Design of the utility network for a polymer recycling plant

Identifier:  TFG:9320

Handle: https://hdl.handle.net/20.500.11797/TFG9320

Authors:  March Miravete, Andreu

Abstract:
This End of Degree Thesis focuses on the design of the utilities network for a polymer recycling plant, specifically for polypropylene (PP) extrusion, with a production capacity of 25,000 t/year and the possibility of future expansion. The objective of the project is to develop an efficient and reliable utilities network that supplies the plant’s essential services while ensuring compliance with environmental and safety regulations and optimizing operational and investment costs. The design is structured around four main areas: water supply, compressed air, refrigeration, and pumping. Different technological alternatives were analyzed for each system, selecting the ones that offered the best balance between efficiency, cost, and reliability. For the refrigeration system, air-cooled chillers were chosen to minimize water consumption and eliminate health risks associated with Legionella. In the case of compressed air, screw compressorswere selected to ensure a stable supply with optimized energy consumption. For water treatment, sand filters and ion exchange units were implemented to guarantee the required water quality. Finally, a centrifugal pump system was designed to transport fluids, considering demand variability and energy efficiency. The project development followed international standards such as ISO 5199, ISO 8573- 1, ASME B31.3, and ISO 1217, ensuring safety and compliance with industrial regulations. Additionally, a detailed economic analysis was conducted, evaluating both capital expenditures (CAPEX) and operational expenditures (OPEX), with the aim of keeping the utilities network within 5% of the total project budget. The plant will be located in Aliaga, Turkey, a strategic industrial area with strong logistics infrastructure and favorable environmental conditions. In conclusion, the proposed design guarantees a reliable, flexible, and efficient utilities supply, providing a solid foundation for the proper operation of the plant and its future expansion.