FEL-3 Project Dashboard — Engineering Platform
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Project Summary — FEL-3 Decision Package
Methanol-to-Olefins Unit
Greenfield Process Plant
Client: Industrial Chemicals Corp.  |  Location: US Gulf Coast  |  Prepared by: CapCo Engineering Platform
FEL-3 / PRE-FEED AACE CLASS 3 · ±30% Issue: March 2026
1Identify✓
2Assess✓
3Define ◀ HERE
4Execute
5Operate
🚦 FEL-3 Readiness — Gate Status
Mass & Energy Balance
Closed ±1.2% · 5 streams
Process Flow Diagram (PFD)
Issued for review
Equipment Sizing
All major items sized
CAPEX Estimate
Class 3 · vendor quotes pending
Relief & Safety Review
PRV sized · HAZOP scheduled
Environmental & Permits
Pre-app meeting completed
Project Economics (DCF)
NPV positive · IRR > hurdle
Offtake / Commercial
MOU in progress — not signed
📋 Gate Recommendation
CONDITIONAL PROCEED
Project meets FEL-3 technical and economic criteria. Recommend proceed to FEED subject to: (1) execution of binding offtake agreement, (2) receipt of ≥3 vendor budget quotations for major equipment, (3) completion of pre-FEED HAZOP. Estimated FEED cost: $2.8M over 8 months.
👤 Decision Information
Decision required by April 15, 2026
FEED budget required $2.8M
FID target date Q1 2027
Plant start-up target Q3 2029
Economics Snapshot
NPV (@ 10% WACC)
+$148M
real terms · 20yr life
IRR
18.4%
vs WACC 10% hurdle
Simple Payback
6.2 yrs
undiscounted
Discounted Payback
8.9 yrs
at 10% discount rate
Annual Revenue (SS)
$124M
steady state yr 3+
Annual EBITDA
$48M
margin 38.7%
Total OPEX
$76M
per year steady state
Break-even Price
$610/t
vs base case $850/t
CAPEX Estimate — AACE Class 3
💰 Capital Cost Build-up
Purchased Equipment Cost (PEC)$42.1MAACE 3
Total Installed Cost (TIC)$163MLang 3.88×
Engineering & Procurement$16.3M10% TIC
Contingency$26.9M15%
Owner's Costs / OSBL$16.5M8%
Total Project Cost (TPC)$238M±30%
📊 Estimate Accuracy Range
$167M $238M $309M
Base Estimate
−30% lowBase · Class 3+30% high
CEPCI escalation: 567→820 (1.447×)
Location: US Gulf Coast (1.00×)
Phased CAPEX: 40% Yr0 / 40% Yr1 / 20% Yr2
Major equipment: 14 items · 3 quotes pending
Process Metrics — Mass & Energy Balance Summary
⚗ Stream Summary
Methanol Feed12,500kg/h · 40°C · liquid
Ethylene Product3,840kg/h · 25°C · vapor
Propylene Product2,960kg/h · 25°C · vapor
C4+ By-product1,200kg/h · liquid
Steam (HPS)4,200kg/h · 380°C · 40 bar
Cooling Water85,000kg/h · 28°C supply
⚡ Energy Balance
Feed stream enthalpy4,820 kW✓
Product stream enthalpy3,960 kW✓
Reactor heat (ΔHrxn)−2,840 kWexo
Net process duty18.4 MWfired
Utility steam demand8.4 t/hest.
Electricity demand3.2 MWest.
Mass balance closure99.2%✓
Risk Register & Key Assumptions
⚠ Key Risks
Product price below break-even ($610/t)HIGHOfftake agreement
CAPEX overrun — vendor quotes pendingHIGHGet 3 quotes
Catalyst performance below designMEDIUMVendor guarantee
Permitting timeline slippageMEDIUMPre-app submitted
Feedstock (methanol) cost escalationMEDIUMIndex-linked contract
Skilled labour availability onsiteLOWEPC tender Q2
Utility infrastructure adequacyLOWSite survey done
📌 Key Assumptions
Plant capacity120 kt/yr olefinsconfirmed
Ethylene selling price$850/tonneQ4 2025 spot
Methanol feedstock$320/tonnemarket index
On-stream factor8,000 hr/yr91.3%
Catalyst life18 monthsvendor est.
Discount rate (WACC)10%board approved
Inflation / escalation2.5%/yrCPI basis
Tax rate25%US federal
CapCo FEL-3 Engineering Suite — Module Navigator
⊞ Engineering Calculation Modules
🌊
Liquid Hydraulics
Line sizing · ΔP · pump head
Darcy-Weisbach / HW 💨
Gas Hydraulics
Compressible flow · Weymouth · API 14E
General Flow / Panhandle B ♨
Heat Exchanger Design
TEMA S&T · LMTD · U coefficient
NTU-Effectiveness 🔧
Relief Valve Sizing
API 520/521/526 · ASME VIII
Vapor / Liquid / 2-Phase ⚙
Pump Selection
H-Q curves · NPSH · Affinity laws
System curve intersection ⚗
Mass & Energy Balance
Stream table · Sankey · Closure
5 process templates 📈
Project Economics
NPV · IRR · Payback · Tornado
DCF · Sensitivity 💰
Equipment Cost Estimator
Lang/Hand · CEPCI · 6 types
±30% AACE Class 3 🗂
Project Dashboard
Executive summary · Gate review
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All modules are standalone HTML files — no server, no login, no dependencies. Deploy to any static host or share as a file. Each module produces FEL-3 grade outputs suitable for capital sanction packages.