Manufacturing/production operations

Gut Rubber and Extruded Latex. The manufacturing technology for cut and extmded mbber thread is much older and more widely known than that for spandex fibers. Because production faciUties can be installed with relatively modest capital investment, manufacture of mbber thread is fragmented and more widely distributed with a few major and many minor producers. On a worldwide basis, Fikattice of Italy is the largest mbber thread producer with modem extmded latex plants in Italy, Spain, Malaysia, and the United States. Second in production capacity is the Globe Manufacturing Co., Fall River, Massachusettes with production operations in the United States and the UK. These firms also produce spandex fibers. 

Manufacturers. Besides manufacturers in the United States, commercial fluorine plants are operating in Canada, France, Germany, Italy, Japan, and the United Kingdom (see Table 5). Fluorine is also produced in the Commonwealth of Independent States (former Soviet Union) however, details regarding its manufacture, production volumes, etc, are regarded as secret information. The total commercial production capacity of fluorine in the United States and Canada is estimated at over 5000 t/yr, of which 70—80% is devoted to uranium hexafluoride production. Most of the gas is used in captive uranium-processing operations. 

These factors can all be shown to influence the operating and/or capital costs of the plant (1). In addition a key concern is to reproducibly manufacture products having the desired physical and chemical properties. 

SPC on manufactured products SQC on laboratory operations communicate with corporate CIM system improved QA/QC on products reduced testing costs correlate laboratory analyses and process measurements faster solutions to production problems tested in laboratory faster notification of backlog problems improved electronic data interchange capabiUties automated communication with inventory, ordering, and materials planning systems... 

Dry Milk. Dry milk provides long-term storage capabHities, suppHes a product that can be used for food manufacturing operations, and because of its reduced volume and weight, transportation and storage costs are reduced. Dry milk has been used for manufactured products, but is used to a much greater extent for beverage products. Its properties are Hsted in Table 15. 

Understanding the Reactive Chemicals and Reactive Chemicals Systems Involved The main business of most chemical companies is to manufacture products through the control of reactive chemicals. The reactivity that makes chemicals useful can also make them hazardous. Therefore, it is essential that people who design or operate chemical processes understand the nature of the reactive chemicals involved. 

The gas-powered drilling and production internal combustion engines can be set up at the manufacturer to operate on gasoline, natural gas, or liquified petroleum gas (LPG). The manufacturer can also set up the engine to operate on all three types of gas fuels. This is accomplished by providing engines with conversion kits that can be used to convert the engine in the field. 

Compressors of various designs and manufacturers are used in many operations throughout the oil and gas industry. Compressors are used in some drilling operations, in many production operations, and extensively used in surface transportation of oil and gas via pipelines. 

The use of vibration analysis is not restricted to predictive maintenance. This technique is useful for diagnostic applications as well. Vibration monitoring and analysis are the primary diagnostic tools for most mechanical systems that are used to manufacture products. When used properly, vibration data provide the means to maintain optimum operating conditions and efficiency of critical plant systems. Vibration analysis can be used to evaluate fluid flow through pipes or vessels, to detect leaks, and to perform a variety of non-destmctive testing functions that improve the reliability and performance of critical plant systems. 

The manufacturing process must be fully defined and capable of yielding, with the facilities available, a product that is microbiologically acceptable and conforms to its specifications. This demands that a process be sufficiently evaluated before commencement to ensure that it is suitable for routine production operations. Processes and procedures should be subject to fiequent reappraisal and should be re-evaluated when any significant changes are made in the equipment or materials used. 

Instead, the producer, with the help of the biocide manufacturer, must critically look at the whole production operation from a microbiological point of view. 

With increasing dominance of multinational personal care companies, there is an additional factor now to be considered when choosing the preservative the need for the same product formulation to be sold on a global basis. Hence a large manufacturer with operations in many sites around the world may prefer to have one single formulation which can be produced at any, or all, of their worldwide factories. This means that the preservative must meet all local and national regulations. The chart below summarises the position of some of the most widely used preservatives in the three key markets of USA, Europe and Japan. 

The main business of most chemical companies is to manufacture products by means of controlled chemical reactions. The reactivity that makes chemicals useful can also make them hazardous. Chemical reactions are usually carried out without mishap, but sometimes they get out of control because of problems such as the wrong or contaminated raw material being used, changed operating conditions, unanticipated time delays, failed equipment, incompatible materials of construction, or loss of temperature control. Such mishaps can be worse if the chemistiy under both normal and abnormal conditions is not fully understood. Therefore, it is essential that chemical process designers and operators understand the nature of the reactive materials andchemistry involved and what it takes to control intended reactions and avoid unintended reactions throughout the entire life cycle of a process facility. 

An industrial grade, skid-mounted unit (see Fig. 11.2) has been operating successfully at Occidental Chemical s Delaware City mercury cell plant since September 1997. Operating results have met both the expectations of the client and Kvaerner. This chapter discusses the operating experience at OxyChem and the resulting optimised commercial product, the Kvaerner Chemetics Sulphate Removal System or SRS . The acceptance in the market-place has been excellent four systems have been ordered and three are in the process of manufacture, with operations commencing later in 2000. Approximately 50 firm price proposals have been issued in the past two years. Several of these evaluations are in the final stages and will lead to the sale of units in the near future. 

Sodium tripolyphosphate manufacmre generates no process wastes. Wastewaters from the manufacture of calcium phosphates are generated from a dewatering of the phosphate slurry and wet scmbbing of the airborne solids during product operations. 

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