Innovation for Process Improvements

Innovation forProcess Improvements

Malcolm Saunders

Alpha Design

and Project Technology

Necessityis the

Mother of Invention

Challengesare the

Father of Innovation

Manufacture of aPolyester Resin

Manufacture of aPolyester Resin

Phthalic Anhydride in flake form

Manufacture of aPolyester Resin

Phthalic Anhydride in flake form 25 kg bags

Manufacture of aPolyester Resin

Phthalic Anhydride in flake form 25 kg bags Reactor charged manually by Operators

Manufacture of aPolyester Resin

Phthalic Anhydride in flake form 25 kg bags Reactor charged manually by Operators Dust masks and face shields

Manufacture of a Polyester Resin

Phthalic Anhydride in flake form 25 kg bags Reactor charged manually by Operators Dust masks and face shields 8 tonne charge - 320 bags 2 hrs for 2 Operators

Flake Form Phthalic AnhydrideDisadvantages

Flake Form Phthalic AnhydrideDisadvantages

Operators need to wear protective equipment

Flake Form Phthalic AnhydrideDisadvantages

Operators need to wear protective equipment

Phthalic flake generates a combustible dust

Flake Form Phthalic AnhydrideDisadvantages

Operators need to wear protective equipment

Phthalic flake generates a combustible dust Charging - time consuming

Flake Form Phthalic AnhydrideDisadvantages

Operators need to wear protective equipment

Phthalic flake generates a combustible dust Charging - time consuming Low density - delivery and storage not cost

effective

Flake Form Phthalic AnhydrideDisadvantages

Operators need to wear protective equipment

Phthalic flake generates a combustible dust Charging - time consuming Low density - delivery and storage not cost

effective Disposal of empty bags

Flake Form Phthalic AnhydrideDisadvantages

Operators need to wear protective equipment Phthalic flake generates a combustible dust Charging - time consuming Low density - delivery and storage not cost

effective Disposal of empty bags Need to raise temperature of cold flake

Other Options

Big Bags

Ground Level Feed Station

Ground Level Feed Station

Advantages– Better control of environment around the

discharge station– Intermediate storage area not required in

Production area– Avoid handling between main and intermediate

storage

Ground Level Feed Station

Disadvantages– Difficult to measure charge– Difficulty of conveying ‘sticky’ flake material– Flake P.A. can generate combustible dust

Bulk Storage of P.A. Flake

Bulk Storage of P.A. Flake

Advantages– more cost effective delivery– Eliminate need for storage of bags– Eliminate costs associated with disposal of

empty bags

Bulk Storage of P.A. Flake

Disadvantages– Difficulty in conveying ‘sticky’ flake– Difficulty in measuring and controlling charge– Flake P.A. can generate combustible dust

Molten Phthalic Anhydride

Storage and Distribution

Molten P.A. - Advantages

PA could be delivered and stored in bulk Density in liquid form greater than flake Liquid could be pumped and charge capacity controlled Charging process could be controlled by plc Charging time could be reduced Eliminate dust and flake particles No bags to dispose of Molten product - less heating time in reactor Storage in Production Areas eliminated Stock level can be monitored in tank

Molten P.A. - Challenges

Product to be transported in molten state Insulated tankers - guaranteed delivery

times Need to offload & store at elevated

temperature Control of vapour Piping flexibility

Meeting the Challenges

The Road Tankers

Meeting the Challenges

The Road Tankers Offloading and Storage

Meeting the Challenges

The Road Tankers Offloading and Storage Control of vapours

Meeting the Challenges

The Road Tankers Offloading and Storage Control of vapours Distribution

Meeting the Challenges

The Road Tankers Offloading and storage Discharge of vapours Distribution Reactor charging

BENEFITS

Improved working conditions Reduced charging and process times Liberated Production area space Lower process costs

SUMMARY

Concept of changing from flake to liquid was innovative

Meeting the challenges posed required innovative thinking

Result - a successful method of supplying, storing and distributing a raw material to a process

Innovation forProcess Improvements

Malcolm Saunders

Alpha Design

and Project Technology

Tel: 020 8657 1795

www.adapt88.com