design 2011 ecocomics and control
TRANSCRIPT
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Some Guidelines
A) Process Economics - Plant Cost Estimation
B Process Control Methods
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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
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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
$1.07/share $1.60/share $2.67/share
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$1.23/share $1.83/share $3.05/share
9 - - 32,760 48,861 81,414
. . .
10 - - 36,400 54,290 90,460
$1.54/share $2.29/share $3.82/share
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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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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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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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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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Acid Scrubber
$500K
Bag House
$480K
J Lucas 2008 14$250K Install$130K Install
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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
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ow ery mp e xamp es
Breakdown into sections
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Show Very Simple Examples
Breakdown into sections
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e eta s are n t s eport rea own nto ect ons
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,
80 Measurement
300 Alarms
Extract Slide - example
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Extract Slide - example