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Resin Type Heating Source

Acrylated Alkyd Steam heated


Acrylic Resin Steam Heated
Alkyd Modified Oil Heated
Amino Resin Steam Heated
CED Flexibiliser Oil Heated
CED Base Resin Oil Heated
CED Crosslinkar Oil Heated
CED Grind Resin Oil Heated
CED Resin Oil Heated
CED Solution Oil Heated
Dispersion Oil Heated
Fatty Acid Alkyd Oil Heated
Long Oil Alkyd Oil Heated
Medium Oil Alkyd Oil Heated
Modified Polyester Oil Heated
Polyester Oil Heated
Satin Resin Oil Heated
Short Oil Alkyd Oil Heated
Tinter Resin Oil Heated
Water Based Alkyd Oil Heated
Water Based Epoxy Oil Heated
DBU Resin GBU Resin
Resin Classification Resin
APKYD R 9968 (EXP) R - 8836
R 2346 Long Oil Alkyd R 6710
R 2349 Long Oil Alkyd R 6742
R 2356 Long Oil Alkyd R 6743
R 2368 Long Oil Alkyd R 6744
R 2369 Long Oil Alkyd R 7762
R 3437 Medium Oil Alkyd R 8805
R 3464 Medium Oil Alkyd R 8808
R 3468 Fatty Acid Alkyd R 8834(EPOXY AMINE ADDUCT)
R 4070 Short Oil Alkyd R-7796
R 4541 Short Oil Alkyd R 3225
R 4544 Short Oil Alkyd R 3418 (PART I)
R 4562 Short Oil Alkyd R 3472
R-2358 Satin Resin R 3474
R-2360 Long Oil Alkyd R 3497
R-2361 Long Oil Alkyd R 3499
R-2363 Long Oil Alkyd R 4548
R-2364 Satin Resin R 4549
R-2365 Long Oil Alkyd R 4560 .
R-2366 Long Oil Alkyd R-3481
R-3480 Medium Oil Alkyd R-3500
R-3487 Tinter Resin R-3501
R-3488 Medium Oil Alkyd R-7788
R 9980 Dispersion
R 9966 Dispersion
R 9932 Dispersion
R 3469 Alkyd Modified
R 6738 Acrylic Resin
R 6746 Acrylic Resin
BU Resin APPG Resin
Classification Resin Classification
Amino Resin PR 6732 CED Crosslinkar
Acrylic Resin PR 7779 CED Flexibiliser
Acrylic Resin PR 7780 CED Grind Resin
Acrylic Resin PR 9961 CED Crosslinkar
Acrylic Resin R 14501(ALKYD FOR T/C) (PPG) Short Oil Alkyd
CED Resin R 14502(ALKYD FOR T/C) (PPG) Short Oil Alkyd
Amino Resin R 14504(ALKYD RESING - PPG) Short Oil Alkyd
Amino Resin R 16701(POLYESTER FOR PR SURF (PPG) Polyester
Amino Resin R 16702(POLYESTER FOR MET B/C) (PPG) Polyester
CED Resin R 16703(POLYESTER FOR PR SURF) (PPG) Polyester
Medium Oil Alkyd R 16705(POLYESTER FOR GRINDING) (PPG) Polyester
Medium Oil Alkyd R 16709(ACRYLIC FOR CL COAT) (PPG)_ Acrylic Resin
Medium Oil Alkyd R 16711(ACRYLIC FOR PLASTIC)(PPG) Acrylic Resin
Medium Oil Alkyd R 16712(ACRYLIC FOR PLASTIC)(PPG) Acrylic Resin
Medium Oil Alkyd R 16715(POLYESTER FOR PRIMER) (PPG) Polyester
Medium Oil Alkyd R 16716POLYSTER FOR B/C (PPG) Polyester
Short Oil Alkyd R 16752 Acrylic Resin
Short Oil Alkyd R 16759 Acrylic Resin
Short Oil Alkyd R 17787 CED Grind Resin
Medium Oil Alkyd R 19901(PPG) water Based Alkyd
Medium Oil Alkyd R 19902(PPG) water Based Epoxy
Medium Oil Alkyd R 3418 (PART I) Medium Oil Alkyd
Epoxy R 3418 (PART II) Acrylated Alkyd
R 4070 Short Oil Alkyd
R 4079 Short Oil Alkyd
R 4099 Short Oil Alkyd
R 4124 Short Oil Alkyd
R 4548 Short Oil Alkyd
R 4549 Short Oil Alkyd
R 4551 Short Oil Alkyd
R 4559 Short Oil Alkyd
R-16718 Polyester
R-16719 Acrylic Resin
R-16722 (ACRYLIC RESIN ) Acrylic Resin
R-16724 Polyester
R-16725 Polyester
R-16733 CED Crosslinkar
R-16734 CED Crosslinkar
R-16751 (ACRYLIC RESIN ) Acrylic Resin
R-16757 Acrylic Resin
R-16762 Polyester
R-16763 Modified Polyester
R-16764 Acrylic Resin
R-16765 Acrylic Resin
R-17785 CED Base Resin
R-17786 CED Base Resin
R-17789 CED Base Resin
R-17790 CED Flexibiliser
R-17791 CED Base Resin
R-17792 CED Flexibiliser
R-19906 CED Solution
R-19907 CED Crosslinkar
R-3484 Acrylated Alkyd
R 6710 Acrylic Resin
R 6743 Acrylic Resin
R 6745 Acrylic Resin
R 7796 Epoxy Resin
BHP RESIN HOUSE CAPACITY CALCULATION
TFHS
Reactor Number REA-B401 REA-B402 REA-B403 REA-B404 REA-B405
Reactor Size (MT) 7.5 10 10 1 0.5
Reactor Type OH OH OH OH OH
Batch Size (MT) 11.1 17.54 17.1 1.4 0
Cycle Time 18.2 21.03 19.36 24.25 0
Stabilisation Factor 85% 90% 90% 80% 80%
Batches per day 1.12 1.03 1.12 0.79 0.00
No. of batches per month 21 21 22 16 0
Output per day (MT) 12.4 18.0 19.1 1.1 0.0
Days available 365 365 365 365 365
Stock Taking 8 8 8 8 8
Paid Holidays 8 8 8 8 8
Reactor cleaning days 50.01 29.79 32.41 35.48 0.00
Preventive Maintenance days 9.00 9.00 9.00 6.00 0.00
Weekly Off days/year 52 52 52 52 52
Days lost/Yr due to holiday closure 17.3 17.3 17.3 17.3 17.3
Net Days available 221 241 238 238 280
Resin Capacity MT 2729 4340 4546 264 0
Annual Capacity MT 13018
% Solids 60% 55% 57% 65% 0%
Resin Capacity TSR 1642 2386 2589 171 0
Annual Capacity TSR 7441
Emulsion Capacity 5203
CED Capacity 771
Consent : 11880 TSR
Total capacity ( in TSR) 13415

Please include all reactors of your plant other than emulsions in this sheet
1) Batch Size is the weighted average batch size based on the product mix in that particular reactor . Calculated in the respectiv
2) Batch Size is the weighted average batch size based on the product mix in that particular reactor . Calculated in the respecti
3) Stabilisation Factor : To consider deployment inefficiency e.g batch getting completed in the middle of the shift , shift chang
4) Number of batches per day = (24/ cycle time)*Stabilisation Factor
5) Number of batches per month = Batches per day *net days available/ 12
6) Reactor cleaning days = Average cleaning time per batch * batches per day * net days available ( excluding cleaning days)
7) % Solids is the weighted average figure that comes from the individual reactor sheet
Y CALCULATION
SHS
REA-B406 REA-B407 REA-B408
3 1 3
SH SH SH
3.25 0 3
21.09 0 27.75
80% 80% 80%
0.91 0.00 0.69
17 0 13
3.0 0.0 2.1
365 365 365
8 8 8
8 8 8
52.81 0.00 40.13
6.00 0.00 6.00
52 52 52
17.3 17.3 17.3
221 280 234
654 0 485
13018
57% 0% 58%
371 0 282

r reactor . Calculated in the respective reactor sheet


r reactor . Calculated in the respective reactor sheet
the middle of the shift , shift changeovers etc

ilable ( excluding cleaning days)


CED
Rea-B501

capacity/month
620.1 TFHS+SHS
771.00 64.3 CED
433.6 Emulsion

1117.9 total
Cleaning Time
Batch Cycle DBU/GBU/
in hrs per
Time in hrs APPG
S.N0 Product % Mix Batch Size Solids batch
1 R-2360 58% 11.7 60% 16.5 3 DBU
2 R-2361 6% 11.7 60% 16.5 3 DBU
3 R-2369 8% 11.7 60% 16 3 DBU
4 R-4562 20% 9 60% 22 3 DBU
5 R-4560 1% 9 60% 33 5 GBU
6 R-4541 3% 11.7 65% 16 5 GBU
7 R-3437 1% 14 45% 30 2 DBU
8 R-4548 2% 9 55% 39 3 GBU
9 R-9980 1% 4.7 94% 12 5 DBU

Total 100% 11.06 60% 18.2 3.1

Opportunities for improving cycle time

a) Availability of blender: Blender is available for MT based resins one unused blender is lying, limpetting of the same can be d
b) Manpower constraint
c) Utilities improvement
Classification
Explain the details of cleaning
Flushing with MT, if changeover to R4 then boiling ( 5Hrs) else flushing in 1 hr
Flushing with MT, if changeover to R4 then boiling ( 5Hrs) else flushing in 1 hr
Flushing with MT, if changeover to R4 then boiling ( 5Hrs) else flushing in 1 hr
Xylene boiling if industrial or R2 , 5hrs else flushing in 1 hr
Xylene boiling
Xylene boiling
Flushing with MT, if changeover to R4 then boiling ( 5Hrs)
Xylene boiling
before (MT) & after (xylene) the batch

limpetting of the same can be done and can be used for xylene based resin
Cleaning Time
Batch Cycle DBU/GBU/
in hrs per
Time in hrs APPG
S.N0 Product % Mix Batch Size Solids batch
1 R-2349 9% 16.3 60% 16.5 2 DBU
2 R-2360 51% 16.3 60% 16.5 2 DBU
3 R-2361 3% 16.3 60% 16.5 2 DBU
4 R-2369 4% 16.3 60% 16.5 2 DBU
5 R-3437 34% 20 45% 30 2 DBU
6
7
Total 100% 17.54 55% 21.03 2

Opportunities for improving cycle time

a) Availability of blender: Available


b) Manpower constraint:
c) Utilities improvement:
Classification
Explain the details of cleaning
Cleaning Time
Batch Cycle DBU/GBU/
in hrs per
Time in hrs APPG
S.N0 Product % Mix Batch Size Solids batch
1 R-2349 12% 16.3 60% 16.5 2 DBU
2 R-2360 57% 16.3 60% 16.5 2 DBU
3 R-2361 6% 16.3 60% 16.5 2 DBU
4 R-2369 5% 16.3 60% 16.5 2 DBU
5 R-3437 21% 20 45% 30 2 DBU
6
7
Total 100% 17.1 57% 19.36 2

Opportunities for improving cycle time

a) Availability of blender: Available


b) Manpower constraint
c) Utilities improvement: LEAF Filter machine
Classification
Explain the details of cleaning
Cleaning Time
Batch Cycle DBU/GBU/
in hrs per
Time in hrs APPG
S.N0 Product % Mix Batch Size Solids batch
1 R-3500 3% 1.0 55% 30 3
2 R-9932 11% 1.0 94% 12 3
3 R-9966 3% 1.5 72% 28 3
4 R-4070 29% 1.6 55% 24 3
5 R-4548 5% 1.6 55% 22 3
6 R 4124 2% 1.4 55% 26 3
7 R3499 3% 1.0 55% 28 3
8 R4560 34% 1.5 60% 30 3
9 R9980 7% 1.0 94% 11 3
10 R 7796 2% 1.0 80% 27 8
Total 100% 1.40 65% 24.3 3.1

Opportunities for improving cycle time

a) Availability of blender
b) Manpower constraint
c) Utilities improvement
Classification
Explain the details of cleaning
MT boiling
Xylene boiling
Xylene boiling
Xylene boiling In Bl-b407
Xylene boiling
Xylene boiling
MT boiling
Xylene boiling
Xylene boiling
caustic+water +solvent boiling
Cleaning Time
Batch Cycle DBU/GBU/
in hrs per
Time in hrs APPG
S.N0 Product % Mix Batch Size Solids batch
1
2
3
4
5
6
7
Total 0% 0 0% 0 0

Opportunities for improving cycle time

a) Availability of blender: Available


b) Manpower constraint Additional W/M requirement in each shift for running this reactor
c) Utilities improvement

Stirrer modification would be requuired.


Classification
Explain the details of cleaning
Cleaning Time
Batch Cycle DBU/GBU/A
in hrs per
Time in hrs PPG
S.N0 Product % Mix Batch Size Solids batch
1 R-6738 67% 3.25 60% 21 4 DBU
2 R-6746 33% 3.25 50% 21 4 DBU
3 R-6744 70% 25 4 GBU
4 R-6742 50% 30 4 GBU
5 R-6710 1% 3.25 69% 32 4 GBU, APPG
6 R-6743 65% 30 4 GBU
7
Total 100% 3.25 57% 21.1 4

Opportunities for improving cycle time

a) Availability of blender: Blender Available, Blender usage for industril resins need to supported by TF
b) Manpower constraint
c) Utilities improvement
Classification
Explain the details of cleaning
Cleaning Time
Batch Cycle DBU/GBU/
in hrs per
Time in hrs APPG
S.N0 Product % Mix Batch Size Solids batch
1
2
3
4
5
6
7
Total 0% 0 0% 0 0

To Run Rea-B407 there will be requirement of 1 additional W/M in each shift

Opportunities for improving cycle time

a) Availability of blender
b) Manpower constraint
c) Utilities improvement
Classification
Explain the details of cleaning
Cleaning Time
Batch Cycle DBU/GBU/A
in hrs per
Time in hrs PPG
S.N0 Product % Mix Batch Size Solids batch
1 R-6738 8% 3 60% 27 4 DBU
2 R-6746 52% 3 50% 27 4 DBU
3 R-6744 17% 3 70% 25 4 GBU
4 R-6742 2% 3 50% 30 4 GBU
5 R-6710 19% 3 69% 32 4 GBU, APPG
6 R-6743 2% 3 65% 30 4 GBU

Total 100% 3 58% 27.75 4

Opportunities for improving cycle time

a) Availability of blender: Blender not available, additional blender under 408 and consent from TF increases capacity by 15T
b) Manpower constraint
c) Utilities improvement

D:\Shailesh\SHS\
new blender install_REA408.xls
Classification
Explain the details of cleaning
If switching from one resin to the other then 4 hrs else flushing only 0.5 hrs

TF increases capacity by 15T