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某铸造某公司节能改造项目可行性研究报告

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2018-09-30
简介
本项目项目主要建设内容:本项目拟对现有3条搪瓷生产线的烧结炉进行燃气改造,拆除现有的2台315kW电加热烧结预热炉和3台800kW电加热烧结炉,新建3套天然气加热式高效节能车载式回转搪瓷烧结炉,并配套建设天然气调压站1座,铺设管道800米;拆除已淘汰的2台铸造用焦炭冲天炉(2t和3t各1台);建设1台3t/h燃气锅炉及配套设施,拆除现有的3台1t/h采暖燃煤锅炉。项目实施后,年可节约标煤1027.91tce;年可间接减少CO2排放量2693t,减少SO2排放量8.74t,减少NOx排放量7.61t。本项目报批总投资为1200万元,其中建设投资为1195万元,铺底流动资金为5万元。本报告主要从项目概况、建设规模、发展规划及产业政策、资源开发及综合利用、节能方案、建设条件、环境影响、经济影响、社会影响等方面对项目进行分析,项目建设是可行的。本项目的实施具有较好的环境效益,能为当地实施大气环境治理做出贡献,因此本项目是可行的。

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第一章总论1.1项目名称及承办单位概况1.2编制依据1.2.1相关法律、条例1.2.2相关政策、规范、导则1.3项目建设背景及必要性1.4项目概况1.4.1建设地点1.4.2建设内容1.4.3主要建设条件1.4.4项目投入总资金及效益情况1.4.5主要技术经济指标第二章现状分析2.1铸铁搪瓷生产现状2.2采暖燃煤锅炉生产现状第三章工程方案、设备方案和土建方案3.1工程方案3.2设备方案3.2.1新增设备3.2.2利旧设备3.2.3淘汰设备3.3土建方案第四章场址选择及建设条件4.1建设地点AA4.2场址建设条件第五章实施效果分析5.1改造前能源消耗量5.2改造后能源消耗量5.3项目实施前后节能效果分析第六章节能6.1编制依据6.2项目能源消耗种类6.3项目能源消耗计算6.4项目实施前后节能效果评估6.5节能措施第七章环境保护7.1场址环境条件7.2标准依据7.2项目建设和生产对环境的影响7.2.1项目建设对环境的影响7.2.2项目运营对环境的影响7.3环境保护措施方案7.3.1建设期环境保护措施方案7.3.2运营期环境保护措施方案第八章劳动安全卫生与消防8.1劳动安全卫生8.1.1劳动安全8.1.2卫生8.2消防8.2.1执行标准8.2.2消防措施第九章组织机构与劳动定员9.1组织机构9.2劳动定员9.3人员培训第十章招投标与项目实施进度10.1招投标10.2项目进度安排第十一章投资估算和资金筹措11.1建设投资11.1.1编制依据及投资范围11.1.2编制依据11.1.3编制方法及各项费用的确定11.2流动资金估算11.3资金筹措第十二章财务分析12.1编制依据12.2基础数据12.2.1减排量及副产品12.2.2实施进度及项目计算期12.2.3节约成本估算12.2.4新增成本和费用估算12.3财务评价12.3.1盈利能力分析12.3.2财务生存能力分析12.4财务分析结论第十三章结论13.1结论13.1.1技术评价13.1.2经济评价13.2建议XX铸造XX公司节能改造项目可行性研究报告XX公司二〇XX年四月目录第一章总论·················································································-1-1.1项目名称及承办单位概况··························································-1-1.2编制依据···············································································-1-1.3项目建设背景及必要性·····························································-2-1.4项目概况···············································································-4-第二章现状分析···········································································-8-2.1铸铁搪瓷生产现状···································································-8-2.2采暖燃煤锅炉生产现状·····························································-9-第三章工程方案、设备方案和土建方案···········································-11-3.1工程方案··············································································-11-3.2设备方案··············································································-15-3.3土建方案··············································································-16-第四章场址选择及建设条件··························································-17-4.1建设地点··············································································-17-4.2场址建设条件········································································-17-第五章实施效果分析···································································-19-5.1改造前能源消耗量··································································-19-5.2改造后能源消耗量··································································-19-5.3项目实施前后节能效果分析······················································-21-第六章节能················································································-22-6.1编制依据··············································································-22-6.2项目能源消耗种类··································································-22-6.3项目能源消耗计算··································································-23-6.4项目实施前后节能效果评估······················································-23-6.5节能措施··············································································-23-第七章环境保护··········································································-25-7.1场址环境条件········································································-25-7.2标准依据··············································································-25-7.2项目建设和生产对环境的影响··················································-25-7.3环境保护措施方案··································································-26-第八章劳动安全卫生与消防··························································-28-8.1劳动安全卫生········································································-28-8.2消防····················································································-30-第九章组织机构与劳动定员··························································-31-9.1组织机构··············································································-31-9.2劳动定员··············································································-31-9.3人员培训··············································································-31-第十章招投标与项目实施进度·······················································-32-10.1招投标···············································································-32-10.2项目进度安排······································································-33-第十一章投资估算和资金筹措·······················································-36-11.1建设投资···········································································-36-11.2流动资金估算·····································································-37-11.3资金筹措···········································································-37-第十二章财务分析·······································································-38-12.1编制依据············································································-38-12.2基础数据············································································-38-12.3财务评价············································································-39-12.4财务分析结论······································································-39-第十三章结论·············································································-40-13.1结论··················································································-40-13.2建议··················································································-40-附表附表1投资估算表附表2其他费用估算表附表3项目投资使用计划与资金筹措表附表4财务分析指标汇总表附表5营业收入、营业税金及附加和增值税估算表(增量)附表6总成本费用估算表(增量)附表7固定资产折旧费估算表附表8利润与利润分配表(增量收益)附表9财务计划现金流量表附表10资产负债表附图附图1总平面布置图-1-第一章总论1.1项目名称及承办单位概况项目名称:节能改造项目项目承办单位:项目建设地点:承办单位概况:1.2编制依据1.2.1相关法律、条例(1)《中华人民共和国环境保护法》(1989年)(2)《中华人民共和国清洁生产促进法》(2003年)(3)《建设项目环境保护管理条例》(1998年)(4)《XX省建设项目环境保护管理条例》(1996年)(5)《产业结构调整指导目录(2011年本)》(修正)1.2.2相关政策、规范、导则(1)XX省发展和改革委员会《关于报送中央预算内大气污染防治专项资金备选项目的通知》(2014年4月)(2)《XX省实施节能减排项目促进大气污染防治工作方案(2014~2015年)》(冀发改环资[2014]401号)(3)《国务院关于落实科学发展观加强环境保护的决定》(国发[2005]39号)-2-(4)《国务院关于印发“十二五”节能减排综合性工作方案的通知》(国发[2011]26号)(5)《国务院关于加强环境保护重点工作的意见》(国发[2011]35号)(6)《国务院关于印发国家环境保护“十二五”规划的通知》(国发[2011]42号)(7)建设单位提供的工程基础资料(8)国家发改委、建设部发改投资[2006]1325号《建设项目经济评价方法与参数》(9)《空气环境质量标准》(GB3095-96)(10)《工业企业厂界环境噪声排放标准》(GB12348-2008)(11)《工业企业设计卫生标准》(GBZ1-2010)(12)《供配电系统设计规范》(GB50052-2009)1.3项目建设背景及必要性《气候变化绿皮书》显示,2013年我国以AA等为首的25个省份均被雾霾缠身,平均雾霾天数约30天,创52年来之最。据国家环保部空气质量监测数据可知,受雾霾影响,2013年空气污染较重的前10个城市中有5~7个城市来自XX省,包括AA等。为了解决雾霾污染,国家相继出台了一系列大气污染防治政策。为了贯彻落实《国务院关于印发大气污染防治行动计划的通知》(国发〔2013〕37号),加大京津冀及周边地区大气污染防治工作力度,切实改善环境空气质量,国家环境保护部、发展改革委、工业和信息-3-化部、财政部、住房城乡建设部和能源局等于2013年9月联合发布了关于印发《京津冀及周边地区落实大气污染防治行动计划实施细则》的通知。该文件确定京津冀及周边地区大气污染防治行动的重点XX务之一为:“全面淘汰燃煤小锅炉”、“京津冀及周边地区要提前一年完成国家下达的“十二五”落后产能淘汰XX务”。XX省也发布了关于印发《XX省大气污染防治行动计划实施方案》的通知,并制定了《XX省实施节能减排项目促进大气污染防治工作方案(2014~2015年)》。在此背景下,XX铸造XX公司积极响应国家和XX省加强大气污染防治的号召,拟对公司现有的3条搪瓷生产线进行清洁燃料改造,最大限度的降低能源消耗,淘汰小燃煤采暖锅炉,减少二氧化碳、二氧化硫、氮氧化物等大气污染物的排放,为改善区域大气环境质量贡献一份微薄之力。本项目的建设是XX省大气污染防治工作的需要,有助于改善区域的空气质量。本项目属于《XX省发展和改革委员会关于报送XX省大气污染治理打捆下达投资计划备选项目的请示》(冀发改环资〔2014〕786号)入库项目;属于XX省发展和改革委员会《关于报送中央预算内大气污染防治专项资金备选项目的通知》(2014年4月)中专项资金支持的选项范围之一“燃煤锅炉节能环保提升项目(含清洁燃料替代)、……等项目”;属于XX省发展和改革委员会印发的《XX省实施节能减排项目促进大气污染防治工作方案(2014-2015年)》(冀发改环资〔2014〕401号)中的重点工程之一:“……、燃煤锅炉煤-4-改气、……”;符合《XX省大气污染防治行动计划实施方案》、《XX市大气污染防治行动计划实施细则》等要求。因此,XX铸造XX公司节能改造项目,是当前大气污染防治行动计划实施方案的一部分,项目的建设有利于改善当地环境污染状况,对治理大气污染,改善空气环境是十分有意义且必要的。1.4项目概况1.4.1建设地点XX1.4.2建设内容项目主要建设内容:本项目拟对现有3条搪瓷生产线的烧结炉进行燃气改造,拆除现有的2台315kW电加热烧结预热炉和3台800kW电加热烧结炉,新建3套天然气加热式高效节能车载式回转搪瓷烧结炉,并配套建设天然气调压站1座,铺设管道800米;拆除已淘汰的2台铸造用焦炭冲天炉(2t和3t各1台);建设1台3t/h燃气锅炉及配套设施,拆除现有的3台1t/h采暖燃煤锅炉。项目实施后,年可节约标煤1027.91tce;年可间接减少CO2排放量2693t,减少SO2排放量8.74t,减少NOx排放量7.61t。1.4.3主要建设条件本项目拟建于XX铸造XX公司现有厂区内,是对现有生产线及设施进行改造,不需新征土地。项目所在地交通便利,地势平坦,适合本项目建设。此外,本项目建成后所需的天然气由XX县经济开发区天然气门-5-站供给,电力、水由厂区的现有供电、供水设施提供,完全满足本项目所需。1.4.4项目投入总资金及效益情况本项目报批总投资为1200万元,其中建设投资为1195万元,铺底流动资金为5万元。项目报批总投资1200万元拟全部由企业自筹资金解决。-6-表1.4-1建设投资构成表序号项目金额(万元)比例(%)1建筑工程费322.2326.962设备购置费594.5049.753设备安装费93.687.844工器具及备品备件5.180.435工程建设其他费用99.917.616基本预备费88.507.41合计1195.00100.00经计算,年新增总成本费用为270万元,经营成本为203万元。年增加息税前利润为8万元,净利润为6万元。总投资收益率0.66%,资本金净利润率为0.50%。综上所述,本项目的主要财务评价指标数据均优于基准指标和同行业的平均水平,项目具有一定的财务盈利能力、生存能力、清偿能力和抗风险能力,因此本项目在财务上是可行的。1.4.5主要技术经济指标本项目主要技术经济指标见表1.4-2。-7-表1.4-2主要技术经济指标表序号项目单位数据1项目实施后节能量tce/a1027.912污染物减排量2.1CO2t/a26932.2SO2t/a8.742.3NOxt/a7.613建设期月194报批总投资万元1200其中:建设投资万元1195铺底流动资金万元55流动资金万元176利用原有固定资产万元07项目资本金万元12128年营业收入万元2689年需要补贴收入万元1010年利润总额万元811年息税前利润万元812年净利润万元613投资利润率%0.6614总投资收益率%0.6615资本金净利润率%0.50-8-第二章现状分析2.1铸铁搪瓷生产现状铸铁搪瓷生产主要包括铸铁件生产和搪瓷生产两大部分,XX铸造XX公司现拥有焦炭冲天炉自动铸造生产线2条(DISAline),搪瓷生产线3条(其中年产铸铁搪瓷制品7万套生产线1条,年产铸铁搪瓷制品4万套生产线2条),年产铸铁搪瓷制品15万套。(1)铸造生产过程包括熔炼、球化、造型、浇注、清理等,工艺流程见图2.1-1。图2.1-1铸造生产工艺流程(2)搪瓷生产过程包括前处理、烘干、涂搪、烧成等工序,工艺流程见图2.1-2。-9-图2.1-2搪瓷生产工艺流程图搪瓷制品生产线中,铸造工艺中采用的是以焦炭为燃料的冲天炉,年耗焦炭量1650t,燃烧过程中对大气造成污染,能耗高,污染大;搪瓷生产工艺中预热炉和烧成炉采用电加热装置,据统计3条搪瓷生产线平均小时耗电量为637kWh/h,年总耗电量为504.50万kWh,成本高,能耗高。因此需要进行技术改造,以达到节能降耗,减排增效的目的。2.2采暖燃煤锅炉生产现状XX铸造XX公司主要是生产车间和办公楼,采暖热源由3台1t/h燃煤热水锅炉提供,采暖面积为3000m2。据统计,2013年冬季3台-10-1t/h燃煤热水锅炉年用煤量为61.86吨。燃烧过程中,由于锅炉效率低,仅为60%,容量小,不但污染严重,而且能耗高,造成极大的浪费。按照政府相关部门的要求,亟需淘汰更换。因此,为了响应XX省及XX市大气污染防治行动计划实施方案,XX铸造XX公司决定对现有高耗能、高污染设备及工艺进行改造,淘汰焦炭冲天炉,采用铸造工序外协的办法,从周边大型铸造企业购入铸造半成品,直接进入搪瓷生产工序;新建1台燃气锅炉,取缔现有的3台小型燃煤锅炉,保证生活用热;对搪瓷生产工艺中的现有电加热炉进行改造,改为燃气加热,提高燃烧效率,降低消耗与成本。在实现企业经济效益的同时减少污染物排放,创造更好的环境效益。-11-第三章工程方案、设备方案和土建方案3.1工程方案3.1.1铸铁搪瓷生产线改造方案(1)拆除已淘汰的1台2t和1台3t焦炭冲天炉,铸造件生产外协。(2)对公司现有搪瓷生产线的烧结预热炉和烧结炉进行燃气改造,拆除现有的2台315kW电加热烧结预热炉和3台800kW电加热烧结炉,新建3套天然气加热烧结炉——高效节能车载式回转搪瓷烧结炉。高效节能车载式回转搪瓷烧结炉集喷涂、预热、烧结冷却等于一体,以消耗天然气为主,能有效降低生产线能耗,从而实现节能。改造后搪瓷生产线流程和生产能力均不会发生变化,改造后工艺流程仍包括前处理、烘干、涂搪、烧成等工段。天然气是一种清洁,高效的能源。以天然气为能源的烧结炉具有温度均匀,控温准确,热效率高,清洁无污染等诸多优点。天然气烧结炉炉体的内墙是由异型硅砖及保温砖组成,四壁及顶部为硅酸铝纤维,氧化镁及碳化硅等,外层为保温层及空气夹层,保温效果好,整个炉体只保留出气口,没有传统意义上的烟囱,热量不易损失,热效率可达90%以上。本项目拟选用的车载式回转搪瓷烧结炉具有零件传送机构、高稳定性、高效节能、操作简便、设备维护维修简单等特点,相关技术参-12-数见表3.1-1。表3.1-1单台车载式回转搪瓷烧结炉主要技术参数表部位参数数值预热炉加热速度108℃/min预热炉加热温度350℃烧结区烧结温度720~800℃烧结区烧结时间2min冷却区冷却速度111.67℃/min冷却区冷却时间6min载件车搪瓷速度8000kg/h载件车运行速度3.3m/min天然气平均消耗量12.92m3/h图3.1-1烧结炉温度变化曲线示意图图3.1-2车载式回转搪瓷烧结工艺流程图3.1.2采暖燃煤锅炉改造方案-13-本项目拟拆除原有的3台1t/h燃煤热水锅炉及配套设施,新建1台3t/h燃气热水锅炉及配套设施,燃气热水锅炉拟选用CWNS型燃气热水锅炉,锅炉参数见表3.1-2。表3.1-2CWNS型燃气热水锅炉技术参数型号CWNS2.1-95/70-Y/Q2.1额定蒸发量(MW)2.1出水温度(℃)95回水温度(℃)70冷空气温度(℃)20设计效率(%)大于90燃料天然气受热面积(m2)64排烟温度(℃)198外形尺寸(L×φ×Hm)3700×1900×2250本项目燃气锅炉的供暖面积为2700m2,且各采暖建筑物采取了一系列的保温,有效降低了建筑热耗。因此,根据《城市热力网设计规范》(CJJ34-2002),建筑物热指标按采取节能措施指标值40W/m2计算,则本项目锅炉所涉及的采暖热负荷为108kW。根据《公共建筑节能设计标准》(DB13(J)81-2009)中的规定,项目计算采暖期为98天,采暖期室外平均温度0.8℃,采暖室外计算温度为-3.9℃,室内计算平均温度18℃,按照《城市热力网设计规范》采暖全年耗热量按下列公式计算:hoiaihahttttNQQ0864.0式中:-14-ahQ——采暖全年耗热量(GJ);N——采暖期天数;hQ——采暖设计热负荷(kW);it——采暖室内计算温度(℃);at——采暖期平均室外温度(℃);hot——采暖室外计算温度(℃)。则本项目所涉及的建筑物采暖全年耗热量为718.20GJ。GJQah20.718)9.3(188.018108980864.0燃气热水锅炉出水温度为95℃,焓值为397.99kJ/kg;回水温度为70℃,焓值为292.97kJ/kg;全年采暖时间为2352h。因此,本项目所涉及的建筑物采暖小时用热水量为2.91t/h。采暖小时耗热水量=t/h91.210292.97)-397.99(23521020.71836综上所述,本项目拟新建的1台3t/h燃气热水锅炉完全满足厂区采暖所需。3.1.3天然气系统为保证生产及生活用气需要,本项目拟配套建设天然气调压站1座,铺设燃气管道800米。本项目新建天然气调压站主要包括减压站、高压气站、天然气稳压罐和高压气稳压罐。天然气由气站进入厂区后首先送至减压站,供气压力1.5~2.5MPa,经两级降压后,再经稳压罐送至燃气炉和采暖锅炉使用。在燃气炉和锅炉上的天然气入口之前均设有天然气压力控-15-制和计量装置,安全阀采用全自动气动控制,利用压力敏感元件测量和控制通至用气设备的配气管所允许的最高和最低气压。图3.1-3天然气系统示意图3.2设备方案3.2.1新增设备本项目新增设备包括搪瓷生产线中的燃气烧结炉、天然气调压站;燃气热水锅炉及配套设施等,具体见表3.2-1。表3.2-1新增设备表序号设备名称规格参数数量(台/套)单台功率(kW)总价(万元)备注1天然气烧结炉车载式回转搪瓷烧结炉34352烧结炉配套设施31353天然气调压站1座11104燃气热水锅炉CWNS2.1-95/70-Y/Q2.11455锅炉配套设施1537.5-16-3.2.2利旧设备本项目搪瓷生产线除了新增燃…
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