Biobased Chemical Manufacturer
Batch Process System Redesign
In this project, our team designed multiple viable alternatives to an existing batch process in one of our chemical manufacturing clients’ plants. Our design eliminated multiple unreliable components of the process and gave the client confidence in the new technology and equipment’s ability to withstand unexpected crises.
This major biobased chemical manufacturer is a leading global producer of high-performance chemical materials. The company impacts a wide range of markets across 70 countries worldwide.
When this chemical manufacturer started having issues with a batch process in their plant, Salas O’Brien analyzed the problem and provided options for design solutions to alleviate the problem. The existing system utilized eductors to draw solids, used in a pre-reaction phase as a catalyst for polymerization, into a liquid stream. Unexpected liquid overflows and accumulation of solid slurry on the adjacent charging pot and conveyer were affecting the reliability and consistency of the process, and the client needed a viable alternative.
Working closely with the plant operations, maintenance, and engineering personnel, our team developed a series of design options to improve the reliability of the process. Salas O’Brien also specified agitation testing to validate new equipment selections. Our vetting took into consideration the possibilities of uncontrolled solids addition, power outages, and inadequate liquid charges and gave the client confidence that the new technology and approach could withstand unexpected crises.
The design our client selected successfully eliminated all conveyors and eductors from the process while significantly decreasing the cycle time of the system and improving its reliability. The finished system is able to handle 30% clay solids concentrations.