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