Long Oil Alkyd Resin

Definitions
Time taken to complete a batch at the reactor stage is called as cycle time of the batch. The time loss in-between the batches is called as availability loss. The time loss in the completion of the batch as compared to standard time of the batch is called as rate loss.

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

Improvement can be done in some stages (marked as blue in the earlier slide)

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

Lithium Hydroxide has been used in the Soya DCO and BFRO based batches and required MG temperature is 262-263 deg C MG checked both by methanol tolerance and phthalic compatibility tests

Analysis
We can change the catalyst to Di butyl tin oxide or Lithium stearate (for Soya DCO based batches) and Lead acetate tri hydride (for BFRO based batches) MG should be cleared by methanol tolerance only.The phthalic compatibility can be checked when methanol tolerance is not achieved For new MG catalyst, only heating to 245-247 deg C is required for MG attainment.This will save the heating time by 1-2 hrs. The phthalic compatibility checking time is 20-25 minutes and the time can be saved

Investments
No capex required for change in MG checking procedure Cost of the batch to be calculated with new catalyst and materials to see the availability of catalysts

Benefits

Time taken for charging of post MG raw materials

Existing :- Charging of powders through Hopper from the top floor.It takes 3-4 hrs.to charge the material for post MG charging. Proposed :-Hopper of capacity 3 tons with discharge valve of 12 inch will be required.The post MG powder charging can be done simultaneously during heating of reactor for MG. Benefits:- The effective charging time on reactor will reduced to 15-30 min. Capex investment :For Tank Rs. 70,000 /- (including installation) 12 inch valve (butterfly valve) :-Rs. 15,000/-

Hopper (capacity 3 T)

REACTOR (10 T)

Time taken for heating to Polymerization temperature Problem

Low heating efficiency due to the thermopacs are running on LDO

Analysis
The FO has high calorific value than LDO The thermopac should be switched over to Furnace oil. The reactor % Non Volatile Matter to be checked to re-confirmed the exact quantity of xylene has been charged during polymerization. The stirrer should be provided with inverter drive.

No re-check on the quantity of xylene charged in the reactor during polymerization stage. Constant RPM of the stirrer of the reactor

Investments
Electrical heat tracing of pipeline from storage 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/-

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

Time taken for stripping of the xylene by vacuum application and final constants attainment Problem
The polymerization time of the batches are high

Analysis
Stripping of the xylene can be done after attainment of the acid value by applying vacuum of 500-600 mm of Hg Around 50% of the xylene can be stripped. Filtration system needs to be upgraded.

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

Benefits
The polymerization time will get reduced by 2-3 hrs.

Up gradation of the Filtration system Problem

The filtration system of the needs to be strengthen to take care of batches produced by stripping.

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

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

Benefits
The number of filtration stroke will also get reduced.

Others Suggestions
Inter-connection of thermopac so that both 10-ton and 5ton 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 machineRs.25,000 per strainer (Total requirement 2 Nos.) Emulsion production can be done in-house with installation of new 5-Ton reactor.The cost of in-house emulsion will be less than brought out emulsion.This will give us competitive edge in the market.