1. OPEX and Profitability Analysis-II
Chapter 17 Seider
CH EN 5253
Terry A. Ring

2. Help On Costing Pumps Centrifugal, gear, etc.
Sizing Factor, S = Q*H0.5
Q is the flow rate in Gal/min
H is the pump head
H=ΔP/ρg (pump change in P/liquid density)
CB=exp(A0+ A1(ln(S))+ A1(ln(S))2+ …)
Cp=FTypeFMat CB
There is no Fpressure term but if you had one it would use the outlet pressure
Motor Power, PMotor=Pp/(ηpumpηMotor) =QρgH/(ηpumpηMotor)

3. Measures of Profitability
Return on Investment (ROI)
ROI=annual earnings/capital investment
ROI > cost of capital (commercial interest rate, i)
Payback period (PBP)
Annualized Cost (CA)
Venture profit (VP)
Investor’s Rate of Return (IRR)
Discounted Cash Flow Rate of Return (DCFR)
Hard work to get this all together
Same

4. Definitions of Profitability Measures

5. Total Capital Investment

6. How to determine ROI Annual Sales revenue minus Costs (S-C) Costs
Cost of feedstocks
Cost of Utilities
Cost of Labor and Maintenance
Cost of Overhead
Cost of Taxes and Insurance
Cost of Depreciation
Cost of sales force, R&D, Admin., Management Incentives

7. Utilities Steam Electricity Cooling Water Process Water
Boiler Water
Feed Stock water/Steam
Refrigeration and/or Chilled Brine
Fuels
Natural Gas
Fuel Oil
Coal
Waste Treatment
Stack Gas Cleanup
Waste Water Treatment
Area Scrubbers
Land fill cost for solid waste

8. Costs

9. Depreciation Straight-line Depreciation Other types of depreciation
Equipment Lifetime – Plant = 12 yr
Constant % each year so that plant is totally written off at end of life time
8% of Total Depreciable Capital, CTDC
What would be the depreciation % for 20 yr lifetime?
Other types of depreciation
Accelerated Cost Recovery System (ARCS)
Modified Accelerated Cost Recovery System (MARCS) for Taxes
Declining-Balance Method (DB)
Double Declining-Balance Method (DDB)
Others

10. More On Depreciation Declining Balance Method (no salvage value)
d= range from 1/n to 2/n, typically use 1.5/n
Double Declining Balance Method (no salvage value)
d=2/n
Depreciation amount for year t, Dt=B*d*(1-d)t-1
Book Value after year t, BVt-1 =B(1-d)t-1
B=basis = CTDC
n= service life
t=year

11. More On Depreciation ACRS – Federal Tax Law 1982 – 1986
MACRS - Federal Tax Law in 1987
Accelerated Cost Recovery System

12. Taxes (Local) Property Taxes Used in Cost of Manufacturing
Based upon the value of the property
Used in Cost of Manufacturing
Severance Tax = 12.5% of extracted mineral’s net value
State Taxes
Very between states, Corporate tax in UT = 5%
Federal Income Tax for Business
Typically taken to be 35% of gross earnings
21%

13. More on Depletion (of natural resource)
Cost Depletion = Units recovered this year*Unit value
Unit Value =
Cost to acquire resource/estimate of recoverable units
Percentage Depletion

14. Total Production Cost, C
Cost of Manufacturing minus general expenses
C=COM+General Expenses
General Expenses (see slide 7)
Selling expenses, R&D, Admin. (top management), Management Incentive Package

15. Costs

16. Cost of Manufacturing (COM)
Direct manufacturing costs
Feedstocks, Utilities, labor related to operations, maintenance
Operating overhead
Fixed costs
Property Tax, Insurance, Depreciation

17. Pre-tax (Gross) Earnings
Gross Earnings = Sales (S) – Total Production Cost (C)
Net Earnings(Profit) = (1-t) Gross Earnings
Tax (t) = State (UT=5%) + Federal taxes (34%)
21%

18. Working Capital, CWC Typically 15 % CTCI
More Accurate Working Capital Calculation
CWC=Cash Reserves+Inventory+accounts receivable-accounts payable
Cash reserves - 30 days of raw materials, utilities, operations, Maintenance, operating overhead, property taxes, insurance and depreciation 8.33% of COM
Inventories = 7 days of products at sales prices
Accounts receivable - 30 days at sales price 8.33% of annual sales
Accounts payable – 30 days of feedstocks at purchase price, 8.33% of annual feed stock costs

20. Definitions of Profitability Measures

21. Venture Profit Comparison
VP=(1-t)*(S-C)*i*C_TCI
Taxes, t
0.4
interest, i
0.05
Old Emissions Equipment
Assume 1 calibration failure per day
Extra Work for
Operator
Time (hr)/failure
Hours/year
Salary ($/hr)
Cost OH
Total Cost
0.25
82.5 35
$ 2,887.50
2.5
$ ,218.75
Instrument Technician 1
330
32.5
$ 10,725.00
$ ,812.50
Environmental Engineer
42.5
$ 14,025.00
$ ,062.50
Purchase Spare Parts
$ ,000.00
$/yr
DAQ Fines
????
Total C
$ ,093.75
Impact on VP
$ ,456.25
New Emssion Equipment
Increase in C_TCI
C_TCI
$ ,000,000.00
$ ,000.00
Cost Analysis Emission Equipment Options 1) Fix it/day 2) $1million in New Equipment

22. Selling Price for Given ROI
For a new product without an established market
Sale price may very
High Sales price
Assume ROI say 40% (This is a home run!!)
Back calculate the sales price.
Low Sales price
Set VP to Zero
Back calculate the sales price
(this is the same as ROI calc above when imin is 20%)

23. ROI is not good enough for cash poor companies
They use annual Cash Flow for decisions
Years of Plant construction
CF = -fDCTDC-CWC-Cland
Years of Plant Operation
CF = (1-t)(S-C)+D
Depreciation D=fDCTDC
fD = fraction of TDC which is depreciated that year

24. Plant 1 Cash Flow

25. Using Excel for Profitability Analysis, Cash Flow and OPEX
Steps to get ready
Get Chemical Prices
Get Cost of Utilities
Run Aspen/ProMax
Raw Material Flow Rate (kg/yr)
Production Rates (kg/y)
Utilities used (kg/y)
Determine installed cost of equipment (CAPEX)
Only then are you ready to use this spread sheet