Document 56pDgVE9rQa1L9bNxo2nQ8wz

PRODUCT: SAMPLES; SPECIAL INSTRUCTIONS "PONSOL" SPRAY DRYER NO. 1 "ACETAMINE" SCARLET B CR. S.D. Sample at L ' PRYING CONDITIONS: Atomizing air -- 275 *>c. Drying air - 275 C. Slurry 80-85 C. LOADING AND DRYING INSTRUCTIONS: Load as per green card in the following order: 1. Marasperse CB 2. Tamol SN 3. Ammonium Sulfate ._ The charge may thicken during the addition of ammonium-sulfate. Add water as required. Agitate the slurry until it is completely free of lumps. Sample first.dry barrel to G.A.L. for wet screen test. If fail, shut down dryer and contact Spray Dryer supervisor immediately. Sample third dry barrel to G.A.L. for % A.I. and wet screen test. J^ffiCING:. wash drums with plastic liner. SHIP TOi g &M REF: TA-C-77t 319. dated June 13,- 1977. DATE: 6/13/78 /lu 6/13/78 APPROVAL N32958 W. J. Kng April, 1976 Chambers Works Bldg. 770 1-1-1 ^L "PONSOL" SPRAY DRYER NO. 1 Principle of Process A slurry or solution is pumped to an atomizing nozz.le. A stream of compressed air is impinged upon the liquid stream causing it to atomize. The droplets of material thus formed come in contact with a large volume of hot air and the water is flashed off. The dry product is separated from the air stream. The product is discharged to containers and air stream is discharged to the atmos phere . Reactions There are no chemical reactions done during the drying step. N32958.01 DUP050467541 W. J. Kins April, 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER NO. 1 SUBJECT: OPERATION: Chambers Works Bldg- 770 III-l Plow Diagram N32958.02 DUP050467542 . W. J, King April, 1976 OPERATING INSTRUCTIONS _ "POfJSOL" SPRAY DRYER NO. 1 SUBJECT: f OPERATION: Chambers Works Bldg. 770 III-2 Equipment List D-9 - Dryer 3* diam. x 15' high, S.S. dryer body with conical shaped bottom. The flat top is externally cooled with water. DC-1 - A 5' x 5' x 17* high enclosure which contains 4-181' x 196" "Nomex" collection bags. It has a conical bottom with a rotory air lock for discharging solids. It has a Roots-Connersville blower. Model 18-4 (POS), driven by a 3 HP, 550 V motor to furnish air to the traveling rings which dislodge solids from the collection bags. The ring drive which is powered by a 1 HP, 550 V motor. FN--4 - Main exhaust fan, Zum Model 213, displaces 3*600 CFM. It is driven by a 10 HP, 550 V motor. FN-7 - Combustion air fan driven by a 5 HP, 550 V motor. H-27 - Atomizing air heater. Natural gas fired indirect heater for atomizing air at a rate of 54,000 cu. ft./hr. It can furnish about 750,000 BTU's per hour. H-28-- Drying air heater. Natural gas fired heater furnishing total combustion gases for drying air at approximately 150,000 cu. ft, per hour. It can furnish about 1 million BTU's per hour, P-12A/B - Identical feed pumps. Moyno Style 1, 2 x 3 powered through a variable speed drive by a 1 HP, 550 V motor. P-94 - Circulating pump. Worthington 1-1/2'1 pump, 100 gal./min., powered by 10 HP, 550 V Motor. T-36:- Loading tub. Nominally a 2,950-gallon, S.S. tub with single speed, 56 RPM agitation, driven through a gear reducer by 15 HP, 550 V motor. j T-54/T-86 - Identical feed tubs. Nominally 2,950-gallon, S.S. tub with twin speed agitation, 56 RPM and 28 RPM, driven through a gear reducer by 15 HP, 7-1/2 HP, 550 V motor. i i M U-1361 R2 DUP050467543 W. J. King April, 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 770 III-3 "PONSOL" SPRAY DRYER NO. 1 SUBJECT: OPERATION: Loading Feed Tanks 1. Check T-36 to be sure valves under tank are closed and tank is clean. Foreman must check cleanness of tank. 2. Measure a small amount of water into tank, T-36 (Approximately 250-300 lb.). Turn on agitation. Do not use any water if milled slurry is to be used. If material to be loaded has settled, bucket off the liquid Into the tank, using this liquid in place of the water. 3. Load by shoveling and/or dumping material as called for on the lineup card. Record all amounts of material loaded. Agitation can be helped if the tank is hooked up to recirculate and pump is started. 4. Agitate and recirculate until a smooth slurry is obtained. Sample as called for. Obtain sample from recirculation line. Adjust pH as called for on line-up card. o See sample list and line up card for samples to be taken. 5. Pump charge from make up tank (T-36) to feed tank (T-54 or T-86) through the manhole screen (agitation must be on In feed tanks)'. Omit this step if feed tank is loaded directly, as in the case of milled products. 6. After charge is in feed tank, rinse out make up tank with ho more than 250 lb. of water and pump this fco the feed tank. 7. After feed tank is loaded dry dip tank, record on log sheet and samples to GAL for -Gross Solids. Record dry dip and gross splids on line-up card. Mark sample to GAL - "No Jnusual Hazards1'. 8. Disconnect pump line, wash out with water to ditch. Close valves under tank T-36 aid vat wash the tank if required. See Operating Instructions "Vatting Procedure" for method ,of vatting tank. DUP050467544 W. J. King April, 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 770 III-4 SUBJECT: "FONSOL" SPRAY DRYER NO. 1 OPERATION: Shut down to Operating 1. Hook up proper feed line to P-12. A or B. Hook up return line to same feed tank then start the feed ppmp P-12A or B. Be sure the feed is circulating and returning to the feed tank. It will take 5-12 minutes for feed to return to tank when starting up an empty system. The feed controller TC-209 should be set on manual with at least a 9 p.s.i.g. output. 2. Close all explosion and access doors in D-9 and DC-1. Turn on water to cooling water reservoir on top of D-9. Doors should be closed tightly to prevent air leakage. Water must be turned on reservoir to prevent possible fires in the dryer. This is particularly important when drying sensitive heat products such as ABC Salt. Visual inspection should be made that water is flowing from the reservoir by observing the discharge to the floor. 3. Place an empty drum on scale and start air lock. Mark down the tare weight on the Produce and Ship ticket. 4. If proper action.does not take place in the following steps see alarms and interlock sheet for probable cause and corrective measures to be taken. Turn on FN-4 exhaust fan. Green light on starter switch should go on. Blue d/p should raise to about 11 inches. This d/p measures the pressure difference across the spray dryer and dust col lector. 5. At least one minute after starting FN-4, start positive a?? blower and ring drive. There Is a one minute time delay to ensure that the whole `dryer system Is purged. The green lights on the start buttons should go on and the up-down orange light should change every 26 seconds to indicate that the ring drive system is working. DUP050467545 W. J. King April, 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 770 III-5 "PONSOL" SPRAY DRYER NO. 1 Shutdown to Operating SUBJECT: OPERATION: 6. S|;art FN-7 combustion air blower. Starter button's green light goes on. Alarm light PA-206 goes out. 7. Open natural gas valve. Starter button's green light goes on when valve is open. 8. Open atomizing air valve. The pressure indicator should register and the alarm light PA-211 should go out. 9. Start H-27 (atomizing air burner). Turn controller to "manual" operation and move burner controls set point to 3 psig (0C). This puts burner in low fire, position. ^ ID. Push start button on H-27. This actuates the spark plug and a greet; light above the starter button. 11. After about 5-10 seconds, a green light should show on the start button and the alarm light WA-205 goes out. Hold start button in for about 15 seconds after the burner is lit. t 12. ^f the green light does not show after 15 seconds, release the start button. Three or four starts may be necessary when starting a cold burner. Wait for 30 seconds between tries. If after 3 or 4 tries, there is still no green light, call supervision. 13. After the burner is lit, move the burner's sot point up until the controller's output is; 9 psig. Then switch to seal position, line up control point and indicator temperature. Then switch to automatic and move pointer to set point. \ See list of Drying Control Set points fir specific product being dried. it i DUP050467546 W. J. King April , 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 770 III-6 "PDNSOL" SPRAY DRYER NO. 1 Shutdown to Operating SOBIECT: OPERATION: 14. Follow Step 8-12 to light drying air burner H-28. When bags are to be dried after clean up, use only Steps 8-12. 15. As the temperature of the mid point of the dryer approaches the set point, switch controller 209 from manual to automatic and open slurry feed valve. Green light on slurry feed valve starter button will light when valve is open to dryer. The set points for the temperatures of atomizing air, drying air, mid point of the dryer designated as ''slurry temperature" are given on the line up card. 16. Adjust the following safety shut down points - 208, 212, 216, 308. (See list of drying control set points). After the feed has been established, the red d/p (213) should start to climb. Normal operation is 2-4 inches. If above 4 inches contact supervision. 17. Check drums on scale to be sure material is coming through unit. 18. If trouble develops during this procedure, contact foreman and check alarms Interlock sheet. MU--2361 R 2 '`CaJP'' DUP050467547 W. J. King April, 1976 OPERATING INSTRUCTIONS ^SUBJECT: "PONSOL" SPRAY DRYER NO. 1 OPERATION: Chambers Works Bldg. 770 III-7 Normal Operation 1. Follow instructions given on the instruction sheets. See also the line-up card. This card will indicate any hazards involved in handling individual products. 2. Maintain temperatures on burners and dryer as instructed. Check lineup card and list of Drying Control Set Points. (III-14) 3. Check periodically for dust losses at the stack by visual inspection of the stack discharge. The dryer should be shut down when a dust loss is evident. Most of the products are very expensive. Dust losses constitute a source of atmospheric pollution. 4. Keep a check on the instruments to be sure the dryer is operating properly. 5. Replace the drum on scale when it is full. 1 6* As drums are being filled, add the specified amount of anti dusting oil if called for. 7. Label, tag, and head each drum immediately. Include on barrel label, net weight, code nos. of product, name of product, and barrel number. Also tape a paper label on inside of drum. 8. Maintain an adequate supply of clean dry drums. Be sure the drums are stored in a safe manner. Do not use wet drums. 9. Maintain the Produce and Ship ticket up to date. 10. At the beginning ,and end of the shift, record the events of the shift on the shift log sheet. Dry dip the tanks and record. Check weigh scale at beginning of each shift. Be sure to note unusual occurences in detail. Leave information on needed repairs, malfunctioning equipment, etc. ' , ^ 11. Keep the area clean and trash picked up. The panel board must be kept clean and dry at all times. MU-2141 M2 DUP050467548 W. J. King April, 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 770 III-8 "PONSOL" SPRAY DRYER NO. 1 Operation to Shutdown SUBJECT: OPERATION: 1. When the feed stock level is within 1 inch of the feed tank's outlet, wash down the tank using less than 100 lb. of water. This will clean the tank and lessen the product loss, 2. Repeat Step 1 using up to 500 lb. of water. 3. As the output of slurry controller decreases, indicating that the wash water is reaching the nozzle, turn off the following ip this order by pressing the stop buttons: a. H-28 drying air burner b. H-27 atomizing air burner c. Atomizing air d. Natural gas valve e. Combustion air blower FN-7 f. Peed pump P-12 A or B (only after lines have been thoroughly flushed). As each part of the system is shut down, the appropriate alarm will sound. Shut off P-12 A or B if the tank is empty. Do not run P-12-A or B dry. 4. After the unit has cooled down (drying air below 100C, midpoint of dryer below 50C), open the atomizing air valve. This is done to cool down atomizing air heat exchanger without overheating the spray dryer. 5. After unit has cooled down; turn off atomizing air, ring drive, positive air blower and FN-4. 6. Check barrel on scale. If there is a hang-up in bags, the barrel will fill rapidly when FN-4 is shut down. 7. Open dust collector doors and shake bags. Pack out all product. Then turn off air lock. FN-4 must be locked out before opening the unit. HZ DUP050467549 Ww. J. King AApprirlil,, 1976 OPERATING INSTRUCTIONS SUBJECT: "P0N30L" SPRAY DRYER NO. 1 OPERATION: 7 Chambers Works Bldg. 770 III-9 Cleaning System 1. Check dryer and dust collector to be sure there are no hang ups of material. If hang ups are found, contact supervision. 2. Place special cleaning funnel under air lock. Turn on air lock. This is done to protect the scale from excess water. 3. Turn on the hot water to the bags. This puts water on the inside of each bag. Be sure doors are closed on dust collector. 4. Turn on hot water to the dryer. This puts a water spray on the inside of the dryer. Be sure doors are closed on dryer. 55. Disconnect the recirculating line from the feed tank. Allow line to discharge to the floor. 6. Start to fill the feed tank to be cleaned with water (turn on agitation). Be sure to check this tank. Continue to clean this tank by use of a vat. See Vattlng Procedure, Ponsol Area Special Instruction No. 35. 7. Chain off door to loading room. 8. Check valves under feed tank to be sure they are closed. 9. Disconnect feed tank from P-12-A or B. 10. Wash out flexible feed line. Inspect it to be sure it is clean. 11. Place running water hose into suction side of P-12-A or B. 12. Start P-12-A or B. This will wash out line from P-12 to floor of loading room. Green light on starter button should go on. 13. Start FN-4 exhaust fan. If FN4 does not start, see Alarms and Interlock sheet for probable cause and corrective measures to taken. The green light on FN-4 switch should go on. The blue d/p should go to 11-12 Inches of water and the red d/p should go off scale, (above 5 inches) MU-2KI R 2 DU P050467550 W. J. King April, 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 770 HI-10 "PONSOL11 SPRAY DRYER NO. 1 SUBJECT: OPERATION: Cleaning System 14. At least one minute after starting FN-4, start positive air blower and ring drive. Thp green light on the starter buttons should go on and the up-down orange light should change every 26 seconds. 15. Open atomizing air valve. The pressure indicator should register and alarm light FA-211 should go out. 16. Open by-pass 209 by turning switch to ON. This will allow water from P-12 A or B to enter the dryer thereby cleaning the valve and feed line to the dryer. 17. After 10-15 minutes, close Bypass 209 and close Bypass 227. This adds more water to the dryer and helps to clean it faster. 18. Stop P-12-A or B and pin it out. '\ 19. Drain feed line. 20. Remove Magnetic Trap from line and clean. 21. Reverse flush the feed line. Allow water to drain out magnetic trap. 22. WJien discharge from dust collector is colorless, open Bypass 227. Turn off'hot water to dryer and bags. 23. Open and inspect the following to see if unit is clean. a. Doors on dryer b. Inspection ports in duct work: - one on second floor the other at end of duct on first floor. If unit is still dirty, clean with high pressure water before continuing. c. Open the port in the cone of the dust collector. If this requires that a man enter the cone to clean it by hand, use the tank entry procedure. Obtain an air system for human consumption, an alarm horn, a stand-by-man. Tag and lock out FN-r4, the ring drive, air lock, tag the dust collector doors and the wash valves to the dust collector. Remove the_J) air lock blades. Loosen the hold bands from the bottom of each bag. Slip the bags off their sleeves. Tie the bags together so all four sleeves into the cone are open. DUP050467551 w. J. Kirig April, 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER NO. 1 SUBJECT: OPERATION: Chambers Works Bldg. 770 rii-11 Cleaning System 23. c. (Continued) Put a plank across the doors and under the ring drive to prevent the ring drive from falling in case of mechanical failure. Enter the cone through a bag sleeve. Clean the cone by hand. When the cone is clean, climb back into the dust collector through the bag sleeve. Replace the bags and clamps. Replace the air lock blades. Remove the locks and tags. Shower and change clothes. 2h. Start FN-7 combustion air blower. Starter button's green light goes on. Alarm light PA 206 goes OUT. 25. Open natural gas valve. Starter button's green light goes on. 26. Start No. H-27 (atomizing air burner). Turn controller to "manual" operation and move burner controls set point to *' 5 3 psig (0C) . This puts burner in low fire position. 27. Push start button on H-27. This actuates the spark plug ar}d a green light above the starter button. 28. After about 5-10 seconds, a green light should show on the start button and the alarm light WA-205 goes out. Hold start button in for about 15 seconds after the burner is li,t. 29. If the green light does not show after 15 seconds, release the start button. Three or four starts may be necessary when starting a cold burner. Wait 30 seconds between trials. If after three or four tries, there is still no green light, call supervision. 30. Afper the burner is lit, move the burner's set point up until thp controller's output is 9 psig. Then switch to seal position, line up confrpl point and Indicator temperature. Then switch to automatic and move pointer to set point. Do not exceed 300C as a set point. 31. Continue drying out the bags for 5-10 minutes after the red D.P. has leveled off at 1/2-1 Inch. i DUP050467552 W. J. King April, 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER NO. 1 SUBJECT: OPERATION: Chambers Works Bldg. 770 III-12 Cleaning System 32. Turn off H-27 by pressing stop button. The alarms should sound and indicate as the equipment is shut down. Shut natural gas valve. Stop FN-7. 33. Allow unit to cool down. (TC-209 below 50C). Then turn off atomizing air, ring drive, positive air blower and FN-4. 34. H^ve FN-4 locked out and inspect the unit. If either dryer and/or dust collector are dirty, contact supervision. 3b. If no bag change is required, have FN-4 unlocked and proceed with next operation. 36. If the next product to be dried Is not dispersed, precoat the dryer and the dust collector as follows: a. Lock out FN-4 and open dryer doors. b. Coat the inside of the dryer with Marcarb N solution. Be sure to cover the inside of the door. Close the dryer doors. J c. Remove the southwest bag from the lower dust collector ring. This gives access to the duct and dust collector hopper. d. Coat duct and hopper of dust collector with Marcarb N Solution. Refasten the bag. Unlock FN-4. e. Dry out the unit by using hot atmoizing air (See III-4 shutdown to operation Steps 2 thru 13). i MU'ZKI R DUP050467553 W. J. King April, 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 770 III-13 SUBJECT: "PONSOL" SPRAY DRYER NO 1 OPERATION' Cleanins system"BaS Change 1. Do Steps 1 through 3** of Cleaning System. 2. Open Dust Collector doors. Be sure all four doors are open. Wear a respirator when entering the dust collector. 3. Loosen hold bands from bottom of each bag. Slip bag off sleeve. 4. Lower platforms and push bars into place, at upper doors. 5. Loosen and remove hold band from top of a bag. Lift the bag off the hooks on sleeve. Then remove bag from unit. Fold and place in wash drums and send to laundry for cleaning. 6. Repeat Step 5 on the remaining three bags. 7. Secure bags to be hung from storage. 8. Place a bag on rail and put over sleeve. The hooks on the upper sleeve must go through the grommet to prevent bags from falling. 9. Allow bag to hang to bottom of dust collector. Replace hold band and tighten. 10. Repeat Steps 8-9 for the remaining three bags. 11. Pull platform rail against side of dust collector wall. Lift up platform and fasten to rail. This must be done to both platforms. Platform.must engage interlock switch or ring drive will not operate. 12. Slip bottom of bags over sleeves and fasten with hold straps. 13. Close all doors in dust collector. 14. Do Steps 35 and 36 of Cleaning System if they apply to the next product. M u-un n a DUP050467554 W. J. King April, 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 770 III-14 SUBJECT: "PONSOL" SPRAY DRYER NO 1 Drying Control Set Points mOPERATION: Condition Atomizing Air Controller 205 Drying Air I 400 C to 450 C 450C Slurry Control 209 * 95C to 115C TC-20 8 475C TC--212 120 C TC--216 TC-308 85C 625C. L 1P 270 C 270C S 350 C LC 270C 300C 300C 375 C to 400 C 270aC 80C to 85C 80C to 85C .............. 350 C 350 "C 85C to 90C 450 C 78C 350C 95C 95C ________i ............... 80 C 80 C 100C 85C 625C 62[)C. 525c . 95C 80 C 625C. Mu-nci * ? DUP050467555 W. J. King April, 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER NO. 1 SUBJECT: OPERATION: Chambers Works Bldg. 770 III-15 Type of Product Intermediates I "Latyl" Disp. Crs. 1 L 3 ' "Ponsol*1 D Pdrs. P Slurry Sample 1 pint prior to drying for 6. S. 2nd Barrel Sample - % Moisture Every two hours Dry Composite 1 qt. to G.A.L. 1 pint prior to drying for pprp G . S . 4 oz. to lab. for D.P.T. 4 oz. to lab. for A.I. Once per shift. 1 qt. to Gene Childs 1 pint prior to drying for Gross Solic oz. to lab. for Cloth Test Once per shift. 1 qt. to G.A.L. for D.T. nSevron" S S 1 pint prior to drying for Gross Solids' Once per shift. 1 qt. to G.A.L. Note: Slurry sample should be taken just prior to drying, the dry dip must also be taken at this time- and recorded both on log card and sample label. 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P O c C\ od 01 Or O P o N Cl --c d Vi 3 d d CJ op d N d r- Vi 3 *0 -rl p O d r-| d d -d -d O o id dd 3 Dl -rl pd Id Id -rl dn tn d * d Or E tr>-r| 6 q d >, CJ P *r| d P 3 P na id d O' U co CJ CN C) <n tr> > i 04 i d O S3 OSH VI -% U r-l (SID rH c n co *sr rH OJ fO H CN CN O* g M n CJ r--i X) 3 o d , E-t 0 p r? rH a, <u cj ,54 p 0 d H H -d S P 3 P P Vl nS P M * r~l r-i H > f-' CN 1 M-9 p Vl d P 0 P O d H H -d 3: Vl d d 3 P w id tn * Vi d <0 CJ u> O c "d d >1 w Vl P Td 3 XX CO W 03 Vl S3 o P A iA Oi a AC P O d rH ' rA rl Js P 3 P P Vl id P M i--1 rH rl s 00 CN 1 S3 d 0 do N d O 0 CJ CJ lM P 0 d H rH H OJ > rl id > u oj d O3 *H O n3 N d i/i dp 33 1 XX ww iU J . K ing A p ril 1976 DUP050467559 W, J. King April, 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER NO. 1 SUBJECT: OPERATION: Chambers Works Bldg. 770 III-19 "These Operating Instructions have been issued after a complete review of current technology and conform to current C. W. Process and subsequent recommendations recorded in TA's and TC's." -0,j ____________ __________________ (Author's signature) Building Supervisor_ U' J i(wj Senior Supervisor Chief Supervisor, Operations______ Chief Supervisor, Tech, or Plant Assist /paw/bkq #4750 Date tfj'Liht Date Date v*- A^->6 Date MU-2141 R 2 DUP050467560