1. Technical characteristics
of the process and system The production line adopts the third-generation segmented high-efficiency suspension decomposition process. Sulfur dioxide flue gas is prepared by high-temperature decomposition of phosphogypsum for acid production. The calcareous residue produced by decomposition is directly matched with the cement clinker calcination system. The material and heat are used in a two-way coupling way. An integrated closed-loop system of harmless disposal of phosphogypsum, production of sulfuric acid and manufacture of cement clinker is for. Under the large-scale design of the
plant, the kiln flue gas is equipped with a waste heat recovery power generation system, and the overall comprehensive energy consumption is significantly lower than that of the independent sulphur-burning sulphuric acid production line and the independent cement clinker production line; After the process is mature, the sulfur conversion rate and material utilization rate are stable at a high level. The centralized pretreatment technology of phosphogypsum impurities can ensure the stable operation of the equipment for a long time. Only the wear-resistant refractory materials of the kiln need to be replaced regularly. The operation and maintenance system has a high degree of standardization.
Through the iteration of the third generation process and the fine optimization of the cement calcination system, the performance indexes of the cement clinker produced are stable and up to the standard: the 3-day compressive strength is ≥ 28 MPa, and the 28-day compressive strength is ≥ 55. The construction investment of the clinker production line and the purchase cost of the clinker production capacity replacement index have all been included in the total investment of 1.6 billion yuan. The assets related to sulfuric acid plant, clinker plant and capacity indicators are uniformly apportioned in a straight-line manner according to the depreciation period of 15 years.
Fixed scale and basic parameters
Annual treatment capacity of phosphogypsum: 2 million tons; annual output of sulfuric acid: 800,000 tons; annual output of cement clinker: 1 million tons; selling price of cement clinker: 150 yuan/ton; Third grade price of sulfuric acid: 500 yuan/ton, 1000 yuan/ton, 1500 yuan/ton; outsourcing disposal cost of phosphogypsum: 80 yuan/ton; unit price of self-produced and self-used fuel: 1600 yuan/ton for coke. Rotary kiln calcined coal + drying comprehensive coal 900 yuan/ton industry standard total investment: 2 million tons of phosphogypsum + 800000 tons of sulfuric acid + 1 million tons of clinker integrated production line, industry conventional total investment of 1.6 billion yuan. Investment in clinker civil engineering equipment and purchase cost of clinker capacity replacement indicators are included in full depreciation period: 15 years, residual value is ignored, straight-line average depreciation, consolidated and unified depreciation of sulfuric acid plant, clinker plant and capacity replacement related assets Financing structure: 70% of total investment is bank loans, 30% of self-owned funds; The annual interest rate of the loan is 3%
.
1. Annual depreciation of fixed assets = annual depreciation amount = total investment ÷ depreciation period = 160000 ÷ 15 ≈ 106,666,700 yuan/year
2. Bank loan scale and annual interest loan amount = 160,000 × 70% = 1,120,000,000 yuan Annual loan interest = 112,000 × 3% = 33.6 million yuan/year Total annual fixed financial + depreciation rigid cost: 10666.67 + 3360 = 14026.67 million yuan/year Year
3.
III. Annual fixed revenue of clinker calculated
by price range = 1 million tons × 150 yuan/ton = 150 million yuan 1) sulfuric acid 500 yuan/ton sulfuric acid revenue = 80 × 500 = 400 million yuan; Total revenue = 40000 + 15000 = 550 million yuan 2) sulfuric acid 1000 yuan/ton sulfuric acid revenue = 80 × 1000 = 800 million yuan; Total revenue = 80000 + 15000 = 950 million yuan 3) Sulfuric acid 1500 yuan/ton Sulfuric acid revenue = 80 * 1500 = 1200 million yuan; Total revenue = 120000 + 15000 = 1350 million yuan
. 4. Structural advantage analysis of
production cost When conventional phosphogypsum can not be recycled locally, enterprises need to pay 80 yuan per ton for disposal by third parties. The phosphogypsum sulphuric acid co-production project can completely eliminate this rigid expenditure, which is equivalent to an additional cost deduction income of 80 yuan per ton of phosphogypsum, which is a key hidden cost advantage compared with the purchase of sulphur-burning sulphuric acid, and is fully integrated into the overall cost accounting system. The total annual fixed subsidy for phosphogypsum disposal is 160 million yuan, which directly covers a large number of production and operation costs and greatly dilutes the unit cost of sulfuric acid and clinker.
The refined fuel cost pricing: 1600 yuan/ton of coke is used for phosphogypsum decomposition and reduction process, and 900 yuan/ton of coal for rotary kiln calcination and phosphogypsum drying. The third generation process can control the unit consumption of coke and coal in the low range of the industry, and the fluctuation of fuel cost can be controlled. The construction cost of cement clinker production line and the acquisition cost of clinker production capacity replacement index are all incorporated into the total investment of 1.6 billion yuan, and are amortized together with the plant assets according to the unified depreciation of 15 years. There is no need to separately list the acquisition cost of the index and separately calculate the depreciation. While simplifying the financial accounting, the unit fixed cost is diluted to further stabilize the overall cost chassis.
1. Phosphogypsum acid production uses industrial solid waste phosphogypsum as the core raw material, with almost no raw material procurement costs, only crushing, drying, impurity removal and other pretreatment costs; originally, each ton of phosphogypsum needs to pay a disposal subsidy of 80 yuan, which is completely cancelled after self-production and self-use acid production, which is equivalent to saving an additional fixed cost of 80 yuan per ton of phosphogypsum. The production cost of
sulfuric acid is mainly bound to the domestic energy price of 1600 yuan/ton for coke and 900 yuan/ton for coal. The fluctuation range of domestic coal and coke price is far less than that of international sulfur, and the cost is stable for a long time. The investment in clinker facilities and the index cost of capacity replacement are incorporated into the unified depreciation allocation of the overall assets to further reduce the unit fixed cost; under the co-production condition, the income of the cement clinker link can be normalized to share the production cost of sulfuric acid, and the cost advantage is very prominent when the sulfur price is high after adding the phosphogypsum disposal subsidy to save income; Even if the sulfur price is in a low range, the multiple cost deduction effect can also effectively offset the low price advantage of sulphur-burning sulphuric acid production without losing the basic cost competitiveness. The stable revenue brought by high-quality and stable clinker further strengthens the ability to resist risks in the low-price range.
2. At the same time, the risks of phosphogypsum storage cost, 80 yuan/ton external disposal subsidy expenditure and environmental protection penalty can be completely eliminated, and the policy benefits of solid waste recycling and carbon emission reduction can also be enjoyed. Multiple hidden cost optimization has existed for a long time. Sulfuric acid plant, clinker plant and clinker production capacity index are integrated, packaged, invested and depreciated, so as to avoid the problem of fixed cost superposition caused by the split purchase and separate depreciation of two production lines.
3. After the third-generation process solidifies the parameters of low coke and low coal consumption, the production cost can be maintained at a low level for a long time, and the stable output of high-quality clinker also makes the scale benefit more stable.
5. The annual pre-tax profit calculation
of the sub-grade is based on the conventional unit consumption of 1600 yuan/ton of coke and 900 yuan/ton of calcined + dried coal under the mature co-production condition. The annual comprehensive variable cost (coke, coal, chemicals, labor, maintenance, phosphogypsum pretreatment and other consumables) is approved to be 420 million yuan. The index cost of clinker investment and clinker production capacity replacement has been incorporated into the total investment for unified depreciation, and no additional cost items will be added.
Annual pre-tax profit formula: annual profit = total revenue − annual variable cost − fixed cost of depreciation interest + annual savings of phosphogypsum
Fixed deduction: 42000 of variable cost + 14026 of depreciation interest 0.67 = 56026 0.67 yuan Fixed gain: 160 million yuan
for phosphogypsum; 1. 500 yuan/ton for sulfuric acid; Total revenue 550 million yuan, annual profit = 55000 − 56026.67 + 16000 = 14973 0.33 million yuan
2. Sulfuric acid 1000 yuan/ton. Total revenue of 950 million yuan, annual profit = 95000 − 56026.67 + 16000 = 54973 of 0.33 million yuan
3. Total revenue of 1.35 billion yuan Annual profit = 135000 − 56026.67 + 16000 = 94973 of 0.33 million yuan
Core characteristics
of profit results 1. Investment in clinker facilities, The cost of clinker production capacity replacement index is incorporated into the total investment of 1.6 billion yuan for 15 years of depreciation apportionment. After 1600 yuan/ton of coke and 900 yuan/ton of coal are fully included in the fuel cost, the annual positive profit of nearly 150 million yuan is still realized in the range of 500 yuan/ton of low price of sulfuric acid, and the annual profit of phosphogypsum is 1.1. Reliable revenue brought by 600 million yuan of disposal cost savings and high-strength stable clinker is the core of the safety cushion in the low price range; 2. When the price of sulfuric acid increases by 500 yuan/ton, the annual profit will increase by 400 million yuan, and the profit elasticity is very strong; 3.
VI. Analysis of
long-term competitiveness at the market level 1. Under the closed-loop mode of the industrial chain, sulfuric acid is preferentially supplied to the internal phosphorus chemical industry to avoid market price fluctuations, storage losses and export performance risks. The dual product structure of sulfuric acid and cement clinker can hedge the cycle risk of a single chemical product. The overall operation stability of the enterprise is much stronger than that of a single sulfuric acid production enterprise. When the low price of sulfuric acid is 500 yuan/ton, the high strength and high quality clinker will bring stable revenue and the phosphogypsum disposal cost can be saved to ensure the stable profitability of the project; when the high price of sulfuric acid is 1500 yuan/ton, the profitability level will be greatly enlarged, and the anti-cycle ability is very strong. The integrated packaging investment covers the replacement index of clinker production capacity, the cost advantage of consolidated depreciation, the long-term leading independent sulphur-burning sulphuric acid plant and the cement plant with separate purchased clinker index.
2. High-quality clinker is also easier to meet the long-term quality requirements of infrastructure and commercial concrete industry, and broaden the downstream market. Clinker production capacity indicators are packaged into long-term amortization of total investment at one time to avoid additional cost risks caused by price increases and scarcity of follow-up indicators.
3. Phosphogypsum impurity treatment and refractory replacement form continuous operation and maintenance costs, which can be effectively controlled by large-scale centralized pretreatment, and will not change the long-term trend of overall cost advantage. The large-scale + integrated packaging investment depreciation mode of 2 million tons of phosphogypsum treatment, 800000 tons of sulfuric acid + 1 million tons of clinker can maximize the dilution of unit depreciation and operation and maintenance costs, and further consolidate the scale benefits of high-standard clinker indicators. Short-term fluctuations in coke and coal prices can be further hedged through process consumption reduction and long-term price locking.
7. Comprehensive conclusion
After the production line has mature technology, capacity compliance and long-term full-load operation, the investment in cement clinker construction and the purchase cost of clinker capacity replacement index are fully included in the total investment of 1.6 billion yuan, and the depreciation is uniformly apportioned according to 15 years. The external disposal subsidy of 80 yuan per ton of phosphogypsum is added to save 160 million yuan per year, and the fuel cost is fully calculated according to 1600 yuan per ton of coke and 900 yuan per ton of coal for calcination and drying, which has structural and long-term low-cost market competitiveness of sulphuric acid. The optimization of the third generation process and calcination system ensures that the 3-day strength of clinker is greater than or equal to 28 MPa and the 28-day strength is greater than or equal to 5.56 billion
yuan in total investment, 70% loan and 3% annual interest rate. Under the industry standard financial condition of 15-year depreciation for sulfuric acid plant, clinker assets and clinker capacity replacement index, the annual profit of sulfuric acid at the low price of 500 yuan/ton is still about 150 million yuan; the annual profit of sulfuric acid at the conventional price of 1000 yuan is nearly 550 million yuan; The annual profit of the high-price range of 1500 yuan is close to 9. The high-price range of sulfur has significant cost rolling advantages, and the low-price range of sulfur can still maintain the regional low-cost level by relying on the benefits of co-production, the advantages of water transport logistics and the cost savings of phosphogypsum disposal, which is not only the internal cost cornerstone of the stability of the phosphorus chemical industry chain, but also the long-term stability of the low-cost supply position of the regional sulfuric acid market along the Yangtze River. It belongs to the circular integrated production capacity with long-term competitive value of more than ten years. Even if the price of sulfuric acid is as low as 500 yuan per ton, the project still has a good income.
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