Open navigation menu
Close suggestions
Search
Search
en
Change Language
Upload
Sign in
Sign in
Download free for days
0 ratings
0% found this document useful (0 votes)
2K views
7 pages
Sugar Plant Cost Estimation Calculations PDF
Uploaded by
tsrinivasan5083
AI-enhanced title
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content,
claim it here
.
Available Formats
Download as PDF or read online on Scribd
Download
Save
Save Sugar Plant Cost Estimation calculations.pdf For Later
Share
0%
0% found this document useful, undefined
0%
, undefined
Print
Embed
Report
0 ratings
0% found this document useful (0 votes)
2K views
7 pages
Sugar Plant Cost Estimation Calculations PDF
Uploaded by
tsrinivasan5083
AI-enhanced title
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content,
claim it here
.
Available Formats
Download as PDF or read online on Scribd
Carousel Previous
Carousel Next
Download
Save
Save Sugar Plant Cost Estimation calculations.pdf For Later
Share
0%
0% found this document useful, undefined
0%
, undefined
Print
Embed
Report
Download
Save Sugar Plant Cost Estimation calculations.pdf For Later
You are on page 1
/ 7
Search
Fullscreen
AND ECONO! ICS Given in the literature is the cost versus size Nomograph, from which the cost of cane sugar plant within the crushing capacity between 500 — 5000 TPD can be calculated. The cost for 5000 TPD crushing capacity plant with Chemical Engineering Plant Cost Index (CE) =130 (Basis = 1957 -59; CE = 100) is as follows: Cost for 5000 TPD crushing capacity = Rs. 10.25 x 10” /- To find present cost: ‘A cost index is merely an index value for a given point in time showing the cost at that time relative to a certain base time. If the cost at some time in past is known, the equivalent cost at the present time can be determined by multiplying the original cost by the ratio of the present index value to the index value applicable when the original cost was obtained. Obtained from the Internet that Chemical Engineering Plant Cost Index is given as: Cost index in 2002 = 402 Original cost value is obtained when cost index was 130. Thus, Present cost of Plant = (original cost) x {(present cost index)/(past cost index)} = (10,25,00,000 /-) x (402/130) = Rs. 31.70 x 10” /- Fixed Capital Investment (FCI) = Rs. 31.70 10" - Generally fixed capital investment cost is 85% of total capital investment. Therefore Total Capital Investment = (FCI/0.85 = 37.29 x 10" Rs Estimation of Total Capital Investment Cost: (I) Direct Costs: (A) Material and labour involved in actual installation of complete facility (70-85% of fixed-capital investment) a) Equipment + installation + instrumentation + piping + electrical + insulation + painting (50-60% of Fixed-capital investment) a. Purchased equipment cost (PEC): RANGE — = 15-40% of Fixed-capital investment Let Purchased Equipment Cost = 30% of Fixed-capital investment PEC = 30% of Rs. 31.70 x 107 8. 9.51 x 107 b. Installation, including insulation and painting: RANGE — = 25-55% of purchased equipment cost.Let Installation Cost 5% of Purchased equipment cost = 35% of Rs. 9.51 x 107 - = Rs. 3.33 x 107 /- Instrumentation and controls, installed: RANGE = 6-30% of Purchased equipment cost. Let Instrumentation Cost = 10% of Purchased equipment cost = 10% of Rs. 9.51 x 107 - =Rs. 0.951 x 107 4. Piping Installed: RANGE = 10-80% of Purchased equipment cost Let Piping Cost = 40% of Purchased equipment cost = 40% of Rs. 9.51 x 10? - = Rs. 3.804 x 107/- e. _ Electrical, installed: RANGE = 10-40% of Purchased equipment cost Let Electrical cost = 25% of Purchased equipment cost = 25% of Rs. 9.51 x 10? - = Rs. 2.3775 x 10" - Therefore Total cost for (A) = Rs. 19,9725 x 10" /- (B) Buildings, process and Auxiliary: RANGE = 10-70% of Purchased equipment cost Let Buildings, process and auxiliary cost = 30% of PEC = 30% of Rs. 9.51 x 107 Rs, 2.853 x 107 /- (©) Service facilities and yard improvements: RANGE = 40-100% of Purchased equipment cost Let Facilities and yard improvement cost 0% of PEC = 50% of Rs. 9.51 x 107 = Rs. 4.755 x 107 + (D) Land: RANGE — = 4-8% of Purchased equipment cost Let the cost of land = 6% of PEC = 6% of Rs. 9.51 x 10" /- = Rs. 0.5706 x 10” /- Therefore Total Direct Cost = 28.1511 x 107 /-(ID) Indirect costs: Expenses, which are not directly involved with material and labour of actual installation of complete facility (15-30% of Fixed-capital investment) (A) Engincering and Supervision: RANGE = 5-30% of Direct costs Let the cost of engineering and supervision = 10% of Direct costs 0% of Rs. 28.1511 x 10" /- = Rs. 2.815 x 107 /- (B) Construction Expense and Contractor's fee: RANGE = 6-30% of Direct costs Let construction expense & contractor's fee = 15% of Direct costs = 15% of Rs. 28.1511 x 10" =Rs, 4.223 x 107 /- (©) Contingency: RANGE = 5-15% of Fixed-capital investment Let the contingency cost = 8% of Fixed-capital investment = 8% of 31.70 x 10’ /- . = Rs, 2.536 x 10" Thus, Total Indirect Costs = Rs. 9.574 x 10! /- (111) Fixed Capital Investment Fixed capital investment = Direct costs + Indirect costs = Rs 37.7251 x 107 (IV) Working Capital: RANGE = (10-20% of Total-capital investment) Let the Working Capital = 15% of Total-capital investment = 15% of 37.29 x 107 /- = 0.15 x 37.29 x 10" /- = Rs. 5.5935 x 10” (V) Total Capital Investment (TCD): Total capital investment = Fixed capital investment + Working capital = 43.3186 x 107 + Estimation of Total Product cost: (D) Manufacturing Cost = Direct production cost + Fixed charges + Plant overhead cost.(A) Fixed Charges: (10-20% total product cost) i, Depreciation: (depends on life period, salvage value and method of calculation-about 10% of FCI for machinery and equipment and 2-3% for Building Value for Buildings) Consider depreciation = 10% of FCI for machinery and equipment and 2.5% for Building Value for Buildings) ile. Depreciation = (0.10 x 37.7251 x 10”) + (0,025 x 2.853 x 10”) = Rs. 3.8443 x 107 /- ii, Local Taxes: (1-4% of fixed capital investment) Consider the local taxes = 2% of fixed capital investment ie, Local Taxes = 0.02 x 37.7251 x 10’ = Rs. 0.7545 x 10” /- ili, Insurances: (0.4-1% of fixed capital investment) Consider the Insurance ~ 0.6% of fixed capital investment i.e. Insurance = Rs. 0.2264 x 107 /- iv, Rent: (8-12% of value of rented land and buildings) Consider rent = 10% of value of rented land and buildings = Rs. 0.2853 x 10" /- Thus, Total Fixed Charges = Rs. 5.1105 x 107 - (B) Direct Production Cost: (about 60% of total product cost) Now we have Fixed charges = 10-20% of total product charges ~ (given) Consider the Fixed charges = 15% of total product cost Total product cost = Total fixed charges/0.15 Total product cost = 5.1105 x 107/0.15 Total product cost (TPC) = Rs, 34.07 x 10" /- i. Raw Materials: (10-50% of total product cost) Consider the cost of raw materials = 25% of total product cost Raw material cost = 25% of 34,07 x 10” = Rs. 8.5175 x 10" /- ii, Operating Labour (OL): (10-20% of total product cost) Consider the cost of operating labour = 12% of total product cost Operating labour cost = 12% of 34.07 x 10’ = 0.12 x 34.07 x 10” = Rs. 4.0884 x 10" /- iii. Direct Supervisory and Clerical Labour (DS & CL): (10-25% of OL) Consider the cost for Direct supervisory and clerical labour = 12% of OL Direct supervisory and clerical labour cost = 12% of 4.0884 x 10" /- = 0.12 x 4.0884 x 10! /- Direct supervisory and clerical labour cost = Rs. 0.4906 x 107 /- iv. Utilities: (10-20% of total product cost)Consider the cost of Utilities = 12% of total product cost Utilities cost = 12% of 34.07 x 10" = 0.12 x 34.07 x 10" /- = Rs, 4.0884 x 10" - y. Maintenance and repairs (M & R): (2-10% of fixed capital investment) Consider the maintenance and repair cost = 5% of fixed capital investment Maintenance and repair cost = 0.05 x 37.7251 x 10” = Rs. 1.8863 x 107 /- vi. Operating Supplies: (10-20% of M & R ot 0.5-1% of FCI) Consider the cost of Operating supplies = 15% of M & R Operating supplies cost = 15% of 1.8863 x 10” = 0.15 x 1.8863 x10" /- = Rs. 0.2829 x 10" /- vii. Laboratory Charges: (10-20% of OL) Consider the Laboratory charges = 14% of OL Laboratory charges = 14% of 4.0884 x 10’ = 0.5724 x 107 /- viii, Patent and Royalties: (0-6% of total product cost) Consider the cost of Patent and royalties = 2% of total product cost Patent and Royalties = 2% of 34.07 x 10’ = 0.6814 x 10" /- Thus, Direct Production Cost = Rs. 20.6079 x 107 /- (C) Plant overhead Costs: (50-70% of Operating labour, supervision, and maintenance or 5-15% of total product cost); includes for the following: general plant upkeep and overhead, payroll overhead, packaging, medical services, safety and protection, restaurants, recreation, salvage, laboratories, and storage facilities. Consider the plant overhead cost = 10% of Total Product Cost. Plant overhead cost = 10% of 34.07 x 10” /- = Rs. 3.407 x 107 /> Thus, Manufacturing cost = Direct production cost + Fixed charges + Plant overhead costs Manufacture cost = (20.6079 x 10") + (5.1105 x 10”) + (3.407 x 10”) Manufacture cost = Rs. 29.1254 x 10" /- (I) General Expenses = Administrative costs + distribution and selling costs + research and development costs (A) Administrative costs:(2-6% of total product cost) Consider the Administrative costs = 5% of total product cost Administrative costs = 0.05 x 34.07 x 10” Administrative costs = Rs, 1.7035 x 10" /-(B) Distribution and Selling costs: (2-20% of total product cost); includes costs for sales offices, salesmen, shipping, and advertising. Consider the Distribution and selling costs = 15% of total product cost Distribution and selling costs = 15% of 34.07 x 10” /- = 0.15 x 34,07 x 10” = Rs, 5.1105 x 107 /- (©) Research and Development costs: (about 5% of total product cost) Consider the Research and development costs = 5% of total product cost Research and Development costs = 5% of 34.07 x 107 /- = 0,05 x 34,07 x 10" = Rs. 1.7035 x 10" /- (D) Financing (interest): (0-10% of total capital investment) Consider interest = 5% of total capital investment i.e. interest = 5% of 43.3186 x 10’ = 0.05 x 43.3186 x 10” = Rs. 2.1660 x 107 /- ‘Thus, General Expenses ~ Rs. 10.6835 x 10” /- (IID Total Product cost = Manufacture cost + General Expenses = (29.1254 x 10”) + (10.6835 x 10”) Therefore Total product cost = Rs. 39.8089 x 10” /- Gross Earnings/Income: Wholesale Selling Price of cane sugar per T = Rs. 8000 /- As we know sugar factory operates only 120 - 200 days in a year and the production of cane sugar per hour is 26.4818 T per hour (fom material balance). The working hours per day are 20. Assuming factory operates only 150 days ina y Total Income = Selling price per T x Quantity of product manufactured (T/year) = 8000 x (26.4818 x 20) Tiday x 150 days/year Total Income = Rs. 63.56 x 10" /- Gross income = Total Income — Total Product Cost = (63.56 x 10") ~ (39.8089 x 10”) Gross Income = Rs. 23.75 x 10" /- Let the Tax rate be 40%. Taxes = 40% of Gross income = 40% of 23.75 x 10' = 0.40 x 23.75 x 10? Taxes = Rs. 9,50 x 10” /= Net Profit = Gross income - Taxes = Gross income x (1- Tax rate) Net profit = (23.75 x 10") x (1 — 0.40) = Rs. 14.25 x 107 /-Rate of Return: Rate of return = (Net profit x 100)/ Total Capital Investment Rate of Return = (14.25 x 107 x 100)/ (43.3186 x 10”) Rate of Return = 32.89% Payout period = (FCT)/(Net profit + Depreciation) = (37.7251 * 107/(14.25 * 107 + 3.8443 10") = 2 years
You might also like
Mill Setting VSK
PDF
100% (1)
Mill Setting VSK
17 pages
2G BioEthanol-Civil and Structural Works Spec-BPCL-TCE
PDF
No ratings yet
2G BioEthanol-Civil and Structural Works Spec-BPCL-TCE
415 pages
Biorefinery Concept Design & Evaluation
PDF
67% (3)
Biorefinery Concept Design & Evaluation
185 pages
Biorefinery Concept Design & Evaluation
PDF
67% (3)
Biorefinery Concept Design & Evaluation
185 pages
TNPCB & You-2020 Guide
PDF
100% (1)
TNPCB & You-2020 Guide
327 pages
Process Optimization To Reduce Sucrose Loss With Final Molasses, The Case of Metahara Sugar Factory
PDF
100% (1)
Process Optimization To Reduce Sucrose Loss With Final Molasses, The Case of Metahara Sugar Factory
123 pages
whr08 en
PDF
No ratings yet
whr08 en
357 pages
Capacity Notes Final
PDF
No ratings yet
Capacity Notes Final
46 pages
Solar PV PP 8 MW Tender Hubballi Airport PDF
PDF
No ratings yet
Solar PV PP 8 MW Tender Hubballi Airport PDF
189 pages
Sugar Plant Buyers Guide 2019
PDF
No ratings yet
Sugar Plant Buyers Guide 2019
60 pages
Manufacturing of Refined Sugar
PDF
No ratings yet
Manufacturing of Refined Sugar
14 pages
DPR Ethanol Plant 20klpd Latur
PDF
100% (11)
DPR Ethanol Plant 20klpd Latur
124 pages
Sugar Plant - Cost - 2 PDF
PDF
No ratings yet
Sugar Plant - Cost - 2 PDF
23 pages
Haryana Excise Policy 2019-2020
PDF
100% (1)
Haryana Excise Policy 2019-2020
51 pages
Acetaldehyde Cost 2520Estimation&Economics
PDF
No ratings yet
Acetaldehyde Cost 2520Estimation&Economics
8 pages
Sugarcane Material 2520balance
PDF
No ratings yet
Sugarcane Material 2520balance
7 pages
Liquid - Liquid Heater (Condensate or Duplex Juice Heater) Calculation
PDF
No ratings yet
Liquid - Liquid Heater (Condensate or Duplex Juice Heater) Calculation
8 pages
Boiling House
PDF
100% (1)
Boiling House
155 pages
2G BioEthanol-Civil Works Tender-BridgeRoof-BPCL-TCE
PDF
No ratings yet
2G BioEthanol-Civil Works Tender-BridgeRoof-BPCL-TCE
85 pages
Specifications of 1250Tcd Sulphitation Sugar Plant Expandable To 2000 TCD
PDF
100% (1)
Specifications of 1250Tcd Sulphitation Sugar Plant Expandable To 2000 TCD
73 pages
Sugar Industry
PDF
100% (1)
Sugar Industry
50 pages
FGD & ESP Tobe Installed in India Power Plants
PDF
No ratings yet
FGD & ESP Tobe Installed in India Power Plants
87 pages
Chlorine Cost-2520Estimation Economics
PDF
No ratings yet
Chlorine Cost-2520Estimation Economics
9 pages
DIIPA Lecture-5 Thy Y P Y D E FE 07042020
PDF
50% (2)
DIIPA Lecture-5 Thy Y P Y D E FE 07042020
2 pages
06 - Sugar Industry (B)
PDF
100% (1)
06 - Sugar Industry (B)
35 pages
Concepts in Condenser System (Vacuum Equipment)
PDF
No ratings yet
Concepts in Condenser System (Vacuum Equipment)
27 pages
Melt Clarification System Design Criteria For Sugar Refinery Process
PDF
No ratings yet
Melt Clarification System Design Criteria For Sugar Refinery Process
5 pages
002 Milling
PDF
No ratings yet
002 Milling
29 pages
Plant Design PDF
PDF
No ratings yet
Plant Design PDF
181 pages
Distillery Wastwater Treatment-CDM Project-2012
PDF
No ratings yet
Distillery Wastwater Treatment-CDM Project-2012
60 pages
Manufacture of White Sugar From Sugar Cane: Project Report On
PDF
100% (1)
Manufacture of White Sugar From Sugar Cane: Project Report On
98 pages
Jaggery Powder Plant Project
PDF
0% (1)
Jaggery Powder Plant Project
11 pages
Chemical Control PDF
PDF
100% (2)
Chemical Control PDF
85 pages
Ethanol Plant Commissioning Startup and Shutdown
PDF
No ratings yet
Ethanol Plant Commissioning Startup and Shutdown
5 pages
Lecture 2 Sugar-1
PDF
100% (1)
Lecture 2 Sugar-1
55 pages
Cement Plant-Heat Balance PDF
PDF
100% (2)
Cement Plant-Heat Balance PDF
14 pages
Sugar Written Report
PDF
No ratings yet
Sugar Written Report
25 pages
Sugar - Mill Settings
PDF
100% (4)
Sugar - Mill Settings
3 pages
Caking of Raw Sugar
PDF
No ratings yet
Caking of Raw Sugar
52 pages
Sulfuric 2520acid Cost 2520Estimation&Economics
PDF
No ratings yet
Sulfuric 2520acid Cost 2520Estimation&Economics
8 pages
Sugarcane Processing Technologies: by Md. Akram Hossain
PDF
100% (1)
Sugarcane Processing Technologies: by Md. Akram Hossain
16 pages
Liquid Sugar
PDF
100% (2)
Liquid Sugar
4 pages
Ethanol Distillation Plant Design
PDF
No ratings yet
Ethanol Distillation Plant Design
9 pages
Power Generation Targets For The Year 2020 For India
PDF
No ratings yet
Power Generation Targets For The Year 2020 For India
24 pages
Cumene Cost 2520Estimation&Economics
PDF
No ratings yet
Cumene Cost 2520Estimation&Economics
7 pages
Sugar Manual PDF
PDF
100% (1)
Sugar Manual PDF
66 pages
Sugar Plant Project Report
PDF
No ratings yet
Sugar Plant Project Report
5 pages
Sugar Cane Ethanol Plant Best Parctice
PDF
No ratings yet
Sugar Cane Ethanol Plant Best Parctice
23 pages
"Tips For Sugar Quality Improvement": Lal Bahadur Shastri Ganna Kisan Sansthan, Lucknow, UP
PDF
No ratings yet
"Tips For Sugar Quality Improvement": Lal Bahadur Shastri Ganna Kisan Sansthan, Lucknow, UP
36 pages
M.S. Sundaram
PDF
100% (1)
M.S. Sundaram
21 pages
Sugar Plant Piping Colour Code
PDF
100% (1)
Sugar Plant Piping Colour Code
2 pages
Draft EM-12-04-20 PDF
PDF
No ratings yet
Draft EM-12-04-20 PDF
12 pages
Cement Plant Thermal Energy
PDF
No ratings yet
Cement Plant Thermal Energy
7 pages
CHAPTER 4: Vacuum Pan Boilers
PDF
100% (1)
CHAPTER 4: Vacuum Pan Boilers
4 pages
Inplant Training Report
PDF
No ratings yet
Inplant Training Report
79 pages
Sugar Cane Juice Evaporator
PDF
No ratings yet
Sugar Cane Juice Evaporator
9 pages
Sodium Carboxymethyl Cellulose Information
PDF
No ratings yet
Sodium Carboxymethyl Cellulose Information
8 pages
ISO 10437 2003 (E) - Character PDF
PDF
No ratings yet
ISO 10437 2003 (E) - Character PDF
11 pages
Ign Schematic Block Diagram of Sugar Processing
PDF
No ratings yet
Ign Schematic Block Diagram of Sugar Processing
1 page
SISSTA SEMINAR 2024 - Technical Papers Only
PDF
100% (2)
SISSTA SEMINAR 2024 - Technical Papers Only
95 pages
Styrene Cost 2520Estimation&Economics
PDF
No ratings yet
Styrene Cost 2520Estimation&Economics
8 pages
Optimization of Sucrose Loss From Sugar Industry: European Chemical Bulletin December 2016
PDF
No ratings yet
Optimization of Sucrose Loss From Sugar Industry: European Chemical Bulletin December 2016
10 pages
JPMA-Warter Conservation in Sugar Industry
PDF
100% (1)
JPMA-Warter Conservation in Sugar Industry
8 pages
1990 - Wienese - Mill Setting and Extraction
PDF
100% (2)
1990 - Wienese - Mill Setting and Extraction
4 pages
Cost Estimation - Aadarsh Shukla
PDF
100% (1)
Cost Estimation - Aadarsh Shukla
6 pages
Continuous Pan Operation Manual
PDF
No ratings yet
Continuous Pan Operation Manual
12 pages
M.SC Sugar Tech Syllabus
PDF
No ratings yet
M.SC Sugar Tech Syllabus
39 pages
Energy Conservation in Sugar Industry1
PDF
100% (3)
Energy Conservation in Sugar Industry1
59 pages
A Structured Approach To Sugar Factory Design
PDF
No ratings yet
A Structured Approach To Sugar Factory Design
14 pages
Pan Section Vapour Header and Pan Vapour Line Dia Calculation in Sugar Industry
PDF
100% (2)
Pan Section Vapour Header and Pan Vapour Line Dia Calculation in Sugar Industry
3 pages
Vacuum System Parameters
PDF
No ratings yet
Vacuum System Parameters
7 pages
M13 - Materials Handling - Rev02
PDF
No ratings yet
M13 - Materials Handling - Rev02
10 pages
Toluene Cost Estimation&Economics
PDF
No ratings yet
Toluene Cost Estimation&Economics
10 pages
The Calculation of Mill Material Balance: PT Indocode Surya
PDF
100% (1)
The Calculation of Mill Material Balance: PT Indocode Surya
10 pages
Solar Pump Installation-MNRE Office Memorandum-22.06.20 PDF
PDF
No ratings yet
Solar Pump Installation-MNRE Office Memorandum-22.06.20 PDF
3 pages
1964 - Van Hengel - Suggestions For The Settings
PDF
100% (1)
1964 - Van Hengel - Suggestions For The Settings
4 pages
Minimising Sucrose Loss in Final Molasses PDF
PDF
No ratings yet
Minimising Sucrose Loss in Final Molasses PDF
12 pages
Operations at Daurala Sugar Complex
PDF
100% (1)
Operations at Daurala Sugar Complex
2 pages
Direct Contact Type HeatEr Sizing Calculation For Sugar Factories
PDF
100% (4)
Direct Contact Type HeatEr Sizing Calculation For Sugar Factories
2 pages
Bagasse Test:: Moisture Content (Initial Weight (100gms) ) - (Final Weight)
PDF
No ratings yet
Bagasse Test:: Moisture Content (Initial Weight (100gms) ) - (Final Weight)
1 page
Acetaldehyde Cost 2520Estimation&Economics
PDF
100% (1)
Acetaldehyde Cost 2520Estimation&Economics
8 pages
1994 Gibbon Cad Thrashplate Design
PDF
No ratings yet
1994 Gibbon Cad Thrashplate Design
3 pages
Me303-4 1 1
PDF
No ratings yet
Me303-4 1 1
2 pages
Rectifier Design For Fuel Ethanol Plants
PDF
No ratings yet
Rectifier Design For Fuel Ethanol Plants
7 pages
Civil-Indian Standards-Revised-2021
PDF
No ratings yet
Civil-Indian Standards-Revised-2021
1 page