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

n Phthalic Anhydride in flake form

Manufacture of a Polyester Resin n Phthalic Anhydride in flake form n 25 kg bags

Manufacture of a Polyester Resin n Phthalic Anhydride in flake form n 25 kg bags n Reactor charged manually by Operators

Manufacture of a Polyester Resin n Phthalic Anhydride in flake form n 25 kg bags n Reactor charged manually by Operators n Dust masks and face shields

Manufacture of a Polyester Resin n Phthalic Anhydride in flake form n 25 kg bags n Reactor charged manually by Operators n Dust masks and face shields n 8 tonne charge bags n 2 hrs for 2 Operators

Flake Form Phthalic Anhydride Disadvantages

n Operators need to wear protective equipment

Flake Form Phthalic Anhydride Disadvantages n Operators need to wear protective equipment n Phthalic flake generates a combustible dust

Flake Form Phthalic Anhydride Disadvantages n Operators need to wear protective equipment n Phthalic flake generates a combustible dust n Charging - time consuming

Flake Form Phthalic Anhydride Disadvantages n Operators need to wear protective equipment n Phthalic flake generates a combustible dust n Charging - time consuming n Low density - delivery and storage not cost effective

Flake Form Phthalic Anhydride Disadvantages n Operators need to wear protective equipment n Phthalic flake generates a combustible dust n Charging - time consuming n Low density - delivery and storage not cost effective n Disposal of empty bags

Flake Form Phthalic Anhydride Disadvantages n Operators need to wear protective equipment n Phthalic flake generates a combustible dust n Charging - time consuming n Low density - delivery and storage not cost effective n Disposal of empty bags n Need to raise temperature of cold flake

Other Options

Big Bags

Ground Level Feed Station

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

Bulk Storage of P.A. Flake

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

Molten P.A. - Challenges n Product to be transported in molten state n Insulated tankers - guaranteed delivery times n Need to offload & store at elevated temperature n Control of vapour n Piping flexibility

Meeting the Challenges n The Road Tankers

Meeting the Challenges n The Road Tankers n Offloading and Storage

Meeting the Challenges n The Road Tankers n Offloading and Storage n Control of vapours

Meeting the Challenges n The Road Tankers n Offloading and Storage n Control of vapours n Distribution

Meeting the Challenges n The Road Tankers n Offloading and storage n Discharge of vapours n Distribution n Reactor charging

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

SUMMARY n Concept of changing from flake to liquid was innovative n Meeting the challenges posed required innovative thinking n Result - a successful method of supplying, storing and distributing a raw material to a process

Innovation for Process Improvements Malcolm Saunders Alpha Design and Project Technology Tel: