Innovation for Process Improvements Malcolm Saunders Alpha Design and Project Technology.
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Transcript of Innovation for Process Improvements Malcolm Saunders Alpha Design and Project Technology.
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