BIOREFINERIES: INTEGRATION OF DIFFERENT TECHNOLOGIES - Biomass as a Sustainable Energy Source for the Future - page 491

TABLE 15.5 Calculation sheet for cost + return price of a chemical product
Production costs US $.(unit) −1 Unit.t −1 US $.t −1 US $.year −1

Raw materials
Added materials
Utilities
Miscellaneous
Yield of by-products (negative
value!)
Total variable costs
Operation
Maintenance
Lab
Staff/support
Rent of land
Insurances
Total fixed costs
Total expenses production
(= variable + fixed costs)
Depreciation
Costs for sales, research
Total production costs
Profit at x% ROI (before taxation)
Cost + return price

TABLE 15.6 Explanation of cost items in Table 15.5
Production costs “Unit” can be mass, volume, or energy, e.g., t , kg, m 3 , and kWh. The
third-column value is the multiplication of the first two; the fourth
column is the mass flow per year times the third-column value
Raw materials Follows from material balance; prices can, e.g., be retrieved from the
“Chemical Marketing Reporter.” Use consistent sources for prices
Added materials These comprise of materials that are used but are not included in the end
product, e.g., catalysts
Utilities An internal calculation price consisting of a fixed and variable part but
without depreciation and profit
Miscellaneous For example, environmental taxes
Yield of by-products Use a conservatively estimated market price
Operation Salaries of operators and their chiefs; select number of employees and

number of shifts

Maintenance Materials and labor, can be estimated as 5% of TDI

Lab Estimated as 15% of operation costs

Staff/support Salaries for local management, administration personnel, process

engineers, safety manager, etc. Estimated as 50% of operation costs

Rent of land Estimated as 1% of the TPI

Insurances Estimated as 1% of TFC

Depreciation Guideline; 10% of TDI plus 5% of total added costs and TAI

Sales and research Estimated at 10% of the total production costs

ROI Rateof return (“imposed”profitmarginbefore taxation); here, definedasx

% of the sum of on-site investments ( I 0 ) and working capital ( I wc )