Optimization of Sugar-Based Resin contribution to polymerization 

 

Mixture designs, DOE, S

 

Production capacity is enhanced for bio-existence in sugar-based resin prevention using DOE mixture design tool. 

 

 

Opportunity & Problem

 

In this project, it has been investigating alternative binder system, which does not contain nor emit formaldehyde. An intrinsic advantage of phenol-formaldehyde resin is that act as a biocide naturally. The consequence of removing this effect from the process may lead to create appropriate conditions for microorganism growing in the process water. As a result in PW, personnel may be exposed to a health risk. In addition to this; some microorganisms may cause corrosion of process equipments or block process piping.

Furthermore, natural sugar based resins are alternative resins to substitute formaldehyde resin. These sugar-based resins started to be an additional risk with its organic content. In the factory, already one raw resin storage tank was removed because of flies’ existence. Since the natural based chemistry has been developing in recent years, these studies are invaluable for company know-how especially in resin decision process.

Essentially, after production trials using sugar based resin, there were critical appearance of bacteria that threaten production operations. Therefore, the project was absolutely one of the vital items on the agenda of the production managers. The bacteria and fungi existence was an enigma that factors are unknown.

 

Objective

Taking into account these possibilities, the objective of the study is to assess microorganism growth in process water of different resin and prevent it in current phenol resin as well and to propose solutions to avoid health, corrosion and blockage risk.

 

Project Work

The bacteria growth is influenced by temperature, pH, composition, osmotic pressure, oxygen pressure and stability of water. The process is examined according to these globally true rules. Then using colony count method ISO 6222, the design of experiment is prepared. The risk for different mixtures was determined in a conceptual way that covers all possible portions.

 

The design of experiments (DOE) was made using mixture design with 3 mixtures. In the ternary plot the blue colored area is free from bacteria and safe to operate for production processes.

Conclusion

The knowledge of bacteria growth is created in the organization and it is proved that the mixtures of one type of resin are risky for bacteria and fungi existence. This risk might be in a broad range of collecting flies in raw material storage tanks to blockages and health risk for associates and environment. This risk depends on plenty of factors such as mixture portions, concentration etc. This risk is identified and clarified in this project. The appropriate biocide was determined for each solution and process taking into account the process fitting design materials and chemical characteristics of resins.

The processes and factories that operate in risky area were noticed and corrected using appropriate biocides. The knowledge is distributed, communicated and associates were trained to operate in safe bio-existence zone.

Contamination in all plants was made using bacteria existence protocol that is created in the project.

A periodical process assessment tool was created to sustain the technical solution and prevention in long term. In assessment plan the sampling plan, sampling locations and pre-determined trusted laboratories were cited. 

 

 

Results

The essential result of this project was to enlighten a dark side for the organization. The bacteria growth was mysterious for the process owners as their expertise area was totally different. The unknown is always scary. This time it is enlightened using DOE and supporting it with theoretical knowledge. The risk of a delay in manufacturing operations due to bio-existence was driven away.

The knowledge of that encourages the process owners to work in a safe place, knowing the risk and how to prevent it.