Document 71v7E6vdXbwRVw2BdpZeVKzoE

REACTIVE CHEMICALS REVIEW PROPYLENE GLYCOL PLANT MARCH, 1985 I.REACTIVE CHEMICALS CONCERNS II. OVERVIEW OF PLANT III. WORST CASE AS: ag 3/20/85 oonftdfnttai Do 004911 I, REACTIVE CHEMICALS CONCERNS A. REACTOR AREA 1. WATER BACKUP INTO PO FEED TANK 2. LOSS OF WATER FLOW 3. INSUFFICIENT HEAT TO CARRY OUT PO/WATER REACTION A. DEADHEAD PO FEED PUMP 5. NAOH ADDITION TO SWEET WATER DRUM (D-9) 6. NH4 IN PO FEED 7. PDC IN PO FEED B. EVAPORATION 1. RERUN OF SLOP FROM SUMPS C. DISTILLATION 1. BREAKING VACUUM ON GLYCOL COLUMNS D. HYDROGENATION 1. HYDROGEN FLAMMABILITY 2. HARSHAW CATALYST 3. GLYCOL BACKUP INTO HYDROGEN BANKS II. OVERVIEW OF PLANT A. REACTOR AREA 1. HEAT OF REACTION 2. TEMPERATURES AND PRESSURES 3. REACTOR TRIPS/CONCERNS conft^nTTM 004912 DO B. EVAPORATION 1. TEMPERATURE AND PRESSURES 2. CONCENTRATION OF GLYCOL 3. CONCERN a. RERUN OF SLOP FROM SUMPS C. DISTILLATION 1. TEMPERATURES AMD PRESSURES 2. CONCENTRATION OF HEAVIES 3. CONCERN a. BREAKING VACUUM ON GLYCOL COLUMNS D. HYDROGENATION 1, NORMAL REACTION 2, TEMPERATURES AND PRESSURES 3, CONCERNS a. HYDROGEN b. CATALYST c. GLYCOL BACKUP INTO HYDROGEN BANKS III. WORST CASE A. GLYCOL PLANT B. HYDROGENATOR AS: ag 3/20/85 CONFIDFNTTAL. DO 004913 VUJ1J\llLJL V _11 JLik^ _LL JLL U-J-L OF THE GLYCOLS of ti;z c-ivccLr Djeci^fOD n:^i:rs ROOllLUT ARE: HYLENE GLYCOL METHYLENE GLYCOL fRJETHYLENE GLYCOL TfTRAETHYLENE GLYCOL PROPYLENE GLYCOL dipropylene glycol tripropylene glycol f^ i Jr,--{S-77--<r7. '.-I :.VJ ri .j a J- ' . CH, - OH 1 CH* - OH * S7'.- ^CH,-CH,-OH \-T x CH, - CH, - OH : '* * v; CH, - O -CH, - CH, - OH *1 J ^ * ch3-o-ch2-ch2-oh /j y- 3 ^CH, - CH, - O - CH, - CH, - OH ao Cl VCH, - CH, - o - CH, - CH, - OH t '-S&kTizFl ; i- yt * \-"' #-' T A ' ?/ t V. r",V /^ h. *-^'./n l-> i -.Vj -tT.; al wr>, . 'f-"* *i -"%-O>f r--' - S'J -ii r r 'J OH OH -= 1 1 0 i i CH, - CH - CH, ./ * i 1 OH OH *7 1 % ] CH, - CH - CH, - O - CH, - CH -CH,* i * 5i _V-i yI-*.;' ? : `f.'* - rm' * V#.>*". pi rL'j- OH 1 CH, OH .++2 11 CH, - CH - CH, - O - CH, - CH-0-CH,-CH-CH,* r i ; r- rj 7Z V ; Artd Kemcn. CONFIDETNTIAl D0 004914 *'/W P.d s"),oJa ^Ak 4 ^/h/t ._ /5S.? tfoltsf.O. "11T7" * Z)tSu/faC y /t tJs rffG> - <?/.>' D/6 * #o 7*7 ~ a.r piUd^G& /fl/6 ~ /c`,C(*'7.S r o/6 ~ rzz. V.? T^) ' 4) I '53>.2 fault?- P.O. i I<1LS fauJi?L Jifto * ^ <v` ^(-yucT-fi^O /9J^7 /d ^^7, r a(7S//- VS) * &w/nc -' Hi.u xf 4/z - ?stf|) ^ /$Jtf/*/< 77^ r <tf. t * ( K>r,t - r*.?)1 I &r^sr /w/toti P2o - 5'-r ?ri,e $/ i x{Vi/-?r7^) fkK. ft *p r <?/ &!/uc TbyK fi/f " 5 5?Zpoo 47tf/fi/ prt-1 ' JSolo j}7lJ 'Ah#'/* /to &c$ j/ A p,D. fluf6^ IhfdpJ^ Cfr^cM^O F/Mfr CONFTDFNTT Al. S DO 004915 67 ^ ' 7^^ _ -fy DOW CONFIDENTIAL REACTIVE CHEMICAL HAZARD >A*ERlAk A C,yJ. it PROPERTIES AND PRECAUTIONS - - TwLe.___gu-tteX___ ITNO.'lYMj DATA ftEPEPEsClNyvOcS G(w DATE 0* ii: "t7/?/7-F n't/' revision date RcF *OLECU,aR F^SfMv.A KAIVTul^. *TRUCT0AL FORMULA, CCPOS*TiOn, C0M*0fw = N7i * IMPURI TIES J^{. (^C- \ P.O. UHTt'tV"*!*) mOl ECU-, a R - Eight PnrstCAL STa1!; |S4ml5 PUPt"v ____________________ L=^_____________________ THERMOCHE^ICAL INFORMATION HEAT OF FORMATION FROM THE ELEMENTS K col. Grom Mol* HEAT CF self DECOM POSITION IN OXYGEN K col. 130 Grom* HEAT Or SELF OECGmPOSiT ON K ccl. ICO G'=rik AH, , AH0 AHd = S LC i LG 1 FLANg TEmPERATURC REPORTED AT S "L G DECOhPOSItIOn TEMP* c REPORT MUf P c LABORATORY SCREENING TESTS WARMING: Dotg fco*d on laboratory t**f condition!; u*o caution in titondinf to diffornt onironnonfi. DIFFERENTIAL THERMAL ANALYSIS RaTE OF T'^TTnCR'EaTe "r uAVmLm test TEMP. po c minJ Exo ty* EMD3 STAOT *c PEAK X I&ZoS ^9 ^Tl 37 5 4oQ *C | END 32_9 3 $\ t\zD -c *C SIZE S*tV TEST METHOD Solid * L'Ruid TEST TEMP. C drop-weight shooc sensitivity NUMBER of TESTS HEIGHT cm WEIGHT *9 NEGATIVE wments- ^0 COMMENTS 'Pi50, Ejq): TEST RUN 3 v i.L,. fvWwr/ TEST DATE "1/17/7 4 TEST REFERENCE JZM- ___ P*ek___ FLAMMABILITY PROPERTIES (In oir ot omb'trit prcitwp* unltti othorwito notod) METHOD TEST P^N ST COMMENTS and SPECIAL PRECAUTIONS FLASH POINT TEST RUN 3y c c TEST Date eF METHOD F TtST REFERENCE ?--------test day fcST sjf0:t.C5 AUTOIGNITION TEMPERATURE Tf*r RUN By fTST D* 7 c -F YE4TreFESEkc? F LAMMABL e LIMITS LIm'TS - VOL. > PRESSURE TEMP. LO#ER UPPER P5IA op m-nHj C IGNITION SOURCE CONFIOENnM . t ST RUN Sr *t. Onv TEiV O-Tf "TEST beTTTFnTT--- km DO 004916 7isil Ui'iO ITT? L --I -- Am w*r*M I - --(Tf7 SU*------------- NV*>r -J r> o z n oO wo am z MH o *> vO -i a>J> wnvmf*___**_*__,_n, mi anno etact Utxm ' Mr If>j . o> lr) i*iti T55W7 ____ CP REACTOR AREA CONCERNS 1. WATER BACKUP INTO PO FEED TANK 2. LOSS OF WATER FLOW 3. INSUFFICIENT HEAT TO CARRY OUT PO/WATER REACTION 4. DEAD HEAD PO FEED PUMP 5. NAOH ADDITION TO SWEET WATER r NH4 IN PO FEED 7. PDC IN PO FEED PLANT PREVENTION 1. LOW DIFFERENTIAL PRESSURE TRIP ACROSS MIX TUBES 2. LOW AMP SHUTDOWN ON WATER FEED PUMPS 3. E-510 LOW OUTLET TEMPERATURE TRIP 4. HIGH PUMP DISCHARGE TEMP ERATURE SHUTDOWN 5. ROUND ANALYSIS TO VERIFY TANK CONTENTS 6. UNWANTED REACTION, CLEAN UP CAUSTIC FEED TO HYDROLYZERS 7. ROUND ANALYSIS ON PO FEED OTHER REACTOR TRIPS A. HIGH PRESSURE ON MIX TUBES B. LOW PRESSURE ON MIX TUBES AS; ag 3/20/85 DO 004919 CONFIDENTIAL V BREAKING VACUUM ON GT.YCOT. STTT.T.K Glycol, under vacuum and above its flash point temperature, can possibly explode upon contact with air. To be completely safe, vacuum on each glycol still should not be broken until the still bottoms temperature reaches 80 C. If necessary, at a supervisor's discretion, vacuum can be. broken on a given still if all the still components are below their flash point temperatures* Flash Points: MPG - 99 C DPG - 138 ( TPG - llo 1 DO 004920 Co^-T0 FNTTAI HYDROGENATION (R-7) 1. NORMAL REACTION HYDROGENATION IS USED TO REDUCE CONJUGATED SYSTEMS TO SATURATED COMPOUNDS. THE CONJUGATED SYSTEMS ARE FORMED BY ALDOL CONDENSATION REACTIONS OF ALDEHYDES IN THE GLYCOL FORMED BY HEAT OR OXYGEN. 2. TEMPERATURE AND PRESSURES 3. CONCERNS A. HYDROGEN - LOW IGNITION ENERGY - MINIMAL BREAKING OF LINES - FIRE DETECTORS IN VENTS B. CATALYST - HARSHAW NI-3266E - FIRE CATALYST - R-7 OUTLET FILTER DISPOSAL C.GLYCOL BACKUP INTO HYDROGEN BANKS AS: ag 3/20/85 DO 004971 C.ONFTOFNrf^1 % SUGGESTED STARTUP PROCEDURE FOR HARSHAW REDUCED AND STABILIZED NICKEL AND COBALT CATALYSTS CO NFIDENTIAL SCOPE The suggested procedure is applicable to Harshaw Chemical Company's reduced and stabilized catalysts, such as Ni-0104 T, Ni-0148 T, Ni-1404 T, Ni-3210 T, Ni-3266 E, Co-0127 T, Co-1506 T, etc. Proper startup will result in extended life and greater productivity through elimination of exotherms lead ing to physical degradation of the catalyst. BACKGROUND For many years the Harshaw Chemical Company has manufactured nickel and cobalt catalysts in reduced and stabilized form. Stabilization permits simplified handling and loading of catalysts which are normally pyrophoric in their reduced state. Since the stabilizing process involves the use of car bon dioxide gas, the finished catalyst contains a measurable amount of sorbed C02. It is necessary to remove the C03 prior to subjecting the catalyst to commercial use. This procedure provides some general guidelines for this removal. CHEMISTRY Nickel catalysts are universally employed for methanation reactions. These involve the reduction of CO or C03, as follows. CO + 3H: CH4 + H30 C03 + 4Hj 2 CH4 + 2Hj O - . ih reactions are highly exothermic. Other reactions which are possible and which may warrant considera tion are as follows: CO + H2 CO + H: 0 Ni + 4CO 2 C + H3 0 (carbon formation) COj + Hj (water gas shift) ^ Ni (CO)4 (carbonyl formation) DISCUSSION If hydrogen is contacted with a stabilized catalyst, even at embient temperatures, an exotherm may traverse the catalyst bed. In a pilot unit, the bed temperature rise may be in excess of lOCTC. Actifel particle temperature is probably much higher. An exotherm such as this could damage the catalyst in a commercial reactor not designed for rapid heat removal. There are two general procedures for activating the catalyst which avoid this problem. One involving a gas purge and the other involves activation in the presence of liquid. DO 004923 ACTIVATION WITH GAS PURGE i Most of the CO; can be rernoved by heating the catalyst under a nitrogen purge at ambient pressure. An inlet temperature of at least 150C is recummended. Desorption rate improves with higher tem perature, but there is no need to exceed 250tC. The thermal removal of C0: does not make the catalyst completely immune to exotherms when contacting it with hydrogen. The sorption of H3 (and H; 0, if present) on a freshly activated surface is also exothermic. Some H3 0 may appear as a result of reduction of nickel oxides still present. We suggest desorbing down to 0.2% C03 in the vent gas, followed by a slow careful H3 addition until over 95% H: is present. Following hydrogen activation, the catalyst should be cooled under H3 to 100c'C or less to allow for the exotherm when the unit is pressurized and liquid feed is introduced. The following general procedures are suggested, allowing for modifications as a specific commercial unit may require. 40? MAT..UAL SAFETY DATA Sh.ET (Similar fo OSHA Form 20) SECTION I 3 NFPAV 704V; 'JPPLIERS NAME : The Harshaw Chemical Company EMERGENCY TELEPHONE NUMBER 21-6/721-E3C0 jDRESS 1945 E. 97th Street, Cleveland, OH 44106 CODE 474-077-44 -lEMlCAL NAME Reduced Nickel Catalyst \ PRODUCT NAME Ni - 3266E 1/8" -.$ No. FORMULA Proprietary SECTION II - HAZARDOUS INGREDIENTS MATERIAL OR COMPONENT % THRESHOLD LIMIT VALUE Total Ni/NiO d 50Z 3 1 mg/m as Nickel - SECTION III - PHYSICAL DATA V OILING POINT ^ECIFIC GRAVITY (fytW) APOR NSITY (Air-*]} k/a No Data Available N^A MELTING POINT N/A VAPOR PRESSURE N/A SOLUBILITY IN H20 (?i BY WT.) Insoluble VOLATILES BY VOL N/A EVAPORATION RATE (BUTYL ACETATE-1) N/A -PEARANCE AND ODOR ** black extrudate, bulk density 451bs/ft SECTION IV - FIRE AND EXPLOSION DATA This product may be Induced to kindle at temperatures over 175. F. Ignition Point 275 F (135 C). Exothermic heat from reaction with excess moisture and air combined with an external heat source could conceivably raise the catalyst temperature to the critical range. Refer to SectionTX for precautions to eliminate this remote hazard. Dust explosions may be possible.__________ SECTION V - HEALTH HAZARD DATA FECTS OF OVEREXPOSURE 1) Eye contact causes irritation. 2) Prolonged skin contact may cause irritation. 3) Allergic skin reactions are possible with hypersusceptible individuals. 4) Inhalation of dust ray irritate respiratory tract. DO 004924 ERGENUY & FIRST AID PROCEDURES CONFIDENT!Al 1) Eyes - in case of contact, immediately flush with water for at least 15 minutes. Call a physician. 2) Skin - in case of contact, immediately wash skin with soap and plenty of water. 3) Inhalation - remove to fresh air. Call a physician. MlO 1 ft 1Q79 _ ________________ SECTION VI - REACTIVITY DATA dlTIOHSCQVTRIUTi:;G TO INSTABILITY : heat, humidity * JCO.v ..TAEIL1TY ; Mineral acids will react with the nickej. content to liberate hydrogen. HAZARDOUS DECOMPOSITION PRODUCTS : Hydrogen under the above condition. SECTION VII - SPILL OR LEAK PROCEDURES 7EPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED * if not contaminated, scoop up for reuse. If contaminated, scoop or vacuum into container for disposal. Wear respirator if dusting is unavoidable. / . . *- V/ASTE DISPOSAL METHOD ` dispose contaminated material in approved landfill. t SECTION VIII - PROTECTIVE EQUIPMENT VENTILATION ` local exhaust ventilation is recommended to control dust. PERS. ,L PROTECTIVE EQUIPMENT : 1) If ventilation is inadequate, use KICSK/MESA approved respiratory protection. 2) Eye Protection. 3) Hand Protection. SECTION IX - PRECAUTIONARY LABELLING AND SPECIAL PRECAUTIONS . WARNING I . * caution! Kay be induced to kindle^ unstable at temperatures over 175 F Store in a cool dry place. Keep sway from sunlight, heat or fire. Keep drum closed. Do not expose to combustible vapors. Contains Nickel Compounds May be harmful if ingested or inhaled. Prolonged or repeated exposure to skin may cause irritation. Avoid breathing dust. Wash thoroughly after handling and before eating or smoking. Keep away from food or feed products, avoid confusion of this product with meof SECTION X - PERSONNEL SAMPLING PROCEDURE NIOSH Manual of Sampling Data Sheets, method S203, 1S77 Edition is the recommenced procedure. DO 004925 conftdfnttal m. WORST CASE A. GLYCOL PLANT PUMP PO INTO REACTOR AREA WITHOUT SUFFICIENT WATER TO CARRY OUT REACTION. PROBLEMS: 1. HOT PO VAPORS IN GLYCOL PLANT 2. POSSIBLE POLYMORIZATION REACTION METHODS OF PREVENTION: 1. EXISTING TRIPS ON REACTION AREA 2. EXISTING ALARMS OTHER QUESTIONS 1. CAN WE RUN AT 1,2,3 WATER RATIOS WITHOUT TRIPPING? 2. WHAT REACTIONS OCCUR AT THESE RATIOS? 3/20/85 D0 004926 rONFln(:N'nAl WORST CASE/ CONT'D B. HYDROGENATOR RUN AWAY EXOTHERMIC REACTION IN REACTOR PROBLEMS: 1. HEAT REMOVAL 2. H2 IN REACTOR 3. EXPOSURE TO AIR COULD CAUSE FIRE METHODS OF PREVENTION: 1. SAMPLE AND ANALYZE FEED TO HYDROGENATOR 2. CUT H2 FLOW 3. INCREASE TPG FLOW OTHER 1. MONITOR TEMPS BETTER WITH ALARM 2. VERIFICATION OF HYDROGEN BANKS 3/20/85 OONFTDFNTT Al. DO 004927 REACTIVE CHEMICALS REVIEW PDC FINISHING AND THROX MARCH 21 1985 I. AREAS OF CONCERN A. PHASE SEPARATION TANKS B. PDC DRVTNG AND FINISHING C. PDC STORAGE TANKS D. THROX II. CHEMICAL COMPOUNDS III. PROCESS DISCRETION A. PDC DRYING AND FINISHING B. PCH RECOVERY C. THROX IV. STREAM COMPOSITIONS V. OPERATING PARAMETERS A. PDC SYSTEM B. THROX VI. INTERLOCS DO 004928 AREAS OF CONCERN FOR REACTIVE CHEMICALS I. PHASE SEPARATION TANKS PRESENTLY IN SERVICE AT GLYCOL I ARE TWO PHASE SEPARTION TANKS EQUIPPED TO HANDLE THE BOTTOMS FLOW FROM THE LAST P.O. DEOILER. THESE TANKS HAVE ATMOSPHERIC VENTS WITH NO SAFE GAURDS TO HANDLE A FIRE IF ONE WOULD BE INITIATED II. THE SAME SITUATION EXIST IN THE PDC DRYING AND FINISHING AREA AS MENTIONED ABOVE. III. PDC STORAGE TANKS THE SAME SITUATION EXIST IN THE PDC STORAGE AREAS AS MENTIONED ABOVE. SOLUTION: INSTALL FLAME ARRESTORS OR AN ADEQUATE PURGE/ PAD SYSTEM. IV. THROX THE MAJOR CONCERN IN THIS AREA WOULD BE ACCULATING A COMBUSTIBLE MIXTURE IN THE MAIN FIRE TUBE PRIOR TO IGNITION. OONFTDFNTT Al. DO 004929  Po pep P^> o be i P ? I cH Pfeo pt 0 Ij'A^ r - HO| ' r OH^ voX a oh tf d-CJ+Ofi Ol+c^ t4c- - ct> - ef-- f o-c- ~ c."- S d* H a /d? 1 - "ft_Cs z O X " o 0/ ^2. 0 n f(3c - C^z- C.H DO 004930 CONFTOFNTTAL PROCESS DISCRIPTJON PHASE SEPARATION: THE BOTTOMS FROM THE P.0 DEOILER IS FED TO A SEPERATI ON TANK. THE TOP PHASE CONSIST OF MAINLY WATER AND LIGHTS WHICH IS USED AS REFLUX TO THE HYDROLYZERS. THE BOTTOM LOWER WHICH CONSIST OF TOWER OIL ( A BY-PRODUCT MADE IN THE PRODUCTION OF PCH) IS FED TO A PDC DRYING COLUMN. T-10: T-10 FUNCTIONS AS AN AZETROPE PDC DRYING COLUMN. THE OVERHEADS RETURN TO THE P.O. DEOILER WHILE THE BOTTOMS ARE FED TO A PDC FINISHING COLUMN. T-102-A T-102-A FUNCTIONS AS A PDC FINISHING COLUMN. THE OVERHEAD STREAM IS SENT TO THE SOLVENTS PLANT AS ONE OF THEIR RAW MATERIALS. PCH IS RECOVERED OUT OF THE BOTTOMS STEAM PRIOR TO BEING UTILIZED AS WASTE HEAT. T-400 T-400 IS A COUNTER-CURRENT WASH SYSTEM USE TO RECOVER PCH. THE PCH IS PUT BACK INTO THE SYSTEM AT THE SUCTION OF THE FOAM TOWER PUMPS AS YIELD RECOVERY. R-4 R-4 IS A THERMAL HEAT RECOVERY OXIDIZER WHICH USES TOWER OIL AS FUEL TO CONVERT CONDENSATE TO 235 PSIG STEAM. DO 004931 CONFIDENTIAL COO | 'ih>Mn i DO 004932 CONFIDENTIAL **:* :*:** DO 004933 CONFTDFNTTAL FEED CONC. PIUONALDEMYDE PROPYLENDICHLORIDE FPICHLOROUYURIN PROPYLENECHLOROHYDRIN TRICHLOROPROPYLENE DICHLOROPROPY LENE DICHLOROISOPROPYLETHER 1.4% 30.7% 17.2% 5.4% 3.2% 1.4% 40.7% GLYCOL I THROX i (]-o -JO-1 A/D P-20S A/U CO <1 O' o o z Ui c o o tL z c c I * V$-l BIOX CEU'CPFLUDIT PItOCCSS NATLIl i 7J PA? c-3* c-[wi:: L'i* lCL"l;*m Division DATA SHEET %23-92 ' vV % f WA7ZP ! p.fl. 1 fi.A. 1 P^ET6/.' 1 Aor. ! PPT .QiN 5.V6>* 1- 9.7/ 93 ! n. 9z/9 r 65.352, ! 9.VV71! P(LH 72 P P~X t-jC-P' 2> MP6 2. rnP .603? ! 6.3972 .6.375 . //97 .6,503 TamL /OO.O To,xpL-/iyet i p7 UteP V* .ooze l-QTb 1 2.662 0.159 Its-266 6.-7605 0. 7755 7. /V93 !c>. 7/76 0-//60 c. 7/79 /OO.O /3.3o5/ 73.7/59 A5.553 /. 6737 97.33 9 /.3V5fi I.Z656 0.6V5L OJ/2/> t. c/5g /.33V6 0.041! lOO'O a N* w .OObb /.35S 3.367 >.938 ^4.21(0 O.OOZ/ C./053 -- -- -- -- -- /oo.o /t. *i K- 6.6059 9.03V3 6.o tin -- / 2- 5759 1 /S.eoG\y_ 2AJ490 3.0AW7 31.5216 6.2ju 0-2WS> 7.9/79 ioo.D 3. 6e>&<! CONFIDENTIAL DO 004935 PDC SYSTEM OPERATING CONDITIONS FEED RATE REB. PRESS. TEMP. PRESS. LEVEL F.F REFLUX T-10 11 GPM -- 99 C ATM. 50% 2 GPM -- T-102-A 9 GPM 15 PSIG 115 C ATM. 50% 6 GPM 18 GPM DO 004936 CONTROL SPECIFICATIONS FEED ATOMIZING AIR SUPPORT FUEL % OXYGEN % CO 2100#\Hr. 550#\Hr. START-UP 7% 75 pprn TEMP.- PASS ONE PASS TWO FLUE GAS OUT SCRUBBER BTM SCRUBBER TOP ph ACID STRENGTH 900 C 285 C 220 C 65 C 38 C 8-10 2% DO 004937 CONFIDENTIAL. INTERLOCS PDC: NONE PCH NASH: NONE THROX: 1. LON FEED FLON 2. LOW ATOMIZED AIR FLO 3. HIGH STEAM PRESSURE A. HIGH TEMP.- PASS ONE 5. LON TEMP.- FLUE GAS OUT 6. HIGH TEMP.- T-200 BTM 7. HIGH TEMP.- T-200 TOP ALARM <3 2 GPM TRIP (JUMPERED) ALARM <3 150# TRIP <3 100# ALARM <3 280 TRIP <3 290 ALARM <3 960 C TRIP <3 1110 C ALARM <3 220 C TRIP <3 200 C ALARM 0 75 C TRIP 0 85 C TRIP <3 85 C C.0MF1 00A938 00 REACTIVE CHEMICALS CONCERNS 1. LIQUID CHLORINE IN REACTOR FEED LINE - Cl2/C3H6 imbalance 2. LIQUID PROPYLENE IN FEED LINE - Cl2/C3H6 imbalance 3. AIR IN HYDROLYZERS - POSSIBLE PO EXPLOSION A. WATER IN CL2 HEADER C- Fe - l reaction 5, LOSS OF H20 TO REACTORS - TITANIUM MIXERS DO 004939 OONFTDFNTTAL Ifc'TEF LIMED PIPE +4 -vh- FJ. VENT 50' CLz- HzO e3Hfc Hz0 rJ*> -L demsseR 20' /6^ P. F. reactor TO HYbZoLYZER LA. PLUG FLOW REACTOR CONFIGURAl ION CONFT DFNTIAI DO 004940 PLUG FLOW REACTORS LOUISIANA DIVISION OPERATING CONDITIONS: PROPYLENE RATE PROPYLENE PURITY CHLORINE PURITY WATER RATIO WATER TEMP, PRESSURE S MIXER MIXER TEMP. OUTLET TEMP. 261,000 m 97 - 99% 98 - 99.9% 50/1 60 - 62C 6 - 8 PSIG 65C 88 C MECHANICAL DESIGN: DIAMETER LENGTH MATERIAL PROPYLENE INLET CHLORINE INLET 16" 100750' UPFLOW FEP LINED PIPE TITANIUM MIXER BOTTOM OF REACTOR INSIDE SPARGER OUTSIDE OF SPARGER BELOW ANNULUS CONTROL PDP-8 MASS FLOW BALANCE PROPYLENE MASS FLOW IS SET - CL2 FOLLOWS C3H6 AUTO BLOCK VALVES ON GAS FEED LINES BACKPRESSURE HIC VALVE AT FOAM TOWER VACUUM BREAKER FROM TOP OF REACTOR TO FOAM TOWER AUTO & HIC VENT VALVES ON FOAM TOWER LOW PROPYLENE FLOW SHUTDOWN LOW CHLORINE FLOW SHUTDOWN LOW TOTAL WATER FLOW SHUTDOWN LOW OUTPUT TO CHLORINE VALVE HIGH MIXER OUTLET TEMP LOW CHLORINE DIFFERENTIAL PRESSURE CONFIDENTIAL DO 004941 PLUG FLOW REACTORS LOUISIANA DIVISION MONITORED PARAMETERS: PROPYLENE MASS FLOW CHLORINE MASS FLOW CHLORINE PRESSURE CHLORINE TEMPERATURE CHLORINE DIFFERENTIAL PRESSURE REACTOR MIXER TEMPERATURE REACTOR OUTLET TEMPERATURE WATER RATIO PROCESS WATER TEMPERATURE REACTOR PRESSURE O.'R.PV PROBE RESPONSE DUPONT PROBE RESPONSE 3-WIRE PROBE RESPONSE VENT STACK G.C'.' ANALYSIS CONFIDENTIAL DO 004942 PCH REACTOR AUTOMATIC SHUTDOWNS A. LOW PROPYLENE FLOW 0.656 K.LB/HR B. LOW CHLORINE FLOW 1.12 K.LB/HR C. LOW TOTAL WATER FLOW 22.08 K.LB/HR D. LOW OUTPUT TO CL2 VALVE 2.0% OUTPUT E. HIGH MIXER OUTLET TEMP 85C F. LOW CL2 DIFFERENTIAL PRESSURE 250" H20 (A67 MMHG) PLUG PlOW RE.AC.T6R VEA/T <,Y5T/A /?X mCUUAA BR/i/c/< C O N F ID F N T T A l DvPq/jt /fs/ztcyg-f/i 3-J/& Po&. 0-3% c./^ O-O'Z. % c/* PLUG FLOW REACTOR VENT SCRUBBER SYSTEM t. LOUISIANA DIVISION CELL EFFLUENT RECYCLE FLOW CELL EFFLUENT MAKE UP FLOW CONDENSATE FLOW ' 50 GPM 5 - 7 GPM 3 - 5 GPM COND . kEACTd/Z. V//r ^cUB&E&S> c * LA. AO. //^0A/r E//D) <L DO 0 0 4 9 4 6 7~0 0X/2> ^////SA'/zVc, }