Publication: ESTUDIO TÉCNICO-ECONÓMICO PARA ADQUISICIÓN DE NUEVA CALDERA PARA PLANTA DE PRODUCCIÓN DE EMPRESA CIAL ALIMENTOS
Date
2017
Authors
HADDAD OSORIO, JORGE IGNACIO
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Abstract
Este trabajo fue realizado con el fin de satisfacer la petición de la empresa CIAL Alimentos en realizar estudio sobre la factibilidad técnica y económica de la adquisición de una nueva caldera de vapor para la operación de su planta N¿1, la cual está ubicada en Américo Vespucio 2341, Pudahuel, Santiago.La principal problemática a resolver es la confiabilidad y eficiencia de su operación con vapor, la cual es el principal suministro energético para su producción de cecinas y embutidos. Actualmente de sus dos calderas, la empresa desea reemplazar la más pequeña y antigua por una que cubra todo el consumo de vapor a corto plazo, y a un horizonte de al menos 20 años de plazo.Mediante un exhaustivo y limitado levantamiento de información y datos de consumos, debido a falta de tecnología y herramientas en los equipos, además de cálculos estimativos y análisis varios, se logró estimar el consumo de vapor actual de la planta de forma mensual y en forma de perfil de consumo por hora. Para esto se tomó la información del agua de entrada al sistema de calderas y se calculó la purga promedio, obteniéndose un 16%. En cuanto al máximo y mínimo de consumo de vapor por hora se estimaron 13.5 y 1.7 [ton/hr], respectivamente, y un consumo promedio mensual de 4,385 [ton/mes] de vapor con una eficiencia global del sistema promedio del 79%. Sobre estos cálculos obtenidos como base, se aplicó una tasa de crecimiento estimada de consumo de vapor de un 2% anual, lo cual se traduce en la necesidad de una caldera con capacidad de 19.5 a 20 [ton/hr] para cubrir la demanda actual y futura de la planta.La evaluación técnica, permitió levantar los requerimientos y características mínimas para que los proveedores pudiesen enviar sus ofertas de calderas. El estudio conllevó a que debido a las características de la sala de calderas, el tipo de combustible habilitado, emisiones de NOX máximas y condiciones de trabajo, la caldera deber ser de tipo pirotubular, trabajar a presión media de 7 [bar], tener una eficiencia de al menos 90%, tener opción de uso de gas natural y petróleo como segunda opción, y además tener ciertos extras para mejor operación de los caldereros y control de la eficiencia tales como; economizador, medidores de flujos de vapor, de agua, de purga, de combustible y purgas automáticas.La evaluación económica, se basó en el cálculo del costo de la tonelada de vapor de agua actual, el cual es de $23,567, de lo que $21,321 corresponde solo al gas natural (+90%). Por el gran impacto, el gas natural se tomó como base de comparación para los beneficios del cambio de caldera y los flujos para la evaluación. Después de estimar el costo de la tonelada de vapor de las opciones disponibles, estimar el ahorro respecto a situación actual y generar los flujos futuros dado el consumo de vapor actual y a largo plazo, se concluyó que la caldera que cumple con todos los requisitos técnicos y económicos de sobre manera, es la caldera Bosch UL-S 18000. Esta opción de proyecto posee el mayor VAN de $1,307,227,703, una TIR de 42% (tasa de descuento de 7%) y el payback más bajo siendo este de 34 meses. Además, es la opción con mayor flexibilidad a la fluctuación del precio del gas natural, la cual podría elevarse hasta $33 más por metro cúbico (12% de variación), y aún sigue siendo rentable.
This work was carried out in order to satisfy the request of CIAL Alimentos company, to perform a study on technical and economic feasibility of acquiring a new water steam boiler for the operation of its production plant, which is located in Americo Vespucio 2341, Pudahuel, Santiago.The main problem to solve, is the reliability and efficiency of its operation with water steam, which is the main energy supply for its production of sausages. Currently, the company wants to replace the smallest and oldest steam boiler with one that would cover all steam consumption within short term and for at least a 20-years-term.Despite going through a limited data gathering due to the lack of technology and tools in the equipment, which involved several estimates and various analyzes, it was possible to estimate the current steam consumption of the plant on a monthly basis and hourly basis as a consumption profile. In order to do that, it was necessary to take data from the incoming water to the boiler system and calculate an estimated blowdown percentage, which was 16%. The maximum and minimum steam consumption per hour was estimated at 13.5 and 1.7 [ton / hr], respectively, and an average monthly consumption of 4,385 [ton / month] of steam, with an overall system efficiency of 79%. Based on these calculations, an estimated annual steam consumption growth rate of 2% was applied, which translates into the need for a boiler with a capacity from 19.5 up to 20 [ton / hr] to cover current and future demand of the plant.The technical evaluation allowed to raise the minimum requirements and characteristics so that the suppliers could send their offers of boilers. The study led to the fact that due to the characteristics of the boiler room, the type of fuel enabled, maximum NOx emissions and working conditions, the boiler must be fire-tube type, works at an average pressure of 7 [bar], have an efficiency of at least 90%, have the option of using natural gas and oil as spare, and also have certain extras for better operation of employees and efficiency control. The extras must be economizer, inlet and outlet water flowmeter, steam flowmeter, fuel flowmeter and automatic blowdown.The economic evaluation is based on the estimated cost of the current ton of steam, which is $ 23,567, where $ 21,321 corresponds to natural gas (more than 90%). Given the great impact, natural gas was taken as the basis of comparison for the benefits of the boiler change and the flows for the evaluation. After estimating the cost of the ton of steam of the available options, estimating the savings with respect to the current situation, and generating the future flows given the current and long-term vapor consumption, it is concluded that the boiler that meets all the technical and economic requirements of over, is the Bosch UL-S 18000 boiler. This project option has the largest NPV which is $ 1,307,227,703, a 42% IRR (7% as discount rate) and the lowest payback being this 34 months. In addition, it is the option with greater flexibility to the fluctuation of the price of natural gas, which could rise up to $ 33 more per cubic meter (12% variation), and still remains profitable.
This work was carried out in order to satisfy the request of CIAL Alimentos company, to perform a study on technical and economic feasibility of acquiring a new water steam boiler for the operation of its production plant, which is located in Americo Vespucio 2341, Pudahuel, Santiago.The main problem to solve, is the reliability and efficiency of its operation with water steam, which is the main energy supply for its production of sausages. Currently, the company wants to replace the smallest and oldest steam boiler with one that would cover all steam consumption within short term and for at least a 20-years-term.Despite going through a limited data gathering due to the lack of technology and tools in the equipment, which involved several estimates and various analyzes, it was possible to estimate the current steam consumption of the plant on a monthly basis and hourly basis as a consumption profile. In order to do that, it was necessary to take data from the incoming water to the boiler system and calculate an estimated blowdown percentage, which was 16%. The maximum and minimum steam consumption per hour was estimated at 13.5 and 1.7 [ton / hr], respectively, and an average monthly consumption of 4,385 [ton / month] of steam, with an overall system efficiency of 79%. Based on these calculations, an estimated annual steam consumption growth rate of 2% was applied, which translates into the need for a boiler with a capacity from 19.5 up to 20 [ton / hr] to cover current and future demand of the plant.The technical evaluation allowed to raise the minimum requirements and characteristics so that the suppliers could send their offers of boilers. The study led to the fact that due to the characteristics of the boiler room, the type of fuel enabled, maximum NOx emissions and working conditions, the boiler must be fire-tube type, works at an average pressure of 7 [bar], have an efficiency of at least 90%, have the option of using natural gas and oil as spare, and also have certain extras for better operation of employees and efficiency control. The extras must be economizer, inlet and outlet water flowmeter, steam flowmeter, fuel flowmeter and automatic blowdown.The economic evaluation is based on the estimated cost of the current ton of steam, which is $ 23,567, where $ 21,321 corresponds to natural gas (more than 90%). Given the great impact, natural gas was taken as the basis of comparison for the benefits of the boiler change and the flows for the evaluation. After estimating the cost of the ton of steam of the available options, estimating the savings with respect to the current situation, and generating the future flows given the current and long-term vapor consumption, it is concluded that the boiler that meets all the technical and economic requirements of over, is the Bosch UL-S 18000 boiler. This project option has the largest NPV which is $ 1,307,227,703, a 42% IRR (7% as discount rate) and the lowest payback being this 34 months. In addition, it is the option with greater flexibility to the fluctuation of the price of natural gas, which could rise up to $ 33 more per cubic meter (12% variation), and still remains profitable.
Description
Catalogado desde la version PDF de la tesis.
Keywords
CALDERA , ECONOMICO , ESTUDIO , TECNICO , VAPOR