THE PROJECT
«CREATION OF ENTERPRISE ON PRODUCTION OF
HEAT-INSULATING NEW GENERATION CONSTRUCTION
MATERIALS AND ROW MATERIALS FOR METALLURGY
FROM INDUSTRIAL WASTE»
Executive Summary
TOPICALITY OF THE PROJECT. The total quantity of waste, accumulated in Europe,
including the Ukraine, is about 25 billions tons, of which 4.7 billions tons are toxic. It equals 40
thousand tons per square meter or 500 tons per inhabitant.
Ash-and-slag waste from the thermoelectric power station covers hundreds of thousands of
hectares of fertile land and is continuously expanding and polluting aerial and aquatic areas. This has
a negative impact on the environment and the health of its people. Suggested technology can be
used for the utilization of ash-and-slag waste from industrial and municipal utility plants.
Heat production is one of the main environment pollutants. Since the increase in costs of
natural gas, the thermoelectric power stations are using solid fuel. This causes an increase in the
quantity of solid wastes and will have a negative impact upon the ecological and socio-economical
situation in the Ukraine.
Also there are numerous unclaimed waste products accumulated in factory dumps and slag
storages. These areas have almost turned into man-made ecological environmental problems.
Donetsk, Zaporizhzhya, Kryvyi Rih, Mariupol and other regions have become zones of ecological and
environmental catastrophes.
There are no nickel, chromium, or non-ferrous metal mines in the Ukraine. These metals ores
were all imported for refining. This situation has brought forth new interest in reprocessing the waste
or slag from previously refined ore slag heaps. Up to now there has been very little interest in
reprocessing these waste sites for their ore potentials. Processing this metal scrap has been
performed with technologies that allowed only perfunctory extraction. Old technologies were not
adequate to reprocess the potentials from this slag. When tested, it was established that 95% by
volume of this metal waste slag contained up to 75% oxides, hydrates that had formed compound
with chlorine, sulfur and silicon.
The absence of updated processing technology does not allow for the proper processing of the
waste slag itself. With the help of newly proposed technology, slag-heaps can be processed for metal
extraction and simultaneously refining other materials. With the implementation of the new
technology, it is now economically advisability and critical for Ukraine to reprocess this waste slag
metal for building materials. We would be able to reduce the over-all refining expenses while
implement an environmental protection program to solve ecological problems in the region. Taking
into account, that all industrial facilities are site specific, it is proposed to organize a separate
manufacture program that will specialize in slag-heap processing. This manufacture procedure will
process almost any type of industrial metals waste that contains alloys, ferroalloys and building
materials. It could be the waste of ferrous and non-ferrous metallurgy, chemical and utility production
facilities, etc.
DESCRIPTION OF THE TECHNOLOGY: Slag waste treatment technology that is based on
the "know-how" to implement a revolutionary metal recovery technology through the application of
electroslag re-melting methods that control the processes to obtaining recoverable end products.
1
The first portion of the treated slag is fused in a furnace of special design to melt the fitted flux
or finely ground slag (initial phase). In doing so, under the action of a direct current, the high melting
temperature mode is set and the formation of two immiscible liquids melt: metal alloyies and slag
separation occurs. An introduction of special additives removes the oxygen from the metal oxides and
the recovery of the metals take place. Slag is part of the lighter fraction and is located above the
metal, this prevents waste and the corrosion of the metals. When the melted metals fill the whole
furnace space, slag is discharged through the upper furnace window, and metal alloys are
discharged through the lower tap-hole, and the process repeats. This technology provides a high
performance furnace unit with a semi-continuous smelting process. Metal alloys are applied during
production as an additive for various steel grades. Slag obtained under this process contains no
metals or metal alloys and is ready for the production of bricks, paving , clinker for production of
cement and other construction materials (e.g. heat insulation). Furthermore, metal alloys obtained
during the initial refining process will contain no less than 85% metals, which may be nickel,
chromium or copper, depending on the treated slag.
Metal alloys obtained during the galvanic treatment, results in the production of highly purified
electro-technical metals.
Particular qualities of the proposed technology are as follows:
In the course of re-smelting, the entire process creates little to no wastes, except for the metal
alloys extraction. The materials are of the quality utilized in construction and other needed areas.
There are provisions for securing various metal alloys to fulfill specific requests.
This technology is able to separate metals and silicates from the smelting process during the
silicates foaming process. The process receives a solid, porous, nonflammable and an insulation
material (foam-silicate) from different fractions. It is used to as a covering to thermal insulation,
overlaps, roofs, floors and filling materials as described in the production of thermal isolation articles
(slabs, building and facing blocks, brick, etc.), with an apparent density from 50 to 300 kg/m 3.
Also, the technology also manufactures as an end product, high-purity glassware made from
the foam-silicate based adsorbents which may be used in industrial waste purification, burial and so
on.
Thus, the integrated products range is not limited only to slag’s or galvano-slag’s chemical
composition, but has the technology for utilizing additional additives and fluxes.
The universality of the electric arc direct-current furnace’s design allows the treatment of
practically any production waste.
The implementation of this proposed technology allows for additional products to be received:
 foam-silicate (solid, porous, nonflammable, insulation and soundproof materials based on
their make-up)
 high-performance fillings for pavement and building construction for use in high work loads
(“doorsill”)
 iron based with a high percentage of alloys that contains up to 30-80% of nickel, chromium
and other expensive metals.
2
SCHEME OF CREATED PLANT MANUFACTURING IS SHOWN BELOW
THE PLANT, PRODUCES TWO BASIC GROUPS OF PRODUCTS: FOAM-SILICATE AND METALS.
MAIN MANUFACTURING WORKSHOP
THE PROCESS OF ASH-AND-SLAG WASTE PROCESSING AND OUTWARD OF FOAM-SILICATE
6
BRIEF TECHNICAL INDICES.
A foam-silicate brick is 1.5 - 2 times lighter than usual (silicates). Life expectancy is 75 years
(versus 50 years for normal production brick). The cost of foam-silicate brick is 50% lower while it’s
insulation quality is 10 times more effective. The insulation and mechanical characteristics of foamsilicate production exceeds all similar building materials.
The comparison of all technical and consumer characteristics show that foam-silicate
construction materials surpass all of the parameters of the traditional construction materials currently
in use in the Ukraine. Costs of the new energy-efficient materials are important. Comparison of the
Ukrainian construction markets shows that foam-silicate materials surpass greatly the currently used
materials in every area, including Cost.
It is significant that the foam-silicate is pollution-free, it breaths and is nonflammable. In the
manufacturing process of the foam-silicate, no toxic substances are produced during the production.
The foam-silicate compared to wood: the ecological coefficient of wood is 1, brick is 10, and haydite
blocks are 20. Heat resistance insulation of foam-silicate is 1000 оС. Foam-silicate is fire resistant
and satisfies the first level of refractoriness.
Another road constructional material, obtained through use of the new technology is
“DoorSill”. This material surpasses any foreign replacement and road mixes, of natural products, by
all operating characteristics. Asphalt and concrete composite pavement filled with “DoorSill” filling
when compared with traditional pavement made with granite rock, as a filling, has a 2-3 times longer
maintenance cycle (especially in arduous climatic conditions and high mechanical loads), better
adherence between tire and the pavement (shorter stopping distance), the capability to scatter light
widely during night time driving to create better visibility.
According to cost and for fast introduction of the foam-silicate ware into the market, it is
possible to establish a price that is 30-60% lower than existing products.
Existing Products
_
_
_
New Technology Prices
poured foam-silicate $47 per m3cost price $17 per m3
insulation board $72 each cost price $27
thermo-insulating building blocks
1 thousand standard units - $70 cost price $30
Average for Ukraine cost prices of building materials by January 2007:
keramzite blocks $78-89 per 1 m³
lime-sand brick $88 per 1 m³
red clay burnt brick $250 per 1 m³.
It is significant that cost of building material is rising constantly.
The costs of “DoorSill” is lower than the cost of the natural granite rock and at least 2 times
lower than the price of the foreign product “Sinopal”.
The quantity of raw materials (ash-and-slag waste) for the proposed technology is unlimited
in Ukraine. For example there are more than 30 millions tons of ash-and-slag waste at the Trypilska
thermoelectric power station. The location of the power station is situated i 40 km away from Kyiv.
Annual program of production output for manufacture is:
- Technical foam-silicate – 3,500,000 m3
- Metals – 35,000 tons.
Prices of production (dated March 1st 2008):
foam-silicate and wares - $47 per 1 m3
metals (high alloy on basis of iron or half for it producing, that contains up to 30-80%
of nickel, chromium) - $3 500 per ton.
Annual gross revenue from manufacture reaching productive capacity is $287 millions.
The customers’s letter of guaranty the manufactured products, will be present on demand.
7
Economic indicators under the Project
Table 1. Expense of investment capital on production development
№
1.
1.1
1.2.
1.3.
Cost,
US Dollars
Name and work types
Technology, formation, management
Purchase of waste recycling technology
Developing WCD specialized melting facility
Developing of power supply systems and technological process control
Тотal:
2. Planning works
2.1 Project of the waste recycling complex stage of technical and economic
2.2.
assessment.
Development of the Environmental Project
3.2.
3.2.1.
3.2.2.
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7.
4.8.
Main technological equipment
Melting facility – the set consisting two electric arc furnaces of direct
current, capacity – 12 t. , new development with production and supply.
Electric power equipment
2 580.000,00
The sources set – two standard transformers 9,0 МVА
1 800.000,00
2 300.000,00
Current-limiting inductors (reactors), transducers, heat-exchanging unit,
control systems with producing of control box and desk – new
development and producing.
Total:
6 680 000.00
Supporting facilities.
Low voltage circuit (copper bus with compensators, cable set)
Outside furnace equipment (casting molds, slag pots, tools etc.)
Gas treatment complex with exhauster on the base of two ФРИР- 1000
Watercooling (cooling stacks, pumping equipment)
Laboratory rapid analysis ( equipment)
Preparing of burden material (grinders, blending machines,
weigher)
Cranage crampon
desiccator,
The set of equipment for foam-silicates production.
Total:
Total technological equipment:
5.
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.
5.8.
5.9.
5.10.
5.11.
840 000.00
60 000.00
900 000.00
Total:
3.
3.1.
1 200 000.00
240 000.00
320 000.00
1 760.000.00
600.000,00
960.000,00
1 200.000,00
800.000,00
140.000,00
960.000,00
1200.000,00
600.000,00
6 460 000.00
13 140 000.00
Building and assembly works.
Production building of melting facility
Firing substation buildings
Understructure of equipment and furnace working platform
Assembly of technological, crane and electric equipment of furnace
Construction and assembly of gas treatment equipment
Construction and assembly of cooling stacks equipment.
Laboratory area
Construction of the site for preparing of burden material
Start-up work
Administration building (complex0
Gas treatment system
1 960.000,00
76 000,00
900.000,00
1 600.000,00
600.000,00
300.000,00
200.000,00
150.000,00
1 900.000,00
850 000.00
450 000.00
8
5.12.
5.13.
5.14.
5.15.
375 000.00
295 000.00
175 000.00
955 000.00
Complex of circulating water supply cycle
Electrical substation
Compressor room
Storage houses
TOTAL:
10 786 000.00
26 586 000.00
Total value
Additional expenses
1 109 000.00
2 745 000.00
Social city development 10%
Total value of the complex
30 440 000.00
ECONOMICS OF PRODUCTION
Table 2. Nessesary investment capital
№
Cost items
Cost,
US Dollars
4 274 400,00
1.
Planning work and technology
2.
Equipment cost «ready-to-operate»
13 140 000,00
3.
Construction and reconstruction cost including
extraordinary expenses
9 067 0000,00
4.
Funds for enterprise organization
300 400,00
5.
Funds for initial production needs
913 200,00
6.
Socials services
2 745 000,00
Total:
30 4400 000,00
Including construction of administrative building, gas cleaning, water supply complex, electric
substation, compressor unit and workshop premises.
Calculating of economic results of melting complex on base of ДСППТ-12 ИР.
Enter data (period of works - year):
1.
2.
3.
4.
Productivity of melting complex makes 20 000 tones per year.
Final product - foam-silicates: 18 000 tones.
At density of 150-160 kg/cub.m. the volume of produced foam-silicates will make 120 000 cub.m
Quantity of workers): 135 persons
5. * Power consumption at full capacity of enterprise operation.
Operation
Name
Quantity of electric
power on
1 ton of metal in
melting
Quantity
tones of
metal in
melting
Melting
1350 kW/h
1.86
Quantity of Quantity of electric Quantity of electric
melting per
power per day
power per year,
day
350 day
8
30 900 kW/h
10 800 800 kW/h
9
Table 3. Cost of consumable row materials, materials and energy resourses at full capacity of
enterprise operation during 1 year.
№
Expenses name
Expenditure
Price per unit,
US Dollars
Total sum,
US Dollars
Initial materials
1.
Industrial waste
20 000,00 t
10,00
200 000.00
2.
Regenerator
16 000.00 t
250,00
4 000 000.00
3.
Lime-stone
24 000,00 t
25.00
600 000.00
Total
60 000,00 t
4 800 000.00
Energy recourses and others
6.
Electric power*
10 800 800 kWt/h
0,1
1 080 000.00
7.
Furnace electrodes
80 t
2.600.00
208 000.00
8.
Covering material
40 t
300,00
12 000.00
9.
Worker’s salary fund
94 persons
11 371,00
1 068 640.00
Total
2 368 640,00
All expenses
7 168 640,00
Production cost
Table 4. Cost of equipment service at full capacity of enterprise operation during 1 year.
№
Name of cost items
Sum of
expenses,
US Dollars
1.
Wages of production workers
740 000,00
2.
Charge on payroll
275 295,00
3
Current equipment repair
409 169,00
Total:
1 015 295,00
Table 6. Workshop expenses at full capacity of enterprise operation during 1 year.
№
1.
2.
3.
4.
Name of cost items
Wages of engineers and administration
Charge on payroll (40%)
Buildings and constructions services
Work safety expenses
Total:
Sum of expenses,
US Dollars
322 800,00
122 315,00
650 714,00
335 463,00
1 431 292,00
10
Summary Table 7. Income and expenditure at full capacity of enterprise operation
№
Name of cost items
Per month, US
Dollars
Per year, UA
Dollars
Production expenses
1.
Variable (row materials, energy recourses
etc.)
-698 303,00
-8 379 638,00
2.
Fixed (building and equipment services,
etc.)
-204 945,00
-2 459 340,00
Total expenses
-903 248,00
-10 838 978,00
5.
Income from sales of foam-silicate and
metal row (net of VAT)
+2 566 042,00
+30 792 500,00
6.
Income
+1 662 794,00
+19 953 522,00
7.
Profit tax (25%)
-415 699,00
- 4 988 381,00
+1 247 095,00
+14 965 141,00
Profit after tax payment
CONCLUSION:


Total investment sum makes 30 440 000 US Dollars
Annual profit after tax payment will make 14 965 141 US Dollars
11
Schedule
of project investing
ГРАФИК
ИНВЕСТИРОВАНИЯ
ПРОЕКТА
3 500 000
3 000 000
2 500 000
2 000 000
1 500 000
1 000 000
500 000
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
месяцы проекта
Credit term, months
Period of grace, months
16
17
18
19
20
21
22
23
сумма, дол. США
Project months
Credit sum, $$
15
Sum, US Dollars
30 440 000
156
36
Annual % rate
12,50%
% due for payment
12,50%
4,43%
1,00%
12
Schedule of disbursement and credit repayment 1
Compensation
for granting of
credit 4,44%
Commission
for Agency
contract
services 1%
14 000 000
620 894
140 000
760 894
0
30 440 000
729 106
164 400
893 506
3-12
0
30 440 000
0
0
0
13-24
0
30 440 000
0
0
0
25-36
0
30 440 000
0
37-48
3 044 004
30 440 000
3 037 500
3 037 500
3 037 500
Months
of the
project
1
2
Credit disbursement
14 000 000
16 440 000
Repayment
of loan
principal
0
The sum of
undercharged
loan
Credit
payments
(total)
Credit
payments
(%%)
49-60
3 044 004
27 396 000
3 037 500
61-72
3 044 004
24 352 000
3 037 500
3 037 500
73-84
3 044 004
21 308 000
3 037 500
3 037 500
18 264 000
3 037 500
3 037 500
15 220 000
3 037 500
3 037 500
12 176 000
3 037 500
3 037 500
9 132 000
3 037 500
3 037 500
6 088 000
3 037 500
3 037 500
3 044 000
3 037 500
3 037 500
32 029 400
30 375 000
3 044 004
85-96
3 044 004
97-108
3 044 004
109-120
3 044 004
121-132
3 044 004
133-144
3 044 000
145-156
TOTAL
30 440 000
30 440 000
1 350 000
304 400
13
Pro forma statement of movement of funds 1-st year, $$
Cash flow from operational activity
1
2
3
4
5
6
7
8
9
10
11
12
TOTAL
Sales income
0
0
0
0
0
0
0
0
0
0
0
0
0
Variable
0
0
0
0
0
0
0
0
0
0
0
0
0
Fixed
-41 088
-48 539
-54 050
-57 495
-60 893
-64 245
-67 069
-69 855
-72 603
-76 550
-78 822
-81 063
-772 273
Payments into the budget
-12 194
-9 607
-9 483
-8 808
-8 233
-7 667
-7 108
-6 638
-6 174
-6 230
-5 715
-5 336
-93 194
0
0
0
0
0
0
0
0
0
0
0
0
0
3 461
4 460
5 135
5 709
6 276
6 834
7 305
7 769
8 227
8 742
9 121
9 495
82 536
0
-3 461
-7 921
-13 056
-18 765
-25 041
-31 876
-39 181
-46 950
-55 178
-63 920
-63 920
0
-3 461
-4 460
-5 135
-5 709
-6 276
-6 834
-7 305
-7 769
-8 227
-8 742
-9 121
-8 742
-760 894
-893 506
0
0
0
0
0
0
0
0
0
0
-1 654 400
-814 176
-951 653
-63 533
-66 303
-69 127
-71 912
-74 178
-76 493
-78 776
-82 780
-84 537
-86 399
-2 519 867
0
0
0
0
0
0
0
0
0
0
0
0
0
-2 932 683
-1 363 439
-798 961
-1 098 406
-1 098 406
-1 098 406
-953 683
-953 683
-953 683
-831 850
-831 850
-831 850
-13 746 900
-2 932 683
-1 363 439
-798 961
-1 098 406
-1 098 406
-1 098 406
-953 683
-953 683
-953 683
-831 850
-831 850
-831 850
-13 746 900
14 000 000
16 440 000
0
0
0
0
0
0
0
0
0
0
30 440 000
0
0
0
0
0
0
0
0
0
0
0
0
0
14 000 000
16 440 000
0
0
0
0
0
0
0
0
0
0
30 440 000
Months of the project
Credit VAT
Debit VAT
VAT reclaimed progressive total
VAT Payments into the budget
Interests and commissions (credit №1)
The outcome from operational activity
Cash flow from investment activity
Founders contribution
Fixed asset acquisition
The outcome from investment activity
Cash flow from financial activity
Credit entry 1
Credit repayment 1
The outcome from financial activity
Funds
At the beginning of period
At the end of period
Cash flow
0
10 253 141
24 378 050
23 515 555
22 350 847
21 183 315
20 012 997
18 985 136
17 954 960
16 922 500
16 007 870
15 091 483
0
10 253 141
24 378 050
23 515 555
22 350 847
21 183 315
20 012 997
18 985 136
17 954 960
16 922 500
16 007 870
15 091 483
14 173 233
14 173 233
10 253 141
14 124 909
-862 494
-1 164 708
-1 167 532
-1 170 318
-1 027 861
-1 030 176
-1 032 460
-914 630
-916 387
-918 249
14 173 233
14
Pro forma statement of movement of
funds, $$
Months of the project
Sales income
Variable
2
3
4
5
6
7
8
9
10
11
12
13
1 year
year
year
year
year
year
year
year
year
year
year
year
год
TOTAL
0
0
33 710 925
36 951 000
36 951 000
36 951 000
36 951 000
36 951 000
36 951 000
36 951 000
36 951 000
36 951 000
36 951 000
403 220 925
0
-63 585
-3 374 312
-3 488 765
-3 641 369
-3 809 233
-3 993 884
-4 197 000
-4 420 428
-4 666 198
-4 936 545
-5 233 927
-5 561 047
-47 386 294
Fixed
-772 273
-1 194 299
-3 454 582
-3 662 577
-3 680 699
-3 700 633
-3 722 560
-3 746 680
-3 773 212
-3 802 398
-3 834 501
-3 869 815
-3 908 661
-43 122 891
Payments into the budget
-93 194
24 913
-5 473 695
-6 705 277
-10 184 210
-10 306 722
-10 381 800
-10 418 043
-10 421 794
-10 397 665
-10 348 926
-10 277 800
-10 185 680
-105 169 892
Interests and commissions (credit №1))
-1 654 400
0
0
-3 037 500
-3 037 500
-3 037 500
-3 037 500
-3 037 500
-3 037 500
-3 037 500
-3 037 500
-3 037 500
-3 037 500
-32 029 400
The outcome from operational activity
-2 519 867
-1 232 971
21 408 336
20 056 880
16 407 222
16 096 912
15 815 256
15 551 777
15 298 066
15 047 239
14 793 527
14 531 958
14 258 111
175 512 448
Cash flow from investment activity
0
Founders contribution
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-13 746 900
-16 693 100
0
0
0
0
0
0
0
0
0
0
0
-30 440 000
-13 746 900
-16 693 100
0
0
0
0
0
0
0
0
0
0
0
-30 440 000
0
Fixed asset acquisition
The outcome from investment activity
Cash flow from financial activity
Credit entry 1
Credit repayment 1
The outcome from financial activity
Funds
At the beginning of period
At the end of period
Cash flow
0
0
30 440 000
0
0
0
0
0
0
0
0
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-30 440 000
30 440 000
30 440 000
0
0
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
-3 044 000
0
0
0
0
14 173 233
-3 752 837
17 655 499
34 668 379
48 031 601
61 084 513
73 855 769
86 363 546
98 617 612
110 620 851
122 370 379
133 858 337
797 546 883
14 173 233
-3 752 837
17 655 499
34 668 379
48 031 601
61 084 513
73 855 769
86 363 546
98 617 612
110 620 851
122 370 379
133 858 337
145 072 448
942 619 330
14 173 233
-17 926 071
21 408 336
17 012 880
13 363 222
13 052 912
12 771 256
12 507 777
12 254 066
12 003 239
11 749 527
11 487 958
11 214 111
145 072 448
15
Calculating of debt service ratio, $$
1 год
Amortization
36 659
53 877
64 883
78 959
92 828
106 493
117 985
129 305
140 458
150 125
159 644
169 018
1 300 233
Net profit for the period
-847 373
-1 851 904
-1 979 645
-2 124 332
-2 285 721
-2 463 568
-2 655 259
-2 860 593
-3 079 369
-3 311 759
-3 555 562
-3 810 605
-3 810 605
Credit Interests payments
760 894
893 506
0
0
0
0
0
0
0
0
0
0
1 654 400
0
0
0
0
0
0
0
0
0
0
0
0
0
All expenses
-49 821
-904 520
-1 914 761
-2 045 373
-2 192 893
-2 357 074
-2 537 275
-2 731 288
-2 938 911
-3 161 634
-3 395 917
-3 641 587
-855 972
All repayments for the period
760 894
893 506
0
0
0
0
0
0
0
0
0
0
1 654 400
Credit repayment
Debt service ratio
-0,52
Calculating of debt service ratio, $$
1 year
2 year
3
4
5
6
7
8
9
10
11
12
13
ВСЕГО
Amortization
1 300 233
3 695 010
4 760 526
3 791 400
3 033 886
2 439 360
1 970 753
1 599 747
1 304 662
1 068 858
879 527
726 783
602 969
27 173 715
Net profit for the period
-3 810 605
-13 666 566
2 235 933
12 758 094
13 219 525
13 548 046
13 770 389
13 906 621
13 971 709
13 976 714
13 929 679
13 836 302
13 700 433
121 376 273
Credit Interests payments
1 654 400
0
0
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
32 029 400
0
0
0
3 044 000
3 044 000
3 044 000
3 044 000
3 044 000
3 044 000
3 044 000
3 044 000
3 044 000
3 044 000
30 440 000
All expenses
-855 972
-9 971 556
6 996 459
19 586 993
19 290 912
19 024 906
18 778 642
18 543 868
18 313 871
18 083 072
17 846 707
17 600 585
17 340 902
180 579 388
All repayments for the period
1 654 400
0
0
6 081 500
6 081 500
6 081 500
6 081 500
6 081 500
6 081 500
6 081 500
6 081 500
6 081 500
6 081 500
62 469 400
-0,52
#ДЕЛ/0!
#ДЕЛ/0!
3,22
3,17
3,13
3,09
3,05
3,01
2,97
2,93
2,89
2,85
2,89
Credit repayment
Debt service ratio
16
Project months
1
2
3
4
5
6
7
8
9
10
11
12
1 год
Calendar month of the project
1
2
3
4
5
6
7
8
9
10
11
12
ВСЕГО
Gross income
0
0
0
0
0
0
0
0
0
0
0
0
0
VAT
0
0
0
0
0
0
0
0
0
0
0
0
0
Updated Gross Income
0
0
0
0
0
0
0
0
0
0
0
0
0
Fuel
0
0
0
0
0
0
0
0
0
0
0
0
0
POL
0
0
0
0
0
0
0
0
0
0
0
0
0
Tiers
0
0
0
0
0
0
0
0
0
0
0
0
0
Accumulator storage battery
0
0
0
0
0
0
0
0
0
0
0
0
0
Electric power
0
0
0
0
0
0
0
0
0
0
0
0
0
Wages of main personnel
0
0
0
0
0
0
0
0
0
0
0
0
0
Transport rent
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Administrative personnel wages
32 516
34 849
37 181
37 181
37 181
37 181
37 181
37 181
37 181
38 553
38 553
38 553
443 293
Communication and community facilities
1 458
1 667
1 875
1 875
1 875
1 875
1 875
1 875
1 875
1 979
1 979
1 979
22 188
Business trips
2 100
2 400
2 700
2 700
2 700
2 700
2 700
2 700
2 700
2 850
2 850
2 850
31 950
Operational expenses
VARIABLE:
FIXED:
Service and repair of fixed assets
175
200
225
225
225
225
225
225
225
238
238
238
2 663
Transport
1 458
1 667
1 875
1 875
1 875
1 875
1 875
1 875
1 875
1 979
1 979
1 979
22 188
Security
1 633
1 867
2 100
2 100
2 100
2 100
2 100
2 100
2 100
2 217
2 217
2 217
24 850
Clerical and other expenses
10 480
14 499
16 902
19 772
22 604
25 397
27 751
30 072
32 362
34 449
36 343
38 210
308 841
Total operational expenses
49 821
57 147
62 858
65 729
68 560
71 354
73 707
76 028
78 318
82 265
84 159
86 026
855 972
Amortization
36 659
53 877
64 883
78 959
92 828
106 493
117 985
129 305
140 458
150 125
159 644
169 018
1 300 233
Electric power
Credit interests and commissions
760 894
893 506
0
0
0
0
0
0
0
0
0
0
1 654 400
Profit before-tax income (for period)
-847 373
-1 004 530
-127 741
-144 688
-161 388
-177 847
-191 692
-205 333
-218 776
-232 390
-243 803
-255 044
-3 810 605
0
-847 373
-1 851 904
-1 979 645
-2 124 332
-2 285 721
-2 463 568
-2 655 259
-2 860 593
-3 079 369
-3 311 759
-3 555 562
-3 810 605
-847 373
-1 851 904
-1 979 645
-2 124 332
-2 285 721
-2 463 568
-2 655 259
-2 860 593
-3 079 369
-3 311 759
-3 555 562
-3 810 605
-3 810 605
Net operating loss carry-back (at rising )
Assessable incomes/losses
17
Income tax
Net profit / losses
0
0
0
0
0
0
0
0
0
0
0
0
0
-847 373
-1 851 904
-1 979 645
-2 124 332
-2 285 721
-2 463 568
-2 655 259
-2 860 593
-3 079 369
-3 311 759
-3 555 562
-3 810 605
-3 810 605
Profit and material losses pro forma statement for 1-13-th years, $$
Project months
Calendar month of the project
1
2
3
4
5
6
7
8
9
10
11
12
13
year
year
year
year
year
year
year
year
year
year
year
year
36 951
000
36 951
000
36 951
000
36 951
000
36 951
000
36 951
000
36 951
000
36 951
000
36 951
000
year
36 951
000
TOTAL
403 220
925
6 158 500
30 792
500
6 158 500
30 792
500
6 158 500
30 792
500
6 158 500
30 792
499
6 158 500
30 792
498
6 158 500
30 792
497
6 158 500
30 792
496
6 158 500
30 792
495
6 158 500
30 792
494
6 158 500
30 792
493
67 203 488
336 017
410
Gross income
0
0
33 710 925
VAT
0
0
5 618 488
Updated Gross Income
0
0
28 092 438
Operational expenses
0
VARIABLE:
FIXED:
Fuel
0
45 000
999 000
1 080 000
1 188 000
1 306 800
1 437 480
1 581 228
1 739 351
1 913 286
2 104 614
2 315 076
2 546 584
18 256 419
POL
0
6 750
149 850
162 000
178 200
196 020
215 622
237 184
260 903
286 993
315 692
347 261
381 988
2 738 463
Tiers
0
1 013
22 478
24 300
26 730
29 403
32 343
35 578
39 135
43 049
47 354
52 089
57 298
410 769
Accumulator storage battery
0
225
4 995
5 400
5 940
6 534
7 187
7 906
8 697
9 566
10 523
11 575
12 733
91 282
Electric power
0
0
173 333
173 333
173 333
173 333
173 333
173 333
173 333
173 333
173 333
173 333
173 333
1 906 667
Wages of main personnel
0
0
1 687 560
1 687 560
1 687 560
1 687 560
1 687 560
1 687 560
1 687 560
1 687 560
1 687 560
1 687 560
1 687 560
18 563 160
Transport rent
0
0
83 333
83 333
83 333
83 333
83 333
83 333
83 333
83 333
83 333
83 333
83 333
916 667
Utilization service (ground)
Service and repair of fixed
0
0
500 000
500 000
500 000
500 000
500 000
500 000
500 000
500 000
500 000
500 000
500 000
5 500 000
assets
0
6 292
139 688
151 014
166 116
182 727
201 000
221 100
243 210
267 531
294 284
323 713
356 084
2 552 761
Administrative personnel wages
443 293
385 532
385 532
385 532
385 532
385 532
385 532
385 532
385 532
385 532
385 532
385 532
385 532
5 069 677
Communication and community facilities
22 188
35 000
99 627
99 627
99 627
99 627
99 627
99 627
99 627
99 627
99 627
99 627
99 627
1 153 081
Business trips
31 950
50 400
50 400
50 400
50 400
50 400
50 400
50 400
50 400
50 400
50 400
50 400
50 400
636 750
Electric power
2 663
4 200
4 200
4 200
4 200
4 200
4 200
4 200
4 200
4 200
4 200
4 200
4 200
53 063
Transport
Consulting services
22 188
35 000
35 000
35 000
35 000
35 000
35 000
35 000
35 000
35 000
35 000
35 000
35 000
442 188
0
0
1 685 546
1 847 550
1 847 550
1 847 550
1 847 550
1 847 550
1 847 550
1 847 550
1 847 550
1 847 550
1 847 550
20 161 046
Security
24 850
39 200
39 200
39 200
39 200
39 200
39 200
39 200
39 200
39 200
39 200
39 200
39 200
495 250
Clerical and other expenses
308 841
624 359
624 359
624 359
624 359
624 359
624 359
624 359
624 359
624 359
624 359
624 359
624 359
7 801 147
855 972
1 232 971
6 684 101
6 952 809
7 095 080
7 251 579
7 423 727
7 613 090
7 821 390
8 050 519
8 302 562
8 579 809
8 884 780
86 748 389
1 300 233
3 695 010
4 760 526
3 791 400
3 033 886
2 439 360
1 970 753
1 599 747
1 304 662
1 068 858
879 527
726 783
602 969
27 173 715
1 654 400
-3 810
605
0
0
-4 927 980
16 647 810
3 037 500
17 010
792
3 037 500
17 626
034
3 037 500
18 064
061
3 037 500
18 360
519
3 037 500
18 542
161
3 037 500
18 628
945
3 037 500
18 635
618
3 037 500
18 572
906
3 037 500
18 448
402
3 037 500
18 267
244
32 029 400
190 065
906
Total operational expenses
Amortization
Credit interests and commissions
Profit before-tax income (for
18
period)
Net operating loss carry-back (at
rising )
Assessable incomes/losses
Income tax
Net profit / losses
-3 810
605
-3 810
605
-8 738 585
-13 666
566
0
-3 810
605
0
-13 666
566
-13 666
566
2 981 245
745 311
2 235 933
0
17 010
792
0
17 626
034
0
18 064
061
0
18 360
519
0
18 542
161
0
18 628
945
0
18 635
618
0
18 572
906
0
18 448
402
0
18 267
244
-26 215
756
167 660
755
4 252 698
12 758
094
4 406 508
13 219
525
4 516 015
13 548
046
4 590 130
13 770
389
4 635 540
13 906
621
4 657 236
13 971
709
4 658 905
13 976
714
4 643 226
13 929
679
4 612 101
13 836
302
4 566 811
13 700
433
46 284 481
121 376
273
Calculation of index of the project effectiveness
Calculation of indexes of project effectiveness
1
2
3
4
5
6
7
8
9
10
11
12
13
Expected economic effect:
0
0
28 092 438
30 792 500
30 792 500
30 792 500
30 792 499
30 792 498
30 792 497
30 792 496
30 792 495
30 792 494
30 792 493
Variable expenses
0
51 654
7 185 157
7 278 134
7 402 104
7 538 471
7 688 475
7 853 479
8 034 984
8 234 639
8 454 259
8 695 842
8 961 583
Fixed expenses
851 146
1 460 523
1 742 286
2 175 429
2 209 605
1 839 688
2 288 552
2 334 041
1 976 568
2 439 120
2 499 665
2 158 754
2 639 525
Expected expenses
851 146
1 512 177
8 927 442
9 453 563
9 611 710
9 378 160
9 977 028
10 187 520
10 011 552
10 673 759
10 953 925
10 854 596
11 601 108
-851 146
-1 512 177
19 164 995
21 338 937
21 180 790
21 414 340
20 815 471
20 604 978
20 780 945
20 118 737
19 838 570
19 937 898
19 191 385
1 300 233
3 695 010
4 760 526
3 791 400
3 033 886
2 439 360
1 970 753
1 599 747
1 304 662
1 068 858
879 527
726 783
602 969
ДВПНА
Amortization expenses
Credit interests
1 654 400
0
0
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
3 037 500
Profit before tax
-3 805 779
-5 207 187
14 404 469
14 510 037
15 109 404
15 937 480
15 807 218
15 967 730
16 438 783
16 012 379
15 921 543
16 173 615
15 550 916
Minus: income tax
0
0
745 311
4 252 698
4 406 508
4 516 015
4 590 130
4 635 540
4 657 236
4 658 905
4 643 226
4 612 101
4 566 811
-3 805 779
-5 207 187
13 659 158
10 257 339
10 702 896
11 421 465
11 217 089
11 332 190
11 781 547
11 353 474
11 278 316
11 561 514
10 984 105
Plus amortization
1 300 233
3 695 010
2 757 332
2 067 999
1 550 999
1 163 249
872 437
654 328
490 746
368 059
276 045
207 033
155 275
Minus: investment
30 440 000
0
0
0
0
0
0
0
0
0
0
0
0
Net cash flow
-32 945 546
-1 512 177
16 416 490
12 325 338
12 253 895
12 584 714
12 089 526
11 986 518
12 272 293
11 721 534
11 554 361
11 768 547
11 139 380
Cumulative net cash flow
-32 945 546
-34 457 723
-18 041 234
-5 715 895
6 538 000
19 122 714
31 212 239
43 198 758
55 471 050
67 192 584
78 746 945
90 515 492
101 654 872
Net profit
Payback period without discount:
4,46
Average deposit rate for legal person
12,0%
Discount rate:
12,0%
Discount cash flow
Cumulative discount cash flow
10 465 655
-1 205 499
11 684 933
7 832 975
6 953 189
6 375 808
5 468 687
4 841 154
4 425 512
3 774 020
3 321 603
3 020 693
2 552 858
-29 415 666
-1 205 499
11 684 933
7 832 975
6 953 189
6 375 808
5 468 687
4 841 154
4 425 512
3 774 020
3 321 603
3 020 693
2 552 858
-29 415 666
-30 621 165
-18 936 231
-11 103 256
-4 150 067
2 225 741
7 694 428
12 535 582
16 961 094
20 735 114
24 056 716
27 077 409
29 630 268
19
Discounted payback period:
5,42
Net present value:
29 630 268
Internal rate of return:
0,2815
Profit index:
1,97
1,00
Services cost
1,00
Variable expenses
1,00
объем услуг
1,00
1,00
1,00
1,00
1,00
1,00
1,00
Services volume
20
NET PRESENT VALUE (NPV)
Discount factor
Year
(Initial cost)
Net cash flow
13%
Real value of net cash flow
30 440 000
1,0000
-30 440 000
1
-2 510 372
0,8889
-2 231 442
2
-9 971 556
0,7901
-7 878 760
3
6 996 459
0,7023
4 913 837
4
16 549 493
0,6243
10 331 767
5
16 253 412
0,5549
9 019 489
6
15 987 406
0,4933
7 886 111
7
15 741 142
0,4385
6 901 899
8
15 506 368
0,3897
6 043 519
9
15 276 371
0,3464
5 292 337
10
15 045 572
0,3079
4 633 226
11
17 014 214
0,2737
4 657 299
12
6 081 500
0,2433
1 479 723
13
21 127 072
0,2163
4 569 372
Disposal value
15 045 572
0,2163
3 254 063
NPV
28 432 439
INTERNAL RATE OF RETURN (IRR)
IRR
Year
Net cash flow
18,8%
1,0000
13
30 440 000
-2 510 372
-9 971 556
6 996 459
16 549 493
16 253 412
15 987 406
15 741 142
15 506 368
15 276 371
15 045 572
17 014 214
6 081 500
21 127 072
Disposal value
15 045 572
0,1067
(Initial cost)
1
2
3
4
5
6
7
8
9
10
11
12
0,8419
0,7088
0,5967
0,5023
0,4229
0,3560
0,2997
0,2523
0,2124
0,1788
0,1506
0,1268
0,1067
NPV
Real value of net cash flow
-30 440 000
-2 113 422
-7 067 389
4 174 673
8 313 365
6 873 607
5 692 017
4 718 158
3 912 860
3 245 283
2 690 847
2 561 771
770 881
2 254 570
1 605 584
7 192 806
21
Payback period, months
80,7
Projected period of credit repayment, months
156
Net Present Value-NP
28 432 439
Profitability index of investment (PI) for discount of 13%
1,93
Rate of gross profit margins
99%
Rate of operating profit margins
78%
Rate of net profit margins
30%
Cumulative
of project’s
Коммулятивный profile
профиль рисков
по проектуrisks
Cumulating NPV,
$$ $$
Кумулятива
NPV,
7 000 000
6 000 000
5 000 000
4 000 000
3 000 000
2 000 000
1 000 000
0
-1 000 0001,000
3,000
5,000
7,000
9,000
11,000
Рис.
- Кумулятивный
показатель
событий
Pic1 1.
Cumulative
indexвероятности
of event наступления
probability
22
Indicator PI
Project sensibility to variable expenses changing
Level of variable expenses, % to the planning
Indicator PI
Project sensibility to product cost changing
Cost service level
Indicator PI
Project sensibility to the planning production volume changing
23
Rendering service volume
24