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
Manufacture of a
Polyester Resin
Phthalic Anhydride in flake form
 25 kg bags

Manufacture of a
Polyester Resin
Phthalic Anhydride in flake form
 25 kg bags
 Reactor charged manually by Operators

Manufacture of a
Polyester 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 Anhydride
Disadvantages
Flake Form Phthalic Anhydride
Disadvantages

Operators need to wear protective
equipment
Flake Form Phthalic Anhydride
Disadvantages
Operators need to wear protective
equipment
 Phthalic flake generates a combustible dust

Flake Form Phthalic Anhydride
Disadvantages
Operators need to wear protective
equipment
 Phthalic flake generates a combustible dust
 Charging - time consuming

Flake Form Phthalic Anhydride
Disadvantages
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 Anhydride
Disadvantages
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 Anhydride
Disadvantages
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 for
Process Improvements
Malcolm Saunders
Alpha Design
and Project Technology
Tel: 020 8657 1795
www.adapt88.com