Runcorn, UK Vinyls & Electrochemical Tech Lavera, France
Green Lake, TX
Brussels, Belgium
Venice, Italy
Rolle, Switzerland
Vinyls
Board
PO/PS
Nitriles
R&D/ Technical/ Manufacturing Centres
~400 people World-wide. Extensive Intellectual Property and 6000 patents Commercial Centres - Rolle (Switzerland), Lyndhurst and Runcorn (UK), Lisle (USA), and Shanghai (China)
Shanghai, China Technologies General
117 chlor-alkali projects over 30 years
Monopolar Cell rooms
BICHLOR Cell rooms
Americas Strong and Growing Presence
Company
Location
Year
HF Chlor-Alkali
USA
2014
Skymine
USA
2013
Fluoders
Paraguay
2013
Kuehne
USA
2001 / 2011
Olin
USA
2011 / 2014
FSTI/CSP
USA
2008
Allied
USA
2009
Lapsolite
Mexico
2006
Proquimsa
Ecuador
2005 / 2009
Proctor + Gamble
Guatemala
2003 / 2006
Successful Plant Lifespan Vital to INEOS ChlorVinyls
1800 1600 1400 1200 1000 800 600 400 200
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A major European ChlorVinyls Manufacturer
2000
7 cell-rooms across Europe,
total capacity 1,600,000 MTPA Cl2
1000's metric tonnes of Chlorine per annum
A designer and operator of
chlorine plants for over 110 years
Successful Plant Lifespan Key Factors
Successful Lifespan
Safe Operation
Reliability
Efficiency
INEOS Runcorn Driving Continuous Improvement
430kte/yr chlorine
20 BiChlor electrolysers
Designed to Lifecycle Principles
INEOS Know-How applied
World Class Performance
Techniques A Structured Way of Working
1. Process Description/ Purpose Performance of O Ring carriers
2. Potential Failure Mode Wrong material used in manufacture
3. Potential effect of failure Splits/cracks
4. Sev . 10
Dissolves/ Wear away Chemical Degrades
10
Thermal Expansion effect on seal
10
Porous
10
Sticks to tup tube
Cause reaction with other materials/ products
10
5. Potential cause of failure Supplier changes RM without informing ICL
6. Occ . 2
7. Current Controls None
Lifecycle Value Analysis
Critical Items Analysis
10. Recommended actions
Change of BOM Process Agreed BOM integrating into ETB systems
30
Change of supplier
Specification QA systems & registration
60
Generate approved supplier list
Raw materials to supplier changes without their knowledge
4/5
Specification maybe not detailed enough QA systems & registrations
450
Review specification & produce audit trial & review Specifications agreed with supplier.
Lack of detailed agreed specification
10
Operator inspection & operational experience
900
10
100
Establish if there is Shelf life Develop Stock rotation process Develop robust spec
None -
shelf life not known no stock rotation
11. Responsibility/ start date
12. Action Results
200
Dimensional ly wrong
9. RPN
Supplier changes RM informs ICL
Shelf Life: - Components
Performance of O Ring carriers
8. Det . 10
Too Narrow Cant Assemble
Supplier delivers outside of spec
Drawings Operator
48
Too Wide Leaks in service
10
Supplier delivers outside of spec
Drawings Operator Cell room measurements
720
Carry out QC Check
on tolerances Sample test
Loss Elimination - FMECA
Risk Based Inspection
INEOS Technologies Team Chlorine Experienced
Design Engineers
Project Commissioning Managers
Scientists
INEOS TEAM
Technical Managers
Plant Engineers
Plant Managers
Safe Operation
Successful Lifespan
Safe Operation
Reliability
Efficiency
Safe Operation Built In
Modular Technology AvoidsJ..
Interaction with live electrolysers Leaks modules are bolted, sealed & pressure tested
Fully Wetted Membrane
Gas/Liquor interface above the membrane Avoids damage and pin-holing of membrane Prevents mixing of Cl2 / H2 to avoid explosions
Safety in Plant Design
Inherently safe design features HAZOP
Reliability
Successful Lifespan
Safe Operation
Reliability
Efficiency
Reliability INEOS has the Knowledge
Accessible Headers
High Integrity Design
Stray Currents
Optioneering
Rapid Module Change
Dynamic Modelling Materials of Construction
Robust electrode coatings
Layout analysis
Reliability Avoiding Damaging Pressure Excursions
P02 (-20 mbarg)
PCV 01B
185 mbarg
Chlorine
SD1 PIC 01A
PIC 01B
V01 (10 BiChlor Electrolysers)
205 mbarg
dP02 (Headers and coolers)
Stream 01
SD1 dP03 (Headers, dryer, filter)
V02 (Headers and coolers)
Stream 02
V03 (Headers, dryer, filter)
P13 (165 mbarg)
Stream 11
dPIC 11B
dPCV 11B
dP = +15 mbar
dPIC 11A
V11 (10 BiChlor Electrolysers)
P03 (xxx barg)
Stream 03 P12 (0 mbarg)
Hydrogen
PCV 01A
Dynamic model of the gas section downstream of electrolyser
77th Conference on Glass Problems: A Collection of Papers Presented at the 77th Conference on Glass Problems, Greater Columbus Convention Center, Columbus, OH, November 7-9, 2016
77th Conference on Glass Problems: A Collection of Papers Presented at the 77th Conference on Glass Problems, Greater Columbus Convention Center, Columbus, OH, November 7-9, 2016
