Document 91DbvpNVeZ5EoLrgM0eODrBg7

tmsusro oiaaou. cchp jh umsm, mjjum SZIMVOS m%XBtlCTUkli& PR0CXS3 ?0R BIFHJDnX R. L. H*<teorek Jack Clagorn J, I. Crouck MWV 018257 | WATER PCB-SD0000044993 ' JJf jt ^ ^ V> '' '#7 -' jr edit-1A. ^1*3 V oisnuxmw ust Uirsctor of MmxJ&eCuring - Grgjade SsbsIcaIb Cd-rUdom E. L. Xlneklar L S. Boims 2. Aaaiatca ?la*t Items ex 0, B. Boaster 3. Production Snporintiadjat - J. E. Creuefa / liph^ayl Plant Supervisor - Jack defers St. Lout* 2uurd> SC. Louis kssMrch Technical rvic B^p^rmanC - Amis tea Plant Standards Dapartnt - Anniston Plant Standards L^iartuMt - Anniston Plant Extra Copy . III 'kj?.'. m r..* tT* DSW 048615 -1 -*:.`v-.is-,^ **-*':# * a**I*?d Mi ]ytWV 018258 WATER PCB-SD0000044994 T Irr * .- . ,;1 'r. - '"/^;/ , latMS :?i> "' ' '#$* ; ."$;*& < ;$$> ' i's.W f (rJjerWt'i^3> ' : '.'ju&iul Xatuemiuim C*en-y - 36, 1, (g) fetsstarltj' T'll* 5, g. fvwur - G. 0, J, 4. ZL'iU&i a. a. ib*^ a, 3. Bive&ov* 5 , 2, vRW'a SB Ills (3) !> gtM^sris (s6su) iwran unsv couna / Safety Craanfetea 6/14/64 _. _______ sobaubj eeAa? AJKSSOI, AU2ABA 8? Jol 64 ftvS *4l ,y,f Ei-EU . ?e tgam g?AW4> MUaqcmCTO ?MCW Of 17 Sep 57 tmil Swat A&ateaa as Prsaotar la 3ifbsayl Tubular Dale, QSJSfffryf t tkia (mjAm6 pwrlda# fe? & els m& &m6 e Ebs *** of Mai-ao as prentatar Is Uifi Blpknsyi Tuimle* tele presses. msaumma' Ltoyropessl is praaEly used as eks pretests? to kelp aoovwt t glflwt^l,. ' SEuraTO caoau lWM vaald bs 6iikjeitu*d w iscproptiasi, laictsl U*6 wld k# witt es lot tuM&UiM sls * #*sl|p**d s#e tm w^n fmmzimg taraofcs?-' iMies e.As4Mt mcm* Img Ussm tmt *111 W er*i*4 ms& *6&a fiksst tmem 6mI feosilns pswiess fimiiage, mmmsmt ' Of A pnwtui tri4 by fUssaroit, Acstao* U ties beet wick lMpnpMl i*a bes6. Otji&s tks tsEiijg fum&ae coaiieioni Isejir^sul pyrelysoo fes e*m 7U*rok data tadiesfesa a ICB. iseresss Is carrcra ion Mlsg A&stwia tete*i Iacptepassl. ' Cost dllfarwelsl aaooute Co $5000 per y*r S.X. uvls^s If AmUm is us*4. DSW 048616 % u ?&&&< m r Jlfc!?/' plMUlHiSliiSi b';W WATER PCB-SD0000044995  p VVc fc u I'- jr *" *. ..iojssx .Kjt^'in Widuiit E Efjoeeyi huaufsecuring Frocaaa m- Sip W r*S 1. T3B Progress Report 370t25>8, So. 1, JO Jfa 4 - Analysis of Ststistiselly daslgmd test data shows Isopropanol inertness its offast on eoeverslo* with increasing tss^cratars. Pyrolysis mt TTA tons Acstana at ferases condition* which la a battsr proaotsr than I?A.. 2. Ammena Tyroi/ifia in t Laboratory Tubular Basetor - Beware So. 277 2, 1 Apt 61, by Z. Sorach, A. Z. li/pesa ssd W, B. Bob Usee. IUm proaotars triod vith Acstooa bt ttid Xscpropeoel baat. / 3. Siphyl, Tubular Process, Report Mo. 2491, 23 May 30, by J. H. Saandnrs ' u4 X. J. Sloconbs, found to ha sffsotivs promoter, 4, Diphaeyl fro* Iuhm, Pinal Report 117-381, 5 Oet JS by C. Coasvor lad A, t, Hoff. Of 17 promoters triad, Acstoea boat and Xsopropanol sseeod boot, mm* Mo Additional precautions ar eaadad for using Aeetoaa aa the promoter. The short ter* dru tasting vill provide the proper grounding eeessseties to smn safe baedliag of the Acetous, Ssiotlag >pc ea Aaatoaa shws less than Q.0OJ& Aeotie Acid whleh eh^ld not Urxenae eerToetoe. Water contest iJ about 0.21 whieh eheeld not appreciably , increase Acetic Acid iormatiea. Long tana toot will check this. SEApT Th ese of kmtmm shield have bo effect cm the quality of Siphtrayl-'Seatewu predated, mm w PPosmiMi ' ' The toot period vill be sin sooths. WW Vj(:. >>-i r, ; .'c 1 v*t'. ;? / V*t> '*. *.: WATER PCB-SD0000044996 rtasifcir* iMafecat t *3* 27 Jml 4 Aj2S2AJj!I Bc?rtJM&t Sup**!**] TSB S vjHKdiitaaUaat l '[T&im&l&g, Sv^sriatastefit: Plttfe laager: *@e&rek Croup I^dar; UAg^arek isAruLgert tmk. Frwiwtclea Steaagsr s <Li. (^TiraoClaia s/ S, V. Saeima'1 t, W. lueka*U S/ B. L, Hubbard E. U KabVrd S/ J. A, Mnllaadara J, A, Jtallttier* WATER PCB-SD0000044997 LecstUes &smLtcm, {.Iibu& j 27 Jul -54 i Knusioa w raniu rmo s nr&n-a AL~^ttu , sio is sriguva Ki&akci^uxsa ncwu'4 m STOIC, <^t. 17, 5.757) Uca*4 9 Jt* 64 70 i .:. *. Module X. C. Moody r C. Tshaswlstee * 3, 0. Cwerewe / Z>, B&iiut. - 6. 0, V^ rs, B. Xtmmr - 0. 0, till a. L. 3iimix4 - So, Sad ^s. a. V. iesfaiell - Se. Sad ft. * Central Tecfcaieai File * So, ud JuasJtU&i! .forasftflfc'aai Testin'; el Saai-Coaeic .suo Distillstioe el Crude iipheayl Is insA^Ists. See Crude Bipheayl Distillation Sapeirt e. 370t2e>4 dated 1 Jul 64 lor eutliM e the testing pregrsa, da ericas lea el the notmX six Maths eeeef tssee or rejection period lor Saatative 4*a^at S is te^eeated. Should Tea have say ohjeetioa, please let It he ksotm by - 7 Aag 64 es this Is the end e the el* Math period. rau ?. a DSW 048619 L *1<-),i iS "I h ,.t* i WATER PCB-SD0000044998 Dlsiributioej Technical,, lofenmatioa Center Security Fils D. 1. Emt - 0. 0, J. R. >W5lai t. C. Ko4y . S. 0. Snrerso* L. C. Sprague TT3 Pile (3) Plant Standards (Sztru) It. I* (2) sarat txrm comma. 1L -ctM,. 2-7-fi* CONFIDENTIAL mo CHaaox caAit ABKSTOJf, AUfcWl 29 Jan 64 ZEgSfflg-Am^LS To i' Bipusm gtAxmsp wimgACTatisQ process ; kj-.tain m H.X-5 ,Vu*. n Of 17 Sw 57 TITUt gmsre* TXJTUG or ssa-covrmooBs dtsthlatios or grubs bipesrtl. This een<Ueat cancel* Tentative iam<kat C and provides for a els nosth test of seei-oentlnuo*# distillation of cruda Bipheapl to plaid specification grate llpbeapl tad Slpbeapl "free* Saatawns C. j.mua.iuenai Crude Bipheapl w foraerlp purified bp hatch distillation. Tentative AMa&aat c allowed th testing of continuous distillation. CoatLnoeua distillation did not plaid Biphuspl "fre 8&tewx C and, therefore, a naai-eoatianou distillation of llpteayl is carried out at present, JPTOIg.fflMtg The skills will be fed oa the eighth trap fro the top of the eela eoatinnoaslp until the Btill pot fills. Then a tails fraction will be reewved leaving Biphasp1 "free" laatewss C to be trass!erred for further purification. Jos-TiricmoKi ' Scsd-ctjatlasmui distillation LaeT&m&e protection eapacitp and piIds a higher parity lipkaayl than that of batch distillation. .50TOCT 07 DAIAi . ' See TSD Progreso Report J70:2, Ho, 2, entitled "Continuous Distillation of Crude BJLphenpl" for details on S*i*eontinuou* distillation, ' DSW 048620 I.,G? 3T ?rwV 018263 WATER PCB-SD0000044999 '{.' '0 TtatAtir* A--d--at D BipJeyl Process J 64 msMssM' .. B additioaal procaueloas mo ttesdsd for SMi-eeatiaaona dtutill&iim iWn tiut of batch distil latiim, mm: Ssel-cogtlaaooa distilled Biphenyl tea a higher erystalliata poiat aad a lover color (Cardvar stale). ' OTEKT C? DgWiyiTJ.TIO:.1; The Lest period vill be six Moths. iffef J&lT * m AP7BWAit Departaaat Supsrriscr: Prodoctioa Spet\'isor: & Pleat Heaager: ^ Origioatad by_ r. 1. Kaapt 8. 0; Severson l. C. xJody / ^ & VvCkJ. J^j. HoClaia ^UJZZJLJL.----- - ' Date ^Date ' T-rwi &>V. mi ... ?/3/<f_ Date Research Manages t S/ R, L. Hubbard H, i. Hubbard e/6/64 Date S/ D. 2, Boner , 1, Honor e/n/64 Date hi Research Croup Leader: 2/ R, V, Buckasll R, V. Buckaall .....itm________ Data m DSW 048621 li I.-..* 1^018264 sm WATER PCB-SD0000045000 V;' JL' ; '* - ' ?. t'? MONSANTO CHEMICAL COMPANY /sler>0//toe C*i***pd*ec* Aakistwi, Alabama . Kerch 18, 196J feteaulon of 7*ai:.iBg ifertod `itXX7XPt IZZSMSXS BO, C TO T&d rauahua -.tortfAcryaiaci nuxu vot si?ram (Japtu*Jer 17, 1957) Ae.tdv4*t C U*4 10/12/62 J. X. McClain ?.. G. Hoody J. C. Larkin , 0. arn'Mit J, f. 3cltU7 - G. 0. 3. 5. uomir - G. 0, H. L. HnhUrd - Bo. 2a,d H. 1). Robinson So, 2nd /0.. Central Technical File - *" ** ~ CJC< Delays tm iaatallatloe sad prediction requlr--nta have ceased a daisy la the casuist ion el the Continuous Biphenyl Dlitillatloo Study. Those teste nade to date have been highly successful, bat have bees hampered by eoatlnued aochaalesl problems, An extension of the normal six neatha acceptssee or rejection period for lentatlvu iaaoduBt C la requested, Should you have aey objection, please let it be known by April 15th, This data la the and of this ilx noeth per iod. DSW 048622 &r$ %4 ' *1 MWV 018265 WATER PCB-SD0000045001 'S.mxtt wiry cohhittss Hester copy signed by haluty C'spltccfl 10/22/oa CONHDENTIAL cc: J. ft. McClain ft. C. Moody J. C. Lark is B. 0. Severs# V. ft. ll&i#fc D, 1. Houmar - e. 0. ft. L. Hubbard -Bo. 2nd W. D. Robin** - to. 5SM& Central TtduiMl I'll* - 8a. &A J. f. Stickley - G. 0. '3 1. ,'i' ;? 7** H V- J *4* MD1S5AJT0 CHDQCU, CCWABT . AIHI3T0*, kUMKA a? October 12, 1962 an&i3oaBMESJs- 's ^ TO T^E STAJfPAIO HAjmr^CTtTKDfC ?MC$8 12* srpuarex Slpteaber 17, 1957 J mV *}.. ;V I2HS-OBJECTm: TESTING OF C0HTIOT003 DISTIlUTlOH Of CRUM BIPEmi. ' * This oasikHnC cover* the testing of continuous distillation of crude Biphenyl to /laid apaclfication grad* Biphenyl and Biphenyl "free" Santovax C, PEESBgT PRACTICE; ' Croft* Biphenyl la presently purified by mu* of & batch distillation, Four fractions ara removal; benaeue, head* (banaant and Biphenyl), Biphenyl, tails (Biphenyl uft Terphenyla), aad Santovex C as residua. The heads and tails fraction* are recycled tram batch to batch, TEST; '. The teat will be carried out In the two existing distillation colaal, Th first colusn trill separate banians as overhead* and Blpbenyl, Santovax C as bottoms, The second col can will produce Biphenyl overhead and Saatom C as bottoms. The specific scale of this test are: 1. To prove the fusibility of producing speciflcatioa trad* itphaayl on a continuous hasis, 2. To prove the feasibility of producing Biphenyl "free" (lees than IX) Santovax C on a continuous basis. Specific details of the test nay be found In a Maurraadua entitled "Operating Instructions for Biphenyl Continuous Distillation Test", authored by V, R. Haup t, -*>>. ` 't i ' *' 'I Cl : <: r>v WATER PCB-SD0000045002 $: ' # ** vvtE' WATER PCB-SD0000045003 WATER PCB-SD0000045004 ssenex a STfsomi or raocass Biphenyl is produced by the pyrolysis of 2utM. The procaas uhd is the mMuf^ocure of Biphenyl is oamouly knows &m the Lead Pet Preeas*. the ajuipaat consists of a vaporiser coil, three stainless atael lead filled gas fired pots sad two fractionating eoluaua, ell la eeriea. Benaol Lb continuously vaporised in the vaporiser eoil and heated to the pyrolysis tusperaturs a it is bubbled through.the aoltea lead in the three pots, the uarsacted Seasol and the reaction produces. Biphenyl, Terphenyl end Hydrogen, paae through tvo orifice plates and into the stripping colon, the superb- heat in the gas drives the uareacted Beasol up the colon, with the Hydrogen, where it is condensed end returned to the feed tank. The Hydrogen, saturated with Beasol, la cooled and coppressed to raovt the remainder of the Beasol, This Bensol la recycled through the process with fresh Benrol. The underflow, flows by gravity to a crude Biphenyl storage tank. the units aro operated between 10 and 30% conversion by regulating the con verter tsspersture between 750 end 810C. the higher temperature* giving the higher conversion. , The pet pressures reag.i ft cm 60 to 100 psig cm the Bo. 1 Preheater, to 30 to 70 psig oa the converter. The higher pressures are encountered when the units axe nearly plugged. the crude Biphenyl, which is approximately 7 SI Biphenyl, 15% Terpheayl, and 10% Benrol is charged batch-vise to a fractional distillation unit and the Biphenyl is distilled off. Heat for the distillation is provided by cir culating the charge through a coil in a gas fired furnace. Boor .distillation cuts are unde: (1) a Beaaol cut, - te recover eba Baoaol that was left in the underflow from the first coluaa, (2) a heads cut which is a mixture #i Beaaol and Blphaayl, (3) a Biphenyl cut and, (4) a tails cut which le a ixture of Biphenyl and Terpheayl. ' The heeds end tails cut are recycled to the next distillation charge. The still residue, Sentovax C, consists essentially of Ortho, Meta, and Para Tarphesyle and certain higher boilisg eea^ouads. Ifc is pussped to eter&gsi fee as* in the Saatowax K proesfs. DSW 048626 WATER PCB-SD0000045005 M\VV 018270 WATER PCB-SD0000045006 sscnok c IQOTFHOT consisc# of a pipe coll vr-orfser Locatsd in the flue gas exhauet stack, three stainless steel pots partially filled with molten lead and suspendad in a firebrick setting for burning natural gas, and a fractionating colvumx with * condenser end split flow box. The pots are 24" 0.0. x 72" long, wi th s dished bottoa, The units' era numbered 2 through 13, there having been a No. I unit at one ties. The present number o units were erected in five installments, Noe. 2 and 3 having been erected at different times, Noe. 4 and 5 together. Nos, 6, 7, 8, 9 end 10 together, and Noe. 11, 12 and 13 together. These groups are all slightly different in acme details. There are, however, only two fundamentally different types of units. Nos, <* and i differing from the rest in that one of the preheater pots is replaced by a shall and tube heat exchanger. Although the heat exchanger effected a gat savings as predicted, it proved impractical due to carbon and tars fouling the tubes, and the Idea was abandoned on the subsequent units. A larger converter pot (sojourn pot) ha* been installed on No. 11 unit to provide additional sojourn time. This additional time results in a lower temperature for a given conversion as compared to the other units. The heat input to the unit remains at a maximum and this extra heat is utilised by the addition of more Beniol feed tt the unft. The reduced pyrolysis tamparaturet made possible by the larger pot result In; 1. A 10-15X production increase, 2. Reduction in gss consumption per pound of Biphenyl produced, 3. Seduction of pot ftilures and maintenance cost. 4. Reduced carbon formation, thus permitting better operating efficiency of the unit, 5. Reduced lead carry over., has been observed on the unit equipped with the sojourn pet. . Drawings which describe the equipment used in this process are listed in Phosphate. Dlvlsioe Engineering Department leport Ho. 117. DSW 048628 WATER PCB-SD0000045007 WATER PCB-SD0000045008 Monsanto Chemical Company ORGANIC CHEMICALS DIVISION ANNISTON, ALABAMA PLANT RAW MATERIAL SPECIFICATION MATERIAL BENZENE.- NITRATION GRADE Chemical formula *ooucr ioce 14700 METHOO IDENTITY surpuie* (ASTM D-835) . Issued Sept. II, 1957 STAKJQAJtDS DEPT. Anniston, Ala. Plant iu)*iitco>> App. 1952 I * 4W* wf. r oft a,m y jji 5 2 x 16 02. MW Bottles W. B. Dunlap 1 MOL. VT. 78.108 UNCLASSIFIED SPECIFICATIONS GENERAL' TESTS /Appearance Acidity Acid wash test Color ' Crystallizing point Distilling range; 100% over in Range to include Specific gravity; 60/60F 25/25c ' Copper corrosion sulphur compounds Total sulfur ASTM METHODS Clear liquid with no free water or suspended matter . No free acid Barrett 2 max AFHA 25 max. 5,30C min. wet basis 5.39C min. dry basis D-847 D-848 D-853 D"8o2 D"850 1C 80,lc (Using Bunsen Burner) 0.8820 to 0.8860 0.8740 to 0,8780 Negative Free of HzS and S0z 0,020% Max. ' d-849 D-853 d-90 DSW 048630 WATER PCB-SD0000045009 fe V .. -V[WV 018274 J WATER PCB-SD0000045010 xm " Monsanto Chemical Compaq OHCAWC CHEMICALS Division ANNISTON, ALABAMA PLANT RAW MATERIAL SPECIFICATION UArEBI'L ISOPROPANOL, 99% C H E m c * L >*o nuyt, x. PRODUCT COOK 10950 METHOD IDENTITY JUPPUEfl CARBIDE & CARBON Issuftd Sept. U, 1957 STANDARDS DEFT. A r:ston, Ala. Plant I ut^kj^ \V. B. D\iALa.p SUPERS EOE.5 SRrC* SAMPLE row AMAUrSIS 1 x 16 oz. yarrow nouch bottle unclass ij-'ispecifications General Tes t s Specif!: ca t j on a .. ' Specif!/: Gi'avihy (20/20c) Distillation (7cQ m.m.) Isopropanol f;i). Acidity (7,,) (as Acid no.) Dilution Test. Water (%) . Non-volat.ile (g/10Q ml) caloe (apha) Odor Suspended matter Flash point (F) 0.7862 - '5.7876 Shall be entirely distilled within 1C rente which shall include 82.3C " 99,5 min. 0.002 max. as acetic acid ' 0.019 max. Clear 0.5 max. 0.002 BAX. 10 max, ' . ' Non-residual Substantially free 70 Specif!on furnished by Supplier may 18, 1956 DSW 048632 MWV 018275 WATER PCB-SD0000045011 sgcrxci? i x i FWOtfS XM DOAU, biphmyl h.M.a lti iuiaiikiU;W by the 1 tsjuk pet preeesa eiaio 122$ afe teal etea. The pr&ewi Is estiatiaiiy toe tom as when it hi Sixes difmley&L I&a mdy varieties bedag the use i' a cmwiin preeter aad a higher eparatlag pre*ar*. Process iHvestisatiea ha* psiaEfed n fctay e Eke variables which affect Eke predoctlea a Blpaaayl e&4 th by-predmcE lamtmtmiu 7ms lutm, it has been decarmi&d that a belaacs beL-reea BiphiMtyl asd Seatows* product!** eea be maintaiaad ever a tide reags of raquiraaMMts doa Ea Ehe reladauhip betarecu the psreaat eemvarsis* sad the relative sweat f Blpheayl fee EaatMMX predated. That: ralaciomship b,iag: 1.053 (x) (Parent C#VBr*iea) Parent CaaCevaz (Terphaayl) i* the ez-uJj Blpatmyl The 1,058 it referred to at tbs ilpu (!) faetar. This lip** fee tar reoaias relatively ccmstaat ever the eparatlag raag a f the ptKui, cnse^Matly, . it vti pesalble te dtvsisp the Biphnyl eparatieus chart which sears the rolatiaaahip betwees Bipbeayl predactiea, SaaEswaz predactie*, the pereeaE ceaversiea. asd the Beuasts feed race. ' A&ether i^ertamt develepsaE is the aamufactura ef Sipbasyl ms establlsh&MC of the reletiaa betreea the psreeat cesrversiaa asd the eejeora tins at different ep ex atlas fcamiperaturas. This relation brsmght abeet ea evalaatioe e optima eoJenna tliM which resulted le 8 larger caavertar pet, emmmimly temm as the nrjaarm pet, (af baiag daMastrated) sad a higher perati&g prsarore. Beth have permitted iacreased feed rates aud lswar eperetisg tsaperaturas ter a gv<ia casrvaiaica rate. Tie actual relation betmas teener star a, watvarai* m4 eejeura claa has set b&ea datearml&ed. uhaa a esaversiea preeteear is used. The eajearm Clue, ttemparatura, pex&mx cmurtssuim chare le preantod to pietotally ekm the gtacrel tel&tim e these f&sters, Te Houtiu - three factors affect the mat sf leeHM that is eamvertad per pass threads the oaic, they are: (1) te^cjters, (2) *sj*s Horn us, (3) to* sweeeiaa prmster. The relative ataeuat ef ttpbnyl pradaatie te Samteeas praductin eaa bs cia&g&f ey charngiag the peresat Mwersiee. Kuit ii--at high eseversiM rstea isare peusd* ef Smtmmsx ere predated per p#*rai f Biphenyl them at mm Imi eeevarviem rate. The eeurrersiea rate la esc Erelled by ehsagimg toe t|>*rature eitoia toe pete. r -n f ?; (fs*: S j r DSW 048633 WATER PCB-SD0000045012 1-2 7resh liens el Is added coatinuaily te the food Cult frm the Bonsol etsrage tank, laspropyl Alcohol la asdsd tt the Sms el food la. mmrmt* varying haKWsaiLXJja^aT? jj7il~To^i^tT7h8caTiv*riiicn J^at , iJraslly 0.151 is ada.,d to the,&uol aa 1C is peaked through automatic centre! valve* te the individual umita. The food tha passes through a Mil is the batten of the eolono^vhers the liquid i* yruhsatsd, tad t a cil la the flat gas erhAust acack^tf* the liquid luuiiol it vapsrised. The Jowl Taper it babbled through lead ia Lise bn praiseter and MartrUr p-ate wh*& it it heated t cbe pyrolysis re*etiaa teapaxatura, After leaving the eeaverter, the Saas'.l and csaversioa pridact* pass through a lud trap fms smtsrL&g eatraiasd land and Chen eacif the hittea at the r actios*ting colissa. TbsS teupai-etore is the coevurter pee if uwully controlled bete*a 750 - diO*C. The temperature seeded fer the desired cemerelea changes as the p#ts begin te plug with etrbea due te taa higher pressures and reeal tieg laager eajsar time la tha pots. Every JO to 90 days the carbarn is physically el eased frm the distributer ud vapor Uses. (See attach ad table far feed rates, reflux, tneyeratarea.) The super-heat ia the vapors frm the converter is utilised ia a fraetismating colum te effect s partial separation sf the Isual fraa the conversion product*. The eeluas tep la mol a tailed at a taeparatnra at 100*C (at higher temperature* sense Biphenyl bsgias te cbm over) by refluxing Che condensed Sensei vapors back, te the top plate. The units are usually operated with a 60-70% reflux, vith 90% being sat as a marines. If 90X reflux dees aet eeel the vapors, leaving the tep plats of the celiusa below 100c, the* it is meteaaary te reduce the feed. The conversion preduet sad aesaa Bessel Is condensed in the coluxa and allowed te overflew fraa a carbon trap ea the bet toss ef the column te a crude Biphenyl catch tank fer storage pries te batch distil Lades, The over head vapors tram the colwa are cooled t>y a esmdeaser and the liquid Beasel drained ts a retaweir for splitting the flew into reflux and recycle Beanel. The recycle Beasel flows te the Benxei feed tsnk by gravity. The by-product Hydrogen, saturated with Beanel vapor flew* from the condenaer and rotaweir, is collected in a enuss header at a pressure ef approximately 3 pels' "ad passes through a series ef coolers where uu ef the Beasel la condensed. This Bensoi ru&s by gravity back te the feed tank. Trial the coolers Che saturated hydrogen gas is passed te a celiac ting teak la which b#ts ef Che Beanel condenses eat sad drains te the Beanel pup^ task. This pap tank la 1 seated in the compressor ream, and periodically the Beanel'is pumped te the Bnasel feed tank. ' The Rydroge* from the coll acting task it compressed by three 2-stage eepressnrs, in parallel, te between 250-350 prig. The tjrttwm ineledea an intarceeler and aitsrceelK fer ceadeaeiag the I easel vepers. This liquid Sensei is eel 1 acted in pressure receivers after each stage, Hi Bonsai is Porieditally blawe by the Hydrogen pressure late the passa tank fee return te the Benxel fj*d tank. The hydrogen Is used ia the mwnifaetare sf JIB-40, SB-20 or vented te the atmosphere. t ;<k K. t{.''- o *\ SJ* ' * Jf m m- .-sv ''M DSW 048634 V:? WATER PCB-SD0000045013 Process X*3 2m the second type ef unit (.Us. 4 sad 3) the flaw ef material Is ess--tlil.ly the is-mm as that described above except the vaporised Beajel feed --arcing Stem, the vaporiaar coil passes through the shall side ef a hast ecehaager la live f w of the preheaters. tha conversion preduets sad Banal tern tkm cobvarc&r pot eru pas*d daraugh the tubes ef the host escha&gss1, esaater current t* the Beaiel fesd, thus transferring asLalble hast fr-- the con verter gases ta preheat the feed, the c--version products aad vapors fr-- the converter pet thee pass to i eeltea, as It the esse with the ether salts. The underflow fro the celts--s is ealleeted by gravity la tM ends Biphenyl catch tasks, the piping to the tasks Is stem Jacketed ta preveat the crude Bipheayl, which Is approximately 752 Biphenyl, 152 Terpheayl sad 102 B--xal, fro* freezing sad has e liquid trap ee preveat vapors fr-- entering the catch tasks l\m the cal--. The tasks are vested late the Hydrogen gas header t ocoaliaa the pressure and preveat lost of teasel. The crude Bipheayl is punpad directly to -- ef the. tv* batch Bipheayl stills. The eve batch stills each ceasiet ef a heriseatfll, cyllsdrical teak surmounted by a fractionating solus--, a submerged pue^i and a gae fired cell heater. B> stills are operated at a css spheric pressure. The pop elrcolataa the still charge frm the teak, through the esil heater sad back te the teak. The rate ef distilled-- ef the crude Bipheayl is e--trelled by the c--bustle* rate ef natural gas la the gas firtd heater, which Is c--trolled by aa adjustable antstatic t--persture recorder sad comtrailer te heat the crude Biph--yl sufficiently te give a t--parature ties ef 15-25*0 between the Inlet and --tlat of the coll. The vapors fr-- the still ere separated in a 20 plate fractionating colu--. She first cut fro* the colu-- is Sense--. This cut is takes at a top plate vapor t--perature of 80*0 and et a reflux fate ef 202 return and 902 fesward flow. The Benaeaa flows by gravity te e'caEBlr'EMJnar subsequent recycling through thd Bipheayl units. The nest fraction, distilling above 80C, Is take* until the freezing point of the distillate reaches 68.6*C. This cut Is called the head cut end consists ef a mixture ef Beano1 and Bipheayl. It is --da with 502 of the materiel being rsturned te the el* as reflux. The Upfe--yl eat is taken after the .frees! ng point ef the distillate rw^ss 68.6C --d is continued until the pot temperature reaches 330C, This cut Is --de with a 202 reflux. The tall cut, at 152 reflux follows the Bipheayl eat and Is continued until the distillate on the top plate reaches e t--peraturs ef 300*C. This wt e--slat* ef a nLstura of Biphenyl sad Terpheayis. Occasionally it is ncsessary te make i cut ef material Wiling between Beanei and fiiph--yl which accuoiilates in the eysten. This material, usually about 20 te 30 g&ll--s, is cell--ted in a dnat and discarded. Water is circulated through the condenser at the top ef the fractiseating colu-- during the distillation and is cut back at the end ef a distillation in order te keep the condenser fr-- freeslng. , * J , ' t ` q | ,V '! !l fl ^ ;y WATER PCB-SD0000045014 tfaa Saatowax C, maiaiag la ths a till m raeidua coaslseisg Mseatdally e Ortie, Rata, sad Para TarphasyLa m& ess tale higher belling tm^etmdt, it pumped 6 the Seatevmx C catch task sad thee t Che tMtMU a till, SuUwi C storags task, or late druse far ster&ga. ' BipheayL it stored for imtsmal nm or flaked fee Mia. Bn* ts^arsture of the sfcer&g# tank should not asoasd f03e as higher fet^essfcaxes will uwt dieaftl ratios. A water cool ad Aran flekms ta used for Jiphnyl. 1# teeparature eoatrsia are aacMaary. The flaked giph*yl Is packaged la papr tags or fiber dmj. Charts Tig. 1 - Shews tie theoretical BeasaL practise fit various pcs cent owrwa'**. Tig. I - Shows the monthly Biphenyl aed Saatowo: production rates it various parent coevertioae hatw 2,000 md 3,100 gallon* per hoar BsaasM feed. Pig. 3 - Shews the pooed* of Eydrog** produced par pound of liphnyl fit vsrioae parent eesverBiee*. ' Tig. 4 - Shews the pounds of Saateoss rtC" produced per pad of Biphenyl fit various parent eonversiee*. Fig. 3 - Shows the parent cosnrsrsieu that caa be expected at different reaction tss^ecatws* and various sojourn times. Pig. 6 Shows Bsatily Blphseyl product!# fit various parent eeuversims UlMia 2,000 sad 3,400 gal Leas par hour e Bsimm feed. Pig. 7 - Shews the o-rper*i<m beiag sfetaiBed tm the tmitfi as indicated by the specific gravity of the eoMdsased vapors passing fc the eelusi y vi- ' 3 ' ' . "<> DSW 048636 >> 018279 WATER PCB-SD0000045015 WATER_PCB-SD0000045016 WATER PCB-SD0000045017 WATER PCB-SD0000045018 WATER PCB-SD0000045019 WATER PCB-SD0000045020 WATER PCB-SD0000045021 WATER_PCB-SD0000045022 WV 018287 WATER_PCB-SD0000045023 SECT!OH f COKHWTS ON THX PROCESS IE has ban established that a higher eotrreraiom can he obtained at a give* temperature with all fresh Benzene feed than with all recycled tuui feed. The fresh Benseae has heaa postulated to cental a a conversion promoter which is used up as the Benzene it patted through the units, accounting for the lower conversion with recycled Jtuut, To eliminate tha fluctuating conversion a level control has been provided ia the feed tanks to continuously add fresh B mu tote to the recycle 1> the feed tanks. , Conversion Promoter ' The actual meehaaie* by which Isopropyl Alcohol promotes ronveraioa is act known. It is believed to sensitize the Benzene tc tha formation of Bipheayl and Terphenyl by increasing tha rate of free phenyl radical formation. Isopropyl Alcohol is only one of a number of products'which sensitise the Benzene. Isopropyl Alcohol was chosen becauss of economics. Other sensitizers are listed in Research Report Ho. 117-SB1 by Huff and Conover, dated October 5, 1935. ' Lead Levels The lead is adjusted to a 25" outage la the No. 1 Preheater, a 50" outage in the No. 2 Preheater, aad a 15" outage ia the converter whenever these pots are opened for inspection, cleaning or repairs. These outages have been found to be optimum with respect t>. lead carryover and heating of the Benzene feed. Lead Prose Occasionally lead dross will contaminate tho lead and raise the malting temperature. When this contamination occurs the lead in tha top of the pot is dipped out aad fresh lead added. Water in Benzene Peed Water is drained from the Benzene feed teaks about every tvo hours. If this water is permitted to enter the units, it will cause a sudden surge lm pressure aad rupture the pot fleage gaskets. jfeciilyi_TeMPsraturss Higher than normal temperature sometimes results fro a thermocouple failure. When this conditio* is encountered carbon is formed. This car bo* plugs the distributor end pipe lines, * DSW 04&645 . l i r > ih l c WATER PCB-SD0000045024 Safetjr lamt, eh* major raw material handled in tha Bipb&nyl Department, it a flcakabl* liquid and le vapor* fora explosive mixtures with air. It pr**ac* * fir* has&rd uni*11 proper c.ar* 1* cakes la storage aad handling. It poaie*** a higH degree of texicicy. Comdaued inhalation of low con centrations may cause serious, eves fatal blood change*. The liquid, after prolonged contact, may cause defatting of the skin resulting la dermatitis or ecoadary infection. Benzene can be handled, shipped, and stored safely, provided the personnel handling the product recogaix* the baser da and are thoroughly familiar with the lectiiuy pracauticns. Some of the principle prt 'autiona era: (1) Keep tvav from spark* or open flame, j (2) Provide adequate ventilation. (3) Ground all containers aad equipment before discharge to reduce - danger from static elec.tricicy. (4) Avoid Inhalation of Bensana vapor. (5) Avoid skra contact vich Benzene. Hydrogen 1 a a highly inflammable gas which fora* explosive mixtures with air. In areas where Hydrogen is handled r scored, every effort should be made to prevent sparks or tires of any kind. Biphenyl and 'Untovax I'Tarpheayl) Both Biphenyl aad Saatewax have a very low order of toxicity. These products axe not to be taken internally mt maintained in contact with the skin, eyes or other body parts. Biphenyl has a flash and fire point ef 106C and 124*C respectively. DSW 048646 WATER PCB-SD0000045025 szcncm c p&ocess cornoL pROdami Samples are Cakes irtm Benxel task eari bafera the cart Are uiltidMl fer a freezing point determination. Freeaing point on the BimoI wet he 5. 3C ndiiisja, Saaplas of the gee leaving the Biphenyl converters are taken dally and the conversion rate determined by spec!fic gravity. The percent conversion la regulated to produce the required amounts of both Biphenyl and San towax, (See Chart Pig. 7) The percent converiton is regulated by changing the converter pot temperature. The converter pot it usually operated at a toperator* of approximately 780C to give a conversion of 15-171, The temperature required to get this con version changes at the pots begin to plug with carbon, causing increased sojourn tine due to the increased pressure. Ho. 1 and He. 2 preheaters are usually operated at approximately 490 C and 670*0 respectively. When the pressure on Ho. 1 preheater pot reaches 100 lbs, the unit is shut down and cleaned out. At this point the pressure on Ho, 2 preheater will be approximately 80 lbs, and on the convex tor approximately 60 lbs. * The units are usually operated with a 60-701 reflux, with 901 being set as a maximum. The reflux cools the vapors leaving the top plate below 100C. If 901 reflux doe* not fool the top plate vapors below 10OC, then it is necessary to cut the feed. Biphenyl /reeling points are usad as a control point for the Blphamyl dis tillation cut. The /reeling point Is to be 68.6C minimum before this cut is taken. Typical batch data sheets are attached. t WATER PCB-SD0000045026 FORM MCC 117 SW > 6*K Monsanto chemical company ANNISTON. ALABAMA. PLANT FOR 24 HOURS BEGINNING 7:00 A. M.. 9-13 Biphenyl Ope ______________19_5Z_ OPFPATOF? . -.- " TIME feed RATE I [ FLOW I}:` ItBOX COLUMN 0. P. H. SET'0\ j' a I 33.5 |fc5-X3 {j >1 0 1 78 lo " 1| If 2| 31 . ! i ir I ! 1 | 90 | 00 | 82 84 54 | j ! TEMPERATURE. DEGREES CENT. J BUMP LINE XCONV'R NO. P.H. NO. I P.H.i LEAD LEAD LEAD j LINE 198 , 744 60 200 I 743 6 173 | 740 ! 678 183 | 742 j 678 495 | 1 I 433 i 493 | 493 ji 164 j| li 165 || 178 j 743 ; 6S0 188 743 i 673' | 495 i ! 497 ij 154 1 182 | 746 ! 6 !i 500 -i 162 J... No. 1 PRESSURE POUNDS . 1) ' FEED j NO. I 1 NO. i I : j} GOOUjI ! j PRtH. 1 PR EH. conv : *cck j} Hi | 1 ?s 1 IT'V - ' ! ' "ij ' ; i 67 ! 4? i 27 il 68 ! ii !i i- ii 1 1 94 1 1 1 1 65 . 1 55 II i 40 ; 25 l! 71 i r! |'i! 1 | 9S ss 1 S3 I ! 144 23 72 i i i! i 96 66 J. 57 42 26 ! 73 1 i :! ! REMARKS:/ Enxol fcvaback trap. #2-78, #3-80, #4-64, #5-45, #6-49, #7-48, #9-72, #10-44, #12-74 IT OPERATOR..,^:.- 4 215 I 85-15 II 90 5 '! U s 9 |l S3 65 7i 60 8 78 9 io 75 T1 REMARKS: NO. 2 S -. -................ --__________________________________________________________ 205 1 182 198 193 190 j 740 j 740 | 740 i 732 730 j 675 i 675 | 672 j 662 ! 660 189 735 668 492 495 43? j 468 468 j 475 I 164 I II m IL ii 164 I2I! 1i 165 | 96 | 66 i 58 11 1 - i L. . ! ?5 | 66 58 j !_96 1 J 66 1i 58 ! 92 68 58 j42 \Z5 || 74 i ' il i. . l___ ^ til____ l_ 142 j 25 if 72 ! ! : ii f i ii- t t 42 25 Il 72 I1 I : | f 42 25 |72 ( l .L 1. 1 11 OPEPATOP Hortoa 12 215 i 85-15 ]J 75 j 190 1I 2 i. . !i ' J 77 j3 I' il 77 <i i :l S 78 5 ! , ,lii II 78 198 193 1B5 182 8 !( 'i 77 186 _7j! li `i il "1 REMARKS: j 738 665 1 738 662 738 660 740 668 740 668 740 | 668 NO. 3 Sh 470 165 | 94 68 468 ! 468 i [4tT! 165 165 475 j 478 |j 165 95 95 ' 1 95 1 68 68 68 57 57 | j 57 1 58 i 42 j 25 | 70 6 i 42 i 25 1 70 ! 6' ji 42 | 26 | 70 | 6( || ____ 1f___ ! 43 1 26 j 70 i 67 1 ' -i ___ j._ MWV 018291 WATER PCB-SD0000045027 myl Operating Record 3__!9iZ_ UNIT NO.. NO. J SHIFT , 1 cooac iV 1 NECK HYDROGEN COOLER TEMPERATURES DEG. c. . Hi IN i.j S.4 1 l I I Hi OUT `2 !3 s "4 ! !WATTS I IN 1 WATER OUT ! 1 2 ia : i tl 63 : 65 1 34 43 ! 17 i 32 ! 24 30' 30 ! 30 ii f| SUMP. TANKS j| MtAJSUREMCKT Ai i 23 |i 3r10" ! 1,3,t 3aSt=r MYtSR'N , COHPfl. * OK CONVERStON SAMPLE III! 71 ^1 J 70 ! 23 , 44 l 1 1 i j' C.O, :Ii1 ,> *A ! 1 71-1 40 ! 44 : li 1 ! 1! ,j&S 73 j 71 i 40 | 45 i T* II J___ L i1 22 1 35 28 1 AO 1| 36 23 ii 26 i 36 ! 30 1 32 34 j 34 (II !T 32 32 j 32 (bhg. *twl 1 '6" | 11 .34 ,, | ----- 1; -*7N* !'i.| ii UJmf !| i AfAtl ^ ** !l ;i i! !i | 34 ( 34 ! 34'J l'O" | 2,ioM:| CX cs Oil TIME CONY'R. TIuMP. NO. 2 P.H. TEMP. BP. GRAVITY AT TEMP,, C. CONVERSION 12;00__ 745 600 ____ 892-- 31 .. 16.3 j PLUS GAS i OS -44,' #12-74, #13-68 /Water press 60 Ibe, NO. 2 SHIFT ! 25 |'| 74 j 72 ( 41 | 47 j 26 :I 1 1 T5 1! 72 72 ' 38 461 24 : i: | 1 25 ii 73 68 35 44 | 21 | !i i 25 72 67 34 j 4-3 ; 2D 'i CHIEF OPERATOR_MiIIien_ 37 | 30 i 34 | 34 34 | 34,;jMty 3.6 4 OX iI 11 11 361 29 ! 34 | 34 II 34 { 34-i aty 1 '! j 4.2 !i CK ! i1 32 j 26 j 30 j 30 ! ;! 30 | 30:; i.o i ! | Ktr j} oc i i i i- i i i r 21 j 25 j 31 30 29 | 29 1.8 | |J j Hty :j OK 1 TIME CONV`R. TEMP. NO. 2 P.H, TEMP. 3Pi GRAVITY AT TEMP.. C. CONVERSION FLUE GAS -NclJELS HIFX. CHIEF OPERATOR__ 25 ; 70 ! 68 i 34 44 ! 18 i? i= ii |ii 25 : '70 i 66 | 32 44 j 18 i _L |. ! 26 | 70 ' ii !i 26 i 70 1 j 66 | !: 1 1 68 j 1 34 44| Ii 1! 34 44 ! j 20 ; ! 20 32 I 24 1 1 30 30 ?4 29 1 32 24 30 32 26 30 j1 || 28 28 21 i| 2-0 1-3 _1 J 29 28 .2*1 2-9 1-3 ;1 |i 30 28 28 ij 3-5 1-3 | 1 ;1, 30 29 i 29 : 4-0 1 t 1 j 1-3 i liaised coirv. 20750 OK m K OK TIMS CONV'R. TEMP. NO. 2 P.H. TEMP. BP. GRAVITY AT TEMP.. C. CONVERSION 12:00 733 665 0883 32 14-0 FLUE GAS MWV 018292 WATER PCB-SD0000045028 MCC--2-A--5M-3-H BIPHENYL DISTILLATION RECORD Distillation No. 165 Stiff No. Data St&rtacL. Jtek. Operator Started .Operator Finish. Started Charging Stiff at. C, 9* 5:30 ?.K. --------- , 19-iA. -Shift----- 1___ -Shift. Charge: H&T Tank; inches before. 34 .inches after. No, 1 S. T. inches before_____ ____________inches after .Gallons Charged. tm .Galfons Charged_____^85. No. 2 S. T, inches beforeinches after .Galfons Charged. fNo, 3 S, T, inches before______ --inches after_____________ _ No. 4 S.' T. inches before. Jnches after. .Gallons Charged. .Gallons Charged. Benzol Still inches before. .inches after. .Gallons Charged___ Total Oallonn Charged. J.3_ Circulating at. 6*30 ?M. ; Fire on at___ JLeJAJLHL Flow Box Settings: 1. On 20 10 4. On. rt _at_ .at. _at_ 5i 30 ?,& 6)35 P.H. 11:20 P.H, 1:00 iuM. 3 On On_____ 7:45 A.K. at at___ Benzol: Heads: Tails: Biphenyl: High Boiler: Ran 22 * nr 506 Started over at Ran 11)20 P.K. 24" Started over at,. Ran Total in Distillation 12 76 Finished at " nr .Finished at " nr 2314 3)30 AM 1*157 nr 16.796 f^rnsc W>l<rht Net TOJe " Weight_________ 6,000 Jbs. No. of Drum'? __lbs. inT !hs. IK*:. lbc. MWV 018293 DSW 048650 WATER PCB-SD0000045029 SECTION H WATER PCB-SD0000045030 1 ;j fl MONSANTO CHEMICAL COMPANY PRODUCTION COST STANDARDS ------- Anniston jpftOOJJCT--------- - .Blp.heoxl_____ 1__ DEFT. NO-- _20_ 82601 _ EFFECTIVE OATE_JjlZxJL -19JS7:. <l< YfCLO _%ON---------------------------------------------------------------------- CAPAC/TY__ 2.100.000 lb; .INVENTORY STANDARD. .ZJlSSLSDQ.Iba, 3 YIE10 ON . il " "".^1.. i *!' * -- a - _S -- COST 1* 1 UNIT- ~W -T, 13, . > \ JLOfl,IbAs, |,l In - inventory corr - " .* V' --^ I 'l. .WAMTITT P..CX iiXirtBKf jj tMtoAr u/irf l* <9* ;" ` . % '! 10950 Tsnprnpvl Alcohol ! '650 06231 i! 14700 Beriol" i 1331770 ' >05250 !! .38400 Lead 1 ' ' ! 200 118100 ` 11 i ! ii 1 i ' 5 ! i I- P II! 040 7 023 036 . --jM! 1 ! ! r 1, i i ! p HAW MATERIAL WARCNOUSINC ft HANDLING CROSS TOTAL MATERIALS |cD!T. / . j i i ! * j _ i 1............................ ; ! | "J 099 !!, a2Pcl/HydroRan i 0 Santovax C I) TOTAL CREDITS j N CT TOTAL MATERIAL* 1.510 261670 ! 10000 103520 051 ............. ... . .... l 42-2. . . ... 523^ -------------------------------------------------------- 5 1576 MONTHLY PRODUCTION BRACKETS F JLO iPl I 1, 050, 000 lbs. 000 lbs. II 2,100 000 lbs. fi ji UNIT COST AMOUNT j UNtT COST | AMOUNT ij UNIT COE? I AMOUNT jj UNIT COST | amount 1 MATERIALS |i TtAM lj ELECTRICITY j: coMRncsTes air WATCR-MURCMASEO WATER.PLANT \ 5 576 58548 S f 068 714 i fl 0491______ 515 l i| i !l 3 Oil) 116 i 0831 872 5i576 87822 1068 1071 iIl 049 _______ 2Z2_ i ... ... J i Oil 173 i 0831 1307 515761 117096 1____ !_____1______________ ' I1 C0A6891i 1478 I _____ 1029 j 1 1 i. ..... 1 | 1 ...join 231 1 1 0831 -1243. 1 ruei'CAS. COAL, OIL 13281 3439 1328 5158 ! 328 6878 I fttrmcewATJON a ict ;{ labor ;l supervi sion i i. 5. TAX A COMA. !OK. MNJ.[ I ! 225! 0581 0311 23 65 610 327 i 265 i 0391 i 033 4183 610 527 >122. 029 025 .4183. 610 .527 ] RETAINS.EQUIPMENT RCPAIflS.BUlLOiNO 429 0041 4500 44 1406 003 6400 M- m 1202 _amL 2t4_ 1 LABORATORY | CLUTMINO A UUNONY Tech. Service TOTAL DIRECT CONY, oc^ccunoN PACTCfPY INDIRECT tXPCNSC 034i 007 001 041! l!369i j 128> i 618: 360 72 10 A10_ 14374 6488 _l033 1007! I 0011 1 0?-7 j liI53L 1121 i 412 i J2Q-J Jk24_ _L5_ 2tl0_ il31A JL8.fi9_ 6486 034 MZ 020| 237 | 0Mj_ 1309! J2JL -144. _20_ .430... 25987 II -136.9. 6488 1 I TOTAL INDIRECT CDNV. f; TOTAL PRODUCTION COST 796' 71741.- 8357 81279 -1 1531! 714601 8357 ! 398) 117493 i 7 i 2llj 8357 151440 l OPCni-TiNC CRIOO 30 LAno* -O'J-, j 953 t 0 . Sfl.AU CLL' ;uCK . - :: C -x . cHXBAtPCrflOn* - * " * 1 ' *'Ajf-tl WAttR 'IdM. r U wATrn.PLini , 1050 420 30 1680.2 ' 1575 630 30 1680.2 2100 840 || il il <? , ' LiSimitonT PmcCT COHVCRYIOK COST WATER PCB-SD0000045031 SECTIOK x FINISHED GOODS SPECIFICATIONS Tha following page Is a specification sheet for finished goods WATER PCB-SD0000045032 " Mootamto ckkm/cal CoMmm Oft9M4fC CHleiCAkS &JVI1308 Y HteeucT ee 26 bStr*o iomtitt FINISHED PRODUCT SPECIFICATION rmaucT (iftsJs mJ BIPHENYL s seeu r {Uasded *jtmJ JA#' AM. 83 CQOS i i-4eo-n-w fTR* TSCHJGCA.I, _____IXCagCAL linMl Jnlj I, IfST STAJdUAia MPT* [Anlgtat, A1&* Pfal c12tho wpM6sou t^ecs or ______- iwu U4A4ral | WQ^Aataiste^ S&Ua Plat can molton, 2-p-gmaJ hag-flaj^yd UNCLASSIFIED SPECIFICATIONS Routine Teats Specification Test N Appearance Colorlais to pale yellow crystallised solid r UJcas Pressing Point (C) 44.7 win. Coler (Oardoer 1953) 4 Dietiilatitt Rang (1) (C, Corrected 1st drop - dry) 2.5 NOTE! (1) DistilUtdc* mast include 25SC within the range Gardner 1953 Lifidd Celer Standards Using Jlnureseeat Li^lsied Comparator, Cat. Me. 434 or using Gardaer-HflULigs Comparator, Cat. K. 44fli45T Gardner LaWmt&ry, Inc. Be the da 14, Uarylaad . \ WATER PCB-SD0000045033 'defendants"! EXHIBIT g I HISTORY OF THE ANNISTON PLANT Monsanto, Anniston ... 1935-1987... over 50 years of performing. The plant has undergone many changes and today is almost a totally different plant than it was 50 years ago. The plant, however, is here today solely because of its employees. Anniston employees have demonstrated their flexibility to change and dedication to a plant that has changed dramatically in 50 years. The story of Monsanto's Anniston Plant began in 1915, at a time when Anniston was a community of less than 18,000 people. Mr. Theodore Swann became interested in the manufacture of six-inch explosive shell cases for the army. He began the Anniston Ordinance Company for that purpose. In 1917, he formed the Southern Manganese Corporation and began operations at the _ present plant site. The company initially manufactured ferro-manganese and then later silico-manganese, ferro-silicon and,_ ferro-phosphorus. Eventually, a method was developed to collect the fumes from the ferro-phosphorus furnaces, thereby giving birth to a new product, phosphoric acid, which was far more profitable than the ferro- phosphorus. In 1927, the Anniston Plant entered the field of organic chemicals when they first began producing biphenyl, today one of our two major product families. In 1930, chlorinated biphenyl . DSW (188002 WATER PCB-SD0000045034 and Arodors were first made. By 1930, Southern Manganese became Swann Chemical Company with plants in Anniston, Carondelet, Missouri and Camden, New Jersey. In May, l;?35y Swann Chemical was purchased by Monsanto and became the new phosphate division. The plant continued to serve as.division headquarters until 1954 when the phosphate division became the inorganic division and control of the plant was transferred to the organic division. From 1940 until the early 1950's, many Anniston Plant departments were shut down as phosphate manufacturing was shifted to other Monsanto plants. In 1952 the plant again began to grow. with the construction of a chlorine plant. In 1957, the decision was made to build the parathion department at Anniston. In 1961, parathion was expanded by 50%, a waste treatment plant was built and a new tubular biphenyl reactor was started up. In 1964, parathion was again expanded by 50% and construction began .on the PNP department, a parathion raw material, which started up in April, 1965. In 1966-67 , the P2S5 department, another parathion raw material, came on stream. In 1969 a new warehouse was completed, new flaking and bagging equipment for biphenyl and solid Aroclor was added and a new Aroclor tank farm was built. On the loss side the chlorine plant was shut down and dismantled in 1969. In 1970 a large solid Aroclor expansion DSW 088Q88 WATER PCB-SD0000045035 started up. HB-40 capacity was expanded in 1971. In July of 1971 the decision was made to discontinue liquid Aroclor production at Anniston. In September of 1971 the Annistbn Plant became part of the Agricultural Division. Solid Aroclor production was discontinued in April of 1972. In 1972, increased demand for parathion began to place strong pressure on the capacities of the finished product and parathion intermediate departments. At this same time, new legislation placed heavy environmental constraints oh plant operations. The Anniston Plant undertook an extensive debottlenecking program and by 1974 had increased parathion capacity to 47M pounds per year, meanwhile becoming self-sufficient in PNP and P2S(_. Pollution control projects to reduce sulfur dioxide were initiated and provide more effective dispersion of the remaining sulfur dioxide. Several projects were installed in 1974 - 1977, which allowed the plant to make great strides in the environmental area. The plant was able to reduce sulfur dioxide emitted to the atmosphere by over 96% and eliminated process water flowing into local streams. These projects included an H2S ball, construction of a Recycle department and a claus sulfur recovery unit. The claus unit reduces sulfur dioxide by greater than 90%. These projects also eliminated the necessity for incineration of sulfur J3SW 088089 WATER PCB-SD0000045036 bearing residue and created significant yield improvement for the Intermediate process. ... . The expanded PjS^ operation was successfully demonstrated in early 1977 and as a-result of the increased capacity, Anniston became a merchant seller of P7S^. Due to changes in the ?2S5 merchant market these sales were consolidated to the WG Kruromrich Plant. Early in 1985 Anniston once again, responding to Monsanto1s needs, entered the P^S^ merchant market. The PNP expansion was started up in October,.1977. In a development arising after the PNP expansion, MICC finalized plans for APAP production requiring PNP from Anniston. This application has grown to a significant portion of pur business in 1985. A facility to produce Refined Ethyl PCT (parathion intermediate) was constructed in 1980 to supply material to Dow Chemical Company. In 1983, the final phase of the parathion environmental control projects was successfully started up. This project recovers sulfur which was previously landfilled and recycles not only the sulfur but also liquid organic material to the existing processes. DSW 088090 WATER PCB-SD0000045037 1984 proved to be a year of many changes and improvements to the Anniston Plant. v'fl? ... - A process to manufacture Refined Methyl PCT was developed and Anniston began production. - A Steady State Chlorination project was developed to improve raw material usages in Parathion. - A process change was developed to reduce sulfuric acid usage in PNP and improve product quality. - A Host computer was installed in April, 1984. Computers were purchased to replace the outdated lab computers and a Provox Computer System was installed in the PolyphenyIs area. This project has significantly reduced costs and improved ease of operation of the unit. Accounting, Maintenance, Personnel and Shipping all have purchased computers to assist in administrative work while other areas of the plant.have obtained terminals to the Rost computer. osw &>s91 WATER PCB-SD0000045038 On October 25, 1985, Monsanto announced that it was withdrawing from the Parathion business and would put the Anniston Plant on the sale block. Since that time several attempts to sell the plant have been unsuccessful. During the past 18 months however, the demands for the Anniston Plant Biphenyl products has improved to the point that efforts to sell the plant have ceased and a major restructuring of the plant is taking place to position it to stand alone as a small Monsanto facility. The plant has reduced its workforce from near 300 employees in .the 70's to approximately 100 today. There are two ,? ' * basic products manufactured at the plant, Biphenyls which are a part of Monsanto's functional fluids products and PNP which is used as a raw material in Monsanto's APAP process at the Luling, Louisiana Plant. Over the next several months many unneeded facilities will be dismantled and others will be consolidated to further reduce the plants operating cost. The kev to the success of the Anniston Plant has been and will continue to be its employees. The plant has changed dramatically in 50 years. The faces of Anniston plant employees have also changed over the years but their dedication to the company, flexibility to change, and pride in the plant have brought this plant where it is today. Without the dedication of our employees, the plant would not be here today. SAPETY/sag D.SW 08 8 0-92 WATER PCB-SD0000045039 WATER PCB-SD0000045040