innovation for process improvements
DESCRIPTION
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. - PowerPoint PPT PresentationTRANSCRIPT
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Innovation forProcess Improvements
Malcolm Saunders
Alpha Design
and Project Technology
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Necessityis the
Mother of Invention
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Challengesare the
Father of Innovation
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Manufacture of aPolyester Resin
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Manufacture of aPolyester Resin
Phthalic Anhydride in flake form
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Manufacture of aPolyester Resin
Phthalic Anhydride in flake form 25 kg bags
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Manufacture of aPolyester Resin
Phthalic Anhydride in flake form 25 kg bags Reactor charged manually by Operators
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Manufacture of aPolyester Resin
Phthalic Anhydride in flake form 25 kg bags Reactor charged manually by Operators Dust masks and face shields
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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
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Flake Form Phthalic AnhydrideDisadvantages
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Flake Form Phthalic AnhydrideDisadvantages
Operators need to wear protective equipment
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Flake Form Phthalic AnhydrideDisadvantages
Operators need to wear protective equipment
Phthalic flake generates a combustible dust
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Flake Form Phthalic AnhydrideDisadvantages
Operators need to wear protective equipment
Phthalic flake generates a combustible dust Charging - time consuming
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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
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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
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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
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Other Options
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Big Bags
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Ground Level Feed Station
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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
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Ground Level Feed Station
Disadvantages– Difficult to measure charge– Difficulty of conveying ‘sticky’ flake material– Flake P.A. can generate combustible dust
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Bulk Storage of P.A. Flake
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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
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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
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Molten Phthalic Anhydride
Storage and Distribution
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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
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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
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Meeting the Challenges
The Road Tankers
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Meeting the Challenges
The Road Tankers Offloading and Storage
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Meeting the Challenges
The Road Tankers Offloading and Storage Control of vapours
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Meeting the Challenges
The Road Tankers Offloading and Storage Control of vapours Distribution
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Meeting the Challenges
The Road Tankers Offloading and storage Discharge of vapours Distribution Reactor charging
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BENEFITS
Improved working conditions Reduced charging and process times Liberated Production area space Lower process costs
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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
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Innovation forProcess Improvements
Malcolm Saunders
Alpha Design
and Project Technology
Tel: 020 8657 1795
www.adapt88.com