Document By1g1rNwdgeKbzmxJY1dK5BNX
PROGRESS REPORT ` TECHNICAL SERVICES DEPT. - W. 0. KRUMMR1CH PLANT
W.O. KRUMMRICH PLANT
0, D, Dressel
J. N. CONNAUOHTON
00.A.Meyer
m. Brawley
:0D. Fitzgeralc
IJOB NO.
1716:2*16
RESEARCH
REPORT NO.
L
GENERAL OFFICE
0 R. E. BILGER
D. DANNA
)
QW. P. DUNLAP
DATE
11,29/67
OTHERS iPg
'0 J, R. Savage
MITIIO 'CD W. R. KELLOGG
ANNISTON '0 L. C. PUHRMEISTER
t. W. DALTON
QG.L.Bratsch
0C. E. ANAONOSTOPOULOS P. W. EDWARDS
' General Office
Qm. heisler 0 j. r. McClain QjH.I. PATRICK
!0T.M.Morrow
OR.}). Munch
OVi.L.Rice
1 BV.V/.Saeger
General Offic 0
0 R. E. Howard 0. A. HEININGER
Q D. B. HOSMER
0J.B.Benignus
i:Ql. R. Buchanan *EP.O.Bright
0*. J. WILSON
'EJV.R.Haupt
O
0I).C. Armstrong !0R.P.Stevens
EDH.F.Ray
0H. Y/illiams
> TO RECEIVE DETAIL SECTION
O
0
0H, C. Carder -0J.C. Bryant
0K. L. (AMPLE
K0J. Cresce
HR. J. Stratmey
R. S .Yates
AROCLOR AND AROCLOR BLENDS: PROCESS IMPROVEMENT PLAN
PERSONNEL!
R. M. McCutchan (J. W. Molloy)
The objective of this report Is to present the Dept. 246 (Aroclors, Pyranols, and Pydrauls) Process Improvement Plan.
The existing batch chlorination plant will meet 1968 sales needs of 52.75 M lbs Aroclors by operating at 95^ maximum capacity. Ready for 1969 production will be a new continuous chlorination plant with accompanying stills, earth treatment columns., storage tanks, and increased blend capacity_at a cost of $1.5 M. The total VJGK Aroclor capacity of 65.0 M lbs/yr will be sufficient
to meet sales needs through 1972 with a 40% excess. cJ;
It Is anticipated that corporate quality goals will be met with the completion of the continuous chlorination system and earth column treatment startup. The "in plant" goals are as follows:
1242
1254
Resistivity, x 1CP ohm-cm
10,000
Power Factor, ft
0.6/S
Thermal Chemical Chloride, ppm < 0.1
15,000
0.5^ <0.1
Savings of $
will be realized during 1963 as a result of
Increased capacity.
bo
00 0>^
Acknowledgments
.
0196075
Thanks goes to D. C. Armstrong, V. Brawley, D. Fitzgerald, J. A. Gloeckner, and H. F. Ray for their assistance and cooperation in the gathering of data and writing of this report.
j?X X'-CJiL,
/gP R. M. McCutchan, Tech. Ser. Dept.
COMPANY CONFIDENTIAL INFORMATION Thle document le t1u> propotty of Monsanto Company and the recipient la responsible for Its safekeeping and disposition. It contains confiden tial informntlon of Monsanto Company which must not bs reproduced, revealed to unauthorised persona or sent outside the company without proper authorisation. Either retain in aecuro files or destroy.
pr.>anciAir'u*^eL^rT:/i>ci:.-MmmpnTu
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DETAILS
1 Synopsis of Process
.
The Aroclor process consists of the following steps:
Chlorination Batch chlorination of biphenyl (Bi.,0) with snift gas (approximately 86 mole % CI2) at 150C produces Aroclor. The byproduct is hydrogen chloride (HC1) gas.
Blowing Crude Aroclor from the chlorlnators* is blown with air to remove excess HC1 before distillation.
- Distillation Crude Aroclor which has been air blown Is continuously fed to the stills. These stills are straighttake-over type with no fractionation.
Earth Treatment and Filtration The distilled Aroclor is earth (attapuigus']-'treated, filtered, and transferred to storage.
Blending and Loading The finished product from the storage tanks "is loaoccV into cans, drums, tank trailers, and tank cars, or used for making blends (electrical and non-electrical).
The principal Aroclors produced at VJGK are 1242, 1248, 1254, and 1260. The last two digits indicate the % chlorine (weight) contained in the chlorinated biphenyl mixture (Aroclor).
II. Scope of Report
This report pertains to both the existing batch chlorination plant and the proposed continuous chlorination plant which is expected to be on-stream by January, 1969.
III. TSD Process Job List
Prio.
Job
Capital
Savings/Benefits
EDC
1 Install heat exchanger $8,000 Meet 1968 sales needs, 2/1/68
on Project 5334 (app
insure $25,000 rate
roved). Follow startup.
savings in 1968.
2 Coordinate quality te'sts - o'- Protect $5 R market in conjunction with PR&D effort.
3/1/66
3 Make nitrogen blanket system opgrable.
- 0 - Quality $15,000
4/1/68
4 Determine biphenyl losses - 0 - Quality, minimize
3/1/68
under various chlorinator
losses
conditions. Recommend con
ditions for 1968.
01960761
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November 29, 1967
III. TSD Process Job List (Continued)
Pri 0.
Job
Capital
5 Investigate possible blend specification
changes
-0-
6 Check still operation
-0-
at pressure lower than
40 ppm
7 Evaluate level recorder $1,500 for still #2, Install if justified
8 Evaluate liquid nitro gen supply system for Depts. 246/254
TBD
9 Evaluate automatic drum $200
flushing and drumming
500 M
Installation with new
bull ding
10 Evaluate equipping #1
$15,000
still with horizontal
pump and boildown fac
ilities
Savings/Benefits
EDC
Increase blend capacity 3/1/68 $l,000/yr in lab costs
Quality
3/1/68
Process control
4/1/68
Lower nitrogen costs
I/I/69
$20,000/yr labor sav ings and quality improvement
7/1/69
Increase distillation capacity by 5 M lbs/ yr
1/1/70
IV. Capacity
A. Aroclor
0196077
1. Current Capacity
Department 246 Is rated at 2.4 M lbs Aroclors/mo, or 28.8_H lbs Aroclors/yr. The department is averaging
2.5 M lbs/mo through October 1967. Aroclor-1967 sales needs will be met. Presently the bottleneck is chlorine availability and distillation rate.
2. Sales Forecast - VJGK (H. J. Day, 9/7/67)
~ M Lbs
Aroclor
1968
1962
1910
1971
1972
1242
1248 1254 1260 1262
16,107 5,049
4,831 6,638
125
19,037 4,596
5,039 6,953
135
21,484
4,571 5,462
7,345 145
23,772 4,447
5,957 8,l4o
155
25,572 4,861
6,257 8,485 _JLjf>5
TOTAL
32,750
35,760
39,007
42,471 45,340
Dept. Cap. 37,200*- --New 40 M lbs/yr iPlant ---------
*(Based on installation of still preheater and Increased Cla rate. )
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IV. Capacity (Continued)
3. Capacity to Meet 1968 Sales
Current department capacity Is not sufficient to meet 1968 sales needs. Capacity increases are planned in both the chlorination and__dlstillation steps to an_ overall capacity of 37-2 Mlbs Aroclors/yr, or 3.1 M lbs/month.
a. Chlorination
.
1. Project 3824 installs a 6" chlorine feed line to Dept. 246 (EDC 2/1/68).
2. Project 4864 increases chlorine revaporization capacity (EDC 1/13/68).
3. The capacity of the brink's mist eliminators
is being checked. Work may be necessary to
eliminate excessive yield losses at elevated
rates and temperatures.
'
4. In-line specific gravity instruments are needed, and will be installed in the continuous chlorina tion plant.
b. Pi stillation
Project 5334 installs a spiral heat exchanger to preheat the still feed (EDC 1/1/68). This gives a 10$ surge capability and insures needed pro duction until the expansion is complete.
4. Storage Capacity, M Gal
Product
Present Capacity, After Blending Project Complete
1968 Add 5 Tanks & Remove Un'gd.
1242
1248 1254 1260
55 80 20 40
20 40 30 20
TOTAL
125
180
1971 Add Three
Tanks
14 0 40 40 20
240
Minimum 1971 Storage Recoin. By H. J. Day,
6/67
132.0 25.2 34.4 20.2
211.8
All new tatfks will be 20,000 gallon aluminum tanks with nitrogen blanket facilities.
onoo-*8
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November 29, 1967
IV. Capacity (Continued)
B. Aroclor Blends
1. Current Capacity
Dept. A-246 is rated at 1.2 M_lbs/mo Pyranols (14.4 M lbs/yr) and B-246 at 0.575 M lbs/'mo Pydrauls (6.9 M lbs/yr). However, this capacity can not be achieved
because of lack of mix tank capacity. During the first nine months of 1967 these blends were produced:
Nine Months, Lbs. Extrapolated
Pyranols: 1260 PPO 1254 PPO
A13B3B
5,618,590 2,559,788 1,o4o,o8q
for year 1967
Pydrauls: A-200
6,998,458 1,555,118
9.5 K lbs 2.0 M lbs
TOTAL BLENDS
8,555,576
11.5 M lbs
2. Future Capacity and Sales Forecast
Project 2844 provides for changes and additions to loading and transfer lines, metering facilities, and the conversion of No. 8 storage tank to No. 5 mix tank. This will increase mix tank capacity from 27.5 M gal. to 47.5 M gallons,__and should make possible the rated capacities of 14.4 M lbs/yr Pyranols and 6.9 M lbs/yr Pydrauls.
Aroclor Blend Sales Forecast, II Lbs.
(irrj. Day, ~9726767r^
~
Pyranols:
Expanded Capacity
1968
1969
1970
1971
1972
Inerteen PPO (1260) lnerteen 54201 KA Pyranol A 15 B 3 B
7,200 2,000
1,756
7,500 1,800 1,800
8,000 1,950 1,900
8,700 2,100 2,200
9.200 2,100 2.200
TOTAL PYRANOLS 14,400 10,956 11,100 11,850 .13,000 13,500
Pydrauls:
019607V
Pydraul A-200 Pydraul 280
2,540 197
1,700 24 0
1,600 280
1,100 320
1,100 __3_20
TOTAL PYDRAULS TOTAL BLENDS
6,900 21,300
2,557 1,940 15,475- 13,040
1,880 15,750
1,420 14,420
1,420 14,920
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IV. Capacity (Continued) f
C. Drumming
1. Current Capacity
Drumming is done on two shifts, one standard operator
per shift, 5 days per week. The standard operator also
helps load trailers and tank cars (25$ of time).
--
During the 12 month period, June 1, 1966 - May 31, i960
the following drums and cans were filled: (see
Appendix A for detailed drumming report)
Size
55 Gal.
30 Gal .
gjtal.
Total
Aroclors Blends
7221 8249
-0-
569 2,148
7,790 10,937
TOTALS
15,470
540
2,717
18,727
Grand Total: 18,727 drums and cans Average Output: 36 drums and cans/man/shift
2. Future Drumming Needs
Total Production, M Lbs
1967 (Est. )'
1972 (Sales Forecast)
5 Year $ Increase
Aroclor Blends
29.4 11.5
45.3 14.9
54 31.9$
On the assumption that drumming requirements increase proportionally in 1972 with total production, 26,600 drums and cans will be needed. By adding one man on third shift drumming, these needs can be met with an average output of 34 drums and cans/man/shift. After 1972, a seven-day operation may be needed.
If drumming requirements increase sharply, a more auto mated drumming facility might be considered. (A rough
estimate of such an installation including building is $200-300 M.) Another source of justification for an automated system is the possible need of a drum flushing system for improved "as packaged" quality. Anniston TSD has the assignment of determining total company needs for Aroclor drum flushing. Results of their studies will dictate drumming needs for future quality require ments.
D. Tank Car and Trailer Loading
The following table shovis the number of tank cars and trailers loaded during June 1, 1966 - May 31* 1967, and the projected loadings for 1972:
0196060
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i
Tank Cars: Aroclors Pyranols
Total
Trailers 95$ Aroclors 5# Pydrauls
-7-
,6/66 - 5/67 72 95 167
197
December 15, 1967
1972 111 125
' 256
500
The existing loading facilities plus the two unloading docks included in the proposed plant expansion (CEA 1800) will be adequate through 1972.
E. Expansion - Continuous Chlorination (CEA - 1800)
1. Scope
a. Five new 22,000 gallon aluminum storage tanks (EDC 7-1-68)
b. Railroad spur and two unloading docks c. One 100,000 gallon biphenyl storage tank d. Three existing 15,000 gallon underground tanks
will be dismantled. e. Separate transfer lines for each product from
day tanks to tank farm, and from tank farm to loading or drumming areas. f. Chain of four chlorinators with external cooling and continuous feed tank (EDC 12-1-68) g. Continuous blow tank and intermediate storage tank h. Two semi-continuous distillation systems i. Four continuous porocel column treatment systems j. A complete thermlnol heating system k. Additions to the existing control room including instrumentation l. Electrical substation changes to supply power m. Motor control center n. Foreman's office
2. Capacity
After the continuous chlorination plant is on stream, all biphenyl will be chlorinated to the 1142 level in the new plant. It will then be chlorinated to the 1148, 1154, and 1160 levels in the batch plant. In 1972, based on H.J. Day's forecast of 9-7-67, the capacities and requirements of each plant will be:
a. Chlorlnator Capacity, M lbs./yr.
01S60B1
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December 13, 1967
1972 Sales Forecast
Maximum Capacity Based on 1972 Product Split
For Internal Use:
Continuous System (1142)
For Sales:
Continuous System (1142)
Batch System using 1142 as feed for 1148, 1154, and 1160
Batch System using biphenyl as feed for 1148, 1154, 1160
15.9
25.6 19.8
0.0
6.5
36.5 8.0
21.0
Total Aroclors For Sales b. Still Capacity, M lbs./yr.
45.4
65.5
Still No.
Product
1972 Sales Forecast
Maximum Capacity Based on 1972 Product Split
1 2 3 (new) 4 (new)
Total Aroclors
1260-62
8.6
Boildown only, all aroclors
1242
25.0
1242
0.6
1248 1254
4.9 6.3
45.4
12.0
25.0 10.0
6.5 8.5
62.0
Based on the current sales' forecast and maintaining a 30* surge capacity at W.G.K., the expanded plant will be adequate through 1973-
V. Quality A. Goals
0196062
^^The following Aroclor quality goals were set at the corporate
aroclor meeting held on May''9-lo, 1967:
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1242:
Resistivity Power Factor TCC
1294:
Resistivity Power Factor TCC
In - Plant }
10,000 0.6$
<^0.1ppm
13,000 0.3$
< 0.lppm
As Packaged
3,000 0.9$
1(3,000 0.4$
Delivered
3,000 1.0$ 0.lppm
5,000 0.5$ 0.lppm
B. 1967 firoclor Quality
In December 1966 the removal of the catalyst baskets from the chlorinators was completed at W.G.K. No other normal operating conditions have been changed. During 1967 the only quality shift has been an improvement in the electrical properties of both 1242 and 1254 during the third quarter. This is unexplained. Normal quality ranges have been as follows:
W.G.K.. - 1967 - In Plant A
1967 Normal Range
8/67 - 11/67 Average
Spec.
1242:
Resistivity Power Factor Tcc
1254:
Resist!vity Power Factor TCC
1)000-10,000 0.5-3.0
0.45-0.6
5,000-40,000 0.2-1.0 0.6-1.0
6,000 0.7
0.49
40,000 0.2 0.8
500 5.0 0.65
None None None
For a complete storage tank analysis record of Aroclor 1242 and 1254, see Appendix B.
C. Batch, Quality, Studies and Recommendations
Since early in 1967 there has been a concerted effort to improve Aroclor stability and electrical properties. This is a corporate effort headed by D.C. Armstrong of W.G.K. PR&D. It was initiated by the realization that Monsanto's Arsclor was surpassed in quality by foreign competitor's products.
The following quality factors have been considered and/ or investigated: (For a complete report of FR<3cD batch work, see J.A. Gloeckner's progress report 91370:
3794-1.)
1. Chiorlnation
01.96083
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Higher temperature chlorination will improve Aroclor quality. Four storage tanks of 1242 have been made at 195C with an average 0.J0 ppm TCC. The normal material made just prior to the tests averaged 0.45 ppm TCC. Optimum temperature has not been determined.
Higher ferric chloride concentrations (0.2$) are beneficial at 150C. 'At 200C, the benefit is doubtful.
Catalyst particle size was checked and found to vary considerably. (See Appendix C) Pennsalt Is the only supplier of anhydrous ferric chloride and they do not attempt to control particle size.
Biphenyl quality is an important variable under normal conditions. At higher temperature or catalyst level the effect of blphenly quality is greatly reduced.
Initial reaction temperature does not affect quality as long as it is at least 120C.
Bromine was added to the chlorine to a 700-800 ppm level and used to make a storage tank of 1242. At reaction conditions of 195C and 8 lbs. FeCla/batch, a TCC of 0.47 was obtained. This material was life-lested by F,lectric Utilities and approved.
Sparger design has been changed to give better chlorine distribution and to prevent catalyst settling. Resulting quality data has not been obtained.
Off-gas condensate is not suitable as a raw material for electrical grade aroclor, but could be used for non-electrical grade. In an initial test, off-gas losses increased by five times when increasing the reaction temperature from 150C to 195C. Cost.of yield loss_would increase by $40,000 for production of 50 M lbs.
Only one change can be recommended to improve Arocl-or quality in the chlorination step. A temperature of 195C should be used if off-gac losses can be minimized.
2. Filtration of Crude Aroclor
.
If'catalyst concentrations higher than 0.05^ are used, the undissolved ferric chloride should be removed before distillation. A centrifuge installation would cost $25-40,000.
19608*
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3 Distillation
a. A lime charge equivalent to 0.8% of the chlorination mass should be used (present practice).
b. For good process control, a level recorder Is
recommended for No. 2 Still. Especially during boil-downs, guess work risks line pluggage and considerable downtime.
-
4. Earth treatment vs. Porocel.
In the present plant, 201bs. of attapulgus earth is mixed into a blend tank of distilled aroclor for 30 minutes and then filtered to a finished product tank. Varying amounts of earth and porocel were tried, but no signif icant quality difference was noted. Power factor was measured on a temporary in-line instrument.
5. Storage and Transfers
a. All aroclor storage tanks should be 21-25,000 gallon aluminum tanks with a nitrogen blanket. The existing nitrogen system does not work and is being checked for modifications. It will be operable by
4-1-68.
b. Separate aluminum transfer lines should be available for each aroclor product.
D. Continuous Chlorination Recommendations
WGK PR&D recommends the following process conditions be used In the continuous chlorination Aroclor plant expansion:
Chlorination
a Temperature
Min. Temp
Max. Temp
Biphenyl Feed Tank Chlorlnator 1
2
3 4
'
100C 140 150 170 190
120C 160 170 190 210
b. Catalyst
Use 0.1^ FeCl3 having a mesh size specification of 50^ less than 15 microns and 10CK less than
50 microns. Direct addition of the catalyst to the chlorinators is being explored. No baskets
are to be used.
'c. YieJ.d__Losses_ (coht'd following page)
oi'608^
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December 13, 1967
c . Yield Losses(cont'd) Based on laboratory
i1
continuous chlorlnations, vapor losses are expected to be 2-3 times that experienced at
the Anniston plant. This material should be
used for non-electrical grade Aroclor production.
d . Circulatlon rate should be as high as possible compatible with good maintenance (narrows isomer distribution).
2 Crude Aroclor (1142) Storage
a . Temperature should be as high as possible, 150-190C minimum.
b . Residence times should be as long as possible with a 12 hour minumum.
c,. The catalyst present in the storage tank forces polymerization of known types of unstable compounds.
d,. Agitation is recommended for optimum contact of catalyst and 1142. It will also minimize catalyst build-up in the tank.
e,. HC1 removal will be accomplished by maintaining a mild vacuum (650 mm absolute) on the 1142 storage tank. Further work will determine if this is necessary. Air blowing is not recommended.
3 Distillation
a,. Lime charge of 0.8^ adequately handles up to
0.2^ catalyst concentration. b,. Pressure is not very critical, but the lower
000 -o
the better. Starting with the same crude and S
distilling to the same yield, pressure and TCC 0
are related as follows:
Pressure
r 5im
k~Tr^'" y 40 ^ l'60^ '
96,0
?tf.O
Temperature f)
190c llgJ?
240
'
280
U TCC
e>,l 7 aaeppmr,.
,013'- 0.27"JV^^;i.
-52
*
c,. A forecut of 1^ will result in an improvement of 0.01-0.03 ppm TCC, independent of earth treat ment method, chlorination conditions, or ageing. The forecut could be added to the condensate from the chlorlnators and used for non-electrical aroclors. Present plant expansion does not
anticipate making this forecut.
0196086
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December 13, 1967
4. Earth Treatment
Use porocel columns as den onstrated at Anniston.
5. Future Work
a. Assist In plant demonstration at Anniston using chlorination conditions of 190-195C in the third chlorinator and 0.04-0.06^ FeCl3 added directly to the first chlorinator.
b. Define where catalyst should be added.
c. Determine necessity of HC1 removal from crude.
d. Investigate effect of water and trace impurities in biphenyl on aroclor stability.
E. Aroclor Blends.
Specifications are normally met on all aroclor blends, but sometimes with great difficulty. The following conditions hinder the production of high quality blends:
1. General
a. The blend tanks are inadequate in size and TTCB storage non-existent. Project 2884 will provide a third blend tank (20,000 gallons). It is recommended that one of the underground storage tanks (15,000 gallons) be retained for TTCB storage.
b. There is only one supplier (Hooker) of TCB and TTCB. These raw materials have poor
electrical qualities and are difficult to clean up.
c. To aid in the mixing process, the blends are blown with plant air. The use of nitrogen would be a better practice.
d. Earth treatment of the blends does little good, sometimes degrading the electrical prop erties. During 1967 earth treatment of 1260 PPO and 1254 PPO has been stopped. Less difficulty in meeting specifications has resulted.
e. The chloride scavenger harms electrical properties.
0196081
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December 14, 1967
VI. Yields
.2 Specifications
a. Pydrauls - No problems
b. 1254 PPO - No problems
c. 1260 PPO - Two causes make the specific gravity and refractive index specification difficult to meet:
(1) The specifications for the blend are narrower than for the components.
(2) The specific gravity and refractive index specifications do not correlate well with each other.
The per batch average is three blend adjustments and eight control sample analyses. This means increased lab costs, but more importantly, delay in shipments, below minimum drummed inventory, and poor TCB and TTCB yields.
A program to correct this problem was set up in 1966 by Don Harris and Bill Caraway, but was dropped after preliminary woTk because the dollar value was low ($10-12M/yr.) Completion of this work is still needed as the time factor becomes more important and blend sales increase.
d. A 1? B ? B - This blend suffers from the same specific gravity and refractive index problems as does 1260 PPO. In addition, blends must be adjusted with 1260 since there is no TTCB storage. Finally, because of the poor quality TTCB, the electrical property specifications are difficult, and occasionally Impossible to meet. Five electrical property checks and seven specific gravity and index analyses are
.. made on an average batch.
Year
1964 1965
1966
167 (thru Sept.)
Actual Yield
96.57^ 98.59
Standard
0196088
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December 14, 1967
The yield loss is In the off-gas condensate and is worth $12-15,000 in 1968. In the continuous chlor ination plant this material will be used in the feed stream.
B. Chlorine
Chlorine usages are calculated by the chlorine depart ment and therefore are not a meaningful gauge to the aroclor department operations.
C. TCB and TTCB
.
Actual Yield 1967 (thru Sept.)
Standard
TCB TTCB
98.22 95.92
99.0$ 99.0
The yield losses are worth $10-12 M in 1968 and are due to lack of TTCB storage and mix tank capacity.
VII. Manufacturing Costs (First 5 quarters 1967)
Total cost variance on the Aroclor production and blending operation is (-) $25,000 for the first three quarters of 1967. This is primarily due to unscheduled capacity in the blending operation. The blending facility is actually operating at its capacity, however.
The following items represent the larger cost variances for aroclor and blend production:
A. Compressed Air Act $8,584 Sch $4,425 Var (-) $4,159
Aroclor blends are agitated with air during the time an in-specification analysis is being achieved. As specifications are difficult to meet, more than a normal amount of air is being used.
B. Supplies
Act $15,080 Sch $16,974 Var $5,894
Supply costs appear normal and are itemized in Appendix D.
C. Packing Containers Act $92,658 Sch $81,274 Var (-)
----------- *---------------------
$11,364
'A larger than expected percentage of aroclor and aroclor blends are being sold in drums.
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December 14, 1967
D. Laboratory Act $27,601 Sch $23,576 Var (-) $4,225
As noted previously, many control sanpies are analyzed in achieving blend specifications.
E. TSD, Experimental, and PR&D
'
Act $83,409 Sch $23,062 Var (-) $60,347
Since early in 1967, an intensive program has been planned and pursued in an effort to improve Aroclor quality.
F. Mechanical Expense
Act $94,045 Sch $144,585 Var $50,540
A plant expansion expected in 1967 which did not materalize causes the large positive variance.
Mechanical expenses and downtime during 1967 YTD are
above 1966, but in line with 1964-65. Process downtime results primarily from low chlorine pressure. This should be corrected with the completion of projects 3824 and 4864. For a summary of 1964-1967 YTD mechanical expense and downtime, see Appendix E.
Appendix F. itemizes the mechanical expenses for 1966 1967 YTD. Pumps continue to be a source of high main
tenance costs. It is recommended that all new pumps installed be equipped with mechanical seals. Replace-
went or modification of existing pumps to pumps with mechanical seals will be evaluated.
Appendix G. lists all projects currently pending, or
completed during 1967-
,
VIII. Stream and Air Pollution
The principal stream pollutants from Dept. 246 are
biphenyl and chlorinated biphenyl. These are sewered
at a rate of 700-800 lbs./day and are not considered a
pollution problem. The sewering of this material will
' be eliminated with the aroclor plant expansion by January,
1969.
The principal air pollutant is HC1 gas. This is minimized by drowning the blow tank vapors.
TOWOLDMON0045410
APPENDIX "A" DRUMMING OF AROCLOR & BLENDS, 6/66 - 5/67
Prod.
Type Container,
Gallons
55 50 5 June 1966
1232 1242
1248 1254 1260 1262
A 13 B 3 B 1254 PPO
1620 PPO
88 985
158 249
59 56
64 16
PYD A-200
196
PYD A-2 80
1254 + 10% XYL
5
s i} j
THERM 1 THERM 2 THERM 3
jj 40 j
? i
i1 |
i
TOTALS
i 1696 I
64
91 ! (
55 50 July
502 158 510
251 95 91
205
7 22
42 104
1656 29
5 | 55
5
Aug.
55 50 Sept.
22 40 192 66 402 19 552 96
438
76 1 14 |
66 | 1641 j
195 20 50 183 : < 152 297
155 i i i 577 t 1 | 0
1 1
190 s j I
162 I 1475
148 148
5 61 255
4 320
0196091
TOWOLDMONOQ45411
APPENDIX "A" (CONTINUED) DRUMMING OF AROCLOR & BLENDS, 6/66 - 5/67
Prod.
Type Container,
Gallons
55 50
Oct. 1966
5
55 30 Nov.
1232 124-2 1248 1254 1260 1262 A 13 B 3 B 1254 PPO 1260 PPO
PYD A-200
PYD A-2 80
1254 + 10# XYL
THERM 1 THERM 2 THERM 3
150 345 23 216 366 i
!
j 70
t
i | 142 J \?
231 12 178
91
i t 1 2?1
| j
i
! 59
i i ! 52 |
TOTALS
| 1229
142
!
KN CO
5 1 55
5
I Dec , |
j
138 84 35 354
1034
170 64
161
200 52
174
.
tl! ! 174
1069 i 1319
252
55 -30 Jan. .
5
120 221 24 58 70 134
116
152
39 28 75
100 50
10 61
32
1037
150
103
ibO^bXO
TOWOLDMONOQ45412
APPENDIX "A" (CONTINUED) DRUMMING OF AROCIOR & BLENDS, 6/66 - 5/67
Prod.
1232 " 1242 1248 1254 1260 1262 A 13 B 3 B 1254 PPO 1260 PPO
PYD A-200
PYD A-280
1254 + lO'i XYL
THERM 1 THERM 2 TK2RM 3
Type Container
Gallons
55 5 1
REB.
41 176 108 134
I 1 53 1
| i
55 30 MAR.
92 72' 250
37 2 143
223
74 i
i i 1
i { 1
30 14 255
60
15
39
16 110
i j 38
| 52 ] 90
16 i
5 f 55
30
APRIL
18 104
448
52 i1 : 141
i 224
1
i
35
I
; 112 143
16 44
5
_ 36 53
34
55
98 201 456
130 151
158
30 MAY
99
5 'r 55 t
30 TOTAL
j* 71 ::
175:! i; j| i:
if
63 1560 1039 4456 24 79 1571 244 1790
2766
453
37 50
5
4l6 I84g 10 203
212 .
! t: 231
480 36 14 825 34
130 16
TOTALS
1029 127; 969 15 16 1287 35 1231 1208 99 246 55 Gal 15,470 \ 30 Gal 540 5 J.-Gal 2,717
TOWOLDMONOQ45413
609610
APPENDIX B ANALYSIS ELECTRICAL GRADE 1242
Mo., 1967 January
February March April May June July August September October
November
Spec.
Lot No.
KI401 402 4 OJ 4o4 406 407 408 411 412 415
417 421 422 42J 427 428 431 436
437 440 444 447 448 451 455 456
457 459 462
465 469 471 472
475 476
477 480 482
O.65 max.
500 min.
TCC Resistivity x 10
0.25 0.29
0.30
0.37 0.4l 0.49
0.51 0.45
0.33 0.59 0.4o 0.28 0.34
0.45 0.47
0.52 0.48 0.32 0.36 0.62 0.61
0.53 0.28
0.59 0.55 0.49 0.47
0.55 0.63 0.46 0.47
0.38 0.30 0.44 0.4l 0.26 0.50
0.37
1850
3950 2000
600 800 600 1030 3200 2040 1600
960 700 680 900 1600 880
730 2150 1300 4240 2500 3250 2880
2620 2)40
7489 5000 . 2560 2610 10400 6900 22400 13600
13690 7350
13750 4000 8000
'
5.0 max. P.F.
Comments
0.66 0.82
Normal operating condition
1.83 2.20
I.29
unless otherwise noted. (150C, 2 lbs
2.64
FeCl3)
4.44
0.90 0.76
All other material sold as
1.80
non-electrical
3.00
3.03
2.37 3-38
1.62
3.06
1.86
0.26
3.24
0.66 0.84
0.85 0.81 -- (195C,8 lbs
O.89
FeCl3)
1.39
0.31 1.56 -- (195C, 8 lbs
0.9? 0.94
FeCl3 700800 ppm Br`2)
0.52
0.78 0.40
0.36 -- (195C, 2 lbs
O.23
fc C13)
0.40
0.24 -- (195C, 2 lbs
1.26
FeCl3)
0.19 -- (195C, 2 lbs
FeCl3)
019609A
TOWOLDMONOQ45414
m iiiiwxA o ^ouiiumueu j
Mo., 1967
January February March
April May
June
July
August September October
ANALYSIS ELECTRICAL GRADE 1254
Spec. - No plant specifications.
Lot No.
KI601 604
605 606 607 609 613 616 618 619 621 623
625 628 651 6J2
TCC Resistivity x 10^
P.F.
0.69 0.65 0.68
0.69 1.00
1.07 1.00
0.99
1.19 0.89 0.96
0.79 1.06
1.05 0.50 0.67
8800 510
5^50 4 080 22000 1200 10400 22400 6650 5900 6400 56020
24015 45250 800460 160000
0.65 ' 4.12
1.06 0.90 0.24
2.55 0.49 0.29
0.51 0.65 0.78 0.14
0.15 0.25 0.11 0.20
Comments
Operating con-
ditions were
150C, 2 lbs
FeCl3.
.
0196095
TOWOLDMONOQ45415
APPENDIX C FERRIC CHLORIDE PARTICLE SIZE Particle size was determined by St. Louis Testing Laboratories, Inc.
Plant
Date Sample Tested
Per Cent less than 1 micron Per Cent less than 5 micron Per Cent less than 10 micron Per Cent less than 20 micron Per Cent less than 50 micron Per Cent less than 100 micron
WGK 5/8/67
Anniston 5/25/67
___
--
17.4 40.6 85.5 96.1
6.6 24.5 42.5 93.4
--
WGK 7/6/67
Anniston 7/6/67
5.4 69.9 91.4
--
______
---
______
8.5 21.8 69.7 89.7
0l9fc09b
TOWOLDMONOQ45416
APPENDIX D SUPPLIES
Items over $200 bought from the storeroom during 9 months of 1967:
Filter paper. Sparkler Glass bottles, 5 pt. Oaklte cleaner Seals (labels) Filter cartridges Soaps and detergents 16 oz. bottles and caps Kerosene
Filter cartridges, Alsop Pressure gauges Rags Steam hose 5-2" flanged tees, 4 gate valves
$662,50 607.52 502.26 475.00 462.00 351.88
335-93 277.20 272.00 245.46 244.86 221.61 240.00
The above items account for about 50$ of the total supply cost. The balance is made up of non-repeating items bought through the storeroom and through purchase orders.
0196097
TOWOLDMONOQ45417
APPENDIX E
SUMMARY OF TRUE REPAIR, MECHANICAL EXPENSE, AND DOWNTIME FOR 1964 - 1967 YTD (JULY)
CateRory
1964
True Repair
$ 8o,4o4
Mechanical Expense 116,834
Repair D.T.
1.9256
Process D.T.
5.29
Total D.T.
9.03
1965 $ 82,302
100,379 2.9356 2.00 9.20
1966 $70,450
88,592 0%
0.46 2.76
1967 YTD $47,397
65,998 1.6056 3.44 8.03
0196098
TOWOLDMONOQ45418
APPENDIX P
Category
Pump Furnace Dept, repairmen Instrument Ejector Platform Plant Improvement Work to Assist Tank, Closed Piping Electrical Miscellaneous All Others
Total M.E.
MECHANICAL EXPENSES, 1966-1967 YTD (JULY)
1967 Thru July
$10,571 1,384
4,799 3,539 2,030 15,338 8,684 5,702
575 2,844
686 1,820 4,236
% of Total M.E.
17.0$ 2.2
7.7 5-7 3-3 24.7 14.0 9-2 0.9 4.6 1.1
2.9 6.8
$62,208
-.
ISM
$10,048 1,844 8,560 7,340 2,554
13,208 9,132 9,124 2,647 8,722 4,351 3,439 7,623
$88,592
% of Total M.E.
11.3# 2.1
9-7 8.3 2.9 14.9 10.3 10.3 3-0 0.8 4.9 3-9 8.6
0196099
TOWOLDMONOQ45419
APPENDIX G
Engr. Auth.
No.
Est. No.
5334 2844
Date Aop.
8/67 4/66
S-842 S-892 S-893 S-67O
~
s-650
5639 1138 42'63
4467
10/67 12/66
1/67 3/67
4448 4871 5018 5411 3446 3528 2698
4/67 4/67
5/67 8/67 7/66 7/66
12/65
S-647 S-7060 M-6049 R3771
M-5034 3491 Minor
8/66 8/66
PROJECTS CURRENTLY PENDING OR-COMPLETED DURING 1967
Desoription
Cost
Install heat exchanger Blending & Loading
Facilities
$ 8,000 60,000
Relocate TCB Dock
2,100
Install alarms on chlor. 3,450
Dism. gravity instrument
500
Replace steel & hand-
18,810
rails
Replace vacuum Jet
4,620
Install Exp. Filter
2,600
P.M. painting steel
23,380
P.M. insulation repairs 5,375
Install safety showers
2,700
Alter shower tracing
1,000
Alter 3 loading docks
5,700
Dismantle & replace
30,500
lean-to
Upgrade control room
4,000
Upgrade office Upgrade lighting Relocate 6" fire pro-
tection line Roof over loading dock Install mech. remote
room valve Install spare #2 still
pump
6,000 8,000
Status
EDC 1/1/68 Given to CED for construction; materials being order*
Comp. 8/67 Complete Complete
80it complete Comp. 6/67 EDC 12/1/67 Complete Comp. 5/67 Comp. 5/67 Complete Held up pending study of drumming required. Held up pending dept, exoansion by CED. Est. sub. 8/67
Comp. 5/67
Comp. 2/67 Sch. for Dec. turn-around. Estimate submitted
0196100
TOWOLDMONOQ45420