23-Chem-A5 Chemical Plant Design and Economics · Undated paper
Nivaar worked solution (AI-drafted; not reviewed by a licensed engineer)
National Exams / EGBC — May 2019 — 16-Chem-A5 Chemical Plant Design and Economics. Three-hour closed-book examination; one aid sheet (both sides) and an approved calculator are permitted. Six questions are printed and any five constitute a complete paper (each worth 20 marks); all six are solved below for completeness. Three questions carry numbers (Q1 route economics, Q3 production cost, Q4 depreciation); the other three (Q2 supercritical extraction, Q5 the design hierarchy intrinsic to a chemical process, Q6 VOC-abatement P&ID) are answered as structured description with a supporting diagram where the paper asks for one.
Reference texts: M. S. Peters, K. D. Timmerhaus & R. E. West, Plant Design and Economics for Chemical Engineers (5th ed., McGraw-Hill) — total-product-cost anatomy, straight-line depreciation, after-tax cash flow, profitability; R. Turton, R. C. Bailie, W. B. Whiting & J. A. Shaeiwitz, Analysis, Synthesis, and Design of Chemical Processes (4th ed., Prentice Hall) — the economic-potential screen, reaction-path selection and the process flow diagram; J. M. Douglas, Conceptual Design of Chemical Processes (McGraw-Hill) — the level-2 economic-potential hierarchy and the balanced vinyl-chloride process; G. Towler & R. Sinnott, Chemical Engineering Design (Coulson & Richardson Vol. 6, 2nd ed.) — utilities, VOC control and product recovery; R. H. Perry & D. W. Green, Perry’s Chemical Engineers’ Handbook (9th ed.) — supercritical-fluid extraction. Depreciation is worked in the U.S. MACRS/straight-line framework the question specifies; the Canadian CCA declining-balance analogue is noted where relevant.
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. $\text{FCI}=\$100\text{M}$; gross profit $G=\$50\text{M/yr}$; tax rate $t=0.35$; full-rate operation years 1–10; zero salvage.
Find. Annual depreciation $D$, income tax and after-tax cash flow (ATCF) for 10 years under (a) straight-line and (b) 7-year MACRS.
Approach. Depreciation is a non-cash charge that shields income from tax; taxable income $=G-D$, tax $=t(G-D)$, and after-tax cash flow $\text{ATCF}=G-\text{tax}=(G-D)(1-t)+D$. Only the depreciation schedule differs between the two methods.
MACRS 7-year schedule (all figures in $millions):
| Year | MACRS rate | Depreciation $D$ ($M) | Taxable $G-D$ ($M) | Tax @35% ($M) | ATCF ($M) |
|---|---|---|---|---|---|
| 1 | 14.29% | 14.29 | 35.71 | 12.50 | 37.50 |
| 2 | 24.49% | 24.49 | 25.51 | 8.93 | 41.07 |
| 3 | 17.49% | 17.49 | 32.51 | 11.38 | 38.62 |
| 4 | 12.49% | 12.49 | 37.51 | 13.13 | 36.87 |
| 5 | 8.93% | 8.93 | 41.07 | 14.37 | 35.63 |
| 6 | 8.92% | 8.92 | 41.08 | 14.38 | 35.62 |
| 7 | 8.93% | 8.93 | 41.07 | 14.37 | 35.63 |
| 8 | 4.46% | 4.46 | 45.54 | 15.94 | 34.06 |
| 9 | 0% | 0.00 | 50.00 | 17.50 | 32.50 |
| 10 | 0% | 0.00 | 50.00 | 17.50 | 32.50 |
| Total | 100% | 100 | 400 | 140 | 360 |
| Quantity (10-yr) | Straight-line | MACRS 7-yr |
|---|---|---|
| Total depreciation | $100M | $100M |
| Total income tax | $140M | $140M |
| Total after-tax cash flow | $360M | $360M |
| Year-1 depreciation | $10M | $14.29M |
| Year-1 tax / ATCF | $14M / $36M | $12.50M / $37.50M |
| Present value of ATCF | lower | higher (tax deferred) |
The MACRS rates are the standard IRS 7-year table (200% DB, half-year convention); depreciation therefore spans eight tax years even though the class life is seven. Under Canadian rules the analogue is the Capital Cost Allowance: a Class 43 processing asset at a 30% declining-balance rate with the half-year rule in year 1, which — unlike MACRS — never fully depreciates the asset (an asymptotic tail).