Redesign of an asphalt product packaging plant

Identifier:  TFG:3361

Handle: https://hdl.handle.net/20.500.11797/TFG3361

Authors:  Fernández Barral, Alejo Camilo

Abstract:
The aim of the project is to relocate and redesign the packaging facility of bitumen in barrels and in big bags of the company “Cepsa Comercial Petróleo Asfaltos Tarragona”. Given the increasing demand of bitumen packed in barrels, the space required is now larger. The need for changing the packaging facility of bitumen in big bags is to avoid unnecessary transport of bitumen and to use the current tanks where bitumen for big bags is stored for other processes. Both facilities have been relocated to a larger area, minimizing the risks inherent to the packaging processes and improving the overall plant operational flexibility. During their relocation, Lean Management principles have been used to design an efficient process of packaging. The Value Street Map of both packaging processes and the flow diagrams have been designed. The design was focused on the new pumping system from the new storage tanks to the new packaging facilities, as well as on the semi-automatization of the bitumen packaging in barrels to reinforce the security of the operation. The equipment designed are a gear pump, the new packaging facility of bitumen in barrels (semi-automatized) and an alternative for the packaging facility of bitumen in big bags (consisting of two heat exchangers and a centrifugal pump). Pipes, valves and instrumentation have also been designed. Following the CEPSA management and evaluation model for technical changes (PR-104), a HazOp/SIL study has been carried out to detect accident scenarios. Safeguards and recommendations have been suggested to reinforce the security of the process. The capital inversion of the project has been calculated, obtaining a result of 74.700 €.