46677546 cycle time analysis

8/2/2019 46677546 Cycle Time Analysis

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Long Oil Alkyd Resin


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Definitions

Time taken to complete a batch at thereactor stage is called as cycle time of thebatch.

The time loss in-between the batches iscalled as availability loss.

The time loss in the completion of the batchas compared to standard time of the batch iscalled as rate loss.


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Stages of the Long Oil alkyd batches(MG Process)

Time taken for charging of Oil, polyol ,Catalyst Time taken for heating to get MG temperature Time taken for completion of monoglycerolysis Time taken for cooling the batch Time taken for charging of post MG raw materials Time taken for heating to Polymerization temperature Time taken for completion of polymerization Time taken for stripping of the xylene by vacuum application

and final constants attainment- New step Time taken for cooling the batch to 200 deg C and partial

thinning Time taken for transfer of batch to thin tank Time taken for hot flushing of the reactor- New step


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Improvement can be done in some stages

(marked as blue in the earlier slide)


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Time taken for heating to get MG temp. and completion of MG

Problem Analysis

BenefitsInvestments

Lithium Hydroxide has been used inthe Soya DCO and BFRO based batchesand required MG temperature is 262-263deg C MG checked both by methanol

tolerance and phthalic compatibilitytests

We can change the catalyst toDi butyl

tin oxide or Lithium stearate (for SoyaDCO based batches) and Lead acetatetri hydride (for BFRO based batches) MG should be cleared by methanol

tolerance only.The phthalic compatibilitycan be checked when methanol tolerance isnot achieved

For new MG catalyst, only heating to245-247 deg C is required for MGattainment.This will save the heatingtime by 1-2 hrs. The phthalic compatibility checkingtime is 20-25 minutes and the time canbe saved

No capex required for change in MGchecking procedure Cost of the batch to be calculated withnew catalyst and materials to see theavailability of catalysts


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Time taken for charging of post MG raw materials

Existing :- Charging of powdersthrough Hopper from the top floor.Ittakes 3-4 hrs.to charge the material forpost MG charging.

Proposed :- Hopper of capacity 3 tonswith discharge valve of 12 inch will be

required.The post MG powder chargingcan be done simultaneously duringheating of reactor for MG.

Benefits:- The effective charging time on reactor will reduced to 15-30 min .

Capex investment :- For Tank Rs. 70,000 /- (includinginstallation)12 inch valve (butterfly valve) :- Rs.15,000/-

REACTOR (10 T)

Hopper(capacity 3 T)


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Problem Analysis

BenefitsInvestments

The FO has high calorific valuethan LDO The thermopac shouldbe switched over to Furnace oil .

The reactor % Non Volatile Matterto be checked to re-confirmed theexact quantity of xylene has been

charged during polymerization. The stirrer should be provided withinverter drive .

Electrical heat tracing of pipeline fromstorage tank to fuel pump Rs. 10,000/- Cost of new fuel pump Rs.25,000/- Cost of Pre-heater Rs. 10,000/- Change in burner assembly Rs.15,000/- No capex required for % NVM checking Cost of inverter drive Rs. 1,50,000/-

Time taken for heating to Polymerization temperature

Low heating efficiency due to thethermopacs are running on LDO No re-check on the quantity of xylenecharged in the reactor duringpolymerization stage. Constant RPM of the stirrer of thereactor

With TP on FO,the heating time will bereduced. The exact quantity of xylene will lead tothe constant time of polymerization. The variable RPM gives the flexibility of increasing the RPM for easier batches(e.g.Syn 5927 soya based batches)


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Problem Analysis

BenefitsInvestments

Time taken for stripping of the xylene by vacuum application and finalconstants attainment

The polymerization time of thebatches are high

Stripping of the xylene can be done afterattainment of the acid value by applyingvacuum of 500-600 mm of Hg Around 50% of the xylene can bestripped. Filtration system needs to be upgraded.

Vacuum pump Rs. 35,000/- Pipelines for connection of vacuumpump to condenser-Rs.20,000/- Water circulation system Rs. 45,000/-

The polymerization time will getreduced by 2-3 hrs.


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Problem Analysis

BenefitsInvestments

The filtration system of the needs to bestrengthen to take care of batchesproduced by stripping.

The number of filtration stroke will alsoget reduced.

Up gradation of the Filtration system

The batches need to be filtered at 140deg C Thermic fluid heating to be provided tothe Thin tank

Pipeline from Thermopac to thin tank -Rs. 25,000 /-


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Others Suggestions Inter-connection of thermopac so that both 10-ton and 5-

ton reactors could be run with one TP-10 Rs. 1,65,000/- Strainer for oil tanker un-loading point Rs.25,000/- per

strainer (Total requirement 5Nos.)

Insert pipeline for MTO flushing of reactor Rs. 5,000/-per reactor Strainer between the Thin tank and Filter machine-

Rs.25,000 per strainer (Total requirement 2 Nos.)

Emulsion production can be done in-house withinstallation of new 5-Ton reactor.The cost of in-houseemulsion will be less than brought out emulsion.Thiswill give us competitive edge in the market.


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46677546 cycle time analysis

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