing calculations using
for the characteristics of individual pieces of equipment, data from the stream table. To estimate equipment costs,
while still allowing for automated calculation. calculate capacity parameters appropriate for each piece of
To develop a study estimate, first estimate major equip- equipment. Capacity parameters are quantitative equipment
ment costs and then apply multiplying factors to estimate characteristics that are directly related to purchased cost.
total capital cost. Study estimates are also called major Table 1 lists typical capacity parameters and utilities for
equipment estimates or factored estimates. several types of equipment.
Modular structure. This article presents a modular Utilities are auxiliary services, such as electricity, steam,
approach to TEM. Much like in computer programming, and cooling water. To estimate utility costs, convert all utility
each section or module accepts input from the user or from rates to units of power (i.e., kW), then use the equation:
other sections and processes it into results for use else-
where. The individual modules are easier to understand and Ct = P × Ce (1)
error check, and, once they are built, they can be reused
in future models. The screenshots in this article provide where Ct is utility cost per unit of time, P is utility rate in
examples of how to accomplish this in a spreadsheet. units of power, and Ce is utility cost per unit of energy.
Values for Ce vary based on utility type and are tabulated in
Process model various sources (2).
Start your techno-economic model by developing a The lack of available information in early development
process model. The process model calculates stream proper- will require you to make some educated guesses based on
ties used to estimate equipment sizes and costs, and typically experience or established heuristics. Heuristic tables (2)
consists of a process flow diagram, user input, calculations, can help.
and a stream table. Figure 2 shows a process model for the Figure 3 shows the equipment sizing section of the
ABCD process. ABCD model. Note the organization and how it provides
Process flow diagram. The process flow diagram clarity.
44 www.aiche.org/cep January 2018 CEP Copyright © 2018 American Institute of Chemical Engineers (AIChE)
Membrane
150 160 AC, BD, BC
Separation
130 V-100
Input
170 AD
Stream Table
Calculations
p Figure 2. In the ABCD process, gaseous feedstocks AC and BD react catalytically to form liquid product AD. A membrane separation unit selectively
removes byproduct BC from the recycle stream.
Copyright © 2018 American Institute of Chemical Engineers (AIChE) CEP January 2018 www.aiche.org/cep 45
Process Design and Development
Equipment Sizing
p Figure 3. The ABCD process has, in essence, four pieces of major equipment, but specific sizing calculations are only necessary for the compressor
(K-100), reactor (R-100), and vapor-liquid separation vessel (V-100).
46 www.aiche.org/cep January 2018 CEP Copyright © 2018 American Institute of Chemical Engineers (AIChE)
or the Marshall and Swift Equipment Cost Index, and the Lang factor depends on the type of the chemical process,
the equation: for example, 4.74 for a fluid processing plant, 3.63 for a
solid-fluid processing plant, and 3.10 for a solid processing
C2 = C1 × (I2/I1) (3) plant. However, the Lang factor technique does not consider
any other process characteristics (2).
where C is the cost in year 1 or 2 and I is the cost index in Figure 5 shows a more detailed approach, in which each
year 1 or 2. component of the fixed capital cost is assigned an individual
Fixed capital cost. Fixed capital includes all costs associ- percentage contribution to the total fixed capital cost for the
ated with purchasing equipment and construction. Although ABCD process. Reference 3 provides guidelines for using
major equipment is normally the largest line item, it is typi- this method and percentage values for various cases.
cally only 20–30% of the total fixed capital cost (3). A third and more accurate option is the module cost-
The methods discussed in this article pertain specifically ing technique, which estimates the individual contribution
to full-scale chemical plants, but new chemical technologies of each piece of major equipment to the total fixed capi-
do not always involve building plants. Some are improved tal cost. Reference 2 provides guidelines and parameters
unit operations, and others are smaller chemical-generation for using this technique, as well as a useful spreadsheet
systems. Even if you cannot use these techniques exactly implementation.
as described, they offer a starting point for improvising Working capital. Working capital refers to startup costs,
methods specific to your application. The most reliable and includes salaries and raw material inventories. Most of
cost estimates are those based on internal data from previ- the working capital is recovered at the end of the project. For
ous projects. a typical chemical plant, working capital is between 15%
The simplest way to estimate fixed capital cost from and 20% of the fixed capital (3).
major equipment cost is to use a Lang factor:
Operating costs
Cf = FLang × ΣCp (4) Operating costs can be divided into three categories:
variable, fixed, and general. Variable operating costs scale
where Cf is fixed capital cost, FLang is the Lang factor, and with operating rate (percentage of capacity), whereas fixed
Cp is major equipment purchased cost. The value used for operating costs do not. General operating costs are not
p Figure 4. Purchased equipment costs for the compressor, reactor, and process vessel are estimated using cost-to-capacity correlations, whereas
purchased cost for the membrane system is scaled from a quote.
Copyright © 2018 American Institute of Chemical Engineers (AIChE) CEP January 2018 www.aiche.org/cep 47
Process Design and Development
p Figure 5. Major purchased equipment costs for the ABCD process are the basis for estimating all other capital costs.
Operating Costs
p Figure 6. The four major variable operating costs are raw materials, waste treatment, utilities, and operating labor. Operating costs also take into account
fixed and general costs.
directly related to operation, but still need to be considered lines for making preliminary utility and waste treatment
for a complete economic analysis. cost estimates (2, 3).
Variable operating costs. The four major variable For larger processes, you should estimate operat-
operating costs are raw materials, waste treatment, utili- ing labor costs based on the number and character of the
ties, and operating labor. Start by estimating these based on process steps (2, 3). According to a correlation in Ref. 2, a
the stream table and equipment sizing. Prices for bulk raw process comprising ten pieces of non-particulate process-
materials can be found in a variety of sources, both in print ing equipment is estimated to require approximately three
and on the web (4). Some of these sources provide guide- operators per shift. A process comprising eight pieces of
48 www.aiche.org/cep January 2018 CEP Copyright © 2018 American Institute of Chemical Engineers (AIChE)
Cash Flow Analysis
p Figure 7. A cash flow analysis combines capital cost, operating cost, and revenue to quantify the overall economic value of a technology.
Copyright © 2018 American Institute of Chemical Engineers (AIChE) CEP January 2018 www.aiche.org/cep 49
Process Design and Development
generate revenue directly. Economic benefit can also come important results may also include feedstock, waste, and
in the form of reduced capital or operating costs relative utility stream rates. Graphics make information easier to
to other technologies. In cases like these, you should use absorb, and can be used to show distributions of capital and
net present value, equivalent capitalized cost, or equivalent operating costs or important equipment sizes.
operating cost as economic value metrics (2). This is the page that you will display in a meeting with
your colleagues. Think about the questions that they will ask
User interface and be creative. See Figure 8 for some ideas.
Process and economic parameters are now linked
through your model to economic value metrics. Although Sensitivity analysis
the model is essentially complete, user inputs and results are Sensitivity analysis investigates the impact of individual
scattered across a half-dozen pages. To get the most out of input parameters on the results of the model. It is useful for
the model, you need a user interface. identifying opportunities and threats, as well as for under-
The user interface is the dashboard through which you standing process dependencies. Sensitivity analysis can
and your colleagues will interact with the model. Consoli- be performed using a tornado diagram or Excel’s Data
date the important user input and results onto a single page, Table tool.
using familiar units. It is best to group and organize them Tornado diagrams. A tornado diagram is a special type
in a way that is clear and easy to understand. In addition to of bar chart that is used to compare the relative impact of
economic value metrics, capital cost, and operating cost, input parameters on a result. The result parameter is typi-
User Interface
Input
Results
p Figure 8. An effective user interface presents the important results quickly in a way that is easy to understand.
50 www.aiche.org/cep January 2018 CEP Copyright © 2018 American Institute of Chemical Engineers (AIChE)
cally an economic value metric. Figure 9 shows a tornado Process parameters differ in that they can be changed
diagram for the ABCD process. or improved through R&D and process design. A long
In building a tornado diagram, you specify three values worst-case bar next to a process parameter indicates an
for each input parameter: worst-case, expected-case, and opportunity and a parameter that should be targeted for
best-case. The center axis of the tornado diagram corre- improvement. Figure 9 shows this to be the case for single-
sponds to the expected result — the value of the result when pass conversion.
all input parameters are set to their expected-case values. For process parameters, the worst case represents the
The bars extending to the left and right of the central axis current state of the technology. As progress is made toward
reflect the relative effects of changing the input parameter to improving a particular process parameter, the worst case
its worst-case or best-case value. Arranging the parameters will approach the expected case, and the bar representing the
in order of magnitude gives the diagram its tornado shape worst case will get shorter. The parameter will eventually
and highlights the most influential parameters. Reference 6 drop to a lower position on the tornado diagram, indicating a
provides general instructions for building spreadsheet decrease in relative impact.
tornado diagrams, but certain considerations are specific to Data tables. Excel’s Data Table tool is an excellent way
applying them in new technology development. to perform a sensitivity analysis on one or two parameters.
When interpreting a tornado diagram, consider that It automates the process of varying the input parameters and
there are two types of input parameters: market parameters tabulating the results. Figure 10 shows a data table and graph
and process parameters. Market parameters include raw examining the effects of overall and single-pass conversion
material and product prices and are generally outside of
your control. Input case values for these parameters are set IRR vs. Overall Conversion
at 20%, 25%, and 30% Single-Pass Conversion
based on forecasts and historical data. A long worst-case bar 50%
next to a market parameter indicates a threat — an external
30%
factor that has a strong influence on the economic value
40%
of the process. Feedstock 1 price is an example of this in 25%
Figure 9.
Internal Rate of Return
30% 20%
p Figure 10. This data table sensitivity analysis for the ABCD process
p Figure 9. The tornado diagram for the ABCD process highlights the shows an optimum overall conversion between 91% and 95%, which
relative importance of single-pass conversion and Feedstock 1 price. depends slightly on single-pass conversion.
Copyright © 2018 American Institute of Chemical Engineers (AIChE) CEP January 2018 www.aiche.org/cep 51
Process Design and Development
on internal rate of return for the ABCD process. Microsoft’s Closing thoughts
online documentation describes the procedure for creating A techno-economic model embodies your best under-
data tables (7). standing of a technology, combining your knowledge of the
science, the engineering, and the market. It forces you to
Testing the model come to terms with what you do not know, and it challenges
Upon seeing the results of a techno-economic model for you to either learn more or develop good assumptions.
the first time, it is tempting to immediately issue a group Just as a technology evolves throughout development, so
email about the major implications you have discovered. does a techno-economic model. As you learn and input new
Rest assured, though, that any reasonably complex model information, the model becomes more accurate. Equipment
will initially contain mistakes and questionable assumptions. quotes lead to refined cost estimates. Lab results establish
First, try to catch these yourself. The following checklist can correlations between input parameters. Whether the goal is
provide a starting point. to justify an initial investment, maximize the impact of R&D
• Process design — Check with experienced engineers. efforts, or assess market readiness, TEM can help a business
Does the process flow diagram include all of the necessary make better, more-informed decisions while evaluating and
equipment? developing new technologies.
• Conceptual understanding — Study different scenarios, In a sense, the process of techno-economic modeling
including edge cases. Can you explain the model’s behavior? captures the complete engineering process, from lab to
• Price — Do some vendor research. Are equipment market. As a result, the developer tends to acquire a unique,
costs reasonable? Are the market data reliable? holistic understanding of the technology. This perspective
• Historical data — Look for cost data for similar pro- itself can be a great asset to any organization. CEP
52 www.aiche.org/cep January 2018 CEP Copyright © 2018 American Institute of Chemical Engineers (AIChE)