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Strategic Planning

Problem

A large chlor-alkali plant was concerned about three basic problems involving the compression and liquefaction portion of the production operation. The problems included:

• Catastrophic failure of the reciprocating chlorine compressors, causing safety and environmental problems, high maintenance costs, and frequent production interruptions.
• Uncertainty about the future of continuing to use the existing freon refrigeration systems because of restrictions on using refrigerants classified as Ozone Depleting Substances by the Montreal Protocol.
• Loss of market for waste hypochlorite production due to the phase-out of pulp bleaching using hypochlorite.

The available capital for corrective action was limited and extensive downtime would be detrimental. The plant needed a path forward to address these issues for the next several years.

Solution

As part of a team effort to determine the cause of catastrophic failures of the reciprocating compressors, Universal Dynamics concluded that the Quality Assurance program on incoming critical spare parts did not detect latent defects.

Universal Dynamics engineers analyzed the operation and determined that the maintenance cost was high because the chlorine was inadequately dried through the existing drying system.

Universal Dynamics designed a stepwise approach to bolster the Quality Assurance program, correct the chlorine drying system, upgrade the compressors, and increase the chlorine gas recovery efficiency. The combination of these approaches would dramatically reduce the amount of waste hypochlorite that was being produced. The program was laid out in a stepwise function to be applied as market pressures allowed.

Results

The plant has enjoyed greatly improved reliability and reduced maintenance cost as a result of the program. Specific examples include:

• The corrosiveness of the chlorine handled is directly related to the moisture content. Immediate improvements in the drying system have cut the moisture level of the chlorine by a factor of 12.
• A new supplier of critical spare parts was located and a new Quality Assurance program was instituted. No catastrophic failure of compressors have resulted since implementation thereby saving over $1 million annually in maintenance and lost production costs.
• A plan for conversion to centrifugal compression has been put in place when spare parts for the old machines become unavailable.
• A liquefaction system capable of running for the next 20 years has been identified. Incremental improvements to the liquefaction efficiency will use ozone friendly materials to reduce the amount of waste hypochlorite produced.