commissioning and industrialisation of the mulwala ... · at the end of commissioning, we had a...
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COMMISSIONING AND INDUSTRIALISATION OF THE
MULWALA PROPELLANT FACILITY
TRANSITION FROM PROJECT TO PRODUCTION - SAFELY
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COMMERCIAL IN CONFIDENCE
Mulwala Facility Background Propellant manufacturing plant & infrastructure constructed 1942/43 Facility has been in continuous operation since construction. Only remaining Australian manufacturing source of military propellant, explosives & rocket motors
29 March 2007 – Federal Parliament approves Project
2016 – Transition from Commissioning to Industrialisation commences.
400 Employees (approx)
300 Buildings (approx); Site Area 1030 Hectare
Customers & Products Key Product Streams Propellants – Military & Commercial High Explosives (RDX/TNT 60/40, TNT,
RDX Desensitised, PE4) IM – PBX mixing & filling Calcium Nitrate Dilute Nitric Acid (40 – 60%) Others (hexamine tablets, ether)
Consolidated Quality Management System certified to ISO9001:2008
Laboratory is NATA (National Association of Testing Authorities) registered to ISO17025
Environmental Management System, certified to ISO 14001:2004
cAEO (commercial Authorised Engineering Organisation)
MHF (Major Hazard Facility) licence 2010-001
Facility Accreditation
What features make the plant safer
GUIDING PRINCIPLE
Expose the smallest amount of people, to the smallest amount of energetics, for the smallest amount of time
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people from the process.
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people from the process.Distributive Control System and Safety Integrated Systems.
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people from the process.Distributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Distributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.1.3 HD Fire walls.
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Distributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.Blast walls.LEL monitoring of hazardous vapours.
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Distributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.Blast walls.LEL monitoring of hazardous vapours.Compliant guarding and interlocking.
11
Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Distributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.Blast walls.LEL monitoring of hazardous vapours.Compliant guarding and interlocking.Water Vey of propellants
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Distributive Control System and Safety Integrated SystemsAutomatic transfer of buggy’s between buildings.Blast walls.LEL monitoring of hazardous vapours.Compliant guarding and interlocking.Water Vey of propellantsFire flash screens.
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Distributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.Blast walls.LEL monitoring of hazardous vapours.Compliant guarding and interlocking.Water Vey of propellantsFire flash screens.Ultra high speed deluge systems.
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Camera’sDistributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.Blast walls.LEL monitoring of hazardous vapours.Compliant guarding and interlocking.Water Vey of propellantsFire flash screens.Ultra high speed deluge systems.Automation. (BLDG 258 packing)
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Camera’sDistributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.Blast walls.LEL monitoring of hazardous vapours.Compliant guarding and interlocking.Water Vey of propellantsFire flash screens.Ultra high speed deluge systems.Automation. (258 packing)Camera’s
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Safety by design.
What feature make the plant safer• Expose the smallest amount of people, to the smallest amount of energetics, for the
smallest amount of time• Safety features by design:
Water slurry – transport of NC safely.Remote operations – remove people form the process.Camera’sDistributive Control System and Safety Integrated Systems. Automatic transfer of buggy’s between buildings.Blast walls.LEL monitoring of hazardous vapours.Compliant guarding and interlocking.Water Vey of propellantsFire flash screens.Ultra high speed deluge systems.Automation. (258 packing)Camera’sNitrogen Blanketing
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Safety by design.
What feature make the plant environmentally compliant
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Environmental Compliance.
Group 6 compliance for Nox emissions.MEF emissions levels – 2000 mg/m3MMF emission levels – 350 mg/m3
Group 6 compliance for Vox emissions.MEF emissions levels – NO LIMIT MMF emission levels – 40 mg/m3
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The Process PFD.
The primary intent was to close the old plant, as rapid as possible’ , through industrialisation of the new plant. At the end of commissioning, we had a plant that had made a product that looked and
behaved like propellant – a couple of times.
The challenge in developing final product conformance, and exercising the plant under full consistent operational load means you need an outlet for product produced.
Initial industrialisation phase meant we could pressure the plant, and find a home for it’s manufactured product, by blending back into commercial volumes. Industrialisation was intended to load the
plant to identify plant issue not experienced during the limited commissioning runs, and to replicate and cannibalise volumes from the old plant by blending. Initially by small percentage until we could consume the volume from the old process to the new, and constantly address any safety
issues to ensure the process remained stable and robust.
This phase is nearing completion, and whilst production efficiency remains an ongoing challenge, the new plant is at ‘Initial Operating Capability.’
So, some examples of how we industrialised and safely resolve issues we experienced.
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Mixing Extrusion/Cutting Solvent RecoveryWater Dry Deterrent Coating Drying Glazing /Sieving
Water Vey(Solvent) Water VeyWater Vey
Sample A1Sample A2Sample B3
Sample A3Sample B4Sample C2
Sample A4Sample B5Sample C3Sample D2
Extrusion/Cutting Solvent RecoveryWater Dry Deterrent Coating Drying Glazing /Sieving
Sample B1 Sample B2 Sample C1 Sample D1 Sample E1
1. Test effect of water vey 3. Test Drying 4. Test Glazing2. Test DeterrentCoating
Colloid (MRP formulation)
Base Grain
Wet Deterred
Base Grain
Dried Deterred
Base Grain
1.5 tonne 1.5 tonne 0.75 tonne 0.75 tonne 0.60 tonne
1.5 tonne 1.;0 tonne 1.0 tonne 0.75-1.0 tonne
Lab Water Jet Simulation
How we tested the plant capabilities.
Existing Facility Process
Modernised Process
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Mixing Extrusion DF Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Water Vey(Solvent) Water VeyWater Vey
Extrusion M&T Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Industrialisation
Packing
Blending Packing
Alcoholisation
Nitration
MixingAlcoholisation
Nitration
Industrialisation.Industrialisation.
Modernised Process
Existing Facility Process
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MixingExtrusion DF Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Water Vey(Solvent) Water VeyWater Vey
Extrusion M&T Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Industrialisation.
Packing
Blending
Alcoholisation
Nitration
MixingAlcoholisation
Nitration
Alcoholised NC.Final Grain blended at 50%.Target Grain at 100%
Modernised Process
Existing Facility Process
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MixingExtrusion DF Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Water Vey(Solvent) Water VeyWater Vey
Extrusion M&T Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Industrialisation.
Packing
Blending
Alcoholisation
Nitration
MixingAlcoholisation
Nitration
Alcoholised NC.Final Grain blended at 50%.Target Grain at 100%
Modernised Process
Broken Stirrer shaft
Broken Steam Eductor
Steam Hammer
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Mixing Extrusion DF Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Water Vey(Solvent) Water VeyWater Vey
Modernised Process
Existing Facility Process
Extrusion M&T Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying
Industrialisation
PackingBlendingAlcoholisation
Nitration
MixingAlcoholisation
Nitration
Alcoholised NC.Final Grain blended at 50%.Target Grain at 100%
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Mixing Extrusion DF Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Water Vey(Solvent) Water VeyWater Vey
Modernised Process
Existing Facility Process
Extrusion M&T Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying
Industrialisation
PackingBlendingAlcoholisation
Nitration
MixingAlcoholisation
Nitration
Alcoholised NC.Final Grain blended at 50%.Target Grain at 100%
Product carryover –glaze & Sieve
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MixingExtrusion DF Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Water Vey(Solvent) Water VeyWater Vey
Extrusion M&T Cutting
Solvent RecoveryWater Dry
Industrialisation
PackingBlendingAlcoholisation
Nitration
Mixed Colloid.Final Grain blended at 50%.Target Grain at 100%
Mixing
Modernised Process
Existing Facility Process
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MixingExtrusion DF Cutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Water Vey(Solvent) Water VeyWater Vey
Extrusion M&T Cutting
Solvent RecoveryWater Dry
Industrialisation
PackingBlendingAlcoholisation
Nitration
Mixed Colloid.Final Grain blended at 50%.Target Grain at 100%
Mixing
Modernised Process
Existing Facility Process
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MixingExtrusion M&TCutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Modified Water Vey
Water VeyWater Vey
Industrialisation
PackingBlendingAlcoholisation
Nitration
Mixed Colloid.Target Grain at 100%
Modified Pre Solvent Recovery
process
Modernised Process
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MixingExtrusion M&TCutting
Solvent RecoveryWater Dry
Deterrent Coating Drying Glazing
Sieving
Modified Water Vey
Water VeyWater Vey
Industrialisation
PackingBlendingAlcoholisation
Nitration
Mixed Colloid.Target Grain at 100%
Modified Pre Solvent Recovery
process
Modernised Process
burn rate testing (the modified UN series test for 4.1)
Bdg 210 -Solvent
manufacture and
reclamation
604E – Admin and Control
Room
253 –Propellant
press and cut
252 – Mixing NC with
solvents, etc.
134 – Removing water from NC, adding ethanol
131 –Cellulose shredding
132 – Nitration. (Adding
cellulose to Nitric/sulfuric
acids)
133 – NC stabilisation
258 – Propellant packing
257 – Propellant glazing and
sieving
254A&B –Propellant
solvent removal256A&B –Propellant
drying
Existing Facility Process
SummaryThe ongoing success of industrialisation could not have been achieved without a collaborative approach with the various elements of DoD working to a common goal.
Get the right people, get the right experience, get the right relationships. Once we got the partnership right, we really started getting an industrialised plant.
The plant is new – treat it with great respect – historic safety approaches are not necessarily the same.
To Date:More than a 1000 tonne of NC.140 tonne propellant processed through the Propellant Finishing process. (SR/WD and beyond50 tonne of 100% single pass – entirely manufactured on the new facility.660 tonne through glazing / packing
Safely.
For 2018, the plan is to optimise and attain efficient production rates, and to continue to evolve the safety management of the facility.
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QUESTIONS