High-throughput automated speciality chemicals plant for BASF.
Following the completion of several significant projects within chemicals giant BASF, Ai Process secured a multi-million pound project to redevelop and modernise BASF’s construction chemicals facility at Swinton, North Manchester.
BASF Construction Chemicals is a leading supplier of chemical systems and formulations for customers from the construction industry. Their main business activities comprise Admixture and Construction Systems, offering ready-mix, precast and concrete products and specialised systems for sports and industrial flooring, exterior insulation and building products sectors.
Completion of this project significantly increased site production. Both BASF and Ai Process take pride in the fact that the new plant layout and operating techniques set a very high standard for health and safety on site.
Process automation now gives BASF batch repeatability, which has led to improvements in process performance, flexibility and, more importantly, product quality.
Operated by an efficient and dedicated team, the new facility is capable of producing 20 million litres of product per annum with an operating team of only 3 people.
The Design Challenge
BASF wanted to redevelop and modernise their existing manufacturing facility in Swinton, Manchester. The main challenge for Ai Process was to provide an accurate and detailed solution to significantly increase production and improve:
- Batch accuracy
- Batch repeatability
- Product quality
- Cost efficiency
A crucial element of the design project was to ensure that the plant complied with the very latest health & safety regulations.
Scope of Works
To design, procure and project manage the installation of the following:
- A 740,000 litre capacity indoor raw material and finished product storage facility
- High and low solids powder incorporation systems
- A recipe driven SCADA control system
- IBC and container filling capabilities
- Tanker loading and unloading facilities for both raw materials and finished products
Ai Process is proud to offer continuing post-project support to its clients, including the supply of spares and operator training. Investigations into further process development and additional production upgrades are ongoing with BASF.