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Engineering
  Economics for
Cost Optimization
       Department of Mechanical Engineering
                      Khon Kaen University
รถยนต์    หน่วย           Gasolene        Hybrid
ราคา                    บาท               1,300,000     1,500,000
อัตราการสิ้นเปลือง      กิโลเมตร/ลิตร               9            12
ระยะทางการใช้งานต่อปี    กิโลเมตร            35,000        35,000
ราคาน้้ามัน             บาท/ลิตร                   30            30
ค่าบ้ารุงรักษา          % ของราคารถ                3%            3%
อายุการใช้งาน           ปี                         10            10
มูลค่าซาก               % ของราคารถ            25%           25%




                                                                  2
Tube      Water                                        Tube Length ,   Pump    Surface
Diameter   velocity   Number of tubes per pass      U          L         Power    area
                                                     2                               2
  mm.        m/s                 N               W/m K       ( m. )        W       m
            1.568               506               3565      0.933         2313    44.48
            1.743               448               3837      0.989         2511    41.80
  15
            2.240               349               4034      1.210         3250    39.76
            2.614               314               4265      1.271         3642    37.61
            1.513               363               3394      1.138         2264    46.75
            1.816               303               3741      1.252         2560    42.90
  18
            2.096               260               3979      1.374         2944    40.33
            2.725               202               4433      1.585         3940    36.20
            1.458               249               3505      1.315         2187    45.28
            1.823               199               3786      1.521         2541    41.91
  22
            2.026               179               3969      1.612         2776    39.98
            2.431               150               4115      1.866         3425    38.56




                                                                                           3
Pump             Unit      VSD      Fixed Speed
Investment                    THB       60,000       180,000
                  100% Flow   kW           6.72          6.72
Power Consumption 90% Flow    kW           6.70          4.90
                  80% Flow    kW           6.47          3.44
                  100% Flow   hrs             2000
   Operation hour 90% Flow    hrs             4000
                  80% Flow    hrs             2000
Electricity Cost              THB/kWh           3




                                                            4
–       -
•               -----              Value

    –                   Capital,
    –                   , Value
    –
                 , Depreciation
    –
        ,Life
    –           , Salvage                  Time

        Value
                                            5
•               (Interest)
•
•       (Investment)
    –
    –
    –
•
    –
               . .           6
Basic Technical Terms
•   Capital Investment
•   Annual Income
•   Annual Cost
•   Interest Rate
•   Rate of Return
    – Rate of Return =        x 100% (simple Method)
• Pay Back Period
    – Pay Back Period =   /      (simple Method)
• Investment Life
• Salvage Value


                                                       7
1. Fixed Cost
  1.   Loan Interest
  2.   Depreciation Rate
  3.   Administration and General Expenses
  4.   Insurance Expenses
  5.   Taxes
2. Variable Cost
  1. Fuel Cost
  2. Operation and Maintenance Cost

                                             8
Compound Interest
•                                   %




                        = 100 + 3y x 0.1 y = 130

    Compound interest

                                                   9
Future Worth factor, FWF = (1+i)n
                        F = P(1 + i)n                                      F

                                              0    1       2               n
•    F = Future value
•    P = Present value                       P         i               +
•




                                                               money
     i = Compound Interest Rate                                                time

•    n = Number of Year                                                -
                                      Excel Function:
    Equation:      F = P(1 + i)n
                                        @FV(i, n, A, Pv, type)
                                      Rate   Interest Rate, i
    Notation:      F = P(F/P, i, n)   Nper   Peroid, n
                                      Pmt    Equal amount per peroid, A
                                      Pv     Present Value, F
                                      type   0 : at end of peroid
                                             1 : at beginning of peroid

                                                                                 10
Example                                                 5   4.5
  %            ,

                                                F

                         0   1       2              n

                        P        i
                                             P
                                             n
                                             i
  Future Worth Factor, FWF                ( +i)^n
                 ,F                      P x FWF

                                                             11
Present Worth factor, PWF = 1/(1 + i)n
                                                                         F
                     P = F/(1 + i)n
                                            0    1       2               n
•   F = Future value
                                                     i               +
•   P = Present value                      P




                                                             money
                                                                             time
•   i = Compound Interest Rate                                       -
•   n = Number of Year
                                   Excel Function
                                   PV(Rate, Nper, Pmt, Fv, type)
                                   Rate Interest Rate, i
Equation:       F = P(1 + i)n
                                   Nper Peroid, n
Notation:       F = P(F/P, i, n)   Pmt Equal amount per peroid, A
                                   Fv Future Value, F
                                   type 0 : at end of peroid
                                         1 : at beginning of peroid

                                                                               12
Uniform Annual Series Present Worth factor, SPWF
                           n                                n
                1 (1 i)              1 (1 i )
      SPWF                         P                            A
                    i                    i
    Notation:   P= A(P/A, i, n)             A A A A A
                                        0
•    P = Present value                      1      2            n
•    A = Annual value                                  i
                                        P
•    i = Compound Interest Rate   Excel Function
•    n = Number of Year           PV(Rate, Nper, Pmt . type)
                                  Rate Interest Rate, i
                                  Nper Peroid, n
                                  Pmt Equal amount per peroid, A
                                  type 0 : at end of peroid
                                        1 : at beginning of peroid

                                                                     13
Break Even Point Method
•

•

Simple Pay Back Period   =   First Investment Cost
                              Annual Benefit
•
       (Accumulation Cash Flow)


                                                     14
Present Worth Method

                        (Net Present Value, NPV)

          (NPV)

           (Investment Cost)                  (Annual Operating
Cost)                (Annual Maintenance Cost)
NPV

                                                            15
A                              B
      i %, n yr            year 0         i %, n yr          year 0

    A A A          A                    A A A         A
P                                   P
                       NPVA                               NPVB

                  A NPV

                                                                 16
รถยนต์    หน่วย           Gasolene        Hybrid
ราคา                    บาท               1,300,000     1,500,000
อัตราการสิ้นเปลือง      กิโลเมตร/ลิตร               9            12
ระยะทางการใช้งานต่อปี    กิโลเมตร            35,000        35,000
ราคาน้้ามัน             บาท/ลิตร                   30            30
ค่าบ้ารุงรักษา          % ของราคารถ                3%            3%
อายุการใช้งาน           ปี                         10            10
มูลค่าซาก               % ของราคารถ            25%           25%




                                                                 17
วิธีทำ
อัตราการสิ้นเปลืองน้้ามันต่อปี   ลิตร         3,889     2,917
ราคาน้้ามันต่อปี                 บาทต่อปี   116,667    87,500
ค่าบ้ารุงรักษา+ประกันต่อปี       บาทต่อปี    39,000    45,000
ค่าใช้จ่ายต่อปี                  บาทต่อปี   155,667   132,500
มูลค่าซาก                        บาท        325,000   375,000




                                                         18
NPV
Interest                   8%

Gasolene
Year                         0         1         2         3         4         5         6         7         8         9         10
Investment           1,300,000
Annual Cost            155,667    155,667   155,667   155,667   155,667   155,667   155,667   155,667   155,667   155,667
Savage Value                                                                                                               -325000
Total Cost            1,455,667   155,667   155,667   155,667   155,667   155,667   155,667   155,667   155,667   155,667 -325,000
PWF=1/(1+i)^n              1.00      0.93      0.86      0.79      0.74      0.68      0.63      0.58      0.54      0.50     0.46
PV of total cost      1,455,667   144,136   133,459   123,573   114,420   105,944    98,096    90,830    84,102    77,872 -150,538
NPV                2,277,561
Hybrid
Year                         0         1         2         3         4         5         6         7         8         9         10
Investment           1,500,000
Annual Cost            132,500    132,500   132,500   132,500   132,500   132,500   132,500   132,500   132,500   132,500
Savage Value                                                                                                               -375000
Total Cost            1,632,500   132,500   132,500   132,500   132,500   132,500   132,500   132,500   132,500   132,500 -375,000
PWF=1/(1+i)^n              1.00      0.93      0.86      0.79      0.74      0.68      0.63      0.58      0.54      0.50     0.46
PV of total cost      1,632,500   122,685   113,597   105,183    97,391    90,177    83,497    77,312    71,586    66,283 -173,698
NPV                2,286,515




                                                                                                                            19
Condenser Cost Optimization
• Condenser Design:
• For a given heat load:
  – Vary tube dia. And water velocity give different
    condenser area and pumping power.
  – High water velocity  Less condenser area  Less
    investment cost.
  – High water velocity  More pump power required 
    Higher operating cost.
• Optimum economic cost must evaluate over the
  “condenser life” using “Net present value, NPV
  method”.
                                                       20
Condenser Cost Optimization
 Cost




                  Size        21
Example of 1 MW power plant
      condenser design
  Tube      Water                                        Tube Length ,   Pump    Surface
Diameter   velocity   Number of tubes per pass      U          L         Power    area
                                                     2                               2
  mm.        m/s                 N               W/m K       ( m. )        W       m
            1.568               506               3565      0.933         2313    44.48
            1.743               448               3837      0.989         2511    41.80
  15
            2.240               349               4034      1.210         3250    39.76
            2.614               314               4265      1.271         3642    37.61
            1.513               363               3394      1.138         2264    46.75
            1.816               303               3741      1.252         2560    42.90
  18
            2.096               260               3979      1.374         2944    40.33
            2.725               202               4433      1.585         3940    36.20
            1.458               249               3505      1.315         2187    45.28
            1.823               199               3786      1.521         2541    41.91
  22
            2.026               179               3969      1.612         2776    39.98
            2.431               150               4115      1.866         3425    38.56




                                                                                           22
Economics Design Conditions
• Condenser Life: 15 years.
• Salvage value = 2% of condenser cost
• Operating hour: 8,000 hr/y
• Interest rate: 6% per year
• Electrical Cost: 3 Baht/kWh
• Maintenance Cost: 5%(of Condenser Cost) per
  year
• Condenser cost, C = m + nA Baht
      m = 150,000        Baht
     n = 23,520          Baht/m2
     A = condenser surface area, m2
                                                23
Parameter     Symbol   Calculation   Value              Unit

Condenser Life                   Assume        10               years

Operating hour                   Assume       8000               hr/y

Salvage value                    Assume         5        % of condenser cost

Interest rate                    Assume         7             % per year

Electrical Cost                  Assume        3.2            Baht/kWh

                                                       %(of Condenser Cost) per
Maintenance Cost                 Assume        4.5              year

                         m       Assume       150000            Baht

                         n       Assume       23,520           Baht/m2
      Condenser cost


                         C      C = m + nA                      Baht




                                                                                  24
Assignment
Using Net Present Value (NPV)
1. Select 1 case to calculate NPV by yearly cash
   flow method.
2. From yours calculation results of the
   “Condenser design”, determine the most
   economically deign.




                                               25
Fixed Speed
             Variable Speed Pump
•            Pump
    Pump                5         Pump

              Pump            Unit       VSD      Fixed Speed
Investment                    THB        60,000       180,000
                  100% Flow   kW            6.72          6.72
Power Consumption 90% Flow    kW            6.70          4.90
                  80% Flow    kW            6.47          3.44
                  100% Flow   hrs              2000
   Operation hour 90% Flow    hrs              4000
                  80% Flow    hrs              2000
Electricity Cost              THB/kWh            3

                                                           26
Internal Rate of Return, irr

         Trial-and-error
        Present Worth
              Expenses = Incomes

 •          P             A     0
                                     A A A A A
                    n                1   2       n
 • P = P(SPWF)                  P
                                             i
 •    irr = i

irr
                                                     27
Example Cash Flow, IRR …by using Excel

       year
Investments              -
Annual Cost                  -   -   -   -   -       -

Annual Income
Net annual --(irr)           -
Accumulate (Cash             -   -   -   -       -
Flow)
irr = IRR@(..range.., guess)




                                                         28
Fixed Speed
             Variable Speed Pump
•                Fixed Speed
             Variable Speed

              Pump            Unit      VSD      Fixed Speed
Investment                    THB       60,000       180,000
                  100% Flow   kW           6.72          6.72
Power Consumption 90% Flow    kW           6.70          4.90
                  80% Flow    kW           6.47          3.44
                  100% Flow   hrs             2000
   Operation hour 90% Flow    hrs             4000
                  80% Flow    hrs             2000
Electricity Cost              THB/kWh           3

                                                          29

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Condenser designoptimisation

  • 1. Engineering Economics for Cost Optimization Department of Mechanical Engineering Khon Kaen University
  • 2. รถยนต์ หน่วย Gasolene Hybrid ราคา บาท 1,300,000 1,500,000 อัตราการสิ้นเปลือง กิโลเมตร/ลิตร 9 12 ระยะทางการใช้งานต่อปี กิโลเมตร 35,000 35,000 ราคาน้้ามัน บาท/ลิตร 30 30 ค่าบ้ารุงรักษา % ของราคารถ 3% 3% อายุการใช้งาน ปี 10 10 มูลค่าซาก % ของราคารถ 25% 25% 2
  • 3. Tube Water Tube Length , Pump Surface Diameter velocity Number of tubes per pass U L Power area 2 2 mm. m/s N W/m K ( m. ) W m 1.568 506 3565 0.933 2313 44.48 1.743 448 3837 0.989 2511 41.80 15 2.240 349 4034 1.210 3250 39.76 2.614 314 4265 1.271 3642 37.61 1.513 363 3394 1.138 2264 46.75 1.816 303 3741 1.252 2560 42.90 18 2.096 260 3979 1.374 2944 40.33 2.725 202 4433 1.585 3940 36.20 1.458 249 3505 1.315 2187 45.28 1.823 199 3786 1.521 2541 41.91 22 2.026 179 3969 1.612 2776 39.98 2.431 150 4115 1.866 3425 38.56 3
  • 4. Pump Unit VSD Fixed Speed Investment THB 60,000 180,000 100% Flow kW 6.72 6.72 Power Consumption 90% Flow kW 6.70 4.90 80% Flow kW 6.47 3.44 100% Flow hrs 2000 Operation hour 90% Flow hrs 4000 80% Flow hrs 2000 Electricity Cost THB/kWh 3 4
  • 5. - • ----- Value – Capital, – , Value – , Depreciation – ,Life – , Salvage Time Value 5
  • 6. (Interest) • • (Investment) – – – • – . . 6
  • 7. Basic Technical Terms • Capital Investment • Annual Income • Annual Cost • Interest Rate • Rate of Return – Rate of Return = x 100% (simple Method) • Pay Back Period – Pay Back Period = / (simple Method) • Investment Life • Salvage Value 7
  • 8. 1. Fixed Cost 1. Loan Interest 2. Depreciation Rate 3. Administration and General Expenses 4. Insurance Expenses 5. Taxes 2. Variable Cost 1. Fuel Cost 2. Operation and Maintenance Cost 8
  • 9. Compound Interest • % = 100 + 3y x 0.1 y = 130 Compound interest 9
  • 10. Future Worth factor, FWF = (1+i)n F = P(1 + i)n F 0 1 2 n • F = Future value • P = Present value P i + • money i = Compound Interest Rate time • n = Number of Year - Excel Function: Equation: F = P(1 + i)n @FV(i, n, A, Pv, type) Rate Interest Rate, i Notation: F = P(F/P, i, n) Nper Peroid, n Pmt Equal amount per peroid, A Pv Present Value, F type 0 : at end of peroid 1 : at beginning of peroid 10
  • 11. Example 5 4.5 % , F 0 1 2 n P i P n i Future Worth Factor, FWF ( +i)^n ,F P x FWF 11
  • 12. Present Worth factor, PWF = 1/(1 + i)n F P = F/(1 + i)n 0 1 2 n • F = Future value i + • P = Present value P money time • i = Compound Interest Rate - • n = Number of Year Excel Function PV(Rate, Nper, Pmt, Fv, type) Rate Interest Rate, i Equation: F = P(1 + i)n Nper Peroid, n Notation: F = P(F/P, i, n) Pmt Equal amount per peroid, A Fv Future Value, F type 0 : at end of peroid 1 : at beginning of peroid 12
  • 13. Uniform Annual Series Present Worth factor, SPWF n n 1 (1 i) 1 (1 i ) SPWF P A i i Notation: P= A(P/A, i, n) A A A A A 0 • P = Present value 1 2 n • A = Annual value i P • i = Compound Interest Rate Excel Function • n = Number of Year PV(Rate, Nper, Pmt . type) Rate Interest Rate, i Nper Peroid, n Pmt Equal amount per peroid, A type 0 : at end of peroid 1 : at beginning of peroid 13
  • 14. Break Even Point Method • • Simple Pay Back Period = First Investment Cost Annual Benefit • (Accumulation Cash Flow) 14
  • 15. Present Worth Method (Net Present Value, NPV) (NPV) (Investment Cost) (Annual Operating Cost) (Annual Maintenance Cost) NPV 15
  • 16. A B i %, n yr year 0 i %, n yr year 0 A A A A A A A A P P NPVA NPVB A NPV 16
  • 17. รถยนต์ หน่วย Gasolene Hybrid ราคา บาท 1,300,000 1,500,000 อัตราการสิ้นเปลือง กิโลเมตร/ลิตร 9 12 ระยะทางการใช้งานต่อปี กิโลเมตร 35,000 35,000 ราคาน้้ามัน บาท/ลิตร 30 30 ค่าบ้ารุงรักษา % ของราคารถ 3% 3% อายุการใช้งาน ปี 10 10 มูลค่าซาก % ของราคารถ 25% 25% 17
  • 18. วิธีทำ อัตราการสิ้นเปลืองน้้ามันต่อปี ลิตร 3,889 2,917 ราคาน้้ามันต่อปี บาทต่อปี 116,667 87,500 ค่าบ้ารุงรักษา+ประกันต่อปี บาทต่อปี 39,000 45,000 ค่าใช้จ่ายต่อปี บาทต่อปี 155,667 132,500 มูลค่าซาก บาท 325,000 375,000 18
  • 19. NPV Interest 8% Gasolene Year 0 1 2 3 4 5 6 7 8 9 10 Investment 1,300,000 Annual Cost 155,667 155,667 155,667 155,667 155,667 155,667 155,667 155,667 155,667 155,667 Savage Value -325000 Total Cost 1,455,667 155,667 155,667 155,667 155,667 155,667 155,667 155,667 155,667 155,667 -325,000 PWF=1/(1+i)^n 1.00 0.93 0.86 0.79 0.74 0.68 0.63 0.58 0.54 0.50 0.46 PV of total cost 1,455,667 144,136 133,459 123,573 114,420 105,944 98,096 90,830 84,102 77,872 -150,538 NPV 2,277,561 Hybrid Year 0 1 2 3 4 5 6 7 8 9 10 Investment 1,500,000 Annual Cost 132,500 132,500 132,500 132,500 132,500 132,500 132,500 132,500 132,500 132,500 Savage Value -375000 Total Cost 1,632,500 132,500 132,500 132,500 132,500 132,500 132,500 132,500 132,500 132,500 -375,000 PWF=1/(1+i)^n 1.00 0.93 0.86 0.79 0.74 0.68 0.63 0.58 0.54 0.50 0.46 PV of total cost 1,632,500 122,685 113,597 105,183 97,391 90,177 83,497 77,312 71,586 66,283 -173,698 NPV 2,286,515 19
  • 20. Condenser Cost Optimization • Condenser Design: • For a given heat load: – Vary tube dia. And water velocity give different condenser area and pumping power. – High water velocity  Less condenser area  Less investment cost. – High water velocity  More pump power required  Higher operating cost. • Optimum economic cost must evaluate over the “condenser life” using “Net present value, NPV method”. 20
  • 22. Example of 1 MW power plant condenser design Tube Water Tube Length , Pump Surface Diameter velocity Number of tubes per pass U L Power area 2 2 mm. m/s N W/m K ( m. ) W m 1.568 506 3565 0.933 2313 44.48 1.743 448 3837 0.989 2511 41.80 15 2.240 349 4034 1.210 3250 39.76 2.614 314 4265 1.271 3642 37.61 1.513 363 3394 1.138 2264 46.75 1.816 303 3741 1.252 2560 42.90 18 2.096 260 3979 1.374 2944 40.33 2.725 202 4433 1.585 3940 36.20 1.458 249 3505 1.315 2187 45.28 1.823 199 3786 1.521 2541 41.91 22 2.026 179 3969 1.612 2776 39.98 2.431 150 4115 1.866 3425 38.56 22
  • 23. Economics Design Conditions • Condenser Life: 15 years. • Salvage value = 2% of condenser cost • Operating hour: 8,000 hr/y • Interest rate: 6% per year • Electrical Cost: 3 Baht/kWh • Maintenance Cost: 5%(of Condenser Cost) per year • Condenser cost, C = m + nA Baht m = 150,000 Baht n = 23,520 Baht/m2 A = condenser surface area, m2 23
  • 24. Parameter Symbol Calculation Value Unit Condenser Life Assume 10 years Operating hour Assume 8000 hr/y Salvage value Assume 5 % of condenser cost Interest rate Assume 7 % per year Electrical Cost Assume 3.2 Baht/kWh %(of Condenser Cost) per Maintenance Cost Assume 4.5 year m Assume 150000 Baht n Assume 23,520 Baht/m2 Condenser cost C C = m + nA Baht 24
  • 25. Assignment Using Net Present Value (NPV) 1. Select 1 case to calculate NPV by yearly cash flow method. 2. From yours calculation results of the “Condenser design”, determine the most economically deign. 25
  • 26. Fixed Speed Variable Speed Pump • Pump Pump 5 Pump Pump Unit VSD Fixed Speed Investment THB 60,000 180,000 100% Flow kW 6.72 6.72 Power Consumption 90% Flow kW 6.70 4.90 80% Flow kW 6.47 3.44 100% Flow hrs 2000 Operation hour 90% Flow hrs 4000 80% Flow hrs 2000 Electricity Cost THB/kWh 3 26
  • 27. Internal Rate of Return, irr Trial-and-error Present Worth Expenses = Incomes • P A 0 A A A A A n 1 2 n • P = P(SPWF) P i • irr = i irr 27
  • 28. Example Cash Flow, IRR …by using Excel year Investments - Annual Cost - - - - - - Annual Income Net annual --(irr) - Accumulate (Cash - - - - - Flow) irr = IRR@(..range.., guess) 28
  • 29. Fixed Speed Variable Speed Pump • Fixed Speed Variable Speed Pump Unit VSD Fixed Speed Investment THB 60,000 180,000 100% Flow kW 6.72 6.72 Power Consumption 90% Flow kW 6.70 4.90 80% Flow kW 6.47 3.44 100% Flow hrs 2000 Operation hour 90% Flow hrs 4000 80% Flow hrs 2000 Electricity Cost THB/kWh 3 29