Plant Layout Research Articles

Planning for wastewater infrastructure adaptation under deep uncertainty

Infrastructure in low-lying coastal areas faces challenges from climate change, sea level rise, and the impact of compound hazards. Dynamic adaptive pathways planning (DAPP) is increasingly being applied as a way of planning under deep uncertainty. Stress testing for robustness is an integral part of DAPP which provides decision-makers with confidence. We outline a seven-step approach—combining scoping workshops, systems mapping, DAPP, exploratory modelling, robust decision-making, real options analysis and validation workshops—to support decision-making for infrastructure in low-lying coastal areas. We apply the seven steps to two wastewater treatment plant (WWTP) case studies in New Zealand to quantify indicators, signals, triggers and adaptation thresholds within DAPP plans and to identify adaptation pathways that are robust against future uncertainty. Case study one focuses on the implementation of an existing DAPP at Helensville WWTP. Our modelling enabled the challenge of quantifying indicators for adaptation thresholds and triggers to be overcome. We show that an adaptation threshold occurs at 31 cm of RSLR, the trigger point is sufficient lead time to enable relocation, and the indicator is the rate of observed RSLR. Case study one demonstrates in a quantitative way how an existing DAPP can be functionally implemented by a water management agency. Modelling for case study two, the Seaview WWTP, showed that 26 cm and 56 cm of RSLR are key thresholds. Nuisance flooding may occur after 26 cm of RSLR, which could happen as early as 2040 under a high emissions scenario. Inundation of plant assets may occur after 56 cm of RSLR, which could occur as early as 2060. Modelling showed that implementing changes to plant layout would allow the plant to remain on site for its design life (until 2080). Five adaptation archetypes were developed—sequences of adaptive actions that achieve the performance objective of continuing levels of service and avoid inundation of WWTPs. The seven-step approach is a way to stress-test a DAPP, to quantify signals, triggers and adaptation thresholds and to simulate implementation of a DAPP under a range of scenarios. This can facilitate more robust decision-making for wastewater infrastructure assets under future uncertainty.

A new optimization model for carbon capture utilization and storage (CCUS) layout based on high-resolution geological variability

Carbon capture utilization and storage (CCUS) is expected to play a pivotal role in achieving carbon-neutral pledge. However, the neglect of geological volatility in existing models will lead to obvious bias in the CCUS layout optimization results. Therefore, a new optimization model for CCUS layout is developed based on high-resolution geological variability. Finally, the model is validated by solving the optimal CCUS layout of coal-fired power plants (CFPPs) in a case region till 2060. The obtained results show that (i) To accomplish the same emission reduction targets, the total length of the pipeline network by 2060 in the scenario considering high-resolution geological variability (HGV) will decrease by 12.5% compared with the scenario without geological variability (NGV); (ii) The total crude oil production can be enhanced by about 19.0% in HGV scenario compared with NGV due to the optimized CO2 source-sink matching; (iii) Comparing with the NGV, the CCUS layout under the HGV can decrease 26.1 and 32.7 CNY/tCO2 in capital costs and O&M costs respectively, and ultimately improve the total profit by 149.4 CNY/tCO2. In summary, the proposed new model can solve the optimal CCUS layout and operation more practically and accurately.

Mapping winter fallow arable lands in Southern China by using a multi-temporal overlapped area minimization threshold method

ABSTRACT In China, a nation facing farmland scarcity, accurate mapping of winter fallow arable lands is crucial for enhancing crop rotation and land use efficiency. The Dynamic Threshold (DT) method commonly used in phenology and winter fallow land studies often employs empirically set subjective thresholds. This approach tends to uniformly apply a single threshold across diverse vegetation types and geographical regions, neglecting the variations in physiological traits and spatial heterogeneity. This study developed a multitemporal overlapping area minimization threshold method (MOAMT). This approach constructed Normalized difference vegetation index (NDVI) probability density functions for both winter fallow and non-winter fallow arable land across a time series to attain a statistically significant threshold. We use MOAMT and DT methods for winter fallow arable land extraction in southern China, respectively. And then, comparison of identification accuracy between MOAMT and DT has been implemented by using confusion matrix method. Compared to the DT method, MOAMT exhibits better performance. The mapping of winter fallow arable lands highlighted their predominant distribution in the middle and lower reaches of the Yangtze River (MLR-YR) Basin, covering approximately 20.8 million hectares, with potential for development. This study will provide information support for the optimization of planting layouts in China, offering new opportunities for further increasing grain production. While in the sense of research approach, this study indicates the superiority of threshold obtained through statistical probability calibration over empirical universal thresholds for classification accuracy. We advocate for prioritizing threshold calibration in future applications of threshold classification methods.

Maximizing Efficiency in Compressed Air Energy Storage: Insights from Thermal Energy Integration and Optimization

Motivated by the suboptimal performances observed in existing compressed air energy storage (CAES) systems, this work focuses on the efficiency optimization of CAES through thermal energy storage (TES) integration. The research explores the dependence of CAES performance on power plant layout, charging time, discharging time, available power, and cavern volume. Hence, a range of solutions are examined, encompassing both solid and liquid TES options, alongside the potential utilization of external air heaters. Inefficiencies in solid TES due to significant retention of thermal power within the medium after complete discharge are identified and mitigated through optimization strategies. In addition, solutions to prevent ice formation at the low-pressure expander phase are suggested to avoid icing issues in CAES layouts with liquid TES. Through this comprehensive investigation, the study provides valuable insights into enhancing the efficiency and sustainability of CAES systems. By constructing a volume–power–time conversion table, the research contributes to the advancement of CAES technology, facilitating more efficient energy storage and utilization, thereby addressing critical challenges in the field of energy storage.

Waste heat utilization using organic rankine cycle from a pressurized pulverized combined cycle power plant

Power plants release a massive amount of waste heat at very low temperatures. Posing a challenge for efficient conversion into useful work through conventional methods. By selecting appropriate working fluids, low-grade power cycles can solve this problem by converting waste heat to electricity. The present work dealt with waste heat utilization using the Organic Rankine Cycle (ORC) from a 400 MWe coal based supercritical Pressurized Pulverized Combined Cycle (PPCC). The working fluid for the ORC is the refrigerant R245fa. High-ash (HA) Indian coal and low-ash (LA) South African coal are used as fuel to assess the plant’s ability to produce electricity under ambient conditions in India. The simulation flowsheet program “Cycle-Tempo” models and simulates different plant layouts. The thermodynamic assessment unveiled that the standalone plant has energy and exergy efficiencies of 43.46% and 39.87% for HA & 45.42% and 43.84% for LA, respectively. According to this study, the proposed plant has energy and exergy efficiencies of 44.63% and 40.94% for HA & 46.69% and 45.07% for LA, respectively. Moreover, using ORC, the waste heat generates additional electricity of 9.38 MWe, with an energy efficiency of 12.92% and exergy efficiency of 34.63%.

Towards the decarbonization of ammonia synthesis – A techno-economic assessment of hybrid-green process alternatives

This paper analyzes the retrofitting of a conventional, “gray” ammonia plant for its partial decarbonization. Specifically, the retrofitting involves the hybridization of the process by providing a certain amount of green hydrogen (i.e. by water electrolysis) for the ammonia synthesis to reduce the demand for the original gray hydrogen route (i.e. by fossil-based steam reforming) and consequently reduce CO2 emissions. As such green hydrogen is produced through an electrolyzer that consumes renewable electric energy, two design configurations are considered: (Option I) the supply of clean electricity from renewable sources; (Option II) the generation of clean electricity by an in-house photovoltaic power plant. Once having analyzed the advantages and limitations of the hybrid plant layouts, the ammonia production costs achieved by the three simulated plants (i.e. the reference “gray” plant and the two hybrid alternatives) are estimated by considering the United States (USA) and European Union (EU) market quotations in 2022 and previsions for 2030 and 2050. The main outcomes are that (i) hybrid-green ammonia proves to be a feasible, environmentally friendly retrofitting option for the ammonia production industry, showing production costs that are no more than 36 % higher than gray ammonia; and (ii) Option I achieves better cost-effectiveness than Option II in the USA, while the opposite happens in the EU. Specifically, the resulting 10 %-green-on-average hybrid-green ammonia production costs range between +0.3 % (EU-2022) and +30.8 % (USA-2022) for Option I, and between −1.3 % (EU-2022) and +35.3 % (USA-2022) for Option II, compared to the reference gray ammonia plant. (iii) Lastly, the projected (i.e. in 2030 and 2050) CO2 avoidance costs associated with hybrid-green ammonia configurations exceed 400USD/tCO2 in the USA and 500USD/tCO2 in the EU.

A Work Study for Upgradation of Plastic Product Manufacturing Unit

Abstract: This paper discusses about the project on work study of plastic product manufacturing unit.The factory is well renowned for its plastic products .This unit is present at Electronic Zone, Hingna MIDC ,Nagpur .This factory has plastic injection molding machine for product manufacturing .In the project ,we will study examine ,investigate about the existing ways of doing work. We are going to do systematic recording and critical examination of existing working structure ,plant layout ,management ,allocation of work to workers ,way of completion of work from taking delivery of raw materials upto delivering finished products. We are using principles of Industrial Engineering which comprises work study,method study ,work measurement ,plant layout, material handling ,ergonomics to study the existing ways of production in the industry. Our purpose of studying the existing way is to find out loopholes in the current process and to eliminate all unnecessary operations and waste .Again, We are identifying non-value adding operations while investigating all operations processes .This study will guide us to discover new ways of doing work with developing and applying more effective methods to reduce cost, increase overall productivity and efficiency.

Modification and Development of Process for Improving Productivity

Abstract: This paper discusses about the modification and development of process for improving productivity of plastic product manufacturing unit.The factory is renowned for its plastic products.This unit is present in Electronic Zone, Hingna MIDC ,Nagpur .This factory has plastic injection molding machine for product manufacturing .In the project , we are going to modify the existing process ,the existing ways of doing work in the industry to increase its productivity. Also reducing time consumption for particular process and reducing workers fatigue is our main focus. We are using Industrial Engineering principles, tools and techniques such as work study,method study ,work measurement ,plant layout, material handling ,ergonomics to upgrade the existing ways of production in the industry.The modification of manufacturing line will lead to increased productivity of the production unit.

Field study of an arsenic removal plant for drinking water using activated carbon and iron in a rural community in the province of Pisco, Peru.

The presence of arsenic in Peru is a serious public health problem due to the geographical extension of populations that consume water with arsenic concentrations above the value recommended by the World Health Organization (WHO). An arsenic removal plant has been studied in a community of 50 families located in the province of Pisco, Peru, a filter media of activated carbon impregnated with iron (AC-Fe) was applied, the adsorption capacity of the material was studied against As(V) and As(III) species, also, a possible decrease in the adsorption capacity of chloride and sulfate ions. Modifications were made to the plant layout based on filtration columns and workflows. The arsenic level was reduced to levels recommended by the WHO, the plant production was estimated at 9,000 volumes of water bed until reaching its breakpoint. An optimum working flow rate of 1.8 m3 h-1 was found, it was also found that the zeolite column used for suspended solids removal did not contribute to the reduction of arsenic concentration, and the presence of ions did not reduce the arsenic removal capacity.

Comparative Analysis of the Performance of a Chain Mower and Tools That Perform Under-Row Weed Control with Tillage in the Vineyard

In the Mediterranean area, vineyard soils are often characterized by a high stone content. In these contexts, where tools commonly adopted for under-row weed control are frequently damaged, the utilization of a chain mower could be a preferable alternative. This research aims to compare a modified mower with chains with other tools commonly employed that control weeds through tillage, such as motorized discs, blade weeder, and rotary star hoe. Weed control effectiveness, effects on weed flora composition, soil compaction, and operative efficiencies were evaluated. The chain mower allowed us to obtain encouraging results of weed biomass reduction (55.4 and 25.4%, between and around vine trunks, respectively), weed height reduction (35.9%), and weed cover reduction (79.2%), comparable to the other tools. All the tools showed a lower weed control efficacy around vine trunks rather than between them (weed biomass reductions of 24.8% and 52.6%, respectively). Results regarding the effect on weed flora composition seem to confirm this trend. Despite the higher chain mower field time (3.78 h ha−1) and fuel consumption (24.24 kg ha−1) compared to the blade weeder and the rotary star hoe, its versatility in stony soil and its lower impact on soil (soil penetration resistances of 1602.42 and 2262.83 kPa in 2022 and 2023, respectively) compared to the other tools make it a potentially advantageous implement for under-row weed management in vineyards. Further studies could be useful to improve chain mower performance, particularly around vine trunks, by evaluating in different planting layouts different dimensions of both the cutting element and feeler, which allows the vine-skipping mechanism.

Holistic non-linear optimization of the layout, sizing, and operation of a district heating plant

A large fraction of district heating networks in Europe are still operating without thermal energy storage. While offering operational flexibility, the presence of energy storage complicates the problems of optimal sizing and control of the heat production plant. This necessitates a novel approach to system sizing based on non-linear programming in order to capture the system’s thermal response and inertia. Therefore, the present study focuses on such a typical plant in France and describes a holistic approach to optimize the capacities/parameters of system components, positions of the energy sources, as well as hourly flow rates. Such a simultaneous tuning of the system parameters and operating variables is essential to maximize the cost savings over the system's lifetime. The proposed framework here maintains the original non-linear form of the objective function and the constraints for more accuracy while allowing precise modeling of the thermally stratified storage tank by decoupling its calculations at a lower simulation level. Hence, the computation time in MATLAB® R2020A is mostly below 20 min on a typical personal computer. The lowest levelized cost of heat (57.259 EUR/MWh) is achieved when placing the gas boiler on a parallel line between the biomass boiler and the storage tank while sizing the two boilers using fractions of 0.33 and 0.73 of the maximum hourly demand, respectively, as well as a storage volume of 318.9 m3. Such relatively small storage reduces the lifecycle costs by a maximum of 1.34 % while reducing the specific carbon emissions by 17.33 %. Besides, it dampens the fluctuations in supply flow rates, minimizes unnecessary flow recirculation, and ensures a stable heat supply. Overall, thermal storage has a reasonable positive impact from an economic perspective, but a substantial impact on operational flexibility and mitigated carbon emissions.

Thermo-Economic Analysis of Organic Rankine Cycle with Different Working Fluids for Waste Heat Recovery from Coal-based Power Plant

The utilization of waste heat from power plants, which is generally lost to the atmosphere, can reduce energy waste significantly. Heat recovery systems can be integrated with power plants to utilize the waste heat, improving plant energy efficiency and reducing fossil fuel consumption and carbon emissions. The current study is focused on harnessing waste heat through the Organic Rankine Cycle (ORC) from 500 MWe supercritical power plant with CO2 capture. The simulation flow sheet program “Cycle-Tempo” models and simulates different plant layouts. This study considered five different working fluids for ORC, such as R245fa, Benzene, Methanol, Ethanol, and Acetone. The ORC generates additional electricity of 9.91 MWe for R245fa, 14.11 MWe for Benzene, 13.71 MWe for Methanol, 14.04 MWe for Ethanol and 13.97 MWe for Acetone. The thermodynamic study concludes that ORC based on benzene is the best, and the economic analysis discloses that ORC based on ethanol is the best among all working fluids with a payback period of 0.869 years and cost of electricity of Rupees 1.101 per kWh. This study also concludes that the novel technique used in the present study is economically viable, contributing to a more energy-efficient and environmentally friendly power generation system.

Layout optimization of heliostat field based on genetic algorithm

In order to improve the annual average optical efficiency of a tower solar power plant, a simulated heliostat field layout optimization model is constructed using ray tracing method to calculate the shadow shading efficiency. is constructed using ray tracing method to calculate the shadow shading efficiency. Genetic algorithms are used to encode the variables such as solar pitch angle, solar azimuth angle, and coordinates of heliostat mirrors in chromosomal individuals in binary regions, and to find the near-optimal solutions in iterative populations through the use of ray tracing method. Simulation results show that the model can significantly optimize the layout of the tower solar power system. Simulation results show that the model can significantly optimize the layout of the tower solar power plant and improve the annual average optical efficiency. neighboring heliostats is at 0.398 times the sum of the length and width, the optical efficiency of the Khi Solar One power plant reaches 61.83%, which is an improvement of 15.74% compared to that of the Khi Solar One power plant. improvement of 15.74% compared to this engineering example.

Optimal Wind Power Plant Layout Using Ant Colony Optimization

The optimal layout of wind power plants is very important as the arrangement of wind turbine generators (WTGs) profoundly affects the overall energy output of the wind power plant. To address this important issue, this research investigates the best layout for WTGs in wind power plants with different terrain features across three locations in Thailand using the Ant Colony Optimization (ACO) algorithm. The objective functions of maximizing the net annual energy production (AEP) and minimizing the wake losses were used to achieve the optimal wind power plant layout. Using the MERRA-2 database, computational fluid dynamics (CFD) wind flow modeling was performed to create 10x10 km2 microscale wind resource maps of locations characterized by flat, semi-complex, and complex terrains to install wind power plants. The CFD wind flow modeling yielded wind speeds of 5.00 to 5.76, 4.21 to 8.90, and 3.10 to 4.45 m/s for the flat, semi-complex, and complex terrains, respectively, making them feasible for utility-scale wind power plants. WTGs of multiple blade diameters, ranging from 90 to 126 m, with a nominal capacity of 2.5 MW at 100 m above ground-level hub heights, were used in this study. The Gamesa G126-2.5MW WTG with a 126 m blade diameter produces the highest net AEP of 14.3, 76.1, and 38.9 GWh/yr for the three terrains. Hence, this WTG was used to perform an ACO-based optimization to improve the electricity production of the wind power plants. Such studies are important to improve the efficiency of wind power plants, thus extracting the maximum kinetic energy possible from the winds and improving the economic viability of wind power plants.

Comprehensive ground coverage analysis of large-scale fixed-tilt bifacial photovoltaic plants

In the design of large-scale photovoltaic plants, decisions on array pitch and tilt play an essential role in life-cycle economics. These design issues have been studied extensively in traditional monofacial systems. However, bifacial systems, which are in increasing demand, are being studied and face challenges in system modeling, particularly in characterizing rear irradiance. Studies considering bifacial panels in plant layouts are recent and must be extensive. Existing studies are based on computationally intensive software and are limited to specific configurations. This study presents the development and validation of an analytical model of a multirow bifacial photovoltaic plant against Bifacial Radiance and DUET ray-tracing software. Comprehensive ground coverage and array tilt analyses are carried out for all ranges of configuration parameters (clearance height, albedo, collector length, bifaciality, or yield loss) and latitudes of up to 60° using this model. The results of extensive simulations were used to train the artificial neural networks. These mathematical architectures allow easy and fast execution of the proposed model with a slight accuracy loss and are provided in the supplementary material. In-depth analysis and developed tools will facilitate decision-making to obtain photovoltaic layouts more efficiently in terms of energy and economy for large-scale bifacial plants.

Diseño de una planta para la producción de bolsas oxo biodegradables, en la ciudad de Ocaña, Norte de Santander

This article presents the design of a plant for the production of oxo-biodegradable bags in the city of Ocaña, Norte de Santander, with the aim of reducing the environmental impact generated by plastic bags in the municipality. A market study is conducted to characterize plastic bag consumers and establish demand. In this particular case, customers are focused on the marketplace, retail supermarkets, and plastic bag distribution establishments. Based on customer preferences, the product design (capacity and type of bag) is developed, along with technical specifications and a generic logo. The design of the production process is carried out using the BPMN (Business Process Model and Notation) modeling technique, outlining each phase of production. Simultaneously, a systemic focus matrix is designed, showing the inputs, activities, and outputs of the process. The plant's layout design applies the SLP (System Layout Planning) method, illustrating the arrangement of workstations through the plant floor plan for production, thus observing the flow of materials. For the final design, 3D design software is used to visualize the area, layout, and dimensions of the plant.

Study on Microclimate and Thermal Comfort in Small Urban Green Spaces in Tokyo, Japan—A Case Study of Chuo Ward

Small urban green spaces are abundant in densely populated urban areas, but little is known about their impact on the urban heat island effect and thermal comfort. Therefore, this study selected as research sites four small urban green spaces in a typical high-density built-up area, Chuo Ward in Tokyo, Japan. The ENVI-met software 5.1.1 simulation method was used to analyze these sites’ microclimate and thermal comfort conditions. The following are the results: (1) Small urban green spaces significantly reduce urban air temperatures, particularly during hot weather, with temperature reductions ranging from 2.40 °C to 2.67 °C, consistently lower than the highest temperatures in Tokyo’s Chuo Ward, mainly between 1:00 and 2:00 p.m. (2) Thermal comfort analysis indicates that small urban green spaces can significantly improve urban thermal comfort during the day, particularly around noon, by reducing one or two thermal comfort levels compared to typical urban street blocks. However, these differences gradually diminish throughout the evening and night, and thermal comfort inside and outside green spaces becomes more uniform. (3) Green space size is not the only factor influencing thermal comfort; the layout of plants within the green space and the layout of the surrounding buildings also have an impact. Despite their small size, even small green spaces can significantly enhance comfort. This study highlights the need to promote urban sustainability through the extensive integration of small green spaces in dense urban environments. Small green spaces can serve as a high-frequency, low-cost solution for environmental sustainability by addressing the increasingly severe urban heat island effect as well as environmental challenges that in the urbanization process.

C/CLAY® – Experiences with clay calcining and grinding to achieve high SCM rates

AbstractThe cement industry has committed to take drastic steps to reduce process‐related CO2 emissions to achieve climate neutrality by 2050. One essential part of the solution is the reduction of the average clinker content in cement. However, the limits of availability of common composite materials are already reached, and focus is laid meanwhile on calcined clays as the next generation SCM. The knowledge about the effects of calcined clay in cement and also the development of production technologies are well‐advanced. Now it is the task to earn acceptance on customer's side project by project.For that purpose, the presented paper sums up the state of the art of clay activation by answering the most urgent questions of clients. This also includes a review of LOESCHE's experiences with clay calcination and grinding gained in the recent years. LOESCHE combines its competence in this technology in the product C/CLAY® supplying individual solutions for all process steps from pretreatment over calcination to finish grinding. The most practical C/CLAY® methods, the flash‐calcination and rotary kiln firing, are explained with their complete process chains, whereby the latter provides a suitable option for retrofitting stopped cement production lines. As example, the layout of the world's biggest clay calcination plant designed by LOESCHE's subsidiary DYNAMIS is presented.

Produced-Water Desalination Approach Uses Renewable Thermal Energy

_ This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper SPE 211175, “An Innovative Method of Water Management by Desalinating Produced Water Using Thermal Renewable Energy,” by Sharifa M. Al-Ruheili, Felix Tiefenbacher, and Khansaa H. Almahrami, ARA Petroleum Exploration and Production, et al. The paper has not been peer reviewed. _ The operator is adopting a method to manage high-salinity produced water in an environmentally sustainable way by extracting potable water from produced water and reducing discharge water volume by at least 50%. For desalination of the produced water, a combination of forward and direct osmosis technology is used. This process is driven mostly by thermal energy, which is provided to thermal collectors that are 100% solar. This technology uses renewable energy and will have no carbon footprint. Technology Description The technology involves concentrated solar thermal (CST) power plants that provide 100% renewable water desalination. Forward osmosis (FO) and direct osmosis (DO) can desalinate highly saline and polluted water, such as produced water, mainly with solar thermal energy. A pneumatic solar thermal plant consisting of two HELIOtube collectors, each 121 m long, provides the thermal energy for the desalination process. The plant includes a mirror technology based on CST, a cost-effective heat-transfer system using pressurized water as heat transfer fluid (HTF), and a low-maintenance thermal energy storage (TES) system allowing nighttime operations of 35 m3 volume with an operating temperature of 180°C using a pressurized water tank at 10-bar operating pressure. The desalination system will contain a pretreatment unit for the produced water and a desalination (FO) and brine-concentration (DO) unit. The unit will be integrated with thermal power to operate the desalination plant. In addition, a fully automated control system with a live backup will be installed. The system is classified as having low maintenance and cleaning costs because of its encapsulation features, rotatability of 300°, and convex shape. Fig. 1 of the complete paper shows the planned plant layout. The desalination plant will feature two outputs: fresh water of potable quality and brine. The fresh water will be used to serve the company’s freshwater demand, with excess water used for agricultural purposes or mixed with water in an injector well to improve injectivity. The other output, the highly concentrated brine (20% salt), will be collected in the existing evaporation pond where two main research and development studies are ongoing, one related to mineral extractions and the second related to salt monetization (using salt as a drilling additive).

Expansion of a mechano-chemical plant for remanufacturing waste tires into rubber sheet and profitable wire steel by-products: A quantitative sustainability assessment

Existing mechano-chemical plants remanufacture waste tires into rubber sheet and recover nylon fibers and metal wires. As a novel expansion of this process to improve its profitability and sustainability, this study proposes the integration of a pyrolysis–distillation system to produce energy products and machinery to produce by-products from the waste steel, such as galvanized wire, nails, and crimped mesh. A quantitative analysis was performed to evaluate the amount of steel wire, energy, and CO2 emissions saved by the proposed process. Furthermore, the potential profit was calculated at low and high potential scales, representing sustainable national and international development, respectively, with the aim of establishing a circular economy. Twenty-four alternatives based on technical variations were developed and their technical feasibility and potential profit were evaluated and ranked, providing valuable information for decision makers selecting plant layout options. The economic, environmental, and technical feasibility indexes were calculated and used to specify the social feasibility index. Finally, a quadrilateral-bottom-line sustainability development approach was used to calculate the final sustainability index, showing that the proposed integration is indeed a sustainable business approach. The findings of this study prove that there are significant benefits in expanding existing remanufacturing plants to extract value from the many different materials in waste tires.