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

2. Necessity is the Mother of Invention

3. Challenges are the Father of Innovation

4. Manufacture of a Polyester Resin

5. n Phthalic Anhydride in flake form

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

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

8. 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

9. 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 - 320 bags n 2 hrs for 2 Operators

10. Flake Form Phthalic Anhydride Disadvantages

11. n Operators need to wear protective equipment

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

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

14. 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

15. 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

16. 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

17. Other Options

18. Big Bags

19. Ground Level Feed Station

20. 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

21. Ground Level Feed Station n 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. n 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 n 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 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

27. 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

28. Meeting the Challenges n The Road Tankers

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

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

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

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

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

34. 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

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