Document 3NXb025E3Q6DOB92K992ddM63

Medical Department ' 451 Florida Eaton Rouge, Louisiana 7080! TELEPHONE: Area 504 `387-0131 DISTRIBUTION S , A. D ' Armond S. D. Motsinger W.E.' Rinehart, Sc.D. T. R. Robinson, M. D. H.M. Taylor M.R.. Zavon, M.D. D.E. Cooper October, 1974 ETH00002860 ETHYL CORPORATION Medical Department Baton Rouge, Louisiana STRICTLY. CONFIDENTIAL . INDUSTRIAL HYGIENE SURVEY Of Baton. Rouge Plant Preliminary Survey of Materials and Processes in SODIUM AREA I. General The portion of the Ethyl Baton Rouge-plant designated as the Sodium Area converts brine to sodium, caustic soda, and ' chdo-ine' A simplified chart of Sodium Area operations as supplied by Mr. Motsinger is attached. We have made some supplementary indications on the chart to help tie it into ' the descriptions in this report. The principal manufacturing operations are: . " . 1) -Brine treating. All sulfate must be removed and a . very dry salt prepared "for feeding the'sodium cells." Brine is heated and saturated for the caustic cells. 2) Downs Cells. In these the dry .salt is mixed with some calcium chloride to reduce its melting-.point, '. and the melted salt electrolyzed to sodium and chlorine. (The TEL-TML operations use most of the sodium. Most of the chlorine goes to the Hydrocarbon Area for manufacturing solvents, ethylene dichloride, and vinyl chloride. - By-product HC1 then goes into making -ethyl chloride and methyl chloride there for.use in the TEL-TML plant). ... . 3) Hooker cells. These cells convert.a saturated salt solution to caustic.soda, hydrogen, and chlorine. At present the crude caustic liquor is shipped to Allied Chemical. The hydrogen is vented. The chlorine goes mainly to Hydrocarbon Area operations. 4)- Chlorine recovery. The chlorine from the Downscells is dry, but the considerable water in the hot chlorine from the Hooker cells must be removed in three stages. Part of the dry chlorine.is liquefied and filled into tank cars." The remainder goes to the Hydrocarbon Area. ' ETH00002861 IX.'. Materials (Raw, .Product, By-product, Supportive) 2/ Brine-treating section Barium chloride. This is purchased in bags (e.g. from E. Kuhlmann of France) and dumped into a.dissolver pit. The solid is dissolved in water heated by injected steam, and stirred by injected air. ' Barium sulfate sludge. The sulfate content of the raw brine from Allied is precipitated by addition of barium chloride solution in (five) treating tanks. The resulting, barium sulfate sludge is allowed to settle for hauling to a landfill area. Caustic is added to the'tank to overcome the accumulating acidity from the reaction. . . ;' Diatomaceous earth is added as an assist just .before the ' filtration of the brine. ... ` . Natural gas,fuel for dryers and other operations Dov/ns Cells section (154 cells, 7 volts/cell) (600C) Sodium chloride, dessicated, as feed. Calcium chloride, solid, added to,salt feed for cells Metallic sodium, mainly used in TEL manufacture. Excess to storage and sales. - Chlorine to chlorine recovery.section. : Sodium-calcium sludge is filtered into drums and hauled to river. Sodium oxide vapors. Most of this is an aerosol, drawn into hoods and exhausted through low chimneys. Released several times a day when cells must be opened.. (Face Masks used for personnel protection) Hooker (Diaphragm) Cells section (132 cells) (550 volts) Clarified, saturated brine Hydrogen chloride to reduce pH. Asbestos for diaphragms. Anodes, graphite. See Supportive materials. Cell liquor. Mixture caustic soda plus unreacted salt. Product pumped "across the fence" to Allied Chemical. 11.5% NaOH, 15% NaCl. . '* ETH00002862 i Chlorine, wet, to cooler and dryers. Hydrogen by-product. To roof vent. 3. 'Chlorine Recovery Chlorine, wet, then dried. Some is.liquefied. Chill Water for 1st stage sweat-out. Freon in chiller stage. Sulfuric acid for acid scrub. "Gunk" from liquid chlorine stripper. This is. a mixture of off-gases from caustic cells, and consists of chlorides of nitrogen and carbon. The material is mostly CH3C1, CH^Cl^ CHC1.3 , CCl., with small amounts of NCl^. Separated as bottoms in^.the stripper,, it is washed with caustic, and scrubbings are sewered. (There are plans to move these-bottoms to'the HC area for processing). ; Supportive Materials Graphite anode make-up ,' Spacers .' Graphite - Sheets ' ' Mastic, heated in box . One cell/day is re-built with new anodes. Bus bar clean-up and tinning section }HC1 troughs Copper chloride for clean-up : Metallic tin Metallic .antimony for tinning bars in furnace Metallic lead, formed into bases of cells for- electrical conductor. ` .. Other Supportive and Maintenance Materials- ' Paint, protective, for bases of diaphragm cells Paints, other (check with Maintenance) Roofing Compound - ETH00002863 4 Lime. 2 million lbs, slurried.and also bagged, kept ' at-the-ready, ` in case of sodium cell shut-down .-.or spills. Soda Ash. Scattered on floors, then swept up to maintain dry surface, prevent electrical shock. Soaps and Cleaners, Misc. (Check with Maintenance) HTH. Shower sanitizer. ; Lubes, Misc. (Seealso memo DEC/HMT, 10/14/74 on compressor lubes.) - .. . Charcoal. This is dried as a service to HC Area and returned to them. . III. Indicated Problems, Nov; Under Remedial- Study Sodium Oxide. (See under "Downs Cells") . ' - .Brine-treating tanks. -Hot, salty mist may be capable of being reduced. _ . ' . . ". "Gunk" disposal (See under "Chlorine Recovery") , Sodium-calcium sludge disposal. (See under "Downs.Cells".) Attachment: SODIUM AREA (Simplified lay-out of operations) .DEC: daw D.E. Cooper October, 1974 ETH00002864 ETH00002865