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Project Feasibility Study
Technoconsult Group for Engineering Works
Projects Management Department
Project Feasibility Study
For
Rebar rolling mill Capacity 150000 Tons/year
Introduction:
The project is intended to produce hot rolled steel rebars ( both plain and ribbed ) according to the Egyptian standard specifications . Estimated production capacity is 150000 Tons/year (Tpy).
Project main data :
- Production capacity
: 150000 Tpy
- Raw material
:Billets of square cross-section 100 x 100 mm up to 130x130 mm and length up to 3000 mm
- Production variety
:Rebar of 10mm to 25 mm in diameter
- Needed electrical power:6
MW
- Needed Water
:500
m3 / day
- Total Capital Needed
: 55089 MLE
- Capital Expenditure
:36950
MLE
- Working Capital (One month):18094
MLE
- Project duration
: 12
months
- Land Area needed
: 26646 square meters
- No. of administration crew :
employees
- No. of technicians
:
employees
TABLE OF CONTENTS
Section 1 : Technical Study
1.1. Project Introduction
1.2. Project Raw materials , utility and production supplies needs
1.3. Capital Expenditure details
1.4. Manufacturing expenses details
1.5. Overall capital needed for the project
Section 2 : Financial Study
1.1. Project Introduction :
1.1.1. Production Capacity :
The estimated production volume of the plant is 150000 Tpy of steel rebars (both plain and ribbed ) according to Egyptian standard specifications , rolled from billets ranging from 100x100 mm to 130x130 mm . The capacity calculation assumptions are :
- Mean mill production capacity : 30 Tons/hr
- Net working days
:300 days
- No. of shifts
:3shifts/day
- No. of net working hours
: 7200 hours
- Average process reliability
: 75%
- Actual production hours
: 5000 hours
- Annual production
: 150 Tpy
- Product type
: Ribbed rebar
- Product size variety
: 10 25 mm
- Product Length
:12 m
The following table indicates the actual capacity of the line for the different sizes :
Product Size (mm)Weight of linear meter (LM)Rolling speed (m/s)Production rate (Tons/hour)
100.6161226.6
120.8888.627.5
161.875528.2
192.2253.830.4
22 and up2.9843.133.3
The table above indicates that the production line can deliver more than 30 Tons/hour at certain sizes .
1.1.2. Land and Utility needs :
1.1.2.1 Area of land and buildings :
Total Area
:
37440
m2
1.1.2.2. Utilities and services :
i. Electrical power :
- Connected power :
6
MW
- Voltage
:
11(20)KV
ii. Industrial water :
- Utilization rate
:
120
m3/dayiii. Domestic sewage :
Utilization rate
:
120
m3/dayiv.No of telephone lines :
3
lines
1.1.3 Main production equipment :
i. Reheating furnace :
- Capacity
:
30 Tons/hour
- Type
:Hydraulic pusher type
- Fuel
:Diesel / natural gas
- Firing method
: Air atomization (for diesel)
- Size of used billets :100x100 130x130 mm up to 4 m long
ii. Roughing mill area :
Electrical motor ( either slip-ring or DC ) .
Flywheel complete with bearings and flexible couplings Speed reducer (gear box ) Pinion cage Cardanic spindles between gear box and pinion cage No. (1) three high roughing stand complete with entry and delivery guides Forced lubrication unit No. (1) fixed roller table complete with rollers and accessories No. (1) tilting roller table complete with rollers and accessories iii. Intermediate mill area :
No. (4) rolling stands complete with entry and delivery guides
Gear box Pinion cage Cardanic spindles between pinion cage and stand On stand instrumentation Forced lubrication unit Stands are driven via DC motors iv. Finishing mill area :
No. (6) finishing stands (roller bearings type) complete with entry and delivery guides
Gear box unit reducing speed and acting as pinion cage
On stand instrumentation
Cardanic spindles
Forced lubrication unit
Stands are driven via DC motors
v. Pinch roll :
To transfer the finished product from the rolling mill to the cooling bed .
vi. Flying shear :
To cut-to-length the rebar at 24 m to allow for entry to cooling bed
vii. Cooling bed :
Rebar receiving system and delivery to cooling bed
Mechanical cooling bed 30 m long
Accumulating roller table to enter the cold shear
viiiCold shear :
To cut the rebar to either 6 or 12 m lengths
ixBundling and tying equipment .
1.1.4. Utility equipment :
1.1.4.1. Industrial water treatment plant :
Pumping station
Filters
Piping and fittings
Total capacity of 300 m3/hour
Make-up rate for water 5 m3/hour
1.1.4.2. Compressed air station :
No. (2) air compressors 1500 l/min at 6 bar
Piping and fittings and filters
Drying unit
Receiving tank 4 cubic meters
1.1.4.3. Fuel pumping station :
No. (2) gear pumps
Control and metering equipment
100 cubic meter fuel tank
Daily tank
Pipes and fittings
1.1.4.4. Over-head cranes :
Rolling mill cranes :
- capacity
:10 Tons
- Span
:20m
- Hook travel
:8/10m
- Number of cranes :2
Shipping bay cranes :
- Magnet capacity
:5Tons
- Span
:20 m
- Hook travel
:8/10m
- No. of cranes
: 2 (equipped with magnets)
1.1.4.5. Maintenance work-shop:
Rolls grooving lathe
Notching machine
Conventional lathe 2 m
Spark erosion trade mark machine
Milling machine
Shaping machine
Drill
Reciprocating saw
Hand tools
Work-shop tables
Electric arc welding machines
1.1.4.6 Testing laboratory :
Tensile testing machine
Hardness tester
Scale
Measuring tools
1.1.4.7 Weighing bridge :
Capacity 100 Tons
1.1.4.8. Fire fighting system :
Hand-held fire extinguishers (Carbon dioxide and powder filled)
Transformers room fire fighting equipment
Fire fighting loop and pumps
1.1.5. Transportation and handling equipment :
No. (1) 1.5 Tons capacity truck
No. (2) cars
No. (1) fork truck
1.1.6. Transformers station :
Transformers :
- No. of transformers
: 2
- Capacity of Transformers : 1.5 MW
- Inlet Voltage
: 11(20)KV
- Exit Voltage
:400/500 V
Medium voltage panels 11(20) KV
Low voltage panels
Operation and PLC panels
1.1.7. Civil Works :1.1.7.1. Land leveling works :
Will be determined after selecting the site
1.1.7.2 Fencing and internal roads :
Fencing :
Total length
: 788m
Height
:3m
Type of fencing
: Concrete frame + brick walls
Security Buildings
Internal Roads :
Area
: 6800 m2
Type of roads
: Asphalt paved roads
1.1.7.3. Rolling mill bay :- Length of bay
: 180m
- Width of bay
:20m
- Area of bay
:3600 m2
- Type of building
: Steel Structure
- Approx. weight of structure
: 400 Ton
- Corrugated sheet area
:6600m2
1.1.7.4. Furnace bay :
- Length of bay
:330m
- Width of bay
:20m
- Area of bay
:6600 m2
- Type of building
: Steel Structure
- Approx. weight of structure
: 350 Ton
- Corrugated sheet area
:8400m21.1.7.5. Raw material and finished product ware-houses:- Total area
:17600m2
- Type of building
: Open yards
- Floors
: Compressed soil
1.1.7.6. Foundations + machine foundations and floors :- Excavation
:9600 m3
- Back-filling
:2000 m3 Reinforced concrete :
- Steel structure foundations :800 m3 - Machine foundations
:1560m3
- Trenches for cables and pipes : 360 m3
- Total reinforced concrete :3120 m3
Plain concrete for a/m works :1300 m3 Floors (25 cm thick) Area
:9600m2
Note : These amounts are approximate and will be revised after selecting the land and gathering proper data regarding the typology of the land .
1.1.7.7. Other Buildings : Administration Building and dressing rooms :
- No. of floors
:3
- Area of each floor
:160m2 - Total Area
: 480m2 Transformers station :
- Needed area
: 720m2 Work-shops and store rooms :
- Needed Area
: 1640m2 1.1.8. Installation works :
1.1.8.1 Mechanical installation :
Installation supplies ( anchors , grouting material , bolts and hand-tools )
Machine laying and anchoring works
Piping works for fuel , compressed air and water including fittings
Trained labor
Cranes and handling equipment
1.1.8.2. Electrical installation :
Installation supplies including cables ,wiring , cable trays and connections and fittings etc.
Trained labor
1.1.9. Pre-operational expenses : Hiring reputable specialized technical firms as consultants
Issuing needed approvals and licenses from governmental authorities
Construction follow-up
Hiring the needed management and technical staff
Contracts finalization for equipment
Miscellaneous managerial and technical tasks
Travel and training for technology transfer
1.1.10. Furniture and office equipment :
Office furniture
Computers
Telephones and Fax
Dressing room lockers
First aid equipment
1.1.11. Technical support :
Design and planning for the project
Local manufacturing supervision
Construction supervision and commissioning
1.1.12. Working force (Management and technical teams ) :
AreaNeeded No.
Production Department :
Production manager
Production engineers
Crane operators
Furnace operators
Rolling mill operators
Pulpit operators
Cooling bed crew
Tying machines operators
Finished product area
Department total : 1
4
9
6
15
6
12
6
6
65
Mechanical Maintenance :
Maintenance Manager
Maintenance engineers
Maintenance technician
Work-shop crew
Cranes maintenance crew
WTP maintenance crew
WTO operators
Department Total : 1
3
12
2
1
3
3
25
Electrical Maintenance :
Maintenance Manager
Maintenance engineers
Work-shop crew
Motors maintenance technician
Electrical technician
Department Total :1
4
1
1
12
17
Ware-houses :
Ware-house manager
Ware-house attendant
Weigh bridge operators
Department Total : 1
6
3
10
Quality Assurance :
Quality Manager
Lab operator
Line quality operator
Department Total : 1
-
6
7
Technical Office :
Manager
Supervisor
Department Total : 1
1
2
Work-shop :
Engineer
Lathe operator
Notching machine operator
Facing machine operator
Milling machine operator
Helper
Department Total : 1
6
2
1
3
1
14
Cylinder work-shop:
Supervisor
Technicians
Department Total :1
6
7
Guides Work-shop :
Engineer
Technicians
Department Total : 1
5
6
Cleaning crew :
Cleaner
Tea boy
Gardner
Department Total : 6
2
2
10
Security :
Supervisor
Security crew
Department Total : 1
12
13
Administrative manager 1
Accountants 2
Personnel 2
Plant Total : 180
Project Raw materials , utility and production supplies needs :
1.2.1. Billets :
- Needed volume
: 150000Tons
- Manufacturing losses
: 5-6
%
- Total billets needed
: 158000Tons
Note : The losses of 5-6% consist of oxides inside the re-heating furnace + the head and tail cropping and these are divided as follows :
2% oxidation rate inside furnace
3% head and tail cropping and defined in-process losses
1.2.2. Electrical Power :
- Connected power
:6
MW
- Needed Voltage
:11(20)KV
- Needed power for rolling / Ton :120
KWh/Ton
- Average yearly power consumption:18
MMKWh
1.2.3. Industrial water :
- Water consumption rate
: 5
m3 / hour
- Yearly consumption
:40000m3 / hour
1.2.4. Fuel :
- Diesel oil
: 4800
Tons/ year
or equivalent in natural gas
1.2.5. Lubricants :
- Oils
: 145
barrels/year
- Greases
:20
barrels/year
1.2.6. Production supplies :
Rolling cylinders
Rolling guides for all stands
Complete spare rolling stands ( including cylinders , bearings and guides )
Transmission belts , hoses , oil and water seals
Maintenance supplies for compressed air system and control valves
Work-shop supplies
Pipes , valves and fittings
Chains and power chains and accessories
Contract manufacturing
Miscellaneous 1.2.7. Spare parts : Mechanical spare parts for rolling equipment ( gears , flexible joints, cardanic spindles ..etc .)
Electric and automation spare parts
Spare electric motors
Bearings for gear boxes , stands , pinion cages , guides and utility equipment
Cranes and handling equipment spare parts
Spare refractory materials for the furnace
Miscellaneous
1.3. Capital Expenditure details :
1.3.1. Land :
- Area
:
26646
m2 - Price
:
281.49LE/ m2
Total land price
:
7500
MLE
1.3.2. Utilities :
1.3.2.1. Electricity :
- Connected Power :
6
MW
1.3.2.2. Industrial water :
- Consumption
:
120
m3 / day
1.3.2.3. Domestic sewage :
- Discharge rate
:
300
m3 / day
1.3.2.4. Telephones :
- No. of lines
:
3
lines
Total Utilities
:
3250
MLE
1.3.3. Main production equipment :
Re-heating furnace and accessories
Rougher unit and accessories
Intermediate rolling mill and accessories
Finishing rolling mill and accessories
Different shears
Maintenance work-shop
Water treatment plant
Fuel station
Cooling bed and accessories
Transformers , E-panels and control panels
Transportation , customs clearance and sales tax .
Total Equipment
:
12864
MLE
1.3.4. Transportation and handling equipment :
Truck
Fork-truck
Two passenger cars + ambulance truck
Total Transportation
:
180
MLE
1.3.5. Civil works :
1.3.5.1. Steel Structures :
- Area
:
13200m2 - Weight
:
750
Ton
- Corrugated sheets :
16800m2 1.3.5.2. Land leveling works :
- Area
:
60000m2 1.3.5.3. Fencing and internal roads :
- Length of fencing :
960
m
- Area of fencing
:
4100
m2 1.3.5.4. Foundations and floors :
- Re-inforced concrete :
6700
m3 - Plain concrete
:
1440
m3
- Floors
:
9600
m3 1.3.5.5. Billets and re-bars ware-houses :
- Area
:
5600
m2 1.3.5.6. Other Buildings :
- Total Area
:
2110
m2
Total Civil Works
:
7350
MLE
1.3.6. Construction Works :
- Electro-mechanical installation :
3500
MLE
1.3.7. Pre-operational Expenses :
- Total Pre-Ops expenses :
26
MLE
1.3.8. Furniture and office equipment :
- Total
:
30
MLE
1.4. Manufacturing expenses details :
The total manufacturing expenses per Ton of finished re-bar ready for shipping is 1383.25 LE on average and following are the details :
1.4.1. Direct Expenses :
The direct expenses are 1371.37 LE on average , consisting of the following :
- Raw materials :
- Weight of billet to produce one Ton:1.05Tons
- Billet cost/Ton
:1225LE
- Total expense
: 1286 LE/Ton
Electrical Power :
- Power needed to roll one Ton
:118 KWh
- Price of KWh
:0.20LE
- Total expense
:23.50 LE
Fuel :
- Fuel needed / Ton
:17Kg
- Total expense
:6.80 LE
Industrial Water:
- Consumption / Ton
:0.50m3 /Ton
- Price of cubic meter
:1.00LE
- Total Expense
:0.50LE
Lubricants :- Consumption / Ton
:0.10Kg
- Average cost of Kg
:5LE
- Total Expense
:0.50 LE
Spare parts and production supplies :
- Cylinders and guides
:12LE
- Spare parts
:8LE
- Tools and work-shop equipment :3LE
- Contract manufacturing
:4 LE
- Miscellaneous
:5LE
- Total Expense
:32 LE
Wages and Benefits :
- Total wages / year
:1608MLE
- Total Expense
:7.12LE
- Depreciation :
- Depreciation / Ton
:14.70LE
- TOTAL DIRECT EXPENSES /TON:1371.37 LE
1.4.2. In-Direct Expenses :
The in-direct expenses /Ton are 11.88 LE and following are the details:
- Salaries :
- Total yearly salaries
:750MLE
- Total Expense / Ton
:5LE
Administrative and general expenses :
Payments for financial controllers
Legal fees
Bank charges
Advertisement and campaigns
Mail and telephones
Office supplies
Travel expenses and accommodation
Treatment and medication
Total yearly Expenses
:580MLE
Expense per Ton
:3.85LE
In-Direct Depreciation :
- Consultancy (20%)
:5.20MLE
- Technical support (20%)
:300 MLE
- Deferred .. (20%):150MLE
Total In-Direct Expenses per Ton
:11.88 LE
Summary of Expense / Ton:
Direct Expenses
:1371.37 LE
In-Direct Expenses
:11.88
LE
Total Manufacturing Expenses per Ton:1383.25LEProperty of Technoconsult Group , not to be copied or disclosed prior to written approval