KM 452 CHEMICAL ENGINEERING DESIGN 2. EQUIPMENTS DESIGN Tanks Heat Exchangers Flush Drum Compresor Condenser Reactor Distillation Columns Quench Tower.

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1 KM 452 CHEMICAL ENGINEERING DESIGN 2

2 EQUIPMENTS DESIGN Tanks Heat Exchangers Flush Drum Compresor Condenser Reactor Distillation Columns Quench Tower Pump

3 CALCULATION OF CAPITAL INVESTMENT (TL)

4 % range% I. Direct Costs A. Eqp.+ Install.+ Instrumentation+Piping+Electrical+Insulation +Painting 1. Purchased Equipment Cost PEC 21085493 2. Installation, including insulation and painting 25-55% of PEC459488472 3. Instrumentation and controls,installed 8-50 % of PEC357379922 4. Piping, installed 10-80% of PEC5010542746 5. Electrical, installed 10-40% of PEC255271373 B. Buildings, process and auxiliary 10-70% of PEC408434197 C. Service facilities and yard improvements 40-100% of PEC7014759844 D. Land 4-8% of PEC61265129 78227178

5 II. Indirect Costs % range % A. Engineering and supervision 5-30% of direct costs 1511734077 B.Legal Expense 1-3% of FCI 22306699 C. Construction expense and contractor's fee 10-20 % of FCI 1517300241 D. Contingency 5-15 % of FCI 55766747 37107764 ??

6 % range % III. Fixed-Capital Investment ( Direct+indirect) costs 115334942 IV. Working Capital 10-20% of TCI10 12814994 V. Total Capital Investment FCI+WC 128149936

7 TOTAL ANNUAL COST

8 Estimation of Total Product Cost, TL/Year I. Manufacturing Cost A. Direct Product Costs 176952000 1. Raw Materials 176952000 2. Operating Labor 2880000 3. Direct Supervisory 432000 4. Utilities 35245462 5. Maintanence 6920096.536 6. Operating Supplies 1038014.48 7. Laboratory Charges 432000 8. Patents and Royalities 5000000 9. Catalyst 1087884.065

9 Total Utility Cost(TL/year) Water 100000 Solvent 71862 Steam 24213600 Electricity 10400000 Dowtherm A 152777 Cooling water 460000 TOTAL, TL 35245462

10 B. Fixed Charges(TL/YEAR) 1. Depreciation 72084334 2. Local Taxes 2883374 3. Insurance 8073445 C. Plant Overhead Cost(TL/YEAR) 10899152

11 Estimation of Total Product Cost, TL/Year II. General Expenses A. Administrative Costs 2046420 B. Sales and Marketing 29182244.5 C. Research and Development 14591122

12 TOTAL ANNUAL COST(TL/YEAR) 291822443

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14 FCI = 1.15E+08 TL TCI = 1.86E+08 TL TAC=291822443 TL/year As (100000 ton/year *1000) kg/year of Acrylic acid produced in the plant at 100 % capacity, the unit production cost is; (291822443 TL/year) / (100000*1000)kg/year = 2.91 TL/ kg Acrylic acid

15 Gross earning cost Basis; Minimum Acceptable Rate of Return = 30% Taxes : 30% (Total income - Total product cost)

16 Rate of Return = Np/TCI Net Profit (Np) at 100% capacity, p: Selling Price of Acrylic acid per kg. 0.3x 1.86E+08 = (100000*1000 kg / year) x (p – 2.91) x (1-0.30) ACRYL Selling Price(after taxes)= 3.18 TL/kg ACRYL Selling Price(before taxes)= 3.30 TL/kg

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18 after taxes ; net profit= 26889043.35 TL/yr Before taxes; net profit= 38422538 TL/yr Annual cash flow = net profit + depreciation= (after)=34097477 TL/yr (before)=48905347 TL/yr

19 Payback period =FCI/ANNUAL CASH FLOW= years (after taxes)PERIOD= 1.15E+08 / 34097477.24 = 3.4 years (before taxes)PERIOD= 1.15E+08/ 48905347 = 2.3 years

20 BREAK EVEN POINT(BEP) BEP=TAC/(AFTER TAXES SELLING PRICE) =291822443/3.18 BEP=91768064 (BEFORE TAXES SELLING PRICE) =291822443/3.30 BEP=88431044 SHUT DOWN POINT(SDP) SDP=(TAC- FC)/(AFTER SELLING PRICE) =280923291 /3.18 SDP=88340658 (BEFORE TAXES SELLING PRICE) = 280923291/3.30 SDP= 85128270

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