Oxygen Gas Producing Plant PDF
Oxygen Gas Producing Plant PDF
Oxygen Gas Producing Plant PDF
3rd Floor, Building No. 3, 5TH Floor, Bahria Ground Floor Bungalow No. 15-A
Aiwan-e-Iqbal Complex, Complex II, M.T. Khan Road, State Life Building Chaman Housing Scheme
Egerton Road Lahore, Karachi. The Mall, Peshawar. Airport Road, Quetta.
Tel: (042) 111-111-456 Tel: (021) 111-111-456 Tel: (091) 9213046-47 Tel: (081) 831623, 831702
Fax: (042) 36304926-7 Fax: (021) 5610572 Fax: (091) 286908 Fax: (081) 831922
[email protected] [email protected] [email protected] [email protected]
May 2012
Pre-feasibility Study Oxygen Gas Manufacturing Unit
TABLE OF CONTENT
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12 VEHICLE .......................................................................................................... 20
16 ANNEXURE ...................................................................................................... 28
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DISCLAIMER
The purpose and scope of this information memorandum is to introduce the subject
matter and provide a general idea and information on the said area. All the material
included in this document is based on data/information gathered from various sources
and is based on certain assumptions. Although, due care and diligence has been taken
to compile this document, the contained information may vary due to any change in
any of the concerned factors, and the actual results may differ substantially from the
presented information. SMEDA does not assume any liability for any financial or
other loss resulting from this memorandum in consequence of undertaking this
activity. Therefore, the content of this memorandum should not be relied upon for
making any decision, investment or otherwise. The prospective user of this
memorandum is encouraged to carry out his/her own due diligence and gather any
information he/she considers necessary for making an informed decision.
The content of the information memorandum does not bind SMEDA in any legal or
other form.
DOCUMENT CONTROL
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1 EXECUTIVE SUMMARY
Oxygen Gas Manufacturing Unit is a project of chemicals industry. The proposed unit
would produce gaseous oxygen for medical and industrial use. The project is
proposed to be set up in Lahore. Oxygen is used in hospitals, chemical processes,
general engineering, fabrication, steel manufacturing, motorcycle and steel cutting /
welding industries.
Oxygen has mainly three sectors in which the application of this product is going on.
First and most important is healthcare, all hospitals are involved in this respect. The
second biggest sector concerned with oxygen is the ship-breaking industry, which has
a potential usage for oxygen. The third sector is that of the processes industry, which
includes steel melting. These three sectors are very lively all over Pakistan at present.
With the growing steel, ship breaking and related industries as well as the growing
need of hospitals, the demand for oxygen is increasing, offering a good investment
opportunity.
The total initial cost for setting up the unit is estimated at Rs. 99.325 million. The
project is proposed to be financed through 50% debt and 50% equity. The project
NPV is projected around Rs. 74.382 million, with an IRR of 29% and a payback
period of 4.65 years. The legal business status of this project is proposed as ‘Sole
Proprietorship’.
The total capacity of the Oxygen Manufacturing unit is 2,160,000 m3 of Gaseous
Oxygen per year. The project would initially run at 50% production capacity in year 1
and eventually reach 100% production capacity in year 6. The unit would operate for
24 hours per day at 100% capacity, working in 3 shifts of 8 hours each.
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2 INTRODUCTION TO SMEDA
The Small and Medium Enterprises Development Authority (SMEDA) was
established with an objective to provide fresh impetus to the economy through the
launch of an aggressive SME support program.
Since its inception in October 1998, SMEDA had adopted a sectoral SME
development approach. A few priority sectors were selected on the criterion of SME
presence. In depth research was conducted and comprehensive development plans
were formulated after identification of impediments and retardants. The all-
encompassing sectoral development strategy involved recommending changes in the
regulatory environment by taking into consideration other important aspects including
finance, marketing, technology and human resource development.
SMEDA has so far successfully formulated strategies for industries such as
horticulture, including export of fruits and vegetables, marble and granite, gems and
jewellery, marine fisheries, leather and footwear, textiles, surgical instruments,
transport, dairy etc. Whereas the task of SME development at a broader scale still
requires more coverage and enhanced reach in terms of SMEDA’s areas of operation.
Along with the sectoral focus a broad spectrum of business development services is
also offered to the SMEs by SMEDA. These services include identification of viable
business opportunities for potential SME investors. In order to facilitate these
investors, SMEDA provides business guidance through its help desk services as well
as development of project specific documents. These documents consist of
information required to make well-researched investment decisions. Pre-feasibility
studies and business plan development are some of the services provided to enhance
the capacity of individual SMEs to exploit viable business opportunities in a better
way.
This document is in continuation of this effort to enable potential investors to make
well-informed investment decisions.
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This report is based on the information obtained from industry sources as well as
discussions with businessmen. In the financial model, since forecast/projections relate
to the future periods, actual results are likely to differ because of events and
circumstances that do not occur as expected.
4 PROJECT PROFILE
4.1 Opportunity Rationale
Oxygen gas comprises 21 percent of atmospheric gas. Its symbol is O2. Atomic
weight of oxygen is 16 and atomic no. is 8. Oxygen gas is non metallic element.
Oxygen is colourless, odourless and tasteless. Oxygen reacts with all elements, but
not with inert gases to form compound called oxides. Oxygen support combustion
and support flammable materials to burn more rapidly. And this combustion
supporting property prefers it for different industrial applications.
Atmospheric air is used to produce Oxygen and Nitrogen, in most industrial
processes. Atmospheric air mainly contains the elements given in the table below.
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free saturated air sucked from the atmosphere. The process adopted to produce
oxygen and nitrogen is called liquefaction and fractional distillation of air.
The unit would produce 300m3 per hour of gaseous oxygen. The plant is proposed to
operate for 24 hours per day at 100% capacity, working in 3 shifts of 8 hours each.
5.1 Strengths
Continuous availability of and easy access to raw material, i.e. free
atmospheric air.
Availability of Skilled and Unskilled labour.
Latest technology oxygen producing plant with high working efficiency and
trouble free operations, safety and low power consumption.
Oxygen manufacturing plant is simple to operate.
Easy availability of spare parts.
Latest molecular sieve technology with out recurring cost of chemicals. About
3% of nitrogen gas is used for the regeneration of the molecular sieve battery
and nitrogen cascade cooler
5.2 Weaknesses
The big players in Oxygen Gas manufacturing business have already captured
a major part of the market share. Therefore, the project would require strong
promotional strategies and some orders already available.
The process is completely automated and requires technical expertise of
machine operators on a continuous basis.
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5.3 Opportunities
With the growing industrial and medical sector the demand for Oxygen gas is
also likely to grow.
Provisions can also be made for tapping up to 25% liquid oxygen / liquid
nitrogen simultaneously with gaseous oxygen, at an additional cost.
High purity Nitrogen of up to 2 PPM can also be tapped simultaneously with a
separate liquid Nitrogen pump in modified plants, at an additional cost.
5.4 Threats
In case of the power failure to the engine its braking mechanism will fail and
this accelerating speed of the machine.
The fire extinguisher should be installed and smoking should be banned near
the production area as the out of the project is very sensitive and highly
flammable.
7 MARKET ANALYSIS
7.1 Major Players
Major players in the oxygen manufacturing industry are located in Lahore and
Karachi. Major players are as below:
1. Linde Industrial Gases (BOC)
2. Ghani Gases Limited
3. Fine Gas Company Limited
4. Medi Gas Private Limited
5. Sultan Oxygen
6. National Gases Limited
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8 PRODUCTION PROCESS
Free atmospheric air is sucked in by a multi-stage air compressor through a filter and
compressed to the working pressure. After each stage, intermediate coolers and water
separators are provided. The compressed air then passes through the (evaporation)
pre-cooler and then to the molecular sieve battery where the moisture and carbon
dioxide are removed from the process air. It then passes through the exchanger No. 1
where it is cooled by the out-going waste nitrogen and product oxygen.
A part of this cold air then flows through an expansion machine and the balance
through the 2nd heat exchanger. The ratio of the two air streams is controlled by an
expansion valve, RI.
Both these streams of air then unite in the lower pressure column where it partially
liquefies.
The liquid air (rich air) then passes through the expansion valve R2 to the upper
column which is at a lower pressure than the lower column. Similarly the liquid
nitrogen (poor liquid) travels from the lower column to the upper column through an
expansion valve R3 where the separation of oxygen and nitrogen occurs. Nitrogen
being more volatile passes out as a gas from the top of the column and this waste
nitrogen flows through both the heat exchangers cooling the in-coming air. Similarly
product oxygen is also passed through the two heat exchangers to cool the in-coming
air and then to the filling manifold via a liquid pump. If a small amount of air is
vented out from the upper column, higher purity nitrogen can also be obtained from
this plant. R4 Valve is provided in order to fasten cooling during start-up.
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Figure 8-2: 300 m3/hr ASU & Expansion Engine and M.S.B
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is designed in accordance with the plant size and the liquid produced is constantly
pumped off.
The drive unit is similar to any reciprocating machine with the Crank Shaft,
Flywheel, Connecting Rod, Cross Head, etc.
The Liquid Oxygen Pump consists of a stainless steel inside liner with liquid inlet and
evaporated gas outlet ports. There are no valves on these ports, which are closed by
the piston itself on the pressure stroke. The third outlet is the main discharge outlet
with the two non-return ball valves. The two ball valves remain firmly closed during
suction stroke, due to high pressure in partly filled cylinders. To ensure that these
valves are fully closed, a positive pressure of about 60 kgs/cm2 must be maintained
on it. When a fresh batch of cylinders is taken for filling, open the manifold valve
slowly or use a spare batch of cylinders to ensure positive pressure on these valves.
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3 AFTER COOLER: 1
MS Cooler consisting of MS Vessel submerged in cold
circulating water
4 MOISTURE SEPARATORS: 2
This is a Capsule shaped Vessel made of MS Duly fitted
with Drain Valves for removal of moisture present in the
process air.
5 CASCADE COOLER: 1
This is a specially designed container consisting of MS
Coils in two separate chambers. The process air that passes
through this Cooler is cooled through incoming Nitrogen
from the ASU. These coils are immersed in water with a
provision for water level indicator.
6 CHILLING UNIT: 1
This is a Refrigerant based cooling unit. The refrigerant is
expanded in the copper coil installed between the air coils
for bringing down the air temperature between 8 Deg. C to
10 Deg. C. The temperature mentioned is required for the
efficient working of the Molecular Sieve Battery enhances
the life of the Molecular Sieve which is expensive.
7 ACTIVATED CARBON FILTER: 1
This equipment is made of MS Capsule shaped Vessel with
activated Carbon with 2 Nos. Sand Filters inside. This
assists absorption of Hydro-Carbons in the Process Air.
8 CERAMIC FILTERS : 2
This equipment is made of MS and is Cylindrical in shape.
It consists of micro ceramic filter to avoid entry of dust to
the ASU.
9 MOLECULAR SIEVE BATTERY: 1
This consists of 2 Nos. MS Vessels interconnected pipelines
of Nitrogen and Air, Electric Heater for regeneration,
Temperature Sensor and Control Panel with automatic
Temperature control. This assist in the removal of moisture
carbon-dioxide, traces of Acetylene and other Hydro-
Carbons present in the process air.
10 AIR SEPARATION UNIT: 1
For liquefaction and partial distillation of Air. This unit
consists of lower and upper column with a Condenser in
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Table 9-2 gives details of Oxygen gas cylinders proposed for the unit.
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Table 9-3 gives total machinery and equipment cost, installation charges and freight
costs.
10 MANPOWER REQUIREMENTS
The Oxygen Manufacturing Plant is assumed to operate for 24 hours daily at 100%
capacity; working in 3 shifts of 8 hours each. Production capacity utilized in year 1 is
around 50%. The plant would run for 12 hours at 50% capacity. The production staff
hired shift wise would be increased according to the number of operational hours.
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12 VEHICLE
Vehicle requirement for the project is given in the table below for delivery of oxygen
cylinders. Motorbikes would be provided to the sales officer for sales calls.
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14 PROJECT ECONOMICS
The total project cost is estimated around Rs. 99.325 million. The capital cost is
estimated around Rs. 98.704 million and working capital of Rs. 0.620 million. The
total cost, project returns and financial plan are given in the tables below:
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Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Production capacity (units) 2,160,000 2,160,000 2,160,000 2,160,000 2,160,000 2,160,000 2,160,000 2,160,000 2,160,000 2,160,000
Starting capacity utilization 50% 50% 50% 50% 50% 50% 50% 50% 50% 50%
Capacity utilization growth rate 10% 10% 10% 10% 10% 10% 10% 10% 10%
Capacity utilization for the year 50% 60% 70% 80% 90% 100% 100% 100% 100% 100%
Production per year 1,080,000 1,296,000 1,512,000 1,728,000 1,944,000 2,160,000 2,160,000 2,160,000 2,160,000 2,160,000
Production quantity sold 1,035,000 1,287,000 1,503,000 1,719,000 1,935,000 2,151,000 2,160,000 2,160,000 2,160,000 2,160,000
Production quantity in finished goods inventory 45,000 54,000 63,000 72,000 81,000 90,000 90,000 90,000 90,000 90,000
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Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Revenue 40,365,000 56,216,160 73,529,165 94,187,778 118,745,639 147,841,081 166,274,823 186,227,802 208,575,138 233,604,155
Cost of sales
Transportation costs 618,750 680,625 748,688 823,556 905,912 996,503 1,096,153 1,205,769 1,326,346 1,458,980
Direct labor 1,863,000 2,542,147 3,257,848 4,088,815 5,050,707 6,161,144 6,789,290 7,450,305 8,175,677 8,971,673
Machinery maintenance 1,136,523 1,193,349 1,253,017 1,315,667 1,381,451 1,450,523 1,523,050 1,599,202 1,679,162 1,763,120
Direct electricity 13,500,000 17,820,000 22,869,000 30,546,450 39,530,700 50,006,336 55,006,969 60,507,666 66,558,433 73,214,276
Generator expense 6,041,700 7,975,044 10,234,640 8,845,653 7,076,522 4,865,109 5,351,620 5,886,782 6,475,460 7,123,006
Direct water 96,000 105,600 116,160 127,776 140,554 154,609 170,070 187,077 205,785 226,363
Direct gas
Total cost of sales 23,255,973 30,316,766 38,479,352 45,747,917 54,085,846 63,634,224 69,937,152 76,836,801 84,420,862 92,757,418
Gross Profit 17,109,027 25,899,394 35,049,813 48,439,861 64,659,792 84,206,858 96,337,671 109,391,001 124,154,276 140,846,736
Other income (interest on cash) 26,289 - 310,698 1,756,357 4,420,630 8,811,831 15,217,309 23,053,149 32,469,011 43,710,203
Gain / (loss) on sale of machinery & equipment - - - - - - - - -
Gain / (loss) on sale of office equipment - - 274,500 - - 455,018 - - 595,365
Gain / (loss) on sale of office vehicles - - - - - - - - -
Earnings Before Interest & Taxes (223,696) 7,618,547 16,346,109 30,225,539 47,968,184 71,740,277 88,536,144 108,050,963 131,315,840 156,963,446
Tax - 29,987 2,718,869 6,668,833 11,619,795 17,928,031 22,129,331 27,010,792 32,828,960 39,240,862
NET PROFIT/(LOSS) AFTER TAX (8,493,007) 369,840 8,156,608 20,006,499 34,859,386 53,784,093 66,387,993 81,032,375 98,486,880 117,722,585
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Year 0 Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Assets
Current assets
Cash & Bank 525,781 - - 6,213,961 28,913,169 59,499,438 116,737,174 187,609,013 273,453,977 375,926,250 498,277,816
Accounts receivable 3,317,671 3,969,089 5,332,000 6,892,477 8,750,688 10,955,619 12,908,873 14,486,409 16,224,778 18,171,752
Finished goods inventory 1,011,129 1,272,032 1,612,907 1,916,143 2,264,059 2,662,520 2,914,048 3,201,533 3,517,536 3,864,892
Equipment spare part inventory 94,710 99,446 104,418 109,639 115,121 120,877 126,921 133,267 139,930 146,927 -
Total Current Assets 620,492 4,428,246 5,345,539 13,268,507 37,836,910 70,635,062 130,482,233 203,565,200 291,281,850 395,815,491 520,314,460
Fixed assets
Land 4,000,000 4,000,000 4,000,000 4,000,000 4,000,000 4,000,000 4,000,000 4,000,000 4,000,000 4,000,000 4,000,000
Building/Infrastructure 13,207,500 12,547,125 11,886,750 11,226,375 10,566,000 9,905,625 9,245,250 8,584,875 7,924,500 7,264,125 6,603,750
Machinery & equipment 75,768,200 68,191,380 60,614,560 53,037,740 45,460,920 37,884,100 30,307,280 22,730,460 15,153,640 7,576,820 -
Furniture & fixtures 718,000 646,200 574,400 502,600 430,800 359,000 287,200 215,400 143,600 71,800 -
Office vehicles 1,301,920 1,171,728 1,041,536 911,344 781,152 650,960 520,768 390,576 260,384 130,192 -
Office equipment 457,500 305,000 152,500 529,613 353,076 176,538 613,094 408,729 204,365 709,733 473,155
Total Fixed Assets 95,453,120 86,861,433 78,269,746 70,207,672 61,591,947 52,976,222 44,973,591 36,330,040 27,686,488 19,752,669 11,076,905
Intangible assets
Pre-operation costs 3,201,609 2,561,287 1,920,965 1,280,644 640,322 - - - - - -
Legal, licensing, & training costs 50,000 40,000 30,000 20,000 10,000 - - - - - -
Total Intangible Assets 3,251,609 2,601,287 1,950,965 1,300,644 650,322 - - - - - -
TOTAL ASSETS 99,325,220 93,890,966 85,566,250 84,776,822 100,079,179 123,611,284 175,455,825 239,895,240 318,968,338 415,568,160 531,391,364
Other liabilities
Deferred tax - 29,987 2,748,856 9,417,689 11,524,307 9,630,102 7,735,897 5,841,692 3,947,487 2,053,282
Long term debt (Project Loan) 49,352,364 42,469,594 34,340,025 25,002,610 13,624,035 184,256 132,734 71,879 - - -
Long term securities against cylinders 6,952,500 6,952,500 6,952,500 6,952,500 6,952,500 6,952,500 6,952,500 6,952,500 6,952,500 6,952,500
Long term debt (Working Capital Loan) 310,246 - - - - - - - - - -
Total Long Term Liabilities 49,662,610 49,422,094 41,322,512 34,703,966 29,994,224 18,661,063 16,715,336 14,760,276 12,794,192 10,899,987 9,005,782
Shareholders' equity
Paid-up capital 49,662,610 49,662,610 49,662,610 49,927,417 49,927,417 49,927,417 49,927,417 49,927,417 49,927,417 49,927,417 49,927,417
Retained earnings (8,493,007) (8,123,167) 33,441 20,039,939 54,899,325 108,683,419 175,071,412 256,103,787 354,590,667 472,313,252
Total Equity 49,662,610 41,169,603 41,539,443 49,960,857 69,967,356 104,826,742 158,610,836 224,998,828 306,031,204 404,518,084 522,240,668
TOTAL CAPITAL AND LIABILITIES 99,325,220 93,890,966 85,566,250 84,776,822 100,079,179 123,611,284 175,455,825 239,895,240 318,968,338 415,568,160 531,391,364
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Year 0 Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
Operating activities
Net profit (8,493,007) 369,840 8,156,608 20,006,499 34,859,386 53,784,093 66,387,993 81,032,375 98,486,880 117,722,585
Add: depreciation expense 8,591,687 8,591,687 8,591,687 8,615,725 8,615,725 8,615,725 8,643,552 8,643,552 8,643,552 8,675,765
amortization of pre-operating costs 640,322 640,322 640,322 640,322 640,322 - - - - -
amortization of training costs 10,000 10,000 10,000 10,000 10,000 - - - - -
Deferred income tax - 29,987 2,718,869 6,668,833 2,106,618 (1,894,205) (1,894,205) (1,894,205) (1,894,205) (1,894,205)
Accounts receivable (3,317,671) (651,418) (1,362,911) (1,560,477) (1,858,211) (2,204,930) (1,953,254) (1,577,536) (1,738,369) (1,946,973)
Finished goods inventory (1,011,129) (260,903) (340,875) (303,236) (347,916) (398,461) (251,528) (287,485) (316,003) (347,356)
Equipment inventory (94,710) (4,736) (4,972) (5,221) (5,482) (5,756) (6,044) (6,346) (6,663) (6,997) 146,927
Accounts payable 101,586 5,079 5,333 5,600 5,880 6,174 6,483 6,807 7,147 (5,175)
Other liabilities 6,952,500 - - - - - - - - -
Cash provided by operations (94,710) 3,469,552 8,729,623 18,413,812 34,077,783 44,026,048 57,902,352 70,932,694 85,916,843 103,182,005 122,351,566
Financing activities
Project Loan - principal repayment (6,882,770) (8,129,569) (9,602,223) (11,378,575) (13,439,779) (51,522) (60,855) (71,879) - -
Working Capital Loan - principal repayment (310,246) - - - - - - - - -
Short term debt principal repayment - (3,197,683) (2,597,629) - - - - - - -
Additions to Project Loan 49,352,364 - - 264,807 - - - - - - -
Additions to Working Capital Loan 310,246 - - - - - - - - - -
Issuance of shares 49,662,610 - - 264,807 - - - - - - -
Cash provided by / (used for) financing activities 99,325,220 (7,193,016) (11,327,251) (11,670,238) (11,378,575) (13,439,779) (51,522) (60,855) (71,879) - -
Investing activities
Capital expenditure (98,704,729) - - (529,613) - - (613,094) - - (709,733) -
Acquisitions
Cash (used for) / provided by investing activities (98,704,729) - - (529,613) - - (613,094) - - (709,733) -
NET CASH 525,781 (3,723,464) (2,597,629) 6,213,961 22,699,208 30,586,269 57,237,736 70,871,839 85,844,965 102,472,273 122,351,566
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15 KEY ASSUMPTIONS
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16 ANNEXURE
16.1 Machinery Suppliers
Company Name: Sanghi Overseas
Address: 1-2 Turf view, Opp. Nehru Centre, Seth M.G.Sanghi Marg,
Worli
City/Country: Mumbai – 400018, India
Tel: +91-22-24945464
Email: [email protected]
Website: www.sanghioverseas.com
Company Name: ING. L&A. Boschi
Address: Okhla Industrial Area
City/Country: New Delhi – 110020, India
Tel: +91-124-4386250,
+91-124-6519863,(International calls only)
Email: [email protected]; [email protected]
Website: www.universalboschi.com
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