Identifier: TFG:9134
Authors: Castillo Cortes, Ana
Abstract:
The production of synthetic resins plays a crucial role in various industrial sectors, including construction, automotive, electronics, and cosmetics. In response to increasing market demand, Ercros has launched an expansion project aimed at enhancing resin production capacity at its Almussafes site through the design and integration of a new reactor. The main objective of this project is to develop a reliable, safe, and efficient reactor system, supported by an appropriate heating and cooling setup and auxiliary equipment necessary for continuous and controlled operation. The project has an annual production of 49000 tons, divided into 725 batches of UF/MUF resin. Throughout the project development, the resin reactor has been the primary equipment designed, followed by the main process equipment such as the internal coil, agitator, valves, pumps, filter, and instrumentation such as transmitters. In addition, the process has been represented through the development of the Process Flow Diagram (PFD) and the Piping and Instrumentation Diagram (P&ID). Control strategies have been defined to ensure operational stability and safety, and the piping system has been dimensioned accordingly. The project also includes a comprehensive industrial safety study, covering hazard identification (HazOp), ATEX zone, and risk mitigation measures. Furthermore, maintenance and operations manuals have been prepared, along with environmental and economic analyses to assess the project’s viability and sustainability. The project, with an initial investment of 3€ million, has a payback period of 1 years. With a 15% discount rate, the net present value is estimated at 117 million of euros, and the internal rate of return is 419%, exceeding the required minimum profitability.
Repositori URV