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Technology Commercialization by Raja Wajahat

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Technology commercialization
Workshop Lecture by Raja Wajahat at University of Sargodha , Pakistan

Published in: Engineering

Technology Commercialization by Raja Wajahat

  1. 1. Technology Commercialization Presented by Raja Wajahat R&D Engineer - Shafi Reso Chemcials
  2. 2. ABOUT SHAFI RESO-CHEMICALS  Established in 1994 –A Leather specialty Chemical Manufacturing Company  Foreign Collaboration with Italian Company ALPA  ISO Certification : ISO 9001, ISO 14001, ISO 18000  Won export PerformanceTrophy 2009 Presented by Raja Wajahat 2
  3. 3. Products  Acrylic Emulsion polymers  Condensation polymers/Resins  PolyvinylAcetate adhesive/Dispersions  Solution adhesives  Fat liquors/Emulsified Oils  Wax Emulsions/Nitro cellulose emulsions  Wetting agents, Detergents and Degreasers  Pigment emulsions  Acid Dyes / Dyes Intermediates  Basic Chromium Sulfate/Chromium Compounds  Shoe Finishing Chemicals  Boiler and Cooling water Treatments Presented by Raja Wajahat 3
  4. 4. ABOUT SHAFI RESO-CHEMICALS We believe in R&D basedTechnologies for the progress of Pakistan Presented by Raja Wajahat 4
  5. 5. Role of Academia in Technology Development Presented by Raja Wajahat 5
  6. 6. FACILITIES at RESO CHEMICALS  R&D Lab: Lab scale reactors, mixers, Micro grinders, high speed homogenizer and autoclaves etc  Quality Lab: Spectra flash SF 550, Spectrophotometer, Refractrometers, Digital viscometers.  Application Lab: All the facilities needed for leather application.  Pilot Plant: SS Polymer Pilot, Rubber Lined Dyes plant, Glass Lined plant, Spray dryer, Pilot BCS Plant, filter press  Production Plant: Stainless Steel, Glass Lined, Rubber lined Plants, Spray Dryes, Filter Presses & Ovens. Powder Mixers. Presented by Raja Wajahat 6
  7. 7. Technology Commercialization In 7 Steps Presented by Raja Wajahat 7
  8. 8. The Technology Commercialization 1).Technology Identification with User End Market Potential 2). Literature & Market Survey for Production Methods 3). Costing for Selection of Optimum Route 4). LabTrials 5). PilotTrials 6). User End ApplicationTrials 7). ProductionTrials 8
  9. 9. Case – 1 Sodium Dichromate and the 7 Steps Presented by Raja Wajahat 9
  10. 10. 1. Technology Identification  Basic Sodium Chromate is major product of SRC  Sodium Dichromate is its basic raw material  Imported above 1500 MT/Annum Presented by Raja Wajahat 10
  11. 11. 2. Literature Survey for Production Methods  A consultant was hired who was in key position in one of the three chromite ore extraction facilities that failed in the past  Team of engineers Presented by Raja Wajahat 11
  12. 12. 3. Costing for selection of Optimum Route  Initial costing proved the feasibility of the product  But  After two years of experimentation the challenge of finding the optimum route still remains Presented by Raja Wajahat 12
  13. 13. 4. Lab Trials  Analysis methods were a big challenge  Took almost three months to find a reliable and efficient method  300 + Lab trials to get maximum conversion to set best performance conditions Presented by Raja Wajahat 13
  14. 14. 5. Pilot Trials  Building a pilot plant with optimum performance parameters from lab trials  Production limits 50 – 100 kg  To reproduce the results obtained in the lab trials  90% of the times, adjustment of process parameters is required  In the time frame of two years only 17 pilot trials have been completed with less conversion than in lab trials Presented by Raja Wajahat 14
  15. 15. 6. User End Application Trials  If the pilot trials confirm  SDC will be used to produce Basic Sodium Chromate Presented by Raja Wajahat 15
  16. 16. 7. Production Trials  Success in application trials will open the gates for engineering of commercial production facility  Also for the commercial production of the product Presented by Raja Wajahat 16
  17. 17. Case – 2 Tile Bond & Grout and the 7 Steps Presented by Raja Wajahat 17
  18. 18. 1. Technology Identification  Thousands of tons is imported from Lafarge under the market name of ExtremeTile Bond  Same for grout Presented by Raja Wajahat 18
  19. 19. 2. Literature Survey for Production Methods  A University Scientist through IRP provided the formulations and methods of production Presented by Raja Wajahat 19
  20. 20. 3. Costing for selection of Optimum Route  Initial costing proved the feasibility of the product  Later  Was confirmed by the lab and pilot trials Presented by Raja Wajahat 20
  21. 21. 4. Lab Trials  RAW MATERIAL Sourcing was a big challenge  It took us about two months to locate the suitable raw material for optimum cost  Lab trials easily completed  Method of analysis completed with the help of PCSIR Lahore  1 Month for 1Test Presented by Raja Wajahat 21
  22. 22. 5. Pilot Trials  100 kg trials were completed in equipment available in RESO  Tests from PSCIR Lahore  Quality and cost was confirmed Presented by Raja Wajahat 22
  23. 23. 6. User End Application Trials  Samples were given to some construction companies Presented by Raja Wajahat 23
  24. 24. 7. Production Trials  Waiting for the confirmation of the application trials Presented by Raja Wajahat 24
  25. 25. Key Factors of Identification of Technology How to identify a potential Technology? Presented by Raja Wajahat 25
  26. 26. Technology Identification 1. Market Demand and Import Data 2. Requirement of Low price Raw Materials/Finished 3. Technologies based on Local Resources 4. Local Plant Designing and Fabrication Presented by Raja Wajahat 26
  27. 27. Challenges at Lab Scale Which Key Factors can affect Lab trials? Presented by Raja Wajahat 27
  28. 28. Challenges at Lab Scale 1. Time Frame of Development. 2. Cost issue/ short technology life/Quick alternates 3. Selection of Raw materials. 4. Availability /Volume/ Ecology /Environment. 5. Cost effective routes 6. Safe & Flexible Parameters with reference to process handling. 7. Few Bulk trails 8. QA & QC Protocol. 9. Consideration of Market Demand. Presented by Raja Wajahat 28
  29. 29. Challenges at Lab Scale 10. Working with new opportunities 11. Utilization of RejectedTrails 12. Ecological & Environmental Issues 13. International Regulations (FDA, REACH, EU) 14. Designing of required Equipments 15. Data Collection for Pilot Process 16. Future variant and alternatives of technology Presented by Raja Wajahat 29
  30. 30. Challenges At Pilot Level Which Key Factors can affect pilot trials? Presented by Raja Wajahat 30
  31. 31. Challenges At Pilot Level 1. Availability of parameters , Conditions and capacities 2. Bulk Lab trail data can support 3. Selection of Pilot Plant & Designing of Required Equipment 4. Selection of materials of Construction 5. Standard Data is for pure & standard conditions 6. Availability of Material of Construction. 7. Availability of Equipment 8. Mini Flow meters/Valves/ Pumps/gauge 9. Fabrication limitations for Pilot scale equipment Presented by Raja Wajahat 31
  32. 32. Challenges At Pilot Level 11. Selection of economical and effective Heating source. 12. Minimum inter Process Steps 13. Charging/Unloading/Shifting/ Filtration/Time 14. Environmental Issues regarding process. 15. Processing at Pilot and Safety Issues. 16. Optimization of Material,Temp, Pressure, Time at pilot. 17. Achievement ofTarget QA and Application results. 18. Training of Staff 19. Confirmation of Cost 20. Confirmation of Product by Customer. Presented by Raja Wajahat 32
  33. 33. Success Indicators of Technology Development What are the success indicators in different stages of technology development? Presented by Raja Wajahat 33
  34. 34. Success Indicators of Technology Development 1. Clearly Identified Product withTargeted market Potential 2. Smooth production process & Consistent Quality 3. Market competitive Price 4. Accepted by the User Presented by Raja Wajahat 34
  35. 35. Technologies we need Presented by Raja Wajahat 35
  36. 36. Technologies we need Presented by Raja Wajahat 36
  37. 37. Technologies we need Presented by Raja Wajahat 37
  38. 38. Thank You! Presented by Raja Wajahat R&D Engineer - Shafi Reso Chemicals

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