Appendix

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APPENDIX

Appendix A

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Table A.1 : HYSYS Workbook Data

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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


Tariff Ds – Special Industrial Tariff (for consumers who qualify only)



2. Tariff E1 - Medium Voltage General Industrial Tariff

For each kilowatt of maximum demand per month RM/kW 23.40



Tariff E1s – Special Industrial Tariff (for consumers who qualify only)




3. Tariff E2 - Medium Voltage Peak/Off-Peak Industrial Tariff


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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



For each kilowatt of maximum demand per month


RM/kW 25.20




4. Tariff E3 - High Voltage Peak/Off-Peak Industrial Tariff



RM/kW 28.10







RM/kW 22.20




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

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Figure E.3 : Engineering Drawing for E-106

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Fgure E.4 : Engineering Drawing for T-101

Figure E.5 : Engineering Drawing for T-102

Appendix

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