Document 1QO8dJoabXROqQodXRMdvvLNo
* NT
V
F F I C E MEMO
TEHHECO
V
To PVC Committee *
at
CHEMICALS,
prscatawety
* "
INC.
Date ; July 6
1972
From Subject
Mr. J. Fath PVC EXPANSION
at piscataway >
Copt to ^ Mr . G. S. Flint
As all of you know, we have individually discussed the possibility of a sizeable PVC expansion for Tenneco. This is relative to various preliminary market studies, exploration of new large reactor technology and an understanding of the future supply and demand picture. The PVC industry is facing a critical shortage over the next several years and, therefore, the time to consider such a project is now at hand.
As a result of several preliminary discussions with Corporate Management, we, have been able to create considerable interest in such a project. The Intermediates Division plans to,make a full fledged presentation of about twenty minutes' duration during the next Tenneco Chemicals' Board Meeting scheduled for August 21. Our Division has an overall assignment to effect such an expansion plan and has accepted the responsibility for presenting the necessary subject material and backup data for this presentation.
The recipients of this memo are, therefore, designated by me to form an interim PVC committee for the purpose of gathering facts and all of the elements of such a study in the short time available.
While this committee is excessively large to be used as a working body, we ultimately plan to function as several sub-committees for the gathering of these facts. I am, therefore, calling a meeting for 9 AM, July 11, to begin discussions of the various assignments.
Please plan to attend in the Main Conference Room.
JF :AS
* PVC Committee
Mr. R. Bucsko Mr. G. Disch Mr. J. F. Kilcullen Dr. P. A. Lobo Dr. T. E. Maggio Mr. R. J. Miller
Mr. F. X. Ritter Dr. M. Rosen Mr. G. Rozand Mr. C. Thompson Mr. M. Zaleski Mr. T. Zuhl
J. Fath
COLOR!TE 007220
OUTLINE FOR TOTAL PVC PROJECT
I. MARKETING
v"
*'
A. Size, growth over ten years - supply and demand
"
r . .f ' > } ` \ it
~
.. ,
l 1' ' ^
B. Geographical distribution and supply - demand pattern by territory pAi''
C. Homopolymer, copolymer, dispersion resin-supply, demand and growth OP' by type
D. Manufacturers of each type and relative rank. Manufacturers of PVC and other components by rank, e,g., plasticizers, stabilizer,
E. Tenneco sales forecast 1972, 1973, 1974 and forward with customer ^.p. detail backup
F. Tenneco present production, locations and types 1 '"
G. Tenneco pos it ion i^n 1975 as a_ result of project. Assume two other C P'
plants at 300MM# each homopolymer - *<...*-.a; n . <m t,n SatWC w//
la H C - ' M c t
II. Tenneco position in 1975 without project
\ 1r
(Vl'T , , , ^, v, r f 5 f v''f i/; ;'cti r/ (./,
0 t"o-,1
t k C uvit i K I < r' <IJ fj'M. o l'1'-' ' '
II. , PLANNING
Total Project Concept
1. Large plant at Pasadena for three types of homopolymers - other'\ ^ plants will make specialties
..........
2. Conversion of Burlington - 35 types of specialties where smaller
reactors can function economically
^
I
3. Construction of prototype at Flemington for training purposes and \
expansion of caKpacityJ to 110KM#' p
r
! '
;I
4. Compound expansion at Flemington - 50MM# in old Fabrical building- i
Capital cost estimates for each and on-stream dates. ROl's DCF's for V- individual projects and total ROI - DCF
C&T
i r.L.
C. Effect on FI emi ngt on ROC employe:.] before and after - five years ahead j
D. Effect on Burlingtoa ROC employed before and af ter
(/ f ^ ' L,
E. Effect on Pasadena
\
1. Ten year history ROC on Pasadena by product
'it.'9 fill e ir,tj
'' in
ilr.i'i'/
COLORITE 007221
2
2. PVC project versus do nothing cose. First project not directly LNG dependent .it Pasadena - others, e.g., PO to polyols follow. Up to now integrated product loop - tnis project outside loop. / * '\.
F. Special advantages for PVC at Pasadena
1. Over the fence VCM from Shell, VCM shipments via land problematic
in long term
Jt / '
.,G ' .
2. Dock-water shipments from Pasadena up Mississippi, East Coast and
New England
3. Supervision - existing, high quality and trainable at Flemington j on large prototype reactor
4. feast community and pollution problems
5. Lowest production costs
XIX. DISTRIBUTION AND RAN MATERIALS
A. Terminal concept - New York, New England, Midwest versus direct shipments (Sea Land - is quantity possible?)
B. Ma j or consuming points and freight s tudy, direct shipments versus in and out through terminal concept
C. Present costs, projected costs, projected redistribution costs via terminal system, bulk shipments in barges or ships as per grain shipments.'
D. VCM supply - Shell, PPG, Goodrich, Conoco, Dow - supply and demand status, typical contract pricing (present and future), freight to Northern plant
E. Terminal possibility at Burlington
| ,;f| ; )! , , Mr.,
l"'
IV. ENGINEER]NC
\ ,,m f,
/.
(5v r \) \ $ n't t [4 n 'tObJ
1" " j\
A. State of indus t ry - batch process, reactor sizes - I I' I'.';'
i iZ
i Tf K
B. Now techno]opy - savings on conversion and yield --, (J, u . c G'i i -/
C. AnaJ v_s_Ls_ oj)
plan t g_' _sij;e reac_tors. and pounds produced in each size--V
D. New P^ant at good economics of such size that it does not disturb market by creating severe overcapacity. One new plant can be 77. of market, equal to growth per year
, ofntA i;t\
; ` St^t
COLOR!TE 007222
-3-
V. COMPOUND PLANT
A. Integrates well into present business - marketability demonstrated
1. Location at Flcmington ups average selling price out of plant and distributes manufacturing facilities
2. Technical supervision for move complex compounding on site because of R & D lab
,t
3. Base loads plant - saves freight on part of PVC poundage
4. Two 25MM pound lines are planned. Start custom manufacturing American Biltrite, now to build market prior to completion of plant
VI. R & D
t*
A. Quality of resin produced in large reactors
1* Gels, particle size distribution, clarity and heat stability.
2. Effect on non-deionized 1^0 and water analysis at Pasadena
3. Quality of other grades
4. Experimental work at Aberdeen catalyst - royalty question with Uniroyal patent
B. Types produced by large reactors and, comparison to Tenneco resins C. Compound program
COLOR!TE 007223
CAPITAL COST ESTIMATE - 550MM LBS PVC PLANT BURLINGTON, NEW JERSEY
Installed Cost, $
1. Major Machinery & Equipment Tank Farm Utilities
5,856,000 593,800
1,564/500'"
Installation Cost: Installed Cost:
Not Installed
25$ of M&E lx .25 = .25
7,794,300 `
%, jj
JUL 13 WZ Of
1.25 X 7,794,500 =
c. G. THOMPSON 9,740,000
2. Piping
4,180,000
3. Electricals
4. Instrumentation
2,045,000 1,750,000
5. Paint & Insulation
589,000
6. Structural (yard. bldg, steel, concrete)
6,710,000
24,814,000
I. 1.
Indirect Costs (function of direct labor costs)
Direct Labor Cost
Item I.,l. not installed
7,794,300
Add 10$ for Material
779,000
7375,500
Direct Labor Manhours = 700,000
Burlington: $8.59 x 700,000 = 5,971,000
Indirect (Field) Costs: 40$ x 5,97i,000 -
2,588,000
III. 1. General Contractor's Costs (Home Office) 7,79^,500 x 1.25 = 9,7l|0,000 9,740,000 x .52 =
IV. 1. Contractor^ Fee 9,740,000 x .16 =
Plus additional offsite facilities for Burlington
Plus 5$ Contingency
5, 117,000
1,-5 !>8,ooo 51,877,000
1,997,000 53.874.000 _I,Lot JQoo 35.568.000
Revision 1
>V,,v./sCA <o- i. (
H.JI. Duhamcl
COLORXTE 007224
330MM LB PVC PLANT
BURLINGTON, NEW JERSEY
Tank Farm
.1 MVC Storage Tanks 64' D x 64' H,
2. Evaporative Refrigeration, 200 3. TCE Storage Tank 4. VCM Unloading Station
.5. VCM Vaporizer
6 VCM Unloading Compressor 7. TCE Charge Pump 8. VCM Filter 9. TCE Filter 10. TCE Unloading Station
2.5MM gals. insulated tons
ea.
Purchase Price,
321,800
72,000 Existing
It It It It 11 It M
393,~8oo
B. Utilities
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Steam Generator, 200,000 lbs/hr Electrical Substation, 9,000 KVA
Instrument Air, 3 - 2,500 cfm cent, comps Nitrogen Generator, 200 cfm cap Well Water, 1,200 gpm City Water Water Softeners (& brine tank) 7,50 gal DM Water Units, Mixed Beds, 6 x 80 gprri Caustic Bulk Tank, 33,000 gal (20^3
Sulfuric Acid Bulk, Tank, 5,000 gal (66;
Effluent Plant, incl. pit pumps Fire Protection
(incl cap
306, 000
117, 000 dryers) 219, 000
10, 000
30, 000
Not Requir<
32, 800 226, 000
13, 4oo
5, 500 250, 000
354, 000 1 ,W, 500
0. Offsite Facilities (additional)
1, Site Preparation 2. Railroad Siding 3- Dock for Sea-going Vessels 4. Area Drainage 5. Access Roads 6. Yard Lighting 7. Communications Equipment
8. Concrete chilled water sump, 500,000 gal,
50, 000 20, 000 1,633, 000 50, 000 2JI, 000 20, 000 - ,-20' 000 1,817, 000
180, 000
$1,997,000
COLORITE 007225
CAPITAL COST_EST.I MATE
.^UMK LB PVU rnAWi
BATTERY LIMITS EQ.IJJPMFNT COMMON TO ALL SITES
Purchase Price, $
1. Six (6) 34,000-gal. SS reactors - 6 x 230M 2. Twelve (12) jacket water pumps - 2,000 gprn
n
1,380,000 32,400
3. Six (6) steam-water mixers
o
4. Six (6) hot water hold tanks - 6,000-gal. - ,
6,000 9,900
5. One (1) solution MU tank - 4,000-gal. & 10 HP agit.
19,000
6. One (1) solution hold tank - 4,000-gal. & 7 HP agit. 7. Two (2) solution transfer pumps gear, 200 gprn, 60 lip, 304 SB
8,600 6^000
8. One (1) monomer charge purnp, 2,000 gpm, 150 psi
9. One (1) DM water charge pump, 2,000 gpm, 150 psif
10. One (1) catalyst bldg, 14,000 ft3, refrigerated -20 P
11. Two (2) DM water storage tanks, 60,000-gals. ea.
2. One (I) DM water heater
13. Three (3) 1,100-ton refr:i geration units
1.4. One (1) cooling tower - 10,000 gpm incl. 2 IIlCVJ pumps
15- Pour (4) recovery compressors, 600 cfm ea.
16. Four (4) Intercoolers - 9-1 ft'3 ea.
17- Four (4) recovered monomer condensers, ,910 ft/3 c>a.
18. One (1) defoamcr tank & agit., SS 304
19. One (1) defoamer pump
20. Three (3) 10,000 gallon recovered monomer ta
21. One (1) distillation column and retailor, ^
22. One (1) reflux condenser, 1380 ft .2
23. One (.1.) monomer cooler, 165 ft.?
P4------ rotm go-ral-j^rr--tht^ Q5. One (1) gas holder, 60,000 ft.3
/J
^'
One (.1) rccov. mon. column feed pump, 50 gom J wo (2) caustic circulation feed pumps, 25 gpm
COLORITE 007226
Page 2 ^8`. Two (2) purified monomer charge pumps,, 500 gpm
Purchase Price,$
C
9- Two (2) rec. rnon. filters, 500 gpm
50. One (1) 10,000 gal. caustic storage tank
251. One (1) heavy ends incinerator
j52. Pour (*l) Go, 000 gal, slurry tanks SS30*1 & agitator
u 35. Throe--(30 centrifuge feed pumps, 200 gpm
, -i
34. Three (3) *10x60 centrifuges, SS30t & motors - y|>-)
35. Three (3) Flash & fluid bed drying systems
36. Three (3) product sifters w, motor
37. One (1) solvent evaporator system, 225 ft2 heating; surface 38. Two (2) residue receivers 1,000 gal. each 39. One (1) feed preheater to evap.
*K). One (1) recov. solvent storage tank', 15,000 gal.
*U. One (1) used solvent hold tank, 15,000 gal.
12. One (l) solvent heater
jl3. One (l) seal vent circulation pump, 200 gpm
*IJI. One (1) solvent filter, '200 gpm
*15. Three (3) pressure tanks & blowers 30,000 Ibs/hr. each
. jr
*16. Thirty
10,000 ft.3, overhead a.l urn. storage bins
*17. twelve (12) 5)000 it.3, inside bolding bins, alum.
48. ) 25,000 lb s/hr. bagging; un:i ts
*19. Two (2) fork trucks
50. C omp u.t e r control.
*l,*100 5,000 /250,000 . 18*1,000
216,200 1,125,000
33)000
XOr&QQ 1
IGt/DtKT 1-67000"
lTTJtpr *tT&0TT
")'/ "V'-
COLOR!TG 007227
auxiliaries and offsite facilities
DESIGN CALCULATIONS 33QMM LB PVC PLANT BURLINGTON, NEW JERSEY
Purchase Price,__$
A. Tank Farm
1 MVC Storage Tanks:
. n6
Daily usage:
356 x "98 = 962,000 lbs MVC/day
= 128,000 gals/day
One monthJs inv. - 128,000 x 31 = 4,000,000 gals Tanks, at 83/ capacity:
(4 x 10r>)
^5-------
4.7 million, say 3 million gals.
2 - 2.3 million gal. tanks
Cost: Vert. Cyl.rr>. 4
: (2.5 X 10G)/7.5
X 3= 262,000 ft3 X -- 64 ft = D' & H'
120,000 x 1.2 index = $144,000 each
Insulation: Area: 7XR2 -I 2 7/'Rll
= yr32 + 2 7/'32x64 - 16,100 ft2
2" polystyrene foam: .69$/ft x 1.33
16,100 x .92 -- $14,800 each
Total: 160,960 x 2 = 321,800
333,000 (index)
ft3 =- ,92$/ft2
.2 Evap , Ref rigerat- ion
Mantua: 2p0 tons for 2 x 3.36MM for 2 x 2.5MM, 200 tons - 60000 60,000 x 1.2 = 72,000
B. Utilities
2. Electrical Substation
,13 K/lb. f 330 x 10G lb./yr) - 5900 Klffl
~~~ 8400 hrs/yr .
Allowing 50/ more for peak .load, 9000 KVA.
Cost: 7500 KVA: 103,000 Q
f
for 330: 105,000 (xLHH)-: 117,000.
4. Nitrogen Generator Concrete pad 10,000.
5. Well Water
D.M. water, & Make-up only
Steam: Condensate return
D.M. water:
320 gpm
C.T. 10/ of 10,000 = Steam 10/ of 400 =
1000 gpm 40 gpm
I36O gpm
$30,000
COLORITE 007228
Page 2
Olfslte Facilities 1. Site Preparation (same as Pasadena) 2. Railroad siding (same as Pasadena) 3. Dock for sea-going vessels Dredging, 1.15 million yds x 1.20 - $1,380,000
Total Price,$
$50,000 20,000
so<y Wharf, T shaped '.zn r "500' x 50' = 25,000
250' x 50' - 12,500 %l- 37,500 ft2
x 50
.$/ft - 1,125,000
2 mooring dolphins, 16' diam. (75' total height) 20' below river bottom & 15' above L.W.L.
Pile driver set-up
50,000 15,000
$2,570,000
4. Wharf for sea going vessels - Revised Estimate for lighter construction.
(Poppet 102)
Wharf: 3 in. deck, light construction
max. 7.5 $/ftp x 1.2 (index) 9 $/ft2
T shape Quote from Mr. Earle: $10/ft2
500' x 25' paralled to channel - 12,500 ft?
250' x 25' shoreward
6,250 ft 2
"18,750 fta
18,750 x 10 = 2 mooring dolphins, 16' diam. Pile driver set-up
Dredging: 1..15 million yd3 x 1.20
say Total
$ 187,500 188,000 50,000 15,000 253,000
1,580,000
$1,633,000
COLORITE 007229
CAPITAL COST ESTIMATE - 330MM LBS PVC PLANT PASADENA, TEXAS
I. 1. Major Machinery & Equipment
5,836,000
Tank Farm
468,300
Utilities
1,581,700
Not Installed 7,886,000
Installation Cost: 25%> of M&E x O.75 of Burlington labor cost: .25 x .75 - 0.188
Installed Cost:
1.188 x 7,886,000
2. Piping
3. Electricals
4. Instrumenlation
5- Paint & Insulation
6. Structural (yard, bldg, steel, concrete)
Installed 'Cost,$
1 wx-2 '
o.*.****
9,360,000 4.030.000 1.968.000 1.686.000
375,000 6.460.000 23,879,000
II. 1. Indirect Costs (function of direct labor cost)
Direct Labor Cost
Item I.,l. not installed
7,886,000
Add 10% for Material
789,000
87675,00 0
Direct.Labor Manhours
710,000
Pasadena: $6.42 x 710,000 |4,560,000
Indirect (Field) Costs: 40^ x 4,560,000 -
1,824,000
III. 1. General Contractor's Costs (Home Office)
Same as if plant was built in Burlington, i.e. 9,360,000 x .32
3,000,000
IV. 1. Contractor's Fee Same as above 9,360,000 x .16 =
Plus additional offsite facilities for Pasadena Plus 5% contingency
1.500.000 30,203,000
364,000 1.930.000
32,097,000
Revision 1
If.Jl. Duhamol'
COLORITE 007230
AUXILIARIES AND OFFSITE FACILITIES 33QMM FVC PLANT PASADENA, TEXAS
Purc ha s e Pr 3 c e, $
A. Tank Farm
1. MVC Storage Tanks 2. Evaporative Refrigeration 3. TCE Storage Tank, 5,000 gal. 4. VCM Unloading Station 5. VCM Vaporiser 6. VCM Unloading Compressor 7- TCE Charge Pump, 34 SS 100 gpm 8. VCM Filter SS 304 9. TCE Filter SS 304 100 gpm 10, TCE Unloading Station 11. Resin conveying system 12 units (2500 ft.)
Total
pipeline delivery) pipeline delivery)
3.000 (pipeline delivery) (pipeline delivery) (pipeline delivery)
5.000 (pipeline delivery)
1,800 2,500 456,000
$ 468,300
B. Utilities
1. Steam Generator 200,000 lbs/hr (6,000 II.R.)
2. Electrical Substation switchgear, bldg. MCCMs
306,000 150,000
3. Instrument air 3 - 2,500 cfm cent, comps, incl. dryers 219,000
4. Nitrogen Generator 200 cfm cap
(existing)
.5. Well Water, make-up only, 50 gpm
6 City Water 9,000 gpm (60)
25,000 (not required)
.7. Water Softeners (& Brine Tank) 7,500 gal. each
8 D.M. Water Units, Mixed Beds 6x80 gpm.
32,800 226,000
.9. Caustic Bu.l k Tank 35,000 gal. (209))
10 Sulfiric. Acid Bulk Tank 5,000 gal. (66)
13,400 5,500
.11. Effluent Plant incl. pit pumps
12 Fire Protection
250.000 354.000
Total
$ 1,58.1,700
C. Offsite Facilities (additional)
1. Site preparation
2. Railroad siding
3- Dock for sea going vessels (existing) 4. Area drainage (little) 5. Access roads
6. Yard lighting
7. Communications e quipmeni
50,000 20,000
--
50,000 24,000 20,000 20,000
Total 8. Concrete chilled water sump, 500,000 gal.
!
184,000 180,000
$ 364,000
COLORITE 007231
CAPITAL COLT ESTIMATE
ppUMM LE Jr'VO P-UiUM'.l'
BATTERY LIMITS EQUIPMENT COMMON TO ALL SITES
Purchase Price, $
1. Six (6) 34,000-gal. SS reactors - 6 x 230M 2. Twelve I'12) jacket water pumps - 2,000 gpm
1,380,000 32,400
3. Six (6) steam-water mixers 4. Six (6) hot water hold tanks - 6,000-gal. 5. One (1) solution MU tank - 4,000-gal. & 10 HP agit. 6. One (1) solution hold tank - 4,000-gal. & 7 HP aglt. 7. Two (2) solution transfer pumps gear, 200 gpm, 50 HP, 304 SS 8. One (1) monomer charge pump, 2,000 gpm, 150 psi
6,000 9,900 19,000 8,600 6,000 13,900
9. One (1) DM water charge pump, 2,000 gpm, 150 psi 10. One (1) catalyst bldg, 14,000 ft3, refrigerated -20F
13,900 67,000
11. Two (2) DM water storage tanks, 60,000-gals. ea.
80,000
12. One (1) DM water he ate 3'
8,000
13. Three (3) 1,100-ton refrigeration units
200,000
li|. One (1) cooling tower - 10,000 gpm incl. 2 H&CW pumps 15. Pour1 (M recovery compressors, 600 cfrn ea. 16. Pour (1|) intercoolers - 91 ft2 ea.
108,000 229,500
13,900
Pour (J0 recovered monomer condensers, 910 ftH ea. l8. One (1) defoamer tank & aglt., SS 304 19. One (1) defoamer pump 20. Three (30 10,000 gallon recovered monomer tanks 21. One (1) distillatjon column and reboiler, 5*dia. 22. One (1) reflux condenser, 1380 ft.2 23. One (1) monomer cooler, 163 ft.2 24 . One (1) 50-ton refrigeration unit, -20 25. One (1) ga s ho1d e r, 6 0,0 0 0 ft.3 26 . One (1) recov. men. column feed pump, 50 gum 27. Two (2) caustic circulation feed pumps, 23 gpm
40,500 6,100 1,000
27,600 75,000 25,000
7,300 25,000 82,000
1,600 2,000
t-
H
COLORITE 007232
Page 2
Purchase Price,$
M8. Two (2) purified monomer charge pumps, 500 gpm
14,400
29. Two (2) rec. mon. filters, 500 gpm
4,400
30. One (1) 10,000 gal. caustic storage tank
5,000
31. One (1) heavy ends incinerator
250,000
32. Pour (4) 60,000 gal. slurry tanks SS304 & agitator
184,000
33. Three (3) centrifuge feed pumps, 200 gpm
6,900
34. Three (3) 40x60 centrifuges, SS304 & motors
216,200
35. Three (3) Flash & fluid bed drying systems
1,125,000
36. Three (3) product sifters w. motor
33,000
37. One (1) solvent evaporator system, 225 ft2 heating surface
125,500
38. Two (2) residue receivers 1,000 gal. each
10,600
39. 40.
41.
^2.
One (1) feed preheater to evap. One (1) recov. solvent storage tank, 15,000 gal. One (1) used solvent hold tank, 15,000 gal. One (l) solvent heater
1,500 16,000 16,000
1,500
43. One (1) solvent circulation pump, 200 gpm
4 600
44. One (1) solvent filter, 200 gpm
3,000
45. Three (3) pressure tanks & blowers 30,000 Ibs/hr. each 46. Thirty (30) 10,000 ft.3, overhead alum, storage bins
47. Twelve (12) 5,000 ft.3, inside holding bins, alum.
' 18.1,200 645,000 168,000
48. Two (2) 25,000 lbs/hr. bagging units
50,000
49. Two (2) fork trucks 90. Computer control
18,000 POT 000 $ 5,836,000
COLORITE 007233
AUXILIARIES AND OFFSITE FACILITIES
MILLION FOUND PVC PLANT
FORDS, N. J.
Purchase Price,
Tank Farm
.1 MVC Storage Tanks, 64'H x 64'D insul. 2.5MM gals ea.
2. Evaporative Refrigeration 200 tons 3. TCE Storage Tank 5,000 gals 4. VCM Unloading Stations, 4
.5. VCM Vaporizers, 2
6 VCM Unloading Compressors, 2
7. TCE Charge Pump, 304 SS, 100 gpm 8. VCM Filter SS 304, 2,000 gpm 9. TCE Filter, SS 304, 100 gpm 10. TCE Unloading Station
321,800 72,000 3,000 24,000 4,000 5,000 5,000 6,000 900 2,500
444,200
B. Utilities
1. Steam Go orator, 200,000 lbs/hr.
306,000
2. Electrical Substation, 9,000 KVA
117,000
3. Instrument air 3 - 2500 cfm cent. comp. incl. dryers 4. Nitrogen Generator, 200 cfm
219,000 10,000
5. Well Water, make-up, steam, DM, 500 gpm 6. City Water
25,000 -
7. Water Softeners & Brine Tank 8. D.M. Water Units, Mixed Beds 6 - 80 gpm
32,800 226,000
9. Caustic Bulk Tank 35,000 gal. (22^) 10. Sulfuric Acid Bulk Tank 5,000 gal. (6651)
11. Effluent Plant incl. pit pumps
12. Fire Protection
13,400 4,500
250,000 354,000
~1~, 564,500
Offs ite Facilities (additional)
1. Site preparation 2. Railroad siding 3. Dock for sea going vessels 4. Area drainage 5. Access roads 6. Yard lighting 7- Communication s e quiprne n t
8. Concrete chilled water sump, 500,000 gal.
1,000,000 20,000
1,633,000 50,000 24,000 20,000 20,000
$ 2,767,000 180,000
$ 2,947,000
COLORITE 007235
CAPITAL COST ESTIMATE - 330MM LB PVC PLANT BATTERY LIMITS EQ.UIPMENT COMMON TO ALT, SITES
Purchase Price, $
1. Six (6) 34,000-gal. SS reactors - 6 x 230M
1,380,000
2. Twelve (12) jacket water pumps - 2,000 gpm
32,400
2- Six (6) steam-water mixers
6,000
4. .Six (6) hot water hold tanks ~ 6,000-gal.
9,900
5- One (1) solution MU tank - 4,000-gal. & 10 HP agit. 6. One (1) solution hold tank - 4,000-gal. & 7 HP agit.
19,000 8,600
7. Two (2) solution transfer pumps gear, 200 gpm, 30 HP, 304 SS
6,000
8. One (1) monomer charge pump, 2,000 gpm, 150 psi
13,900
9. One (1) PM water change pump, 2,000 gpm, 150 psi
, 13,900
10. One (1) catalyst bldg, 14,000 ft3, refrigerated -20F
67,000
l.i. Two (2) PM water storage tanks, 60,000-gals. ea.
80,000
r
13.
One: (1) PM water heater Three (3) 1,100-ton refrigeration units
8,000 200,000
14. One (1) cooling, tower - 10,000 gpm incl. 2 H&CW pumps
108,000
13- Four' (4) recovery compressors, 600 cfm ea.
229,300
16. Four (;0 inter-coolers - 91 ft2 ea.
12,900
17. Four' (4) recovered monomer condensers,,910 ft3 ea. 18. One (1) defoamer tank & agit., SS 34
40,300 6,100
19. One (1) defoamer pump
roo
Three (3 ) 10,000 ga.l Ion recovered monomer tanks
21. One (1) distillation column and reboiler, 5'dia.
22. One (1) reflux condenser, 1380 ft.2
22. One (1) monomer- cooler, 3,65 ft.2
24 . One (1) 20-ton rofrigcrat.ion unit, -20
26.
k
27.
One (1) gas holder, 60,000 ft.3 One (1) rec0v. mon. c.01unur fecd purn]), 30 gp> 11 Two (2) cau.st.ie circu.l ati on feed pumps, 23 gpm.
1,000 27,600 73,000 23,000
7,300 25,000 82,000
1,600 2,000
COLORXTE 007236
Page 2
Purchase price;, $
8. Two (2) purified monomer charge pumps, 500 gpm 29. Two (2) rec. mon. filters, 500 gpm
14,400 4,400
30. One (l) 10,000 gal. caustic storage tank
5,000
31. One (1) heavy ends incinerator
250.000
32. Four (4) 60,000 gal. slurry tanks SS304 & agitator
184.000
33- Three (3) centrifuge feed pumps, 200 gpm
6,900
34. Three (3) 40x60 centrifuges, SS304 & motors
216,200
35- Three (3) Flash & fluid bed drying systems
1,125,000
36. Three (3) product sifters w. motor
33.000
37. One (1) solvent evaporator system, 225 ft2 heating surface
125,500
38. Two (2) residue receivers 1,000 gal. each
10,600
39. One (1) feed preheater to evap.
1,500
40. One (1) recov. solvent, storage tank, 15,000 gal.
16.000
*11. One (l) used solvent hold tank, 15,000 gal. 12. One (1) solvent heater 43. One (1) solvent circulation pump, 200 gpm 44 . Ono (1) solvent f :i Iter , ' 200 gpm
16,000 1,500 4,600 3,000
45. Three (3) pressure tanks & blowers 30,000 lbs/br. each 46. Thirty (30) 10,000 ft.'g overhead alum, storage bins 47. twelve (12) 5,000 1L.-^ ins.i do holding bins, alum. 48. Two (2) 25,000 lbs/hr. bagging units 49. Two (2) fork trucks 50. Computer control
181,200 645.000 168.000
50.000 18.000 267.000 $ 5,836,000
COLOR!TE 007237
AUXILIARIES AND OFFSITE FACILITIES DESIGN CALCULATIONS 33OMM LB PLANT FORDS, NEW JERSEY
A. Tank Farm 4. V'CM Unloading Stations VCM Vaporizer 2 x 2000 - 4,000 Unloading comp. 2 x 2500 = 5,000 Unloading platform 4 x 6000 = 24,000 $33,000 9. TCE filter, 34 SS 100 gpm 200 psi 25 microns, quote: $891. (l8 cartridges) 8. VCM filter, 2000 gpm, 304 SS 200 psi 25 microns, quote $6,000. (330 cartridges)
C. Offsite Facilities 1. Fords: South of existing plant - Raritan river frontage Site preparation (C.G.T. to II.H.D. 5/18/72) Soil stabilization: 20 Acres: Muckout 4 to 10' , replace with fill. 50,000 $/acre x 20 = $1,000,000. 2. Fords: North of existing plant (C.G.T. to II.H.D. 5/18/72) Soil stabilization: $'>25,000/acre x 20 = $500,000. 3. Normal Site Preparation (P & T 113) 1/ of fixed capital investment 1/ x 37,000,000 - $370,000.
COLORITE 007238
(7C,*JiK5t
*" GcvvfVaj^O SHIN-ETSU CHEMICAL INDUSTRY CO., LTD.'
o4^_3-rD
eu, u*JT
July 1, 1972
ESTIMATED CONSTRUCTION COST
1. Assumption 1) Basis of cost estimate All cost estimate are based on the cost in Japan as of June, 1972. 2), Plant cnpn=ity(/^^vfjwJ)^4
150,000 MTPA in terms of Shin-Etsu's grade TK1000
3) Working hour
tiff ^4)
350 days per year, 8,400 hours per year The battery limit covers processes starting from the pure VC measuring tank up to the "sj^les for dried PVC
product. All the utilities including deionized water
br
are beKintlar^ies of the battery limit.
2. Construction cost (Japanese Yen)
Process equipment
Foundation
Installation
Building & structure -
Piping
l<AS*UJ
Pipes Fittings Valves
Sub total Insulation & painting
3^-e
844,200,000 67,400,000 42,600,000
149,700,000
27,000,000 33,500,000 57,400,000 77,300,000 195,200,000 34,500,000
CHS
COLORITE 007239
SHIN-ETSU CHEMICAL INDUSTRY CO., LTD.
Wiring
Electrical equipment Cable & wire Miscellaneous Words' c/\go<_ Sub total
59.400.000 27.100.000 33.000.000 34.000.000 153,500,000
Instrumentation
Analog instrument & control valves Panel & sequence devices Computer & power source Miscellaneous Works Sub total
250.700.000 191.200.000 <^120,000,000N
95,500,000 33,000,000 690.400.000
TemporaryO'N'Ii'^Ar^^^ Grand total
?'- 18,000,000 2,195,500,000
3. Cost of main equipment (FOB, Japanese main port)
Polymerizer (130mJ) with
63,000,000^ - 3 7/;c>o o
Dryer (7MT/H) with auxiliary equipment (XyCM**^ Uenc/r^-
55,000,000^, |V( oo-
fODT^
C'M
r41/ /f
f ImcLu/)^
jW/hf^CP
COLORITE 007240
'V'?
l-
\ /<, *w
\
v/_
/4/^
^ z_ /VI
COLORITE 007241
PROCESSES & PROCESSING EQUIPMENT
4
PVC reactors provide precise temp control, automated cleaning
Top view of one of the 20,000-gal, conventionally jacketed reactors for the Deer Park plant on flat car prior to installation
Note jacketing on top head
Six large, jacketed reactors for the production of polyvinyl chloride at Dia mond Shamrock's PVC plant in Deer Park, Texas meet specific requirements for precise temperature control and auto mated cleaning capability
In the production of polyvinyl chloride, Diamond Shamrock uses a proprietary suspension technique to polvmerize vinyl chloride monomer under agitation in the presence of an initiator that is soluble in the monomer Precise temperature control, water and a suspension agent are abso lutely essential to the reaction
Reactors were provided wuth conven tional jackets completely surrounding the shells Chilled water is eueulated through the jackets to dissipate the heat generated by the reaction To provide added cooling capacity, the top heads of the reactors are also jacketed All of these efficient heattransfer methods contribute to extremely accurate regulation ol reaction tempera ture which is critical to the process
Health and safety considerations de manded remote control hydraulic clean ing A .special cleaning system, specifically dcvclojicd for this plant, does riot require
maintenance personnel to enter the reac
tors for manual cleaning Nozzles on the
hy'drauhe units direct jets of exticmcK
high pressuie water against the interior
surfaces of the reactoi to clean and remose
residual poly met from thioughout the
inside ol the vessels
The six reactors each have a capacity of
20.000 gal They are fabricated from Tyjrc
30-4 ELC clad stainless steel and built with
a special "mini-skirt" design with legs
Super-finished interior surlaces, which
include both an 180-grit mechanical finish
and an eleetrojiohsh finish, make the use of
these computerized cleaning units practi
cal The high-release electrojxihsli finish is
applied to the mechanical finish in the
reactor's intcriot to prevent product adhe
sion This process, which is guaranteed not
to fracture, chijj, crack, flake or peel is
particulark valuable where frequent be-
tueen-batch cleaning is icqinrcd
With the use of jacketed reactors,
accurate temperature regulation of PVC
production is achieved Health and safety
of plant operators is jrrovidcd through the
use of remote control livdrauhc cleaning
Roth factors contribute in making this 200
million lb/vr l'VC plant safe and effi
cient
Reactor structure is shown with control room above pipeway at Diamond Shamrock's Deer Park plant
Additional information on the reactors is available from Brighton Corp, 11861 Hosteller Bd , Cincinnati, OH 45241
Circle 352 opposite last page
Engineering, design, procurement and construction services at Diamond Sham rock PVC plant were provided by C F Braun tb Co., 1000 S Fremont Ave, Alhambra, CA 91802.
Circle 353 opposite last page
124 FEBRUARY 1978 CHEMICAL PROCESSING
COLORITE 007242
INSTRUMENTATION & LABORATORY APPARATUS
Shintech's master control room keeps continuous track of all operating units, while CRT screens display operating conditions and product status upon call
Computer control raises throughput 40% on basis of capital cost
CHARLES HARRINGTON, Technical Manager Shmtech Inc Houston, Texas JOSEPH POWERS, Associate Editor
Precise computer control, augmented In proven large-reaotor technology and advanced engineering, is helping the recentL expanded 320-milhoii-lb/yr plant of Shmtech Inc to produce uniform, high-quality poly (vinyl chloride) resin Shintech's 35,000-gal reactors, designed to operate at the industn 's highest efficiency ratios, provide economies of scale and also ultrauniform resin for critical rigid and plastier/ed PVC products
Th is plant, located in Freeport, 'Texas, has the largest PVC suspension-polymerization reactois on-stream in the country Shintech employs sophisticated computer control to specify the grade and quantity of resin to he made for am specific run, then directs the entire processing operation -- sequencing and actuat ing the equipment to assure quality consistency of the finished resin, Continuous exact reactor control provides a product with excellent uniformity and consistency,
The PVC process, developed h\ Shin-Etsu Chemical industries Ltd , of Tokyo, Japan, became a commercial reality with the 1970 completion of a plant lor the mass production of PVC in Kashima, Japan The process provided the resolution to numerous longstanding barriers to scale-up of batch polymerized suspension PVC manufacture. In particular, the precise control of large volume polymerization vessels became feasible,
Shin-Etsu then provided the engineering design for a new U S plant utilizing the new process It was constructed in 1974 bv Shintech Inc,, Shin-Etsu's subsidiary, in Freeport The Freeport plant integrates all the mass-pioduetion design features of the Kashima plant with direct digital computer control
Shm-Ftsu has numerous international licensees for the new process, including Shintcch, Tenneco Chemical, and Firestone Plastics in the US
Important to large-scale production of PVC are the demands of process safety and product consistency Both require absolute reproducibility of what goes into the process and of what is allowed to happen within the process This can be achieved only by computer control At the Shintech plant, twin direct-digital computers are major components of the overall control scheme,
210 JUNE 1978 CHEMICAL PROCESSING
COLORITE 007243
CORROSION CONTROL new literature
measurable economic advantages of internal pipeline coating are shown by graphs which compare bare pipe and coated pipe for pressure drop in a 30" gas pipeline, and loss of head in a 6" water pipeline Rro F-412S -- Industrial Services Subsidiary, Union Carbide Corp
Circle 797 opposite last page
Cold galvanizing compound can bo applu\l b\ brush, roller or spray on ferrous and non-ferrous surfaces to prevent rust and rust croepage Surface preparation, federal/industnal test conformance data, and information on re-gal vanizing damaged and worn hot-dipped galva nized surfaces is included in 4-pg Rul 101 ZHC Chemical Products Co
Circle 799 opposite last page
# FLLD HAAONj nVXXXTS
Valves, fittings and tubing are made from Teflon PFA for corrosive applications over a temperature range from cryogenic to 500F Technical data and detailed significations for individual items are covered m Fluid Handling Products Catalog Fluid handling cat, Fluoroware Inc,
Circle 796 opposite last page
In-place pipeline coating based on a corrosionand solvent-resistant polyamide epoxv formula tion is highlighted in 8-pg brochure Timesaving features of the process are described and
^4eroquip
Aalrte//
/tee;
Pfodu'.o
1, J=L
ttSS S
'i , '3' i fie !
!> 3 i a: isc=j
Stainless steel connectors for corrosive fluid services are featured in catalog that contains detailed specifications on hose fittings, quickdisconnect couplings and adapters Bui 5506, Aeroquip Corp , a subsidiary of Libbey-OwensFord Go
Circle 798 opposite last page
Tubes, pipes and plates for critical applications are available in commercially pure nickel, titanium and copper and their alloys, in addition to a full range of stainless steels Chemical composition, physical and mechanical proper ties, and typical applications are detailed in 60pg "Vital Dimensions in Metals" booklet V.D M Div , Ore & Chemical Corp
Circle 800 opposite last page
Copper-based alloys are highlighted in 86-pg capabilities brochure that includes sections on the cast, wrought and fabricated forms m which aluminum bronzes and other alloys can be speci fied Detailed charts cover the composition, properties and specifications for more than 75 alloys with nominal chemical composition, mechanical properties, specifications and forms available. Copper Alloys Capabililies/apphca tion Bro Ampco Metal Div , Ampoo-Pittsburgh Corp
Circle 801 opposite last page
V ^ f'
* yi*
*, Prevent freezing and protect^ against high temperature degradation.
UniTherm Dekatrace thermally insulated liquid transportation lines for process, sampling / Sand insfrument impulse applications. Dekatrace ' provides low heat loss zero maintenance re*.v; |ucec| downtime low installation costs/
employee protection easy installa predictable thermal
//pharacteristips. Availableinfour different
constructions. Dekatrace ^felines arp,supplied as a -//'complete package con-
'V
,.\
7** ?:.***::t:
taming a small diameter process tube or tubes,
steam tracer, high-efficiency (K-Tex*) thermal
insulation and a rugged protective outer jacket.
Rated for a maximurn steam temperature of ,
i .4Q0OF ^hd fnsulated to produce a ^drfac64i '
temperature of less than 140F at S0//.
;''^lambientsl///;;;;
^"^'For^oWpleteinfoVmMpn'Cpn^-1:
tact UniTherm Division. Samuel
Moore and Company. Twins-
1 burg, Ohio 44087. Phone; /
^16)425-384ff^|^7;;;,' ; : ;
Circle 802 opposite last page
'! i.r'i Samuol Moor* and Company
..... UnlTharm
JUNE 1978 CHEMICAL PROCESSING 209
COLORITE 007244
The computers perform a number of functions such as sequencing, additions, DDC (direct-digital control), monitoring and emergency contingencies
In the sequencing function, the batch polymerization process is divided into sub-processes and further subdivided into discrete operating steps Computer control ensures that all prerequisites for each operating step are met, For example, before starting a pump, tank levels and valve positions must be confirmed Each operating step takes place in the correct order
Furthermore, each of the raw materials tor the suspensionpolymerization of PVC must be added in precisely the correct amount at exactly the proper time in the process sequence The computer monitors and verifies all materials changes Everything that goes into the process is controlled
Major process variables, such as polymerization temperature, are under DDC As part of a carefully conceived process engi neering scheme, the computer provides a degree of precise process control -- hence batch-to-hatch reproducibility -- previ ously unattainable in PVC manufacture
Dependent process variables and important equipment param eters are monitored on-line against preset standards Conditions such as pump-discharge pressures, rotating equipment speeds, valve positions, and tank levels are followed continuously This provides the operating technician with immediate fingertip access to all important process conditions
As the scale of any manufacturing process increases, so does the scale of potential emergency situations Integral to the new PVC process are contingencies tor safely terminating the polymeriza tion reaction at an}' point should an emergency condition occur The computer plays a role in initiating emergency-control proce dures, including computer malfunction sequences
The safe design of the process includes both passive and active safeguards -- passive safeguards, such as detailed process moni toring and double-checking to prevent the occurrence of emer gency conditions, and active safeguards to provide contingency sequences in case an emergency does occur
Computer control can give increases of 30 to 40%, m throughput per unit of capital cost, when compared with manual control Under the latter, a polymerization cycle may take about Id hours Computer control can cut this time signifacanth, depending upon grade
It accomplishes this by severai means First, it takes dead tunc
out of the process by making certain that the reactor and its
associated equipment arc never standing idle waiting for an
operator to do something Second, it optimizes and hastens the
heat-up and cool-down phases of the process And third, it allows
simultaneous performance of steps that must be done serially in a
manually controlled plant,
Charging a PVC reactor involves a large number of steps and
the operation of as many as 50 valves and other devices, Opening
and closing that many valves can be time-consuming When a
few seconds are trimmed from the operation of each such device,
and when sequential makc-rcady steps that take an horn are
replaced by a computer-controlled operation that takes a feu
minutes, the saving of time can be substantial
Further information about the direct-digital computers employed at this installation can he obtained by circling reader sertnee number below.
Circle 803 opposite last page,
Line printers produce hard-copy continuous diagnosis of operating processes throughout every run, controlling
process variables when operating parameters or product quality exceed preset limits
Automated gas chromatographs are used for consistently accurate analyses
COLORITE 007245
INSTRUMENTATION & LABORATORY APPARATUS
Operators can reprogram flow of streams through pipelines with microcomputer-based system
New Solutions to Plant Problems
From the control panel of a microcom puter-based system, operators at Phillips Philrock Station in Borger, Texas, can reprogram the flow calculator and moni tor the flow of ethane-propane streams through pipelines in widespread locations
Phillips Petroleum is one of several petroleum processors who are using the microcomputer-based flow calculator to provide an economical, yet accurate means of measuring their products in w idespread areas. The system can calculate the flow of liquids, gases or steam in volume, mass, standard 60F barrels or other units of measure.
A microcomputer automates the com plex process of measuring the different products, It works in conjunction with turbine rncters which measure the gross volume and calculates the number of pounds The microcomputer is especially instrumental in its conversion capacity as the material being piped must be mea sured at 60F and equilibrium pressure, impossible constants to maintain while it is actually being pumped The microcom puter is capable of correcting it back to these standards
Measuring the flow' of gas and petro leum products involves a series of complex calculations Factors such as temperature, pressure, compressibility, and gravity of the material to be measured must be entered into a complex equation in order to accurately calculate flow
The microcomputer automates a process which formerly involved recording the flow factors, manually interpreting this data, and subsequent computer processing to determine a totalized flow
A field-replaceable PROM in the instru ment eliminates the need for the user to send hard-wired memory back to the manufacturer for reprogramming Since the system easily adapts to majoi basic changes in operating parameters, users no longer need to scrap and then replace expensive, hard-wired, electronic measure ment devices
From this control panel, operators at Phillips Petroleum can monitor flow of ethane* propane streams through pipelines in widespread locations
The microcomputer is custom-pro grammed for each users specific flow measurement requirements When pre selected parameters such as pipeline diam eter or place orifice size are later changed, the microcomputer can be reprogrammed on site with the keyboard console
This built-in keyboard and digital display allows operators to enter data, monitor overall system operation, and recall data from the microcomputer mem ory for verification From the console, the operator can also check such operations as transducer calibration from the remote sensor sites to further assure accurate measurement An optional printer can provide direct printout for hard-copy needs,
The instrument can be used to verily costs from outside suppliers, control inter nal flow operations, and determine the billing to downstream industrial custom ers
Besides calculating totalized flow, the unit can monitor points along a pipeline for variations in basic flow conditions, such as a sudden change in pressure, It can also provide data to downstream processing operations and control such functions as
merging the correct mix from multiple
streams of liquids or gases
;
The basic system accepts any combina-'
tion of up to 16 analog inputs, and provides
two analog outputs Expanding the 16
analog inputs is accomplished by adding
more I/O modules
Other major oil and chemical companies
currently utilizing the system include Shell
Oil, Continental Carbon and Dow Chemi
cal, They are using it for such applications
as measuring ethane-propane mixed
streams, measuring crude oil flow through
long-distance pipelines, and metering at
custody transfer points along pipelines V
Microflo measurement system is a pro duct of UGC Industries, lnr., Box 3736, Shreveport, LA 71103
Circle 804 opposite last page,
Model 1806 microcomputer, around which the flow measurement is based, is manufactured by Process Computer Systems, Inc,, 5467 Hill 23 Dnoc, Flint, MI 48507,
Circle 805 opposite last page
212 JUNE 1978 CHEMICAL PROCESSING
COLORITE 007246
XNEWS FEATURES
PVC makers move to mop up monomer emissions
Twin derricks move cleaning devices from one reactor to the next at Georgia-Pacific Plaguemine, La., PVC plant.
<
V* r
Production improvements lead the drive by U.S. polyvinyl chloride producers to meet strict federal limits on suspected carcinogen vinyl chloride.
Photo- Georgia-Pacific Corp.
f~1 U.S. manufacturers of polyvinyl
chloride are girding themselves for stringent strictures on vinyl chloride monomer (VC) levels.
For instance, when a U.S. Occu pational Safety and Health Admin istration (OSHA) standard for VC comes into full force on April 1, the ceiling for worker exposure to the monomer will harden, eliminating today's option that allows plants to run at up to 25 ppm without using respirators.
A link--which became a cause celebre in early 1974--between VC and a rare liver cancer called angio sarcoma is spurring the clampdown from the pre-April 1974 limit of 500 ppm. And U.S. plants are not alone in facing stiff VC curbs: exposure regulations also are tightening in Western Europe and Japan. Sweden, like the U.S., has adopted a 1-ppm limit. Most other nations are head ing for monomer ceilings in the 5-25-ppm range, though.
SOME SUCCESS--Through new or improved manufacturing methods, many operators of larger and newer PVC plants already claim to be un der 1 ppm--at least for most normal operations, if not during upsets or maintenance or in every single part
of the plant. They've been buttoning up their facilities to hold in fugitive emissions (such as leakage through flanges), changing both polymer ization formulations (recipes) and vessel-cleaning procedures to cut down the frequency of opening up reactors, and adopting improved techniques for stripping residual VC from product PVC resin.
H owever, a few smaller and older PVC plants apparently are limping along without making much head way toward OSHA's limit. New en gineering controls for VC either can't mesh very well into these in stallations' equipment setups, or can't be economically justified.
Adding to their dilemma, the U.S. Environmental Protection Agencs (EPA), at presstime, was on the verge of proposing standards to regulate VC emissions to neighbor hoods around plants. Many of the steps needed to satisfy the OSHA ceiling undoubtedly will go hand in hand with efforts required to meet EPA's standards. However, com pliance with the latter may demand sizable additional outlays.
-If an operator was staggered by the OSHA rules, the coupe-de-gracc will be EPA's," predicts one industry
source. Already, Uniroyal Chemical, a division of Uniroyal Inc. (New York) has revealed plans to close its decades-old Painesville, Ohio, PVC plant (Chan, Eng,, Oct. 13, p. 67) be cause of the "exceedingly large capi tal expenditures" needed to satisfy OSHA and EPA standards. At least some industry spokesmen expect one or two other older and smaller PVC plants to shut down, too,
CAPTURING FUGITIVE VC-Before the VC health hazard was recog nized, fugitive emissions were the largest source of monomer losses, ac cording to an EPA analysis. But conipanies are clamping down.
"One of the first things we did was to tighten all the flanges," says a Continental Oil Co. (Stamford, Conn.) spokesman. And throughout the industry, flanged pipe couplings are replacing leak-prone threaded couplings, and welded joints some times are eliminating both.
"We are continuing to look for better gasket materials and pump seals," adds John Nelson, vice presi dent of manufacturing for B. F. Goodrich Chemical Co. (Cleveland, Ohio), the largest U.S. PVC pro ducer. EPA, for its part, plans to in sist on double-sealed or canned
______________ 25_____________
CHEM1CU. ENGINEERING NOVEMBER 24, l'.?S
COLOR!TE 007247
pumps (or an equivalent); the agency also will call for rupture disks under relief valves, to avoid leaks if a valve reseats improperly.
The trend to larger-size polymer ization reactors, aimed primarily at boosting productivity, also helps stem fugitive emissions, because one large vessel has only half the possible leakage points of two smaller units of the same total capacity. Industry had relied on less-than-7,500-gal re actors for 85% of its output as late as 1972, but now much bigger vessels are favored. For instance, GeorgiaPacific Corp. (Portland, Ore.) uses 20,000-gal vessels at its new Plaquemine, La., plant, and Shintech, Inc. (Freeport, Tex.) features 35,000-gal units at its Freeport installation. Massive, 55,000-gal reactors already are employed by Germany's Chemische Werke Hiils AG (Marl) and BASF AG (Ludwigshafen).
COPING WITH CLEANING--The opening of reactors for manual cleaning can also allow monomer to escape. Pre-venting vessels and flush ing them with an inert gas prior to opening is limiting VC losses, espe cially at the handful of smaller and older plants where workers wearing respirators still do the necessarychipping and scraping by hand. However, companies are striving to reduce the frequency of the manual cleaning.
"Balancing the reactant recipe" can thwart the formation of deposits in the first place, says A. B. Steele, operations manager for Union Car bide Corp.'s Performance Plastics Dept. He adds that firms are regu larly improving their understanding of fouling and how to cope with it through changes in recipe and oper ating conditions. But the recipe work remains highly proprietary. Conti nental Oil, for example, declines fur ther comment on a "clean-wall for mulation" that it says it developed last year--but it has told EPA that the frequency of reactor openings might be cut to once every 200 batches However, in Italy, ANIC SpA (Milan) does identify its pro prietary additive as an "inorganic colloid," which minimizes deposits and makes those that do form softer and easier to remove.
Special reactor-wall surfaces can also help. For instance, Shintech uses a chemical coating, developed by its
half-owner, Shin-Etsu Chemical In dustry Co. (Tokyo). Before each polymerization batch, walls are "thinly coated with a chemical, so thin you can see the basic structural material, stainless steel," reveals Teruhiko Aihara, assistant general manager of Shin-Etsu's PVC div. and a member of the Japanese firm's board. "Scale just does not stay on the walls." A simple, low-pressure water spray after each batch is enough to wash away any "specks" on the reactor. The technique al ready has proven itself in five years' commercial use by Shin-Etsu.
RELYING ON WATER-PVC makers in the U.S. (and even more so in Western Europe and Japan) use water sprays themselves as the main means to keep reactors clean. A number of proven techniques are available, including the HRC system from Goodrich Chemical, which fea tures a 6,000-8,000-psi spray, and a rival method from Pfaudler Co. (Rochester, N.Y.), which works at much lower pressure (several hun dred psi) but consumes more water.
Overall, water cleaning can halve or even further reduce the frequency of opening reactors for manual cleaning, depending on vessel design and the PVC-resin grades being made, notes Harry Connors, vice president and general manager, Plastics Div., Diamond Shamrock Corp. (Cleveland, Ohio). But on a 0-100 scale, he adds, it's "closer to being 50% effective than it is to being 1007c effective" in reducing cleaning frequency.
A patent-pending system invented and manufactured by Georgia-Pa cific promises to raise the score. Computer positioning of a waterspray nozzle is the key. The speciallydesigned nozzle is programmed to come within an inch or so of reactor walls, heads and internals, a spokes man says, in contrast to conven tional systems in which nozzles oscil late within the vessel sometimes a few feet away from surfaces.
The firm's Plaquemine plant fea tures two such units, handling four and five reactors, respectively. Two tall derricks, shown in the photo on p. 25, move the system's cleaning heads into and out of the reactors, and from one vessel to the next. A 200-gal/min flow of 5,000-6,000-psi water ensures cleaning.
SOLVENTS GAINING? --Nonaqueous cleaning fluids had been proposed even a decade ago as a way of doing a more thorough job. Ac tual use remains limited, though, be cause of obstacles such as high capi tal cost, complexity of solventrecovery equipment, solvent traces left in the reactor, and solvent safety and environmental hazards. How ever, with better reactor cleaning now a priority, producers of PVC seem more anxious to tackle the problems.
A number of solvents rate as possi bilities: ethylene dichloride, featured in a system from Stauffer Chemical Co. (Westport, Conn.); methyl-ethyl ketone, used by Union Carbide at its Texas City, Tex., PVC plant; M-Pyrol, GAF Corp.'s (New York) nmethyl-2-pyrrolidone solvent; tetrahydrofuran, favored by Monsanto; and dimethyl formaldehyde.
The Union Carbide solvent-wash ing system has been running for about ten years. But Carbide's Steele points out that the firm has the sol vent available at Texas City for a myriad of other tasks there, so exten sive special facilities did not have to be built for the PVC.-reactor clean ing chore. Carbide washes vessels with the solvent after every 5-15 batches.
GAF, another pioneer in solvent cleaning, is working to bring to mar ket a complete process/equip ment package using M-Pyrol. An al ready piloted solvent-recovery- step rates as the key to GAF's new push. In it, water is added to spent solvent to precipitate polymer, which is then removed by centrifugation; the sol vent/water mixture is distilled to re coup the M-Pyrol.
PURIFYING POLYMER-The PVC product in the reactor also needs cleaning to remove VC. Stripping by post-polymerization venting of head gases from the reactor eliminates some monomer, which then passes through a refrigerated-condenser system and is recycled. However, sig nificant quantities of VC remain, and they give emissions problems in subsequent resin processing and han dling operations.
To avoid specifying diverse point controls on all the various post-strip ping operations, EPA plans to set a limit on VC content in resin leaving the stripping step: 2,000 ppm for dis-
26______________
CHEMICAL ENGINEERING NOVEMBER 24. 1075
COLORITE 007248
rsion resins and 400 ppm for
her PVC grades, including
ose made by the predomi>nt suspension process. If VC ere is held at a low level, the ;ency figures there simply on't be enough potential loss
'^Sr
worry about later on, both the PVC plant and at fabri-
LUL
ttors.
Heating the reactor product
. place can boost VC liber-
,ion rate during venting,
owever, temperature control
critical; too high a tempera-
irc or heating for too long can
amage product quality, par-
cularly with easily degraded
ispersion resins (hence their
igher VC limit). PVC makers,
evertheless, are turning to the
se of vacuum and heat, the
itter through external steam
mkets and, more recently, di-
tet steam-sparging. Some
rms are working on additives
tat stabilise resins to better
ithstand the rigors of the
.ripping operation. Continuous stripping, sim-
arly, can help reduce VC con-
Continuous stripping columns remove residual monomer from PVC resin at Goodrich plant.
ent. Little used so far, the ap-
iroach got a boost in August
rom Goodrich Chemical. The firm cleanup developments. But technical
nnounced an advanced system that and economic feasibility still remain
t has already or will install at all its unproven on a large scale, contends
ive PVC plants within a month, an expert at the Society of the Plas
joodrich admits that setting up the tics Industry, Inc. (New York).
tripping system poses high initial
Combustion to oxidize VC to car
osts, but this has not deterred sev- bon dioxide, water and hydrochloric
ral other PVC makers from already acid is generally discounted: flares,
aking out licenses to use the new direct-flame afterburners and steam
echnology.
boilers all suffer cost penalties, espe
The closely guarded technique cially because they require protec
vorks by steam-stripping resin slurry tion against acid corrosion, scrub
n a countercurrent-flow' column. bing of the hydrochloric from off
The method is faster and more ef- gases, and supplementary fuels
tcient than batch procedures, Good- when handling dilute VC streams.
ich claims. It has tried the system Catalytic afterburners seem some
m suspension resins, but not yet on what more favored; industry sources
iispersion grades.
hint that some new catalytic VC-de-
CLEANING \ ENT GASES-VC es- struction techniques are now in the
:aping to the atmosphere in off offing.
gases--especially from the refrig-
PVC makers arc looking with con
rated-vent-condcnser in the mono siderable interest at carbon adsorp
mer-recovery system--also draws tion, says Calgon Corp. (Pittsburgh,
EPA's attention. The agency plans Pa.), which claims to be working
to put a 10-ppm ceiling on sueli with a half-dozen or so firms on pi
losses in offgases. Control technology lot-plant projects or design specifica
is already available, or nearly so, tions. A spokesman stresses that in
with consideration centering on inci work so far there have been no prob
neration, carbon adsorption, and sol lems with unloading spent beds for
vent scrubbing, as well as some new VC recovery, or with bed clogging or
27
CHLMICU. KXUIM.I.lUNt-, NOM.MHIK _M. I'CS
monomer polymerization in
the beds. Tenneco Chemicals (Saddle
Brook, N.J.) installed in Febru ary the first fullscale carbon system, which it says meets the 10-ppm limit.
Adsorption on resinous or polymeric materials is under going some preliminary in vestigation by Rohm and Haas Co. (Philadelphia), because they may retain more VC than carbon does.
Another alternative, solvent scrubbing, has chalked up years of experience as an econ omy-prompted technique for recovering VC for recycle in plants operated by Goodrich Chemical, Union Carbide and Firestone Plastics Co. (Pottstown, Pa.). Solvents include ethylene dichloride, acetone and methyl-ethyl ketone.
Early last month. Union Carbide extended the tech nology to emission control by commissioning a system for vent-condenser purge gas at its Texas City PVC installation. The 5500,000 + setup uses cold methyl-ethyl ketone. Carbide hopes to recycle and reuse the recov ered monomer. A no-moving-parts, drt process called oxyphotolvsis rates as the newest control candidate. Developed by Robintech, Inc. (Fort Worth, Tex.), Shin-Etsu's partner in the Freeport PVC plant, the technique destroys VC to form carbon dioxide, water and chlorine in an undisclosed manner believed to involve ultravio let radiation. Other hydrocarbon pollutants can also be handled A pi lot plant for VC elimination now is going up at Freeport, and should be running early next year. John Ertell, manager of Robintech's PVC Di\.. claims that according to lab work oxyphotolysis will turn out cheaper than incineration, carbon adsorption or solvent scrubbing. Another alternative cleanup tech nique is being groomed by PPG In dustries, Inc, (Pittsburgh, Pa ). The firm credits the method "with tre mendous potential," but is keeping details under wraps; outsiders hint that the new process involves cata lytic technology.
Nicholas R. lummartino
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