design 2011 ecocomics and control

7/31/2019 Design 2011 Ecocomics and Control

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Some Guidelines

A) Process Economics - Plant Cost Estimation

B Process Control Methods

th

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Income - from sales, annual/monthly Expenses

fixed incl. cost of Ca ital

variable (per unit sold)

-30 years for process equipment)

ro t oss c art o accounts, a st

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Account to 31 Au Bud et variance

7-0415 New Site Preparations

7-04151 Site- Concrete Pad & Prep 105,971.50 159,820.00 -53848.50

7-04152 Site- Temp Services & Connect 372.90 14,200.00 -13827.10

7-04153 Site - Utilities (Electricity) 71,737.88 150,000.00 -78262.12

7-04154 Site - Utilities (Natural Gas) 42,577.27 90,000.00 -47422.73

7-04155 Site - Utilities (Water) 5,537.92 12,000.00 -6462.08

7-04156 Site - Fence Install & hire 0.00 29,010.00 -29010.00

7-04157 Site - Miscellaneous & Advert. 4,269.11 5,000.00 -730.89

7-04158 Site Office Set Up & Rental 17,947.38 48,350.00 -30402.62

- , . , . .

7-04160 Innova Labour & Proj. Mgmt 0.00 14,278.85 -14278.857-0415 New Site Preparations - Other 0.00 44,169.00 -44169.00

Total 7-0415 New Site Preparations 304,459.14 611,827.85 -307368.71

7-0420 Springvale Lab Treatability St

7-0421 Springvale Soil Analysis 9,425.85

7-0420 Springvale Lab Treatability St - Other 0.00 20,000.00 -20000.00

Total 7-0420 Springvale Lab Treatability St 9,425.85 20,000.00 -10574.15

7-0430 Mobilise, Transport & Set Up

7-04301 Break Up Electrical Contractor 17,707.53 45,000.00 -27292.47

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Earnings before Interest and Taxation (EBIT)

, ,Amortisation (EBITDA)

Net Profit after Taxation (NPAT).

Balance Sheet: Assets

Liabilities

Depreciation Net Tangible Assets (NTA).Fire sale

J Lucas 2008 4


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Year End 30/06/2008 30/06/2009 30/06/2010 30/06/2011 30/06/2012

Tonnes 10500 33000 110000 135000 155000

% of Capacity 6% 19% 31% 39% 44%

Sales ($'000) 4,471 7,616 25,445 32,825 38,875

EBIT ($'000) -179 -636 5,200 7,755 12,922

EBITDA ($'000) 15 -150 6,135 8,851 14,032

NPAT ($'000) -125 -445 3,640 5,429 9,046

Issued Shares (number) 15,707,255 23,707,255 23,707,255 23,707,255 23,707,255

EPS (cents) -0.8 -1.9 15.4 22.9 38.2

NTA's ($'000) 3,583 5,137 10,078 14,719 22,979

NTA's/Share (cents) 22.8 21.7 42.5 62.1 96.9

NET DEBT ($'000) 1,935 1,861 4,992 1,271 -2,389

NET DEBT/NTA'S 0.54 0.36 0.50 0.09 N/A

ENTERPRISE VALUE ($'000) - - 29,120 43,432 72,368

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(Based on 8 x Earnings Multiple)

ENTERPRISE VALUE/SHARE ($) - - $1.23 $1.83 $3.05


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07/08 08/09 09/10 10/11 11/12

NPAT ($'000) -125 -445 3,640 5,429 9,046

EARNINGS

MULTIPLE

6 - - 21,840 32,574 54,276

$0.92/share $1.37/share $2.29/share

7 - - 25,480 38,003 63,322


- - , , ,


9 - - 32,760 48,861 81,414

. . .

10 - - 36,400 54,290 90,460


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Investment/Purchase on NTAs Investment/Purchase on Earnings Multiples

Pa back Period time for investment aid

back -

NPV net present value (purchase value) IRR internal rate of return on investment

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8/22

Perry

Direct Quotation (requires someone's time, rarelydonated for a non- a in ro ect challen e for

student projects) 2nd Hand Equipment Sales

Personal Experience

Consultation with the experienced Estimation methods rules of thumb

six tenths rule scaling: C2 = C1*(Q2/Q1)**0.6

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Industrial Land Purchase - $100-$300 /m2

20 year lease - $8-$20/m2/annum

Statutor A rovals and Licences $60-150K for variation/6-12 months

$400-$1M for new/12-36 months

Basic Site Establishment

$30 /m2 for raw/Brownfield site $5 /m2 for previously occupied site

Buildin s - $800-$1200 /m2

Services Power - $150K per 1000 Amps

Gas $100K er 40 GJ/hr Water $50K

Other $20K

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Materials Mild Steel - $2000 per tonne

Stainless Steel - $10,000 per tonne

Fiberglass ??

Information

xo cs - , per onne

Fabrication Consumables Mild steel minimal $20 per day

1 kg wire per hour 3 m weld per hour

$45 per kg wire

Basic: 40-50 hours per tonne

Intricate: 80-90 hours per tonne

Highly complex/specialist: 100-120 hours per tonne Labour Rates: $60 - $80 per hour

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11/22

Pumps Motors and Drives - $10K per unit ar ware: nstrumentat on an ensors - per

unit

ec r ca ns a a on = os o ar ware Control Systems = 50% Cost of Hardware

Installation

Commissioning ..etc..

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12/22

Sort key

(hide

column) MODIFICATIONS / CHANGES / ADDITIONS Supplier

CURRENT COST

ESTIMATE

Task 1 Replacement of Twin Screw Auger with Single Shaft Pugmill $132,000Sub Task 1.1 Pug mill - single shaft, paddle mixer arms ASTEC _ USA $105,000

Sub Task 1.2 Electrical design/control mods CI $1,000Sub Task 1.3 Electrical installation BBE $1,000Sub Task 1.4 Water cooled refractory lined transition screw for converter dust transfer MCM $25,000

Task 2 Replacement of tipper valve with Double Dump Valve $10,500

Sub Task 2.1 Double dump valve Filtaire - Melbourne $7,500

u as . ec r ca es gn con ro mo s ,

Sub Task 2.3 Electrical installation BBE $2,000Task 3 Replacement of feed screw with Slinger Belt Feeder $32,000

Sub Task 3.1 Slinger Belt ASTEC _ USA $20,000Sub Task 3.2 Electrical design/control mods CI $1,000

Sub Task 3.3 Electrical installation BBE 1 000Sub Task 3.4 Dogbox modifications (steel work) MCM $10,000Sub Task 3.5 Dogbox modifications (refractory) TBA $5,000

Task 4 Drier skid / Lifter modifications for Items 1-3 (HEIGHT INCREASE 1.8m) $57,000

Sub Task 4.1 Electrical works allowing removal of skid BBE $3,000

Sub Task 4.2 Electrical modifications (new junction box/cable extensions) BBE $5,000Sub Task 4.3 Modification of skid MCM $10,000

Sub Task 4.4 Transportation and cranage TBA $4,000Sub Task 4.5 Extension of electrical cables BBE $3,000

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-

Cranes - $320 per hour nsurances - - pa

Land Rates

Workers Comp 9% Legal Fees - $10K per transaction

Company Overheads 20-30 %

Maintenance - $3 er tonne roduced/ rocessed Labour Rates Professionals - APESMA

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14/22

Acid Scrubber

$500K

Bag House

$480K

J Lucas 2008 14$250K Install$130K Install


15/22

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.

Hand Sketch parameters you think should be measured.

Develop a hierarchy, eg Critical redundancy

Interlocks

Alarms

Monitor Visual

Think about benefit of Cascade Control

Feed Forward or other advanced (Add limit switches, motion detectors advanced)

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, , , ,

Set alarms

Set Interlocks pec y a sa es

E-Stops

Work out Operating Procedures

Start-up

Standard Operation

Shutdown

Emergency Shutdown

All the above are related to the Control Strategy

Commissioning Plan is quite Separate

Change Management Plan - advanced

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Control needs to be communicated at several levels:

Overview strategy and principles - PPT

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Detail P&ID report/appendix

Start with a ood readable le end courtes Bo le et al

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- Annotate PFD

- Develop Control Loopsetc

design 2011 ecocomics and control

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