appendix
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Appendix BSummary of production costs (Reference: Coulson and Richardson’s textbook)
Variable Cost (A)
1. Raw material – from flow sheet
2. Miscellaneous material – 10% from 5
3. Utilities – from flow sheet
4. Shipping and packaging – Usually negligible
Fixed Cost (B)
5. Maintenance – 5% to 10% from fixed capital
6. Operating labor – from manning estimates
7. Laboratory charges – 20% to 23% from 6
8. Supervision – 20% from 6
9. Plant overheads – 50% from 6
10. Capital cost – 15% from fixed cost
11. Insurances – 1% from fixed capital
12. Local taxes – 2% from fixed capital
13. Royalties – 1% from fixed capital
Sample of calculation for breakeven analysis
Stream Factor
Fixed Costs
From the previous plant ‘Dyno Nobel Moranbah (DNM)’
Fixed capital cost = USD 52,000,000 for 330,000 tonne in year 2008
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= USD 15,805,083
USD 1 = RM 3.20 (Exchange rates at 10 August 2010)
= RM 50,576,266 / year
≈ RM 50,576,270 / year
1.
= RM 2,528,813.50 / year
≈ RM 2,528,820 / year
Operating labor
Table B.1: Operating Labor
Equipment Number of equipment Nnp
Venture scrubber 1 1
Separator 1 1
Tank 2 2
Boiler 2 2
Pump 5 -
Reactor 1 1
Total 5
No of operator per shift, NOL = (6.29 + 31.7P2 + 0.23 Nnp)0.5
No. of processing step is 0
Therefore 31.7P2 = 0
NOL = [6.29 + 0.23 (5)]0.5
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= 2.73 operator / shift
Estimated the operating labor,
One operator works an average of 49 week / year because 3 weeks are used
holiday and sick leave.
There will be five (5) shift per week
Plant operates 24 hour / days
1 shift = 8 hour
= 5 operator
= 13.65 / shift
= 14 / shift
In Malaysia, 1 operator = RM 6,576 / year (MIDA)
2. Total operating labor costs = RM 6,576 / year 14
= RM 92,064 / year
≈ RM 93,000 / year
3. Laboratory charges = 0.2 RM 93,000 / year
= RM 18,600 / year
4. Supervisory = 0.2 RM 93,000 / year
= RM 19,000 / year
5. Plant overhead = 0.5 RM 93,000 / year
= RM 46,500 /year
6. Capital cost = 0.15 RM 50,576,270 / year
= RM 7,586,440.50
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≈ RM 7,586,500 / year
7. Insurance = 0.01 RM 50,576,270 / year
= RM 505,762.70
≈ RM 505,800 / year
8. Local taxes = 0.02 RM 50,576,270 / year
= RM 1,011,525.40
≈ RM 1,011,600 / year
9. Royalties = 0.01 RM 50,576,270 / year
= RM 505,762.70
≈ RM 505,800 / year
Total Fixed Cost = RM 12,315,620 / year
Variable costs
Raw material
1. Ammonia Price: RM 3000 per tonne
= RM 3,682,158.48 / year
≈ RM 3,700,000 / year
2. Nitric Acid Price: RM 3500 per tonne
= RM 15,894,398.52 / year
≈ RM 16,000,000 / year
3. Miscellaneous material = 0.1 RM 2,528,820 / year
= RM 252, 882 / year
≈ RM 252, 900 / year
Total Variable Cost =RM 19,952,900 / year
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Appendix C
Table C.1 : SESCO Berhad - Pricing and Tariff for Industrial Customer
TARIFF CATEGORY UNIT RATES
1. Tariff D - Low Voltage Industrial Tariff
For Overall Monthly Consumption Between 0-200 kWh/month
For all kWh sen/kWh 32.5
The minimum monthly charge is RM7.20
For Overall Monthly Consumption More Than 200 kWh/month
For all kWh (From 1kWh onwards) sen/kWh 34.8
The minimum monthly charge is RM7.20
Tariff Ds – Special Industrial Tariff (for consumers who qualify only)
For all kWh sen/kWh 32.7
The minimum monthly charge is RM7.20
2. Tariff E1 - Medium Voltage General Industrial Tariff
For each kilowatt of maximum demand per month RM/kW 23.40
For all kWh sen/kWh 26.6
The minimum monthly charge is RM600.00
Tariff E1s – Special Industrial Tariff (for consumers who qualify only)
For each kilowatt of maximum demand per month RM/kW 18.10
For all kWh sen/kWh 25.8
The minimum monthly charge is RM600.00
3. Tariff E2 - Medium Voltage Peak/Off-Peak Industrial Tariff
For each kilowatt of maximum demand per month RM/kW 29.30
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during the peak period
For all kWh during the peak period sen/kWh 28.1
For all kWh during the off-peak period sen/kWh 17.3
The minimum monthly charge is RM600.00
Tariff E2s – Special Industrial Tariff (for consumers who qualify only)
For each kilowatt of maximum demand per month
during the peak period
RM/kW 25.20
For all kWh during the peak period sen/kWh 25.8
For all kWh during the off-peak period sen/kWh 14.7
The minimum monthly charge is RM600.00
4. Tariff E3 - High Voltage Peak/Off-Peak Industrial Tariff
For each kilowatt of maximum demand per month
during the peak period
RM/kW 28.10
For all kWh during the peak period sen/kWh 26.6
For all kWh during the off-peak period sen/kWh 16.0
The minimum monthly charge is RM600.00
Tariff E3s – Special Industrial Tariff (for consumers who qualify only)
For each kilowatt of maximum demand per month
during the peak period
RM/kW 22.20
For all kWh during the peak period sen/kWh 24.3
For all kWh during the off-peak period sen/kWh 13.4
The minimum monthly charge is RM600.00
Table C-2: TNB: Pricing and Tariff for Industrial Customer
TARIFF CATAGORY RATES
1.
For the first 100 units per month 40 sen
For the next 2900 units per month 30 sen
For each additional unit per month 27 sen
Minimum monthly charge RM 10.00
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2 For each kilowatt of maximum demand per
month
RM 16.00
For each unit 22.2 sen
Minimum monthly charge RM 16.00 per kilowatt x Billing
Demand
3
.
For each kilowatt of maximum demand per
month during the peak period
RM 20.00
For each unit during the peak period 23.4 sen
For each unit during the off peak period 14.4 sen
Minimum monthly charge RM 20.00 per kilowatt x Billing
Demand
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Appendix D
Table D.1 : Type of Storage Tank
Term Definition
Dike A dike is a barrier design to contain liquid
spills within a given area for safety reason
Diversion Dike This a barrier design to divert spill from
other storage tank
Double Wall Storage Tank A double wall storage tank has an
innerwall to contain a liquid, an annulus
space usually filled with insulation and
outer wall for spill containment.
Flame Arrester In the event of lighting or another source of
vapor ignition, a flame arrester in the vent
line of a storage tank prevent flames from
flashing to the vapor inside the tank.
Flame Snuffer This a device in a tank vent line that can
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be operate manually to snuff out a flame
at the open out end of the vent.
Floating Roof Tank A floating roof tank is design to conserve
vapor loss and minimize fire hazard.
Figure D.1 : Floating roof tank (source from Braucher, 1993)
Figure D.2 : Double Wall Storage tank with dikes. (source from Braucher, 1993)
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Figure D.3 : Deflagration arrester/ flame arrester installation. (Source: Perry,1997)
Figure D.4 : Flame arrester design - end of line type (Source: Perry, 1997)
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Appendix E
Figure E.1 : Engineering Drawing for PFR-101
Figure E.2 : Engineering Drawing for V-100