Innovation for Process Improvements Malcolm Saunders Alpha Design and Project Technology
Sep 12, 2015
Innovation forProcess ImprovementsMalcolm SaundersAlpha Designand Project Technology
Necessityis theMother of Invention
Challengesare theFather of Innovation
Manufacture of aPolyester Resin
Manufacture of aPolyester ResinPhthalic Anhydride in flake form
Manufacture of aPolyester ResinPhthalic Anhydride in flake form25 kg bags
Manufacture of aPolyester ResinPhthalic Anhydride in flake form25 kg bagsReactor charged manually by Operators
Manufacture of aPolyester ResinPhthalic Anhydride in flake form25 kg bagsReactor charged manually by OperatorsDust masks and face shields
Manufacture of a Polyester ResinPhthalic Anhydride in flake form25 kg bagsReactor charged manually by OperatorsDust masks and face shields8 tonne charge - 320 bags2 hrs for 2 Operators
Flake Form Phthalic AnhydrideDisadvantages
Flake Form Phthalic AnhydrideDisadvantagesOperators need to wear protective equipment
Flake Form Phthalic AnhydrideDisadvantagesOperators need to wear protective equipmentPhthalic flake generates a combustible dust
Flake Form Phthalic AnhydrideDisadvantagesOperators need to wear protective equipmentPhthalic flake generates a combustible dustCharging - time consuming
Flake Form Phthalic AnhydrideDisadvantagesOperators need to wear protective equipmentPhthalic flake generates a combustible dustCharging - time consumingLow density - delivery and storage not cost effective
Flake Form Phthalic AnhydrideDisadvantagesOperators need to wear protective equipmentPhthalic flake generates a combustible dustCharging - time consumingLow density - delivery and storage not cost effectiveDisposal of empty bags
Flake Form Phthalic AnhydrideDisadvantagesOperators need to wear protective equipmentPhthalic flake generates a combustible dustCharging - time consumingLow density - delivery and storage not cost effectiveDisposal of empty bagsNeed to raise temperature of cold flake
Other Options
Big Bags
Ground Level Feed Station
Ground Level Feed StationAdvantagesBetter control of environment around the discharge stationIntermediate storage area not required in Production areaAvoid handling between main and intermediate storage
Ground Level Feed StationDisadvantagesDifficult to measure chargeDifficulty of conveying sticky flake materialFlake P.A. can generate combustible dust
Bulk Storage of P.A. Flake
Bulk Storage of P.A. FlakeAdvantagesmore cost effective deliveryEliminate need for storage of bagsEliminate costs associated with disposal of empty bags
Bulk Storage of P.A. FlakeDisadvantagesDifficulty in conveying sticky flakeDifficulty in measuring and controlling chargeFlake P.A. can generate combustible dust
Molten Phthalic AnhydrideStorage and Distribution
Molten P.A. - AdvantagesPA could be delivered and stored in bulkDensity in liquid form greater than flakeLiquid could be pumped and charge capacity controlledCharging process could be controlled by plcCharging time could be reducedEliminate dust and flake particlesNo bags to dispose ofMolten product - less heating time in reactorStorage in Production Areas eliminatedStock level can be monitored in tank
Molten P.A. - ChallengesProduct to be transported in molten stateInsulated tankers - guaranteed delivery timesNeed to offload & store at elevated temperatureControl of vapourPiping flexibility
Meeting the ChallengesThe Road Tankers
Meeting the ChallengesThe Road TankersOffloading and Storage
Meeting the ChallengesThe Road TankersOffloading and StorageControl of vapours
Meeting the ChallengesThe Road TankersOffloading and StorageControl of vapoursDistribution
Meeting the ChallengesThe Road TankersOffloading and storageDischarge of vapoursDistributionReactor charging
BENEFITSImproved working conditionsReduced charging and process timesLiberated Production area spaceLower process costs
SUMMARYConcept of changing from flake to liquid was innovativeMeeting the challenges posed required innovative thinkingResult - a successful method of supplying, storing and distributing a raw material to a process
Innovation forProcess ImprovementsMalcolm SaundersAlpha Designand Project TechnologyTel: 020 8657 1795www.adapt88.com