Document 963dMbpOdVnZONGV7mXm7ERR

MONSANTO COMPANY Organic Chemicals Division Standard Manufacturing Process For A ROC IX)RS Department 246 Ww Ww W w Wrl WwWwn W W Supersedes: Process description for the manufacture of Aroclors, Dated: December 17, 1962. Prepared by: ^ if. Grh, 1. a. Sole, IPX5T Engineer Approved by: ^,13 Approved by: W*r4. ncovcii vii ' ' tn nsTn, Proa .Supervisor * P.'ET Helsler, Cten. Prod.&pt. Issue Copy ^_____r____ ZO CONFIDENTIAL INFORMATION This Process is the property of Monsanto Company, and the recipient is responsible for its safekeeping. It contains confidential information of Monsanto Company which must not be reproduced, revealed to unauthorized -'persons or sent outside the company without proper authorization. Either retain in a secure file or return to the Office Services Department. COMPANY TRAN 00,1,2 CONFIDENTIAL HARTOLDMONO010466 MONSANTO COMPANY Monsanto, Illinois SAFETY REVIEW COMMITTEE Messrs: P. E. Heisler - WGK H. C. Carder - WGK Process Holders Title: ',R, Bucfenel&n * Org. Res, H. LrOtahtrand - Org, Res. Tentative Amendment No. "A" Tentative Amendment No. "A" to the Standard Manufacturing Process for Aroclor (Dept. 246, WGK) dated 7/20/64. Objective: Alter present plant distillation system and operations for a plant test. Plant test will indicate equipment needs and ability to produce improved quality (stable) Aroclor, Present Practice: Two Aroclor Distillation Systems are run in parallel. The two systems are continuous ly fed crude Aroclor from the #2 Blow Tank. The distillation is a straight take-over operation. When a run of one type (1242, 1248, etc.) is completed (80, 000-500, 000#) a final boil down is conducted in No. 2 still and the bottoms are dropped. The boil down material is combined with the previously distilled material and pro cessed to finished product. The bottoms are drawn off and sold as Montar or discardet Following the boil down and bottom's drop the stills are ready for the next product run. Proposed Procedure: Run the two stills in series. Continuously feed the No. 1 still with crude Aroclor and use this system to pre-heat the entire feed and to distill off a low-boiler fraction (up to 10% of feed). Continously feed the No. 2 still from No. 1 still pot. Collect the intermediate fraction in No. 2 receiver and process as in normal operation. At the end of the run (4-5 days) boil down and drop bottoms. Do not combine the boil down (high-boilers) with the intermediate fraction. The low boilers from No. 1 receive: and the high boilers from the boil-down will be isolated in a storage tank, if possible. COMPANY CONFIDENTIAL TRAN 009193 HARTOLDMONO010467 Tentative Amendment "A" - 2- March 10, 1965 If they pass non-electrical Aroclor Bpccifications, they can be used as such. If the total amount has to be discarded because no storage is available, or because they are out of specification, the cost would be $3, 000 based on total product costs. Specific operating conditions for the stills will have to be determine d in the field by cut and try methods. Justification: Foreign competition appears to be capable of producing Aroclor which is more stable than that presently made by Monsanto. An improvement of product stability is necessary to protect our market position. Laboratory data* indicates that the distillation operation has a significant effect on product stability. These data indicate that product stability can be improved by: 1. Removing an unstable low-boil fraction 2. Preventing entrainment 3. Preventing contamination by high-boilers or b6il down This test will evaluate our ability to control the plant distillation in the three areas mentioned above, with existing equipment. Failure of the test will indicate that more drastic revisions to the existing equipment will be needed to approximate laboratory conditions. Comments: The production rate will be limited by maximum vapor and heat loads that can be sustained in the entrainment and condenser systems on N. 2 still. In the past 55, 000#/day have been attained in these systems. The upper limit is not presently known. Duration: The test duration will be 4-5 days. If desired operation conditions cannot be obtained during this interval the test will be cancelled or revised. Prepared by: COMPANY CONFIDENTIAL *WGK PR&D Reports J-62, 2/15/65 and J-78, 3/ 8/65 D. R. Middleton TRAN 009194 HARTOLDMONO010468 Tentative Amendment "A" Approvals: -3- March 10, 1965 D. E. Harris vmd A. Mullendore 4 ( L H.. X. Hubbard COMPANY CONFIDENTIAL TRAN 009195 HARTOLDMONO010469 MONSANTO COMPANY Monsanto, Illinois July 12, 1965 Messrs; P, E. Heisler - WGK H. C. Carder - WGK Process Holders R. W. Bucknell - Org. Res, H. L, Hubbard - Org. Res. Tentative Amendment No. "B" TITLE: Tentative Amendment No. "B11 to the Standard Manufacturing Process for Aroclor (Dept. 246, WGK) dated 7/20/64, OBJECTIVE; Run two plant tests using revaporized Cl2 and dilute (25 mole %) Cl2, as feed stock for Aroclor 1242 production. PRESENT PRACTICE: The Dept. 246 Chlorinators are batch charged with biphenyl (Bit#). The Bi0 is then chlorinated by continuously feeding "Snift" gas to the chlorinator mass until the desired specific gravity is reached. The "Snift " Gas is a mixture of Cl2 (from DeNora & Hooker Cells) H2, N2, 02, C02 and trace amounts of organic impurities. The Cl2 concentration is in the range of 75 * 95 mole % and varies with operations in the Cl2 depart ments . PROPOSED PRACTICE (Two Plant Tests, 1242 Aroclor) 1. A plant chlorination test will be run using revaporized Cl2 from Dept. 232 as the Cl2 feed stock, Due to limited capacity of the revaporizing facilities in Dept. 232, we will probably be able to run only two chlorinators at a time, making a total of 5 - 6 chlorinator batches and processing through the remainder of the system as normal. Necessary samples and measurements will be taken to determine effect of concentrated and impurity free Cl2 on Aro clor stability. This material will be treated as normal production as it passes the routine plant controls. .2 A plant chlorination test will be run using revaporized Cl2 diluted to 25 mole % with dry air as Cl2 feed stock. This test will be limited to 2 chlorinators due to dry air capacity, making a total of 5-6 chlorinator batches and processing through the remainder of the system as normal. Necessary samples and measurements will, be taken to determine effect of dilute and impurity free Cl2 on Aro clor stability. This material will be segregated from normal electri cal grade 1242 Aroclor. It will be used for non-electrical 1242 if it passes specification. COMPANY ' CONFIDENTIAL TRAN 009196 HARTOLDMONO010470 Tentative Amendment No. "B". JUSTIFICATION: Foreign competition appears to be capable of producing Aroclor which is more stable than that presently made by Monsanto. An improvement of product stability is necessary to protect our present U,,S. market position and for possible expansion of foreign sales. These tests will provide information as to the effect of contaminants in chlorine, and the possibility of local overchlorination due to concentration effects. COMMENTS: For the revaporized Cl* test the production rate will be limited to about 32, 0000/day for a duration of 1 - 1 1/2 days. For the dilute Cl2 test the rate will be limited to about 11, OOOif/day for a duration of 3 days. SAFETY: No increase in safety hazards is for seen in these two test runs. APPROVALS: Prepared by: h a, % -juuD. R. Middleton it* 7S6-6SD. E. Harris SAFETY REVIEW COMMITTE COMPANY CONFIDENTIAL tout 7-A3 TRAN 009197 HARTOLDMONO010471 I MONSANTO COMPANY Monsanto, Illinois September 1, 1965 Me ssr 6: P, E. Heisler - WGK H. C. Carder - WGK Process Holders R. W. Bucknell - Org Res H. L. Hubbard - Org. Res! Tentative Amendment No. C TITLE: Tentative Amendment No. C to the Standard Manufacturing Process (Dept. 246, WGK) dated 7/20/64. OBJECTIVE: Run plant test using chiorinator without catalyst basket. PRESENT PRACTICE: The Dept. 246 batch chlorinators (31 diam. x 16' high) are batch charged with biphenyl, which is chlorinated with snift gas. At the present, each chiorinator has a catalyst bed. The catalyst bed is 2'3" in diam. and 8' high and consists of 1 1/2" pipe nipples, 2" long. PROPOSED PROCESS (1242 and 1260 Aroclor) Remove the catalyst bed from one chiorinator and run three to five 1242 and three to five 1260 batches in that chiorinator following standard operat ing procedures, except without the catalyst bed. The test material will be kept separate from other production and will be used only if it is equivalent to normal production aroclor, according to routine analyses, During the test batches the chiorinator off-gas will be sampled and analyzed for chlorine,, to check chlorine utilization of the chlorinators without the bed. The purpose of the catalyst bed is to provide iron, which is chlorinated to ferric chloride, the reaction catalyst. It is standard operating procedure to charge 0. 05% by weight ferric chloride to each batch. Ferric chloride will, of course, be added to the test batches, JUSTIFICATION: During operation the catalyst becomes plugged with tars and ferric chloride and it is probable that only a small portion of the iron of the bed is available for utilization, Also, the plugged bed hinders chiorinator circulation and probably leads to hot spots in the chiorinator. There is a problem of cross contamination from batch to batch with the bed, which results in an excessive amount of overchlorinated products. COMPANY 009198 CONFIDENTIAL HARTOLDMON0010472 Tentative Amendment C 2 JUSTIFICATION: (Cont'd.) During 1956 there were severe problems with aroclor stability. One of the problems was a lack of a consistent analytical method for checking stability Previous to that time the catalyst bed was relied upon to supply ferric chloride and ferric chloride, per se, was not added. One of the results of the stability problem was the addition of ferric chloride to each chlorinator batch, to assure that sufficient catalyst was available . Since that time analytical methods have improved and any unstable aroclor produced would be detected immediately. The removal of the catalyst bed, then, improves chlorinator operation by increased circulation, elimination of hot spots, and prevention of contamina tion. The addition of ferric chloride provides sufficient catalyst. Any unstable aroclor produced would be detected immediately by the present routine analyses, SUPPORTING DATA : It is reported in St. Louis Research Report Nos. 1640 and 2072 that a minimum level of 0. 03% FeClj is necessary to produce stable aroclor. No mention is made of the need for iron, and none was used in the lab chlorinator s. SAFETY: No increase in safety hazards is anticipated. QUALITY: Work is in progress to improve aroclor quality (stability). It is anticipated that the removal of the basket will not harm quality but, if anything, will improve it due to improved circulation, elimination of hot spots in the chlorinator6, and elimination of cross-contamination from batch to batch, DURATION OF TEST Three to five 1242 and three to five 1260 batches will be made without the catalyst bed. If this material is equivalent to normal production material, according to routine analyses, the chlorinator without the catalyst bed will be used for normal operations, and this amendment incorporated&s a process revision. If the test material is not equivalent to normal production the bed will be replaced. COMPANY TRAN 009199 HARTOLDMONO010473 I Tentative Amendment No, C -3 COMMENTS: This plant test would normally involve some lose of production. The pre sent aroclor stock position is such that it is anticipated that it will be nec essary to run only three of the five chlorinators during September, Also, some repairs to be made during September will require removal of the catalyst bed from the No. 3 chlorinator. September, then, is an ideal time to run this test. APPROVALS: P, E, Heisler ^ 4 h-pMb**. Jh-A-- f J. A. Mullendore Prepared by: W G. Krampyt 5h lr Date Date 9-7-df Date Tht ;' Ll .r_' Tht irobard ' SAFETY REVIEW COMMITTEE J? emc COMPANY CONFIDENTIAL TRAN 009200 HARTOLDMONO010474 MONSANTO COMPANY Monsanto, Illinois SAFETY REVIEW COMMITTEE October 20, 1965 Messrs; P. E. Heisler - WGK H. C. Carder - WGK Process Holders R. W. Bucknell - Org. Res. H. L. Hubbard - Org. Res. Tentative Amendment No. "D" Title: Tentative Amendment No. "D" to the Standard Manufacturing Process for Aroclor (Dept. 246, WGK) dated 7/20/64, Objective: Evaluate potassium carbonate as a replacement for lime in the Aroclor distillation system. Present Practice: Aroclor is distilled in two parallel systems, continuously fed from the No. 2 blow tank. At the start of a run (1242, 1248, etc.) 200 lbs. of lime (calcium hydroxide) is added to each still pot. At the end of a run (250,000-500,000 lbs.) bottoms are dropped and the cycle is repeated. Proposed Procedure: Segregate the two distillation systems at the start of a 1242 run. To one system, add the normal amount of lime to the still pot and proceed normally throughout the run. To the second system, substi tute 200 pounds of anhydrous potassium carbonate for the lime. Dis till away from the potassium carbonate for a minimum of two days. The product distilled from the potassium carbonate will be analyzed by routine tests before it is combined with normal production , material. If'the proddct deviates fyf>m norp&l in any adverse>Way, '-`it will bvTso^sted and will/not be/sold ap elactxdcal grade COMPANY CONFIDENTIAL TRAN 009201 HARTOLDMONO010475 Tentative Amendment "D" 2 October 20, 1965 Justification: The presence of a base during distillation serves two known purposes: It neutralizes free acid, and it reacts with the FeCl3 present. It is also thought that the base can react with some unstable Aroclors, converting them to a more stable form. Recent WGK PR&D laboratory data indicates that distillation from K2CO3 increases the stability of the high boiling fractions of Aroclor 1242 (low boil and mid fractions are essentially unaffected). If this proves to be the case, it would indicate that using K2CO3 and making a simple low boil cut may be a practical way of making a stable Aroclor. Safety: No increase in safety hazard is anticipated. No unusual effect was seen in laboratory distillations uBing K2C03. Comments: No production Iobs will be involved since WGK Dept. 246 is presently running at only 75# of demonstrated capacity. Prepared by: APPROVALS: . J. Luecken /o/'/if Date A. Mullendore ''// r Date /Zb**- d**- COMPANY CONFIDENTIAL TRAN 009202 j HARTOLDMONO010476 MONSANTO COMPANY Monsanto, Illinois December 3, 1965 Messrs: P. E. Heisler - WGK H. C. Carder - WGK Process Holders cc, R. W. Bucknell - Org. Res. H. L, Hubbard -Org, Res. Tentative Amendment No. ME" TITLE Tentative Amendment No. "E" to the Standard Manufacturing Process for Aroclor (Dept. 246, WGK) dated 7/20/64. OBJECTIVE Produce more stable Aroclor 1242 by chlorinating without a catalyst basket in the chlorinator and processing as normal. Produce more stable Aroclor 1242 by chlorinating without a catalyst basket in the chlorinator and processing it through the still system with potassium hydroxide adpled in place of the normally used lime (calcium hydroxide). Provide sufficient product, produced as above, for testing by customers. PRESENT PRACTICE Biphenyl (Bi0) is chlorinated in the chlorinatore which contain catalyst baskets. Previously the basket furnished FeClj catalyst for the reaction. Presently (since 1957) sufficient amount of catalyst, needed to produce stable Aroclor, is added to each chlorinator when batch charged. At the beginning of a product (1242, 1240, etc.) run 200 pounds of lime is added to each still. The purpose of the lime is to tie up FeClj and neutralise HC1 in the crude. PROPOSED PROCEDURE Produce 8-9 batches of 1142 in No. 5 chlorinator with the catalyst basket removed. This has been done previously as per Tentative Amend ment No, "C", Process half of this crude material through the remainder of the system a s normal, and drum it off from the finished product tank. Process the other half through No. 1 still system, but substitute potassium hydroxide (0. 06% of crude charge) for the lime in the still. Drum this . ( material off from the finished product tank, thus producing approximately 1, 000 gallons of each type of test material to be used as samples for evaluation by electrical grade customers. Any excess test material will COMPANY TRAN 009203 CONFIDENTIAL HARTOLDMON0010477 . PROPOSED PROCEDURE (Cont'd.) be sold as non-electrical grade 1242 providing it passes all specifications. JUSTIFICATION From previous plant testB, the Aroclor produced in a chlorinator without the catalyst basket was equivalent or better than normal material. By removing the baskets, hold-up and cross-contamination are reduced. Results of PR ti D Laboratory studies indicate more stable Aroclor (i.e. 0.15 ppm Cl by thermal chemical chlorides) can be made by addition of KOH to the still pot and stripping off the first 1.2% of the low boilers. Plant equipment will not permit this type of fractionation, but an improve ment over normal production is expected. SAFETY No increase in safety hazzards is anticipated. No unusual effects were seen in the laboratory distillation using KOH. Normal precautions in handling KOH will be followed. APPROVALS: Q, D. R. Middleton P, E. Heieler . A. Mullendore Prepared by: D. R. Middleton Date / y/thr ite D. E. Hiaarrxs Qu/d^-irUlP R. W. Bucknell Date SAFETY REVIEW COMMITTEE 'Z/(/6 Date 1A~ 11 Date J^U ft fx 1 /*/** JL/mcCP A 4^ -- /f company 009204 tran CONFIDENTIAL HARTOLDMONO010478 Monsanto, Illinois .May 10, 1965 AMENDMENT DISPOSITION .Tentative Amendment No. "A" to the Standard Manufacturing Process for Aroclor(Dept.246, WOK) dated 7/20/64, Tentative Amendment No."A" is dated 3/10/65. .TO; Messrs; P. E. H. C. D. E. J. J. Heisler - WGK Carder - WGK Harris - WGK Luecken - WOK R. W. Bucknell H. L. Hubbard J. A. Mullendore Process Holders - Org. Res, - Org. Res. - Gen. Off. -c/o P. J. Prader - WGK This memo is to serve as a disposition of the subject tentative process amendment. The purpose of the amendment was to alter the present plant distillation system and operations for the duration of a plant test, The purpose of the plant test was to indicate equipment needs and ability to produce improved quality (stable) Aroclor, No improvement in stability was realized and the need for fractionation was demonstrated.* The distillation system was returned to normal operation as specified in the Standard Manufacturing Process. The subject amendment should be recorded in the Standard Manufacturing Process, but not incorporated as a process revision. D. R. Middleton Technical Services Dept. vmd *WGK TSD Report - Aroclor; Improve Electrical Grade Quality 91370;5198, Report No.l, dated 4/14/65. COMPANY CONFIDENTIAL TRAN 009205 HARTOLDMONO010479 DISTRIBUTION SHEET 1. Technical Information Center St. Louis Research 2. Technical Information Center St. Louis Research 5. Security Pile (Records Center, St. Louis General Offices) 4. Director of Manufacturing/Technical Production Manager Organic Engineering 5. Production Oeneral Superintendent/Production Supervisor - W.Q.K. 6. Plant Technical Services 7. Extra 8. Extra 9. Extra Q't- 10. Extra Copy 9 COMPANY CONFIDENTIAL TRAN 009206 HARTOLDMONO010480 -.r> - TABLE of CONTENTS I. SYNOPSIS OP PROCESS . . . ............................. Page II. PLOW SHEETS . . ............................................... A. COMPLETE PROCESS PLOW SHEET B. CHLORINATION REACTION STEP C. AERATION AND DISTILLATION C. BLENDING, FILTRATION AND STORAGE III. PROCESS IN DETAIL.................................. . . A. NOMENCLATURE AND BATCH DATA B. CHLORINATION REACTION STEP C. AERATION AND DISTILLATION D. BLENDING,FILTRATION AND STORAGE E. BY-PRODUCT HYDROGEN CHLORIDE 4 5-6 7 7-8 8 IV. COMMENTS ON PROCESS................................................................................. 9-12 A. B. ' C. D. CHLORINATION STEP AERATION & DISTILLATION BLENDING & FILTRATION GENERAL 1 APPENDIX A - EQUIPMENT LIST..............................................................15-21 APPENDIX B - FINISHED GOODS AND RAW...........................................22 MATERIAL SPECIFICATIONS APPENDIX C - PHYSICAL AND CHEMICAL DATA.................................. 23-29 APPENDIX D - UTILITIES...........................................................................30-34 APPENDIX E - PERSONNEL................... '..................................................... 55-56 APPENDIX F - PACKAGING AND SHIPPING............................................ 57-.53 APPENDIX G - MATERIAL BALANCE..........................................................39-41 APPENDIX H - ATMOSPHERIC DISCHARGE AND . :................... .... . . M2 WASTE DISPOSAL APPENDIX I - PROCESS CONTROL PROCEDURES...................................... 43 APPENDIX J - SAFETY AND TOXICITY DATA................................. . .44 APPENDIX K - BACKGROUND.............................................. .... .51 APPENDIX L - TIME CYCLES......................................................................52 ( APPENDIX M - QUALITY CONSIDERATIONS......................................... .53-59 APPENDIX N - MISCELLANEOUS................................................................. 6.O-63 COMPANY CONFIDENTIAL TRAN 009207 HARTOLDMONO010481 AROCLOR SECTION I SYNOPSIS OF PROCESS Aroclor Is a trade name used to designate chlorination products of biphenyl, biphenyl high boilers, or mixtures of the two. Liquid Aroclors are produced by chlorinating biphenyl to 21, 52, 42, 48, 54, 6o, and 62# chlorine content. Chlorination above 65# yields a solid product at normal temperatures. Liquid Aroclors are identlfie< by four digit numbers: The last two digit numbers represent the chlorine content (percentage by weight), and the first two numbers represent the Aroclor condition (crude or distilled). Crude Aroclor! start with the prefix 11 whereas distilled Aroclors start with the prefix 12. For example, Aroclor 1242 is a distilled chlorinated biphenyl containing 42# chlorine. The first process step in the manufacture of Aroclors is a chlorina tion reaction. Biphenyl ( 0-0) and chlorine (Clg) gas in the presence of a Ferric Chloride (Feds) catalyst are reacted to form a chlorinated aromatic compound. Hydrogen chloride (HC1) gas is liberated during this reaction and piped to the muriatic acid department. The exact chemistry of biphenyl chlorination is unknown. Many isomers are formed. A schematic representation of biphenyl chlorination is as follows: n varies 5.05 120-170C. n Clg FeCli_ _ " win HUB-------- BIPHENYL M.W. = 154 CHLORINE M.W. - 71 Btu . AROCLOR HYDROGEN M.W.=(257-1- CHLORIDE 595.6) M.W. = 56.5 COMPANY CONFIDENTIAL TRAN 009208 HARTOLDMONO010482 -..fl Dept. 246 - Process Description 2 AROCLOR SECTION I SYNOPSIS OF PROCESS The second process step is the aeration and distillation of the crude Arocior. Dry air is blown through the crude Aroclor for a period of two hours or more. Aeration removes mo6t of the free hydrogen chloride. Distillation of crude Aroclors is done under vacuum auto matically controlled with the controller pre-set between 30 - 50 mm Hg. abs. to obtain the best performance. Distillation of crude Aroclor separates residue* lime, ferric chloride, and tars from the finished product. The third process step includes blending, filtration, and storage of Aroclors. Approximately 0. 1 - 0.2% by weight of Attapulgus earth is added to the distilled Aroclor, The mixture is agitated and filtered to the finished product tank. The purpose of the Attapulgus earth is to absorb moisture and chloride ion to improve the electrical properties of the Aroclor. During the filtration of distilled Aroclor, 2-16 oz. samples of the finished product are taken to the laboratory for control analyses. If the control analyses pass specifications, the batch is transferred to a storage tank. This process description will describe the production of Aroclors 1242, 1248, 1254, 1260, 1254 Kylene mix, and 1262. , COMPANY CONFIDENTIAL TR4N 00,2' HARTOLDMONO010483 Dept. 246 Process Description AROGLOR SECTION II FLOW SHEETS This section contains the following flow sheets. 1. Complete process flow sheet. 2. Chlorination Reaction Step 3. Aeration and Distillation 4. Blending, Filtration and Storage. COMPANY CONFIDENTIAL TRAN 009210 HARTOLDMONO010484 C H LO R IN ATIO N STEP vf HARTOLDMONO010485 Yf COMPANY CONFIDENTIAL TRAN 009212 HARTOLDMON0010486 I ( < HARTOLDMONO010487 i Dept. 246 - Process Description ^. I AROCLOR SECTION III PROCESS IN DETAIL A. Nomenclature and Batch Data Aroclor is a trade name used to designate chlorination products of biphenyl, biphenyl high boilers, or a mixture of the two. The physical properties vary from light free flowing liquids to crystalline and non crystalline solids, depending upon the degree of chlorination and the composition of the raw materials. Chlorinated biphenyl yields a liquid product of increasing viscosity up to and including 63% chlorine. Chlo rination above 63% yields a solid product at normal temperatures. A numerical system of nomenclature, consisting of four digits, has been developed for identifying the various Aroclors. The first digit denotes the aromatic raw material used in the chlorination step. The figure 1-----indicates 100% technical grade biphenyl. The second digit denotes whether or not the product is distilled. The figure -1 - - indicates undistilled product, and the figure - 2- - indicates a distilled product. The last two digits of the nomenclature system denote the approximate percent age by weight of chlorine contained in the finished product. For example, Aroclor 1242 is a distilled chlorinated biphenyl containing 42% chlorine. Manufacture of all liquid Aroclors is essentially the same. Batch data are listed below: Type Aroclor 1242 1248 1254 1260 1262 Biphenyl Charge 4000# 4000# 4000# 4000# 4000# Chlorination Time 10 - 12 hr. 10-12 hr. 14-17 hr. 16-20 hr. 16-22 hr. Specific Gravity of Crude 1.349-58 1.408-18 1.498-508 1.558-69 1.580-90 at 65*C at 65*C at 65*C at 90"C at 90eC Weight of Crude Batch . 6670# 7580# 8450# 9600# 10,600# Weight of Distilled Batch 6330# 7200# 8040# 9100# 9850# Tons of 100% by-product HC1 per Batch 1.24 1.43 2.27 2.47 2.70 Theoretical Molecular Weight 257.7 292.6 326.6 369.5 395. 6 \ COMPANY CONFIDENTIAL tran 009214 HARTOLDMONO010488 Dept, 246 - Process Description AROCLOR 5. SECTION III PROCESS IN DETAIL B. Chlorination Reaction Step Chlorination of biphenyl is the only process step where a chemical reaction takes place , All other Aroclor process operations are mechanical. The starting raw materials for Aroclor production are biphenyl and chlorine gas. Biphenyl is received in 8, 000 and 10, 000 gallon tank cars from Anniston, Alabama. The biphenyl in the tank cars iB a solid mass because the crystallizing point of biphenyl is .68. 7 *C. Steam must be applied to the tank car coils to melt the biphenyl. It is necessary to melt a vent hole through the solid mass of biphenyl by insertion oC a hairpin steam coil through the tank car dome before applying steam to the tank car coils. The vent hole avoids a pressure build-up in the bottom of the tank car and possible damage to the car. When the biphenyl is completely melted, it is sampled for crystallizing point and moisture content and unloaded through the tank car standpipe by air pressure to the 25,000 gallon storage tank. Dry air is used to unload the biphenyl cars to keep the biphenyl free from moisture. The flash point of biphenyl is 112 *C. Chlorine gas is received in a 4 inch pipeline from the chlorine depart ment. In order to facilitate operation of the chlorine liquefaction system, "sniff gas with a purity of 75-95% (the remainder being air) is transferred from the chlorine department. The normal pressure of the chlorine gas in Department 246 is 20-25 psig. Biphenyl (4000#) is charged into each chlorinator from the measuring tank. The biphenyl charge in the measuring tank can be regulated by valves at different overflow levels. The fotir overflow levels on the measuring tank permit biphenyl charges of 1800, 2800, 3600, and 4000 pounds. The measuring tank is equipped with an agitator and circulating pump. Two pounds of ferric chloride (0,05% of charge) are charged into the measuring tank for each batch. The charge from the measuring tank ' is pumped through the circulating line to the chlorinators. Chlorination is carried out in five chlorinat'ors . Each chlorinator is three feet in diameter by sixteen feet high, and constructed of steel. Each chlorinator has a catalyst bed which is 2* 3" in diameter by 8 feet high. The catalyst bed consists of 1 1/2 inch diameter by 2 inches long pieces of pipe which are similar in nature to raachig rings. The biphenyl charge is heated to 120*C, or higher before chlorination is started. After charging the chlorinator, circulation of the charge is started before the chlorine feed is begun to maintain an even distribution of the ferric chloride catalyst. COMPANY CONFIDENTIAL TRAM 009215 HARTOLDMON0010489 I Dept. 246 - Process Description ^ AROCLOR SECTION III PROCESS IN DETAIL B. Chlorine ga6 from the chlorine department passes through a Brink mist eliminator and evaporator before entering the chlorinator. The . mist eliminator removes most of the impurities, and the vaporator insures that all of the chlorine is gaseous. The purified chlorine gas is admitted to the bottom of the chlorinator through a distributor plate Qsparger) and passes through the catalyst bed. A chlorinator temperature less than 170*C. should be maintained during the chlorination reaction to avoid sublimation and subsequent condensation of biphenyl in the off-gas system. Each chlorinator is equipped with a Brink mist eliminator. The purpose of the off-gas mist eliminators is to trap entrained particles of Aroclor and biphenyl. The chlorination temperature in the chlorinators is controlled by auto matic chlorine gas flow regulation to hold the temperature within + 5*C, The chlorination temperature must be at least 120*C, at the beginning of the batch and no more than 170*C. to finish off a batch. The normal batch temperature is 150*C, The louvers of the aii-cooled heat exchanger located in the external circulating line of the chlorinator are positioned ( such that the batch temperature will remain between 120*C. and 170C. The exact batch temperature will depend on the chlorine flow rate which will fluctuate to maintain a batch temperature of 150*C, The louver adjustment is manually controlled by a hand valve located in the control room. The temperature of the batch is recorded at four different points: (1) in the center of the chlorinator, (2) just above the chlorine sparger in the chlorinator, (3) at the discharge of the chlorinator pump, and ^ (4) at the discharge of the air-cooled heat exchanger. Point 1 is alarmed for high temperatures, and point 4 is alarmed for low temperatures. As a safety device, a high temperature sensing element is positioned at point 2 to shut off the chlorine gas flow if the reaction temperature exceeds 190`C. COMPANY CONFIDENTIAL The batches are continuously circulated at an average flow rate of 200-220 GPM from the bottom of the chlorinator, up through the air-cooled heat exchanger, and back into the top of the chlorinator over the catalyst bed. Chlorine feed up to a maximum of 1500 pounds per hour is fed into each chlorinator through a flow recorder-integrator which is alarmed. The zero return Integrator measures the total amount of chlorine gas flow per batch at any given time and will shut off the gas flow when the desired pre-set pounds of chlorine has entered the reactor. The average chlorine feed rate is 1000 pounds per hour. Progress of the chlorination reaction is checked periodically as needed after a pre-set amount of chlorine gas as measured by the recorder-integrator passes into the chlorinator. The degree of chlorination is measured by determining the specific gravity of a sample taken from the circulating line. More frequent gravity checks are made when approaching the end of chlorination. TRAN 009216 HARTOLDMONO010490 fc Dept. 246 - Process Description AROCLOR SECTION III PROCESS IN DETAIL C. Aeration and Distillation When chlorination 1b complete, the crude Aroclor 1b pumped into number two blow tank (Capacity 2000 gallons). The crude Aroclor Is aerated in the #2 blow tank for two hours or more with dry air. Aeration of crude Aroclor removes most of the free hydrogen chloride. Crude aerated Aroclor is tonesferred from the #2 blow tank to the jfi blow tank. The #1 blow tank is used as a crude Aroclor feed tank to the stills. Crude aerated Aroclor Is transferred from the #1 blow tank to vacuum stills through an automatic control valve which maintains a constant level In the stills. Under normal conditions the automatic feed to the stills Is shut off after distilling about 75,000 pounds of Aroclor. (This is equivalent to filling 7 still receivers). The still is then boiled down until a temperature 0 difference between the still coil inlet and outlet approaches 40 C. At this point distillation is discontinued and all but a small heel of the residue is drawn off to drums and discarded or sold as Montar. The still 1b Immediately recharged with crude Aroclor and 200 pounds of lime is added directly to the still pot. Hydrated lime is received in 50 pound bags. The lime neutralizes any residual HC1 in the still liquor and prevents sublimation of ferric chloride during the distillation period. Distillation of Aroclors is done under vacuum automatically controlled. The best performance is obtained at a steady vacuum which can be pre-set by a controller between 50-50 mm Hg. Abs. Natural gas is used to heat the coil of the Aroclor still furnaces. The pressure of the gas burner (eclipse, st. 108.5, 2", #568, 600,00( BTU/lir.) is adjusted as needed for production requirements. The normal gas pressure is 2-3 psig. . D. Blending, Filtration, and Storage When the still receiver is filled, the distilled Aroclor is pumped tc the blend tank (2000 gallon capacity). After two fillings of the receiver tank have been pumped to the blend tank, approximately 4o pounds of attapulgus earth is added to the distilled 1242 Aroclor. All other Aroclors are earth-treated with 20 pounds of Attapulgus earth. Regular Attapulgus earth is received in 50 pound bags. The mixture is agitated and filtered to the finished product tank (2000 gallon capacity) through a 36 inch stainless steel Sparkler Filter. The Attapulgus earth is roasted at 250C. for a minimum of four houn in a Orieve-Hendry drying oven before addition to the blend tank. The purpose of earth heat treatment is to remove any moisture in the earth and activate it. The Attapulgus earth absorbs water and . ionic impurities. This improves the electrical-quality properties o the Aroclor. COMPANY CONFIDENTIAL TRAN 009217 HARTOLDMONO010491 I Dept. 246 - Process Description 0. AROCLOR SECTION III PROCESS IN DETAIL D. Blending, Filtration, and Storage (Cont'd, ) The filter press is cleaned after about 5-7 batches or as needed. During the filtration, 2-16 os. samples are taken to the laboratory for control analyses. If the control analyses pass specifications, the batch is trans ferred from the product tank to a storage tank. After several batches have accumulated in the storage tank, the contents of the tank are mixed, and composite samples are taken for lot analyses. Three underground (15,000 gallon) tanks and five above - surface (each 20,000 gallons) are available for storage of the finished products. The blend tanks, finished product tanks, and Aroclor 1242 and 1254 storage tanks are blanketed with nitrogen. The pressure of the nitrogen gas is 10 psig. Nitrogen blanketing maintains the electrical properties of the Aroclors. 'The Aroclors from the storage tanks are drummed, 'pumped to tank cars, pumped to tank trucks, or transferred to Department A1-246 orB-246' mixing tanks for the production' of PyranolB, Interteens, or Pydraul A-200. Batches of Aroclor 1254-mix are mixed in the #1 blend tank. This opera tion consists of a mijt of 10% xylene, and 90% Aroclor 1254. Xylene is received in 55 gallon drums, The flash point of xylene is 85 *F. Mixing, sampling and drumming of 1254-mix is accomplished directly from the blend tanks. After the blending operation, the blend tank must be cleaned. The bottom outlet of the tank is opened and the tank is cleaned out with live steam and then blown with air, E. By-product Hydrogen Chloride The by-product hydrogen from the chlorinators is collected in a common pipeline header and flows to the central HC1 absorption unit to manufacture Muriatic Acid in Department F-218. If Department F-218 is unable to handle the off-gas, it may be sewered at Department 248 by passing through a Haveg S-K drowning jet. The removal of HC1 from the off-gas concentrates the original quantity of hydrogen and air to a point well with in the explosive limit. Therefore, it is essential to either dilute thi-p gas going up the vent stack or increase its velocity past the flame propogation rate (15 ft. /sec.). This is accomplished by introducing a sufficient quantity of steam into the vent stack. ( TRAN 009218 HARTOLDMONO010492 Dept, 246 AROCLOR Process Description 9. SECTION IV COMMENTS ON PROCESS CHLORINATION STEP A . Ra w Material Yields Biphenyl and chlorine are reacted to form a chlorinated biphenyl called Aroclor, The yields on biphenyl and chlorine vary with the type of Aroclors produced. Each particular type of Aroclor has its own standard yield factors. Yields are not reported for the individual type on Aroclor each month. An average yield i6 reported monthly and compared with standard and theoretical yields which are calculated according to the quantities of the various ArocloTs produced during the month. Standard and theoretical conversion factors used in computing Chlorine and biphenyl yields are listed below. STANDARD CONVERSION FACTORS AROCLOR CHLORINE H/ff Product BIPHENYL H/ff Product 1242 1248 1254 1260 1262 1232 1254 Xylene . 9032 1.0323 1.6130 1.2903 1.3333 0.6882 1.0452 0. 6180 0. 5580 0.4978 0.4368 . 0.4163 0. 7216 . 0.4480 THEORETICAL CONVERSION FACTORS AROCLOR CHLORINE #/ # Product BIPHENYL #/ ff Product 1132 - 1232 1142 - 1242 1148 - 1248 1154 - 1254 1160 - 1260 1162 - 1262 1254 - 10% Xylene 0.6400 0.840Q 0. 9600 1.0800 1,2000 1.2400 0.9720 0.6891 0.5919 0.5357 . . . 0.4754 0.4147 0.3976 0.4279 COMPANY CONFIDENTIAL TRAN 09219 HARTOLDMONO010493 Dept, 246 - Process Description 10. AROCLOR SECTION IV COMMENTS ON PROCESS CHLORINATION STEP B. Capacity The monthly production capacity of Department 246 is 1,700,000 pounds (2, 400, 000 pounds is expected by August 1, 1964) of Aroclors on a 7 day per week basis. The capacity of the chlorinators is a function of the following variables. 1. Batch Cooling Rate - Chlorination of biphenyl is an exothermic reaction which produces 510 BTUS per pound of chlorine gas under going a reaction with biphenyl. Biphenyl can be chlorinated as fast as the exothermic heat can be removed from the batch and maintain a batch temperature of 150C. 2. Chlorine Flow Rate - the reaction time decreases as the Chlorine ftow rate increases. The chlorine flow Tate is approximately 1000 pounds per hour per chlorinator. A maximum chlorine flow rate of 1500 pounds per hour per chlorinator can be attained if desired. The concentration of chlorine in the "snift11 gas is another factor control ling the rate of chlorination. 3. Catalyst - The chlorination rate increases when ferric chloride catalyst i6 added to the charge. The best results are obtained when the biphenyl charge contains .05% ferric chloride catalyst. C. Quality Some of the factors which affect Aroclor quality are as follows: 1. Temperature - According to research experimental results, the chlorinator temperature must be greater than 120C. at the beginning of the chlorination reaction to produce stable Aroclors. 2. Catalyst - Good contact is necessary to produce stable Aroclors, It is suspected that agitation and circulation of the reactants improve the effectiveness of the catalyst, The catalyst is also responsible for the chlorine positioning on the biphenyl molecule. Ferric chloride catalyst may be responsible for producing the desired end product. Results of research work concerning catalyst and isomeric distribution are given in Appendix N. TRAN 009220 HARTOLDMONO010494 i Dept, 246 - Process Description 11. AROCLOR SECTION IV COMMENTS ON PROCESS CHLORINATION STEP C. Quality (Cont'd.) 3, Raw Material Purity - The purity of raw materials can affect the quality of Aroclors both directly and indirectly. In a direct manner, impurities which are ionic lessen the resistivity of Aroclors, Dis tillation of crude Aroclor separates most of the ionic impurities; however, minute impurities can be carried over to the receiver tanks. Attapulgus earth can remove the remaining impurities in most instances. If any ionic impurities remain after the earth treatment, the resistivity of the Aroclors will be low because such impurities will conduct electricity even in minute concentrations. In an indirect sense, impurities such as sulfates in the chlorine gas, will poison the ferric chloride catalyst and thus unstable Aroclors will be produced. The chemistry and mechanism of the catalyst poisoning are not known for certain. AERATION AND DISTILLATION Steam is not applied to the coils of the blow tanks when aerating Aroclors 1142 and 1148. This prevents the loss of Aroclor vapors. Eighty.psig steam is applied to the coils when aerating other Aroclors. High moisture may be removed effectively by blowing the crude Aroclor with dry air. Vacuum trouble on the Btills is usually caused by flashing of product, air leaks, plugged vacuum lines, or improper functioning of the vacuum jets. Flashing can usually be stopped by operating the still at a slower rate or increasing the flow of cooling water to the vapor condenser. Vacuum trouble can be traced systematically from the jets and usually ieolated. High color and entrainment will result from overheating (around 25 C. . above normal distillation temperature) Aroclor, faulty operation of the distillation step, or boiling down the still too far. (Tare will carry over). The "tail - end" still fraction (tars) is a possible source of unstable Aroclors. COMPANY CONFIDENTIAL TRAN 009221 HARTOLDMONO010495 AROCLOR SECTION IV COMMENTS ON PROCESS BLENDING AND FILTRATION Attapulgus Earth is added in the blend tanks to reduce moisture and inorganic chlorides as well ae improve electrical properties. If batches do not meet specification (See Appendix B), redistillation may be necessary. The Attapulgus Earth is roasted for 4 hours at 250 C. before addition to the blend tanks. TRAN 009222 HARTOLDMONO010496 Dept, 246 Process Deacription f AROCLOR APPENDIX A 12. EQUIPMENT LIST This section contains an equipment list with each piece of equipment listed by Item Numbers in a consecutive numerical sequence. Miscellaneous items of Dept. 246 such as Instruments have not been assigned Item Num bers. Equipment without Item Numbers is not included in this equipment list. All equipment of Dept. 246 will have Item Numbers assigned some time in the future. This equipment list should be expanded as additional Item Numbers are assigned. Item No, Equipment Name_________ Equipment Number De script ion 101 BiphenylTransfer 19-0582 Pump 66-3930 Taber vertical submerged cent. pump, size C-3, 2 1/2" inlet, 2" outlet. Connection bronze except Bhaft which is monel. Motor is 3 HP, 1800 RPM. 102 Biphenyl Storage 21-2210 Tank ( Tank purchased from Rogers and Wrigler, Capacity is 25, 000 gallons. 10" 6" DIA x 40' 6" long. 3/8" plate shell. Design pressure is 50 psi. 103 Biphenyl Head 21-0767 Tank 16-7225 Tank made by Graver. Dwg. C-799. Steel tank 4' 6" ID x 5' 6" str, side, dished heads, shell 3/8", top head 3/8", and bottom head 3/4" with 1/2" jacket over it and ending 9" up on ' tank side. Welded throughout. Test of tank is 60# and jacket is 105# hydro, pressure. Mixer is Mixco Model N33G75, gear driven propeller. Motor is 440/3/60 TEFC, 1725 RPM. 104 Biphenyl Feed 66-7224 DurcoHoriz. Cent! pump. 2" inlet, 2" outlet. Cap. 100 GPM Motor is 7 1/2 HP, 1760 RPM 105 Chlorinator #1 21-3261 ( 106 Chlorinator #2 21 -3245 Tank made by Nooter. Dwg. E-880 3' ID x 16' long with pig. head. Shell 3/8" and head 7/16" thick, 3/16" jacket over lower half of tank. Same as Item No. 105, COMPANY CONFIDENTIAL TRAN 009223 HARTOLDMONO010497 I Dept. 246 - Process Description 14. AROCLOR APPENDIX A EQUIPMENT LIST (Cont'd.) Item No. Equipment Name Equipment Number Description 107 Chlorinator 21-5251 Tank made by Leader Iron Works. Otherwise, same as Item No. 105. 108 Chlorinator 21-1285 Same as Item No. 107. 109 Chlorinator 21-1452 Same as Item No, 107 110 #1 Mist 15-0581 Eliminator 111 #2 Mist 15-0582 Eliminator 112 #5 Mist 15-0585 Eliminator 115 #4 Mist 15-0584 Eliminator 114 #5 Mist 15-0586 Eliminator 115 Chlorine 21-4042 Mist Eliminator 116 Chlorine . 58-5487 Vaporizer 120 Knockout 121 Chlorinator 19-4505 #1 Pump 66-8109 Tank made of carbon steel. Element made of carbon steel. Design pressure is 50 pslg. and design temperature is 5005F. Same as Item No, 110. Same as Item No. 110. Same as Item No. 110, Same as Item No. 110. Tank made by Alpha. Carbon steel construction. Coded tank. Element 516. stainless steel. 15" Dia, glass fiber inverted type. Design pressure is 50 pslg and design temperature is 500F. Chlorine vaporizer made by Armstrong Company. 8 5/8" OD x 11* long. Carbon steel construction. Chlorine side designed for 250 psig. at 400F. Steam side designed for 100 psig at 400F. Steel vertical 60 gal. tank. Durco Mark II horiz. cent. pump. Inlet is 5" and outlet is 2", ductile iron, with Durametallic seal and Manzel lubricator. Rate is 200 GPM at 25' static head Sp. Or. of 1.5. Motor is 10 HP, 1800 RPM. COMPANY CONFIDENTIAL TRAN 009224 HARTOLDMONO010498 I Dept. 246 - Process Description 15. AROCLOR APPENDIX A EQUIPMENT LIST (Cont' d.) Item Equipment No. Name Equipment Number Description 122 Chlorinator 19-4506 #2 Pump 66-8110 Same as Item No. 121. 12? Chlorinator 19-4507 #5 Pump 66-8111 Same as Item No. 121. 124 Chlorinator 19-4508 #4 Pump 66-8112 Same as Item No. 121. 125 Chlorinator 69-5892 #5 Pump 66-6509 . Same as Item No.121. 126 Blow Tank 21-2086 #2 Tank made by Graver. Dwg. E-865. 71 Di x 7' str. sides, dished heads 1/2", Shell 5/8", 5 turn coll of 2" pipe sup ported on brackets welded. 127 Blow Tank 66-2956 #2 Pump 69-0577 Taber horiz. cent. pump. Type L-2. 2f" x 2". Semi-steel with monel shaft and water Jacketed stuffing box. At 20' static head, rate is 80 GPM, 1.5 Sp. Or. at 500P. Motor is 5 HP, l800 RPM. 128 Air Dryer 14-0104 Anders Lykens Corp. Air dehydrator. Two code welded tanks filled with 55 to activated alumina. Dwg. >6456. 129 Blow Tank 19-0629 #1 Pump 66-9080 Same as Item No. 127. 150 Still #1 20-0045 .1 Vacuum still purchased from Graver. Dwg. C-809. Size 6' Dia. x 5'6" Ig. on str. side, shell, dished head 5/8". 60# hydro, pressure test. 151 Furnace #1 27-0045 Steel heater furnace. Steel shell 5/l( x 5'9" Dia, x 4' 10" lg. lined with insulating fire brick. One coil 2" xH: pipe, 12 turns formed into a 2' Dia coil with spare blocks and legs. Dwg. E-886, 152 Still $1 Pump 19-0594 66-4891 COMPANY CONFIDENTIAL Taber vert. sub. cent. pump, type L-2. Casing, yoke, and Impeller made of steel. 2" inlet and 2" outlet. Length I 7 a. o ( 7 ui m f v v\* *>-'* 15', Sp. Or. 1.8 at 700F. Motor is 5 HP., 1750 RPM. TRAN 009225 HARTOLDMONO010499 i 10. Dept, 246 - Process Description 1 AROCLOR_____ APPENDIX A EQUIPMENT LIST (Cont'd, ) Item No, 133 Equipment Name Still n Equipment Numbe r 20-0062 De ecription Vacuum still purchased from Noote r Dwg, 6944. 6' ID x 11' 10" str. shell, internal pipes, standard dished heads. Glass wool insulation 3" with 1/2" finished coat. 134 Furna ce #2 20-0066 Same as Item No. 131. 135 stiii n Pump 66-1759 69-1277 Taber vertical sub. cent, pump. Type CL-4, 2 1/2 X 2", size 384. Pump is dynamo steel. Capacity is 75 GPM at 25' static head, Sp. Gr. 1.8. Motor is 7 1/2 HP, 1750 RPM, 136 Condenser HI 38-0770 Heat exchanger made by Nooter. Dwg. B-651. 12" DIA 5' long having nineteen 2" O. D. 11 ga. monel tubes, monel tube sheets, monel reducer, and carbon steel jacket and back up rings on flanges 137 Condenser HZ 38-1378 Same as Item No. 136. HI138 Receiver Tank 21-0771 Vacuum receiver tank made by Nooter. Dwg. C-795. Size i6 5' 6" DIA x 5' 6" str. side, 3/8" shell, 1/2" bottom and removable head. 2" IP, size xHy monel coil with 2" inlet and 1" outlet. 3 turns, 5' DIA along side and 3 turns Hspiral on bottom. 60 hydro, pressure Htest on tank and 300 on coil. 139 Receiver Tank #2 21-1377 Tank made by Nooter. Dwg. C-795. Same as Item No. 138. HI140 Receiver Pump 66-9067 Blackmer pump. Type PA-50L, bronze 69-0565 rotary pump, monel shaft, C.l. base. Capacity is 50 GPM, 1,65 Sp. Gr. , 350 to 500 *F. Motor is 2 HP, 1740 RPM. 141 Receiver Pump #2 66-5670 Same as Item No. 140. 69-1258 COMPANY CONFIDENTIAL TRAN 009226 HARTOLDMONO010500 -..ft Dept, 246 - Process Description 17. AROCLOR ( APPENDIX A EQUIPMENT LIST (Cont'd.) Item No. Equipment Name Equipment Number _______ Description 142 Blend Tank 21-0779 #1 Tank made by Graver, Dwg. E-862. Welded steel tank, 7' Dia. x 7' high, dished heads shell 5/8", All sur faces sprayed with .005" zinc then .005 tin. 2" xHy pipe coll and supports. Cape bronze stirrer and bronze shaft. Test of tank Is 60# and coll is 500# hydro, pressure. 143 Blend Tank 21-1399 #2 66-0217 Same as Item No. 142. 144 Blend Tank 19-1757 Pump 66-3718 Taber Horiz. Centrifugal pump. 304 s.s. 2" x l" capacity 60 GPM, 100' head. Motor is 10.0 HP, 1800 RPM. 145 36" Sparkler 15-0238 Filter ( 146 Finished Product Tank #1 21-0780 Filter made by Sparkler Mfg. Co., 33-D12 horizontal plate filter. Type 504 s.s. Jaoket tested for pressure of 50 psi. Filtrate receiver tank. Dwg. E-862. Same as Item No. 142. 147 Finished Product Tank #2. 21-1400 Tank made by Nooter. Otherwise, same as Item No. 142. 140 Storage Tank #3 21-0768 Tank made by Graver. Dwg. C-609. Horizontal steel, 10' Dia. x 2o' long on str. side, dished heads, Bhell head 9/16". Test of tank is 60# and coil is 500# hydro, pressure. All coils, supports, inside surface sprayer with ,005" zinc and .005" tin. 149 Storage Transfer Pump #3 19-0585 66-0853 Taber Vert. Sub. pump. Dwg. A-587. Type C-5> 2" x 2", C.I. body, length 11'6". Cap. 50 GPM, 60' static head, Sp. Gr. 1,18 at 170F. Motor is 5 HP, 1800 RPM. 150 Storage 21-0769 / Tank $4 Same as Item No. 148. 151 Storage Transfer Pump #4 19-0584 66-1501 Taber Vert. Sub. Pump. Type L-2. 2" 2". Length 11'6". Cap 50 GPM at 40' static head. Motor is 3 HP, 1800 RPM COMPANY CONFIDENTIAL TRAN 009227 HARTOLDMONO010501 t Dept. 246 - Process Description AROCLOR 18. APPENDIX A EQUIPMENT LIST (Cont' d. ) Item Equipment No, Name Equipment Number Description 152 Storage Tank #5 21-1510 Tank made by Leader Iron Works. Dwg. C-609. 10' OD x 26' Long on str, she Same as Item No. 148 for other characteristics. 155 Storage Transfer Pump #5 19-0Q29 66-O856 Same as Item No. 151, except length 1 4'7". 154 Storage Tank #8 21-5526 Alpha tank 12'6" Dia. x 22' high. 20,000 gallon storage capacity. Aluminum constructed Dwg. TS-D-5011. 155 Storage Transfer Pump #8 19-5172 66-2651 Durco pump, model WH2 Alloy constr. 2 x l", 8" impeller. Cap. 160 QPM at 55' head. Motor is 7$ HP, 1740 RPM, 156 Storage Tank ffj 21-2404 Slpha tanlc. 15' O.D. x 20' high. Vertical tank, constructed of 5/8" mi steel. Capacity is 20,000 gallons. 157 Storage Transfer Pump in 19-2077 66-1691 Pump made by Blackmer. Monel shaft, 2#" x 2i". Cap. 90 QPM, 15' head. Motor is 5 HP, 1750 RPM. 158 Scales 24-0246 24-0187 Made by Toledo Scale Co. 800# capacit; dial type scale. 167 Blow Tank 21-0750 #1 Tank made by graver. Dwg. E-865. 7' Dia. x 7' str. side, dished heads f", shell 5/8". 5 turn coil of 2" xHY pip? 169 Surge Tank 22-0751 Cyclone collector made by Graver. Dwg. B-695. 48" Dia. x 27" on str. side, 5' 6" long and tangential inlet near top of side. 5/l6" steel throughout of welded construction. 170 City Water 69-IO85 Pump Hi 66-5565 Taber Horlz. pump, Model CB5, 5" x 22 9" impeller. Cap. 180 GPM, 50' head. Motor is 7i HP, 1800 RPM. 171 City Water 69-2078 Pump HZ 66-1796 Same as Item No. 170 180 Exhaust Blower 11-0265 Made by American Blower Co. Type 450E Capacity is 6408 SCPM at 1510 RPM. Dw< E-10699. Motor is 15 HP. COMPANY CONFIDENTIAL TRAN 009228 HARTOLDMONO010502  Dept. 246 - Prooess Description 19. AROCLOR APPENDIX A EQUIPMENT LIST (Cont'd.) Item No. Equipment Name Equipment Number Description 185 Coke Scrubber #1 21-0756 186 Coke 21-1396 Scrubber $2 Scrubber liquor tank made by Graver. Dwg. C-800. 4'6" Dla. x 5'6t' on Str. Side. Coil 3 turns of l" xHY pipe. Same as Item No. 185, 200 Cyclone Separator 21-1413 Separator made by Helntz Steel. 3' Id 6' high tangential separator with integral vapor pipe complete. 201 Air-cooled Heat tbExchanger 38-5528 Air-cooled heat exchanger made by Dialer. Cooling capacity is 1,200,00( Btu/hr. Steel construction except for aluminum fins, Fan motor is 2 HP, 1150 RPM. 205 Steam Vacuum 55-5525 Jet #1 #2 i Worthington 3*Btage vacuum Jet. 204 Steam Vacuum 35-1686 Jet #2 Same as Item No. 203. 205 Steam Vacuum 55-5555 Jet #5 3-stage porcelain Kubati vacuum eject with 10" ID porcelain condenser. Jet has a capacity of 10#/hr. air at standard conditions. Jet designed for 150# steam and 2 mm Hg absolute. 206 Off-gas Drowning Jet 55-4756 Made by Schutte-Koertig. 8" Haveg fum scrubber. Complete with standard nozzle. 207 Drying Oven 14-0158 210 211 212 215 Air-cooled Heat Ex changer #1 Air-cooled Heat Ex changer #2 Air-cooled Heat Ex changer #3 Air-cooled Heat Ex changer jf4 38-5564 66-8113 H-JSS 38-5566 66-8115 im Grieve Hendry drying oven, 440 V., 3 phase, 60 cycle, manual reset temp. controller range 0-400C. Same as Item No. 201. <C, S- |z Same as Item No. 201. Same as Item No. 201. CL q *5 0 u- OQ q Same as Item No. 201. TRAN 009229 HARTOLDMONO010503 Dept. 246 - process Description 20. AROCLOR APPENDIX A EQUIPMENT LIST (Cont'd.) Item No. Equipment Name Equipment Number Description None Chlorine Pressure Recorder 29-1547 Made by Taylor Instrument Co. Pressure Recorder with 2 pens. Cat. No. X176JF255. Range 0-100 None #5 Chlorinator Flow Recorder 29-2019 Made by Taylor Instrument Co. Flow Recorder - Controller. Cat. No. 157RF155- 12" chart, 0 to 10 Sq. root chart. None Water Meter 29-2486 Made by Worthington Corporatlo 5" model IH turbine type water meter. None #1 Still Tempera ture Recorder 29-5885 Made by Leeds & Northrup Co. Temperature Recorder. Range 0 - 400C. None #1 Still Absolute 29-1170 Pressure Controller Made by Taylor Instrument Co. Absolute pressure Recorder - Controller. None 200# Steam Flow Recorder 29-0855 Made by Bailey Meter Company. Flow .Recorder. None #2 Still Absolute 29-5555 Pressure controller Made by Taylor Instrument Co. Absolute Pressure Recorder Controller. None #2 Still 29-0244 Temperature Recorder Made by Leeds & Northrup Co. 6 point Temperature Recorder. None #2 Still Level Controller 29-1465 Made by Taylor Instrument Co. Liquid Level Recorder - Controller. None Chlorinator 29-0288 Temperature Recorder Made by Leeds & Northrup Co. 12 point Temperature Recorder None #1 Blow Tank 29-2916 Temperature Recorder Made by Taylor Instrument Co. Temperature Recorder Control1< Adjusts 200# steam to #1 Blow Tank Cat. #86 RM45185-12. COMPANY CONFIDENTIAL TRAN 009230 HARTOLDMONO010504 Dept. 2^6 - Process Description 21. AROCLOR APPENDIX A Item No. Equipment Name None 80# Steam Plow Recorder None 200# Steam Flow Recorder EQUIPMENT LIST (Cont'd.) Equipment Number______ Description 29-5452 Made by Foxboro Company. Type T57, recording flow meter with integrator and indicator., Meter body 516 S.S. Integrator for 80#, 400F. Steam. 29-5455 Made by Foxboro Company. Type T57 Recording Flow meter with integrator and indicator. Meter body 516 S.S. Integrato for 200#, 510F. Steam. COMPANY CONFIDENTIAL TRAN 009231 HARTOLDMONO010505 Vf' ' Dept. 246 - Process Description AROCLOR APPENDIX B SPECIFICATIONS The folliwlng is a list of the raw materials used for the manufacture of Aroclors. Specification sheets are included w.ere they exist. Material Code Raw Material 82601 ................................. .... ....................... Biphenyl 55500 .............................................................. Ferric Chloride 58800 ..............................................................Lime 19400..............................................................Attapulgus Earth 81059 ..............................................................Chlorine 45099 ..............................................................Nitrogen The following 1b a list of the finished products manufactured in department 246. Specification sneets are included where they exist. product Code Product MCS 295 Aroclor 1254-10# Xylene Aroclor 1252 81101 (Electrical & Non-Electrical) Aroclor 1242 81102 (Electrical & Non-Electrical) Aroclor 1248 81105 (Electrical & Non-Electrical) Aroclor 1254 81105 (Electrical & Non-Electrical) Aroclor 1260 81107 Aroclor 1262 81101-81102 (Mix) 1242 - 1248 Mix ' 82868 Montars 1,2,5and 4. COMPANY { confidential TRAN 009232 HARTOLDMONO010506 MONSANTO CHEMICAL COMPANY OROAttIC CHEMICALS DIVISION *-a'NmmiRun SPECIFICATION MATERIAL DI PHENYL (BIPHENYL) CHEMICAL FORMULA (material cool 82601 USINO DEPTS. 246 SUPPLIER ANNISTON PLANT t Issued 6/9/61 W.O.Krummrlch Plant By <P, In MOL WT. 1 54 20 SUPERSEDES SPECS OP 4/6/51 SAMPLE POR ANALYSIS 2 x l6 oz. W.M.Bottles UNRESTRICTED INFORMATION Routine Tests Property Appearance and Color Crystallizing Point GENERAL INFORMATION Distillation Range: First Drop to Dry Point Specification Light Yellow Cryst. Solid 68.7C, min. 2.5C, max. Must include 255*0 within Range Method Number 10,252 10,298 10,299 e1 This specification is the property of Monsanto Chemical Company and is for Internal use only. ___________ __ ' IN SS (REV. It/tSI COMPANY CONFIDENTIAL TRAN 009233 HARTOLDMONO010507 MONSANTO CHEMICAL COMPANY ORGANIC CHEMICALS DIVISION W. G. Krummrlch Plant FINISHED PRODUCT SPECIFICATION PRODUCT COOK 81059 U8H Internal SALKS CODE OENT. OR JOS 252 PROOUCT (Trade Nmc) Chlorine (Snift QasJ. PRODUCT (Chemical time) TTPE TYPE CHEMICAL FORMULA Mixture MOL WT. New MMPLI FOR ANALYSIS 100 c,c. Gas Burette iBsued DEC 23 TO W. Gw Krummrlch Plant By- " * ^)' __ RAW IV; A 1 L;R;.\L Date ApprovedPEC 2 3 1963 For Dept UNCLASSIFIED INFORMATION General Tests (made only on request) Property Typical Analyses Chlorine (Cl2) 86$ By Volume Oxygen (02) Carbon Dioxide (C02) Carbon Monoxide (CO) Hydrogen (H2) 5$ " 1.5$ " 0.1$ " 1.0$ " " " " " Inert Gases (By difference) 8.4$ " MoiBture @ Std. Conditions 2.4 ^A10~s Wera ./ft.s Direct pipeline transfers to using Depts. 2??, 256, 257, 246 This specification is for internal use at WGK Plant only. Method 'Number m IN 84 IREV. tft/SSI COMPANY CONFIDENTIAL TRAN 009234 HARTOLDMONO010508 1 UNCLASSIFIED INFORMATION General Teats (made only on request) Property Specification Appearance Fine white or slightly gray powder, free from lumps or gritty material Assay (Ca(OH)t) 92,00#, min. Carbonates as (CaGOe) 5.00#, max. Magnesium 0,50#, max. Sulfates (as SO*) . 0,50#, max. Method Number 10,188 10,191 10,19? 10,192 10,189 ni*m (MV. W/W *85^ I TRAN 009235 HARTOLDMONO010509 UNRESTRICTED INFORMATION General Tests (made only on request) Property Specification Appearance Black pov.de r or granules ABBay 97.O56, min. Sulfates 0.05^6, max. Ferrous Salts Trace, max. Solubility: 10:10 of Water Complete to slightly turbid, max. 10:10 of Formula 50 ale ohol Complete to slightly turbid, max. J.F .Q. Method, No . l6-A 22-570 120-570 S-570-1 112-J3 CD IN * (MU. (/>) COMPANY CONFIDENTIAL TRAN 009236 HARTOLDMONO010510 UNRESTRICTED'INFORMATION Routine Teats Property , Volatile Matter (at 950c) ^.et : " . . ; iT,hrouh USS ?25 ' ;. Specification 6> 8^ 90# win. Method Number V - '-'V- This material 1b not aoobpted without the supplierb analyslB of the above properties, ; ' fTl m m my. m/mi COMPANY CONFIDENTIAL. TRAN 009237 HARTOLDMON0010511 MONSANTO CHEMICAL COMPANY PRODUCT CODE 81115 OROANIC CHEMICALS DIVISION W. Q. Krummrich Plan use ' Internal FINISHED PRODUCT ALCtCODE SPECIFICATION DEFT. OR JOB ____ 2M__________ J.F.G, issued W. APR PRODUCT (Tr*4 Nam*) Aroclor PRODUCT (Chtaileat 1232 TYPE (MCS - 236)____________ T TP E 32$ Chlorinated Biphenyl CHEMICAL FORMULA 7 1964 "filan MOL W7. New ' SAMPLE FOR ANALYSIS ___________ 2 x 16 oz, w. M. Bottles _______________ Routine Tests Appearance Sp. Gr. @25/15.5C Acid Number Color, APHA H20 General Tests Chlorine Specification Clear Liquid 1.266 - 1.276 0.014 mg. KOH/grm. max. 100, max. 35 ppm., max. 51.5 - 32.5* Method No. 10,114 10,087 10,084 10,620 This specification is for internal use only. m IN 14 (REV. It/M) COMPANY CONFIDENTIAL TRAN 009238 HARTOLDMON0010512 MONSANTO CHEMICAL COMPANY OROAMIC CHIMCALI DIVISION ANNISTON AND KRUMMRICH FINISHED PRODUCT SPECIFICATION PRODUCT (Trmt* AROCLOP 1342 PRODUCT (CtumloMl nm<) product cooe |Mf* opJJlfjniBton 1246 - WOK Issued 1/24/62 use W.Q.Krununrich Plant SALES.................................. .b--y.--E-- .--O-. . Martin ALES CODS 104 0 - I3-0_!lQ 4/l 1 /l6-- 03 /O Q________ TYPE CRUDE COMMERCIAL. TYPE CHEMICAL FORMULA MIXTURE MOL WT. --- SAMPLE FOR ANALYSIS 5/28/58------------------ I Q.t, JBottle Annlatom2x16 o?.. m.m.Bottle WQK UNRESTRICTED INFORMATION Routine TestB Property Specification Method Number Appearance and Color Brown to black oily liquid Anniston --- WQK 10,084 Specific Gravity 25/l5.56C 1.584 - 1.594 14-49-54 10,114 Acid Number (mg. KOH/g.) 0.7, max. 14-46-54 . 11,552 RESTRICTED INFORMATION Acid Number of the crude, which is stored in non-lacquered metal containers shall be 0.2mg. KOH/g. max. fT] IN II IRBV. IS/66) COMPANV CONFIDENTIAL TRAN 009239 HARTOLDMON0010513 MONSANTO CHEMICAL COMPANY OROANIC CHEMICALS DIVISION KRUMMHICH and ANNISTON FINISHED PRODUCT SPECIFICATION 'OTWi'Wk 8261? ANN. __ 27L ANN._____ USE r.o 1 e s BALES CODE 1040-240-04/11/16-05/09 PRODUCT ftVarf Nmtt) . TYPE AROCLOR 1242 ELECTRICAL GRADE (PYRANOL 1499) PROOUCT (Chamleal Nemo) TYPE Issued 4/15/62 W ,G.Krummrich Plant By 0, O, Ttj CHEMICAL FORMULA Mixture MOL WT. " - SUPERSEDES SPECS OP 4/17/61 SAMPLE POR ANALYSIS 5 x 5 pt. Amber Bottles UNRESTRICTED INFORMATION Routine Tests P* ~r o-r->-A--r--fr.'fv Color (APHA) Condition Sp. Or. @ 25/15.5C Acidity (mg. KOH/g.) Moisture (H20) Refractive Index @ 25C Inorganic (Free) Chlorides Pour Point Dielectric Constant (1000 cycles @ 100C) Resistivity (500 VDC @ 100C 0.1" GAP) As OHM-CM x 109 Hydrolysis Stability Test (As Chlorides) Monsanto Stability Test (As Chlorides) Distillation Range (ASTM D-20, Corrected) 10# Distilled by wt. 90# Distilled by wt. Specification 50, max. Clear 1.581-1.592 0.010, max. 55 ppm., max. 1.6240-1.6260 0.05 ppm., max. -l4C or Lower 4.70-4.90 500, min. 1.0 ppm., max. 0.4 ppm., max. >25C, min. 36oC, max. Method Number UAtr nun A t om/'stt /irm loi uiv 10,084 10,084 10,114 10,087 10,620 10,125 T-2092 10,115 11,608 . 14-44-54 G-l 14-49-54 14-42-54 14-53-54 14-34-54 014 14-47-54 14-36-54 11,607 14-35-57 T-2087 11,505 10,117 010 14-61-57 14-31-54 GENERAL TESTS (Made only on request) Sulfates Dielectric Strength @ 25C Flash Point (F) Fire Point Viscosity @ 100F (SUS) Corrosion Test (6 hrs @ 210C with bright aluminum foil) Change in wt. of AL (#) None 12,169 35 KV, min. 11,605 556-592 10,125 None 10,125 82-92 10,086 10,126 COMPANY 0.0 CONFIDENTIAL 045 14-28-54 14-28-54 14-4-52 14-55-57 (Over) TRAN 009240 C7I in >4 (REV. It/M) HARTOLDMON0010514 i A.C. Color (APHA) A.C. Condition A.C. Acidity (mg. KOH/g.) A.C. Inorganic(Free)ChlorideB GENERAL INFORMATION . Specific Heat @ 25C Coefficient of Expansion (25-65C) Fixed Chlorine SPECIAL CUSTOMER REQUIREMENT General Electric Hydrolysis Stability Test (As Chlorides) Thermal Chemical Chlorides 60, max. Clear 0.010, max. 0.05 ppm., max. 0.50 0.00068 cc/C 42.5-45.5* 0.5 ppm., max, 0.75 ppm., max. 10,084 10,084 10,087 T-2092 T-2087 12,722 14-44-54 0-1 14-42-54 014 010 COMPANY CONFIDENTIAL TRAN 009241 HARTOLDMON0010515 I MONSANTO CHEMICAL COMPANY ORO AMIC CHEMICALS DIVISION Krummrlch and Anniston FINISHED PRODUCT SPECIFICATION fAOOUCT (Trm4m Hessac) Aroclor 1248 PRODUCT (Oittmloal Heme) PRODUCT CODE DEPT. OR JOB 81102 - 82641 USE Sales WOK 246-Ann.27 issued JUL 1 5 1984 w. u. Krummrlch Plant By SALES CODE 1040-260-04/ii/i6-05/09 TYFI Non-Electrical Grade TTPH CHEMICAL FORMULA Mixture MOL WT. SAMPLE FOR ANALYSIS ....5-4-61______________________ UNRESTRICTED INFORMATION Routine Tests Appearance Condition Color, APHA Sp. Or. @65/15.5*0 Acidity (mg. KOH/g.) Moisture (HgO) (ppm.) Viscosity @150*F (SUS) General Tests Flash Point (*p) d 1 000 Specification Colorless to light yellow-green liquid Clear 100 max. 1.405 - 1.415 0.010, max. 50, max. WOK Anniston MethodfRo7" 10084 0-1 10084 10084 10114 10087 10620 10086 0-1 046 052 050 047 049 570, min. 10125 14-28-54 COMPANY CONFIDENTIAL TRAN 009242 HARTOLDMON0010516 MONSANTO CHEMICAL COMPANY ntooucT ea 81102 osP$44-'t#QK 27 Ann. Sales @At.SS COM SPECIFICATION 1040-260-04/11/16-05/09 mtOIKT (YM* (Ml - TTP1 Aroolor 1248 Electrical Grade (pyranol 1498) <FM*OUCT (Wmmteml mmo) TVPI jEMBtacAL Pa*ULA Issued l/lO/64 Corrected 2-16-64 ' Mixture Wt. WT. SUPBRSH&et Witt OP 2-12-60 iWU AKAlfnS _____ 5 x 5 Pt. Amber Bottles________________________ ____ UNRESTRICTED INFORMATION Routine Tests Color, APHA Condition Sp. Or. @65/l5.5C Acidity (mg. KOH/gm.) Moisture Refraotive Index @25*C Inorganioe (Free) Chlorides Pour Point Dieleotric Constant (1000 cycles #100C) Resistivity (500 VDC #100#C.0,1M GAP) as OHM-CM x 10* Hydrolysis Stability Test (as Chlorides) Monsanto Stability Test (as Chlorides) IDistillation Range (ASTM D-20, Corrected) lOjg Distilled by Wt. 90* Distilled by Wt. Specification 50, max. Clear 1M0A5 - 1.415 0.05 ppm., max. 0*Cf max. 4.5 - 4.7 500, min. 1,0 ppm., max. 0.5 ppm., max. 545*0, min. 585*C, max, Method No*s WQK Annlsto 10,084 14-44-5 10,084 0-1 10.114 14-49-5 10,087 14-42-5 10,620 14-52-5 10,125 14-J4-5 T-2092 014 " 10.115 14-27-5 11,608 14-56-5 11,607 14-55-5' T-2087 010 11,505 14-61-5' 10,117 14-51-54 [general Teste (made only on request) Sulfates Dielectrio Strength @25*0 Fire Point . Visoosity @54,4*0 (SUS) Corrosion Test (6 hrs. @210*C with bright aluminum foil) Change in wt. of A1 (*) None 55 lCV, min. None to boiling point 75 - 80 12,169 - - 11,605 045 10.125 14-28-54 10,086 14-4-52 10.126 14-55-57 COMPANY CONFIDENTIAL (over) TRAN 009243 ID- M (RIV. tft/M) HARTOLDMON0010517 i A. C. Color, APHA A. C. Condition A. C. Acidity (mg. KOH/g.) A. C. Inorganic (Free) Chlorides 60, max. Clear 0.010, max. 0,05 ppm., max. OENERAL INFORMATION Specific Heat @25C Fixed Chlorine 0.27 47.5 - 48.5% 10,084 14-44-54 10,084 Q-l 10,087 14-42-54 10,118 010 COMPANY CONFIDENTIAL TRAN 009244 HARTOLDMON0010518 MONSANTO CHEMICAL COMPANY PRODUCT CODE DEPT. OH JOB 81103 - 82613 W0K-246-Ann.27 Issued JUl 1 5 1964 use Krummrich and Anniston Sales W. Q. Krummrich Plapt By------ ~Yw tD IS , I FINISHED PRODUCT tALEft CODE SPECIFICATION 1040-280-04/ll/l6-03/09 PRODUCT (Tr*A> ffeme) TYPE Aroclor 1254 PRODUCT (Otliafoat ftam*) Nonelectrical Grade TYPE CHEMICAL FORMULA Mixture MOL WT. WMMINI SPECS OP SAMPLE FOR ANALVMS 5-4-61 ___________________ --- 5_X_l6_OZj_M_ UNRESTRICTED INFORMATION Routine Tests Color, APHA Sp. Or. @65/15.5*0 Acidity (mg. KOH/g.) Moisture (H2O) (ppm.) General Tests Flash Point Viscosity @210*F (SUS) Specification 100, max. 1.495 - 1.505 0.010, max. 50, max. None 44-48 , WOK Anniston MethodnroT--- 10084 10114 10087 10620 046 052 050 047 10123 10086 14-28-54 049 COMPANY CONFIDENTIAL TRAN 009245 HARTOLDMON0010519 ORIANTO CMQMCAL COBPASY ' mwi iwaiR1 SPECIFICATION ' TMnsLi TBrtRg7 HUM-_____________ Sales 1040-280-04/11/16-03/09 pweouet mm) m* AROCLOR 1254 ELECTRICAL GRADE (PYRANOL 1476) Pft90UVf (musalmd mum) TfPB Issued 4/13/62 W. 0. Krummrlch plant By E. 0. Martin CMKCH POftMULA Mixture ti, wt. eursRSBDBS srses or 10/10/61 li pee ahalvbs 3x5 pt, Asher Betties UNRESTRICTED INFORMATION Routine Testa Property .. SpSeiHeaHon Color, APHA , Condition 8p Or. 65/15.5*0 t Aoidity (mg. KOH/gm.) Moisture (HgO) Refractive Index @ 25*0 Inorganio (Free) Chlorides pour Point Dieleotrio Constant (1000 oyoles 100*0) Resistivity (500 VDC ft 100*0 0.1" OAP) as OHM-CM x 109 Hydrolysis Stability Test (As Chlorides) Monsanto Stability Test (As Chlorides) Distillation Range (ASTM D-20, Correoted) Ojl Distilled byVt. 30$ Distilled byVt. 90* Distilled byVt. 50/ sax. Clear ~ I.495-I.505 0;010, sax. 35 Ppm, sax. I.6370-I.6390 0.05 ppm., sax. 7-12*0 4.15-4.35 500, sin. 1.0 ppm., sax. 0.5 ppm.j BHUC. 366-3 371-3 379-3 OKNKRAL TESTS (Made only on request) Stflfates Dieleotrio Strength 25*0 FIbah Point Fire Point Va>OOBlty 210*F (SUS) Corrosion Test Ip hr 210*C with bright alusdmus foil) Change in wt. of A1 (*) Hone 35 KV, sin. Hone Hone 44-48 0.0 (Over) O m mtm COMPANY CONFIDENTIAL Method Mufflber VOK ANNISTON 10,084 10,084 10.114 10,087 10,620 10.125 T-2092 10.115 11,608 14-44-54 8-1 14-49-54 14-42-54 14-53-54 14-34-54 014 14-27-54 14-36-54 11,607 14-35-57 T-2087 11,503 10,117 010 14-61-57 14-31-54 12,169 11,605 10,123 10,123 10,086 10*126 &9 043 f 14-28-54 14-28^54 14-4-52 14-55 <-57 TRAN 009246 HARTOLDMONO010520 A.C. Color, APHA A.C. Condition A.C. Acidity (mg. KOH/g.) A.C. Inorganic(Fret/Chloride EXTERNAL SPECIFICATION Cornell - Dubliler Resistivity (500 VDC 0 100*C 0.1" OAF as OHM-CM X 10) GENERAL INFORMATION Speolfio Heat 0 25*C Coefficient of Expansion (25-65*0 Fixed Chlorine 6o, max. Clear . o.oio;*ax. 0,05 ppm., max. 1500, min. 0.00066 ee/*C 54.5-55.5* 10,084 10,084 , $10,087 10 11 14-44-54 0-1 14-42-54 010 11,607 14-35-54 COMPANY CONFIDENTIAL TRAN 009247 HARTOLDMONO010521 I UNRESTRICTED INFORMATION Routine Tests Property Appearance and Color Specific Gravity 90/l5.5C Acid Number (mg. KOH/g.) Specification - Brown to black viscous sticky mass 1.558 - 1.569 0.7, max. Method Number Anniston WOK 10,084 14-49-54 14-46-54 10,114 11,552 RESTRICTED INFORMATION Acid Number of the C'-ude, which 1b stored in non-lacquered metal containers shall be 0.2 mg. KOH/g., max. m IN 84 <*V. 1'88> COMPANY CONFIDENTIAL TRAN 009248 HARTOLDMONO010522  UNRESTRICTED INFORMATION Routine TeBts Condition Color, APHA Sp. Gr. @90/15.5*0 Acidity (mg. KOH/g.) Moisture (Ha0) (ppm.) Viscosity @210*F (SUS) General Tests Flash Point Fire Point Specification Clear 150, max. 1.555 - 1.566 0.014, max. 50, max. 72-78 None None WGK AnniBtc Method "too. 10084 10084 10114 10087 10620 10086 0-1 046 052 050 047 049 10125 10125 14-28-5 14-28-5 m IN H lBV. /*) COMPANY CONFIDENTIAL TRAN 009249 HARTOLDMONO010523 1 MONSANTO CHEMICAL COMPANY OMAMC CHKkSCALS DIVISION mflW*Ve-0Xnn. fin. 81105 - WOK 1 246 - Anniston end Krummrich Plants U98 FINISHED PRODUCT Sales SPECIFICATION SALSA COOS 1040-290-04/11/16/-05/09 (T *mtHtOOUCT Ham*) AR0CL0R 1260 TYPE ELECTRICAL GRADE PKOOUCT (Chmmlamt Hama) TYr (PYRANOL 1482) CHBMtCAL FORMULA Mixture Issued 2/7/62 W.0.Krummrich Plant By P, 0<)n WOi. WT* 5/28/58 SAMPLt SOS ANALYSIS 5 x 5 pt. Amber Bottles UNRESTRICTED INFORMATION Routine Tests Property Specification Color (APHA) Condition Specific Gravity 90/l5.5#C Acidity (mg K0H/g.) Moisture (Ha0) (ppm.) Viscosity 9 210*F (SUS) Refractive Index 25C Inorganic (Free) Chlorides Pour Point (*c) Distillation Range (ASTM D-20, Corrected) 10# Distilled by wt. 505$ Distilled by wt. 90# Distilled by wt. Corrosion Test (6 hrs. @ 210*C with bright aluminum foil) Change in weight of A1 (#) A.C. Color (APHA) A.c. condition ' A.C. Acidity (ng.KOH/g.) A.C. Inorganio (Free) Chlorides 150, max. Clear 1.555-1.566 0.014, max. 55# max. 72-78 1.6455-1.6470 No detectable amt. 25-54 585-598*0 590-404C 400-420*0 0.0 , 150, max. Clear 0.014, max. No detectable amt. (Over) Method NO. WOK Anniston 10,084 10,084 10,114 10,087 10,620 10,086 10,125 10,118 10,115 10,117 14-44-54 14-49-54 14-42-54 14-55-54 14- 4-52 14-54-54 14-48-57 14.47-54 14-51-54 10,126 14-55-57 10,084 10,084 10,087 10,118 14.44-54 14-42-54 14-48-57 m IN M IUV. tt/SB) COMPANY CONFIDENTIAL TRAN 009250 HARTOLDMONO010524 I UNRESTRICTED INFORMATION (oont'd) Property Specification Qeneral Tests (made only on request) Flash Point Fire Point . Fixed Chlorine (%) Dielectric Strength 50C Resistivity (500 VDC 0 100*Co0.1" gap as ohm-cm, x 10") None None 59.5-60.5 JO K.V., min. 500, min. Dielectric Constant J.6-J.8 1000 eyoles, 100*C Method Number WOK Anniston 10,12J 10,12J 10,088 11,605 11,607 14-28-54 14-28-54 14-1J-54 14-J5-57 11,608 14-J6-45 RESTRICTED INFORMATION Monsanto Stability Test (As Chlorides in ppm.) 0.7, max. ll,50J 14-61-57 GENERAL INFORMATION Evaporation Loss after 6 hrs* 0 100*C (*) 0.2, max. 10,116 14-J2-54 Stability teat - after JO days at 100*C in glass sealed In air No libaratlon of ohlorine or ohloridos COMPANY ' CONFIDENTIAL TRAN 009251 HARTOLDMON0010525 I MONSANTO CHEMICAL COMPANY OHOAMC CHKMCALS DIVISION ANNIfTN'|NSH^Dp%UCH SPECIFICATION PNOOOCT <Tr& Name) AROCLOR 116? PRODUCT fCfteraloal Mama) DEPT. ON JO J use SALES BALES COOS . 1040-170-04/11/16-03/00 TVF ____ CRUDE COMMERCIAL TYF8 C MIMICAL FORMULA . MIXTURE Issued 1/24/62 W.0.Krummrich Plant by E.0. Martin MOL T. - - - SUPERSEDES SPEC! OP AMPLE PON ANALYSIS 3/28/58_____ ;_______________ 1 pt, can, Anniston; 2 x 16 oz. W.M. Bottles wok UNRESTRICTED INFORMATION Routine Tests Property Appearance Color Specific Gravity @90/15.5*0 Acid No. (mg. KOH/g.) Specification Viscous liquid Brown to black 1.577 - 1.587 0.7* max. Method Number Anniston WOK b m m m 10,084 *"W" 14-49-54 10,084 10,114 14-46-54 11,532 RESTRICTED INFORMATION AoId No. of the orude which is stored in non-lacquered containers shall be 0.2 mg. KOH/g., max. m IN M (RIV. Il/Btl COMPANY CONFIDENTIAL TRAN 009252 HARTOLDMON0010526 MONSANTO CHEMICAL COMPANY OftOAMC CHCMCAtl DIVISION ANNISTON AND KRUMMRICH FINISHED PRODUCT SPECIFICATION PROOUCV (TreOa Hunt) AROCLOR DISTILLED FROOUCT (Ctmmlcaf Hmm*) CHSMICAL FORMULA FBOOUCT COOI um OBFT. OR JOB 246-&GK SALES (ALES COOI 1040"300"04/ll/l6"O`5-0Q TVPB 1262 TYH Issued 1/24/62 W.G.Krummrich Plant by E,0. Martin MIXTURE MOLWT. -- - sufbribobi (Pies of SAMPLE FOR ANALV8IS ,^/gS/58 -2_______________________________________ Z-lfLoz*.W. M. Bottles____________________________ UNRESTRICTED INFORMATION Routine Tests Property Appearance Color Specific Gravity @ 90/15.5*C Acid No. (mg. KOH/g.) ViBCOBity @ 210F Specification Viscous liquid APHA 150, max. 1.572 - 1.585 0.014, max. 86 - 100 SUS Method Number 10,084 10,084 10,114 10,087 10,086 GENERAL INFORMATION Pour Point (ASTM) Distilling Range Total Chlorine Specific Gravity t coeff (85 - 1J>0C) 55 - 58C 590 - 425C 61.5 - 62.5% 0.001/C ITU IN M ISBV. 18/Sil COMPANY ' CONFIDENTIAL TRAN 009253 HARTOLDMONO010527 I MONSANTO CHEMICAL COMPANY OROANIC CHEMICAL! DIVItlON Krummrich and Anniston PRODUCT CODE 82868 USE FINISHED PRODUCT SPECIFICATION IALES CODE *See PRODUCT (Ttada Nam*) Montars 1 and 2_______________ PRODUCT (Chemical Nmn) _ Polychlorinated Polyphenvls CHEMICAL FORMULA DEPT. OR JOB WOK 246 Ann. Sales Below TYPE TYPE 2 Issued 1 5 1964 W. 0. ITFuTnmr ichi>lant MOL WT. 6-15-61 Mixture AMPLE FOR ANALYtlt 2 x l6 02. W. M Bo11les UNRESTRICTED INFORMATION Routine Tests Appearance Oeneral Information Specification Black Solid Anniston WGK " Method No-- 14-17-52 11521 Physical Properties (Typical Values) Softening Point (ASTM E-28-51T) Acidity Chlorine Content CaO Fe Benzene Insoluble Flash point RESTRICTED INFORMATION Montar 1 54-l6o*C Slightly Basic 56-42* 5-15* 0.5-1.0* ---500-620F Montar 2 70-170`C Slightly Basic 44-48* 5-15* 0.5-1.0* 12.5* ~ am ^ Montars 1 and 2 are the still residues from distillation of Aroclors 1242 and 1248 respectively. Composition of these Montars is not controlled, being entirely dependent on conditions required to make acceptable distilled product. SaleB Code Nos. Montar 1 64 05 - 001 - 04 - 05/09 Montar 2 6405 - 002 - 04 - 05/09 COMPANY CONFIDENTIAL TRAN 009254 o IN H I* HARTOLDMONO010528 1 MONSANTO CHEMICAL COMPANY OAOANIC CHEMICALS DIVISION Krummrich and Anniston FINISHED PRODUCT SPECIFICATION PRODUCT COOI dept, or job issued JWl- 1 5 1964 82868 WGK 246 Ann.27 W. 0. Krummrich Plant UBt Sales ..... `~yv\, o . SALES CODE See Below PRODUCT (Trad. Nes>e) Montars 5 and 4 PRODUCT fOiaalMl Hint) Polychlorinated Polyphenyls TYPE TYPE CHIMICAL FORMULA MOL PT.________ urf H1KDKI BPS Cl 6-15-61 Mixture BAMPLt rOH AMALVMB 2 x 16 oz. W. M. Bottles UNRESTRICTED INFORMATION Routine Tests Specification Anniston WQK HeTHoH* No. Appearance Black Solid 14-17-52 11521 General Information Physical Properties (Typical Values) Montar 5 Montar 4 Softening Point (Method ASTM E28-51T) 86-l68*C 92-206*C Acidity Slightly Basic Slightly Basic Chlorine Content 50-52# 54-56# CaO 5-10# 5-10# Fe 0.5-0.6# 0.5-1.0# RESTRICTED INFORMATION Montars 5 and 4 are the still residues from distillation of Aroclors 1254 and 1260 respectively. Composition of these Montars is not controlled, being entirely dependent on conditions required to make acceptable dis tilled product. Sales Code Nos. Montar 5 6405 - 005 - 04 - 05/09 Montar 4 6405 - 004 - 04 - 05/09 m IN S4 IRE V. IS/SS) company CONFIDENTIAL TRAN 009255 HARTOLDMONO010529 Dept. 246 - Process Description AROCLOR APPENDIX 0 PHYSICAL AND CHEMICAL DATA 22. COMPANY CONFIDENTIAL TRAN 009256 HARTOLDMONO010530 Dept. 246 - Process Description AROCLOR APPENDIX C PHYSICAL CONSTANTS 24. COMPANY CONFIDENTIAL GENERAL PHYSICAL PROPERTIES OF AROCLORS F orm.................................................................... Color..................................................................... Aroclor 1242 Practically colorless mobile oil 100 Max. (APHA) Aroclor 1248 Aroclor 1254 Yellow tinted Light yellow mobile oil viscous oil 100 Max. (APHA) 150 Max. (APIA) Aroclor 1260 Light yellow soft sticky resin 150 Max. (APHA) Aroclor 1262 Light yellow sticky clear resin 150 Max. (APHA) Acidity-Maximum (Mgm. KOH per Gm.) 0.015 0. 015% 0. 015 0.015 0. 02 Average Coefficient of Expansion........................................ cc/ccC. 0.00068 (25-64C) 0.00070 (25-65C) 0.00066 (25 -65*C) 0.00067 (20-100C) 0.00064 (25* -65"C) Typical Density Specific Gravity 25/25*C (77*/77f)l. 380 Pounds per Gal. -25*C (77F) 11. 50 1.445 12. 04 1. 538 12. 82 1.620 13. 50 1.646 13. 72 Distillation Range-ASTM D-20(Mod) c ...................................... 325-360 340-375* 365-390" 385*-420* 400-430 Evaporation Loss-%-ASTM D-6Mod. 163 C............................................. 5 hrs. 3: 0 to 3. 6 100*C................................................ 6 hrs. 0.0 to 0. 4 Flash Point-Cleveland Open Cup. . C 176-180 F 348-356* 3. 0 to 4. 0 0.0 to 0.3 193-196 379*-384* 1.1 to 1. 3 0. 0 to 0. 2 None 0. 5 to 0.8 0. 0 to 0.1 None 0. 5 to 0. 6 0. 0 to 0.1 None Fire Point-Cleve. Open Cup. . . .C None* F Four Point-ASTM D-97............. C -19 F 2 None -7 19- 4 None 10 50 None 31 88 None 37 99 Softening Point-ASTM E-28 "C _____ -- -_ -- -- F --- - -- -- -- HARTOLDMONO010531 TRAN 0 0 9 2 5 7 AROCLOR APPENDIX C PHYSICAL CONSTANTS (Cont'd.) GENERAL PHYSICAL PROPERTIES OR AROCLORS (Cont'd.) Form Aroclor 1242 Practically colorless mobile oil Aroclor 1248 Y ellow tinted mobile oil Aroclor 125-4 Light yellow viscous oil Aroclor 1260 Light yellow soft sticky resin Aroclor 1262 Light yellow sticky clear resin Fefraetive Index -D-line 20" C 1.627-1.629 1.630-1631 1. 639-1. 641 1.647-1. 649 1.6501-1. 6517 Viscosity-Saybolt Universal 210 *F (98. 9*C) 34-35 36-37 Sec. (ASTM)-D-88) 130F (54. 4" C) 49-56 69-78 100*F (37.8 C) 80-93 185-240 44-48 260-340 ' 1800-2500 72-78 3200-4500 --- 90-103 600-103 (160 F or 71*C) x> o o M cUol HARTOLDMONO010532 '.** pept. 246 - process Description AROCLOR APPENDIX C PHYSICAL CONSTANTS (cont'd.) PHYSICAL AND CHEMICAL DATA piphenyl Specific Gravitys 0.992 at 75C/4c. The swann chemical company bulletin of 1920 data on diphenyl. Viscosity of Diphenyl (from Anniston Files) P. Centipoises I6o ------- 1.4-59-- 170 1.209 180 1.20b 190 1.114 200 1.024 220 0.901 250 0.752 200 0.574 250 0.459 400 0.274 ^50 0.212 482 0.282 Specific Heat (from Anniston Files) P. B.T.U./lb. 200 200 4 00 500 600 700 800 900 1000 0.4l6 0.470 0.547 0.616 O.658 0.679 0.686 O.690 O.696 t 2b . COMPANY CONFIDENTIAL 009259 HARTOLDMONO010533 I pept. 246 - process Description AROCLOR APPENDIX C . PHYSICAL AND CHEMICAL DATA (cont'd.) Diphenyl (cont'd.) Another record gives the following values for liquid diphenyl: C. sp. Heat cals,/gram 100 1^0 200 250 .500 550 400 450 Vapour CP = 0.460 0.560 0.580 0.412 0.460 0.518 0.575 0.610 0.625 0.625 450C. (d. a. Roper, Design Data for units 4 & 5) Density of Liquid Diphenyl (from Anniston files) o C 75 100 150 200 250 500 550 400 450 Grams./cc O.9885 0.9695 O.9294 0.8885 0.8470 0.8010 0.7510 0.6918 0.6180 Heat of vaporization; 65.4 g. cal./g. at 258.5C. COMPANY CONFIDENTIAL TRAN 009260 HARTOLDMONO010534 Dept. 246 - process Description AROCLOR APPENDIX C PHYSICAL AND CHEMICAL DATA (pont'd.) 28. Specific gravity of Aroclors at Various Temperatures' For 1242 1248 1254 or GE l4?6 Temp. o C. 60 65 TO 75 80 85 90 95 100 60 65 70 75 80 85 90 95 100 60 65 70 75 80 85 90 95 100 1260 or QE 1482 60 65 70 80 85 90 95 100 SP. Or. 1.547 1.344 1.558 1.335 1.332 1.32? 1.324 1.319 1.315 1,413 1.410 1.405 1.400 1.397 1.394 1.390 1.385 1.381 1.505 1.500 1.495 1.490 1.485 1.48o 1.475 1.470 1.465 1.584 1.580 1.575 1.570 1.565 1.560 1.555 1.550 1.545 Lbs, per Gallon (us) 11.23 11.20 11.16 11.13 11.10 11.07 11.03 11.00 IO.96 11.78 11.75 11.71 11.68 11.65 11.62 11.58 11.55 11.51 12.55 12.50 12.46 12.42 12.38 12.34 12.30 12.26 12.21 13.21 13.17 13.13 13.09 13.05 13.01 12.96 12.92 12.88 company TRAN 009261 confidential HARTOLDMONO010535 pept. 246 ~ process Description AROCLOR APPENDIX C PHYSICAL AND CHEMICAL DATA (cont`d.) 29. For 1262 Temp. o 60 66 70 75 80 65 90 95 100 Specific Qravlty of Aroclors at Various temperatures [contld) Sp. Qr. Lbs, per Gallon (us) 1,6o4 1.600 1.597 1.595 1.568 1.562 1.5Y7 1.572 1.568 15.40 15.56 15.52 15.28 15.24 15.19 15.15 15.11 15.07 Heat capacity of Aroclors at various Temperatures '^temperature i .......... .... i .......... ............ i ............. i " 1 1 r (Cal/gmc.) > m, . ,----- L AroclcT?'''*^' 0 50 100 125 150 175 200 250 500 1242 1248 1254 1260 Aroclor 1242 1248 1254 1260 .280 .270 .255 .220 .500 .280 .265 .255 .520 .295 .275 .250 .550 505 .285 .260 .555 .515 .295 .265 .540 .520 .500 . 270 550 .550 .510 .280 .565 .540 525 .290 .580 555 .540 505 Latent Heat of vaporization of Aroclors Temp. Range Latent Heat of vaporization 500-510C. 500-550?c500-550c. 50C-370C. 6l cal/gm 54 cal/gm 0 cal/gm 8 cal/gm COMPANY " CONFIDENTIAL TRAN 009262 HARTOLDMONO010536 4, O'M ' ' PHYSICAL CONSTANTS DATA TBffrfSir /> . AROCLOR 1142 iTechnical) TRUCTUBAL FORMULA 5^$\ 479 . .V J reu(S'ILTTJ rv______ * Rev. Bv A. M. Ellenburjg tb1947. 7/5/57 3 NAME Formula_______ MoFeculai Weight ;____ dmxmtL_____ Total CU41. 5 - 42. 5% SOURCE > DATE -Specs 12-2.L^i_ Brown to black oily liquid Specs \T~-2\ -53~~ gjUlUH Pointa 760 fflm_ Bonify Point & am Boiling Point A aim Boiling Point at__mm_ CfYStallmra Point Melting Point__________ SoljlifinffiltlLf. __ as/15.5c' Specific Gravity v_____25j_ii^5.0i- Pounds per Gat, a 25 C Coefficient o< Expansion__________________ 1.348-1,360 | 1 .'384- 1. 397 JJL5_________ Specs 12-21-54 Refractive Index *_____________ __________ Infra Red Specttum (Referencr) _ Uj[ri Violet SpectrunuRe/rwf> ViKpsrtjr ^ j ______________ yiscosity.tf___ ____________ Surface Tension ......... ............ Solubility in Water J Sflftllilittin______________ Solubility in Sp-.Gr. .T^pp. Cofifl *155 *_LD5._Q-- o^jmsT-C- I FIsshPoM F/%Wj Q.JT. Fire Point^C~^ HillSLl.Q-OntuisUorL......... ..... . . Heat of Formation Thermal Stability (caLAfZflMJ_____ Kent Kelt.9/Eiston._____________ Ueni IMulla.______ 1____ Specific Heat_________ :__________ Critical Temperature .Ctilml Pimm-- Dissociation Coas&ffll ._ lNoQe_ l'); < H < UJ Q Q 2o o oo TRAN 009263 Toxicity (Give HtftrenctJ Scftwarta. U. S. Pub. Healt Service Bull. #229 1931i_ "Industrial-Poisons. Hazards aj NOTE: Theie Jala tkovli not k* tl*a**i tyU lie not linn if ntctuary. HARTOLDMONO010537 < .F> T>iP r3H #i PHYSICAL CONSTANTS DATA 'fvWrltyct Tf uctwhai. roAMui.a A R-QC LO H 114 S--(T c hn ics I) Sysr 47? 2 58o TPwyrcrtT trz--~ H'. v, i v A M. Ellenbur^ NAME o]muJ_* ________ MoleculiiJNeijjht tosMisms..._________________ Bs'!iQt-PA'!l! .MJSOjV? gflirim . mm Boiling F-aml A _jnm. Boiling Point A mm' gffsUHUinjPojni__________ ;______ tkliing Poml Soldi ion Point_____________________ Specific Gravity f 65/15, 5, Sgecific Gravi (y o'_______ __________ Pounds pei Gal. * 25 dC ___ Coefficient ol Expansion__________ Refractive Indext> "& Infia Red Spectrum (Reference) uina Violet Spectrum {Kefvtnct)________ __ _ viscosity 4_________ _____________ __ _ iiosiiyj______________ .. _______ Suites Isnsioa1 Solubility in Wist____________________ Solubility in; Solubility m____ ___________ __________. __ So. Gi-rtemp/Coeff. (50-100C) ~BTfe----mr. . 7/5/57 Total Cl; 47,5 - 40. 5 % n t- i o I *1 v 'unii>. 1.410-1.420 ..L2^C.- EMWLtfZ Ct SoC5. 1411/. 5 5 _t ;jt >. < Specs. 47T[/n5 Spg-gg. Jj.lil.55. FlishP_giiit0F r/toW; C. O. C. Fite Point^C___________ __________ Heft of fonniion__________ Thermal Strbillty [fiil/Vi/min.l. Uent~.Htai.ol fiaisn________ Ue&HU 9LlL_________ SeficiiicjMf_____________ Critical Tenoer^we Ctllitli ___ :_______ 382 MdO_ Aroclor Bullet try OF -1 JO _____________ y i. t IfjJl TRAN 009264 Toticity (Givi RtftrenttJ Schwartz, lh St Puj^lfeaUkSmyism.. Bujl, p-- NOTEl fAtit dole iSeuld not if rihaitd oum<i of momonte CAomtem Comjf&ny. Vtt additional thritt i I necti ion HARTOLDMONO010538 Vw w LLjin #i PHYSICAL CONSTANTS DATA ~Iu nmugy STRUCTURAL raRUUL A AROCLOR 1160 (Technical) W*r' J2 ,S85 Rev. Bv A. M. ^ 'lvnburg OAf1947 ____ 1/5/5.1 NAME Formula__________________ X.L2H3, 75 Cl^, 35 Molecular Weight______ Appearance__________ Total Clg 59.5-60,5% Boiling Point it 760 mm Boilinf Point it __mm ikiiint PswLt____ jml 801 ling Point at mm_____ Crvstalliting Point telioii'ajnl. ______ ______ Specilic Gravity 4______ 90/ 15HT Specilie Gravity 4_______ ________ Pounds pcTGal. 25 ~~C 1 558 - 1,572 Coefficient ot Expansion Retractive Index I n5 Mi* Red SpeCtmm (RtSttemt) UltllViolel Spectium (Rtfatnct)______ _______ Viscfisill i______ ________________________ ViscosityJ1________________ ._________ Ssulii.IinsiL________________________ 5oMiity.Jit.llaL__ . Solubility in ', L Solubility in_____ _________ ____________ Sj> Gr. Te mp. CoefT (75- 130^)' /0. 06l0/uC~ 1 r, 2: SOURCE ft PATE .Specs__ 12-21 -fj4 s specs 12-21-54 _ Specs.12-21-5 4 ___Specs 12-JLL-. H. pTash Ppint Df (Method) Fire Point C .__ HmLbI Combustion____ Heat of Formation Thermit ability (cal.Al/<mLUent Htii pl.fiajM_______ UtfiQi.HMl.iOaL_________ 5eaiIJc Heji____________ Critical Temperature Cfiiicii Pjbimi .. Dissoclititm CBit -None.. None COMPANY CONFIDENTIAL TRAN 009265 Tosicity fGiwe Rtfcrtntt) Schwatriz USPiih Health Service Bull, rf y.1. l'.'iO.. "Industrianil Poiso-n...s........H...ga..Sz- aM-r1ds and Solvents .by M R. NOT 1: Thttt fait iKouli nor it rtltasti on 1it oirflliOftaf iktlU if met <ary HARTOLDMONO010539 if nDN-i* "wwrrxf Sysr 47? PHYSICAL CONSTANTS DATA ^ 5S, STRUCTURAL rORMUL * AROCLOH 1154 fTechnicall <o-r> TBUPICEB IT' Ji i__ _ NAME re oimuU________ _____C i j H - Clr MolecuIar. Weight t..... ...... ' *Te fSTT 7/5/3 7 Total Cl3 53.5 - 54. 5^ SOURCE & OATS, _Spees.._L2.7 2 1 -54_ Afificaiinit____________________ Brown_to black oily liquid _ i?qucs^..ll.- 2.L-3.1 gojIJOI Boiling ________________ fun SdJinii'aiDLM _jmi Boiling Point at mm__ __ __________ Crystal I Ul.ng_Pojnt___________________ Bulling Pninl. Solution Point__ _____________________ Sfiesilii_Qivjiy_y______ fi&v 1 aJi_____ Specific Gtavity ?______ _ Pounds pci Gal. > =, C ri. 5^o - i BTo_____ i_. .ij; Coelficient ol Expansion________ __ Rett active Index *___ "i Infra Red Spectrum {Rzl-.'n.Zll__________________ -*-- Ultra Violet Spectrum _______ _ Viscosity >__ _ _____j________________________ Viscosity ___________ _______________ Surtki.Ignsion_____________ _________ Sol*>ili.ty.mW.ioi.... fcMUity'iD. _______________________ Solubility In______________ _____________ ______ Sp.A-Cr.i.'j. l.POP i. tlafiLii5r_lQ5_Cl. 0. 00095TPc" tr Flash Point F (Method) _ _ F]iePointC_____ I_________ ________ Heit o.l Formation____________ (cai/ji-'iin..L. Utflt H*9J Etftion_______ UenLHMtjj! .*_________ Specific Heat 1___________ Critipal Temperature Ciitiul Pman Disaociation CtaMat Norte N on <l K - -..... 9 ol oo ft) ` TRAN 009266 Toxicity (Pint Reference) Schwartz. U. S. Pub. Health Service. Bull. 221' I j "Industrial Poisons. Vol, -463-364 1041 , HOTS l There dote thouid not It released outs HARTOLDMONO010540 l^Jiw Ml PHYSICAL CONSTANTS DATA Sy 7f7f *fuftTTRTS" AROCLOR 1162 (Technical) rfmjcfuHTL A6Aul/l"a 9 ysu* rr trrrr-r-r^r- J^ry^ Dv_A^L-lIenburg name Formula_________ Molecular Weight -Cl.2H3Ct.y_ Appearance_______ Boiling Point at 760 ML Boiling 5'iflLJjI fflD_. Boiling Point a jaa_. Boiling Point i nun CrysUlliiini Point Ifcltint.Poinl._______________ .___ Solution Point' Specific Gravity t90/15-5_. Specific Gravity 4 __ __________ Pounds pef Gal. * ~^C Coefficient of Expansion ReTiactive index y ___ ILL Infra Red Spectrum (Reference! Ul 11 aVi01 dSpedrum/Re/Mtncej_______________ yi^oyty a__________ VilCPUty^_____ r________ ________ _ Stufat Tension______________________ Solubility in W49___________________________ SfiJlSLititKJl!________________________________ Solubility in_________ _ __ _ __ SM*xl, .TampCoilLX9Sl- i2Q^l 1947 7/5 /47 Total Cio 61.5 -62. 5% cl -SfiysiiA.oATt Brown to black sticky mais Spec 4-11 ^55 JL. 577 --LJ87_______IT jixxtxiiztz Spec 4-11-55 (L.0Q10/C Spec 4-11-55 FJnh^P^ojnt F (Method)________ Fue Poini ^C________________ Hfajif tombusilon......... ...... Heat o| formation_____________ thermal Stability {cal_./Kfc.lmin_J_. CienlHtoI.Fuum. .......... UfOl HfiaLpf y,_______ ______ Sp.ec.i0? h1_________________ Crit iC*LIl*n9*JJllt!l____________ CiiiitH Emaai__________ Dissociation Comtant .Non,p. l-Wone -- rr ?" 0 1 o TRAN 009267 Toxicity f(J4ve Reference) JScfavsfartz. U. 5. PobuHeallMervlfie.iiuJLl. >229, ia.it o .flflri.JSfliY.ntS...by ..\L.^-- NOT 1! Theee date should not li released eels %##tcoo01/ Monsanto Chemical Company. (/* ej/itione/ sheets if neces mjry. HARTOLDMONO010541 a i> PHYSICAL 'CONSTANTS DATA Tcrtrmrvr ARt>C 1.0 R ,142. 4TRUCTURAL rOKMDl a" ST 1. 9o Qiti eBomen rv ~---- A. M. H :1 e- bb r e ..___ _ ________ NAME Formula ____________ Motecuiat Weight _ __ _ flcp(Mce..................... yoijinj Point <g ?60jnm___Ra/' g t-___________ Doilmg jj ____ 1________________ BciJini PfiinLl.-. -am_________________ - Bolting Point..*____ hot_____________________ _ Crystallizing Point____ ______________ UeJliug Point_'... Solution_Pp!nt ____ ____________________ Cprgjftc Grayily.i C ,_______ __ Specific Gravity 2 j / i s. 5 C.___ ______ Poundsj>ei Gal. .* C ________ Coefficient ot Expansion ,2 3-b5 C._________ Refractive Index 4S Cj . n h Infra Red Spectrum iRejtrenee/____________ ____ Ultra Violet Spectrum {Reference)______________ Viscosity ...410.X*. _________________ Viscosity i.OO I- s _____ ___________ Surface Tension. Pyi e.?.l STM JLIOlOL.. Soltfiilj.ty in Water Solubility JO.. \A A; LC-fil. (SOSl-Cu--. solubility in_.pyir:. &j. t___ M. J0ic*_ oAH -Ii^V,S7 Ciz H? CJ_v .j^sjliri.f 8.5 McXle 0L~. *25 _,,j_ _________ No- -c .rys.tj.IJ jtr e_ ^ K ISO _l ,J8L - I . '3. ______ -XLilOQbi?. .<.cy.cc/: J.Xa.feife5_ -JJ--J5. S'JS________ ..Lz'r.n .3Vs._.: JLi_3____________ Ir.A,- ' .b,c- ____ ____ Al^5_g../10g.^_____ V. / SOURCE ft PATE DP 1~.'-f Sp.ec. Ic.vw- d-lh-- _M._D._QP:u,.; . JjppL.Lr.uj.r. _ 2. \\ .M-.Jia QP-. . 11 . i e r, gS |9 o u- XZ o .o flash Point c . o. c , fue PoinPc________ c.o.c. Hg.aJ jl lompuslioo__ .. Heat ol formafion Thermal. Stability k*.Ag|min.}__ LAftnt Hgat o[ Fusififf_________ Ultfll HfAgt V. ca! / am. Spec.ilieHeal ___ Cnt ical Temperature____________ Critical Piossuro Dissociation Coftsdk Spec IcHeat (&JQQlC, Po.. r Pr: r* T'enna Cryducivii^a cal/ cm 7t x77ee D e ec r:c Ccrsta-* 100 C. 60 cy. J 80 C. None 6J 0, 29 JLJ-ilL H C. nr louser IIOIlE 4.9 Cajxu-Atejl. . J M..--._QP TRAN 009268 Toxicity (<Utr Re/erente) Contact Medea Dec' fwL B. QP -1 1 *>____________ T- 1 NOTE: 1 he se doia should not be tel eased outside of Hopsonto Chemical Company. Use oddittonal sheets 1/ neees. jo HARTOLDMONO010542 ~prf7^ s5~y fTTltM <t PHYSICAL CONSTANTS DATA amiTiwcf- --------------- IT^yCTUNAL FORMULA -#5? ARQCLQR 1248 r OTTOUir oTTi--------- Plp^ ^4<a A. M, Ellenburg NAME Formula Molecular Weight ft>jmnn . Boiling Point it 760 mm Boiling Poirt at 3 mm _____ _________ Range " 4-25-57 C12 H6 Cli . 292 (Avg.1 . Yellow Tinted MobP Oil 345-385C. 1B5~-210C SOURCE & DATE Monsanto Bull. OP -115(19; If It Bolling Point * . mm Boiling Point at mm Crystallising Point . Non-crystallizing t ' . Jdelltnf Point ... Solution Point .. . o SoecilicGrivltY4- 25/25 C. Specific Gnvity * 6 5/15. 5VC. Pounds per Gal. 25 C Coefficient ot Expansion 25-65*C. 1.445 ............ ..... . 1.405-1.4 IS 0.00070 cc/cc*^ n" .-.Specifications-^ 9. .54. ---M- -i.B.OP-U5 ' Refractive Index * 25uCn S Infta Red Spectrum (Reference) ' 1.6285-1.6305 Soeclficatlor: 9/ y ,'54 ~~ Ultra Violet Spectrum (Reference) Viscosity-* 130F. yiscosity v Surface Tension .......... Dvnes/cm @2QUC. Solubility in Water Solubility in 3A Alcohol @ 25"C. __... Solubility m Pyridine 29WC. 73-80 SUS 44. 2 Insoluble 15 g. /100 cc 111.4g./10Q cc M.B. OP-115 J. Coll. Sci. 7 . 1G6. {1957 II |z ? UJ |Q z oo Flash Point ^K/Uethodi c.o. c. Fire Point C c.o.c. Heat of Combustion .......................... Heat of Formation ... Theimal Stability fcal./Wmin.) . Latent Heat of Fusion .................... . LWent Heat of Vip. cal/gm. Specific Heat r 25ur Critical Temperature ' Critical Pleasure . Dissociation Cwutant Specific Heat & 300UC,, i96c. None ^ ..54 ... ............................................ 0. 277 0.356 Pour Point Vi Thermal Conductivity, cal/ cm/C/sec. pe Dielectric Constant. 100C.. e 60 cy. ..... U 0C. or lower 2/3.6 @ 28yr. 4. 5-4.7 1 o A * Toxicity (Ctve Refrrtnee) CoAact Medical Dept. M If Calculated ............ _ M,n, DP-115 It II To be Published M.B. OP-115 TRAN 009269 *` M.B. OP-ii'5 HOTE: rHeit Uoro should not he oatude of Moneonto Chemieol Company, Vt* additional sheets if next \sary. HARTOLDMONO010543 I VifT HD** PHYSICAL "ibirXWet--^ 1 A ROC LOR 12 S 4 CONSTANTS DATA $ T ffti/C Ty R A L FORMULA S-jSr ais stsio TBWFTCt 0 IT " A . M , El.erb jrg NAME Fotmy)3_ _______ KtoicculajLWcjjht __ Aepuittct_________ goilintPoja i M.m. Botlir'l PeitS Jt ILm. Bmling Cornl A___ mm. Boilint Point at ,jm___ *1 rystalliring Poml_______ MfiUtBgPoml__________ 5plu(ion Pojnt__ _____ ___ L:1^> c*f VC, " " .6li' 1> .=l_C,________ Pounds pet Gil. '?1'' ^"C Coefficient of Expansion 2 ~~ 6S~C. Reffactive Index * I'lPjClUL Infld Red Splcltutn iReferenee/____________ Uljta Violet SpecUum (Rjl^en^_______ _l _____ T__Viscosity \___________2i (?-F._______ Viscosity*:.... ... SwiKI-IfiDSion_______ Pv!LC5.LCm_. soijMty .id. Ms__________l______ o_ SoliAtlitv in. _3 A A L :ot~ol @ 2" C Solubility in Pv L.diS&JLlLlCL... DAT! 41^4; Cl? HaCU 326 . Av%. ' Palp Yplow 36*- 40. C 1-fiQ..?10gL (^O SOURCE a OATS oil -Mor.ier_oJ2.iL .QP_ ill rial Nor crys- al. u~ it k____ L .. . L-L38 J 1. .495_:l.:0f___ .12,81___________ n nop66 1.63?Q 1.639^ Srr-C^l.`ixr J1 e J ----'A i.q--. 2.' -11-- _________________ . _ i ' 44 4 8 s~. s jOiPP JjJL ..Z" 50.3~fti?<C. 4Z.0Ql_nnD r*r it* JD2fiktiS_*..i_____________ H* -^ - 114, g.Tlpn C: ______ "77 " " ~ ~ Hash Point %juahqdi___ c.o, c. C'i*foiJl?P________c.o c. ^li.Ot QPi**M|Uon__________________ Heat of formation _ _ Theimaf SlabjIlly [caL^.'imnJ Uej)( Holt.of Fuiipn UtS"! Hal of y,______ zallam. SP.Ofii0cJ.eaL___________@ IL-CL Critical _________________ : Critical Piessutt Oiu^iation Cuo&M. Pp,.r Poi.'. ' WVrwTr,r , ,4'rfCt Wty. Cal' .cm/C7S D.oler r:c Co' .'a:', 10QUC< <?n C'. N?r-f JSor.e.______ 50 _ _ _ ILJti___________ 0-33* ITT. *y> q ig orvr i, 3- CblculA' pd LjflpjQE 111 To be o .bli Jeci_ MR OP -111 . TRAN 009270 TcHCltV fUve Reference) -Cor-artl -M r. d i: a 1. ile-jL HOT 1: these dole should not he released outside of Monsanto Chemseol Company. Vie additional sheets if nteei < COMPANY CONFIDENTIAL HARTOLDMONO010544 lie pi JU ( r. ItN 111 ' PHYSICAL tUBTTXw'TT* AHOCLOH 12P0 CONSTANTS DATA STRUCTURAL FORMULA SySr -775 ^ sec ') ronwrvfr'B?" _ ^ name 3 fMffluia............. _ _____ Molecular Weight ___________ AfiPtHaM______ _______ Hojl'ng Poi.rH .atJfiO mw. H jr go Ooinng Pfljii 'ai ^nim.._.... j"o* t e" t. i6- ------- rr ----T-1-------r ___ JiiL.id.VlL i______... ...50U5E.&_o.ate L^.Yii`1 iPfLili.ciLV.L'il^'l] .iio'L^iTLO aas jjic____ ___ _ l_.ld;..llLDC... .... CJ' - i (filing Piiull - mm.._............ Boiling P<n|.|,,.. m_______ Cfyntallizyig Point ___ ho- i.Cl. >o: aiLu ir. n I4- - - Melting fsunl .*......... ............... l- Solution Point . ......... ....... ......... 1..... Spot'(ic CfAv|?y Id Seecjtjccjstv'ly..* ._ .. t\. *i .. ... ... \ .l..v..' 1< i, i PounJsjwi GaT ' C ___ _ . .i. _ ....-------- -o----------...... Cqetiicienl ol E*p.insion_ ; n ...lU.aL'tT . JJ.ALIJ'L: CL. ;.Q:. L____ .Spi.Ltlica.'..y.... i * ' AUli.UidLL' . . Reljactive Index _> _'i j>_i _____ Inlia Red Spectium [hWrrrn./y . .. .. . ..LA ______ ... -Spc :il iaa_\. i, . .1 It..' UIII3 Violet 5j>Klnjm/HrJermrt> ...... Viscosity*. ___ L.H'I''.......... S' s -Maop^ ij'. . 7. Viscosity *............... .... . ... ___ SmiKt Tension .................. .... . Solubilityjn WSet ......... _ ....... ____ $0ltility m. ... ... ^. . ____ __ . --i 5filubifLtyjn............ ..........1.. ... ... .... Flash Pomt 5f .{'taW.!_L., o.._c_____ _ File Point C ___ . ___ . . Hgat ?( Qpmbustion........... .. . .... . He* ot Fynution. .. _____...______ Thci.mat.Stability (cal. >'miri.] ............... UMtnt Hept ol Fusi_on . . ............. ... LAent Heat oJ Vap. ___suLjzm....... Sp.es ........ w&..-lf-..CL_____ C*i|*ct Tetnpeietuie________________ Cntitil fitwtft_; Qmctifilisfl.Caislfii_____ -------------- Sj^Lg-ilui He ft' lQi.---------- LlrxmLZaiai. -.-er yI .iLt^Icc.ric-CoaaLiir.L .1UIL-C. OS*u-_--_-_--_-_--_____ JjLsll_____________ . JL------------------ T0AtCity IC'iK Reference/ _\p 77. ill t).; II.' HOV .1 i; A rt.... A_____ Co 1 a;: Moox i. Dtp*. ...Cl.LLu.'A.'y.ii ...MH OP.- tl'i TRAN 009271 _____ ..777771... MR OP 1 U NOTE; The it data iAobId nol be relented out tide of Monsanto Chemical Company. I'se additional sheet! if nereis irt . ' ' COMPANY CONFIDENTIAL HARTOLDMONO010545 i pc a-- J-f* ' PHYSICAL constants data Sy.srv?* y "ftfffrxiTEt---- IT fiUC TUR At FORMULA ARQCLQP 1260 10% Toluol Mix Mixture by Weight TSWRTtetf'*'?m _______ A__M_XilILtUiX_________________ ' NAME ' Formula Moiecuiai WetgM ' -rsxrg ~~ 1 7/3/57_______ 90% - Aroclor 1260 10% - Toluol SOURCE tr DATE \ . _ "-- Appearance Boilirvt Point A 760 mm Boiling Point A mm Boilinc Point A ftoilmi Point A m mm ' ................ .Sv rnnv 1 inn iri '' * " ----- T Spnrs 4,11/55 , Crystalline Point IfclUM-Pfiml----------- -------------------- - Solution Point Specific Gravity ' _ .40/1 5. 5C Specific Gravity v founds per Gal. ps C ' Coefficient of Expansion ----- -- -- -----------------;--------------- 1.475 - 1.495 . 12 5 . _ n 't t . . '. ... -- . "" '" Refractive Index n3 Infra Red Spectrum (Reference/ Ultra Violet Sjieium/R^/enre)___________ ,___ Viscosity i_____ :Lioqe_________________ JML 2 xs. (232 jSUSJ -- WGK Lab 3 ViWMtiy i_________ _________________:________ .1L-&.QJL. 138 lUS) M SurfaceIfluififL. ... . ___ ... .* Solubility inWAer SolUbilitv in Solubility in . . 8 / 56 -r- -- -------------------------------------- ----------------------- -- -- ------------------------------------------ -- Flash'Point F (Method) Tag open cup Fire Point fF "% " Heat of Conbustion Heat ol Formation Thermal SIAillty (cat.Afi/min.1 UlTent Hepl of Fusion , ' Ufi.nl HfiiijO.____ Soecific Heat Critical Terweratuft Critical Pressure Dissociation Cms&nA ________ _ .' . ' 105 no *0 ' WGK Lab 12/5/46 11 -------- -------------------- -- ---------------------- ------------------ ....... . .. ----------------------- ----------- -- ------------------- --....................... -- 0 e O e> O Toxicity (Give Reference) m * . 1 " - TRAN 009272 NOTE! These data should not be released outside of Monsanto Chemical Company. Use additional sheets if neeeti'iryl HARTOLDMONO010546 A i?"r w 0 PHYSICAL CONSTANTS DATA SysTWf IlmlTClr A HOCi-.OR 1262 I structural formula TSCfTCTOY A . M. EUenb jre NAME Formula Molecular Weight Beilins Point A KD mm Bolling Pell M ; mm Boiling Point i mm Boiling Point at mm CrvstalHzinfl Point ' ' r>-r /> oaTk __/ v 1 7/3/57_______ Xl7 ri^HgCl? 4 395 , Light veil, sticky Resin 390-425C .... SOURCE A DATE ,, --- Monsanto Bullet ip ()p -1 ] 5 " (195 J Solution PoiriL . tific Gravity s 90/15. 5C Specific Gravity 25/25C Pounds per Gal. * C Coefficient ol Expansion 25-65C Refractive Index 25C "4 Infra Red Spectrum (Reference) Ultra Violet Spectrum (Reference) Viscosity e QF Viscosity # Surface Tension Solubility In WMet Solubility in Solubility in _ l. 577-1. 587 '1.646 13. 72 Q. 00064 cc/cc/uC__________ ... ' 1.64B-1.650________ Soecs. 4/11/55 MR DP -IIS f It ` ii ..... as i oo sus * .f S,pecs. ^ 4/11/55 Jt. " '' " -- * Flash Point F (Method) Fire Point **C Heat of Contustion HiM of FormMion Thermal StAilltv (cM.Ag/min.) LMent Heat of Fusion LMent Heat of Vai. Specific Heat Critical TimpfiMure Crilital Pitaiwa Oiuoeiatlon CeaMaM Poir Pbtnt None None . ................ ....... . ' _ ........ "T5-30C > MB OP - 115 II , % If u 1 ......... - TRAN 009273 , __!_________________a__ .__________ ___ Toxicity (Civ* Reference) 4 Contact Med. Dei1L________ MR OP-11 5 ----------------- f 1 Mlf................ . ~~ ......... NOTE) Thete data ehotdd not l releaeed huMi of Hon* onto Chemical Company, Vi* additional ekeate if necetuvy. . -COMPANY CONFIDENTIAL HARTOLDMONO010547 I -.fl Dept. 2^6 - Process Description AROCLOR APrENDIX D UTILITIES Toe utility calculations are based on design calculations for a 28.8 million pounds per year production rate. The breakdown of utility usage by individual equipment is only on estimate. The estimates of utility usage are average values in most instances as it is difficult to measure the operating time and load for a particular piece of equipment with great accuracy. The total usage of each utility was taken from the cost sheets. Estimates of Individual operating time and percentage of the total load were made to calculate the distribution of utilities as given in the following pages of this section. COMPANY CONFIDENTIAL TRAN 009274 HARTOLDMONO010548 Dept. 246 - Process Description AROCLOR APPENDIX D UTILITIES (Cont'd.) 1. Power Consumption A. Electricity - 440 V., 5 phase, 60 cycle Peak Item Equipment Motor Load No. Motor HP KW 101 Biphenyl transfer 5.00 pump 105 Biphenyl head tank .75 pump 104 Biphenyl feed pump 7.50 2.6 0.7 6.6 121 #5 Chlorinator pump 10.00 8.8 122 #4 Chlorinator pump 10.00 8.8 125 #5 Chlorinator pump 10.00 124 $2 Chlorinator pump 10.00 8.8 8.8 125 #1 Chlorinator pump 10.00 127 #2 Blow tank pump 5.00 129 $1 Blow tank pump 5.00 152 #1 Still pump 5.00 8.8 4.4 4.4 4.4 155 #2 Still pump 7.50 6.6 140 #1 Receiver pump 141 2 Receiver pump 144 Blend tank pump 2.00 2.00 5.00 1.7 1.7 2.6 149 #5 Storage transfer 5.00 pump 151 #4 Storage transfer 5.oo pump 155 #5 Storage transfer 5.00 pump 155 #8 storage transfer 5.00 pump 157 ifl Storage transfer 5.00 pump 170 #1 City water pump 7.50 2.6 2.6 2.6 2.6 2.6 6.6 171 #2 City water pump 7.50 6.6 180 Exhaust blower 15.00 15-0 Miscellaneous Totals 1T5775 0.9 TTJ78 Monthly Usage KWH 80 240 1980 5040 5040 5040 5040 5040 200 1580 1580 2540 20 20 200 160 240 200 80 80 2540 0 0 5<.o 2b ,bbO COMPANY CONFIDENTIAL TRAN 0 0 9 2 7 5 HARTOLDMONO010549 Dept. 246 - process pescrlptl on 32. AROCLOR APPENDIX D UTILITIES (Cont'd.) 1. Power Consumption (Cont'd.) B. Electricity - 110 V. , one phase, 60 cycle Peak Load Equipment KW Monthly Usage KWH_______ Lighting 15 3600 Instrumentation 2 1440 Miscellaneous 2. Natural Gas Item No. Using Equipment Totals 3 20 Normal Use SCFH Peak Use SCFH 2150 .71'0' Monthly Usage MSCF 131 #1 Furnace 1200 2400 430 132 #2 Furnace 1200 Totals 2400 TTBOU" 430 ~wu~ 3. Compressed (plant) Air Item No. Using Equipment Normal Use SCFM Peak Use SCFM Monthly Usage MSCF 127 #2 Blow tank 60 200 2590 148 #3 Storage tank 60 200 90 150 #4 storage tank 60 200 90 152 #5 Storage tank 60 200 90 154 #8 Storage tank 60 200 90 156 #7 Storage tank 60 200 90 Miscellaneous 10 Totals 370 200 1400 330 JVUU~ rr?K?r-MF>ANY confidential TRAN 009276 HARTOLDMONO010550 AROCLOR APPENDIX D Nitrogen Item No. Using Equipment UTILITIES (Cont'd.) k' Normal Use SCFH Peak Use SCFH Monthly U^age SCF 142 #1 Blend Tank 3 143 fj/2 Blend Tank 3 146 #1 Product Tank 3 147 #2 Product Tank 3 140 jf'j> Storage Tank 3 150 #4 Storage Tank 3 152 #5 Storage Tank 3 Totals 2T~ 4 2140 4 2140 4 2140 4 2140 4 2140 4 2140 4 2140 147980 Purchased Water Item No. Using Equipment ' Normal Use Q PM Peak Use GPM Monthly Usage M. Gal. 130 #1 Still 3 131 #2 Still 3 203 #1 Vacuum Jet 20 204 #2 Vacuum Jet 18 205 #3 Vacuum Jet 15 206 S-K Drowning Jet 25 Miscellaneous 2 Totals "B6" 5 150 5 150 20 870 20 770 20 650 30 120 10 100 110 28T0.. High Pressure Steam --200 "PSlG at' Item NO. Using Equipment Normal Use Lb ./hr. Peak Use Lb ./hr . Monthly Usage M . Lb . 167 #1 Blow Tank 203 #1 Vacuum Jet 204 #2 Vacuum Jet 205 #5 Vacuum Jet Totals Low Pressure Steam ""B'O' PS10"O'25UF. 210 450 400 325 Item No. Using Equipment Normal Use Lb ./hr. 310 150 670 320 615 290 500 240 TW Peak Use Lb./hr . Monthly Usage M. Lb . 102 Bipnenyl Storage! 700 Tank 138 #1 Receiver Tank 700 159 #2 Receiver Tank 700 142 #1 Blend Tank 200 143 #2 Blend Tank 200 146 #1 Finished Produ200 Tank Totals 2?0$ 900 900 900 300 300 300 36OO 500 500 500 150 150 150 195^ TRAN 009277 COMPANY CONFIDENTIAL HARTOLDMONO010551 i Dept. 246 - Process Description AROCLOR APPENDIX D UTILITIES (Cont'd.) 7- Low Pressure Steam (Cont'd. ) Item No . Using Equipment Normal Use Lb./hr. Pea* Use Lb ./hr. 147 #2 Finished 200 Product Tank 500 148 #5 Storage Tank 700 900 150 #4 storage Tank 700 900 152 #5 Storage Tank 700 154 #8 Storage Tank 700 900 900 156 #7 Storage Tank 700 900 Miscellaneous 1400 Totals "7OT" 2800 lCTOT- ^. Month] Usage M. I 150 500 500 500 500 500 1000 ~5sm COMPANY CONFIDENTIAL TRAN 009278 HARTOLDMONO010552 \fr' " Dept. 246 - Process Description AROCLOR APPENDIX E PERSONNEL Departments 246, a-246, B-246 and C-246 are closely related. Operating personnel may work in all of the departments In a given day. For this reason, the description of operating classifications and assignments for departments 246, a-246, b-246 and C-246 is given as though all four of the departments are Just one department. Operating Classifications I Job Premium Operator Standard Operator Repairman Packer Porter Swingman Total Number of Men 7 day/week Sohedule * 10 & 4 Schedule 4 5 45 11 22 ti i0 12* 9i The swingman works two shifts per week (Saturday and Sunday) as a relief foreman, two shifts as a repairman, and one shift operating the premium job. There is an open shift on t.ie standard operator Job that is covered by overtime. The premium operator and standard operator cover three shifts each day. The repairman works the day shift, and with the swingman, there is 7 days per week repairman coverage. Packers work the day and middle shift 5 days per week. The porter works half time in department 246 and half time in department 24}. The premium operator has lead responsibility for his shift. The work force works all three departments Aroclor, Pyranol and Pydraul as one coordinated operation. The assignment of time is 70# to Aroclors, 15# to Pyranol and 15# to Pydraul. Operating Assignments; Premium Operator; Has overall responsibility and operates 5 chlorinators 2 stills and covers the necessary absences of the standard operator. Standard Operator; Operates.2 blend tanks filter, 2 finished product tanks,.storage tanks, makes pyranol and pydraul mixes, loads trailer, and tank cars, charges chlorinators and transfers receivers and also belongs to the Fire Brigade. Repairman; Unloads cars and trailers of Biphenyl, Trichlorobenzene and fetra-Trichlorobenzene and finished product, makes weekly safety inspections and department minor repair work. COMPANY TRAN 009279 CONFIDENTIAL HARTOLDMONO010553 I Dept 2M6 - Process Description AROCLOR APPENDIX E PERSONNEL (Cont'd.) Packer: Fills, stencils and labels 5 gallon, 30 and 55 gallon drums and clean^up assignments when not drumming. Porter: Cleans office, control room, repair room, wash room and smoking shelter. Swingman: Works one day per week as premium operator, two days as repalrman and two days as relief foreman. As relief foreman takes overall supervision and day shift on weekends including arranging for maintenance, night sheets and line-up of work. HARTOLDMONO010554 i Dept, 2^6 - Process Description AROCLOR APPENDIX F PACKAGING & SHIPPING Aroclor, Pyranol & Pydraul are filled about half in drums and half in tank cars or tank trucks. A substantial amount (about and Pydraul. of Aroclor is used to make Pyranol Sales are largely directly to the customer. The remainder is in bulk shipments to the J. F. Queeny Plant. All electrical grade tank truck shipments are made in the customers truckB which are stainless steel. Non-electrical Aroclors are shipped in leased trucks and may be iron although other materials of construction are suitable Pydraul is shipped in steel tank trucks. Electrical grade Aroclor and Pyranols are shipped in lined tank cars either H,000 or 8,000 gallons in capacity. The lining is either tin, zinc or aluminum spray because iron contamination is detrimental to the electrical properties. Electrical grade cars are either owned by Monsanto or on a long term lease. Non-Electrical grade Aroclor is shipped in steel cars . All electrical grade lots and bulk shipments of non-electrical material are sampled from the final container. That is all tank cars and tank trucks are sampled and analyzed after loading. All electrical grade drums are sampled from one of the drums. Tank cars and tank trucks are inspected to be sure they are free of dirt and water or other foreign material before loading. Heels are drained before loading some materials. Car washing when necessary is done by the repair track. Tank cars are Bealed with a numbered aluminum seal Lacquer lined drums are used for Aroclor and Pyranol and plain steel arums are used for Pydrauls. A summary of products, weights and containers current use is as follows : Product 1252 12^2 12^8 125^ 125^ Xylene 1260 1262 MCS295 5 Oal. 60 Go 60 - 60 60 . p Weights and Containers ....30 dal.--"35UaT7-- TT 600# - 600# Yes - 600# Yes - 600# Yes - 600# - - 600# Yes - 600# - 6*5# - TC Yes Yes Yes - Yes - 3: >F ^3 21 < Ui 2= 0 oi 0 Pyranol 1^88 Pyranol 1^8l - 675# - 675# -- TRAN 009281 HARTOLDMONO010555 Dept. 246 - Process Description AROCLOR APPENDIX F PACKAGING Sc SHIPPING (Cont'd.) Product Pyranol A-13B3B Inerteen PPO Pydraul A-200 Pydraul 280 5 Gal. 65 65 59 - Weights and Containers ----- 3'OGal. --55~~5aT~ 360# 360# 675# 674# 645# - 625# TT - Yes - TC 4000 Gal. 4000 Gal. & 8000 Oal. - COMPANY CONFIDENTIAL TRAN 009282 HARTOLDMONO010556 -..ft Dept. 246 - Process Description______ AROCLOR APPENDIX G MATERIAL BALANCE 59, The material balance on Dept. 246 was made with a minimum of field measurements. Most of the estimates on the following page check fairly close with actual raw material usages that can be readily measured. The exact composition of some of the intermediate process streams is uncertain. COMPANY CONFIDENTIAL TRAN 009283 HARTOLDMONO010557 -.fx y,'yv. -----v-.-- 5 '/.% v,i? AtR-KCL MIXTURE I si AERATES p__ A ROC LOR co ' // yt % S '/r'//7 t~~ LIMB CO o3TILL _ ir BOTTOMS VACUUM " JW ^ omttijEB ' AJIQCLOR jjj miruLaaa . BLENDES ,,4*suia FILTER 6aki - MC4 .It rl a S DARISOTCILLOLRED'n ATTAFULaUSw BARTS BLESSED t-- AROCLOR FILTER CARS v/ Kinesis ;,, )S FROBCCt TOTAL , U3A08 Si <w |9 O2 o o 00928** HARTOLDMONO010558 -,,.rt - 6 Dept. 246 - Process Description AROCLOR APPENDIX 0 SUMMARY OF MATERIAL BALANCE RESULTS Raw Material & cost ($/lb. ) Biphenyl (.0662) Chlorine (.0217) AROCLOR 1242 Usages - Lbs./]-00 Ibs. product Material Balance Theory Material Balance Usages lbs/100 lbs. 58 6? 58 Finished Prod. 1 Filter cake 3.3 Still Bottoms .5 Off-Gas HC1 BjTa 84 91.8 42 Finished Prod, 1.5 Filter Cake .05 Vacuum Jet 2.8 Still Bottoms .95 Air-HCl Mix ture 44.50 Off-Gas HC1 Ferric Chloride (.129) Attapulgus Earth(.0302) Air (.00055) Lime (.0100) 0.03 15 3 0.5 .03 .15 3 0.5 Biphenyl (.0662) AROCLOR 1248 52 56.5 .03 .15 3.0 0.5 52 Finish Product 1 Filter Cake 3 Still Bottoms .5 Off-Gas HC1 Chlorine (.0217) 96 103.2 48 Finished Prod. 1.5 Filter Cake .05 Vacuum Jet 2.55 Still Bottoms .95 Air-HCl Mix ture 50.15 Off-Oas MCI TO72S These raw materials are the same for production of all Aroclors. COMPANY CONFIDENTIAL TRAN 009285 HARTOLDMONO010559 Dept. 246 - Process Description AROCLOR APPENDIX 0 SUMMARY OF MATERIAL BALANCE RESULTS (Cont'd.) Raw Material & Cost ($/lb.) Biphenyl (.0662) Chlorine (.0217) AROCLOR 1254 Usages - Lbs./lOO lbs. product Theory Material Balance 46 49.8 108 .117.5 Material Balance Usages Lbs./lOO lbs. 46 0.5 2.8 0.5 *T97o Finished Product Filter Cake Still Bottoms Off-Gas HC3 54 Finished Product 1 Filter Cake 0.05 Vacuum Jet 6.8 Still Bottoms P-95 Air-HCl Mixture 54.7 Off-Gas HC1 11775^ BJphepyl (.0662) AROCLOR 1260 4o 45.4 Chlorine (.0217) 120 128.8 40 0.9 2.0 0.5 njTn Finished Product Filter Cake Still Bottoms Off-Gas HCl 60 Finished Product 0.5 Filter Cake 0.05 Vacuum Jet 4.8 Still Bottoms O.95 Alr-HCl Mixture 62.50 Off-GaB HC1 T2878S COMPANY CONFIDENTIAL TRAN 009286 HARTOLDMONO010560 Dept. 246 - process Description AROCLOR 42. APPENDIX H ATMOSPHERIC DISCHARGE - WASTE DISPOSAL Discharge to Atmosphere Lbs. per C Lbs. of Aroclor Produced Total Lbs./Yr. based on Prod. Rate 28.6^]^: 1. HCl fumes from blow tanks 0.01 . .2,000. 2. HCl fumes from other tanks vented to atmosphere 0.01 2,000 ? Chlorine gas from chlorinator vented to blow tank Unknnpp .Unknown 4. Aroclor & Biphenyl vapors of tanks vented to atmosphere Unknown Unknown Discharge to Sewers 3 . HCl from chlorinators 2.5* 500,000* 2. Cla from chlorinators 2.0* 50,000* Discharge to Waste Disposal 1. Montar 0.0176* 5,000* 2. Aroclor 0.53* 95,000* Estimated COMPANY CONFIDENTIAL TRAN 009287 HARTOLDMON0010561 Dept 246 - Process Description ^3. AROCLOR APPENDIX I Sampling Point Chlorinators Blend Tanks Storage Tank Composite Tank Cars & Trajlers PROCESS CONTROL Frequency 2-3 timeB per batch Reason for Sample Specific Gravity """* Normal Ran6e .011 Method Numbe r 3 times each day Color (APHA) 50-150 Max. Sp.Gr. at 25/15.5 C. .Oil Acidity (mg. KOH/g.) .014 Max. "Moisture (He0) (PPM) 35 PPM Max. "Refractive Index at 25C. .0020 "Inorganic (free)Chlorides .05PPM Max. "Dielectric Constant .20 "Resistivity (500 VDC at 100C. 500,Min. 0.1" OAP as ohm-cm X 10y "Hydrolysis Stability 1.0 PPM Test (as Chlorides) Max. "Monsanto Stability Test 0.5 PPM (As Chlorides) Max. ""Sulfates None ""Dielectric Strength at 25C. _ 35 KV Min. ""Viscosity at 100F.(SuS) 10 """Thermal Chemical Chlorid 0.75 PPM es Max. 10,084 10,114 10,087 10,620 10,125 T-2092 11,608 11,607 T-208' 11,503 12,169 11,605 10,086 12,722 Every 1-2 days Same as blend tanks Every Load Same as blend tanks "Tests made on electrical grade Aroclors only. ""Tests made on request only. """Special customer test. """"Maximum range for all Aroclors including electrical and non-electrical grades. COMPANY CONFIDENTIAL TRAN 009288 HARTOLDMONO010562 Dept. 246 - Process Description AROCLOR 44. APPENDIX J SAFETY & TOXICITY DATA Safety Equipment The following 1b a list of safety equipment (personal and departmental) required in department 246. 1. Fire extinguishers: A. Dry Chemical (}) - Southwest corner Bldg. CR - Main Floor. - West wall at top of stairs of Second Floor. B. Carbon Dioxide Snow - Southwest corner of Bldg. CR, ground level. 2. Chlorine Qas Masks (4) - Southwest corner, second floor - Control room, second floor - East side, outside control room - Wall, Southwest corner of sprinkler house, main floor. 5. Scott Air Masks - West of Lean-To 4. Safety Showers (2) - Southeast corner of Bldg. CR, ground level. - Southeast corner of Bldg. CR, 2nd Floor. 5. Davis vapotester 6. Eye Baths 7. Sprinkler System Safety Precautions The folllwing are safety precautions followed in the operation of department 246. 1. Safety Equipment of Employee Each employee has the following safety equipment: (1) Hard hat (2) Safety glasses (5) Goggles (4) Rubber and canvas gloves (5) Rubber overshoes. Special equipment may be Issued as necessary for performing a particular job in a safe manner. COMPANY CONFIDENTIAL TRAN 009289 HARTOLDMONO010563 Dept. 246 - Process Description AROCLOR *5. APPENDIX J SAFETY & TOXICITY DATA (Cont'd.) Safety Precautions (Cont'd.) 2. Sampling of Crude Aroclor The samples of Aroclor taken during the chlorination reaction are hot (170C.). Precaution must be taken to avoid skin contact of samples and Inhalation of Hydrogen Chloride, Chlorine and Aroclor vapors. 5. Fires Fires may result from the ignition of leaking gas, Xylene, Diphenyl, rags, paper, wood, etc. Automatic fire extinguishers and sprinklers have been Installed to combat fires. 4. Explosions " Explosions may be caused from accumulated pockets of natural gas or a rapid burning of Diphenyl in a closed container such as a Chlorinator. Chlorinators are equipped with a 10" diameter pressure relief line with a rupture disc made to burst at 22 psl in case Diphenyl within the Chlorinator ignites. 5. Toxicity Toxicity does not present a serious problem. However, a complete daily change of clean clothes is supplied to each person and time is allotted at the end of each shift to take a bath. Instructions are also issued to avoid actual skin contact with Biphenyl and Aroclor as much as possible and to wash hands and face before eating. 6. Miscellaneous There are many accidents that can occur that may be classified as health and safety hazards. These accidents may result from such things as broken process lines, acid leaks, steam leaks, etc. The worst inherent hazards are as follows: . 1. Free Chlorine from ruptured line or major leak. 2. HCl Qas from ruptured line or major leak. 5. Dropping bottoms from stills. 4. Hot Aroclor & Diphenyl. Safety Record The last lost-time injury in Dept. 246 was January 28, 1948. The frequency of minor injuries is low, around one per month. Toxicity; This material is a liquid under normal conditions and has a medium toxicity range for liquid Ingestion and high toxicity for vapor inhalation. The maximum allowable concentration (M.A.C.) is 1 mg/cubic meter. Fire Hazard: There is no fire hazard under normal conditions. Aroclor mixes (Xylene, Toluene, Butyl Acetate, etc.) may burn and explose at high temperatures when exposed to flames. COMPANY CONFIDENTIAL TRAN 009290 HARTOLDMONO010564 Dept. 246 - Process Description AROCLOR APPENDIX J . 46. SAFETY & TOXICITY DATA (Cont'd-I Other Hazards: This material can cause dermatitis, systemic poisoning Prom the l'umes, and yellow atrophy of the liver. There are skin, mucous membranes and eye hazards encountered in handling this material. Treatment and Antidotes: Call a physician and remove patient from fumes. Storage and Handling: Protect the skin, lungs, and eyes by wearing approved protective clothing, respirator, and goggles. People who handle this material at elevated temperatures should have medical supervision, and the air should be sampled to insure compliance with M.A.C. There are no special storage restrictions under normal conditions except store in a ventilated area. ' Shipping: There are no special shipping restrictions. FERRIC CHLORIDE (FeCl3) Toxicity: This material is a solid under normal conditions and is non toxic or has a rating as low. Fire Hazard: There is no fire hazard under normal conditions, but it will emit toxic fumes at high temperatures. Other Hazards: Some people are allergic to this material and may develop skin rash7 and there is an eye hazard. Treatment and Antidotes: Call a physician. Storage and Handling: Protect the s.<in with approved protective clothln avoid the breathing of PeCl3 dust, wear approved respirator with adequat cartridge, and protect the cyco wltn approved goggles. There are no storuge regulations. Shipping; There are no shipping restrictions. <D -C. DIPHENYL,(C6H5C6H5) Toxicity: This material is a solid at normal conditions and is medium loxld. The M.A.C. of vapor Is 2 mg/cublc meter of air. If ingested, the lethal uouo is 2.4 g/Kg of body weight. The fumes are not dangerously deadly, but'-they are poisonous over a prolonged time. Fire Hazard: Diphenyl is very flammable and will burn when exposed to heat or flame or oxidizing materials. Other Hazards: the eyes. Diphenyl is not too corrosive to skin, but it will affect COMPANY CONFIDENTIAL TRAN 009291 HARTOLDMONO010565 1 !W Dept. 246 - Process Description AROCLOR APPENDIX J 47. SAFETY & TOXICITY DATA (Cont'd.) DIPHENYL (C6H5C6H5) (Cont'd,) Treatment and Antidotes: Wash eyes with water and get the patient to fresh air. Try to ~;et patient to vomic, and call a physician. Storage and Handling: This material can be stored in steel containers away from fire hazards and oxidizing agents. Wear suitable clothes and approved goggles when handling diphenyl. Shipping: Ship in cars or other suitable containers with a red warning label of flammability. XYLENE (C6Hn(CH3)fi Toxicity: This material is a liquid under normal conditions and is very toxic in liquid or gaseous form, but it is less toxic than toluene. The M . A ,C . is 200 ppm. Fire Hazard: This material is very flammable and the limiting explosive concentration is 1-5.5^ by volume in air. It will also react with oxidlzing agents . Other Hazards: This material will cause necrosis if enough 1b inhaled, and is hazardous to eyes, mucous membranes, and the skin. Treatment and Antidotes: Qet patient to fresh air, and call a physician. If injested, get patient" to vomit. Wash eyes and skin with water. Storage and Handling: This material should be stored In a cool wellventilated area away from fire hazards or strong oxidizing agents. The material for Btorage can be steel cars or tanks. Wear approved protective clothing, respirator, and goggles. Ship in containers of steel or appropriate material with a TRICHLOROBENZENE: Toxicity: This material is a solid at room temperature and the vapors are quite toxic. The solid is poison if Ingested. The M.A.C. is 50 ppm. Fire Hazard: This solid is flammable but is listed only as a moderate fire hazard. Will burn at 420C. or above. Other Hazards: This material will affect the liver, eyes, and mucous membranes. Treatment and Antidotes: Wash eyes with water, and get patient to fresh a1r. Call a physician. COMPANY CONFIDENTIAL TRAN 009292 HARTOLDMONO010566 Dept. 246 - Process Description 48. AROCLOR APPENDIX J SAFETY Sc TOXICITY DATA (Cont'd.) TRICHJ/DRODENZENE (Cont'd.) Storage and Handling: Store this material in cool, well-ventilated area away from hazards anu oxidizing agents. Wear protective clothing, chemical safe goggles and approved respirator. Shipping: Ship in steel containers like cars on tanks with red label. TETRA-TRI-CHLOROBENZENE Toxicity: This material is a solid at normal temperatures and is medium toxic. The M.A.C. of vapor is 50-75 ppm. Fire Hazard: ThiB material is not a very great fire hazard, but it will burn at high temperatures and will decompose and emit chlorine. Other Hazards: This material will affect the eyes, skin, and mucous membranes. Treatment and Handling: Wash eyes and skin with water and get patient to fresh air. Call a physician. Storage and Handling: Store this material in a cool place away from fire hazards and strong oxidizing agents. This material can be stored in steel cars, tanks, or etc. Wear protective clothing, approved respirator, and chemical safe goggles when handling this material. Shipping: Ship this material in containers marked with a red label. LIME Ca(0H)e Toxicity: Lime is not dangerously toxic, and it is regarded as more of a nuisance. This material is a solid or slurry. Fire Hazard; This material is not flammable. Other Hazards: Lime Is very hazardous to the eyes. It will burn the skin alBO, and thedust will affect the mucous membranes. Treatment and Antidotes: Flood eyes and skin with large quantities of water. If lime is Ingested, get patient to vomit and call physician. Storage and Handling: Lime can be stored in steel containers, and people should wear protective clothing, respirators, and rubber or chemical safe goggles when handling lime. Shipping: There are no special restrictions for shipping, but the containers should have a white label, a caustic warning. COMPANY CONFIDENTIAL TRAN 009293 HARTOLDMONO010567 Dept. 46 - Process Description AROCLOR J<9. APPENDIX J SAFETY & TOXICITY DATA (Cont'd.) ATTAPULOUS EARTH: Toxicity; This earth is not toxic in general. Fire Hazard; There is no fire hazard. Other Hazards: Attapulgus earth can create a dust hazard similar to other dusts that contain silica. Treatment and Antidotes: Consult a physician. Storage and Handling: Attapulsug earth presents no special storage problem and should be handled by persons wearing an approved respirator. Shipping: There are no special restrictions on shipping. HYDROOEN CHLORIDE (HC1) Toxicity: This material Is a gaB under normal conditions and Is very toxic. The M.A.C. is 5-10 ppm and a concentration of 1500-2000 ppm would be fatal to humans in a few minutes. Fire Hazard: There is no fire hazard under normal conditions, but wet gas reacts with some metals to form hazardous hydrogen. Other Hazards: This material is hazardous to teeth, skin, eyes, and mucous membranes. ' Treatment and Antidotes: Wash profusely with water, if injested, eat chalk, magnesium hydroxide, egg whites, and milk, and also administer oxygen. Call a physician. Storage and Handling: This material should be stored in a cool, well ventilated area away from oxidizing agents. This material can be stored in rubber lined, glass, or tantalum vessels. People handling this material should wear suitable clothing like rubber aprons, shoes, and gloves. Also rubber goggles or chemical safe grades and approved pack or canister gas masks. Shipping: Shipping containers must have a white warning label and a non-flammable label. Ship in appropriate containers such as rail car or carboy. CHLORINE (Cle) Toxicity: This material is a gas under normal conditions and is very toxic. The M.A.C. is ,J5 to 2 ppm. A concentration of 1000 ppm would be rapidly fatal. Least concentration with detectable odor is 5-5 ppm r~ COMPANY TRAN 009294 CONFIDENTIAL HARTOLDMONO010568 t v*'* " Dept. 2^6 - Process Description_________ 50. AROCLOR APPENDIX J SAFETY & TOXICITY DATA (Cont'd.) CHLORINE (Cl2) (Cont'd. ) Fire Hazard: There 1b no fire hazard under normal conditions, but there js an explosion hazard if chlorine is mixed with a strong reducing agent such as hydrogen or hydrocarbons at high temperature. Other Hazards: This material causes eye, skin, and mucous membrane irritation. Treatment and Antidotes: The patient should be given oxygen immediately and treated for shock. Call a physician. Storage and Handling: This material should be stored in a ventilated and cool place away from fire hazards. When handling, wear a gas mask or approved respirator, clothing and rubber or chemical safe goggles. In strong chlorine concentrations, wear canister gas maskB, Scott air pack, or oxygen breathing apparatus. Shipping: The shipping containers must have a green gas label and a non-flammable label on. Ship in steel cars or cylinders. COMPANY CONFIDENTIAL TRAN 009295 HARTOLDMONO010569 i p?-Pt. 2^6 - Process npacrjLpt-.lon AROCLOR APPENDIX K BACK GROUND INFORMATION 51 _ The manufacture of Aroclors was developed quite by chance. The Indian Refining Company, in the latter part of 1926, approached the Swann Chemical Company located in Anniston, Alabama, regarding the production of Biphenyl which the Indian Refining Company wanted to use as a heat transfer medium. The Swann Chemical Company agreed to produce Biphenyl, but first a process had to be developed. Two years later, in 1928, a pilot plant for producing Biphenyl became operative. However, in the meantime, the Indian Refining Company dropped all interest in Biphenyl. Since a process had been developed for manufacturing Biphenyl, the Swann Chemical Company started looking for other outlets for this material. The simplest outlet was in the form of Chlorinated Biphenyls which were produced in the laboratory in 1929. The Chlorinated Biphenyls produced exhibited good electrical properties. This was reported to the General Electric Company who Immediately became Interested in the product which ultimately developed into large scale consumption in electrical transformers and capacitors. The trade name "Aroclors" was adopted for the Chlorinated Biphenyl products. The properties of Aroclors vary from mobile oily liquids to fine white crystals and hard transparent resins. The excellent electrical properties, fire resistance and inertness of the Aroclors make them useful for many applications. Plant equipment was installed to produce Aroclors at a rate of 2000 pounds per day or 1 million pounds per year. In the following years, this production rate was insufficient to meet the increased sales requirements. The Swann Chemical Company was purchased by the Monsanto Company in 1925. This purchase gave Monsanto access to the patent rights for the production of Aroclors. Production Capacity needed to be expanded, and since Monsanto had a Chlorine Plant at Plant"B" (now called the W. 0. Krummrlch Plant), the Aroclor production was transferred from the Anniston Plant to the Monsanto, Illinois Plant, where operations at an increased productive capacity started in September, 1926. By 19^0, the Krummrlch Plant production capacity was inadequate, and in 19^1, a similar production unit was Installed in the Anniston Plant. COMPANY confidential tran 00,2,6 HARTOLDMONO010570 Mori3unto Company Monsanto, Illinois Accepted by production WBJ Messrs: P. E. Heisler - WOK E. E. Martin - WGK R. W. Bucknell - Org. Res. SAFETY REVIEW COMMITTEE Original signed by: CWR 2-19-64 ODG 2-20-64 HBP 2-10-61 January 17, 1964 K. L. McHugh - Org. Res. Process Holders TENTATIVE AMENDMENT NO. "A" TITLE: Aroclor Standard Manufacturing Process of Dec 17, 1962 811.01 - 811 07 OBJECTIVE: Increase amount of Ferric Chloride Catalyst added to the Biphenyl in Dept. 246, Aroclor. PRESENT PRACTICE: Presently 1 lb. of ferric chloride is added to the biphenyl charge tank to 4000 lbs. of biphenyl. It is suggested that this amount be increased to 2 lbs. of ferric chloride per 4000 lbs. charge of biphenyl added to the charge tank. It has been shown in the St. Louis Research Reports Nos. 1640 and 2072 that a minimum level of Fe Cl3 catalyst is 0.02$ to produce stable Aroclors. Aroclors manufactured at the W 0. Krummrich plant do not meet specs, by as comfortable a margin as Anniston's AroclorB do. If we are to retain our customers for electrical-grade Aroclors at W.G.K., the quality must be improved. Safety will not be affected in any way. This will be a permanent procedure change. W. B. Johnson COMPANY CONFIDENTIAL TRAN 009297 HARTOLDMONO010571 Tentative Amendment No. "A"(Cont'd.) APPROVAL: Original signed by; DATE:. 2/11/6*4 Bate 1 E- E. Martin E. Martin - VaT 2/11/64 Bate _D_._ BHP. flmHoe--me_r_" G...0. - ,.2/l^/t>^ Bate 2/19/6*4 Bate COMPANY CONFIDENTIAL TRAN 009298 HARTOLDMONO010572 DISTRIBUTION LIST: 1. 2. 5. 4. 5-6. 1: 9 10. n. 12. 15-14. 15-16. H. L. Minckler/R. S. Wobue R. E. Soden - WOK T. W. Dalton - WOK J. R. Kellogg - WOK St. Louis Research Vital Records Center WOK Standards Department WOK Technical Services Vault Copy England England AnnlBton - R. 0 Moody Extra Gen. Offices . May 9, 1965 ' TENTATIVE AMENDMENT NO. A PROCESS DESCRIPTION FOR THE MANUFACTURE OF AROCLOR IN DEPT. 246 OF DECEMBER"T7, 1962 - W, 5Y KHOBBraCTTPiAOT,..M'OWanto, Illinois SUB-TITLE: Preparation of Aroclor 12.52 by the direct chlorination process common to Aroclor 1242, 1248, 1254, 1260 and 1262. PRESENT PROCESS: Aroclors are the reaction products formed by the chlorination of diphenyl in the presence of Iron chloride catalyst. The crude Aroclor, produced in the chlorinator, is air blown, distilled over calcium oxide treated with Attapulgus earth, filtered, and transferred to storage PROPOSED CHANGE: Amend the existing manufacturing process to Include the production of Aroclor 1252, which contains high percentages of dlchlorobiphenyl, to be used in the large scale preparation of MCS 177, a 700-800F. heat transfer fluid. Aroclor 1252 Is prepared by the direct chlorination of diphenyl to a specific gravity of 1.252 to 1.256 at t>5/15-5C. in the presence of iron chloride catalyst. The crude Aroclor 1252 is air blown, and diBtilled over calcium oxide prior to transfer of the product into storage containers at 50 to oOC. Insoluble isomers, present in this special Aroclor 1252, slowly separates out of solution upon prolonged standing at room temperatures and are very difficult to redissolve. Since this product is a starting material for the MCS 177 process, the Attapulgus treatment and final filtration are optional but not necessary. COMPANY CONFIDENTIAL TRAN 009299 HARTOLDMONO010573 I "2" This special Aroclor 1232 cannot be back-blended If the finished product is off on its prescribed chlorine specifications The incorporation of excess monochloroblphenyls into the product will increase the volatility of the MCS 177 and the addition of trlchloro- oiphenyls will drastically raise the pour point of the finished heat transfer fluid. Abnormal compositions of this Aroclor 1232 are readily detectable by gas-liquid chromatographic analyses. Approval is requested to demonstrate this change as a source of the necessary starting material for Monsanto's candidate, in the lucrative field of high temperature heat transfer applications. ORIGINAL SIGNED BY; Written by J. D* Sullivan J. D."Sullivan Date_________ 5/9/63 Approved Byi Original signed by; w. R. Richard p. E. Helsler E. E. Martin W. R. Richard P. E- Helsler E. E. Martin Safety Review Committee; COMPANY CONFIDENTIAL TRAN 009300 HARTOLDMONO010574 1. R. S. Wobus 2. C. Barbre 5. T H. Becker 4 . J. Soffranko 5. St. L. Res. Lib. 6. St. L. Res. Lib. 7. Plant B 8. 9. 10. 11. 12. 13. 14. TENTATIVE AMENDMENT AROCLOR PROCESS Dept. 246, Plant B England P. 0 Marsh Plant B Plant B Plant B H. L. Hubbard J. Mitoray January 23, 1951 This amendment provides for the addition of anhydrous FeCla, O.J$ by weight of biphenyl, to the chlorinator as fortifying catalyst for the production of Aroclor 1160 This change in process operation is a result of a complaint submitted because of the presence of green color in Aroclor 1260. Research work has indicated a trend toward improved color when anhydrous FeCla is used either alone or in combination with plant steel catalyst. To cite an example, using 5# by weight plant steel catalyst, an untreated Aroclor 1260 was prepared in the laboratory having a color of 5656 Transmission (Fisher Electrophotometer, filler 425B), whereas from a batch in which the same catalyst plus 0 3# by weight anhydrous FeCl3 was employed, an Aroclor 1260 of 72% Transmission was obtained. Extensive analyses of the Aroclor 1260, which was prepared using plant steel in conjunction with 0.3# by weight anhydrous FeCla, did not indicate any abnormalities or deviations from usual quality material. A complete summary of the Research work is presented in a memorandum to Dr. R. M. Hitchens, January 24, 1951- It Is proposed to condut a plant demonstration which will comprise the production of three to four chlorination batches of Aroclor 1160 using 0,y% by weight of the biphenyl charge as anhydrous FeCla. Depending on the outcome of this plant trial, that is, if a color Improvement is observed and a normal quality product is retained, a run of longer duration will be planned to study further the effect of anhydrous FeCla catalyst on the color of Aroclor 1260. This may include variations in the amount of FeCl3 charged to the chlorinator. Original signed by: j. p. Mitoray In January 24 1951 APPROVED: J P Mitoray COMPANY CONFIDENTIAL Original signed by; ^1 *||bard ... 1/25^5^ . J^Slggauff----------- 1/gSZ^.--------- T. WT*t)aitjopnalkaot T5T b. Hosmer v>-- Hosmer 2/5^L c. Rarbre Barbre 6/25/51 Date Paul n. Marsh . G. Marsh : TRAN 009301 HARTOLDMONO010575 t SAFETY REVIEW COMMITTEE Original signed by: ___ 2LJjg~~~~------ JFL.E.H. 1 f)-Q_c,7 ____ IQ-9-f'7 September 27, 1957 Distribution: Dr. o. J. Weinkauff - Research R. S. Wobus - Roberts Bldg. T. M. patrlck - Research A. M. Ellenburg - Research T. W. Dalton - WOK J R. Kellogg - WQK Process Holders TENTATIVE AMENDMENT NO. B Title: Aroclor - Standard Manufacturing Process Objective: . This amendment covers changes in the chlorination step of the Aroclor process; in particular, it suggests that the batch of biphenyl be circulated In the chlorinator during the entire period of chlorination, and that a temperature of 130-150C., be maintained during the whole chlorination Previous Practice: . In the Manufacturjng Process, no definite temperature is described for the start of the Chlorination. For the biphenyl measuring tank a temperature of at least 85C., is recommended and as a "finishing temperature" a range of 120-135C is described for Aroclor 12*42 and 1248, a "finishing temp erature" of 120-15>0C., for Aroclor 12^4, 1260 and 12o2. The circulation of each batch in the chlorinator is started after the first four (4) hours of the chlorination (approximately half of the total chlorination time of Aroclor 1242). proposed Amendment s The biphenyl charge will be heated to at least 115-120C., in the me&surJng tank. After charging the chlorinator, circulation will be started before the chlorine feed is begun to allow distribution of the ferric chloride catalyst. The temperature of the chlorinator should be brought up to 130C., in a minimum time usually 20 to 30 minutes after the chlorine introduction The chlorination of bJphepyl to all liquid Aroclors should be carried out at a reaction temperature of 130-150C. COMPANY CONFIDENTIAL TRAN 009302 HARTOLDMONO010576 Tentative Amendment No. B -2- September 27, 1957 Proposed Amendment (Cont'd.) NOTE: In order to mechanically reduce losses due to sublimation and en trainment, it Is suggested that the circulating line introducing the charge into the top of the chlorination be extended to the surface level of the biphenyl charge. This will prevent the reaction mix ture from being sprayed into the exit gas stream and should ell minate some entrainment. Justification: Laboratory experiments and actual plant runs have Indicated that catalyst concentration and reaction temperature are imperative for the production of an end product of good quality. (Final Report No. 1640, October 22, 1956 by H Merten, Progess Report No. 5j Job No 3428 Code IND FL, of August, 1957 by H Merten and A. M. Ellenburg. Circulating each biphenyl batch from the beginning of the chlorination should facilitate the production of a more uniform material, since a better contact of the biphenyl charge with the catalyst at the start of each chlori nation 1b made possible. The catalyst will be distributed more evenly and hot spots will be eliminated. The production of inferior Aroclor caused by too low a chlorination temp erature of deficient catalyst distribution would be avoided by changing the present Manufacturing Process according to this amendment. In addition to the data obtained by laboratory experiments (described above) the following Table I illustrates the effect of temperature changes on the quality of the end product of actual plant runs (shown by stability chloride values). Table II indicates the improvement in the stability of different Aroclors produced by circulation of the batches during the whole chlorination period compared to runs carried out with batch circulation after the lapse of a four-hour chlorination period. TABLE I Batch No. Temperature Low High Stability Chloride ppm./l6 hrs. 519 94 116 320 110 129 321 153 145 0.80 0.74 0.49 COMPANY CONFIDENTIAL TRAN 009303 HARTOLDMONO010577 Tentative Amendment No. B September 27, 1957 TABLE II Circulation Aroclor No. after 4 hours after 4 hours entire period entire period after 4 hours after 4 hours entire period entire period 125* 1254 1254 1254 1260 1260 1260 1260 Lot No. T-631 T-632 T-635 T-656 T-1044 T-1045 T-1048 T-1049 Stability Chloride ppm./16 hrs. .85 .89 .45 .45 .52 .57 .39 .45- Precautions: No increased toxicity or safety hazards will result from this proces Extent of Demonstrations: It 1b suggested that this amendment be incorporated in the standard Manufacturing Process as soon aB possible. Original signed by: H. L. Merten , H. L. Merten Research Department In Approved: Original signed by; j. r. Kellogg ---------- 7. R7 Kellogg A. M. Ellenburg T7 FT.'TrienBufg T. W. Dalton T. W Dalton T. M. Patrick, jr. "P. M. Patrick COMPANY CONFIDENTIAL TRAN 009304 HARTOLDMONO010578 Safety Review Committee ORIGINAL SIGNED BY: H. L. Hubbard 5/18/57 R. H. M. 3/18/57 R. E. Howard 3/18/57 March 15, 1957 Distribution: Dr. 0. J. Weinkauff - Research R. S. Wobus - Roberts Bldg. H, L. Hubbard - Research A. M. Ellenburg - Research T. W Dalton - WOK J. R. Kellogg - WOK Process Holders Tentative Amendment No. A Title: Aroclor - Standard Manufacturing Process for Department 246, W. 0. Krummrich - Revised 3/15/55 - 0. N. Schwartz. Objective: This amendment covers process changes in the chlorination step of the Aroclor Process, Section V Part B, concerning the Catalyst. Present Practice: The biphenyl charge is dropped by gravity to the #1 2, 3 4 or 5 chlorlnators. The chlorlnators are constructed of steel and are 3 feet ;in diameter x 16 feet in height. For catalyst, they contain an 6 foot bed of coarse steel turnings which have been burned free of oil and moisture over an open gas flame prior to their introduction into the chlorinator. Additional catalyst is added to the chlorlnators as required. Normally, this is not necessary more than once a year. Proposed Amendment: , In addition to the present catalyst source, each chlorinator batch of >600 or 4000 pounds of biphenyl will be charged with 2 pounds of an hydrous ferric chloride before the chlorination begins,. justification: Experience has shown that various degrees of unstable Aroclor can result at times from the present method of supplying catalyst to the chlorination step. The use of FeCl3 has been investigated and found to give a very stable product when used in the suggested purport ion The complaints from General Electric Company on Aroclor 1242 re garding the instability of certa n material produced in July and August, 1956, make it mandatory that we maintain our Aroclor quality at its maximum at all times. TRAN 009305 HARTOLDMONO010579 March 15 1957 -2- Tentatlve Amendment No.A Precautions: No increased toxicity or safety hazard will result from this process change. Ferric chloride is hjghly hygroscopic and is acidic in nature, therefore care should be tanke to prevent contact with skin or clothing. Extent of Demonstration: The process change has been demonstrated at Anniston. This amendment will be a permanent change and should be incorporated in the next revision of the manufacturing process. Approved: Original signed by; j. R. Kellogg -----------J. FT." Kellogg A. M. Ellenburg Organic Research Group Leader A. M. Ellenburg TT'W;..Ellenburg------------ T. W. Dalton T. W. baiton In F. B. Zienty 5-19-57 *r. M. Patrick for T. M. Patrick COMPANY CONFIDENTIAL TRAN 009306 HARTOLDMONO010580 Monsanto, Illinois June 8, 1959 CC: C. M. Edelblut - Anniston J. Clegorn - Anniston Safety Review Committee Original signed byj ... T.A.P, 6-12-59 . R-K.H. 6-12-59________ __ R, IL fr-15-59 Messrs. T W. Dalton T. m. Patrick - Research m. M. Ellenburg - Research H. S. Scott Process Holders PROCESS AMENDMENT - AROCLORS Dept46 - w.Q.K. FEM Title Modification of chlorination temperatures for Aroclor production Purpose To provide chlorination temperature ranges that are more compatible with plant conditions Old Procedure 0 Biphenyl chlorination is performed at temperature range of 150 to 150 C. Proposed Procedure Initial chlorination of Biphenyl may be started at a minimum temperature of 95C. provided that 120C is reached within 1/2 hour. Chlorination may be continued for the next tow hours at a temperature no less than 120C. Completion of the batch will then be controlled between 130 and 150C. Reason and Justification ^ Normal Biphenyl storage is maintained at approximately 95 C. to keep safely below the flash point. Therefore to adhere strictly to the process would require heating of the batch to 130C. before chlorination. This results in production delays and increased Biphenyl pluggage in chlorlnator off gas lines. Based on plant experience most chlorlnators are recharged while still hot from the preceedlng batch; this normally yeilds a starting temperature in the range of 120C. However, occasionally delays cause charging to a cooler chlorlnator where the net temperature may approach 95C. This proposal would allow chlorination to start immediately under these conditions The batch temperature would then rise rapidly from its own heat with water being applied later to line out the temperature somewhere Blightly above 120C. A lower temperature range 120 to 130C. is needed for the first two hours to reduce Biphenyl carry-over into the off gas lines. _ COMPANY CONFIDENTIAL TRAN 00930? HARTOLDMONO010581 -2- This proposed process ammendment has tentative approval from Research. In Original Signed by; T. W* Dalton T. W. Dalton A. M. Ellenburg A. M. Ellenburg J'7 RTKellogg J. R. Kellogg 771 Kellogg T. M. Patrick 6-12-59 TTT PaTrick COMPANY CONFIDENTIAL TRAN 009308 HARTOLDMONO010582 Dept. 246 Process Description AROCLOR APPENDIX L . TIME CYCLE 52. The design capacity of the department is 1,700,000 (2,400,000 after August, 1964) pounds per month, or 20,400,000 pounds per year. Figure 1 of this section Illustrates the flow pattern of the Aroclor process and lists the approximate time needed to complete each process step. The time table for the Aroclor process is summorized below: Operation Equivalent pounds Time (hours) of Finished Product Charge Chlorinator Chlorination 1242 1248 1254 1260 Transfer to blow tanks Aeration Distillation 1242 1248 1254 1260 Blending Filtering Dropping to Storage .25 ' 8.70 9.20 11.10 12.JO .25 2.00 1.75 1.75 1.75 1.75 2.00 2.00 2.00 6550 7200 8040 9100 The time required to make completed batches of the various Arocl< tabulated below: Aroclor ~T?T2-- 1248 1254 1260 BatchjgT9im5e--(1-h--r--s--.-) 19.45 21.55 22.55 Process operations including filter press cleaning, sampling, etc. are independent of the batch completion time cycle because production time is not lost. COMPANY CONFIDENTIAL TRAN 009309 HARTOLDMONO010583 ?1 gurc 1. A ROC LOR FLOW SHEET WIT1! riATC!t S17 E ANP RATES Cl, biphenyl Bl- Charge Tank yon oa i. 5 ChlorJnators Two Plow "*anks 2200 Ga1. Two Stl1 is Two ^ Rece 1 vers 1000 Gal. 1.7 ^ bba./Mo. RATE ' Charge: *000 lb. - *70 gaU for 11*2, 11*8, 115* and 1160. Takes 15 minutes to charge and discharge. Capacity: 700 Gal. 1.7 5 Lbs ./So. QST ', 11*2 6*oo u. * 590 Ga;., 12 hi. no' 1 ~oi. m . .'>) Gai.. i5KHi *, - orn 11 .,I M. * On i . , !, T .*' JJ!,n. . JO 'L'. . 'G.T., i in-, .. pkd[ P.VH 5 l.bs./Me>. RA^K , - 11Charge: *000 U>r.. = *70 On I. ' ': ,4.: HIM i-l !. i:<* : BP, . ' .'in i ; *.: 1 l 1 H. 1 > P! h ! I'.O: r . ?* ` , 1 '*! r i-rr 1 .' -; 1 1. / ^ M>* . /Mo. />* onT 1.7 M i,bs./Vo. <JQ? Q2.T AVERAGE P&PW Each batch Is hiown for ? hours. One tnnk Is 3 :low tn^ and erne tank feeds he 12*2 : 12*7 : 5J.5 1 '>, 57.2 HPB - 1*0.000 or 12,000 Gal. 1 CHI jpar-TT'E *p - 150,000* 12*0-21* 'Ml oro PPP 2o70"3ir50Tj00( 2020 5150 65O0C 12S> lb., oo.o or 12,<00 Gal. wi n fr 1^0,000 ' lP`jii-207 1260 2u2 2<2o 21-20 *900 *30 65O0C 65O0C l2do lt..( or 1*,>00 Gal 75 %f urn - r5,?oo ^ r.hs. ^o. '()' rr. ' 2"7<7 It'-, ft 7TT2T~T~.T 1 24*-: ko.`> or 15.200 Gal, OQySbST ~ Hpn Hi B 1 12*2 l?Ay 510 ` 1;22`M>*):: *< .0 urn Vi.o HEP ' 1251* ?< 2 1700 7" 50 P.fcCRX iffyO 7 500 HBO-X 5C60 7000 6bO<K 5160 fc750 0bO<X ---------------------------1 SI* Loading 1 1 , t .1^- t-fwo Mix One Drum Off One Tank Trailer -" * t Pour Tank Car (One Tor Unloading) tt taker. hours to *n1 X I 2* V Gs . HI D * Hours Per Batch l* Charge, chlorinate and en; ty. *2. A still hatch is 22 chlorinVor batches. ni r> Patches let* 'ny OPT * ( n rtrean Tim: G! K - G i . 1 .;!* Ga:. ! `T1 I :l - 1 '*>*ids * i uUitJj -jay f>! Storage in JariKC * j Two * Product Tanks - 2000 Cal. Two Mem) " Tanks 2000 Cal. . 12*2 12*.5 12S* t?rj0 '> and'<Mj, lbc-00 Cal. Each Capacity: 12 brD or 2000 1 .7 H Li-a./Ho. VO? OCT ' 70, WO Oal. *t. 16, 500 Oal. * , TO,000 Oal. ' Cal. i f Two Recel'.ers to a Batch. , 2000 Gal. Batches ` HPD * 2 BPD ' Cac nclty: 1? R! D ___ . _ ^ _ _ __ _ __ 2.<P ^ `.bb^o. <*yi OST t02 - /< ii COMPANY CONFIDENTIAL TRAN 009310 HARTOLDMONO010584 I Dept. 246 - Process Description 5?. AROCLOR APPENDIX M QUALITY CONSIDERATIONS The Aroclor compounds are among the most versatile chemically-made materials in industry, Aroclors are useful in many ways because of their outstanding inertness. Aroclors are used alone for particular physical jobs such as insulating, heat transfer, sealants, and expansion media; and they are used as com ponents or extendors in elastomers, adhesives, paints, lacquers, var nishes, pigment6 and waxes. Aroclors must be highly pure, with dependably minimal traces of electro lytes for use in electrical applications. Electrical grade Aroclors must pass numerous stringent specifications. The following tests determine. Aroclor quality: Hydrolysis stability Measure of chemically unstable chlorine compounds, Munch or Monsanto Stability Test Measure of thermally unstable chlorine compounds at elevated temperatures. Thermal Chemical Chloride Developed by the General Electric Co. to measure chemically and thermally unstable chlorine compounds. Resistivity Measure of insulative properties. Power Factor Measures power Iobs due to current through a capacitor. Dielectric Constant Measures the capacitance of a standard such as air compared to the capacitances of Aroclor. Specific Gravity, . refractive index Measures of chlorination level. The stability and electrical properties of electrical-grade Aroclors are paramount in quality considerations. The chlorination step of the process is most critical because many properties of the final product are deter mined by the properties of the crude Aroclor, Conditions in the chlorinator needed for a good quality product are: 1. Chlorination Temperature - The chlorination temperature must be greater than;120*G<` &t the beginning of the chlorination reaction to pi'Oduce stable Aroclors. Results of research tests indicate that product stability is better as the initial chlorination temperature is increased. COMPANY CONFIDENTIAL TRAN 009311 HARTOLDMONO010585 f 51*2. 3 4 5 6 Department 246 - Process Description AROCLbR APPENDIX M QUALITY CONSIDERATIONS 2. Ferric Chloride Concentration - Research has found that the ferric chloride concentration must be at least 0.03% to form stable products. Research recommends 0.05% ferric chloride. Lower catalyst ratios result in increased "addition" chlorination as opposed to "substitution" chlorination, indicated by higher chloride values and lower yields. The isomeric distribution of the final product is a function of the type and concentration of the catalyst used in the reaction. Homogeneous suspension of the catalyst is extremely important. Good catalyst contact can not be attained without homogeneous sus pension. Since ferric chloride does not mix well with biphenyl, the dry catalyst must not be poured into the chlorinator, 3. Geometry of Reacting VcsbcI - The shape of the reactor affects the circulation and flow pattern bf the reactants. It is suspected that the chlorine gas channels through a void space, in the existing catalyst basket. This problem is presently being studied. The reactor must be designed such that circulation of reactants is rapid and homogeneous and local over-chlorination does not occur. 4. Cleanliness - The ferric chloride catalyst settles to the bottom of the chlorinator. Areas of the packed bed become plugged with ferric chloride and channeling of reactant flow may result. A steam clean-out of the chlorinator may be an expedient method to remove the ferric chloride. This method was tried in the department, and evidently was successful. Further tests by the laboratory will verify the effectiveness of a steam clean-out. 5. Sparging - The sparger controls the gas distribution under the cata- lyst hold-up plate and the size of gas bubbles. It is not known whether the catalyst basket or sparger or both are the critical factors in achieving the proper flow of gas through the reactor. It is believed that the sparger should distribute small bubbles give good gas dis tribution throughout the chlorinator. The small bubbles have a greater surface area per unit volume of gas for mass transfer, and fhis should increase, the rdactidn r&te, ;. 6. Raw Material Purity - The purity of raw materials can affect the quality of Aroclors. Sulfates are particularly harmful in the chlorine gas. It is suspected that sulfates poison the ferric chloride catalyst and Sulfonate some of the biphenyl. If the ferric chloride catalyst is . poisoned, the effective catalyst concentration is reduced and thus un stable aroclors will be produced. The chemistry and mechanism of catalytic poisoning are not known for certain. Sulfonated biphenyl is carried-over during distillation and is not removed by earth treating. TRAN 009312 COMPANY CONFIDENTIAL HARTOLDMONO010586 55. Dept, 246 - Process Description AROCLOR APPENDIX M QUALITY CONSIDERATIONS 6, Raw Material Purity (Cont'd, ) Sulfonated biphenyl has ionic properties which lowers the resis tivity of the finished product. A Brink Mist Eliminator has been installed in Dept. 246 to eliminate the chlorine impurities, 7, Earth Treatment - The factors affecting stability also influence the electrical properties of Aroclors. An absorbent will be inef fective if the Aroclor was not prepared in a manner such that a stable product was formed during the chlorination reaction. However, research has found that absorbents are very effective for improvement of electrical properties by removing ferric chloride and tar b carried-over during distillation, provided the crude Aroclor has good stability. The absorbent used in Dept. 246 (after distillation) is Attapulgus Earth; . . the concentration should be 0.05% for Aroclor 1242 and 0.1% for other Aroclors, The earth must be heat treated at 250C. for a minimum of 4 hours before addition to the Aroclor. Heat treatment reduces the moisture and activates the earth. \ 8. Lime Treatment - It is important that proper amount of lime (250 pounds per, still run) be added to the still to prevent sublima tion of ferric chloride. 9. The blend tanks, finished product tanks, and Aroclor 1242 and 1254 storage tanks are blanketed with nitrogen gas, Nitrogen blanketing maintains the electrical properties of the Aroclors by preventing corrosion of the equipment. , In summary, the chlorination step of the process is the most critical. A good quality Aroclor can not be produced if a stable compound is not formed during chlorination. Once a stable compound is formed, other techniques such as use of lime, absorbents, and nitrogen blanketing are used to maintain and improve electrical properties. COMPANY CONFIDENTIAL TRAN 009313 HARTOLDMONO010587 Dept. 246 - Process Description 56. AROCLOR APPPNDTY M QUALITY CONSIDERATIONS (Cont1d,) Absorbents Numerous absorbentB have been screened in the laboratory at various contact temperatures for their effect on resistivity of plant untreated Aroclor 1242. The most satisfactory absorbent pound for improving the resistivity of Aroclor 1242 was LVM attasorb. Table I of this section lists the laboratory results of the different absorbents used to treat Aroclor 1242. Degradation of Aroclors Degradation of Aroclors, which leads to loss in eleotrical resistivity, is one of the short comings of UBing Aroclor as a dielectric, especially since only a very minor degradation can cause a serious breakdown in electrical equipment. The thermal degradation of fractionated Aroclor has been measured at 250C. and the amount of Hydrogen Chloride liberated was measured. The results of these testa are listed in table II of this section. ' Aroclor 1242 has been degraded by ultraviolent light, and the decrease in electrical resistivity with irradiation time was measured. The plot of resistivity versus time of irradiation (Figure 1 of this section) resembles a conductivity versus concentration curve for a weak electrolyte. It is possible to remove the conducting material brought about by photo-degrad ation, and restore the resistivity to its original value by passing the degraded material over activated alumina. Thermal degradation of Aroclors is minor compared to photo chemical degradation. Thermal treatment causes release of a small amount of hydrogen Chloride initially, but this evolution ceases after a Bhort time. Such behavior is attributed to thermal degradation of impurities. If Aroclor is irrodiated, then exposed to a thermal treatment, appreciably more HC1 is liberated. COMPANY CONFIDENTIAL V TRAN 009314 HARTOLDMONO010588 Dept. 246 - Process Description AROCLOR APPENDIX M 57. QUALITY CONSIDERATIONS (Cont'd.) TABLE I ADSORBENT SCREENING DATA Adsorbent Adsorbent Pretreatment Contact Temperature C. Volume Resistivity : 'at 100c. ohm-cm. x 10 LVM Attapulgus Earth None LVM Attapulgus Earth LVM Attapulgus Earth. LVM Attapulgus Earth, Attasorb LVM Heated at 250C.12 hours. Heated at 350C.12 hours. Heated at 350C.4 hours. None Attaclay None Activated Alumina (Alcoa Grade P-5 -525 mesh) None Voclay 325 (Western Bentonite) Panther Creek (Southern Bentonite) Filtrol Grade 1 Zeolex 7 (Zeolite) Florite 60 mesh (Activated Bauxite) Suprex L-G (Kaolin) Attasorb - LVM Attasorb - RVM . None None None None None None ft Heated 350 C.12 hours. None 60 80 100 120 60 80 100 120 60 80 100 120 60 80 100 120 60 80 100 120 80 100 120 60 80 100 120 80 100 120 80 100 120 80 80 100 100 100 100 v< If Sg0 u- Q TRAN 009315 3400 2000 2800 2900 4200 6400 7200 6100 9300 9000 6300 6300 2400 5600 6000 5700 9700 12,100 13.700 17,800 10,200 5400 6000 2100 2500 2800 3100 5700 3800 9700 6200 11.300 81OO 2600 7000 3600 4500 12,200 '6,200 HARTOLDMONO010589 Dept. 2^6 - Process Description AROCLOR APPENDIX N 58. QUALITY CONSIDERATIONS (Cont'd.) ' Adsorbent Linde Molecular Sieve Type ^-A Laminar Alumina (Dayton) TABLE I (Cont'd.) Adsorbent Pretreatment None Contact Temperature c. 60 None 60 Volume ResJstivlt at 100C. , ohm-cm. x 10 2100 900 Note: Resistivity of Aroclor before treatment -lx 1C) ohm-cm. COMPANY CONFIDENTIAL TRAN 009316 HARTOLDMONO010590 Dept. 2^6 - Process Description aroclor APPENDIX M QUALITY CONSIDERATIONS Aroclor 1221 12)2 1242 1248 1254 TABLE II THERMAL DEGRADATION OF AROCLORD AT 25QC. gm. of HCl/gm x 10^* 6.75 11.07 3.91 6.42 9.81 5.96 9.58 13.00 ).6l 5.44 8.48 3-^3 3.96 6.43 Heating Time 1 hr. 2 hrs . 5 hrs . 1 hr. 2 hrs . 5 hrs. 1 hr 2 hrs . 5 hrs. 1 hr. 2 hrs . 5 hrs . 1 hr. 2 hrs . 5 hrs . 59. COMPANY CONFIDENTIAL TRAN 009317 HARTOLDMONO010591 COMPANY CONFIDENTIAL 10 X TO TO H lCK K*S 7 S to Ruifru. ejyggw +* T323 60. Dept. 246 - Process Description AROCLOR APPENDIX N MISCELLANEOUS REFERENCES 1. St. Louis Report No. 2694, Job No. 171-1028, February 15, 1952. Title: Operation of Aroclor Stills At Increased Pressure For Increased Rates Summary: Distillation runs were made at 20 to 30 mm Hg, The rate of Distillation of 1200 series Aroclors increases with pressure. 2. St. Louis Report No. 2755, Job No. 2-02-760.01 - 3948-3 March 6, 1961. Title: Improved Aroclor 1242 Studies Summary: Studies were carried out to determine the effect of temperature, chlorine content, and catalyst concen tration in chlorinated biphenyl mixtures. 2, 4-dichiorobiphenyl is the percursor of the high dielectric constant, trichlorinated components. 3. St. Louis Report No. 2072, Job No. 2-02-750.01-3428, May 4, 1958. Title: Final Report on Aroclor Process Studies, Summary: Purity of raw mate rials, catalyst concentration, reaction temperature and rate of chlorination were the variables studied with respect to their influence on the stability of the finished product. 4. St. Louis Report No. 2540, Job No. 171-616, December 28, 1958. Title: The Effect of Prolonged Heat on the Electrical Properties of Aroclors, Summary: Aroclors 1232, 1242, 1248 and 1254 were held at 130*C, The power factor was periodically measured. 5. St. Louis Report No. 2234, Job No. 171-451, June 14, 1956. Title: Evaporation Loss of Aroclors. Summary: The evaporation loss of Aroclors was determined at 100*C, under static conditions, COMPANY CONFIDENTIAL TRAN 009319 HARTOLDMONO010593 I 6l. Dept. 246 - Process Description AROCLOR APPENDIX N MISCELLANEOUS REFERENCES 6. St. Louie Report No. 2790, Job No. 171-1028, July 3, 1952. Title: Increased Production of Arociors by More Rapid Rate of Chlorination. Summary: Chlorination rate was increased from 400 pounds per hour to 770 pounds per hour. Arociors produced at increased rate was within specifications. 7. St. Louis Report No. 1842, Job No. 2-02-750.01-3368 July 12, 1957. Title: Use of Ferric Chloride as Catalyst for Production of Aroclor 1242. Summary: The Comparison of stability chloride values revealed no difference between the product made with iron turnings as catalyst and ferric chloride as catalyst. 8. St. Louis Report No. 2096, Job No. 2-02-750.01-3202, June 6, 1958. Title: Resistivity Improvement of Aroclor 1242. Summary: Numerous absorbents were screened at various contact temperatures for their effect on resistivity of plant untreated Aroclor 1242, Heat activation of Attapulgus Earth was also studied. 9. E. E. Martin, OPERATING INSTRUCTIONS FOR DEPT, 246, W. G. Krummrick Plant, 1961. '" 10. E. E. Martin, PROCESS DESCRIPTION FOR MANUFACTURE OF AROCLORS, 1962. : 11. E. Mather, PROCESS DESCRIPTION FOR MANUFACTURE OF AROCLORS, 1955. COMPANY CONFIDENTIAL TRAN 009320 HARTOLDMONO010594 Dept. 246 - Process Description AROCLOR APPENDIX N MISCELLANEOUS 62. The following table showe the results of tests which measured the evaporation losses of the various Aroclors. Aroclor Evaporation Rate gms./cm?/hr./1QQC Aroclor 1221 .00174 Aroclor 12?2 ' .000874 Aroclor 1242 .000238 Aroclor 1248 .000152 Aroclor 1254 ,000053 Aroclor 1260 .0000088 Aroclor 1262 .0000132 From the above results, the evaporation rate for Aroclor 1262 Ib greater than that of Aroclor 1260. This unexpected result may be explained by some difference in the conditions of which the two lots were prepared. The reaction products in Biphenyl Chlorination differ with the type of catalyst used. Results of research investigations are listed below: Catalyst Fe Cl s Sb Cls Ti Cl* Sn Cl* TZ"2Is--omer Distribution of Aroclor 2,2* - TTTr-...- 1232 15* 11 11 . 24 7% 15* 0.7 20 0 20 1 16 6* 3.6 2.2 2.3 38* $8 46 28 iii* 11* 18 14 18 tri 9* 9 7 1.3 i COMPANY ' CONFIDENTIAL TRAN 009321 HARTOLDMONO010595 I Dept 246 - Process Description_________ AROCLOR APPENDIX N MISCELLANEOUS (Cont1d . ) 63. Some of the typical operating diff culties in department 246 and possible remedies are given below: CHLORINATORS Trouble Cause Remedy Chlorinators operating against too much back pressure. Plugged off-gas lineB Open lines and steam them out, Dry out lines with air before resuming operation. Chlorinator slow in picking up gravity 1. Low Chlorine pres 1. Call Chlorine Dept, sure or low chlorine for more gas gas concentration 2. Check Biphenyl 2. Wet Biphenyl storage tanks for moisture. Blow tanks stacking off BLOW TANKS Operating Chlorinators Close chlorinator vent; with vent open. possibly reduce air to blow tanks STILLS Not enough vacuum 1. Ejectors not pull ing properly 2. Coke scrubber Contains water 1. Check Ejectors 2. Drain Coke scrubber Foreign material . In filtrate samples ` 36" SPARKLER FILTER Dirty filter or broken paper Clean & re-paper press COMPANY CONFIDENTIAL TRAN 009322 HARTOLDMONO010596 6 A IV6 A S V , Ifi/e o i rvitii 6in-K 6T WORK PROPOSAL WGK PLANT TECHNICAL SERVICES initia'CO |r cONDR.LlUEi .St Harris i Aroclor ori IoBT 7sr M.% M5Q44 OR I6IN A L TO cc mit (no TsuI p0r, JOS Soon ocsiow V. Brawley J. Savage L. Sprandel R. Spuering ELIMINATE OBNOXIOUS FUMES AT DRUMMINO STATION I1STMMNT 0 RROSLtH AMD OSJSCTIVI ((/ TSrSrAS tUt II MMIII'rl There are obnoxious fumes in the drumming area where an operator must spend long periods of time. These fumes are from cleaning filters in the area, leaks from pumps, and opening drums of raw materials. The obnoxious fumes should be eliminated to provide a suitable work area. CSfWAHD AVISO OS OTrtfR eCMCflTt Elimination of the obnoxious fumes will permit operators to work in an area without irritation. TuTsTTTfT approach, AM*I4h, r*e Provide a vent fan in the roof if it is determined that this will provide adequate ventilation. : MANPOWfft mouiacminIs (VALUATION _Lfi___ Ca C MB. M C. MS l.l Die INST N. DRAPTINO --24 START-UP___________ Mi[LNiOM. iMNSANWY 2. Toevaluation! t> comc/eigtf by Technical Strylct Deo/, T.A.O. COST CSTIMATtD SAVINSS OR PROFITS |Nl 111(0 CAPITAL TRAN OSSSOO TOTAL TOTAL FT Heisler FmrrBmmrAPMOVAIS UIIMWib Tt T.I.b. illT. lNA.TuFUiliTElifttmT L. W. Sprandel TfWHIiiL M6WTi6l M*T HARTOLDMONO010599 I I 1. h Jigs -a--- PROOREiS REPORT 1TECHNICAL SERVICES OEPT. - B. (. )'" ism bo. /report m. #. ERUIEtRICM PI**i___ Lmsninj ______ ___________ - ' i** i,. *B E.Billon B E. Malone 1 B M.Ooldasich B j.Shafer RESEARCH EHORAL OPTICS o c*,0e * J. E. Smith D J. 0. Bright 6Q. babna OTHBRI 1 *_ 3. e. a RfMBTLfLMOSOaOvage B A. E. Lelsy 0T. V. SALTSM Bj. W. Honey B. R.McCutchan B 3. Davis B E.Mares ` t3 W.R. Richard D. E. Cayard e. aAHASR88TOPOVLOS Op. e. seearbs '|B ^06. Hodges OR* B* Howard J.C. Landwehi So. 2nd St. * P.O. DeCarmo 8 0. L. Bratsch S 0.Hudson ' BnT.A.Kuhn 0 A. MMMNH tlT.M. Patrick qD. J. O'Toole B F.Elliott B B. IIBIWBR . *0 J.F. Quinn HD. V* Jaokaon BJ R.Hamlet a. ' H, 0. Oardar B E.S.Tucker- B L. Sprandel B D.Sartor Oe.k.EAMPbS BB.R. Williams g R.Splller B R. Stratmayar TO RieEIVC DETAIL SCCTW TITLE! WATER POLLUTION; AROCLOR CONTROL "PERSONNEL.! PROOLEMi M, Pierle (C. P, Buckley) To determine source and quantity of Aroclor losses to the sewer. Aroclor losses are confined to Departments 238, 217, 218, 243, 245, 246, 258 270, 273, and 275. Department 245 Is now hauling 3600-4800 gallons/year of spent aroclor to the Monsanto landfill. The remaining major source of aroclor In the sewer is Department 246. From yield losses It is estimated that these losses total 40,000 #/yr. to the sewer. A project with estimated cost of $10,000 Is presently being developed to minimize the Department 246 losses. Water and mud samples are being taken to determine both the actual plant losses and the effect of W.G.K.'s outfall on the aroclor levels in the Mississippi River. M. A. Pierle Technical Services Dept. Jo ' COMPANY CONFIDENTIAL IRAN *86^ COMPANY CONFIDENTIAL INFORMATION 'feta 4eoBta is !te prope*; ef HeaaaMte Osrapaay earf tfea teclpte* tm reevesfete tw he Bafetesepiag m& Elepesfcie*. a aMBlae eeafWs*" ttftl lofwaaUaa el Mememta Caapeeg mm>t mtt fe <ts fereea er Mat suIbMs tfea aeapaaf wifceM fBejwr eetboflsetloa. Either relate fe seams Bias at mm--mmmmmmmmmmmm............... HARTOLDMONO010600 u) 91341:4119(1) -2- September 22, 1969 BACKGROUND: The outbreak of adverse publicity toward the use of chlorinated hydrocarbon Insecticides has caused the W.G.K. plant to study the losses of polychlorinated biphenyl (aroclor) from the plant. Recent studies have indicated that PCB materials act similar to the insecti cides in that they are resistant to biological breakdown in the environment, and therefore, they tend to concentrate in animals such as birds or fish. The object of this report is to summarize preliminary information on the sources and quantities of aroclor material in the W.G.K. plant effluent. DETAILS: A. Sources 1. Each manufacturing department was surveyed to determine whether or not aroclor could be present in its effluent. The use of aroclor is oonfined to Departments 238, 243, 245, 258, 270, 273, and 275. 2. Aroclor has also been detected in the catch pot systems In Department 218 and 217 This is contained in the HC1 off-gas from Department 246. 3. The manufacturing department, 246, has aroclor in its effluent. This is readily visible in the department's trench sewers. B. Quantity 1. Although aroclor is used in the above stated departments, only two departments (245, 238) have to completely change out their system on a routine basis. Department 245 uses 600 gallons every 1 1/2 - 2 months, and Department 238 uses about 2,000 gallons/year. Other department losses are from vapor losses due to tank breathing and leaks from pump packing. 2. The amount of aroclor in the HC1 off-gas system is believed to be minor since it is infrequently found in the 217 and 218 catch pots. 3. Based on yield losses, Department 246 losses are estimated at 4o,000#/yr. , COMPANY CONFIDENTIAL FRAN 058843 HARTOLDMONO010601 I 91341:4119(1) ( -3- ) September 22, 1969 B. Quantity (continued) 4. General The following sampling program has been developed to quantify the losses from the W.G.K. plant and to de termine the effects In the Mississippi River. Liquid Samples 1. Plant outfall - one weekly composite sample. 2. One weekly composite sample representing effluent from Department 246. Mud Samples 1. Sample from primary treatment plant sludge. 2. 0.5 miles upstream of outfall. 3. 200 feet below outfall. 4. 1.0 miles below outfall. All of above are taken once per month. To date, due to work priority, analytical results are not available. Samples will continue to be collected. C. Control Measures 1. Dept. 245 - The aroclor which previously had been sewered Is now being hauled to the Monsanto landfill. This amounts to a plant reduction of 3600 to 4800 gallons per year. 2. Dept. 238 - This material has and will continue to be dis posed of at the landfill. 3. A project is presently being developed for Dept. 246 as part of a general paving project which should minimise aroclor losses. It involves the construction of settling chambers In trench sewers which will act as collection basins for the aroclor. The material will be removed by either a steam Jet pump or a sump pump if it is needed. The estimated cost for aroclor loss control is $10,000. COMPANY CONFIDENTIAL TRAN 0S884* HARTOLDMONO010602 < n (' ) 91341:*42.1.9(3.) -4- September 22, 1969 CONCLUSIONS: 1. The major sources of aroclor In the plant effluent is Department 246. 2. Laboratory results are not yet available to actually quantify total plant or Department 246 losses. 3. A project to minimise Department 246 losses is being developed. Estimated cost is $10,000. FUTURE WORK: 1. Continue supplying samples to the laboratory. 2. Improve monitoring system in Department 246. 3. Report on analytical results when obtained. COMPLY CONFIDE "AU TRAN 058845 HARTOLDMONO010603 * L* \ / L* V Plt&D WORK PLAN JUSTIFICATION.' Roduco polychlorinated biphenyl and terphenyl content o plant waste water. J. T. Bell V. R. Haupt J. C. Landwchr C L. Jesses G, W. Miller H. L. Williams G, L. Arnett J. L. Brown W. H. Howard E. G. Wright J. R. Savage - G.O. P, 0. DcGarmo - Queeny W. R. Richard - G.O. P. B. Hodges - G.O. J. E. Smith - G. 0 COST: Estimated per diem PR&D Cost Mandays Total Estimated Cost $87 10 $870 EXPERIMENTAL: i. Run adsorption isotherms with the VASte water at 10*C and ambient temperatures utilizing the following absorbents: a. Carbon (different types) b. Attspulgus clay e. Porocel d. Silica e. Molecular sieve f. Aroclor 5460 . . Target Completion Date 5/8/70 2. The data obtained in the above test will dictate the direction of future work. Another work plan will be Issued upon completion of this work plan. SAFETY: ' The waste water effluent from the Aroclor department contains mainly HCl and Aroclor (i.c., In low concentrations). UCi fumes and acid are very corrosive to the skin and mucous tissue. Repeated exposure to Aroclor can cause a condition of chlorance. Hence, any area exposed to the waste water should be washed thoroughly with copious amounts of water. If exposure Is In a critical area as the eyer, consult a physician. 'ishmcnl Ransaw /b TRAN 059631 DEPOSITION EXHIBIT 7-7-42- 53 HARTOLDMONO010604 W. B. PC'pp'oorcri - Sc. Lov.it December 7, 1970 J. R. Savese I J. Hasou II. iicrcen P. llolzapfel Ci. Bratoch lUV'.'iiirJ.f.M G. Jesses > .;'<:WoVr D. B. She?.m - V P <T Mri ijh Js.'S One very Important objective of oar PCB envir.. mental control program \:v.s to control the lcooea of X'C.B in our plants to achieve a maximum of 50 ppb in the vmnte \:ator effluent by 1-1-71 and 10 ppb by 9-1-71. Burins the month of September, hevrport reported p.n avoxT.sc; of 2^6 ppb. Burins November Anniston re ported 1410 ppb and the Krumiorich Plant reported 495 PPb. Because of the reriousnons of the PCB problem this level of performance cannot be allowed to continue. I do not recall that tiny of the plentr. hr.?; boon denied a resource they requested to achieve the stated objectives. V.'e do not have the luxury of unlimited time to coin bat tills problem. Vhat do i.c need to reduce losses quickly? W. B. PAPAGIttHas ms TRAN 061773 HARTOLDMONO010605 IN THE UNITED STATES DISTRICT COURT FOR THE NORTHERN DISTRICT OF ILLINOIS EASTERN DIVISION I THE UNITED STATES OF AMERICA, ! Plaintiff, ; vs. i ! OUTBOARD MARINE CORPORATION ! and MONSANTO COMPANY, II Defendants. ) ) ) ) ) No . 78 C 1004 ) ) ) ) ) The deposition Of JAMES RICHARD SAVAGE, | called by the Outboard Marine Corporation for examinaII S tion, pursuant to notice and agreement and pursuant to ' the Rules of Civil Procedure for the United States District Courts pertaining to the taking of depositions, taken before Thea L. Urban, a Notary Public in and for the County of Cook, State of Illinois, and a Certified Shorthand Reporter of said State, at the offices of , Kirkland & Ellis, 200 East Randolph Drive, Chicago, Illinois 60601, on the 27th day of January, A.D. 1982, ! commencing at 11:00 o'clock a.m. i PRESENT: MS. ELIZABETH STEIN , {Pollution Control Section Land & Natural Resources Division Department of Justice Washington, D.C. 20530), I' I appeared on behalf of the United States of America; HARTOLDMONO010606 Q That would include the laboratory technical ! service? I A Yes . - Q And manufacturing? II 1 A Yes. And the Maintenance Department. Q Were you involved as Production Supervisor of the Aroclor Department in manufacturing forecasts de termining how much should be manufactured? A No, my job was to produce according to the schedule . . Q Who provided you with the schedule? A I don't really know. It came from the General Office . Q In the Aroclor Department, what steps were taken to prevent water pollution? A In the Aroclor Department? Q Yes. i MR. SCHINK: You are now talking about preventing ; Aroclors from getting into the waste water? ; _MS. OLIVER: Yes. BY THE WITNESS: A I would say the principal precaution was maintenance of equipment to prevent leaks. BY MS. OLIVER: HARTOLDMONO010607 Savage - direct i 29 Q Were there leaks in the equipment? A Some times. Q Would they occur during the normal course of using the equipment? A Yes . Q How were the leaked materials disposed of? A We would use Floor-Dri compounds of some kind to adsorb the material, shovel it into drums. The drums were taken to a landfill. Q Is that the only method that was used? A Yes. Rags instead of Floor-Dri compound, where it was appropriate. Yes, in general, that was the way. Q How would any PCBs find their way out of the plant into the municipal treatment waters outside the plant? MR. SCHINK: I object to the form of the question. He said he was not aware there were any at that time in the waste. -MS. OLIVER: He was aware since then that they had been found. MR. SCHINK: But he didn't say he was aware since then they were in the waste at the time he was there, so there was no foundation. HARTOLDMONO010608 Savage - direct i 30 BY MS. OLIVER: Q Do you know how that could have happened, Mr. Savage? MR. SCHINK: How what could have happened? I object to the question. BY MS. OLIVER: Q Do you understand what I am asking, Mr. Savage? A Not really. You are asking me how something happened that I wasn't aware of and I don't understand. Q You are aware today, are you not, that PCBs were discharged from the Anniston Plant and found their way into streams and municipal treatment plant sewers and waters generally outside the plant? A Yes, I later became aware of that. Q What I am asking you is from your knowledge of the production and the operation of the Anniston Plant and the Aroclor Production Department, how did that happen? A I think based on our later study that we began to understand that that was even very small leaks which later one would be washed down or perhaps due to rainfall could create small concentrations of PCBs in the waste water which we eventually did learn to measure Q Let us start with the leaks. They were from DEPOSITION EXHIBIT Ptfk *32'A \ HARTOLDMONO010609 Monsanto r0 <****( ft S. OATl UAJtCI att *t*Cl R. Near/ (4-8156) General Offices_________________________________ ____ April 6, 1970 et Minutes of Meeting on Aroclor Fractionation UUU Building - 1700 So. Second Street April 2, 1970 H. S. Bergen R. E. Howard/R. M. Kountz W. B. Papageorge W. R. Richard J. R. Savage TO : Those in Attendance: J. L. Bernhardt J. 0. Bright N. F. fueller R. H. Hunch R. L. Neary J. E. Silver This meeting was called to review Aroclor 1142 fractionation work by Research and develop a program of action involving Engineering. The background was reviewed on Aroclor uses and the basis for the proposed fractionation step in the refining process to itprove biodegradability. Dur ing the discussion of product conf>osition, preliminary laboratory batch dis tillations and production rates, the following basis was established for the requested^ economic evaluation study. 1. The fractionated product will be designated as 1242-B. 2. Projduction rate - 30ff lb/yr. 3. Continuous fractionation of 1142 taking 82% overhead. 4. The higher boiling isomers from the colum bottoms will be taken as a side stream and processed to Aroclors 1254 and 1260. The residue will be processed to recover yield in the present residue recovery systems.5 5. The project will be based on blocked operation at one plant. No provisions are planned for co-product manufacture of 1242 and 1242-B. The design capacity will match the existing plant 1242 unit. The futurje plans are as follows for sequential actions: 1. Develop preliminary economics for fractionation by 4/13. 2. Dis!(cuss additional cost with major customers, 3. IdJentify data needed for design, 4. Caijry out process development in Research. 5. Define project and prepare project scope. COlW .r f CONFIDENTIAL IM < M* (I $ DEPOSITION EXHIBIT P/fs *33 TRAN 007185 HARTOLDMONO010610 Minutes of Meeting 2. Future plans (cont'd): 6. Ob! tain project approval. 7. Execute project. April 6, 1970 R L. Neary COMPANY CONFIDENTIAL TRAW 007186 HARTOLDMON0010611 Monsanto ..r. ----- TO Mr. J. R, Savage - general Office May 4, 1970 ` Mr. W. R. Richard QUICK ACTION POSSIBILITIES ON AROCLOR POLLUTION Mr. H. S. Berg. General Off^efe rV (/, i"' j 1. Release to the "scientific community" an estimate of worldwide PCB production, along with % in contained (sealed) applications. Explain that we do this in spite of competitive hazard, because we recognize.... etc. 2. Introduce an Interim HT fluid to keep customers going until more sophisticated fluids are ready. We could auickly start making Aroclor 1237. Call It Therminol BFR(Barely Fire Resistant). Should be substantially laer in 5 & 6 Cl than any other Fire Resistant Therminol. Could put NCR temporarily on same product? Also use as a blend stock In 1232 Instead of 1242? 3. Announce that, in addition to replacing/eliminating the non-biodegradable PCB's from "consumable" products (plasticizers, coatings, etc.) we are setting out to "close the loop" worldwide on contained (sealed) applications by providing a reclamation and disposal service to the customer. An extension of previous Pydraul andTherminol reclamation programs which make it unnecessary to discard used or oontaimated fluids. J. R Savage md M Mi *M V TRAN 009972 DEPOSmON EXHIBIT Pffi 7- ? - 9z g HARTOLDMON0010612 1. * EEROM - ST. LOSTLS MAT 20, 1970 JUlOCLOfS 1232 REPLACBIMT Me 1. iUClIAJ I. f. J08XSOM B. 4. OLSOM J. H SAVAOX to art toaprarily oeitiiiuifii with tel@F 1232 as no Bade for several aeoownts (l#i @11 uni Radiator ^peeialUes). Me msU like to go as soon as possible to a produet as elesi to i?wbr 1232 as possible, tot a ifel@h would not erystalllse and ba essentially biodegradable. X understand that we sight appreaeii this to mIk Aroolor 1236 and blending this with Crosier 1221. ffcere nay to othar ways to get around It also. Mould you please develop as fuiekly as possible eur tost replaoewent for this produet m that we mm plan to Biart waking it as soon as possible. Please keep Marketing, Jia Savage and X advised. thanks. a. i. unn DEPOSmON EXHIBIT P)fs 7-Q'4z. 9*9 TRAN 005571 HARTOLDMON0010613 Monsanto >a r i TO P. 0, Benignus - St. Louis General office Juno 11* 1970 CAPACITOR AROCLOR 1242 MCS 1016 D. A. Olson - St. Louis H. S. Bergen - St. Louis R. H. Munch - J.F. Queeny W. R. Richard - St. Louis J. Savage - St. Louis J. 0. Bryant - St. Louis O. R, Orahan - New York J. R. Fallon - st. Louis N. T. Johnson - St. Louis T. Katayama - MMK Tokyo C. Coleman - Ruabon P.J.A. Marsh - Brussels R. Kountz - St. Louis A. Koenig - St. Louis W. Gordon - St. Louis To improve biodegradability some experimental Aroclor 1242 with some of the higher chlorinated biphenyls removed is being prepared. This material has already been called Aroclor 1242B. Obviously the "B" implies biodegradabillty. \fe now feel that this nomenclature is not desirable at this stage of this new and not fully explored material. Therefore, we now elect to call this material MC5 1016. Please now use this designation. Instead of Aroclor 1242b. Thank you. I Paul Q. Benignus /dn HARTOLDMON0010614 I Monsanto %fftOM (M*M| WOCATli 0*Tt UBJUT Cr*CK L TO : W. B. PAPAOBOROE - ST. LOUIS JULY 17, 1970 H. S. BERGEN ce D. S. CAMERON - BRUSSELS V. S. CLARK S. M. EMERY JFQ M. W. PARRAR - 2ND STREET R. E. KELLER - 2ND STREET R. M. KOUNTZ . J. MASON W. R. RICHARD J. R. SAVAGE J. E. SPRINGGATE B. S, TUCKER - 2ND STREET H. A. VODDIN - RUABON B. P. WHEELER I reviewed our biodegradation studies with R. Munch, R. Kountz, S. Tucker, B. Emery and J. Savage on Thursday, July 16, 1970. 1. Monaanto-USA Studies River die-away studies indicated Aroclor 1221 disappears, Aroclors 1242, 1243 and 1254 were undegraded. ' Semi-continuous activated sludge studies indloate that selective degradation of specific homologs does occur because peaks normally present in Aroclor 1221, 1242 and 1248 disappear. 2. Monaanto-U.K. Studies Shake flask studies demonstrate that 2,4*-, 2,2,3- and 2,3,4'- isomers degrade readily. 2,2',4,6-, 2,2',4,4', and 4,4' do not degrade. Ruabon laboratory also demonstrated by peak anrlysis that MC3-1016 and Aroclor 1130 are more degradable than Aroclor 1242. 3. Environment Samples Investigators in both Europe and USA find Isomers in wildlife that resemble those in Aroclor 1254. Predominant homologs present in Aroclor 1242 are usually not found except dose to industrial plants. Since large quantities of Aroolor 1242 are produced and released to the environment, degradation must be ooourrlng. TRAN 037172 HARTOLDMON0010615 -2" Evidence of degradation has been noted by Monsanto laboratory in studies of foundry plant settling ponds, milk and fish. Peaks which art present in the original Aroclor are modified or missing in the sample extract indicating degradation. 4. MCS-1016 Considerable discussion was held on what is meant by "biodegradable" when describing MCS-1016. Capacitor customers I visited had the erroneous impression that this meant the material could be introduced into the plant sewer system and would be non-detectable a very short distance downstream. For our purposes, the term "biodegradable" means that peaks which persisted through the biodegradation tests with Aroclor 1242 are significantly reduced in this distilled product. Neither Aroclor 1242 or MCS-1016 can be dumped into the environment. Users of either material must exercise control. In some Instances this may require activated sludge treatment units. It is generally agreed that the relative improvement in biodegradability is an advantage which the capacitor industry will find interesting. We must establish if the less controllable hydraulic fluids applications can materially benefit from the use of MCS-1016. 5. Current Work ' At Ruabon, work continues on HB-40, Aroclors and Pyralene 1500 (a competitive product). Dr. W. C. Evans, University of North Wales, Bangor is investigating some microorganisms vfolch he believes are effective on FOB'S. E. Bnery is completing his studies on HB-40 and MIPB. He will immediately start tests to determine relative per cent degradation of Aroclor 1242, Aroclor 1254, MCS-1016 and Aroclor 1230B. These tests take about 3 weeks to oomplete and his equipment provides for testing four produots at a time. Analytical facilities are manned 7 days per week, 12 hours per day. Equipment needs are being evaluated. I TRAN 037173 HARTOLDMONOOIO6I6 -3Ihe backlog of products to be tested continues to increase. The Applied Sciences Group continually reviews the list to re-establish continuing changes in priorities. In summary, emphasis on this work has been accelerated within the past three months, the work is progressing as planned and our facilities are being utilized to the practical limit. ms TRAN 037174 HARTOLDMON0010617 DEPOSITION EXHIBIT P/fs A* J. Heinre - (4-0K2) August 6, 1070 * Project scope Report WCS-10If. Fractionator - WGK CSAJMI?_____________: ____ Kos.ita. i General Offices - (25c.ii:> 2G0) p/?r p J. Ilolnrpfel R M. Konnt* II D. Doll: -r (7)iPrT'f777T', J! (,- i-7* R. . McCut.chan (2) R. II. i;unch d. R. Savage (?) 0H~ '/OOtiC. C%) (3flti~'y s'n.u'1/Hf, (*' C-H OC K AttocftMl is Mie 5 cron R.port for the subject; orojoot. In the interest of expediting finel definition of this projoct, pic nan reviov.' the Jec-po Report hy August 12, 3^70. 'J.t'i Kcnnrs. Fount;: end Hoik will c-.ee fc with you on August 12 (to be arranged by K. 'oik) to review the overall cuejvcf and cliscu&o any co.rucncs you noy l ave, -<- /P-, c.-t vo Attachment A. J. Hoinxe (Acspy./0|(. .4-- of tf Cl f\\0 Tit OM<i Guid~c-t tle^cM&ul >S & $ it, att J^CiaaaJ in &*M't K<rv\ evt'/1 o-T xC (2.< pu *-*4 oC 10 iw W5" pvoU fee, h. >>'>. Q tr<S--fc- cklovt lovpKevuv^l (/Onj b p^vtncj * , (. ul" W $rT>Kci. S'kf f'\e*vH e^,~f ou*v . "T^e 4,4` \ Vvijfc*/ 4t> 44' U'iv <^J n^jr TRAN 037811 HARTOLDMONOOIO6I8 Monsanto B.e W., wOM | MA Mf. kOCAVlOMt PAPA0E0RGE - ST. LOUIS OATft AUGUST 18, 1970 sue sect HM ** M* I PCB ENVIRONMENTAL PROBLEM JULY STATUS REPORT TO : D. S. CAMERON - BRUSSELS W. S. CLARK J. R. DURLAND - TOKYO M. W. FARRAR - 2ND STREET E. V. JOHN R. E. KELLER - 2ND STREET R. M. KOUNTZ D. A. OLSON THThSichard J. R. SAVAOE E. P. WHEELER AUG 1 9 1970 H. S. BERGEN J. MASON J. E. SPRINGOATE I m evv it MARKETING: Market withdrawal programs continue on schedule. Thermlnol food users are converting to Thermlnol 66 or Thermlnol 55, with little loss of business. Customer letters for notification of Pydraul F9A are prepared and will be Issued when manufacture Is complete (estimate 2 weeks). The withdrawal/replacement program for Aroclor plasticizers appears to be going well. Several customers have reported success in reformulating In such applications as epoxy coatlng/pottlng systems and Inks. Production orders for the products being withdrawn have been very heavy, however, the producing plants and production planning have done an excellent Job of keeping shipments moving In an orderly fashion. ENGINEERING* Aroclor Incineration A preliminary project scope for a 10 IT pound/year liquid incineration system was developed and issued for review. A safety review was held. The project scope Is being modified to reflect comments received. The appropriation request data transmittal will be issued in early August. DEPOSITION EXHIBIT TRAN 03910* HARTOLDMON0010619 2 ENGINEERINGS (Continued) MCS-1016 Distillation Economic analyses to establish method and location for distilling 55 JT pounds/year of MCS-1016 were completed and Issued. The preliminary project scope was prepared and issued for comments. A safety review has Just been held. The appropriation request data transmittal will be issued in early August. EUROPE There has been little new activity during July. Neither of the NERO reports has yet been published, although the new Journal "Environmental Pollution" carried the paper written by the Monkswood people on the avian toxicity of PCB's, This provoked one or two reports in the popular press. . A NATO committee is sponsoring an investigation into marine pollution along the ooast from Calais to the north of Holland, with speolal reference to PCB's. They were advised to get in touch with Bayer and Prodeleo for information on the usage of PCB's in Belgium and within the whole of the ESC. Implementation of the PCB plan for Europe is held up pending further meetings with the other PCB producers, firstly to determine their attitude towards a voluntary withdrawal from uncontrollable applications, and secondly to determine their reaction in the event of a unilateral withdrawal by Monsanto. JAPAN No new public developments in Japan. MMK writing revised policy for marketing of Aroclors. U.S.A. customers (3M, Thlokol) investigating Japanese sources. TRAN 039105 HARTOLDMONO010620 MEDICAL Two year feeding studies continue. Twelve month status report is expected in August. Fish toxicity studies are being repeated as well as some of the ohlcken reproduction studies. PDA has issued guidelines establishing upper limits on PCB contents in milk at 0.2 ppm and other food at 5.0 ppm. PUBLIC RELATIONS A news release on Monsanto's recent actions to curb the use of PCB was distributed on July 16. It was primarily a rebuttal to recent stories that PCB caused birth defeots, but Included a complete background of voluntary actions taken to solve the PCB problem. Copies went to all news media who have carried PCB stories in the past two years. Use of our story by the press has been light. T*N 0306 HARTOLDMON0010621 -4- RESEARCH Aroolor 1242 Replacement for NCR The two major problems with monoisopropyl biphenyl (MIPS) are now defined as odor and eye Irritation. Both problems could be solved by changing from propylene to a higher olefin for alkylation of biphenyl. Major interest is now centered on Cg g 10 alkyl biphenyl (ABP-ll) from Ethyl Corp. ^ -oifefin, our oxo process feedstock. Early testing by NCR was highly encouraging, however, print fade looms as a major problem. Back-up candidates include butyl, amyl, and hexyl biphenyl. A series of six odor masks were provided NCR in an effort to improve the odor of MIPB without Interfering with solvent performance. Samples of extender and cosolvents were supplied to NCR to improve dye solubility and to give more rapid color development than NCR's current cosolvent. These materials are (1) heads fraction from alkyl benzene manufacture at Chocolate Bayou, (2) alkyl benzene (Alkylate 215), and (3) alkyl benzene high boiler (Alkylate H-230). Plastlolzer Replacements Blends of Aroclors 5^60, 5442 and 1221 were developed to approximately match the vlsoosities of Aroclors 1254, 1248 and 1242. Replacement recommendations were made to customers to whom visooslty is Important. Specifications are being developed in cooperation with the Anniston Laboratory. MCS-1016 Sixteen drums of the MCS-1016 have been prepared by fractionating Aroolor 1142 in a packed column equivalent to 25 trays in the Dayton Pilot Plant. The distillate was brought here and analyzed. Then the fractions were recombined to give the desired composition and treated with a Porocel column to give the desired electrical properties. The product is now ready for shipment to customers for testing in capaoltors. Since all the electrical properties of MCS are indistinguishable from those of Aroclor 1242 and there are only minor differences in other properties, this fluid should be a direct substitute for Aroclor 1242 in the oapaoltor industry with no capacitor design change or processing changes needed. M'107 I HARTOLDMONO010622 -5- RESEARCH; (Continued) Industrial Fluids Pydraul F-9A Pydraul P-9 was reformulated as Pydraul F-9A to avoid the use of chlorinated biphenyl. The new formulation is compatible with P-9. The lubricity in V105E pump tests is superior to any fluid we have ever run. , NC Phosphate Ester Manufacturing costs are directly proportional to reaction times in the Step I reactor. We demonstrated that foaming in the Step I lab reactor and reaction time could be reduced by concurrent addition of POCI3 and nonylphenol/ oumylphenol. This should bring the reactor cyole to <6 hours. The process pay-load might be further increased by employing the SchottenBaumann Step II and III reactors. The pilot plant is reworking 1000 pounds of plant material by acid hydrolysis and washing to reduce acidity and hydrolyzable material. Aroclor Substitutes Bromoaroclor 1233 (13# Br) was scaled-up in a 35 gallon run in the Pilot Plant. Ibis fluid is being tested in hydraulic fluid applications as a more biodegradable replacement of chlori nated biphenyl. Isomerization of chlorinated terphenyl 5032 results in a fluid with a 100P viscosity of 2800 cs and a 210P viscosity of 11.7. We are seeking the lowest viscosity, all liquid terphenyl for use in hydraulic fluids. a-Methylatyrene dimer was mono and dlchlorlnated for evaluation as a plasticizer in place of chlorinated biphenyl. TRAN 039108 HARTOLDMONO010623 -6- -,r> RESEARCH; (Continued) Biodegradation - Ruabon Priority has been given to the development of more refined GLC analytical techniques so that more selectivity will be available for degradation studies of multicomponent PCB's such as Aroclor 1242. This has caused some delay, but work in progress Includes biodegradation studies of Pyralene 1500 (a competitive product), two of the key isomers for assessing the viability of the theoretical mechanism for degradation and HB-40. We are also studying the soil culture which Professor Evans, at Bangor University, has said will grow on Aroclors 1242 or 1254 as sole carbon souroe. Biodegradation Testing - St. Louis Testing of Aroclor 1242, Aroclor 1254, MCS-1016 (Aroclor 1242B), and Aroclor 1230B in our semicontinuous activated sludge units will be started as soon as sample background problems have been resolved. Identical conditions will be employed to permit a comparison between our present Aroclor product and the proposed substitutes. MANUFACTURING Anniston Current Level Aroclor losses during July averaged 3280 ppb in the plant effluent. *is is equal to 36 pounds/ day of Aroclor. Riant Effluent Suspended Aroclor Control Aroclor sump construction continues. Revision requesting an additional $4500 has been prepared. This was necessitated by unforeseen ground water problems. Completion by 9/1/70 still appears possible. TRAN 039109 HARTOLDMONO010624 "7" MANUFACTURINGi (Continued) Bulk Waste Disposal Data defining magnitude of solid material quantities will be completely collected by week of August 31* Quantities and the baslo estimates from whloh they are derived will be discussed with Production and TSD representatives August 6. Laboratory testing of mixtures of Montar 1 and Montar 5 were not dramatically successful in reducing pumping temperatures required - 200C range still necessary. Experiments with hydrocarbon dilution of chlorinated and unchlorinated Montars appear to Indicate this as an extremely attractive route to effectively reduce pumping temperatures, in some cases to near ambient. Economic evaluations will be made in the next two months. If successful, this will reduce handling costs and also provide auxiliary fuel for Incineration. Sauget PC Levels in Sewer Current losses are about 45 poundB/day to the river which is a concentration of 200-250 ppb. Memo being published by M. Plerle covering the sampling program for the plant. The Aroclor Department and total plant effluent will be monitored daily. Current effort is to improve the sampling technique. Aroclor analyzer received and laboratory is ready for routine analysis. Sampling will begin on a routine basis this week. PC Levels in Atmosphere Points of loss have been determined. Report being published. Most severe losses are from Therminol units in Departments 239, 245, 246 and 255. Work begun to correct these areas. 03,U HARTOLDMONO010625 "8" MANUFACTURING t (Continued) Equipment has been purchased to take vapor samples. Where vapor is flowing, losses can be measured quantitatively. Where vapor flows cannot be measured such as In breather vents, qualitative results will be obtained. Will complete this as per schedule by September 1, 1970. Projects To Reduce Sewered PCB>s From Aroclor iDepariment Absorber rupture disk repiping (Est. 1512) com plete. Basin for trenches (Est. 1795) oomplete. Blow tank demister (Est. 2031) project approved, long delivery Items on order and project package will be issued by August 7, 1970. Provide paving ourbs and catch basin In Aroclor department to prevent losses from spills, especially in the tank car loading area. Ouesstlmate cost Is $60,000 to $60,000. Estimate will be submitted by mid-August. PCB Rework Project (Est. 2095) Estimate completed, $32,000 capital, $3,000 expense. Appropriation request being typed. Incineration Liaison Phenol department fusion reactor area firmed up as location for Aroclor incineration. Tony Rasmussen named Manufacturing Representative. TRAN 039111 HARTOLDMONO010626 I J. R. Savage - General Office September 1970 FOB POLLUTION D. C. Malm JPQ Plant V.S. Papageorge Mr. A. K. Peterson J. P. Queeny Plant i Commenta on the PCS situation at JFQi 1. Central Drumming Ve are now under an edict to eliminate all PCBfs from our industrial fluid (Pydraul) line by the end of the first quarter of 1971. We therefore will not be using any PCBfs in Central Drumming (note that Aroclor 5442 and 54>2 are not PCB's). Therefore, we cannot Justify capital in CD for curbs, eto. on this basis, although housekeeping or "routine" pollution considerations might still Justify some expenditure. It is certainly true that extreme care must be exercised to avoid losses during the next few months. 2. Heat Transfer Systems Any filling or topping off of these systems should be done with Theralnol PR-1 (Aroclor 1242). Ve have begun converting our customers, but the word may not have reached Monsanto users who order fluid under Aroclor nomenclature. D. B. Roush (442529) can answer any technical questions. FR-1 is no panacea, but is less of an environmental problem. 3. ^Aroclor 1232 in TSClt This service should be converted ' to 1221 if possible. Aroclor 1221 is relatively biodegradable, while 1232 is a blend of 1221 and 12*2, which contains several per sent of very persistent Isomers. J. R. Savage TRAN 036358 HARTOLDMONO010627 I Monsanto r",B>Mt 8 Lt>e*T,"1 J, F. Queeny Plant *" eusj.cT ' Pttmb&A 29, 1970 Aroclor Loss - Statu* RepoAt (>. 8epe>t 9/21/70 TO : Messrs t JP. i. Hodge**>. I W. 6. Papageorge ' J. R. Savage Di'.i: 3 0F 'r " P. H. Abresch F. W. Copanas P. F. Gattn* E. C. GhueXzma&hiA W. G. Knapp P. C. Malm E. P. Matone P. E. Manit . V. F. Mtyca J. F. Nemeth 9 A. C. Rehkemper C. R. Sc/iaoc& J. A. Stepp E. P. Tafce 8. 1. TtttfoAd R. t. Wagner R. i. tttefte SturmoAg only. SUMMARY FC8 type AaocIoa* have been used or handled In $oua departments and the Research Pitot Plant at JFQ. Total annual losses have already been Aeduced irom 21,500 tbs. to 14,000 lbs. via Interim and permanent measures taken at a cost o $5,000. A program has been developed which, l{ (ullu Implemented, would essentially eliminate all normal losses to the environment by if 1/71.at a cost oi approximately $55,000. Comments on the program by 1/15/71 are solicltated. The program Is summarized In Table 1. Priorities are based on probability oi loss and estimated cost oi correction. Mv ii-ee deposition EXHIBIT m yy/ *7- 9-9i_ TRAN 036827 HARTOLDMONO010628 Page 2 PxiOXity 1 1 e* 3 4 5 -4 JO > Z TABLE I Axoclox Status and Proposals Pxoblem Axea TSCl Hmh Pump wW" Bldg. TSCl Ueaim,m Est. Lon IbS./tfX. Souxce oh Loss 6000 Seal htuid Sep. 6 Demist. Dxains 1000 Vapoxs, pump leaks, jacket Steam outs. 1500 Vapoxs, pump leaks Possible Actions Dxain headeri connected to disposal (bum. Change hltiid to Theruninal - 66 a. Switch to T-66, -cneet system, ox b. Stoiich to A-1242 pan pumps, cold txap vent. Phthatyl Cktorude ' 1000 Vapoxs pump leaks. Switch to A-1242, penmanent pump pan, pxessuxize system, vent condensex. v nedg. Itsdm Unit 1000 Vapoxs, pump leaks, steam out o( jackets. Clean system. SuUich to A-1242 cold trutp vent new type pump cuxb axea. Status complete Est. 1 500 Timing complete 2000 Topping with 4000 A-1242. Awaiting completion oh 4500 compatibility Study oh T-66 with TSCl. Compatibility xesults by 12/51/ 70. me by 2/1/71. ' Topping with 1500* A-1242. Temp dxip pan 500** pxoj. scope xeady. PAFE by 1/21/71. Unit cuxxently 13*000 down. Top with A-1242. Uajox pump overhaul unsuccess hut. Investigate by 3/1/71. PAFE by 4/1/71. 036828 HARTOLDMONO010629 Page I PhioeUy 6 7 ftwbim Mm v mdg. Vaftd unit Est. Lou lhs./ytt. Smell cm 3000 & Bldg. Centekmit 4 j 0 Source of lots Vapo/u, pump leaks, &tmm out of jackets. Pimp lea.k&, hose drainage, piping leaks. Hot in use. Possible Actions ` . f Switch to A~1t42. Cold tnap vent Pan pump. Install dig. pump. Status Est. $ Unit mAAently down top with A-1242. Pump in good condition. 7090 Timing Investigate by 3/1/71. PAFE by 4/2/11 PCS containing MocIoas vaitl be eliminated fnom all blends by 4/1/71. J. R. Savage memo of 0/23/70. PAFE ion. nettf unloading pump Submitted. 2500 PAFE 410691 Submitted ~ 12/10/70. Isolate to peevent use. down 500 6/1/11. Pi&mantle -- 2500 Vefe*. Total PAFE of $5000 expected/ Justification is pnimnity to prevent coAMo&ion of ve&4e * jacket. m IntvUm mmuMM, tehm. TRAN 036829 HARTOLDMONO010630 -,,.n Page 4 FUTURE WORK h Continue to dtiine details of changes AequiAtd foA the leadeA and sbuth yaAd units seAvicing the "W" Building. 2. PAocetd uxith program as outlined, oa as modified to meet needs based on information Aeceived from addressees. jjm tram 036630 HARTOLDMONO010631 -.JfJ - Page I I. INTRODUCTION PCS'4 containing Are clou art extremely stable and highly inert fluids and as such went considered to he a safe (laid. Recent evidence, however, indicates that PCBs have an adverse effect on the environment. Since arodors are only slowly degradeable through natural means there is concern over their buildup in the environment. Aroclors in the 1200 series are of primary concern. The higher the number, the more resistant is the 4laid to bio degradation. # To protect the environment Monsanto has established a self imposed limitation of PCB losses to the waste effluent of 10 ppb. In addition, volatile losses to the atmosphere are to be essentially eliminated. The purpose of this report is to relate the interim and permanent steps taken to date to reduce PCB losses to the environment and to invite comment* on meo*uAe& proposed to obtain a guAtheA and permanent reduction in losses. II. DETAILS ' A. Gewenot An inspection of the Aroclor using facilities at TSCl, Phthalyl Chloride, 'V Building and the Research Pilot Plant ("UW" Bldg.) was made. Technical advice and recommendations were obtained from P. E. Rou*h 0$ the Fluids Group. Vis cussions were held with Vepartment Supervision and alternate solutions to the elimination of PC8 losses to environment were presented and a course of action chosen. A final decision in TSCl can not be made until the outcome of a compatibility study is complete. Interim and permanent measures where immediately feasible have >bee.n taken. * . , B. Vepartments ' .* I. Research Pilot Plant Two portable high temperature fluid heating systems have . been employed in this facility. A third unit has Just been obtained. Although the units originally used Thtrminol 77, Aroclor 1t4S was substituted many years ago and its use continued. Fluid losses have been incurred from pump leaks and steaming of vessel Jackets to the sewer when changing heating or cooling medium, and vaporization. l TRAN 036831 * HARTOLDMONO010632 Page $ * AlteAnate solutions (ok the m ptwblems wexet ? ?. Continue with AaocIoa (laid. Estimated cost Uooo. al 'Switch to AkocIok 124$ btc&u&t it ii tsoae biodegxade&ble. * b. Pxovide laxge dAain pans undeA pumps. .. ,,c. Coti teap vent to prevent volatile tosses. d. Pxovide (on trapping o( eminent steamed (Horn vessel jackets. S. Change to non PCS containing (hud. cost $2000. a. Switch to TheHminol $6. Estimated b. Inext the systems to pxevent oxidation and eliminate the (ixe hazaxd. A meeting ms held with Pa. Knapp and Me. H. Close o( the Reseaxch Pilot Plant to discuss the aItexnates proposed. Alternate *2 ms xecomended to and accepted by Reseaxch as the best oveAall solution. Since TheHminol 66 contains no PCB, (utuxe conceAn oveA such losses (Aom this (acility will be eliminated. Pa. Knapp agAeed to complete the changes xeguixed be(oxe the next staxtup o( heating systems (12/11/70). TSCl a. Nash Compnessoa - MCI system AaocIoa 1232 is used as the sealing (laid (oa the Nash Compness oa in the HCl system. Losses axe estimated at 6,666 lbs. annually. AaocIoa builds up xegulaxty in the system's instAumentation and is drained periodically to the pump's catch pan. The dxain line (Aom the BKink's demist&A joins the pump pan dnain. This line (onmeAly . Aon dixectly to the setoeA. The tine has been alteAcd so that the dnainings axe now caught in a doom. Full dooms one maAJked "AaocIoa (oa Incinexation" and sent to WGK (oa stoAage. HCl /aom TSCl is used in the manu(actuAe o( Bis phenol A. Samples o( Bisphenol A have been submitted to Reseaxch to detexmine whetheK any PCB's axe pxesent. Analytical problems have been encountexed by Reseaxch. New laboxatoxy (acilities have just been completed which axe expected to pxovide AeJUable ajuuJUs. Analysis o( the BPA sample is expected by yeaA end. TRAN 036832 HARTOLDMONO010633 Page 7 A search was conducted (oh. & Substitute (hud (oh the Hash Compressor, but no satis (actoHy material could be (ound. Bis phenol A manu(acture is scheduled to cease at JFQ by the end o( 1911. At this time it may be possible to alter the HCl system to eliminate the Nash CompnessoH and thereby eliminate the use o( AhocIoh. ' b. Heating Units - Two Two heating system employing AhocIoh 1244 one in me. Annual losses total approximately 25GO pounds (Horn these units. The bulk o( the losses one the Hesult o( pump leaks. Some atmospheric losses one incuHHed as no conservation measunes one employed on the vents. As an interim measure the department is using AhocIoh 1242 (oh loss makeup. Operating instructions have been modi(ied and personnel'instructed to exert extreme care in handling o( AhocIoh (luids to prevent inadvertent sewering. Alternate solutions to correct the problems with these heaters arti 1. Continue with AhocIoh (laid. Estimated cost $4500. a. Switch (laid to AhocIoh 1242. b. Provide large drain pans (or pumps. c. Cold trap vents. 2. Change to non PCS containing (tuid. Estimated cost $4000. a. Switch to Therminol-6S. b. Inert systems with C0. * c. Alter line (rom conservation vent end provide cold trap/(lame arrester. The aUemates were discussed with the department supervisor Von Abresch and alternate *2 recommended. Ur. Abresch agreed with the recommendation providing that Thenminol'66 was (ound to be compatible with the TSCl streams heated. A study has been requested o( the TSP Process Group and results ere expected by 12/51/11. l 036855 HARTOLDMONO010634  Page I - Both units are heated by 550 lb*. Attain. Tht fluids are, used at' & maximum temperature oi f0SeC. Whitt this temperature is above tht flash and fire points of Thtrminol-66, inviting of tht system with C0 should provide adequate fire protection. Tht auto ignition temperature of T-66 is 364*C or 1Z0*C higher than temperature oi the heating steam. Therefore instrument malfunctions cannot result in over heating of the fluid. A PATE for the necessary changes can be submitted by I /1/th *. I. Phthalyl Chloride . This department has one Aroelor system used for both heating and cooling of a reactor. Heating is accomplished by the use of bayonet heater submerged in the agitated jacket. The fluid is circulated through an external, heat exchanger for cooling of the reactor. Losses are about 1000 lbs./yr. and are primarily from pump leaks. Atmospheric losses are estimated to be 69 Ibs./yr. Corrosion of the vessel has become a major problem. The corrosion is caused by the introduction of atmospheric moisture which causes the breakdown of Aroelor to form HCl at the temperatures used (300*0. The moisture is introduced by the breathing action taking place via the open vent as alternate heating and cooling cycles are employed. Jacket maintenance costs from corrosion average $1500/yr. Corrective action is a necessity to prevent the loss of the $15,000 reactor and consequent business interruption. Interim actions have been taken to reduce the PC8 loss and limit its effect on the environment. Aroelor 1241 is used * to make up any fluid lost. A temporary drip pan at the pump packing gland has been provided. Operators have been * instructed to take precautions against allowing Aroelor fluid to enter the waste effluent and operating instructions modified. Two alternatives were developed to solve the combined PCi corrosion problem in this department. They ere* S. Continue with Aroelor fluid. Estimated cost $5000. &. Stitch to Aroelor H4t. b. Provide large drain pan for pump. TRAN 036834 HARTOLDMONO010635 Page f e e. inert the system with W and provide conservation vent. d. Provide condemn on conservation vent. e. Install rupture disc. t. Change to non PC8 containing {laid. Estimated cost 15000. a. Switch to Therminol-66. b. Inert the system with N end provide conservation vent. c. Provide vent condenser. The attematives were discussed uiith the department supervisor C. Schrock. Alternate *1 was chosen primarily {or sa{ety reasons. The use o{ electrical heating units in the jacket was the overriding consideration. Temperatures could exceed the auto ignition temperature. 1{ the inerting System would {ail, an explosive situation could result. A PAFE will be submitted by 7/21/7?, i{ no adverse comments are received. ' "ID" Building The "W" Building has three Aroclor heater systems. The Small homemade unit located in the center section is no longer used and will be isolated to prevent use. The "yard" unit has an excellent maintenance record and addition o{ {laid is rare. The losses that do occur are {rom pump leaks and volatile losses through the open vent. The principle source o{ loss {or "W" Building operations is, the leader unit located south o{ the "888" Building. Last year the pump seal {ailed on {ivt occassions and accounts {or the majority o{ the loss. In addition some volatile losses ere incurred through the open vent. A major overhaul o{ the pump was completed in November, but the seals {ailed within & week a{ter startup. All units are currently down. When operation is required only Aroclor 124t will be used {or makeup losses. The manu{acturing superintendent {or the "(O" Building, F. Copanas reports that current project forecasts indicate that only one heater will be required {or the {oreseeable {uture. Operations will be con{ined to the yard unit as long as only one heater is required. TRAN 036835 HARTOLDMONO010636 -,,.n - t rage 10 Tm basic alternatives for a permanent solution to the. PCS tosses from the too heaters wiki discussed with Musts SutheMin and Copanas. One ms to continue taith Aroclor and the other to switch, to Therminol-66. Both men objected to the use of Therminol-66 {tom a safety viewpoint. The fluids in both units ate heated by open gas flame burners. A ruptured tube in the furnace would result In & fire. Special instrumentation would be required to sense the fire, shut off the gas and extinguish the fire automatically. Curbing to prevent the spread of burning fluid from the unit would also be required. . The stated auto ignition temperature of the fluid is somewhat lower when the material is soaked into insulation. Since the fluid is frequently heated to over 300*C, a leak into the Insulation could result in & fire. System alterations for either Aroclor or TheAminol-66 ere in the same order of magnitude. Although the steps required to fee taken for the continued use of Aroclor fluids is still under investigation, the following changes are being considered. I. Leader Unit. Estimated cost $13,000. a. Change fluid from Aroclor 124# to 1l4t. b. Provide new leakproof pump. e. Cold trap vent. d. Clean system. I. Yard unit. Estimated cost $7000. a. Change fluid from Aroclor 1248 to 1242. fe. Provide system charging pump. e. Provide sump pump. d. Provide drip pan for pump. &. Cold trap vent. f. Partial roofing of area. g. Clean system. It is expected that a PAPE could be submitted for changes to both units by 4/1/71. TRAN 036836 HARTOLDMONO010637 Page 11 I. cm . The magnitude, of PCS losses at CLHS ant unknown, but are believed to be large. Mr. J. R. Savage in hi* memo of 9/23/70 Stated that by 4/1/71 PCS containing Arc dors Witl no longer be handled in CLHS and that capital improvements cannot be justified on this basis. Department supervision has been requested to exert care in preventing tosses within equipment limitations. Mr. E. R. Reagtr has recommended & number of minor improvements to department supervision to minimize losses. The pollution group arranged a film presentation for all personnel involved for motivational purposes. A PAFE has been submitted to replace the present Aroclon unloading pump which has always leaked badly. Prime justi fication for this project is not based on PCS losses, but on unloading capacity, safety and reduced repairs. C. Sewer Sampling Composite samples of the main effluent art submitted for PCS analysis each month. The reported results are: Month PPb June July August September October November 46 43.S 43.0 77 70 11.9 Analytical problems have been encountered by Research and the figures for September and October are open to question. New laboratory facilities have just bttn completed. The November results shown were obtained in the new facilities. P. Volatile Losses The volatile losses from the Aroclor unit in phthalyl chloride were calculated at 69 Ibs./yr. Volatile losses from the other mils are believed to be considerably less. No attempt to calculate or measure these losses was made since completion of the changes proposed in this report will essentially eliminate them. 1 /jam A. E. Peterson TRAN 036837 HARTOLDMONO010638 Monsanto .-PM .N,M, . p.,, . w> Bt PAPAGEORGE - ST. LOUIS December 7, 1970 PCB ENVIRONMENTAL PROBLEM NOVEMBER STATUS REPORT 0C 8 3970 cc H. S. Bergen J. Mason J. E. Springgate TO : P.J.A . Marsh - W. S. Clark J. R. Durland - M. W. Farrar E. V. John R. E. Keller R. M. Kountz Gossage s. Park W. R. Richard J. R. Savage E. P. Wheeler BRUSSELS TOKYO 2nd Street 2nd Street MARKETINGl ' NCR appears to be making very satisfactory progress toward the replacement of Aroclor 1242 In their carbonless reproduction paper solvent. To date, Monsanto has shipped nearly 100,000 pounds of the replacement product - monoisopropyl biphenyl (MIPB) to NCR. An additional 100,000 pounds is scheduled for delivery In January followed by 500,000 pounds in February. NCR is attempting to reach complete conversion by the end of February. Through our Australian organization we have received an inquiry from the Electracity Trust of South Australia. They have recently received corres pondence from General Electric Company, U.S.A., concerning the problems with Askarel Liquid Di electric. As a result, they are requesting infor mation from Monsanto as to the arrangements in Australia for the disposing of contaminated mater ials. We anticipate other Inquiries from other parts of the world. We met with Mr. Katayama of MMK in November. We discussed with him the PCB plans in the U.S. and re viewed the current situation in Japan. As a result, MMK representatives will meet with Kaneka (the other major supplier of polychlorinated biphenyl in Japan) to discuss future PCB plans for Japan. nun 3,80 HARTOLDMONO010639 1 2- - ENGINEERING; - Incineration - Krummrlch - CEA 2415 Plot plans and layouts have been resolved, and process deBlgn Is complete. Design of piping, electrical, and instrumentation are proceeding on schedule. MCS 1016 - Krummrlch - CEA 2417 Customer trials of the pilot plant product indicated an undesirable high level of low boilers. In a meeting with Research and Manufacturing it was decided to provide facilities in the project for removing a percentage of low boilers as well as the high boilers. The project scope and estimate are being revised, and a revised Data Transmittal is scheduled for submission in late December. Trlbutyl Phosphate - Queeny - CEA 2371 An early pilot plant run indicated a severe yield problem in the process. Continued studies by Res earch and Engineering have pinpointed some of the problems, and it is believed a substantial yield improvement can be made. Pre-approval funds have been requested to proceed with definitive design. N-C Phosphate - Queeny - CEA 2451 Pilot plant studies are currently being made on this product, and a project scope report is being developed. Solids Waste Disposal - Krummrlch - CEA 8042 Engineering, Research, Manufacturing, and Marketing have been studying disposal of polychlorinated biphenyls on solids. A test was devised with Enviro-Chem, samples of wastes have been collected, and the test is scheduled to be run December 1. Preliminary discussions have been held with potential equipment vendors. JAPAN: No new action or reports on toxicity to fish/animals. Court action on suits on bran oil exposure humans continuing with attendant newspaper publicity. Major executives of company which processed bran oil cannot be located. More stringent testing and licensing of equipment using PCS as heat transfer will probably occur for food processing equipment. oi^osi HARTOLDMONO010640 -3- NCR-Japan rejecting HB-40 because they prefer one oil for both clay and resin-type granules and Jujo Paper Is definitely switching to resln-coat. Kureha oil refined from heavy oil cracking bottoms (mixed aromatics of complex nature) is also being tested. MMK is pushing MIPB assuming NCR-Dayton preference for MIPS. No final decision yet. HB-40 also offered by MMK but MIPB provides better balance on biphenyl/terphenyl. EUROPE: 1. The decision has been taken to cease sales to noncontrollable applications in the UK by 1 March, 1971. 2. Sales will continue for all applications in continental Europe until the end of 1971* but reformulated products will be introduced where possible. 3. We will continue to supply products containing PCB's to German mines through 1971 even where reformulated products are available, until approval is gained for the reformulated products. 4. Customers will be informed before the end of November 1970 of this policy. 5. We have been assured by the other European producers that they will not knowingly supply former Monsanto customers in the UK or USA. 6. Bayer have indicated that they are in agreement with the Monsanto timing for withdrawal from noncontrollable applications. 7. Progil/Caffaro do not yet agree and wish to study the problem further. We have invited their repre sentatives to Ruabon for technical discussion. 8. The UK Board of Trade, through their Marine Safety Department, have proposed that Aroclor should be classified under Class 9* Dangerous Ooods, for the purpose of carriage by sea. We will meet with the Board of Trade in December to discuss this and following discussion with J. T. Garrett will attempt to persuade the Board of Trade to alter the pro posal. TRAN 039062 HARTOLDMONO010641 MEDICAL: Arrangements were made for initiating acute and sub acute studies at Industrial Bio-Test Laboratory for Aroclor 1221, 5432, 5^42 and MCS 1016. Sub-acute studies will include 90 day rat and 90 day dog studies and sub acute fish studies (according to protocols to be devel oped). Rat and chicken reproduction and rabbit tera tology studies are being deferred for the time being. Rabbit teratology studies were begun with Aroclors 1242, 1254 and 1260. PUBLIC RELATIONS: The Anniston Star, Anniston, Ala., obtained figures from the FDA which showed unusually high levels of PCB in fish samples taken from Choccolocco Creek. A Star reporter contacted the Anniston plant for comments on the data and information about our PCB production oper ations there. Public relations prepared replies to specific questions. Plant management convinced the reporter to visit the plant for a firsthand view of what the plant was doing to eliminate PCB escape to the environment. A factual front-page feature appeared in the Star Sunday, November 22, edition reflecting the value of cooperation with news media planning PCB stories. Quoting both plant management and the Alabama Water Improvement Commission, the feature emphasized the PCB problem was relatively new, was being solved by Monsanto and, at this point, was no cause for public alarm. RESEARCH: Biodegradation Testing - St. Louis TRAN 039083 Statistical analysis (t-tests) of the data accumulated to date in the semi-continuous activated sludge (SCAS) testing of the PCB Aroclor products Indicates that some bacterial degradation is occurring. The percent dis appearance rates, based on a feed level of 1 mg/cycle, were as follows: MCS 1043--55% (p - 0.05)J MCS 1016-- 11% (p - 0.05); Aroclor 1242--30% (p - 0.05)i Aroclor 1254--0% (p 0.05). However, the observed degradation HARTOLDMONO010642 -5- rates are still highly scattered indicating that the units have not reached a steady state yet. Other physical sources of data scatter are being investi gated. The addition of stirring, modification of the sampling method and the elimination of the LAS from the feed all appear to be steps in the appropriated direction* but have by no means totally eliminated the scatter. SCAS testing of trichlorobenzene (TCB) and Arobromochlor 1232 at the 1 mg/cycle level have been started and analysis of the first samples is in progress. River die-away (RDA) tests have been started for Aroclor 1242, Aroclor 1254, MCS 1016, MCS 1043, Arobromo chlor 1232, and TCB. Completion of the RDA tests is scheduled for 1-13-71* A liquid chromatographic method for the analysis of halogenated terphenyl systems is being developed. A liquid-liquid chromatography system using Zipax Permaphaze (a new DuPont chromatography packing) as the stationary phase and water/methanol as the mobile phase appears to give sufficient separation to characterize the isomeric distribution of the materials. The system is being optimized for Bolvent composition and column length. Environmental Program - U.S. Analysis of a second set of Mississippi River fish collected above and below the WGK plant has been com pleted. The levels found in fillets from these fish ranged from 0.2 ppm to as high as 8 to 9 ppm total PCB's. All the necessary equipment for PCB's, with the except ion of two gas meters, required to sample the Enviro-Chem St. Charles incinerator has been assembled and laboratory tested. The PCB burn is now scheduled for 12-1-70. Additionally, analysis of background samples taken at the site 10-29-70 for PCB has been completed. Low levels of apparent PCB's were observed in all cases. The PCB analysis of the JFQ September and October sewer water composites has been completed. The levels found, 77 PPb and 70 ppb respectively, were higher than in previous months. Shrimp from Escambia Bay, fat and liver from a dead pig found near the Anniston landfill, OE plant water samples, Delaware River phthalic acid, and a U.S. Steel plant water effluent sample have also been analyzed for PCB's. TRAN 039084 I HARTOLDMONO010643 -6- Partlcle size analysis by microscopy was performed on a solids sample from the Anniston limestone waste pit. Correlations are being developed between particle size of adsorbent and waste retention in the Aroclor waste treatment studies. Aroclor 1121 and 1129 distillation fractions were anal yzed by QC for Isomer distribution to compile data for plant design. Aroclor 5442 We recently reported tetrachlorodibenzofuran as a possi ble impurity in Aroclor 5442. Additional work has shown that this identification is not conclusive; tetraehloromethyl biphenyl might interfere with this determination. Methylblphenyl has been shown to be an impurity in the Santowax R used to make Aroclor 5442. Efforts are currently underway to develop a reliable method for distinguishing between chlorinated dlbenzofuran and chlorinated methylblphenyl. Environmental Studies - Ruabon Workers at the Tolworth Laboratory of the Ministry of Agriculture, Fisheries & Food have been studying effects of feeding Aroclor 1242 to pigeons and quail. Their analyses have indicated, what we have ourselves sus pected, that the residues tend to resemble 1254/1260. Discussion with Bailey and Bunyan from this laboratory shows that they now believe that Aroclor 1242 may be a major source of the environmental pollution. They have also "discovered" that reproducing paper of the no carbon type is a potent source of Aroclor 1242 and, although they have not published this information yet, they may wish to do so as an explanation of the presence of PCB in cardboard. Feeding trials using single isomers are also planned by the Tolworth group, who are hoping to establish metabolic routes for the degradation of PCB's in animal organs. A visit was made to the Monks Wood Experimental Station of the Nature Conservancy, but little new information emerged from the discussion. Biodegradation - Ruabon TRAN 039085 It has been confirmed that 2,3,2', 3', 4', 5'-hexachlorobiphenyl is degraded by Co when mixed with lower chlorine isomers. This has been achieved under less vigorous conditions of flask shaking than previously, which suggests that the addition of the lower chlorine Isomers has Increased the solubility of the material. We are currently studying a pentachloro-biphenyl. which should degrade, and the 4,4'-dichlorobiphenyl, which should be resistant, using a similar technique to im- HARTOLDMONO010644 "7- prove solubility. The analytical results are awaited on these tests. The results of degrading a series of PCB products with C2 until no further change with time can be observed are now available. Subject to limitations imposed by the difficulties of interpretation of the GLC chromato grams it appears that the order of degradability, or the inverse order of apparent residues, is as follows: MCS 1016, MCS 717, MCS 762, Pyralene 1500, Aroclor 1242 Satisfactory progress in the identification of isomers corresponding to the peaks obtained using high select ivity PLOT columns is reported, but development work is still needed on GLS - Mass before this can be util ized. The moBt recent results on attempts to degrade HB-40 by Co have shown that at low concentrations (5 ppm) con siderable degradation has occurred. The main problem in this investigation has been that of sensitivity in the analysis, but this problem now seems to be overcome. Pydraul Reformulation Factory Mutual Visit A representative of FM visited the fire test facility November 4 and 5* Tentative FM approval was obtained for Pydraul 626-A, F-9A, MCS 1063 (Turbinol 153A), MCS 1066 (312A), MCS 030T, 050T, 065T, 0115E, Santosafe W/0 15, 20 and 30. All fluids submitted were approved. Pydraul 312A A VI05c pump test on MCS 1066 indicated excellent lubri city. A tentative process will be issued shortly. Pydraul 540B The terphenyl version is tentatively defined. The FR is equivalent to old 540. Approximately 3# of a poly glycol VI improver will be incorporated to meet old 540 viscosity specs. Pydraul 230A A terphenyl blend has been developed which looks good on the FM spray test. It will contain 2% of a poly glycol VI improver to meet 230 viscosity specs. TRAN 03W46 HARTOLDMON0010645 -8- Pydraul 135A A blend of TCB, 5^32, oil and Santiclzer 711 has been developed which looks excellent on the PM spray test. Turblnol 153A MCS 1063 demonstrated good lubricity in a V105C pump test. The moderate wear noted was attributed to high TAN Krummrich CDP. This fluid also exhibited low deposits in the Alcor Deposition test. . Pydraul A-200B A lower viscosity F-9A type blend was blended, tested and a tentative process Issued to fill an order from Chevy Messena. They refused to purchase any more fluid containing PCB's. A VI03C pump test was terminated at 225 hours due to mechanical failure of the pump. A lobe craoked off of the rotor. This is considered to be a mechanical failure and not fluid related. The test will be repeated Just to make certain, though. The wear observed up to 225 hours was very low (11.8 mg total) and no problems are expected. Carbon Adsorption Study The pilot unit (series of four five-inch diameter columns), that was put on stream 10/2, continues to operate with minimum difficulties.* The initial flow of 2 gpm/ft2 was Increased to 4 gpm/ftz on 10/28. Effluent quality, at the present flow, is <10 ppb Aroclor for influent con centrations in the range 100-2,000 ppb. The present plan is to increase the flow to 6 gpm/ft2 by II/25. MANUFACTURING: W. Q. Krummrich Plant PCB Levels In Sewer A. Aroclor losses from the Aroclor Department averaged about 1.0 lbs/day and ranged from about 0.4 to 2.5 lbs/day. . Losses from the Sauget Village treatment plant for the period 10/16 - 11/16 averaged 72 lbs/day (495 PPb). Range for 9 samples was 32 to 115 lbs/day (220-796 ppb). TRAN 039087 HARTOLDMONO010646 -9~ Projects To Reduce Sewered PCB1 a From Aroclor Department A. Blow tank demister project was successfully demonstrated. About 100 lbs/day of mist Aroclor Is being collected. Sewer loss has been reduced from about 20 lbs/day to about 0.5 lb/day. B. Project to provide paving, curbs, trenches, and catch basins in the tank car and truck loading areas has been approved as part of the Aroclor incinerator project. The design package is about 75# complete. Program To Eliminate Sewered PCB's From Using Departments A. A second meeting with Don Roush is scheduled for 12/7/70. Don will discuss with plant production and engineering personnel design considerations for changing Thermlnol units to non-Aroclor Therminols. B. Status of work on Thermlnol units is as follows: Dept. 255 Switched from PR-2 to Thermlnol 66 on 11/16/70. Dept. 222 0 & P, Dept. 273, Dept. 246 Plans underway to change out these systems to Thermlnol 66. EDO for all units is 3/1/71. Removal of Soluble PCB's Prom Sewer Stream A test is planned for the week of 12/7/70 to determine effect on Aroclor losses in the treatment plant effluent by neutralizing the sewer flow to the treatment plant. Lime will be added at Dept. 265 for about 3 days to hold the pH above 7.0 at the treatment plant. The re sulting floe is expected to improve PCB removal based on Anniston work. PCB Levels In The Atmosphere Sampling program has been completed. Only significant area of loss is at the mix tanks due primarily to the nitrogen purge. Loss is in the range of 4 to 5 lbs/day. Plans are to replace the nitrogen purge with a nitrogen blanket. PCB Rework Project Project approved as part of the Aroclor Incinerator project. Construction schedule will be determined in December. . TRAN 039088 HARTOLDMONO010647 -10- AnnlBton Plant PCB Levels In Sewer Aroclor losses during November averaged 25#/day (4620 ppb). One high value accounted for l8#/dav, neglecting this the ' November average would be 7#/<*ay (1410 ppb). Based on knowledge of plant operations and performance of abatement devices in November, much of the high level data Is due to sample contamination. Spills Minor leaks were contained by use of sand and disposal in drums. No spills occurred. Projects and Evaluations 1. Laboratory work to date Indicates the presence of minimal amounts of PCB in the residue from Solid Aroclor distil lation (Montar 5). This eliminates 10M pounds per year or solid wastes from our PCB disposal plan. 2. Design work to collect spent carbon from HC1 carbon towers has been deferred to early 1971 to accomplish the No. 1 HC1 Limestone Pit rebuild. 3. Solids removal from plant effluent (part of program to reduce PCB in plant effluent to 10 ppb) Is moving forward with preliminary screening tests at Denver Equip ment Company and Betz Laboratories indicating good to moderate success with flocculation and settling. Fur ther laboratory testing is scheduled for early December. A project has been written, design is underway and equip ment modifications under study working with Monsanto Blodize to set up one of their clarifiers at Anniston for pilot scale testing of the apparent best techniques recommended by Denver and/or Betz. 4. A successful test was made of removal of limestone inerts from the #2 HC1 neutralization pit while in operation. A total weight of 127,000 lbs was removed of which 365S by weight was solids. Lab analysis of the total material revealed more than 100,000 ppb Aroclor or 12 to 15 lbs of Aroclor. Present indications are that this method of removal of solids while the pit is in operation will increase the efficient life of the pit by 25. 5. A project for repair of the No. 1 HC1 neutralization pit was written and approved. This project will be coordinated with the Niran pit project to apply an asphalt lining at the same time, to save money on mater ials. . TRAN 039039 HARTOLDMONO010648 -11Newport Plant The October Newport Report has not been received. W. B. PAPAOBOROE TRAN 039090 HARTOLDMONO010649 ORGANIC CHEMICALS DIVISION RE5 REPORT NO.? P-1590 JO NO. 8-11-760.014113615 *s - - ` TSKTATIVI FROCZES FOR AR00L0R 6037 (M08 1057-1) DAT! - Novmbr 17, 1970 WRITTEN IV L. R. ittrk Monsanto ST. LOUIS, MISSOURI COMPANY confidential trrn ,6Zl Immmmmmmmmmy DEPOSITION EXHIBIT P/71 >13 HART7O-LfD-MteONO091S0650 I SAFETY RFAILW COMMITTEE MONSANTO COMPANY APPKOVE$fe Organic Chemicals Division . St. Louis Research Department! FINAL APPROVAL DATE, MV ?5 W7rt St. Louis Research Report No. P-1590 TENTATIVE PROCESS FOR AROCLOR 60?7 (MCS 1057-1) J0b MO. 8-21-760.01-3113615 DO NOT REPRODUCE, TRANSFER, STORE OR DESTROY RETURN REPORT TO: ORGANIC RES-ARCH DEPARTMENT TECHNICAL INFORMATION GROUP ,,TU cer.OND STREET Date: November 17# 1970 Written by: Work done by: L. R. Stark L. F. Smith L. R. Stark COMPANY CONFIDENTIAL TRAN 037622 HARTOLDMONO010651 1 DISTRIBUTION OF REPORT NO. P-1590 1. File Copy 2. Technical Reports Library 5. Extra 4. Extra 5. Extra 6. Circulate to Organic Res. Mgrs./Library 7. L. R. Stark 8. W, R. Richard 9. J. E. Maurer/W. R. Eberhardt - Patent Department 10. J. R. Savage 11. T. Bell - Anniston Plant 12. Q. Miller - Anniston Plant 15. Standards Department - J. F. Queeny Plant 14. Standards Department - W. 0. Krummrlch Plant /- 2 "~7 J 15. 0. DeQarmo/J. F. Quinn This report contains confidential information which is the property of the Monsanto Company and which shall be disclosed only to duly authorized persons; The recipient is held accountable for the filing and safe custody of the report, which must be returned on demand. COMPANY CONFIDENTIAL TRAN 037623 HARTOLDMONO010652 TABLE OP CONTENTS Page No, INTRODUCTION .............................................................. 1 SYNOPSIS OF PROCESS ............................................. 1 FLOW SHEET................................................................... 1 BILL OF MATERIALS................................................. 1 PROCESS IN DETAIL ................................................. 2 DISCUSSION OF IMPORTANT VARIABLES .... 2 MATERIAL SPECIFICATIONS .................. .... 2 ANALYTICAL METHODS ................................................. 3 TOXICITY AND HAZARDS ............................................. 3 POLLUTION CONTROL.......................... * APPENDIX ....................................................................... 5 TRAN 03762A COMPANY CONFIDENTIAL HARTOLDMONO010653 -1 - INTRODUCTION Aroclor 6057 is a special blend of Aroclor 5460 and Aroclor 1221 to give an absolute viscosity at 75-80 F. equal to that of Aroclor 1242. This formulation was developed to replace Aroclor 1242 in an automatic transmission fluid additive formulation (Radiator Specialty Company). SYNOPSIS OF PROCESS Aroclor 6057 is prepared by blending Aroclor 5460 and Aroclor 1221.' The blended product is filtered to remove any stray debris from raw materials or blending and is transferred to containers or storage. FLOW SHEET BILL OF MATERIALS Basis: 100 lb. of product Haw Material 82616 82622 Aroclor 1221 Aroclor 5^60 Wt., lbs. 65.0 57.0 TRAN 037625 COMPANY CONFIDENTIAL HARTOLDMONO010654 e PROCESS IN DETAIL The blending operation may be carried out in any suitable metal or glass-lined vessel. The materials are not corrosive and carbon steel equipment is suitable. An agitator should be provided. Order of addition is not critical and will be determined by the physical state of Aroclor 5460 and operating convenience. If 5460 18 already In the molten state, it may be added first, then Aroclor 1221. If in the solid, flaked state, the Aroclor 5^60 should be added to the Aroclor 1221 heel. In both cases the lowest viscosity and consequent minimum agitator power requirements will be obtained by adding the Aroclor 1221 fol lowed by Aroclor 5460. After the ingredients are combined, agitation should continue 1/2 to 1 hour or until an homogeneous mixture is obtained. It is suggested that the batch be warmed only enough in the 75-150F. range (25-65C.) to insure adequate mixing. The completed batch is then circulated through a polishing filter (cellulosic string wound filter cartridges of 50 micron nominal rating are sufficient or use filtration normally used in Aroclor production). Samples are taken as required for analytical and control purposes. The batch may be held for possible viscoelty adjustment or sent to storage. After blend ing, the temperature may be reduced to 75-150F. DISCUSSION OF IMPORTANT VARIABLES The most important specification property of Aroclor 6057 is viscosity. Adjustments in the blend should be made to keep the 100F. viscosity within the required range. If the 100F. viscosity is low, add Aroclor 5460. One pound of 5460 per 100 pounds of mixture will increase the 100*F. viscosity about 1.2 cs. If the 100F. viscosity is high, add Aroclor 1221. One pound of 1221 per 100 pounds of mixture will decrease the 100F. viscosity about 1.2 cs. MATERIAL SPECIFICATIONS Raw Materials . Refer to raw material specification sheets Included in the Appendix. COMPANY CONFIDENTIAL THAN 037626 ' HARTOLDMON0010655 -3 - Finished Aroclor 6037 Typical analyses and suggested specification limits follow: Property Tentative Specification Typical Anniston Value Method Appearance Clear yellow liquid, free of foreign matter Same 0-1 Color, HPA Viscosity at 10CTF. 2.0 max. 20 to 24 cs. (98 to 115 SUS) 1.5 0-4 21.3 cs. 049 Specific Gravity 25/25-C. 1.31 to 1.34 1.33 052 Acidity, mg KOH/gm 0.05 max. 0.013 050 Moisture 250 ppm, max. 63 ppm ' 047 As Requested: Flash Point, C<0C. 265 to 290 114 Fire Point, C.O.C. 345 to 360 114 ANALYTICAL METHODS No new or special analytical procedures are required for this product. A cross reference table appears in the Appendix listing standard analytical procedures used at J. F. Oueeny Plant, W. 0. Krummrich Plant, and the Anniston Plant. These procedures are currently used on Bimilar products. TOXICITY AND HAZARDS No unusual toxicity or hazards are expected with the raw materials or finished blend. The process is a simple blend ing procedure and no hazardous reactions or heats of mixing Bhould occur between the components. Aroelor 1221 and 5460 have been produced by Monsanto for many years. Recently these have been combined in such products as Aroelor 6040, a substitute for Aroelor 1242 in plasticizer applications. (Note: Current specific toxicity information COMPANY tran 037677 CONFIDENTIAL - I HARTOLDMON0010656 -4 - ie being reauested from the Medical Department on the Aroclor 6037 blend and it 'is suggested these be Included in the Appen dix when obtained,) Oeneral precautions include the following: 1. (Joggles should be worn where splashing or spillage may occur, 2. Any material In contact with the skin should be removed by washing with soap and water. 3. Prolonged or repeated exposure to the skin may cause Irritation due to removal of skin oils with resulting dryness and chapping. 4. Material may be irritating to sensitive skin areas and eyes. In case of contact with eye tissue, flush copiously with water and then get medical attention. 5. In case of internal ingestion, get immediate medical attention. 6. Avoid inhaling volation material or mists. POLLUTION CONTROL No waste by-products are generated by this process. Used filtering material, flushings from the system during cleaning, as well as any spoiled product should be disposed of as dictated by local regulations. Every effort should be made to prevent chlorinated biphenyl or chlorinated terphenyl from being mixed with water and drained to the sewer. Non-aqueous solvents should be used to clean the blending tanks and eaulpment. Suggested fire resistant solvents are trichloroethylene or trichlorobenzene. Minimum or no equipment cleanout would be needed if production 1b scheduled to have blends with similar components before and after Pydraul 6037, le. 6o4o or MCS 1004. Vapor generation should be reduced by limiting the heating of the blend and raw materials to as low a value as possible consistent with practical blending requirements. 'Solids containing the chlorinated biphenyl or chlorinated terphenyl (filter) must be disposed of at an appropriate land fill. Burning of these materials should be avoided at this time. When suitable high temperature incineration equipment is available, which will completely decompose such materials, burning will be an acceptable method of disposal. COMPANY CONFIDENTIAL TRAN 037628 I HARTOLDMONO010657 St. Louis Research Report No. P-1590 TENTATIVE PROCESS FOR AROCLOR 6037 (MCS 1057-1) November 17 1970 APPENDIX File Copy Approved by: L. R. Stark Manager of R&D (datej Manager of Manufacturing (date) Manager of Process Technology (date) /is 11/17/70 COMPANY CONFIDENTIAL 037629 HARTOLDMONO010658 I PHYSICAL TfufrrFErfir PYDRAUL 6037 CONSTANTS DATA itnuctukal formula AROCLOR l?f?l AROCLOR 5460 T0UPILKB 'U'V L. R. Stark 11/16/70 Formula BTeru!-------------------------------------- Molecular Weight . Araeauaci_______________ :__ !__________ uieat' light yellow iiq rra Bsiline Point at fSOntm__________________________ Bo. ling PoirLjL jam_________________________ Beilin* Point at Boiling Point M mm am Crystallizing Point llAl'inf Point .. ....... None jTcnrn Solution Point Specific Gravity P5/P5 C Specific Gravity # Pounds per Gal. 4 ? 5 C 11.1 Coefficient of Expansion Refractive Index a "i Infra Red Spectrum (Refennc*) Ultra Violet Spectrum (R*!v*nt) Viscosity# 100 P ?1.3 typical Viscosity# Surface Tension ability In Water rm : Sol rbllifyln Solubility In 63* 3756 ------------ ---- Flash Point F (MttM) COC Fire Point C Uei t of Combustion Hexi of Formation Thermal Stability (cal.Ae/min.1 Latent Heat of Fusion LMerrt Heat of Vao. Specific Heat Critical Temperature Critical Pressure ' Dissociation Constant 9 " I A i u 5 s Tonicity (Civ* R*f*rmer) ?65 to ?90 typical 3H5 to 360 typical cqsHiDEiffiAt: TRAN 037630 HARTOLDMONO010659 Analytical Procedures Property Appearance WOK I2809 JPO. 16-B Anniston 0-1 Viscosity 12837 126-A 049 Plash & Fire Point 12803 50-A 114 Specific Oravlty Pour Point Cloud Point 12804 13005 - 116-B 100-A 36-A 052 . 053 - Acidity e a Moisture 12794 12810 80-B 78-3 050 047 Foam . 12805 ,54-A - Refractive Index * . Distillation Range 131?5 10117 104-A . 048 054 M ^Approximate eoulvalent ASTM method. 9 a ... * ' THAN ` COMPANY CONFIDENTIAL ASTM ^ - D-445 D-92 0-97 D-2500 D-664/O-974 D-1744 D-892 D-1218 Modified D-20 HARTOLDMONOOIO66O f WIUII JU4UV/ (inn tilt (Brule n finisiu-.d PRODUCT r.proiFicATiON (*>< *** H. i'VVU.pg*.J-I\ltS3L v._AuU_2HPJiL. ~CLML*W BCI>TW pwam* .f_f_n_VAnii>n*>isutnon'v_i_ JLlU2_ APP9IOVAL* AROCT.OH 1??1_ rHUUUU CUUli nruB'7tt.t6'u.1i0. __ Snlrw io4n.^a5rQ4/n-oo!) Ann. f.OO MP.ISAHCM M. B. Clbbs 3/12/69, guturr CfBTBQt (CW< . B1 ewer. 3/26/69 G. W, Hiller 2/15/69 IHXTUR1 Ml ff. Molten Ptct. p 4/2I/1L CNkftftCTtnttTIC AMPkt POU AMAWVtl* 2 x 1/2 gal. Amber Bottlca iIMfl UItfieeWwBsBBBf c. Hiller (R) Condition . <R> Color, APHA (R) Specific Gravity <25/13.5*C) <R) Aridity, (Hg KOH/g) , ` (R> Tltcoilty 9'100*F i .i Clear 100 Max. i.182-1.192 0.014 Max. 38-41 803 4*0-5.5 Cp easTHoe e-i 046 052 050 049 - ,','K > \ * lv. - . n \ . v . *. V-* 1 * ' . * *, * , * < ' ; . * a' ^* t* i*v.v ^ l . * . ;v: * , . a . . * . / . ! * . , * . . i.% * .. * t . ** , * i* y .* I i. TRAN 037632 (Ht Knttnt Am*tTh, 411 eiitr# Anity"* h '*< B,7 a.see COMPANY HARTOLDMONO010661 Monsanto 04ft|< C**C ALi OIVIIM Aroclor 5460 fiURh Soluble Grade) TCXnT---------------- 1 'iMPOftODBUUCCTT CeOoOoBi- wii..... |oT. 27-S FINIIH1& PRODUCT SPECIFICATION mo'mton t8H2i6n.2a2sr ISatea AA OV Alt KBICAneM , L. R. Stark // 3-8-66 ... _ ..... PliF V. g- Ault /a/ 3-1 -M--------------- -------------- -- 0. Ij JtglliL- N! 12-2g.ilS--------------------------------- Mixture * ,, *, ll x 16 os Can or W.M. BottlalJ. A. Llddle 11-30-65 1. MITNOO UNRESTRICTED INFORMATION (R) Appearance and Color Clear, yellow to ember brittle, reain or flakea (R) Color, NPA, Molten (R) Softening Point, *C (r) Solubility (25 In 25 g, Acetone 9 25*C.) Acid No., Mg ROH/ga. Chlorine, % 2 Max. 98 - 105 3 hpur, Min. 0.05 Max. ' 58.5 - 60.6 RESTRICTED INFORMATION Hydrolyils Stability, ppm Cl 300 Max. 6-1 6-4 115 117 116 093 092 P ...... . (K) fteaUne Analysis. Alt etktra Analysed b TRAN 037633 COMPANY Qb CQfvlFiP^NTiAL HARTOLDMONO010662 I * | Monsanto I * l-oc*T'"' R. H. Munch - Technology Department - South Second Street * June 1, 1971 , AROCLOR 1016 SPECIFICATIONS TO : J. R. Savage W. R . Richard R . McCutchan - WGK W. B . Papageorge D R a Cova O. DeGarmo P. G . Benignus J . Fallon F . Kuater --j. R A a Baxter/H. A. Vodden ' Ruabon A. Fa Reagan - Newport F MacDonald - Newport P. J . A. Mar ah - Brussels J . Durland - Tokyo D. Danna It has been suggested that specifications be set for Aroclor 1016 to be produced by Monsanto as a replacement for Aroclor 1242. The guiding principles to be used in setting the specifications for Aroclor 1016 are as follows: The electrical specifications, specifications for appearance, color, acidity, water content, inorganic chlorides, sulfates, and stability will be the same as those for Aroclor 1242. Specifications for properties such as pour point, viscosity,specific gravity, refractive index, distillation range and fixed chlorine content will be changed to compensate for the higher homologs removed. , One new specification must be added. That is penta and hexachlorobiphenyl content. This is essential because our reason for producing Aroclor 1016 is to produce a product with a minimum content of higher homologs which are more persistent in the environment. The ratio of penta and hexa content in Aroclor 1242 to that of Aroclor 1016 is our one readily quantifiable measure of the improvement achieved by going to Aroclor 1016. The penta and hexa content of Aroclor 1242 ranges from 6 to 7.2%. That for Aroclor 1016 produced so far has been less than 0.3%. On this basis, Aroclor 1016 can be said to be about 20 times better than Aroclor 1242. The suggested specification for penta and hexa homologs is 0.4% max. to have some margin for analytical error and less efficient operation in the plant than in the pilot plant. M-t mtv. it> COMPANY CONFIDENTIAL I**14 HARTOLDMONO010663 -2 One other change is suggested. Current specifications call for a dielectric constanUof 4.7 to 4.9 measured at 1000 H* and 100C and power factor of 5.0% measured at 60 Hz and 100C. It Is suggested that the dielectric constant be det ermined at 60 Hz and 100C so that measurements will not have to be made at two frequencies. The dielectric constant does not change with frequency in this range so the specification range will not change. The 1000 Hz power factor is often too low to measure accurately and should therefore be omitted as a specification. The attached table compares the proposed specifications for Aroclor 1016 with the current specifications for Aroclor 1242. These specifications for Aroclor 1016 are proposed to serve as a starting point for develop ment of final specifications acceptable to all interested groups in Monsanto and to our customers. Your comments are invited. R. H. Munch COMPANY TRAN 043015 HARTOLDMONO010664 Me Be MMtSfZZ - ST. LCUXS APRIL 28, 1970 . Mnmt mm j. yao* clo R. SAVA01 t SPfUMGSATS DEPOSITION EXHIBIT ///r ^ ' PLAINTIFF'S iXHisrrj5 .. With the minting interest in plyeMf!lJmt4 biphenyls (PCI) tad their possible harmful offsets @0 the envlronaent, se are very interested te Adding following st&teaant on preduets <at*iaing PCB'a. lhis product tont&ina polychlorinated biphenyls, shieh son studits havs shgya JZ-t'/J a&j Me &n savirorvaesUal oontasinaBte '`TSSSt ^ should be taken 6 prevent --r"%--ar.wi rw WW envlronaent through spills , leakagei/j^lsposal. vaporisation or otherwise. ms additional wording Is intended for packages containing Aroclors 1232, 1242, 1248, 1254# 1260, 1262. ItCl and 446* and Montar 4. Me alto plan to use this statetent on Pyranol and Znerteen labels, but si sill discuss sith Oeneral Utetrle and Vestlaghouse since the tradeaartcs belong to then. We art very anxious to sake this change quickly. May I have your entente f . v. b. pAPAoaoitax JT/-70 C^mJ <L*f <*1 y > UruXi 1 IHMI ^ 300 2628 *5 HARTOLDMONO010665 V. D. PA?AO*XAOS - ST. LOUIS APRIL P, 17JO AflOCLDR LA3/XS ' B. S. {G4 D. A. CLGCiJ P. 3. PARR j. n. savao:: ` Cob SI do An arrangins for the Modification of Aroclor labels to include reference to ?CB in the environment. \0>en the new labile are available, trill you cue tliat the planto order their supply and laccdlately begin using then on new packaged Arocloro? Dob is cleo preparing & cupploncnteay label for placing on packaged .;aterlal new in inventory. ..'hen theso labels are available. the plants should nrlto sure they are added to the package before Ghippirg. V.'ill you arrsic vith 0. Lirier'o gran? regarding oupplcacncary labeling of packaged Aroclor in outlying warehouses. Den Olsen is checking tdth G.. and '.`putlnghcune regard*<g the \;oei -.icatlcn of Pyranol and Incrtcon labels. As soctj as ngrecaont is reaohed. Bob dido trill i.uhe the ncoecoary changes. The need for using the Modified labels ir urgent and wo thou Id /.fu;c every effort to expedite thia change. Origmsl Signed ty W. B. Pp*g#ofge DEPOSITION EXHIBIT P/f.i wt I ,*n oou HARTOLDMONOOIO666 I F. 0. Benisna* t. Lruit Motrtl office >prll 7$ 1970 H. t. Bergen JQSKS V. *. Meh&nd VAXes vzsTimncms fcs fhcblw mcosszca vu s. sum* m, PRCP05IS ft* Wo imro #. #. tr?sst toSSTAT# AFML 21 o. ft. Qrthta - wm Tsrk 1. ilw ftm 4* Cliaa ft* Kt.Ur_-/SQ Jf5> ' Wfifk I. I. Itllty - SKILL gifts# - JSATA Gary Vilbum# Wetla$h;iist Seuth Beaten, Virginia eenfirtied tnat Trustfir?ip and Capaelt?? Blrialtn p%jpl aro indeed anxious tc ut vita us i* diteuss the FCB pi Xlctlen pr-bl#s# at lb earliest eppuptuoitj ?be Wasting* b^uvt people vill bt vita at Tuesday ecroing April 21 presumably at &iS> a.a* han at Cr#t# Ceeur. Kr, Wilburn vill represent Veetinghcusej S^utb Beaten, Dr. Slcat till represent Vesiin^lfcHtse# Star-.# tad Be Hedsin (wn? la fitaantlf h-sa vith illness) cr^sccecne in him place will represent Wtstinshcust* Blscedngtcn* Indiana. Tuesday, *pril 21 is t setisfaeUry data for Kr, Vfceeler* Dr. Kuachf Dr. Riehard tr.d Hr. Fapege^rge. These people ch-.liId lr.vltt their a*scolatee to participate exactly tleeg the lines cf the vetting t held here in St. Lvuia In the recent past with central Ilectrie Ccepany. It is prrp-aed that wt will ha ft lunch at th# Bath and Teroia Club. F. 0. Senipros /in l;0 002739 DEPOSITION EXHIBIT PUW7 7- f-4z. m HARTOLDMONO010667 HARTOLDMONO010668 > / V; HARTOLDMONO010669 HARTOLDMONO010670 3 as 'spl k^\vk:*$`c,- 3 < *<!*$ HARTOLDMONO010671 HARTOLDMONO010672 HARTOLDMONO010673 HARTOLDMONO010674 Monsanto MOM <N*Ml A kOCAlOM| W. R. Richard - T3A iber 20, 1971 L REFORMULATIONS W. Roos - 1760 H. S. Bergen 0. DeGarmo T. L. Qossage F. J. Holzapfel R. M. Kountz J. Mason R- Savage To keep the record straight on chlorinated products In Pydraul products. Specialty Products first removed Aroclor 1248, 1254 and 1260 as agreed with management In 1970. We believed these were the non-degrading products being found in the environment. Research next developed formulations to remove all chlorinated biphenyls from Pydrauls, feeling this would be a desirable step. (Exceptions were Turbinol 155 and Pydraul being sold in Germany where we could not pass the fire tests.) Management agreed to remove chlorinated biphenyls from Pydraul in 1971. The list of present Pydraul products is given on page 2 and 3 of the attached. The "book" assembled by 0. DeGarmo omitted several reformulations, Pydraul A-20OB, Pydraul 5**0B, which eliminated the use of Aroclor 1242. Research and Marketing are now trying to prepare for the replacement of PCT, should this become desirable. Key products are NCP and NaCP plus certain VI improvers which are required. We need project approvals for changes in EE-Bldg, plus successful trial production this month on NCP. I hope you approve of the efforts we have made and are mak ing to control chlorinated components, phosphate ester toxicity, fire resistance and to maintain continued customer service for Pydraul fluids. /is Attach 6U&. . W. R. Richard DEPOSITION EXHIBIT P/fi W? TRAN 085106 HARTOLDMONO010675 1 HARTOLDMONO010676 Monsanto -- W. B. PAPAGEDROE - ST. LOUIS IBJTAL PROBLEM .STATUS REPORT ..). A . March - BRUSSELS W. S. Clark J. R. Durland - TOKYO M. V. Parrar - 2nd Street E. V. John R. E. Keller - 2nd Street R. M. Kountz T. L. Gossage P. S. Park W. R. Richard J. R. Savage 1. P. toeeler ) ** H. S. Baffin J. Mason J. E. Springgate GENERAL: Performance against tha PCS plan was reviewed with the CMC on September 14. Overall the committee was satis fied with the progress which has been made and compli mented the various departments in the Division who have been involved in the action. However, it was emphasised that we must continue to emphasise to all remaining users of PCS' the importance of preventing escape to the environment and we must ensure that these warnings are fully documented so that they will support the action we have taken in this area should we become involved in legal actions. Two variances from the original plan were requested and approved: 1. 1CH - As the customer has proved unwilling to com mit himself to a take or pay contract, it was agreed that we can go ahead on the basis of pro ducing HXFB in existing equipment or using toll manufacturing facilities ensuring that a satis factory level of profitability is maintained. The eephasls here was to phase 1242 out of HOT formulations as soon as possible. 2. It was recognised that good progress is being made in reformulating lndustrial/nydraulic fluids and that it was not easy to completely replaoe PCB's with alternate material. In view of the progress made, an extension of a further three months (i.e. end first quarter 1971) was granted to enable DEPOSITION EXHIBIT Plfr SIR 007996 HARTOLDMONO010677 us to reformulate those produets still containing Aroclor 1242. It was emphasized, however, that this would he the last extension granted and if we are not successful in reformulating, it will be necessary to discontinue the business in spite of the significant gross profit involved. Preparations are underway to test the disposal of solid waste contaminated with Aroclors in Biviro-Chem Systems pilot unit in St. Charles, Mo. Solid wastes from transformer and capacitor manufactures will be intro duced into the unit during the week of October 12. Negotiations are continuing with Rollins-Purle, Inc. to establish their capabilities and cost of incineration of liquid Aroclor waste. MAHXETINO; The withdrawal of Aroclor plasticizers from the market appears to have been completed with very few loose ends. Only a couple of companies have called claiming that they had not heard of our withdrawal, and to date these inquiries have not caused any significant problems. Our distributors are well on their way to zero inventories of the Aroclors, having pretty well matched their pur chases from Monsanto with firm orders from their cus tomers. It does not appear that there will be any extensive returning of unsold materials. Orders for the products which will replace the withdrawn Aroclors in the market are starting to come in. It will be several months before substantial volumes are be ing sold, however, as most companies have some inven tory of the old products in stock. Two major items of information indicate that the replacement program is progressing well. The first is that 3M has replaced Aroclors 1254 and 4465 with Aroclor 5442 in five product lines in the Industrial Tape and Hectro Products Division, the second is that Thiokol states that Santldser 261 now has the inside track ahead of all ether products including chlorinated paraffins as a replacement for Aroclors 1254 and 1260. BIOINEmNQ; - Waste Incineration - SKA 2415 Design is in progress both internally and at John Zinck's. Approval drawings for the incinerator are expected the week of October ?. SIR 007991 HARTOLDMONO010678 Aroclor Distillation - CIA 2^17 Definitive design la in progress. Because of recent decisions by Corporate and Division Management, market ing forecasts for MCS 1016 have been reduced. Accord ingly, elements of the project are being reviewed with the idea of reducing the scope of work. Tributyl Phosphate - CIA 8371 The project scope report is being reviewed by the plant. The II building explosion and subsequent related work has delayed this plant review, a preliminary estimate has been developed. Timing of the project has become critical so pre-approval funds will be requested for engineering and commitment of long-delivery equipment. N-C Phosphate Although Research has had success in bench scale oper ation, it has been decided to prove out the process in the 1-1 building at JPQ. Thus, the latest schedule for having process assurance is March 1971. Project development will not be resumed until after the process is proven. EUROPE: An informal setting was held with the Directors of some of the voluntary societies, e.g. British Trust, for Ornothology, and they expressed considerable satisfaction at the responsible attitude adopted by Monsanto in northern America and the U.X. The N.S.R.C. REPORT on the Irish Sea incident is now expected to be published Movember/December. We have been promised a copy of the latest draft. further contact with the other European manufacturers has not yet yielded agreement on when or how to act and it has not yet been possible to arrange a decision making meeting with them. sift 007996 HARTOLDMONO010679 4 MEDICAL; The latest status reports on the dog and rat chronic feeding studies, rat reproduction studies and chicken toxicity, reproduction and residue studies were re viewed with representatives of the National Institute of Bivironmental Health Sciences, Bureau of Commercial Fisheries Laboratory, Food and Drug Administration, U.S. Department of Agriculture and the Patuxent Wildlife Research Center. PUBLIC RELATIONS The July news release, stating our position to withdraw from certain PCS markets, was used in whole or in part by 13 more major newspapers. Total to date is 22. As the month closed, plant management at Pensacola spec ulated Monsanto may be sued by the Southeast Fisheries Association, Inc. for polluting Escambia Bay with PCS. At this writing, the suit has not been filed. A pre paredness statement was drafted for use by the Plant Manager, should a suit develop. RESEARCH: Carbonless Carbon Paper Solvents NCR now seems more committed to MIP8-2 as replacement for Aroclor 1242. It appears that an additional 100,000 lbs will be required for full scale trial with a "firm" answer expected late 1970 or early 1971. Assistance has been provided the plant in preparing for the upcoming run of MIPS. An amendment was written to allow the manufacture of a MIPS containing higher (1.5 vs. 0.6) ratios of propylene to biphenyl. The most recent information indicates that this higher ratio material will not be needed by NCR. Manufacturing is searching for a location to make larger quantities of MIP8. Nashus likes a blend of Aroclor 5442/HB-40-1/4 as a dye solvent even though its viscosity is shove their "upper limit". Three more blends are being tent them to help sero in on the proper ratio. .1* oo',,, HARTOLDMONOOIO68O -5- Print fad* on Nashua Clay coated paper la caused by light (as with NCR paper) but not by excess solvent. Use of a resin or rubber to extract excess solvent (beneficial In NCR paper) Is harmful in the Nashua system. Hydrogenation of the aliphatic double bond in AMS Dimer (liquid) eliminates most of the odor and reduced print fade, making this a very good hydrocarbon solvent. Acute toxicity tests show the mono and dlchlorinated AMS Dimer to be comparable to Aroclors of corresponding viscosities. The solid and liquid AMS Dimers and iso propyl biphenyl like KB-40 are "practically non-toxic" (or safe) but are noticeably more irritating to rabbit skin. Twenty four hour patch tests on on* person showed no irritation from any of these materials. Industrial Hydraulics The removal of Aroclor 1242 from all Pydrauls will require reformulation of A-200, 261, 540, 312, 230, 135. 150, MCS 153 and MCS 974. The Pydraul 312 reformulation is farthest along. Tire resistance of the new formulation is greater than the fire resistance of Pydraul 312. Performance in the V-105C was excellent. Samples were sent to Ford for evaluation. It will be desirable to make the hydraulic fluid applica tion into a closed loop system. VC cannot expect to stop leaks but we can expect to minimize contamination of water by (1) minimizing run-off to sewers; (2) treating con taminated water by adsorption (Anniston had no detectable PCS after passing through a limestone bed); (3) recycling adsorbents to remove Aroclor by squeezing, by extraction or by devolatilization-destruction. Aroclor Pollution Study - Anniston In the 13 day pilot run, initial concentrations of 1000 8000 ppb Aroclor in waste water were reduced to a range of 0-15.ppb upon passing through a series of packed carbon beds1 at an average flow rat* of 25 ee/mln. Over 99% of Aroclor removal occurred in the prefilter. This unusual reduction is believed to be due to the filtration of solid on tdiich Aroclor was adsorbed. In tests run at higher flow rates (0.5 gpny/ft.2) through the prefilter, these plugged the prefilter. The study is presently being divided into two phases: 1) feasibility studies for continuous solids (with Aroclor) removal from limestone pit effluent and 2) carbon adsorption from the clear stream at the Aroclor sump; gift oosooo HARTOLDMONO010681 -6- There u & temporary delay in the shipment of the pilot adsorption unit.2 Start-up is now targeted for 9/23. 1 The adsorber consisted of a prefilter (3.5 inch diameter tube packed to 5*5 inch bed depth) and a series of one (1) inch diameter columns packed to a total bed depth of 13.5. 2 Pittsburgh Carbon (Calfon Division) rental unit contain ing pumps, 5 inch diameter columns, etc. Determination of Polychlorinated Biphenyl Residues In Rats from 36 day Aroclor feeding Studies One of the more significant objectives of the AroclorBivironmant program has been to develop a more complete picture of what occurs to Aroclor products once they are released to the ecosystem. The importance of this infor mation is two fold, first it can be used to guide the development of a more "degradable" Aroclor product and . secondly, the general methods developed to study the current Aroclor products can be used to determine the degree of control that must be exercised over the replace ment products to avoid similar problems with these mater ials in the future. As a part of achieving this overall objective. Industrial Bio-Test Laboratories was requested to carry out a 30 day tissue collection study in albino rats with Aroclor 1242, Aroclor 1254 and Aroclor 1260. This report deals with the subsequent analysis of these tissues for residual PCB'a. Summary: The results of this study demonstrate that the residual PCB levels in all tissues decreased significantly as the degree of chlorination and the dietary exposure level of the material fed decreased. Additionally, it was observed that the amount of Isomeric alteration increased as the degree of chlorination decreased re sulting in the fact that the major P Isomers retained by the rat fed Aroclor 1242 were those predominantly present in Aroclor 1254 and Aroclor 1260. There were no significant differences in the type of isomeric alteration from tissue to tissue or between sexes. Aroclor - Bwironmental Program - it. Louis Preliminary testing by the national Hater Quality Labora tory at Duluth, Minnesota of the tolerance of fish and fistfood organisms (survival and reproduction) to our Aroclor products has indicated that Aroclor 5442 is much more toxic to Saphnia than any of the P's. Eleven reserve samples of production Aroclor 5442, one of which was used in test, have been received from Anniston to determine if sir oosooi HARTOLDMONO010682 I -7- any watsr soluble tramp component(s) could be responsible for the alleged Increased toxicity. Initial results Indicate that the pH of the water used to extract and/or solubilise the Aroclor 442 is not changed; however, a number of SC active components can be Isolated from the water extracts via a hexane extraction. An attempt will be made to identify these components. A meeting was held to review the status of the residue analysis of the Bio-Test Laboratories tissues. It was agreed that the work should proceed and that in terms of current priorities the tissues from the chronic rat study should be done first, followed by the fish toxicity study, and then by the chronic chicken study. Provisions have been made for shipment of the rat tissues and fish samples to Monsanto. Arrangements have also been made to have saa?les of fish from the semi-annual Anniston area survey and samples of shrimp from three locations around our Pensacola collected, quick frosen and shipped to St. Louis for confirmatory residue analysis. ' Environmental Studies - Kuabon The paper entitled 1Askarels - Bivlronmental Pollution* was presented at the MORE conference In Paris. This was welcomed by the delegates as a useful guide to good practice and suggestions were made for wider publication. A modified version of this paper Is being made available for the PCS conference organised by the Swedish National Environment Protection Board at Stockholm on Sept. 29. The draft of the report on the deaths of sea-birds on the Irish Sea is now being made available to Monsanto, but we have not yet received a copy. Blodegration Testing - St. Louis Functional fluids Testing of Aroclor 1242, Aroclor 1254, MCS 1016 and fractionated Aroclor 1130 In our.semi-continuous activated sludge wits Is continuing. Calculation of ED/OC analyses for the first five weeks of operation have been completed. Due to the high degree of scatter In the data, no conclusions can be made at this stage concerning differences In bio degradation rates. The source of the scatter Is currently being lnvestigatfd. One of the units has been equipped with a stirrer to determine If agitation is a significant factor. Five additional units are now being added to our setup to permit simultaneous testing of a greater number of products. Testing of trlchlorobenssne, Arobromchlor 1232, and Oulf SIR 008002 HARTOLDMONO010683 -8 Bright Stock will be started shortly. Testing of the chlorinated terphenyls, e.g., Aroclor 5^32, is swilting the development of the necessary analytical methodology. Several enrichment tests involving biphenyl-acclimated sludge and nutrient feed withdrawal art also planned. Plasticisers A three-day sampling of the IS-40 and mono-isopropyl bi phenyl (MIPD) semi-continuous activated sludge units nine weeks after the previous sailing period haa shown sig nificant changes in the biodegradation rates, for MIPS, disappearance rates for the three days by TJV analyses were 75 70 and 77 per cent compared with the mean of 67 per cent in the previous sampling period. OC analyses indicate that the predominant mono-isopropyl biphenyl eonponents are almost oospletely degraded during the cycle, leaving aa the undegraded portion the dialkylated cooponents. For HB-40, the previous sampling period had shown essentially a sero disappearance rate with a high degree of scatter. During the three-day period, dis appearance rates of 54, 52 and 58 per cent were found. Prom OC analyses, it appears that the one-ring hydrogenated components are more readily degradable than the tworing hydrogenated cooponents. Feeding of the MUB and EB-40 is eontlnuing. An additional sampling period is planned to determine if any further significant changes will occur. Five additional units are now btlng added to our setup to permit simultaneous testing of a greater number of products. Testing of Aroclor 1221 will be started in one of the new units. Biodegradation Testing - Ruabon In the presence of lower chlorine isomers and biphenyl we appear to have succeeded in degrading the key hexachlorlnated Isomer with the biphenyl-active soil culture Cg, but the penta-chlorlnated Isomer has not degraded under these conditions. Work is being initiated to check whether any of the "non-degradable" isomers (e.g. 4-4'dlchlorblphenyl) can be degraded under these more severe conditions. The sensitivity of the analytical technique used was not high enough to show conclusively Aether HB-40 was de graded by C. This is being repeated using a higher con centration. Progress continues in the development of OLC-Mass Spect rometry technique* to allow identification and quantifi cation of residues remaining after prolonged biodegradation tests on various products. B1R 00S003 HARTOLDMONO010684 i -9- MAKWACTPRINO Anniston Plant PCB Levels In Snow Creek Average PCB loss for the month was high at 2600 ppb or 32 lbs/day, largely as a result of one very bad day (400 lbs). Contributing causes were: 1. The old limestone pit was overloaded and solid sludges were carried through, # 2. Detergent cleaning of the department, 3. Sewering of excessive amounts of muriatic acid. Since the new limestone bed was placed in service on . September 23, pit effluent has been at 0-3 ppb PCB's. However, leaching of PCB's from the creek bed results in a plant effluent level of 90 - 240ppb or 1.1 2.8 lbs/day, gradually declining. The plant believes that the new pit can handle ordinary upsets and peak loads. Regulatory Action Telephone contact continued with the Alabama Water Improvement Commission. However, a planned meeting did not take place due to illness of AWIC members. Pressure for routine submission of analytical data la not intense at this time. Department Suspended Aroclor Control An experimental skinner operated very well removing the PCB laden scum which accumulates In the new sump. Solid Wastes Solid waste data for evaluation of dlspoaA methods has been accumulated. A report will be Issued in October. IR Q08C0* HARTOLDMONO010685 10- . Q. KpuMHEPieh giant '' PCS Levels In Sewer Current losses to the river from the treatment plant range from 12 to 742 ppb with an average loss of 511 ppb for 11 samples. This is an equivalent average loss of 71.5 lbs/day. Projects To Reduce Sewered PCB*s Prom Aroclor Department. *>low Tank Demister (Estimate 2051) project construction is underway with completion scheduled for October. A Process Amendment was approved. Project for about $50,000 to provide paving, curbs, trenches and catch basin in tank car and tank truck loading areas will be added to the incineration project to speed approval. Program To Eliminate Sewered PCS*a Prom Using Departments Departments 245 and 244 Plans are to replace the Therminol FR-1 with Therminol 55Lab work has been conducted to verify that there is no reaction between Therminol 55 end any process materials. Engineering is underway on system modifications required for use of Therminol 55. Target date for changeover is 12A/fC. Department 245 The major problem here is air pollution from the supply tank vent. Our target is to scope a solution and prepare an estimate by ll/l. Changeover to a different fluid is undesirable in this department due to the high fire potential. Department 251 Ro work has yet been done on the lubrication and hydraulic type systems in this department.. Department . Work is in progress to develop project premise. We expect to eliminate two pumps and a cooler in the Therminol lines. (Pending results of thermal stability of Santophen 1 residue). The project will Include a new expansion tank with submerged B1A 00S005 HARTOLDMONO010686 o. KTuamrieh Flint Department 39 (Cont *d) pump. Ve also plan to upgrade eontrole and make furnace operation more reliable. How to sump the am around potential spills is still unresolved. To go to a flammable heat transfer fluid is considered too great a process safety hazard in this area. Department 255 Plans are to replace PR-2 with Therminol 66 by 11/15/70. Department 248 No progress has been made to date. A definite plan will be developed by 11/1/70 with the objective of solving any problems by 1/1/71. Department 258 (DPS) The unit is still down and most likely will not be started up again. The material on the pad has been removed. Department 270 A 55-gallon drum has been placed under the vent. Chat soaked with Aroclor around the furnace must still be replaced. Department 275 A 55-gallon drum must still be placed under the vent line (the vent will have to be shortened to do this). Chat around the furnace still needs to be replaced. Department ITS Work completed. Drum placed under surge tank vent. Buckets placed to collect material from drip pans under Thermlnol circulating pumps. Department 222 Unit in start-up. No visible souree of loss observed. Estimate 2292 will be revised. This is the project to provide 150,000 gallons of storage for scrap Aroclor. A plant level earning* expense estimate will be prepared ' Ootoo HARTOLDMONO010687 t / X.,'- W. 0. Krtoariife flafit -12- Department ffg (Cont'd) to eovtr the coat of altering the atortf* tanks. Tha 1,000 gallon trailer originally used to haul Aroclort to Qveeny Plant will be used for scrap Aroclor hauling in the plant. PCS Levels In Atmosphere Vapor losses from the.Aroclor Department are estimated at 2.3 #/day now and 1.6#/day after the installation of the blow tank demister. 1. scrubber Stack (from blow tank drowning Jet) 0.90#/day This is a measured quantity. With installation of the demister and closing the batch blow tanks, air flow should be decreased to about 20* of present flow. Assuming the concentration to be the same, loss would be reduced to ^0.2^/day. 2. Fume Removal Stack (from drowning area and stapling stations) 0. M3#/day This is an estimated quantity based on most vapors coming from the drumming station and assuming 10,000,000 #/yar drummed, and 1242 vapor pressure at 80*C. Samples are being taken to verify. 3. Aroclor Transfers Within Department 1.34#/day This is an estimated quantity assuming 7OK #/year production and 2. 5 transfers/pound at 100*C. Samples will be taken at storage vents to verify. ' ajJBtSL Jets unknown Will be'measured. * is oosoo? HARTOLDMONO010688 13 V. 0. Kruamrich Plant PCS Rework Project (Estimate 2095) Phase II Construction sufficiently complete to allow unloading tank cars to the rework still. Phase in Design package will be completed by mid-October. This project will be added to the incineration project for approval. Phase III will be held up until approval is received. This will mean that material will be reworked direct from tank cars until the Phase III storage facilities are Installed. .. sir ccecofi HARTOLDMONO010689 B. 8. lori'an Octobar, 1171 Distribution! 1280 C.' U Bradford* 3040 H. B. Dahlstroa 3080 H P. Dl*on/D, Ooodvlllla* 1070 B. 1. ford* 1010 1, A. Oorela* 3020 K, 1* eil/B. Oaroavorthp 1600 D, R. Banssa* 5270 T. lahljlaa 1280 B. T* Johnses* 13MF A. J. Ketiilt* B28X 0. 0. Kossp* ?4BA 1. M. Kouats* 5040 P. J. A. Karsh* B28K V. 1. PRpagoorga* im. I, M. Pottar* HfSA W. 1. Rlehard* W J, 1. tanrage* 2SD L. D. (hand* G4KA 1. B Sahara 1630 P. L. flajton* 1281 1, 0. Tlbhotta* 0380 J. I footer* COMPANY CONFrDENTIAL TRAN 003308 DEPOSmON EXHIBIT Ejl VS/ D- 9-q-v- HARTOLDMONO010690 Monsanto mu im( t.e*Tioi I28L L, OoHi|l .... October 7, 1971 ........ ^ nmaiM' i SPECIALTY,PRODUCTS MONTHLY REPORT _____Knaaa.tezi---------- TO : H. 8. Bergen* * , ee See distribution list Attached . fa lee 9mmn Septenber domestic eelee were $3,258 K 15% below our budget of $3,831 M, approximately $100,000 higher then August, 1971 and approximately $700,000 higher than September, 1970, All product groups were below budget with the exception of Industrial Fluids which was about 20% over budget, lurope's September sales were $744,000^ ever budget by $49,000, Canada was $25,000 over budget, flydyaullce and Lubricants Ford, Dearborn, has decided to continue their shop trial of our MC8 1044 at laast through November, Laclede Steel Is regained and has received five liqulbins of Pydraul F9A, Pontiac Motore haa decided not to shop trial our competitor's Vital 29 -doe to the product'e polymer separation problem. New Pydraul buslnees at Ramin Dioeaet, 0.8, Steal, Baytown, Kagma Copper and Wadco Corporation, Ford, ghoffield, continues water/ glycol test, Columbia Oulf Tranemlaelon ordered $50,000 In Turblnol 153, Northweet Airlines haa extended their current Skydrol oontrect with 8teuffer until November, 1973, While we have reeelved renewals from World Airways, Hydro-Aire, Xne., end Overseas National Airways, Hughes Air West entered the first eoaa rolal order for 5,000 lbs, of Skylube 450, Unfortunately, they will sign a eontraet with Shall for their lube requirements and will not buy Skyldbe 450 after the flight teet. The flret Veteh of Pydraul hae been formulated at the new Antwerp facility. A reclamation contract haa been signed with WTOO, IMM Shelly Oil has eueeeeefully been turned awny from Pt-l and has purchased twenty-three drtrae of Thorminol 68 for offshore gas processing platform, Chevron Oil has threatened to purchase Dowthorm 6 for their now offshore |as proceeslng plant following rofueel to toll PR-1,. Wo shipped a tank ear of biphenyl to laaatex, bringing yoor-to-dato sales to 347,000 lbs. Biphenyl sales were also strong in the citrus wrap market to Crown Sollorbach, 100,000 lbe, end Paper Pek, 50,000 lbs# COMPANY CONFIDENTIAL TRAN 003509 HARTOLDMONO010691 H. t. lnt Page 2 October 7, 1971 AgrsMtnt ha* been reached vlfch Mi bo supply thin HIPS ae their sole encepeulant through June, 1972, . A Tramformer fluid aalea continue strong, 34% over budget and 321 over Auguet aalea. . Konaanto Europe haa gained the European Tanatex bualneaa eatiaated at 300 tona per pear. Agreement haa been reached with XCX on a three-year biphenyl contract. gaoar pad Wood Chemicals Appleton Paper haa signed a two-year contract for Merelce TFL. Ex pected volume la $400,000 per year. Deatar, tt. Catharlnea la Canada, haa ordered their firat truckload ever of Merelac TFL. Hudson Pulp 4 Paper, Palatka, Florida, received two 5,000 gallon tanktruek orders of Santoaiaa DSC. Thla la our first business aver at this location. Indications are that additional truckloads will oome In '71 and a commitment for 4-500,000 lbs. In 1972. gerlpeets are estimated at 7fS of budget for September. Coder budget performance Is caused by WeyerhAeuser's drop off In PCV-10 usage. Their usage Is expected to be at about 135,000 lbs. per month for the balance of the year as compared to a 210,000 lb, per month budget, A successful tcrlpset 520 trial has been eonplated at Mead Corporation, Chlllleothe. Oeorgla-Paelflc, Kalamssoo, has committed to 520 trial within the next two months. Latex Slnders Major Polvln 2400 ordars recalved from Advance Finishing, 500,000 lhs. and Halter Carpet Mills, 200,000 lbs* Advance Finishing, Delfcon, Georgia, will be running Folvln 2400 in a foam praeoat on all earpat grades for one month, f this run is oueeossful, thoy havs Indicated their desire to eontraet for Choir total voqulramants aatiaatad between 7 and 12 M dry pounds psr yssr. Valter Carpet Mills, City of Industry, California, ere working eg a eontraet to sign with Monsanto severing their 1972 needs for Folvln 2400. Coles Corporation is invsstlgetlng an IVCl/OH blond as their fire retardant system. Trials are aspeeted eve? the nest two months to dotormiee the eoet performanee of that aystsm. Jamaa Carpets ran a flva drum trial with Folvln 2400 aa a replaeeaefft for an 8R aluminum hydrate fire retardant preseat. She garpet le being tested now for fire retardaney, Potaatial is 500,000 to 1,000,000 dry pounds per year. All of this activity is a direct re sult of continuing upset la the carpet industry brought about by FTC action# Slstaan mora manufaeturara are being elted fer failing to COMPANY CONFIDENTIAL TRAN 003510 HARTOLDMONO010692 l. S, lirpa Fags 3 October 7, 1971 meet the lire retardent etenderde. Three eerpet manufacturer* hare gone bankrupt as a reeult of this action. Thera la a tremenou*' Interest In fire retardant latex systems. Timing now becomes critical. Plant production Is needed at the earliest possible date. Sackner Products continues to order development quantities of Monflex 4400. Mo word has yet been heard from Ford on requirements for material made with 1VC1. Mead Packaging. Atlanta, ran the long delayed trial with Pelvic 2000. The product performed well and did the job predicted. St did not. hew ever, outperform a Dow system. Activity contlnuee strong in other paper and board coating application*, paper saturation, barrier eoet* inga and paint /ph * gacaiv* attachments T* l. Ooasags COMPANY CONFIDENTIAL TRAN 003311 HARTOLDMONO010693 I KEEP DRIP PA KIND OP M DEPT. 259 # / MIX TANK icn xo.KAfr/ NOTHING BUT PRODUCT IN SAMPLE DRIMS DAT! 7/ PRODUCT PROM MEASURE TANK B.P. fSzL^3EZl sc yI H& .. .... SiJSL MEASURE GALLONS MIX TANK METERED iMEASURl <9 . #-.s TIME FINISHED ^Ja*L OPERATO 27 C^S* CONTROL SAMPLES TAKEN TIME . * TIKE TAKEN ^ OPERfTOR_ RESULTS ' RECEIVEDbP. QR. ZjlZjz.2,/ n3zm 2H5L INDEX ADJUSTMENT ILOT NO. MmUJL_ PR TANK. --jWHfm,-- SEMZEAZSU&RE uE ph Jli . svz-r. zn 1-3 /) II -u.M2S I I tml It RESULTS RESULTS SP QR~.. ttNDEX I PRODUCT l6t NO 1 AMOUNT ( JAKEN L COMMENTS; 4 Tzrjm ........ Li jimi . '' - DATE T,3Z! '*"AV' jnm-JJ Serf__ HWk,. JL&zkeL HARTOLDMONO010694 %' $8 io '" s n `o 'K > > f* -o >v *\ <* > t* s5 % xA Ci ^A^ r TRAH' 003081 Dv - \ tP V #A M1 f5> ^ ** ^ "* X, ^^ *o lx%' n> o. ^ * > no ^ '*-'1 \\ o^ O % HARTOLDMONO010695 . / rt /* -M90/ "7^^^t/uo L / S 3 /O/c// 7/ .. / 2yZ /s /3 0S<s> zr *_ / 2.2. / /J //73 '/ Mfs^/ JA/A* 2^'C tr f, $3%aI 2* //o^z SM/tToo-* ovt'/iq*' 0 * * / w * * fiettof /t/fi ic/ir* M4r*..*f c-^r To Coajt^o L C*mP l*r fAK*/f 4/4 /Mj/ctT* TMovcy /JC? ZhI ts 3.of as -ZU Z, Vj~i. " trah oojom HARTOLDMONO010696 Don Payer WGK Sip id rporr OTAYT. Production of Turblnol 153 (MC.5-153) has been transferred to the WflK Plant. We have n snail Inventory of packared material remaining which la aa followst QK-20 - 2 x 600 lb. drums 1,200 lbs. V331" 6 x 55 lb. cans - 330 lbs. This material contains Aroelor and should be concentrated at the only regaining location which is your plant. 1 suggest you give un an order for it and plan either to blend it off or incinerate it, based on direction fror. the Business Group. The second item involved is PH-130, which as you know, is an additive in the Turblnol 153 fomulation. 1TI-130 also contains Aroclor. We have lA pieces which total t,2AG lbs. It is also requested that you order this material to be sent to your plant and retain it for future VC"-153 pro duction. The FH-130 has been devalued to sero. We would appreciate your cooperation in this matter. TRAN 003085 HARTOLDMONO010697 C. L. Bradford/J. B. Davidson December 8, 1971 INDUSTRIAL HYDRAULIC FLUIDS TRANSITION FLAN T. .L. Oossage M. T. Johnson R. K. Batton J. R. Savage - B2NB J. Solari - 1760 J. F. Herbar - T30 L. R. Stark - W4A D. H. Bolliger - P4WC i. <4 w The Situation In the past, our major strength in the industrial hydraulio fluids business was our low cost chlorinated raw materials giving superior fire resistance to our fluids* These sane naterials had good solubility with oil snd allowed us to formulate the Pydraul 312 series. The result was a very real and sizeable competitive advantage in terms of both quality and price over other synthetic fire resistant fluids. Our position is changing. We cannot use either polychlor inated biphenyls or polychlorinated terphenyls. This leaves us with s line of resale water glycol fluids (available now), a atraight phosphate ester (available shortly), and a lower cost oil-phosphate ester blend promised for the first quarter of 1972. In terns of quality, we will have the advantages of greater stability and the fact that we are not tied to cresyllc acids. In terms of cost, none of these new products will give us any significant advantage over our competitors. In addition, the changeover (the second in a year) will create an adverse affect, particularly on our major customers, of whloh the top five account for 42 of our business and the top 20 of which account for 6o. This means that when the transition has been completed, we could be left with considerably less market share than we now have, with 111 will et certain customers and potential accounts, and with no cost advantage to regain our position* Our sales growth in the future will not be as steep as our sales growth in the past, and our baae will be lees. Objective Our objective in this transition program simply stated is to be out of FOBe/PCTs by June 30, 1972. to salvage ae large a share of the market as possible at a profit, and to be left with aero inventory of our current fluids. We expect to keep at least 5# of our business, -but we must take several steps as quickly as possible in order to achieve this. HARTOLDMONO010698 -8- alone accounts for l&% of our buainass. Wo atust move immediately to convert 0. H. to our phosphate aster fluid. The Division, which Is over half of the . business and which will probably determine what eouree takes, has told us that they will drain and flush all PCB containing fluids froo their aohlnes and refill with a new product. We will try to sell then our phosphate eater fluid at list prloe and charge fully for incineration of the old fluid. If necessary to salvage the business, we will capitulate on 1nolneration and give some price concession on initial fill. In return, we will ask for a three year supply period to recover our costs. We will not sell a low price phosphate ester as a replacement for A200B. If goes to the phosphate ester and if we sell a low priced phosphate eater to one location, we night be forced to sell it to all of then. Due to the large share of our total business that represents, selling to then at a low price would undermine the profitability of our total Pydraul progran. In addition, due to their else. It is poeiible that such a nova would deteriorate the pricing of the phosphate eaters at all accounts. Is having difficulty with the State of Illinois because of too high phenollee discharge in their effluent. However, they appear to be sold on the nost fire resistant synthetic fluid, which means phosphate esters, and all phosphate ester fluids will create phenolloa in their effluent. We have gone to then end suggested they nova to our straight phosphate ester to avoid fCB problems and that they solve their phenolloe problem with treatment of their effluent. In terns of prising end incineration, we will handle then In the same way ns end, if necessary, make the sane concessions. g^ek PsM This should be i cheek point in our plan. If either are lost, we should re evaluate our situation and decide again how best to proceed. THAN 002493 HARTOLDMONO010699 -3 Selector I Accounts After testing the water with and as soon as sufficient phosphate ester becomes - available, we will move to convert all Selector Z accounts to straight phosphate ester*. Selector IX Accounts We will proceed at onoe to develop, test and get Factory Mutual approval on a line of truly fire resistant oil/ phosphate eater fluids. As soon as the development Job is done and as soon as phosphate ester for these fluids beeomes available, we will begin converting all Seleotor II accounts to these new products. It may be necessary to raise prices on those fluids depending on the amount of phosphate ester necessary to give adequate fire resistance. Reclamation We should move now to work with Flndett Service Co. on reclamation of the Fydraul fluids. This means quoting. In conjunction with Flndett, for reclamation business wherever we can be competitive. If it turns out that due to geography we cannot be competitive in conjunction with Flndett In all locations, we will establish relation ships with other reclaimers in those locales. Cspsolty Note that reclamation ultimately eould have a negative affeot on our volume of new fluid sales, nils along with our lots of business during the transition must be taken into eonsidsrat ion when planning the capacity of our new phosphate ester plant. Vital 89 True Fluids Withdrawal of eurrant Fydraul 312A type flulde from the market and introducing replacement fluids at hlghar prices may force customers to go to either hitter priced photphate eater fluids, inferior quality water glycol fluids, or the Vital 29/Daaeo 300 type fluids which. In our opinion, are not fir resistant. To combat this, once we determine TRAN 00249* HARTOLDMONO010700 whither the phosphite ester content of our replacement fluid Is significantly higher than Vital 29. ve should go'lamsdlately to Factory Mutual, explain tne situation on the fir# resistance of these fluids and aak for Factory Mutual's position. Xn sny case, we should call this question of fire resistance to Factory Mutual's attention when they cone to St. Louis to test and approve our Seleotor ZZ fluids. If they remove their approval, that should solve the problem. Zf not and If Vital 29 does start picking up business, we will develop a fluid in direct competition with Vital 29 and Daaoo 300. Customer Notification On April 15. 1971 we cent out a letter to the Pydreul Bailing list nayings "User are now no PCBg in any of our Pydraul fluids. This letter Is not true and has irritated the----- Division of and probably anyone else who knows that It la not true. Ve will coBBunlcate Immediately to the ease customr clearly stating that the letter waa somewhat in error and giving then the facts on the PCB contamination. Zf possible, we can temper this with our plans for future fluids. However, getting the Information to our customers before they get this information from our competitors should be our primary consideration. Field Sales/Product group Relationship Major aooounta where the Product Group may directly assist In conversion are listed In Appendix H. Current opinion Is that all other accounts can be handled directly by the Field Salesmen (assuming we do have Seleotor ZZ replace ment* ). To help prepare the salesmen for this transition, a meting will be held in St. Louis which will focus on strategic salesmen and their managers who will be In attendance. At the meeting we will lay out for then why we must reformulate, the reasons we will give the customer, replacement products with prloes and benefits relative to our old products and competition, pollution aspects of PCBs, PCTa, and phosphate eaters with a discussion of phanolles, 8.0.D. and C.O.D., and oil contamination, and the legal aspects of our situation. Vo will leave them with a "Transition Handbook". Also at this meeting we will specifically define who will handle what accounts, the order in which they will be handled, and the timing. THAN HARTOLDMONO010701 -5- Advertlsliut To counter the negative effects of reforoulstlon. we should plan end execute an advertising progrus that will " explain why we are asking this nove and point out the ' advantages of our new fluids versus competition. ftiis program should begin now* Appendices Attached are appendloes which give sosm background on what our new Seleotor I and Selector II fluids will be along with their costs, prices and gross profit) what a typical conversion night cost us depending upon whether we get full price for the fluid and who pays for lnoinsration) s list of our major cuetonertf and what our profitability for 1972 nay look like based on oertaln assumptions of conversion rates and ooets of our new products* C. L. Bradford /pep Attaohinente J. B. Davidson TRAN HARTOLDMONO010702 APPENDIX A COMPANY COtfFiBENTIAL Proposed Pydraul Line and Pricing Pricing^ Fluid T/T T/L Drums 10-T/L Drumi 5-9 Drums 1-4 Drums Selector 1 Pydraul 10 E Pydraul 29 E-LT Pydraul 30 E Pydraul 50 E Pydraul 65 E Pydraul 95 E Pydraul 115 E 4.55 3.60 Quote Quote Quote Quote Quote 4.75 3.80 3.65 3.65 ' 3.75 3.85 3.95 4.95 4.00 3.75 3.75 3.85 3.95 4.05 5.00 4.05 3.80 3.80 3.90 4.00 4.10 5.10 4.15 3.85 3. 85 3.95 4.05 4.15 Selector 2 Pydraul 135 C Pydraul 230 C Pydraul 312 C Pydraul 540 C 2.25 2.25 2.15 2.15 2.45 2.45 2.35 2.35 2.65 2.65 2.55 2.55 2.70 2.70 2.60 2.60 2.80 2.80 2.70 2.70 / *5 gallon can pricing - add . 25/gallon to 1-4 drum price ^These prices are based on the fluids containing approximately 60% phosphate ester and development of a shear stable polymer to assure permanent fire resistance. TRAN 002497 ...v v .v * HARTOLDMONO010703 APPENDIX B Pydraul Profitability Fluid Selector 1 1 Cost-Short Term Cost-Long Term* Gross S. P. (Dixie CP) (Monsanto CP) (10-T/L Drums) Long Term Cross Profit 2 lbs, /gaL . 9.1 Pydraul 10 E 9.4 Pydraul 29 E-LT 9.9 Pydraul 30 E 9. 8 Pydraul 50 E 9.7 Pydraul 85 E .,7 Pydraul 95 E .222/lb . 2 04/lb .227/lb .268/lb .285/lb .191/lb .215/lb .198/lb . 213/lb .238/lb .250/lb .545/lb .425/lb .378/lb .383/lb .396/lb .4 07/lb 63% 45% - 43% 40% 35% 34% ,. 6 Pydraul 115 E .295/lb .256/lb .422/lb 35% Selector 2 8.44 Pydraul 135 C 8.44 Pydraul 230 C 8.44 Pydraul 312 C 8.49 Pydraul 540 C - .170/lb .168/lb .170/lb .175/lb .165/lb .160/lb .160/lb .165/lb .. .314/lb .314/lb .302/lb .302/lb 42% 44% 40% 38% * Finished Product Cost Including Conversion and Drum Costs ^ Average Freight and Warehousing at $. 03/pound ,' --W -- I--e^nrs> * c TRAN 002498 HARTOLDMONO010704 ' I APPENDIX C Pydraul Blends ? e V<\ ** All prices, costs and profit figures based on the following blends. jL ............ Pydraul 10 E Pydraul 29 E-DT Pydraul 30 *?.? Pydraul 60 Pydraul 65 E N CP - 35% Sn41 - 63% Polymer - 2% Pydraul 9g E N,CP 3*% TPP *6% 11 cdp 46%*7 <* i rr'/'-to Pydraul 115 E , . Pydraul 50 E N2CP TPP Pc try -70% 67 -30% 5i.f . i7> NP 76% *\ TPP 24% l7.f 4<v* >* yi u* *. Pydraul 135 C N,CP 20% S141 46% Oil 33+% Polymer <1% NCP 88% tpp % to. r A - * l-f Pydraul 230 C NCP 41% S141 16% Oil 42+% Pdlymer 61% NCP 100% Qc-nn ruff*** Pydraul 312 C N.CP 46% S141 9% Oil 44+% Polymer <1% G< & (** I* LI*- o Pydraul 540 C N,CP 56% on 43+% Polyme r <1% f.% Cavu^tHlr*. Oil could be Sunoco 800 N, Mobil 750 or H 230 but cost of all i s $. 04 /pound* ***# 002+99 HARTOLDMONO010705 APPENDIX D 1 Typical Customer Conversion Customer Used for Calculations: Date for calculation of cost to customer and cost to Monsanto for conversion from Pydraul 312 A to Pydraul 65 E: Machine Capacity 50 machines x 300 gallons/machine 15, 000 gallons Flushing fluid * 15, 000 gallons petroleum oil Freight Cost $2.00/ewt. $. 22/gallon Cost of Incineration * $. 03/pound Case 1 pays full price for new fluid plus flushing fluid plus freight for returned fluid plus $. 03/pound to incinerate returned fluid. A. Cost to 1. 15, 000 gallons Pydraul 65 E @ $3.45/gallon 2. 15, 000 gallons oil flushing fluid $. 50/gallon 3. 15, 000 gallons (138, 000 lbs.) 312 A plus 15, 000 gallons (112, 000 lbs.) oil incineration @ $.03/pound 4. Freight on returned fluid: 250, 000 lbs. x . 02/pound $51,175 7, 500 7, 500 5,000 TOTAL Cost $71,175 Cost per Gallon of new fluid * $4.74/gallon (Does not include labor or downtime ) *A11 calculations based on bulk inventory cost of $0.223 per pound for Pydraul 65 E which assumes Monsanto manufacture of cumyl phenol at 30f/pound TRAN 002500 HARTOLDMONO010706 (Case 1 Con't) B. Grots Profit to Monsanto Sales: 15, 000 gallons @ $3.45/gallon COGSi .138, 000 pounds x 223/pound Freight: 146, 000 pounds x . 02/pound Gross Profit % Gross Profit . 17, 581_________ 51,175 - 2, 920 36.4% $51,175 30, 774 "420, ToT 2, 920 $17, 581 Case 11 . pays full price for new fluid plus flushing fluid but Monsanto pays for incineration cost and freight. A. Cost to 15, 000 gallons Pydraul 65 E @ $3. 45/gallon 15, 000 gallons oil flushing fluid @ $. 50/gallon $51,175 7, 500 TOTAL Cost $58%675 Cost per gallon new. fluid $3, 92/gallon (Does not include labor or downtime) B. Gross Profit to Monsanto Gross Sales Lets: COGS Freight (New $30, 774 2, 920 Fluid) Incineration Cost 7, 500 Freight (Returned 5,000 Fluid) . . Gross Profit $51,175 $46,194 A $4,981 % Gross Profit 4,981 a io 3% 51,175 - 2920 " ' ' TRAN 002501 HARTOLDMONO010707 '.-ft ' i Case HI pays full price for fluid but Monsanto pays for flushing fluid plus incineration costs and freight A. Cost to 15, 000 gallons Pydraul 65 E Cost per gallon new Fluid (Does not include labor or downtime) s $51,175 * $3. 45/gallon B. Gross Profit to Monsanto Gross Sales Less: COGS Freight(New Fluid) Flushing Fluid Incineration Cost Freight (Returned Fluid) 30,774 2, 920 7,500 7,500 5, 000 Net Loss * $51,175 53,694 ($2, 519 ) miwim^sttfiwwvf ,, * .**++*** > - 4 v # TRAN 002502 HARTOLDMONO010708 Customer ^ 1,, Z 3 4' 5 6 7 8 9 10 Top Twenty Customer* for Pydraul Products 1971 Projected bounds Dollars 000*8 ooo's *1 Texas Eastern 13 Turbinol 153 14 15 16 17 18 19 20 21 .All Other Pydraul Accounts TOTAL ignificant Industrial Aroclor Accounts 175 60 , 5237 . M,267 (265) 1566 4,200 (51) 0*5 * * III 1 1 .I *** * r . ,.. HARTOLDMONO010709 APPENDIX F 1972 Financial Results Case 1 - 1972 financial results as currently budgeted: Product (ooo's lbs) Volume Pydraul 60 45 Pydraul 150-A 1000 Pydraul A-200-B 2300 Pydraul F-9-A . 1150 ' Pydraul 625-A 275 Pydraul AC-A 600 Pydraul AC-A W. C. 24 Turbinol 153 325 Sub Total 5719 Pydraul 135-A 1400 Pydraul 230-A 240 Pydraul 312-A 6850 Pydraul 540-B 125 Sub Total 8615 Total 14,334 Projected 1971 Results 14,267 (Based on October actual) (Projected 1971 results 15,076 based on 3/31/71 x 4) (ooo's $) Sales 22 400 621 380 83 192 7 107 1812 336 59 1507 26 1928 3740 4200 (ooo's $) Cross Profit 9 185 171 148 24 ' 67 -36 640 98 16 407 7 528 1168 1270 4416 1385 OOl*0* tM* jr * HARTOLDMONO010710 APPENDIX r 1972 Financial Results Case 11 A. (1) Selector 1 fluids sold at 75% 1972 budget volume through 3/31/72 (2) NCP fluids replace Selector 1 fluids on 3/31/71 and sold at 50% 1972 budget volume from 3/31/72 through end of 1972 B. (1) Selector 2 fluids sold at 75% of 1972 budget volume through 6/30/72. (2) NCP/oil fluids replace Seloctor 2 fluid* on 6/30/72 and sold at 50% 1972 budget volume from 6/30/72 through end of 1972 C. plants on NCP from 1/1/72 but at the same relative rates as A and B above. A-200-B to 50 E 312-A to 65 E 2 Product Volume (ooo's lbs) Sales (ooo's) Cross Profit' (ooo's $) Selector 1 f to Pydraul 10 E Pydraul 29 E-LT Pydraul 30 E At*( / Pydraul 50 E t * Pydraul 65 E #! Pydraul 95 E its* Pydraul 115 E 45 560 193 1910 1225 340 152 22 222 63 656 437 128 59 9 101 31 261 147 43 18 Sub Total Selector 2 4425 0 1587 610 Pydraul135 C Pydraul 230-C Pydraul 312 C Pydraul 540 C 825 144 2800 72 263 39 689 17 . 72 12 221 5 Sub Total 3841 1008 310 TOTAL 8266 2595 920 ' ^Financial results for new products include results for old products as specified above ^Based on our cost long term* Appendix B 00250S HARTOLDMON0010711 appendix g Incineration Costs I Gallons*___ 100,000 ISO, 000 200, 000 250,000 300, 000 400, 000 500, 000 Inein. Cost > $. 03/pound $ 28, 800 43, 200 57,600 72,000 86,400 115, 200 144,000 Freight @ . 025/pound $24,000 36, 000 48, 000 60, 000 72,000 96, 000 120, 000 Total $52, 800 79,200 105, 600 132,000 158,400 211,200 264,000 *Average density of fluid @ 1.15 * 9. 6 pounds/gallon UN -w HARTOLDMON0010712 Monsanto appendix h w .B.-I s waw Norman T. Johnson *'* November 24, 1971 ** T.L. Got sage - B2S L eaustBSS TO s Pydraul Accounts C. L*. Bradford B2S G The following are those accounts which 1 fsel may require product group participation during the transition to reformulated Pydrauls: Texas Eastern Transmission Houston IAAN 002507 w.# HARTOLDMON0010713  i . C.L. Bradford November 24, 1971 Page J I .would hope that all other industrial fluids accounts can be handled directly by the salesmen. However, if we have no low cost Pydraul replacement the need for product group assistance to retain the business will be substantially increased. lb WM. 5* HARTOLDMON0010714 MwiScfltO eveifci W. D. Papageorge - B2NK - General Offices February 10, 1972 ee PCB/PCT Action Plan M' ((NCI H. S. Bergen C. L. Bradford F. J. Camargo W. S. Clark W. R, Corey J. R. Durland K. W. Basely D. Goodwlllle T. L. Gossage E. Greene N. T. Johnson P.J.A. Marsh J. Mason B2SL B2SF A2NH B3NC B2SL 5260 1920 5080 B2SL A2WA B2SF 5040 5040 C. Paton E. M. Potter W. R. Richard J. R. Savage W. E. Schalk R. E. Sprague J. E. Sprlnggate J. F. Stapleton H. A. Vodden B2SC B2NK T3A B2SL B3NJ B2N0 B3NA B2SA 5470 This Is the first attempt to present a composite of the action plans of the various product and area groups Involved In the PCB/PCT program. Will each of the managers concerned please forward to me the missing Information and any comments relating to addltlono or deletions which should be considered. WBP:gw W. B. Papageorge I * srv. DEPOSmON EXHIBIT HG Jgy 9*9 TRAN 003025 HARTOLDMON0010715 I i Page 1 PCB/PCT ACTION PLAN Ii Heat Transfer Fluids ! ACTION | C. S. DOMESTIC | 1. Notify key customer { 2. t | 3 ! 4. Mall customer notification Terminate sales FR fluids Special undertaking with | 5. Organize conversion team | 6. Establish returned material liability 7.. Notify Monsanto Installations 8. Develop conversion bulletin 9. Recheck off-shore Installations -Qulf of Mexico ! 10. Notify OEM's by mail . 11. Follow-up visit to OEM's 12. Evaluate response; review policy !u. 3. EXPORT i" i 1. ; i i j Canada a. Notify customers b. Notify govermental agencies c. Notify OEM's d. Terminate sales TRAN 003026 ASSIGNED TARGET ACTUAL . TO DATE DATE REMARKS WRCHSBJ TLO CP WRC,JFS CP WBP,JFS BP CP 12/20 12/15 12/15 2/15 12/15 1/15 1/15 12/28 12/16 12/15 12/15 1/14 Jan'. Exception - -' 0 \ CBD notified on 2/1/72 CP 2/28 1/31 2/15 CP 2/28 CP 4/1 m 1/31. 12/23/71 DO 1/31 12/28/71 DC 1/31 12/28/71 DG 1/31 HARTOLDMON0010716 ACTION U, S. EXPORT (cont) 2. AIPC a. Notify country managers to. Terminate sales 5. Latin America a. Notify managers to. Notify agents c. Terminate sales 4. Australia/AsiaPacific a. Notify manager to. Terminate sales PCB/PCT ACTION PLAN Heat Transfer Fluids ASSIGNED TARGET ACTUAL TO DATE DATS REMARKS GEW 1/31 1/20 GEW 1/31 1/31 PJC 1/31 1/20 PJC 1/31 1/19 PJC 1/31 1/31 EG 1/31 1/14 EG 1/31 1/31 Page 2 TRAN 003027 HARTOLDMON0010717 PCB/PCT ACTION PLAM . Page 3 Dielectrics ACTION . ASSIGNED TARGET ACTUAL TO DATE DATE REMARKS *J. S. DOMESTIC 1, Notify customers of restrictive sales HSB policy. 12/31 12/21 Six additional mailed on 1/7/72 2. Terminate sales to non-approved customers HSBjTLG 1/15 1/14 3. Notify customers replacement fluid available from original equipment supplier. TLO 1/31 ` 2/8 4. Notify original equipment supplier he must supply replacement fluid. TLG Notify customers using dielectrics ' In magnets, motors and switch gear of restrictive sales policy TLQ 5. Notify customers of procedure for returning scrap fluid. FOB 1/31 2/8 1/31 1/31 2/4 1/25 U.3. EXPORT 1. Canada a. Notify customers of restrictive sales policy b. Terminate sales to non-approved customers DO DO AIPC Latin America Australia/Asia pacific a. Inform area directors of policy EG b. Notify customers of restrictive sales policy WAM's c. Check enforceability of hold- harmless letter In appropriate countries. d. Terminate sales to non-approved customers. 1/31 1/31 1/31 3/31 1/6 1/31 1/14 1/21-31 TRAN 003028 HARTOLDMON0010718 PCB/PCT ACTION PLAN Industrial Fluids ACTION Santovac ASSIGNED TO TARGET DATE Phase Out CUB Turblnol n A Present alternate fluid to and Texas Eastern CLB 2. Begin field trial alternate fluid at T. E. CLB 3. T.B. transition to new fluid Turblnol 30E/50B literature 1 Turblnol for bearing literature Price sheets CLB 1/1 1/31 4/1 6/30 Pydraul Finalize reclamation program 2S Visit top accounts CLB CLB 2/15 1/30 3. Mall out customer notification 4. Selector I & II Factory Mutual approvals 5. Visit all accounts 5. Arocior 6037 replacement /# * Aroclor 3460 replacement 5. Selector II Informal price sheet 5. Selector II, 1st literature CLB CLB CUB CLB CLB CLB CLB 1/31 2/7 2/15 2/15 2/15 2/21 2/29 - ACTUAL DATE REMARKS 1/1 1/31 Field trial date will depend . on length of winter and T.E.'s inventory of Turblnol 153. 1/30 1/31 2/r Being reviewed now Completed-Favorable reactions of practically all accounts. , Iran 003029 HARTOLDMON0010719 pydraul (Cont) Industrial Flulda Assigned Target TO_____ Date 10. Application for approval at Bureau of Mines CLB 3/1 11. Finalise advertising program CLB 3/1 ia. Formal price sheet. Selector I & 11 CLB 4/1 13. Start warehousing new fluids CLB 4/1 14. Stop stocking warehouses with PCT fluids CLB 4/15 15. Start delivering new fluids 16. No old fluid accepted for 1 credit after this date 17. Stop manufacturing PCT fluids CLB CLB CLB 4/15 5A 5/1 18. Consolidate PCT warehouse stocks CLB Vi 19. Sell last of PCT fluids CLB 5/30 20. Bureau of Mines approval CLB 6/1 21. Incinerate any remaining PCT fluids CLB 6/30 22, Issue revised sales forecasts CLB 2,3*4,5, 6/1 Actual Date 2/1 *J. Si Export < a Write plan to withdraw all PCT fluid sales after 6/30/72 and convert to new products. CLB 2/15 Page 5 Remarks TRAN 003030 HARTOLDMONO010720 PCB/PCT ACTION FLAW Plasticizers ACTION ASSIONED TARGET ACTUAL TO DATE DATE V S. Domestic & Canada Oenerate withdrawal plan: a. Get time table approved b. Get "Rationale" approved c. Get cuatomer/dlatrlbutor letter approved d. Notify Plasticizer personnel e. Notify ex-plastlclzer personnel f. Set up controls for final shipments W/COP Dlst. g. Set sales limits for all customers w/reg. mgrs. 1 2. Customer Notification: a. Generate key sect, list b. Set up trips for Kgmt pers. wsc WSC wsc WSC CP/WSC wsc Reg. Mgrs. WSC/JDW wsc 12/10 12/10 12/10 12/20 12/20 12/23 12/28 . 12/10 12/16 12/10 12/12 12/18 12/20 12/20 12/22 1/4/72 12/8 c. Hail "Withdrawal" package to field salesmen d. Send wire to reg. mgrs/ salesmen . e. Make calls on regional offices f. Notify g. Key customer calls h. Contact all customers by telephone WSC 12/17 wsc 12/20 wsc wsc Field Sales 12/20 12/17 12/21 12/31 Field Sales 12/31 12/16 12/17 12/17-20 12/17 12/21 12/31 1/7/72 1. Formal customer notification by mall. WSC 12/31 . 12/31 Page 6 REMARKS Travel schedules caused delays. . Delayed pending initial customer contact. i Done by telephone This is probably 95-98* complete. ,, `s 1C0C00 HARTOLDMONO010721 Plasticizers ACTION ASSIGNED TO TARGET DATE S. Domestic & Canada (Cont) 3- Replacement Programs Reg.Sales a. Generate replacement suggestions b. Publish replacement info to field sales force WSC 12/20 12/31 c. Continued contact w/ customers Termination WSC/Reg.Sls. 3/31 Pleld Sales VSC 3/31 ?f S. Export , 1. t Generate withdrawal plan a. Published letter to Lepage and Simpson b. Notified all world area mgrs. of 3/31/72 date c. Detailed plan published to World Area Mgrs. 2. Customer Notifications a. Approved letter wired to all World Area Mgrs. b. Letter sent to customers WSC WSC WSC WSC WAN'S 3. Replacement Program: a. Generate replacement suggestion and distribute WSC b. Continued contact w/customers WAN's <*. Termination - PCT's - PCB's WAM's WAM's IRAN 003032 ? 12/31 3/31/72 3/31/72 1/31/72 Page 7 ACTUAL DATE REMARKS 12/20 1/7/72 Delayed pending input from AWMC and by VSC. * 12/27 12/20 12/23 l/H/72 Key plasticizer actions generated by Qosaage, Bergen, and Corey. 1/19/72 1/10/72 Written confirmation received on all world areas exceot South America and a couple of accounts in Asia Pacific. 1/31/72 Australia & Latin America ceased sales on 12/31/71. HARTOLDMONO010722 PCB/PCT ACTION PLAN MONSANTO rjROPE ACTION ASSIGNED TO________ TARGET DATE 1. Dielectric Fluids; s. Review Monsanto legal PJM liability -situation b. Notify customers of restricted sales policy. c. Terminate sales to non-approved customers d. Terminate sales to "service" users 3/31 3/31 2. Meat Transfer Fluids: a. Notify customers of termination of sales b. Notify OEM's of policy 1 c. Terminate Santotherm PR sales ' 2/31 3- oo u> Ul Industrial Fluids: a. Notify distributors of termination of PCB Pydrauls b. Notify Sustomers of termination . of PCB Pydraul e. Notify OEM's of termination of PCB Pydrauls d. Terminate PCB Pydrauls 1/31 e. Notify customers of termination of Santovac 1 and 2 Sales f. Terminate Santovac 1 & 2 sales 1/31 g. Notify distributors of termination of PCT Pydrauls h. Notify customers of termination of PCT Pydrauls I. Notify OEM's of termination of PCT Pydrauls J. Terminate PCT Pydraul sales 6/30 k. Develop plan for European mine applications WRC# EJP, JM ACTUAL DATE 1/31 1/31 1/31 Page .8 REMARKS TRAN HARTOLDMONO010723 MONSANTO EUROPE ACTION ASSIGNED TO 4. Plasticizers: a. Notify customers of termination of non-electrleal PCB sales. b. Terminate*non-electrical PCB sales c. Notify customers of termination of PCT sales d. Terminate PCT sales TARGET DATE 1/31 3/31 ACTUAL DATE 1/31 1/31 1/31 Page 9 REMARKS TRAM 003034 HARTOLDMONO010724 PCB/PCT ACTION PLAN Page 10 MMK ACTION ASSIGNED TARGET ACTUAL TO DATE DATE REMARKS JAPAN 1. Flastlolzers . a. Discontinue sales of FOB b. Discontinue sale of PCT 12/31/71 7/1 2. Dielectric Fluids a. Notify customer# of termination of sales b. Terminate salts I 3. Heat Transfer fluid a. Terminate sales to new installations 7/31 3/31 Legal counsel advises holdharmless letter probably not enforceable In Japan. Proposed exception: Exports . a. Terminate non-electrical PCB sales b. Terminate unapproved dielectric sales c. Terminate all dielectric sales 1/31 3/31 6/30 1/31 TRAN 003035 HARTOLDMONO010725