Manage site presentation.

Transcription

1 Manage site presentation. 1

2 Manage (Belgium) 2

3 Location From Manage to : - Antwerp port : 100 km - Rotterdam : 220 km - Düsseldorf : 240 km - Paris : 270 km 3

4 History 1968: Start-up of the paint factory by Belgolac-Group Petrofina to 1977: Belgolac makes several acquisitions and becomes Sigma Coatings. 1983: Start-up of the resin factory. 1992: Start-up of the emulsion unit. 1999: Total acquires Petrofina. Sigma Coatings becomes SigmaKalon. End 2003: Bain Capital acquires SigmaKalon, followed by a re-structuring of the Manage site, 23 March 2007: Arpadis becomes the new owner. 4

5 Table of content. Production capacities page 6 Raw material storage capacities page 7 Other storage page 9 Resins production page 10 Emulsions production page 15 Polymers : other facilities page 19 Polymers laboratory facilities page 20 Pilot Plant page 21 Coatings factory page 22 PVC-plastisol page 27 Coatings : other facilities page 29 Sites : communal equipment page 30 Administrative office page 31 5

6 Production Capacities Resins Emulsions Coatings t eq /y 7/7 days-3 shifts 8700 t eq /y 7/7 days-3 shifts t/y 7/7 days-3 shifts 6

7 Raw Material Storage 7

8 Raw Materials Storage (bulk) Bulk storage for flammable raw materials (solvents, monomers) : Connected to the resin plant : 8*24m3(1) + 3*48m 3 (1) + 3*22m 3 (2) + 3*29m 3 (2) Connected to the emulsion plant : 1*15m 3 (2) + 2*26m 3 (4)+ 2*49m 3 (2) Connected to the paint plant : 3*15m 3 (1)+ 4*18m 3 (1)+ 1*20m 3 (1)+ 3*25m 3 (1)+ 3*30m 3 (3)+ 1*40m 3 (1) Dirty solvent (commun) : 1*48m 3 (1) Storage area is fully compliant with Seveso Directive for dangerous goods. Bulk storage for nonflammables inside the resin plant: 6*32m 3 (1) + 3*32m 3 (5) + 4*16m 3 (1) + 2*16m 3 (5) Bulk storage outside for molten (60-80 C), connected to the resin plant. 5*23m 3 (5) (1) Carbon steel (2) Stainless steel+isolated (3) Stainless steel (4) Stainless steel+heating (5) Carbon steel+heating 8

9 Other Storage (non-bulk) 1 x 1000 m² covered area fitted with sprinklers for storage of flammable raw materials (drums, IBC). Space for approximately 2500 drums. or Space for approximately 650 IBC 1 x 1600 m² heated warehouse hall, fitted with sprinklers. 1 closed warehouse (capacity of 120 IBC). 1 bunker for storage of explosive materials (+/- 5mt) 3 warehouses, totally 1700 m², for storage of powders (big-bags & sacks) 2500m² of outside area allocated for storage of rework or waste. Further outside storage area of 3800m 2. 9

10 Resin Plant. 10

11 Resin Plant Summary Maximum working temperature of 260 C. Possibility to apply vacuum (200 mbar). 2 types of filtration: Filters bags Filters cake 2 filling machines: 1 automatic, connected to dilutors 1 semi-automatic, connected to storage tanks. 38 storage tanks for finish products (carbon steel) 28 x 31 m 3 4 x 44 m 3 6 x 20 m 3 (located inside the paint factory) Bulk loading facilities. 11

12 Resin Reactors & Dilutors Reactors for solvent based 4 polymerisation lines included stainless steel reactors, column, condenser and dilutor. Reactor (usable volume) Stainless steel 316 Ti 13 m³ 8 m³ 5 m³ 16 m³ Dilutor (usable volume) Carbon steel 32 m³ 25 m³ 12 m³ 40 m³ Polycondensation reaction possible in all lines, 2 of these are also equipped for radical polymerisation (8 and 5 m³). Possibility to use powder catalyst in the monomers mixing tank. 12

13 Operating conditions resins unit (1/2) material stainless steel (316 titanium) Working temperature max 260 C heating coil on the external lining cooling coil on the internal lining column filled with pall rings Reactors equipments material condensor reflux vessel reflux pump stirrer with 2 agitation stages and 2 rotation speeds (30 and 60 rpm) working at atmospheric pressure vacumm pump (+200 mbar/absolute vacumm) rupture disk and catch tank carbon steel working temperature max 90 C Dilutors equipments stirrer column for VOC collection close circuit filtration pump material stainless steel (316 titanium) Momoners mixing tank capacity Loading 6,3m³ Possibility to load catalyst in powder Initiator tank addition pump material capacity flow max. 1500kg/h stainless steel (316 titanium) 0,3m³ 13

14 Operating conditions resins unit (2/2) material carbon steel Filtration unit equipments filter bags units filter cake units material carbon steel Finish products storage tanks (1176 m 3 ) equipments 28 tanks of 31m³ 6 tanks of 22m³ (located in the paint factory) 4 tanks of 44m³ Finish products loading station equipments 13 loading arms for bulk deliveries Heating system equipments 2 heaters, max temperature of the thermic oil is 295 C Cooling system equipments air cooler tube bundle cooling water at max.35 C 14

15 Emulsion Plant 15

16 Emulsion Plant- Summary (1/2) Water-based 13 m3 Stainless Steel reactor with a pre-emulsion tank of 10m³. Reactor equipped with an overhead condenser. Maximum polymerisation temperature: 90 C. 2 cooling tanks of 18m³. 2 separated filtration lines on bags filters. Finished-product bulk storage capacity: 316 m³. 2 x 33 m 3 ( stainless steel) 2 x 60 m 3 ( stainless steel) 2 x 65 m 3 ( stainless steel) Filling machine for IBC and drums. Bulk loading facilities. 16

17 Emulsion Plant- Summary (2/2) 5 heating rooms for 62 drums or 12 IBC (maximum 80 C) Pneumatic loading silos for powder raw materials, connected to the solvent-based reactor: Phthatic anhydride Pentaerythritol Fumaric acid / benzoic acid 2 gas heaters to warm thermic oil. 2 supervision systems Monitor pro from Schneider for the resins unit. Yokogawa/Siemens for emulsions unit. 17

18 Emulsion Unit- operating conditions (1/2) material stainless steel (316 titanium/molybdenum) capacity 10m³ Momoners mixing tank equipments addition pump material Stirrer cooling system flow max.5000kg/h stainless steel (316 titanium/molybdenum) capacity 14m³ Working temperature max. 90 C heating/cooling coil on the external lining (max 140 C) Reactor empty column condensor equipments stirrer with 3 agiation stages with 4 blades/level and 2 baffles, rotation speed up to 55 rpm working at atmospheric pressure rupture disk and catch tank transfer pump to the cooling tank material stainless steel (316 titanium/molybdenum) Initiator tank capacity 1 m³ flow material max.320 l/h stainless steel (316 titanium/molybdenum) 2 cooling tanks capacity 18m³ equipments stirrer with 2 agitation stages with 6 blades/level and 2 baffles, 2 rotation speeds 30 and 60 rpm close circuit 18

19 Emulsion Unit- operating conditions (2/2) Extra initiator tanks (2) material capacity stainless steel (316 L titanium) 95 liters material inox 316 Filtration unit Finish products storage tanks equipments material capacity equipments filtration pump 2 separate filtrations lines (to avoid contamination risks) * collector of 6 filter bags in serie with 2 extra filter bags * collector of 2 filter bags stainless steel (316 titanium) 2x33m³, 2x60m³, 2x65m³ stirrer close circuit Finish products loading station material stainless steel 316 equipments 2 separate loading lines (to avoid contamination risks) Heating system equipments Heat exchanger thermic oil/water Heat exchanger water/water Cooling system equipments open cooling tower cooling water at max 25 C 19

20 Polymer Laboratory QC lab for polymers production R&D synthesis lab Analytical possibilities for binders Molecular weight or particules size measurements for binders Standard characterisation (acid value, hydroxyl value, epoxy value, viscosity, density, ) 20

21 Pilot Plants SB polymers Pilot unit of 125 l WB polymers Pilot unit of 45 l 21

22 Coatings Factory. 22

23 Coatings Hall 2 : Dispersing and Grinding. Nieman disperser for white with 3 fixed vessel of 5m 3. Coupled to 2 grinding machine HM60 (grinding speed from 300 to 500 kg/hour) HM90 (grinding speed from 300 to 500 kg/hour) 8 mixed tanks (8*10m 3 ) to convert from semi-finished to finishedproducts (2 x stainless steel and 6 x carbon steel). Nieman disperser for mobile vessel (from 1.2 to 2.5 m 3 ) Nieman disperser for mobile vessel (from 0.6 to 1.2 m 3 ) Cowless 25 disperser for mobile vessel (from 0.3 to 0.6 m 3 ) Cowless 55 disperser for mobile vessel (from 1 to 2.5 m 3 ) V80 disperser, coupled to with 3 fixed vessel of 5m 3. Coupled to Vollrath double-bowl grinder (2 x30ltrs) Butterfly-type machine of 1 m 3 for dilution of aluminium paste. 1 Klieverick distribution head for solvents and binders. 1 area for preparation of raw material in drum. 23

24 Coatings Hall 3 : Independent Grinding Machines 1 x Dynomill HM15 grinding machine for white grinding speed from 100 kg/hour. 1 x Dynomill HM45 grinding machine for white grinding speed from kg/hour. 6 x Fryma grinding machines 1 for water-based (bowl of 3 litres) 5 for solvent-based (bowl of 10 litres) 3 x Vollrath double bowl grinding machines 2 with 2 chambers of 15 litres 1 with 2 chambers of 30 litres 1 x Netzsch grinding machine chamber volume of 30 litres 24

25 Coatings Hall 4 : Dispensing & Final Conversion 1 x Fluid dispensing machine for pigment paste, with 24 carbon steel vessels of varying size: 5 x 3000 litres 5 x 1000 litres 4 x 2000 litres 10 x 500 litres 1 x Fluid dispensing machine for pigment paste, with 24 stainless steel vessels of varying size: 6 x 3000 litres 5 x 1000 litres 3 x 2000 litres 10 x 500 litres 20 x tanks of varying size to convert semi-finished to finish products: Stainless Steel: 1 x 7000 litres Carbon Steel: 7 x 2000 litres 1 x 5000 litres 10 x 4000 litres 1 x 7000 litres 25

26 Coatings Hall 5 : Filling and storage of finish products 3 x filling lines for boxes from 0.5ltr to 5ltr 1 x filling line for boxes or pails from 5 to 20 ltr. 1 x semi-automatic filling line for drums of 200 ltr. 1 x hydraulic machine for filling high viscosity products. 23 x storage tanks with mixing : Stainless Steel Ltrs: 6 x litres 1 x litres Carbon Steel ltrs 14 x litres 2 x litres 1 x spray booth. 26

27 PVC-plastisol. 27

28 Hall 6 : Production of PVC-plastisol 2 x 80mt silos for storage of PVC powder 1 x 32 m 3 storage tanks for plasticizer 2 x 24 m 3 storage tanks for plasticizer (1 with cooling capacity) 2 x 1.5 m 3 batch size Cowless disperser fitted with vacuum. 36 x storage tanks with mixing for semi-finished and finished products: 4 x 10m 3 4 x 7m 3 2 x 6m 3 8 x 5m 3 7 x 3.5m 3 2 x 3m 3 9 x 2m 3 2 x 4m 3 stainless steel storage tanks with mixing, for metallic coil coatings 28

29 Coatings : other facilities Automatic Riobeer cleaning machine for mobile vessel, with capacity from 500 to 2500 litres. Bulk loading station for finished products Lab for quality control on finish paints: 7 x spectrophotometers Mechanical tests 4 x oven for coil applications 6 x ovens Paint Laboratory for R&D. 29

30 Communal Site equipment 5 x ATEX diesel forklift trucks(atex) : 4 x 2 mt 1 x 3 mt 3 x ATEX electrical forklift trucks 7 x ATEX electrical-type retracks forklift 5 x ATEX electrical stacker Lobby for maintenance work. 1 x 15m 3 tank of liquid nitrogen 90% of the building area is fitted with sprinklers 30

31 Administrative office 33 office room 4 meeting room 42 desk 31