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Innovation for Process Improvements

Innovation for Process Improvements. Malcolm Saunders Alpha Design and Project Technology. Necessity is the Mother of Invention. Challenges are the Father of Innovation. Manufacture of a Polyester Resin. Manufacture of a Polyester Resin. Phthalic Anhydride in flake form.

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Innovation for Process Improvements

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  1. Innovation forProcess Improvements Malcolm Saunders Alpha Design and Project Technology

  2. Necessityis theMother of Invention

  3. Challengesare theFather of Innovation

  4. Manufacture of aPolyester Resin

  5. Manufacture of aPolyester Resin • Phthalic Anhydride in flake form

  6. Manufacture of aPolyester Resin • Phthalic Anhydride in flake form • 25 kg bags

  7. Manufacture of aPolyester Resin • Phthalic Anhydride in flake form • 25 kg bags • Reactor charged manually by Operators

  8. Manufacture of aPolyester Resin • Phthalic Anhydride in flake form • 25 kg bags • Reactor charged manually by Operators • Dust masks and face shields

  9. 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

  10. Flake Form Phthalic AnhydrideDisadvantages

  11. Flake Form Phthalic AnhydrideDisadvantages • Operators need to wear protective equipment

  12. Flake Form Phthalic AnhydrideDisadvantages • Operators need to wear protective equipment • Phthalic flake generates a combustible dust

  13. Flake Form Phthalic AnhydrideDisadvantages • Operators need to wear protective equipment • Phthalic flake generates a combustible dust • Charging - time consuming

  14. 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

  15. 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

  16. 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

  17. Other Options

  18. Big Bags

  19. Ground Level Feed Station

  20. 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

  21. Ground Level Feed Station • Disadvantages • Difficult to measure charge • Difficulty of conveying ‘sticky’ flake material • Flake P.A. can generate combustible dust

  22. Bulk Storage of P.A. Flake

  23. 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

  24. 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

  25. Molten Phthalic Anhydride Storage and Distribution

  26. 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

  27. 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

  28. Meeting the Challenges • The Road Tankers

  29. Meeting the Challenges • The Road Tankers • Offloading and Storage

  30. Meeting the Challenges • The Road Tankers • Offloading and Storage • Control of vapours

  31. Meeting the Challenges • The Road Tankers • Offloading and Storage • Control of vapours • Distribution

  32. Meeting the Challenges • The Road Tankers • Offloading and storage • Discharge of vapours • Distribution • Reactor charging

  33. BENEFITS • Improved working conditions • Reduced charging and process times • Liberated Production area space • Lower process costs

  34. 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

  35. Innovation forProcess Improvements Malcolm Saunders Alpha Design and Project Technology Tel: 020 8657 1795 www.adapt88.com

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