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23-Chem-A5 Chemical Plant Design and Economics · May 2015

Question 3 of 6: Rate of Return

Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)

Notes on this paper

National Exams — May 2015 — 04-Chem-A5 Chemical Plant Design and Economics. Three-hour, closed-book exam (one two-sided aid sheet and an approved calculator permitted). Six equally weighted 20-mark questions are posed; the candidate answers any five and only the first five are marked. All six are worked below for completeness. Questions 2, 3 and 5 carry the numerical work (equivalent-annual-cost equipment selection, a discounted-cash-flow rate-of-return analysis, and a gravity-decanter sizing); questions 1, 4 and 6 are design / materials-selection / safety questions answered as organised prose, with Question 1 supported by a process flow sheet and a light overall material balance.

Reference texts: M.S. Peters, K.D. Timmerhaus & R.E. West, Plant Design and Economics for Chemical Engineers (5th ed., McGraw-Hill) — the exam's named primary text (cost–capacity estimation Ch. 6, interest and investment Ch. 7, profitability and rate of return Ch. 10); R.K. Sinnott & G. Towler, Chemical Engineering Design (Coulson & Richardson Vol. 6, 5th ed., Butterworth-Heinemann) — separator/decanter sizing (§10.6), materials of construction (Ch. 7) and the process-design safety checklist (Ch. 9); R. Turton et al., Analysis, Synthesis, and Design of Chemical Processes (4th ed., Prentice Hall) — flowsheet synthesis; supporting Canadian practice from CSA B51 / ASME BPVC (pressure vessels), API 650 (atmospheric storage tanks) and NACE corrosion guidance.

Question 3: Rate of Return (20 marks)

Question text not reproduced: the examination questions are © Engineers and Geoscientists BC. Open the official past paper (linked at the top of this page) to read the question, then follow the worked solution below.

Given. Cash flows to the oil company: nothing at $t=0$; net income $+\$50{,}000$ in each of years 1–4; the water-flood investment $-\$650{,}000$ at year 5; secondary-recovery income $+\$100{,}000$ in each of years 6–20. The net present worth at a 10 % minimum acceptable rate of return (MARR) is stated as $\$227{,}000$.

Find. (a) whether to accept the arrangement; (b) the investor's (discounted-cash-flow) rate of return.

Approach. Part (a) is a net-present-worth test at the 10 % MARR (accept if $\text{NPW}>0$); part (b) seeks the discounted-cash-flow rate of return — the interest rate that drives NPW to zero — which we test by scanning NPW across a wide range of rates and applying Descartes' rule of signs to the cash-flow sequence.

(a) Accept or reject?

  1. Confirm the stated NPW at 10 %. Using single-payment and uniform-series present-worth factors, $$\text{NPW}_{10\%}= 50\text{k}\,(P/A,10,4) - 650\text{k}\,(P/F,10,5) + 100\text{k}\,(P/A,10,15)(P/F,10,5)$$ $$= 50\text{k}(3.170) - 650\text{k}(0.6209) + 100\text{k}(7.606)(0.6209)= \$158{,}500-\$403{,}600+\$472{,}400=\boxed{+\$227{,}000}$$ which reproduces the value given in the problem.
  2. Apply the acceptance criterion. Since $\text{NPW}_{10\%}=+\$227{,}000>0$, the venture earns more than the 10 % minimum rate; on the NPW criterion the lease-and-flood arrangement should be accepted — and attractively so, since the company commits no capital of its own up front.

(b) The investor's rate of return

  1. Define the rate of return. The investor's (DCF) rate of return is the interest rate $i^\*$ at which $\text{NPW}(i^\*)=0$. Set the same NPW expression to zero and search for a root.
  2. Scan NPW versus interest rate. Evaluating the NPW expression:
    i10%15%20%25%30%35%40%50%100%
    NPW (k$)22711056322117.917.82130
    The NPW never reaches zero: it falls to a shallow minimum of about $+\$17{,}800$ near 38–40 % and rises again, staying strictly positive at every non-negative interest rate.
  3. Explain with Descartes' rule of signs. The cash-flow sequence is $0,\,+,+,+,+,\,-,\,+,+,\dots,+$ — two sign changes (the $-\$650$k at year 5 is bracketed by positive flows), so there are at most two positive real roots. Here there are none: because the company receives income (years 1–4) before it invests anything, this is a non-conventional, "financing-type" cash flow for which no single finite rate of return exists. $$\boxed{\text{No real positive DCF rate of return exists; } \text{NPW}(i)>0 \text{ for all } i\ge 0.}$$
  4. Give the board a usable answer. The practical meaning is that the return is effectively unbounded — the oil company puts up none of its own money and is cash-positive throughout except at year 5, which the surrounding income more than covers. When the ordinary rate-of-return criterion is indeterminate like this, Peters & Timmerhaus direct the decision back to NPW, which is decisively positive ($+\$227{,}000$ at 10 %). As a reference figure the board can quote the return earned on the only capital genuinely at risk — the year-5 water-flood: recovering $\$650{,}000$ from the $\$100{,}000/\text{yr}$ secondary income of years 6–20 requires $(P/A,i,15)=6.5$, i.e. $i\approx 13\%$, comfortably above the 10 % MARR.
QuantityValue
NPW at 10 % MARR$+\$227{,}000$ → accept
Investor's DCF rate of returnIndeterminate (no real root; NPW>0 for all $i\ge0$)
Return on the year-5 water-flood alone$\approx 13\%$ (> 10 % MARR)
DecisionAccept the lease-and-flood arrangement
Check: this is a genuine multiple-/no-rate-of-return situation, not a computational slip — the NPW curve stays positive (minimum ≈ +$17.8$k) across 0–100 %. The result is a direct consequence of income preceding investment; the board's stated policy of judging by "the investor's rate of return" simply cannot resolve this cash flow, and NPW must govern.