FAUJI CEMENT COMPANY LIMITED

Operating Cost of Coal Fired Project - 120 T/H

Operating Parameters
Per day 24 Hours
Operating hours Per month 29 Days
Per annum 348 Days
Boiler Steam Output 120 T/h
Boiler Specific Steam Consumption 4 kg/KWH

Electricity Generation
Per hour 30,000 KWH
Gross Generation
Per annum 250,560,000 KWH
Self Consumption Per hour 12% 3,600 KWH
Per hour 26,400 KWH
Net Generation
Per annum 220,492,800 KWH

Consumptions
Per unit 0.46 kg/KWH
Coal Per hour 13,800 kg/h
Per annum 115,257,600 kg
Boiler start ups 20 No.
Per start up 2,000 Litre
Diesel Per unit 0.0002 L/KWH
Per hour 10.00 L/H
Per annum 40,000 Litre
Per unit 0.10 kg/KWH
Limestone Per hour 800 kg/h
Per annum 25,056,000 kg
Per unit 5 L/KWH
Water Per hour 157 m3/h
Per annum 1,302,912 m3

By-products
Per unit 0.07 kg/KWH
Slag Per hour 2,000 kg/h
Per annum 16,704,000 kg
Per unit 0.05 kg/KWH
Ash Per hour 1,500 kg/h
Per annum 12,528,000 kg

Rates
US Dollar 175.32 Rs.
Coal fuel cost (Local) 25.70 Rs./kg
Diesel 145.00 Rs./Litre
Lime stone 202.00 Rs/Ton
Water 409.00 m3/h
Slag -2.50 Rs./kg
Ash -2.50 Rs./kg

Annual Operating Cost

Coal 2,962,120,320 Rs.
Diesel 5,800,000 Rs.
Lime stone 5,061,312 Rs.
Water 532,891,008 Rs.
Maintenance cost 220,492,800 Rs.
Operating cost Total 3,726,365,440 Rs.
 Slag -41,760,000 Rs.
Saving by using by-products at cement plant
Ash -31,320,000 Rs.
Operating cost Net 3,653,285,440 Rs.

Per Unit Operating Cost

Coal 13.43 Rs./KWH
Diesel 0.03 Rs./KWH
Lime stone 0.11 Rs./KWH
Water 2.42 Rs./KWH
Maintenance cost 1.00 Rs./KWH
Slag -0.19 Rs./KWH
Ash -0.14 Rs./KWH
Operating Cost Overall 16.66 Rs./KWH

Project Cost
21,350,000 USD
Imported Equipment
3,743,082,000 Rs.
5,764,500 USD
Local 27%
1,010,632,140 Rs.
27,114,500 USD
Project Cost (Imported+Local)
4,753,714,140 Rs.
1,355,725 USD
Contigencies 5%
237,685,707 Rs.
28,470,225 USD
Total
4,991,399,847 Rs.
Project Cost
1,078,418 USD/MW
Per MW
189,068,176 Rs/MW

Saving/Loss
Avergae 19.74 Rs./KWH
Wapda unit cost FPA 1.50 Rs./KWH
Total 21.24 Rs./KWH
Per Unit 4.58 Rs./KWH
Saving/Loss
Per annum 1,009,986,944 Rs.
Payback 4.94 Year