BURMA. FEASIBILITY STUDY FOR A PLASTIC APPLIANCES EXTRUSION DEMONSTRATION ...

334 Pages·2005·9.01 MB·English

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CONSULT ING ENGINEERS
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I UNITED NATIONS INDUSTRIAL DEVELOPl'ENT
ORGANIZATION
ACTING AS EXECUTING AGENT FOR THE
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UNITED NATIONS DEVELOPPIENT PR06RAl'l'IE
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FEASIBILITY STUDY FOR A PLASTIC APPLIANCES
EXTRUSION C>Ef'DllSTRATION UNIT
IN TIE SOCIALIST REPLllLIC OF TIE UNION DF BURl'IA
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UNIDO PRD.JECT DP /Blft/80/015
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FINAL REPORT
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PREPARt;t> BY BALDO & C.
I CONSlLTINS ENSIIEERS
rlILAN, ITALY
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APRIL 1987
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CONSUL TING ENGINEEilS
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INDEX
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Page
I 1. EXECUTIVE SUHMRR~ 1
2. PROJECT BAC~GROUNO ANO HISTORY 13
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16
3.1 OE MANO RHO MRRKET 16
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3 -i - 1 users of olastic: pioi:s ana aooliances 16
3 -, -2 Anal vs is of past ano preser.t demand 1i
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3 - ,_ 3 Forecast aemana for olastic oioes ana 26
latrine pans
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3.2 PRODUCTION PROGRAM RNO SRLES FORECAST 45
3.2.1 Plastic: oioes for water aistriDution 45
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3.2.2 Plastic: casing for tuDe wells 62
I 3.2.3 Latrine Pans ana related accessories 64
3.2.~ uPvC fittinos 66
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3.2.5 Total revenues for the unit 68
I 4. MRTERIALS ANO INPUTS 69
4.1 OURLITATIVE SPECIFICATIONS OF FEEUSTOCK 69
I RESINS RNO OTiiER MATERIRLS
4.1.1 PVC for oioe e•trusion 6:,
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~.1.2 Hign Oensitv Polv~tnvlene for 70
extrusion
I 4.1.3 High Densitv Polvethvlene for injection 71
moulaino
4.1.~ PVC for In1ection Moulding 73
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4.1.5 Raaitives 73
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CONS•JlTING ENGINEERS
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4.2 CONSUMPTION COEFFICIENTS
73
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-t.2.1 uPVC cioes
73
I .;.z.2 HOPE oioes 76
-t.2.3 Latrine oans ana acc~ssories 76
I 4.2.4 PVC Fittinas 79
Factorv Suoolies
.;.~.5 79
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4.Z.6 Total reouirements for raw_~aterials 60
.;.3 SOURCE OF SUPPLY 61
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4.4 RRW MRTERIRL PRICES
I .; . 4 .1 PVC 64
4.4.Z Hian Oensitv Polvetnvlene. 65
extrusion graae
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4.4.3 Hian Densitv Polvetnvlene. 65
injection graae
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4.4.4 Raditives and otner suppliers 6&
4.5 SUPPLY PROGRRM OF THE RRW MRTERIRLS,
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PROCESS MRTERIRLS RNO SUPPLIES. 67
4.5.1 Supoly program 6i
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4.5.2 Raw material store 66
I 4.6 SPECIFICRTION OF OURLITY RN'O CONSUMPTION 68
FIGURES FOR urlLITIES
4.6.1 Electric oower consumotion 88
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4.6.2 Compressed air 90
I 4.6.3 Cooli~J water 90
4.7 EVRLURTION OF THE COST OF MRTERIRL RNO 90
INflUTS
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.;.7.1 uPVC pioes 90
I 4.7.Z uPVC tuoe Wfll casinos ana scrrens 91
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CONSUl.TING ENGINEEllS
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4.7.3 HOPE oioes
91
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4.7.4 Latrine oans ana accessories
91
4.7.5 uPVC fittinos
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5. LOCRTION RNO SITE
92
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6. PROJECT ENGINEERING
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6.1 SCOPE OF THE PROJECT
6.2 TECHNOLOGY RNO EQUIPMENT
95
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6.2.1 Selection ana aescriotion of ootimum
tecnnoloaies
95
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6.2.2 Soecifications of major Plant 111
eauioment
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6.2.3 Summarv of main oroauction eouioment
145
ana maior ancillarv ana service olant
I 6.2.4 Civil works
146
6.2.5 Estimate & allowance of soare p~rts &
consumable
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6.2.6 Foreion technical assistance
150
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i. f.bfil::!T ORGRNIZRTION RNO OVERHERO COSTS 151
6. MRNPOWER
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6. 1 GE.NERJ.'.IL
152
I 6.2 ORGRN I ZRT ION CHRRT
155
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6.3 TOTRL LRBOR COSTS
156
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6.4 LRBOP. cos rs OIVIOEO IN DIRECT RNO INOIREC1
COSTS
157
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6 .... 1 Rnnual Direct Lao or CO.l.U, 157
6 .... 2 Rnnual Indir~q !,;!}Dor !;Q~t s 157
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&.5 PRE-PRODUCTION ST8FF
157
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CONSULTING ENGINEERS
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~- lMFLEMENlATIGN SCHEDULE 15~
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?O. Fl~OHCl~L ~NO E~ONO~IC EVALUATIQ~ 1 0. I
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10.1 FINANCIAL EVALUATION 15 1
10.1.1 lnout o~ta !or tne i1nanc1ai evatuar.ion 1&5
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10.1.2 Confar scr.eaules lbb
10.Z RLiERNATES ANO SENSITIVIT' RNHLYSIS
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10.3 BREA~ EVEN FGINl 21e
I PROFITASILITY
10.~ N~TIONAL
lu.~.1 Price MC1ustm~nt 21S
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1c.~., Economic Intlrnal ~ate of ~eturn 2ZO
10.4.3 value aaoec
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zzz
RDsolute efficiencv
lG.~.4 t~si
I lo.~.s Net foreicn - excnanoe effect 223
10.4.& Otner consiaerations 225
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11. THE IHPRCT OF THE PROJECT IHPLc"ENTRTION ON
THE ACHIEVEMENT OF THE IOWSS OBJECTIVES ZZ6
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12. NOTES ON THE PROJECT FINANCING
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'4 f-4 r~ E >. E S
I 1. H SHOR1 SURVE' OF THE PLASTIC INOuSTRY IN BURMA
2. PRESENTATION ANO CHRRRCTERISTICS OF PLRSTIC PIPES
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3. JNiERNATIONRL STANORRO 1501161/l
OUTPUT TRSLES
~. CONF~R
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5. COSl OF PRODUCTION
6. BIBLlOGRAPHt
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7. LIST OF L~BORRTORY EQUIPMENT
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1. EXECUTIVE su""ARY
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Tne Sociali5t Republic of the union of Burma is giving
I high priority in raising tne standard of living oi its
population. An ambitious program hereinafter referred to
as IDWSSO (1j is underway with tne aim to proviae saie
water to all inhabitants of the UNION by year 2000.
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Within IOWSSD program the use of plastic pioes and other
plastic is of topic importance. In fact
applianc~s
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extruded plastic pipes can replace in Large extent tne
galvanized iron, and other materials because less
expensive, lighter and thereiore easier to transport ano
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The possibility of producing in Burma the Large Quantity
of plastic pipes and other plastic appliances neeaed to
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the IOWSSO program have been studied by an
f~lfill
UNIDO assisted Project Office established in 1984 under
tne control of the industrial Planning Department of the
I Ministry of no.1 Industry.
It was decided to proceed with the feasibility stuay for
tne establisnment o! a •demonstration unit• that snoula
include:
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- plastic pipes extrusion line ls>
- injection moulding machine (s;
- a well equipped quality control and testing
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This aemonstration unit should be the first step toward
the establishment of a number of plastic pipes factories
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to fulfill the of the Country needs and its main
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goats should be:
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- to proauce a wiae of plastic pipes, in size
~ ra~ge
ana characteristics, to fit various applications ana
therefore test the market.
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to prove that plastic pipes can be usea in most oi
tne applications for water supply unaer tne
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prevailing conditions in the country.
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C1> 1.0.W.S.S.O: International drinking water and
sup~Ly
sanitation decade
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CONSUi. TING ENGWtEEAS
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C - to identify the characteristics (size, material,
thickness, etc) of the most widely used pipPs so I
that the future production plants can be optimized
(witn conseauent savings).
G - to train a core of production and maintenance
engineers/technicians that will be very useful in
cas~ large scale production •ill be later attained
by establishing otner units
E - tG proviae, by means· of a very well eQuip~ed
laboratory, a careful quality control of the output
be sure that it meets with internationol quality
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stanaards. The laboratory can De also important for
tne following additional tasks:
- to test types of pipes not considered in the
original production mix (for instance to meet with
reauirements for new applications, to modify
tnicknP.ss of walls to meet with local operating
conditions etc>. This would increase the
flexibility of the deinonstration unit and ·ec:tuip it
better for its preparatory and experimental tasks
- to carry out quality control tests on both raw
material and finished products of other plastic
industries in Burma
- to train laboratory personnel for other plastic
inaustries already operating in the country or
_which may be established in the future.
It has been stated that one of the targets of the
demonstration unit i~ to test the market; that is to
identify the kind of applications plastic pipes are
suitable to specify requirea characteris:ics must be
identified in oraer to select the equipment to be
installed in the demonstration unit. Therefore a
comprehensive market/applications survey has been
carriea out by the team.
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From this study it appears that the forecast demand for
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plastic pipes for water supply and sanitation program in
the decade 1991-2000 is in the range of:
I 4,600 tons/year (!.ow projection>
S,500 tons/yec:r (high projection>
subdivided as follows:
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I I HOPE PVC I
I I <tons/year> I (tans/year> I
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I Rural Water Supply I 1,400 (1) I
or 90
I 2,214 (2)
Urban Water Supply 135 2,677
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Private Sector 105 '45
Public Buildings 62 &6
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Environ•ental & Sanitation 19 19
I Irrigation 25
TOTAL 1,721 (1) I
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or I 2,942
2,535 (2) I
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I Tolal Plastic Pipes Demand: 4,663 tons/year Clow> I
I 5,477 tons/year ChiQh) I
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I (1) Note: (1) Low projectjon - C2> High projection
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CONSUlTING ENGINEERS
Only one factory (the plastic iactory n.2) is presently
involved in olastic pipes production in Burma. The
production capacity is in the range of 200-250 tons/year
uPVC water supply pipes. Its equipment are obsolete and
it can only satisfy a minor portion of the present and
iuture
a~mana.
Rt present all plastic pipes needed for lOWSSD,
irrigation, sanitation ana for other public schemes are
importea either by the executing agency or directly by
the donors CUNICEF~ etc).
It is obvious that only the establishment of several
pipes factories <scattered in the country in order to
decrease the transport costs) can satisfy the large
quantity of pipes and other appliances neeaed.
Tne market survey has also indicated that the pipes
should De made in both High Density Polyethylene and
unplasticized Polyvinyl Chloride are the two most
w~icn
commonly used raw material for this kind of
applications.
The pipes types that should be produced are shown in the
following table.