GIRA RECOPE

Introduction to the Class

Overview of the Session

• Bienvenidos a la clase número trece del curso de verano sobre laboratorio de termofluidos. El profesor se encuentra en la oficina número 13 de la escuela de ingeniería electromecánica, saludando a los estudiantes y esperando que todos estén bien.

Technical Tour and Learning Materials

Virtual Technical Program

• Debido a limitaciones presupuestarias, no se pudo realizar una gira técnica física; sin embargo, se utilizarán materiales producidos por el profesor para fines didácticos. Esto busca generar un aprendizaje significativo dentro del contexto universitario.

Production Process of Asphalt Mixtures

Initial Steps in Asphalt Production

• La producción de mezclas asfálticas comienza con el diseño en laboratorio, donde se localizan bancos de piedra y se toman muestras para determinar su calidad. Esto es crucial para asegurar que el material utilizado sea óptimo.

Extraction and Processing of Stone

• Los bancos o canteras suelen estar ubicados en cerros, donde se utilizan explosivos para fragmentar las piedras y luego son procesadas en trituradoras y cribadoras para separarlas por tamaños adecuados (por ejemplo: tres cuartos de pulgada).

Mixing and Quality Control

• Se toman muestras de asfalto líquido y se realizan mezclas de prueba para determinar el contenido óptimo antes de finalizar el diseño. El asfalto es un subproducto refinado del petróleo, comúnmente usado en la construcción de carreteras.

Transportation and Storage of Asphalt

Handling Hot Asphalt

• El asfalto es transportado desde la refinería a temperaturas controladas (150 grados centígrados) utilizando autotanques forrados, asegurando que permanezca manejable durante su traslado y almacenamiento. A temperaturas más bajas, puede solidificarse como plastilina o volverse sólido a temperatura ambiente.

Asphalt Plant Operations

Material Preparation at the Plant

• Las piedras seleccionadas son llevadas a la planta en camiones volquete y almacenadas según su tamaño antes de ser agregadas a las tolvas correspondientes; cada tolva contiene un tipo específico de material que será secado internamente antes del proceso final.

Final Mixing Process

• Una vez secados los materiales, una computadora mezcla todos los componentes con el asfalto dosificando las cantidades exactas necesarias para lograr la mezcla deseada antes del transporte al cliente o obra designada.

Intellectual Property and Educational Use

Acknowledgment of Sources

• Se menciona que el material audiovisual utilizado proviene de Asfaltos de México y está destinado exclusivamente para fines educativos dentro del Tecnológico de Costa Rica, enfatizando la importancia del respeto por la propiedad intelectual mientras se aprende sobre asfaltos.

Virtual Tour of Refinery Facilities

Overview of RICOAPEL Infrastructure

• Se comparte un mural fotográfico sobre una visita realizada a RICOAPEL Alto de Ocho-Mogo donde se explica cómo funciona el poliducto que transporta productos petroleros desde Puerto Moín hasta Barranca Punta Arenas mediante estaciones robustas diseñadas específicamente para este propósito.

Boiler Systems in Oil Refineries

Types of Boilers Explained

• Se presentan diferentes tipos de calderas utilizadas en las instalaciones: acuatubular (donde el agua viaja dentro) y pirotubular (donde el fuego viaja dentro), destacando sus funciones específicas en relación con los sistemas térmicos utilizados para vaporizar agua necesaria en procesos industriales relacionados con petróleo y asfaltos.

Observing the Asphalting Process

Overview of the Plant Operations

• The chief operator provided safety glasses to observe a jam in the system, specifically related to burning bunker fuel.

• A description of trench systems and control rooms is given, including close-up photographs of the pirotubular boiler and panoramic views of water treatment tanks that prevent scaling through chemical treatments.

• A panoramic view of storage tanks is shared, emphasizing their robust dimensions and providing context for understanding the asphalt plant's scale.

Asphalt Processing Insights

• The process involves heating asphalt to maintain it in a liquid state, supported by pumping systems that keep it moving.

• A panoramic view highlights various containers surrounding the asphalt processing area.

Educational Context

• The session includes playful activities designed for today's class, starting with an instructional video on asphalt processes. It emphasizes the significance of viscous liquids studied in both laboratory and theory courses.

Historical Development of RECOPES

Company Evolution

• RECOPES began its transformation in 2018; originally established as a private company in the early 1960s, it was nationalized under José Figueres Ferrer’s government for symbolic value at one dollar.

• In the 1980s and 1990s, efforts were made to improve fuel quality until 2011 when refining ceased due to outdated facilities; RECOPES then shifted entirely to importing fuels.

Quality Improvements Over Time

• Continuous improvements included removing lead and carcinogens from fuels while introducing super gasoline compliant with Euro 4 standards.

• Attempts were made to rebuild a refinery which led to international litigation; however, RECOPES emerged successfully from this arbitration.

Transitioning Energy Sources

Government Directives

• Starting in 2008, there was a push towards eliminating fossil energy sources particularly in public transport as part of broader governmental goals across multiple administrations.

Strategic Proposals for Change

• Four key actions were proposed for transforming RECOPES into an agile entity capable of integrating alternative energy research and development into its operations.

Legislative Framework

• A new legislative proposal aimed at enhancing operational efficiency was submitted shortly after administration began in August 2018. This sought to incorporate alternative energies like biodiesel and ethanol into fuel production while improving public health by reducing harmful substances.

Future Energy Matrix

• The vision includes diversifying energy sources away from fossil fuels towards alternatives such as biofuels and hydrogen technologies.

Rebranding Efforts

• The rebranding initiative suggests renaming RECOPES to reflect its expanded role beyond oil refining—proposing "Costa Rican Company for Fuels and Alternative Energies" as a more fitting title.

Energy Transition and Environmental Responsibility

The Shift from Fossil Fuels to Alternative Energies

• Recopes emphasizes the global responsibility to transition away from fossil fuels, which are significant pollutants, towards alternative energy sources.

• The urgency for adopting environmentally friendly energies is highlighted, as they are essential for reducing carbon emissions that harm public health and the environment.

• Various alternative energy options are discussed, including electricity, hydrogen, and nuclear fusion, with a focus on hydrogen development initiated around 2010-11 through partnerships.

Challenges in Hydrogen Development

• Legal restrictions have hindered the full potential of hydrogen initiatives in Costa Rica; however, there is a push for "green hydrogen," produced without contaminants from water.

• LPG (liquefied petroleum gas), while derived from fossil fuels, is considered an alternative due to its lower carbon footprint compared to other fuels.

Infrastructure and Distribution Systems

• Recopes has developed a national fuel system that efficiently manages importation and distribution across the country via a network of pipelines.

• The company operates four distribution terminals and supplies fuel to four major airports in Costa Rica.

Future Projects and Strategic Goals

• Two key infrastructure projects are planned: Terminal Chorotega for distribution in Liberia and Terminal Pacífico for improved sales operations on the Pacific side.

• A strategic plan aims at enhancing efficiency within Recopes by focusing on customer needs through measurable objectives set between 2020 and 2030.

Achievements in Environmental Management

• Recopes has received recognition for its environmental management efforts with awards such as the Blue Flag Eco Award across all operational sites.

• Internal reorganization has led to significant improvements without external hiring, demonstrating effective change management within a public enterprise.

Company Principles and Process Orientation

Defining Company Culture

• The company is guided by self-defined principles aimed at being process-oriented, focusing on human resources for customer service, emphasizing operations over administration.

Continuous Improvement and Financial Results

• There has been a significant positive outcome with recorded savings of approximately 12 billion colones compared to the previous year, highlighting the importance of economic savings alongside expected improvements in results.

Automation and Technology Integration

Emphasis on Efficiency and Innovation

• Discussions around automation stress the need for efficiency, innovation, and creativity as essential components of operational success.

Comprehensive System Implementation

• Recope has made extensive efforts to implement integrated systems to avoid reprocessing or duplications, enhancing both administrative support and operational capabilities.

Data Utilization Challenges

Maximizing Technological Investments

• A major challenge lies in effectively utilizing technology; it’s not just about having data but understanding how to leverage it for decision-making and project identification.

Intelligent Innovation Approach

• The focus should be on meaningful innovation that meets actual needs rather than following trends without purpose; investments must align with clear outcomes.

Negotiation Outcomes

Collective Bargaining Achievements

• A lengthy negotiation led to significant achievements resulting in over 20% savings compared to previous agreements due to timely denunciation of prior collective conventions.

Balancing Costs and Employee Benefits

• While achieving cost reductions, new elements were introduced into the agreement, maintaining a balance between employee benefits before and after negotiations.

Cultural Transformation Initiatives

Agile Response Culture Development

• The desired culture promotes agility in responses with an emphasis on teamwork; initiatives include defining guiding phrases that embody respect, extra effort, and accountability among employees.

Team Engagement Strategies

• Approximately 32 teams have been formed across the company to discuss these guiding principles weekly outside regular hours, fostering personal connections through shared practices.

Embracing Change Beyond Comfort Zones

Encouraging Continuous Adaptation

• There is a need for ongoing change beyond comfort zones; embracing new methodologies or technologies is crucial despite regulatory constraints faced by public enterprises. Employees are encouraged to seek possibilities for improvement while taking pride in their contributions to society.

Energy Transition and Economic Development

Gas Storage and Employment Opportunities

• The establishment of a second storage and sales point for liquefied petroleum gas in Barranca Punta Arenas is proposed, which could create approximately 400 temporary jobs during the construction phase.

Tax Revenue and Economic Linkages

• This project presents significant potential for tax revenue generation for local governments in Esparza and Punta Arenas, alongside creating important economic linkages for goods and services required during both construction and operational phases.

Investment in Depressed Areas

• The region discussed is economically depressed, necessitating public investment. Such investments could attract other industries by providing access to cheaper energy sources that are less polluting than alternatives like LP gas, along with proximity to an export port.

Sustainable Energy Matrix

• Emphasizing the need for new projects aligned with sustainable development goals, the discussion highlights the importance of integrating a green energy matrix, including elements like green hydrogen to positively impact population equity.

Impact of COVID-19 on Industries

• The pandemic has forced changes in business models within industries and agro-industries, pushing them towards energy transition and efficiency improvements that can lead to cost savings and enhanced competitiveness both locally and internationally.

Education Initiatives in Renewable Energy

New Educational Programs

• A focus on national investment in education is noted, particularly with the introduction of new programs such as a degree in Energy Engineering emphasizing renewable sources at Universidad Técnica Nacional (UTN), set to commence in January 2022.

Energy Security Measures

National Inventory System

• RECOP's strength lies in its National Compostables System which ensures adequate inventory levels across various regions from importation through distribution, enhancing overall energy security throughout the country.

Distribution Infrastructure

• The presence of two unloading points for gasoline allows simultaneous operations at Atlantic ports, contributing to system redundancy while ensuring efficient fuel distribution via four terminals across the country.

Goals of Pacific Terminal Development

Ensuring Energy Supply

• The primary objective of developing a new terminal on the Pacific coast is to enhance energy security by ensuring reliable supply of liquefied petroleum gas (GLP) essential for hospitals, industrial sectors, and commercial needs throughout the country.

Understanding Pipeline Losses

Broader Implications

• In discussing pipeline losses within this technical course context, there’s an emphasis on understanding not just localized models but also their implications on a national scale as part of broader infrastructure considerations.