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UNIVERSITAS INDONESIA
(1206212514)
(1206238482)
(1206212464)
(1206239724)
(1206212520)
(1206212470)
Universitas Indonesia
Universitas Indonesia
TABLE OF CONTENT
TABLE OF CONTENT..........................................................................................iii
LIST OF TABLES...................................................................................................v
LIST OF FIGURE...................................................................................................vi
CHAPTER 1 CAPITAL ESTIMATE.......................................................................1
1.1 Cost Index.......................................................................................................1
1.2 Capital Expenditure........................................................................................3
1.2.1
Total Equipment Cost.........................................................................3
1.2.2
Site Developmet Cost.........................................................................5
1.2.3
Offsite Facilities Cost.........................................................................5
1.2.4
Supporting Facilities Cost..................................................................6
1.2.5
Contingency Cost and Contractor Fee...............................................7
1.2.6
Piping Cost.........................................................................................7
1.2.7
Controller Cost...................................................................................8
1.2.8
Electrical Equipment Cost.................................................................8
1.2.9
Land and Building Cost.....................................................................9
1.2.10 Additional Cost................................................................................11
1.2.11 Working Capital...............................................................................12
1.2.12 Calculation of TCI............................................................................12
CHAPTER 2 OPERATING COST........................................................................14
2.1 Equity............................................................................................................14
2.2 Raw Material Cost........................................................................................14
2.3 Utility Cost...................................................................................................14
2.4 Labor Cost....................................................................................................14
2.4.1
Direct................................................................................................14
2.4.2
Indirect.............................................................................................14
2.5 Maintanance Cost.........................................................................................14
2.6 Insurance Cost..............................................................................................14
2.7 Depreciation..................................................................................................14
CHAPTER 3 MASS AND ENERGY BALANCE................................................15
3.1 Investment Feasibility Analysis....................................................................15
3.1.1
Income..............................................................................................15
3.1.2
Cash Flow........................................................................................15
3.2 Profitability Analysis....................................................................................15
3.2.1
IRR...................................................................................................15
3.2.2
NPV..................................................................................................15
3.2.3
Payback Period.................................................................................15
3.2.4
ROR/ROI.........................................................................................15
3.3 Cost Breakdown...........................................................................................15
3.4 Sensitivity Analysis......................................................................................15
3.4.1
IRR Analysis....................................................................................15
3.4.2
NPV Analysis...................................................................................15
3.4.3
Payback Period Analysis..................................................................16
CHAPTER 4 CONCLUSION................................................................................17
REFERENCES.......................................................................................................18
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LIST OF TABLES
Table 1.1 Chemical Engineerings Plant Cost Index.........................................................................1
Table 1.2 Projection of Chemical Engineerings Plant Cost Index...................................................2
Table 1.3 Total bare module cost equipment.....................................................................................3
Table 1.4 Site preparation costs.........................................................................................................5
Table 1.5 Offsite facilities calculation..............................................................................................5
Table 1.6 Supporting facilities costs..................................................................................................6
Table 1.7 Straight pipe cost................................................................................................................7
Table 1.8 Fitting and elbow pipe cost................................................................................................7
Table 1.9 Valve cost..........................................................................................................................8
Table 1.10 Controller cost..................................................................................................................8
Table 1.11 Controller cost..................................................................................................................8
Table 1.12 Building Area...................................................................................................................9
Table 1.13 Asphalt Area...................................................................................................................10
Table 1.14 Cost of Land, Building, and Asphalt..............................................................................10
Table 1.15 Additional Cost..............................................................................................................11
Table 1.16 TCI Calculation..............................................................................................................12
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LIST OF FIGURE
Figure 1.1 Starch structure..................................................................................... 3
Figure 1.2 Amylopectin model structure................................................................ 4
Figure 1.3 Amylopectin molecul............................................................................ 6
Figure 1.4 Alpha amylase structure....................................................................... 9
Figure 1.5 Alpha amylase growing...................................................................... 19
Figure 1.6 Textile Production Capacity in Indonesia........................................... 20
Figure 1.7 Alpha amylase production plant location........................................... 32
Figure 1.8 Location of Kediri district.................................................................. 32
Figure 1.9 Molasses produced by PG Pesantren Baru Kediri in 2004................. 33
Figure 2.1 Microbial Enzyme Production............................................................ 35
Figure 2.2 Schematic production process of industrial enzymes......................... 36
Figure 2.3 Blending tank for liquid phase (mixing and sterilization).................. 47
Figure 2.4 A typical submerged culture fermenter............................................... 48
Figure 2.5 Fermentation process scale up............................................................ 49
Figure 2.6 Enzyme storage tank........................................................................... 50
Figure 2.7 Microfiltration principle..................................................................... 51
Figure 2.8 Disk stack centrifugation process....................................................... 53
Figure 2.9 Ultrafiltration technology................................................................... 53
Figure 3.1 Simulation of alpha amylase plant...................................................... 68
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CHAPTER 1
CAPITAL ESTIMATE
In this chapter of economical evaluation, these following assumptions will
be used:
1. Plant lifetime is 20 year; start from 2020 (including the equipment purchase).
2. The building process will be conducted in 1 year and start to operate in the
beginning of 2021.
3. Plant total production for 1 year is 175 batch for 100% capacity (2461 kg per
batch) or approximately 430.675 ton of alpha amylase.
4. Each IDR 13,500 will be converted as USD 1.
5. Depreciation will be calculated using declining balance method.
1.1
Cost Index
The index used is the Chemical Engineering (CE) Plant Cost Index. The
table below shows the data for cost index from 2000 to 2020:
Table 1.1 Chemical Engineerings Plant Cost Index
Year
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
CEPCI
394.1
394.3
395.6
402
444.2
468.2
499.6
525.4
575.4
521.9
550.8
585.7
584.6
567.3
Using the data above, we can projected all the equipment to the purchasing
year of 2020. We plot the data above as the figure below:
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700
600
f(x)
- 34050.49
f(x) =
= 17.22x
- 0.64x^2
+ 2575.5x - 2600642.06
R = 0.92
500
400
300
200
100
0
1998
2000
2002
2004
2006
2008
2010
2012
2014
By extrapolating the data and graphic, we can get a cost index value of 726.3 on
2020, this is shown on the table below:
Table 1.2 Projection of Chemical Engineerings Plant Cost Index
Year
2014
2015
2016
2017
2018
2019
2020
CEPCI
623.0
640.2
657.5
674.7
691.9
709.1
726.3
Capital Expenditure
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The calculation of equipment or total bare module cost is begun with the
calculation of FOB itself. FOB (Free On Board) is the bases cost of the
equipment. This is based on the parameter of each equipment. The parameters and
the formula we can see in Process and Product Design Principles by Seider
exactly in the Table 16.32 or based on the vendor (catalog) that we find at in the
internet.
To get an estimate of the purchase cost at a later date, we need to multiply
the cost from an earlier date by the ratio called cost index at that date to a base
cost index. From the planning, the equipment purchasing on this plant will be
done on 2020. So, we need to know the cost index on the year 2020 which is after
extrapolating about 726.3.
Using the design specification for all equipment, the purchase cost can be
determined, and later converted into 2020 purchase cost using the cost index.
Total bare module cost than will be depreciated.
Table 1.3 Total bare module cost equipment
N
o
Equipment
Code
Price/Unit
Qty.
(USD)
Total
Price
(USD)
Year
Basis
Cost Index
in Year
Basis
Bare
Module
Factor
CTbm in
2020
(USD)
Storage Tank
1 TK-101
2 TK-102
3 TK-103
B Mixing Tank
1
MT-101
1
1
1
16,000
2,000
24,000
16,000
2,000
24,000
2004
2004
2004
444.2
444.2
444.2
1.41
1.41
1.41
37,000
5,000
56,000
219,000
219,00
0
2,004
444.2
1.41
505,000
N
o
C
Equipment
Code
Price/Unit
Qty.
(USD)
Reactor
1 FT-101
2 FT-102
1
1
13,000
57,000
219,000
FT-103
Purification
Total
Price
(USD)
13,000
57,000
219,00
0
Year
Basis
Cost Index
in Year
Basis
Bare
Module
Factor
CTbm in
2020
(USD)
2,004
2,004
444.2
444.2
4.30
4.30
92,000
401,000
2,004
444.2
4.30
1,540,000
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1
2
3
4
E
1
2
3
4
5
6
7
8
9
10
11
12
13
F
1
2
3
G
1
MF-101
DS-101
UF-101
UF-102
Pump
P-101
P-102
P-103
P-104
P-105
P-106
P-107
P-108
P-109
P-110
P-111
P-112
P-113
Compressor
C-101
C-102
C-103
HE
(Autoklaf)
HE-101
1
1
1
1
17,200
12,000
96,000
2,500
17,200
12,000
96,000
2,500
2,000
2,000
2,000
2,000
394
394
394
394
3.20
3.20
2.03
3.20
102,000
71,000
360,000
15,000
1
1
1
1
1
1
1
1
1
1
1
1
1
6,000
12,000
12,000
12,000
5,000
5,000
20,000
6,000
5,000
5,000
4,000
7,000
9,000
6,000
12,000
12,000
12,000
5,000
5,000
20,000
6,000
5,000
5,000
4,000
7,000
9,000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2,000
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.40
37,000
74,000
74,000
74,000
31,000
31,000
123,000
37,000
31,000
31,000
25,000
43,000
56,000
20,000
2000
394
3.24
239,000
180,000
2000
394
3.24
2,151,000
320,000
40,000
360,00
0
640,00
0
2000
394
3.24
3,823,000
38,000
38,000
Total
2000
394.1
3.3
232,000
10,300,000
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In addition, for operating the plant for 20 years or more, we should prepare
the spare parts in order to back up the first equipments work ability. We invest the
spare parts on the beginning, at the same time with the first equipment purchased.
Each of equipment will has 1 spare part. So, the cost for spare parts itself will be
the same as the total cost of equipment. We will be paying for $20,600,000 for all
of equipments and spare parts on 2020.
1.2.2 Site Developmet Cost
The calculation that are involves in site development cost are making land
surveys, land preparation (such as surface clearing, excavation, rock blasting),
fencing, roads and sidewalks, and fire protection facilities. Costs for site
preparation, Csite, can be quite substantial for grass-roots plants in the range of 1020% of total bare-module cost of the equipment. For our alpha amylase plant, we
take Csite as 15% of total bare-module cost of the equipment.
Table 1.4 Site preparation costs
No.
Component Needs
1.
Making land surveys
2.
Land preparation
3.
Fencing
4.
Roads and sidewalks
5.
Fire protection facilities
Total Site Preparation (15% of Total Bare-Module of
Equipment)
Price (USD)
154,200
616,800
231,300
308,400
231,300
1,542,000
Offsites cost sites consist of some calculation which are including waste
treatment equipments, steam boiler, cooling tower, and the generator. The
summarize of Coffsite calculation is shown in the table below:
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No
1
2
3
Qty
W-101
CT-101
GR-101
1
1
2
Price/Unit
(USD)
Total
Price
(USD)
51,000
51,000
12,000
12,000
58,519
117,037
Total
Year
Basis
Cost Index
in Year
Basis
Bare
Module
Factor
Coffsite in
2020
(USD)
2000
2000
2014
394.1
394.1
623
1
0.67
0.73
94,000
15,000
99,700
208,700
Cost/unit
(USD)
Total Cost
(USD)
Office
Faximile Machine
2
90
Telephone
10
56
Computer PC
12
259
LCD Projector
1
190
Printer + Scanner + Photocopy
2
150
Air Conditioner 2pk
4
678
Stand Dispenser
2
75
Attendance machine
2
241
Paper Shredder
1
59
Refrigerator
1
107
Office Desk (President)
1
148
Office Desk
20
74
Office Chair
20
37
Cabinet
5
74
Sofa
3
148
Table 1.6 Supporting facilities costs (contd)
180
556
3,111
190
300
2,711
150
481
59
107
148
1,481
741
370
444
Cost/unit
(USD)
370
Total Cost
(USD)
370
Equipment
Qty
Equipment
Qty
1
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Receptionist desk
Whiteboard
CCTV
Truck
Forklift
1
111
2
15
10
148
4
40,741
6
11,500
Laboratory for Feed and Product Testing
Laboratory set (beaker glass, pipet, microscope,
1
2,222
quality analysis equipment, etc)
Medical Facilities
Medical set (stethoscope, tensimeter, medical
1
741
bed, first aid box, medicine, etc).
Other Service Facilities
Utility lines
741
Control rooms
1,111
Maintanance and workshop
556
Cafetarias
370
Mosque
222
Total of Supporting Facilities Equipment
111
30
1,481
162,963
69,000
2,222
741
741
1,111
556
370
222
250,950
To determine the cost of piping, we should know first what kind of pipe
that we will use and how longer it is. The price for pipe is $3.4 per lb. below is the
result of piping cost.
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Requirements
Material
Nominal Pipe
Carbon Steel
Carbon Steel
Carbon Steel
3/4
1 1/4
2
Sc
ID
h
40
0.82
40
1.38
40
2.067
Total
Lengt
h (ft)
Weight
(lb/ft)
Total
Weight (lb)
131.17
85.38
234.32
1.13
2.28
3.66
148.22
194.67
857.61
Lengt
h (ft)
Weight
(lb/ft)
Total
Weight (lb)
36.18
24.12
60.3
8.61
1.13
2.28
3.66
3.66
41
55
221
32
Total Price
(USD)
500
660
2,920
4,100
Requirements
Material
Elbow 90
Elbow 90
Elbow 90
Tee
Nominal Pipe
3/4
1 1/4
2
2
Sc
h
40
40
40
40
ID
Total Price
(USD)
Qty
0.82
1.38
2.067
2.067
Total
6
4
10
1
Type
Globe Valve
Qty
28
Price/Unit (USD)
1,100
So, by adding all the straight pipe cost, fitting and elbow pipe cost, also
the valve cost that we have, then we will spent $36,090 for these piping system in
the plant.
1.2.7 Controller Cost
Controller is one of the very important equipment for the plant. So, we
also need the spare like the equipment. The amount of our controller are based on
the P&ID. The calculation are shown below.
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140
190
750
110
1,190
15
Type
Level Control
Flow Control
Pressure Control
Temperature Control
pH Control
Component Needs
Qty
200
35
2
3
2
222
593
65
444
35
16
544
20
240
30
Total
7
1
1
148
160
17
1,971
Cost of land (Cland) is the cost to buy land as a place of plant building. The
land cost in Kediri (the place that our plant will be built) is predicting arround Rp
1,500,000/m2. Then, we will also calculate the cost of all building. This cost
included the steel and concrete that we use. We take 20% of C TBM for cost of
building (Cbuilding). There is also asphalt cost for the road and parking area. The
calculation of land and building are summarize in the table below.
Table 1.12 Building Area
Building
Size
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Length
Laboratory
28
Office
43
Raw material storage
18
Control room
18
Product storage
18
Process area
74
Process area
92
Waste water treatment
20
Water utility
12
Electrical utility
12
Fuel utility
12
Workshop
18
Warehouse
18
Cafetaria
18
Clinic
18
Mosque
18
Total Building Area
Wide
12
12
9
6
9
24
16
15
16
16
12
4,5
4,5
12
9
12
336
516
162
108
162
1,776
1,472
300
192
192
144
81
81
216
162
216
5,900
Asphalt
Truck parking lot
Assembly point 1
Assembly point 2
Car parking lot
Motorcycle parking lot
Assembly point 3
Road 1
Road 2
Road 3
Road 4
Road 5
Size
Length
24
24
15
35
14
18
6
6
6
24
24
Wide
14
10
12
12
12
4.5
37.25
29
29
7
1.25
Asphalt
Road 6
Road 7
Road 8
Road 9
Road 10
Road 11
Road 12
Road 13
Size
Length
100
25
69
71
18
7
5
7
Wide
5
6
2.5
2.5
12
37.25
22
46.5
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Road 14
Road 15
Road 16
13
25
2.5
Total Asphalt Area
12
1.25
16
156
31.25
40
4334
Component
Land area (m)
Building Area (m)
Asphalt (m)
Qty
1023
4
5900
4334
Total
111
1.137.111
348
33
2.056.000
144.467
3.337.578
1.2.10Additional Cost
No.
1
2
3
5
Component
Market Research
Industry Design Permission
Brand
Water Utility
Price (USD)
370
111
741
370
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6
7
8
Electrical installment
Communication Line Installment
Internet Nework Installment
Total Additional Cost
630
33
52
2,307
1.2.11Working Capital
Working capital is the 17.6% of C TPI (the things that we already mentioned
above from the equipment to the additional cost. The equation will be sums up on
the next sub-bab that will calculate the overall TCI.
1.2.12Calculation of TCI
Capital Component
Total bare-module costs for equipment
Total bare-module costs for spares
Total bare-module investment (C-TBM)
Cost of site preparation (Csite)
Cost of supporting facilities (Csupp)
Cost of offsite facilities (Coff)
Ammount
(USD)
10,300,000
10,300,000
20,600,000
1,545,000
250,950
208,700
Parameter
Calculated
Calculated
Calculated
15% CTBM
Calculated
Calculated
Capital Component
Total of direct permanent investment (C-DPI)
Cost of contingency
Cost of contractor's fee
Total depreciable capital (C-TDC)
Cost of piping and valve
Cost of controller
Cost of electrical equipment
Cost of land (Cland)
Cost of bulding (Cbuilding)
Cost of asphalt (for road)
Cost of market research
Cost of industry design permission
Cost of branding
Cost of water installment
Cost of electrical installment
Ammount
(USD)
22,604,650
3,090,000
618,000
26,312,650
36,090
28,700
1,971
1,137,111
2,060,000
144,467
370
111
741
370
630
Parameter
Calculated
15% CDPI
3% CDPI
Calculated
Calculated
Calculated
Calculated
Calculated
20% CTBM
Calculated
Calculated
Calculated
Calculated
Calculated
Calculated
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33
52
29,723,296
5,231,300
34,955,000 Calculated
Calculated
Calculated
Calculated
17,6% CTPI
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CHAPTER 2
OPERATING COST
2.1
Equity
2.2
2.3
Utility Cost
2.4
Labor Cost
2.4.1 Direct
2.4.2 Indirect
2.5
Maintanance Cost
2.6
Insurance Cost
2.7
Depreciation
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CHAPTER 3
MASS AND ENERGY BALANCE
1.1
This part will discuss about the mass and enegery balance for every stream
in every unit operation. The calculations are based on the production capacity and
some journals that explain about operating condition and the results, also the
electricity requirement.
1.1.1 Income
1.1.2 Cash Flow
1.2
Profitability Analysis
1.2.1 IRR
1.2.2 NPV
1.2.3 Payback Period
1.2.4 ROR/ROI
1.3
Cost Breakdown
1.4
Sensitivity Analysis
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CHAPTER 4
CONCLUSION
1. Alpha amylase enzyme is one of the needed enzyme in Indonesia. But
unfortunately, Indonesia do not have an alpha amylase plany yet.
2. One of the alpha amylase uses is in textile industry. It used in desizing process
when alpha amylase will hydrolyse the starch.
3. Bacillus licheniformis is used as our enzyme source in plant and the medium
of bacterial growth cosists of molasses, wheat bran, urea, and phosphoric acid
as the bacteria needs carbon and nitrogen.
4. Our plant is placed in Kediri, East Java, due to the availability of raw material
needed, unemployee amount, etc. The production capacity is 132 tons per year
(1 ton per batch).
5. The process that we selected are pre-treatment (wheat bran hydrolysis),
mixing
and
sterilization,
fermentation,
and
purification
(by
using
Input
(kg/batch)
0
0
21397.40493
16523.80952
10963.50247
3680.892703
188.6666667
180.5555556
38559.52381
10250
0
101744.4
Output
(kg/batch)
10533.33333
776.5357667
441.6666667
1982.857143
15535.80247
3337.5
188.6666667
180.5555556
38559.52381
3925.1943
26282.72
101744.4
cleaning
products.
[online]
Available
at
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cleaning
products.
[online]
Available
at
Availabe
at
http://www.sec.gov/Archives/edgar/data/1049210/000119312513136596/d
444805d10k.htm [accessed at September 7th 2015]
Anonim. 2015. Textile Enzymes-Noor Enzymes. Indiamart. [online] Available at
<http://www.indiamart.com/noor-creations/textile-enzymes.html#alphaamylase-enzymes> [Accessed at September 10th 2015].
Anonim. 2015. Textile Enzymes-Noor Enzymes. Indiamart. [online] Available at
http://www.indiamart.com/noor-creations/textile-enzymes.html#alphaamylase-enzymes [accessed at September 10th 2015].
Elmarzugi, Nagib A. et al., 2014, A Amyalse Economic and Application Value.
World Journal of Pharmaceutical Research, ISSN 2277-7105.
Elmarzugi, Nagib A. et al., 2014, A Amyalse Economic and Application Value.
World Journal of Pharmaceutical Research, ISSN 2277-7105.
EOLSS. 2003. Enzyme: The Biological Catalyst of Life. [online] Available at
<http://www.eolss.net/sample-chapters/c03/e6-54-02.pdf> [Acessed at
September 12th 2015].
Gupta, Rani., Gigras, Paresh., Mohapatra, Hanapriya., Goswami, Vineet. K.,
Chauhan, Bhavna. 2003. Microbial a-amylases: a biotechnological
perspective. Process Biochemistry 38 (2003) 1599_/1616.
Sarrouh, Boutros et al., 2012. Up-To-Date Insight in Industrial Enzymes
Applications and Global Market. Bioprocess & Biotechniques Research
Article. ISSN:2155-9821 JBPBT, an open access journal.
Sarrouh, Boutros et al., 2012. Up-To-Date Insight in Industrial Enzymes
Applications and Global Market. Bioprocess & Biotechniques Research
Article. ISSN:2155-9821 JBPBT, an open access journal.
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4,
166-175.
[online]
Available
at
<
Christian.
2015.
Industrial
Biorefineries
and
White
25
25
Universitas Indonesia