Document Dvw9ww1EqboE2G7YgQgE5JD0O
HUM IriL HiL50f THt WGK LAeOKATORV
PR0^i.R^L der^SE
W.G. KftUMMRICH PLANT
gC)H.C. CARDER Qj.m. CONNAUOHTON
'Cl T*w> OM-TON |l.t. HCISLER ["'| W.. RAPACEOROE | H.B. PATRICK *pt| J^trT McClain
Cl W.Q.Kramper d J .R. Savage d d.E. Harris ti V. Brawley
DMflD.C. Armstronf
K1J.J. Luecken a
n
'TO RECEIVE OCT (L KC TJON
J (f ^ ^
JOB NO.
k 's' !
REPORT NO.
91370:1716
RESEARCH
GENERAL OFFICE
r'C*
jiyjjjs
*(^j 0. UANNA
*LJ p*w* EDWARDS
'(X) J.E. SMITH
a R.E. Soden ANAGNOSTOPOLU5 !3| H.L. M1NCKLER
kfllogc 'g| t.c. FUHRMEUT ER
H.T.. Hubbard Q J-A. MULL ENOORE R.W. Bucknei: l.E. KLEIN
'0 K. ELL1NGSON
Ann is f.on i*a E.TrnroiTT
^0 P.G.Benlgnus W/ J . Mol loy *ffl R.G. Moody
1 J.G. Bryant
Q
titli: AR0CL0R: PROCESS IMPROVEMENT PLAN
personnel: p. r. Middleton (J. R. Savage)
PROBLEM: Report status of present work and present future plans.
summary: The status of the previous Process Improvement Plan published 7/29/64, is as follows:
Long Range Target (IQ, 66)
Status
Rate
39. OM #/yr.
Yields (Bijf) 98.0$ Theory
Manufacturing $5.983/cwt
Cost
Quality
0.40 ppm Thermal Chemical Chlorides
(TCC)
36.OR #/yr. only need 26.4 through 1969 98.5$ of theory through June, 1965. $5 859/cwt through June, 1965.
Present average 0.50 ppm TCC. New target less than O.15 ppm.
Presently targeted quality improvements are: Recommend facilities required to make Aroclor 1242 with a Thermal Chemical Chloride (TCC) of less than 0.15 opm Cl by January 1966 and determine how to consistently ship-P./raaols with a power factor of less than 5$ at 100c
and 60 cycles by June 1966.
The capacity of Dept. 246 (Aroclor) Is sufficient to meet forecasted sales plus 25$ through 1969- The capacity of Dept. A-246 (Pyronols) will be Increased to meet forecasted sales by up-grading the blending facilities (6/66) and providing storage for TCB, 1260 PPO, and 1254 PPO (1/67). To meet forecasted sales In Dept. B-246 (Pydraul), Storage for one of the two product (Pydraul 200 and 280) will be provided by using the present TCB underground storage when it becomes available in 1/67.
HONS 060264
CONFIDENTIAL INFORMATION
This document is the properly of Monsanto Company and the recipient is responsible for its safekeeping and disposition. 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 secure files or destroy.
91370:1716
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High speed drumming facilities will enable a reduction of 1 man, $10,000/yr. in 1/67. A work force evaluation will be made by 1/67 to determine feasibility of further reductions.
D-Slu
D. R. Middleton
/Jd
HONS 060265
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DETAILS
Synopsis of Process
The Aroolor Process consists of the following steps:
Chlorination
Batch chlorination of biphenyl (B10) with Snift Gas (contains approximately B6 mole % Cl^ at 150C produces crude Aroclor. The by-product is hydrogen chlorine (HC1) gas.
Blowing
Crude Aroclor, from chlorinators, 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 straight-take-over type with no fractionation.
Earth Treatment & Filtration
The distilled Aroclor is earth (Attapulgus) treated, filtered, and transferred to storage.
Blending & Loading
The finished product from the storage tanks is loaded into cans, drums, tank trailers, and tank cars, or used for making blends (Electrical and Non
Electrical ).
The principal Aroclors which are produced at WGK are 1242, 1248, 1254, and 1260. The last two digits indicate the weight plus % chlorine contained in the chlorinated biphenyl mixture (Aroclor).
QUALITY
Aroclor
The two main quality measures of Electrical Grade Aroclor are resistivity and stability. Presently the major portion of quality work is aimed at improving Aroclor 1242 stability to less than 015 ppm Cl by the Thermal Chemical Chloride (TCC) method.
MONS 060166
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The questions to answer concerning Aroclor stability are:
1. What factors effect stability of Aroclor?
a) Raw Material Impurities
b) Chlorination Techniques c) Distillation Techniques d) Earth Treatment and Filtration
2. What combination of factors are necessary to produce desired quality at the. least cost?
a) Impurity free raw materials
b) Chlorination Technique: temperature, feed rate, catalyst, geometry of chlorinator, etc.
c) Distillation Techniques: stripping and/or rectifying d) Earth Treatment and Filtration e) Chemical Treatment
Chlorination:
Chlorination techniques (in present WGK Plant Equipment) affect the amount of over and under chlorinated Bi/, but not necessarily the final stability of the product. The variables which have been measured were: amount of catalyst, method of catalyst addition, chlorinator, chlorination rate, chlorination temperature. The first three were the most significant variables.
Distillation:
Laboratory distillations, in which low & high boiling fractions (chemical
nature of these are not known) were removed from plant crude, produced
Aroclor with less than 0.2 ppm TCC. Due to variability of plant crudes
the size of the fractions varied from 1-5% for low boilers and 10-15/ for
high boilers. It may or may not be feasible to recycle these fractions
to non-electrical Aroclor production.
.
Future Aroclor Quality Work
1) jOrganic Research is presently running continuous distillation tests to determine column design and operating conditions needed to refine present WGK and Anniston Plant crudes to less than 0.15 ppm TCC.
Start: 6/65 EDC: 9/50/65
2) Run plant test using revaporized Cl2.
Start: 8/65
EDC:
10/65
MGNS 060267
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Future ftroclor Quality Work (continued)
3) Investigate Earth Treatment. On two different tests, material earth treated .In plant was 0.1 ppm Cl higher than laboratory treated material. Current work at Anniston will be followed.
Start: EDC:
By:
9/65 10/1/65
TSD , PR & D
4) Preliminary evaluation of Chemical Treatment of .crude Aroclor to remove unstables.
Start: 7/26/65
EDC:
9 '30/65
By: PR Sc D
5) Vapor Phase chlorination for 1242.
Sta.rt:
EDC: By:
10/65
12/65 TSD
6) By 12/1/66 recommend facilities needed to produce Aroclor 1242 at various TCC levels between 0.5 and 0.1 ppm.
Pyranols
The quality of WQK Pyranols (Transformer Blends) must be improved to meet the market's power factor requirements. The target is to consistently ship material with a power factor of less than 5% at 100C and 60 cycles, and have little or no deteriatlon during transit. Future work in this area is
as follows:
1) Initiate studies to define the power factor problem.
Start: 4th Q of 65
EDC:
6/66
By: TSD
2) From above Information take appropriate action.
Start:
EDC: By:
6/66
6/67 TSD
3) Studies to determine effect of exposure to various metals is presently underway.
EDC: 10/65
HONS 06C268
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CAPACITY
Dept. 246 - Aroclor
Capacity of Dept. 246 (92/ On-Stream Time) -- ~~ Demonstrated 1966 Forecast* 1969 Forecast* 1965 Extrapolated
Potent la 1
Yearly '
27.4m//
31.6 M#
29-9W
56.OR//
Monthly
2.3M#
2.6'IK//
2.6H//
3.0M//
Monthly plus
2.9M//
3.3 M#
23'/ Surge Capacity
ll.J. Day's forecast dated 5/12/65 multiplied by 1.2
-
-
The potential capacity of Dept. 246 Is sufficient to meet the needs of future forecasted sales. The department bottlenecks are:
Product
Bottleneck
12*12
Distillation
1248) 1254)
126O)
Chlorine Availability
The Cl? bottleneck can be relieved by cleaning or replacing the snift gas line from the CI2 Dept.
The distillation bottleneck can be relieved by furnace burner alterations and demonstration of high capacity still pump with 3" furnace coil.
The only active work in the capacity area is the above demonstration. 11/65.
DejfU A-246 - pyronals
Capacity of Dept. A-296
EDC
1260 PPO 1254 PPO
Total for Year Avg. Monthly Avg. Monthly 9 25/
Present Capacity
1966
1969
Debottlenecked
1965 Extrapolated Forecast Forecast
Capacity
6.32W 4.6lM#
6.1 M# 4.3 W
7.5 M 4.5 M
HONS 060269
1.04M#
1.15M#
1.15R#
11.97M//
11.55M# 13.15R#
25.OR#
1.0 M#(Max.)1 0.96m#
1.1 W
2.0M#
--
1.20M#
1.37M#
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For flexibility in Dept. A-246 it is desirable to have sufficient capacity to meet 25% surges and sufficient storage for 200,000# of each 1254 and 1260 PP0.
The present capacity of A-246 is l.OM# (when making the 3 blends). No storage is available for these blends.
A design premise has been submitted for facilities to Increase capacity to 2.0fl#/month. ($25, - 30,000). This increase can't be realized until the following storage is available:
New 20,000 gallon tank for 1254 PP0 New 20,000 gallon tank for 1260 PPO New 20,000 gallon tank for TCB (R/M)
Estimated cost of these storage facilities is $105,000. Design premise will be out 9/65- Installed January 1967.
Dept. B-246 - Pydrauls
Capaclty of B-246
1966
T957 ' ""1969 Demonstrated
Forecast Forecast Forecast Capacity
Future Capacity
A-200 A-280
4.7 W 0.7 1?#
5.22TO# 1.0 FI#
5.26 H# 1.5 M#
6.0 1?#
Total Yearly Total Monthly
5.1* M# 0.45W#
6.221?# 0.52M#
6.75 1?# 0.5b M#
6.0M# .501?#
Meet Fore casted Sales
Monthly 4- 25%
0.56H# 0.651?#
0.7051?#
-
Presently A-200 is the principal blend which is made in the No. 1 Mix Tank. The capacity is limited by sales, because the product is stored in the Mix Tank. The blending capacity will be Increased to at least 1.0M#/month (if sales are available) as part of the $25-30,000 up-grading job for A-246. As A-280 sales materialize storage for one of these blends will be needed to attain flexibility. For short range No. 6 underground storage (present TCB) can be used following installation in New TCB storage.(January 67). Presently
there are no long range (thru 1969) plans for Pydrauls storage.
YIELDS
The raw, materials for manufacturing Aroclor are Chlorine Snift Gas and Biphenyl. The Snift Gas usage is not measured, it is calculated. The Biphenyl yields are as follows:
1964 B10 Yield 1965 Bij( Yield (through June) 1965 Standard BI0 Yield
96.57%
98.5# 95.5#
MGNS 060270
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The Biff yield losses are as follows: Chlorlnator Off-Oas (Collected in Brink and discarded) Still Bottoms Still Vacumm System
Unknown TOTAL
0.4#
0.5% 0.1% 0.4$ 1.4#
On the average, the Aroclor produced_ls about 5056 Cle, therefore the ciz loss la also approximately 1 A%. In a 29M# year the yield losses, based on raw mate lal costs, amount to the following:
Cl2 B10
TOTAL
$4,300 6,400
$10,700
The chlorinated Biff and Biff which Is collected In the Brink ($3,200/yr.) are presently not recycled because Its effect on stability is not known.
The still bottoms are profitably sold as Montar. Presently no extensive future work is planned in this area.
HC1 off-gas recovered by Dept. 217 and P-21? Is 83.4^ of theory, through June 1965. The loss amounts to about $45,OOO/year of Muriatic Acid credit.
COSTS
Dept. 246 - Aroclor - Basis Jan-July 1965
Cost/100# Aroclor
Cost for 29R#/year
Material Costs
Cl* B1 ff Mlsc. HC1 (Credit) Handling
Sub-Total
2.090 3.088
0.015 0.730
0.033
(-)
1+. h 96
606,000 896,000
4,350 (-)211,000
9,560
$1,300,000
HONS 060271
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COSTS (Cont'd)
Direct Conversion
Steam Labor Salaries Supplies Laboratory TSD Prod. Process Res. Mech. Expense Others
Sub-Total
Cost/lOO# Aroclor
0,098 0,223 0,042 0.080 0.082 0,069 0.08l 0.337
.097
1.109
Cost for 29M#/yr
28,700 64,600 12,200 23.200
23,800 20,000 23,500 92,800 28.200
$321,000
Indirect
Dep.. PIE
Sub-Total
0.122 0.152
0.274
35,400 44,100
$79,500
TOTAL PRODUCT COST
5-879
$1,700,000
In 1966 TSD and Prod. Process ReB. costs should decrease after answers to quality (stability) problems are found.
In the first quarter of 1967 when blending facilities (Dept. A & B-246) are
Installed there will be a work force evaluation and possibly a reduction. Extrapoleted labor costs for Dept. A & B-246 in 1965 are:
Dept. A-246 (pyranol)
$14,850/12,000,000#
Dept. B-246 (Pydraul)
$14,900/4,370,000#
In the first quarter of 1967 high speed durmming facilities should also be installed (TSD Job No. M5007) which will enable work force reduction of one man ($10,OOO/year savings).
STREAM AND AIR POLLUTION
MONS 060212
The principal stream pollutants from Dept. 246 are B1J2(, chlorinated B10,
and HC1. None of these are presently considered a problem. In the future approximately 150#/day of Bi# chlorinated B10 can be removed from the sewers by sending all off-gas brink collections to the toxic dump.
The principal air pollutant Is HC1 gas. This can be minimized by drowning the blow tank vapors and gases with the existing water Jet.
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ACKNOWLEDGEMENTS
Much of the Information and Ideas In this plan were obtained from D. E. Harris, V. Brawley, J. J. Luecken, W. G. Kramper, and others.
JX
D. R. Middleton /Jd
HONS 060i?3
TSD 3198 3229 3287 3362 M5007
M5031
TITLE, OBJECTIVE
Aroclor: Improve Electrical Orade Quality
Aroclor: Install 3" coll In No. 2 still furnace
Aroclor: Improve loading and blending facilities
Aroclor: Increase Capacity (to minimian of 2.5R#/mnth)
Aroclor: Provide high speed drumming facilities
Aroclor: Provide storage for 1254 PPO, 1260 PPO and TCB
Aroclor: Provide roof above truck loading dock
Aroclor: Provide level measurement for #1 and #2 still receivers
Aroclor: Provide exhaust fan for Drumming Area
LIST OF CURRENT AND PROPOSED JOBS
SAVINGS BENEFITS
CAPITAL
TSD TIME TO COMPIiTION MAN-MONTHS
EDC
TECHNICAL
SUCCESS
FACTOR
STATUS. COPKENTS
Protect Market Position
7
6 1/66 IOO* (Eval.)
Increase still capacity None coll to be compatable with new low maintenance still pump
Capacity increase needed to meet sales, possible work force reduction
Meet sales In first hair of 1965
Bo,000 None
$10,000 savings from labor reduction
?
Increase capacity to
1105,000
meet sales, flexibility
Prevent shipment delays;
save $l,200/yr demurrage
Improve operationsNo definite savings
3, *00
!/ 10/65 50%
2 6/66 90* 1/2 10/65 100*
3/67 80* 4 1/67 90# i/ 50*
1/66 50X
Presently having maintenance prob lems with new external still pimp
Storage for Pyranols needed to realize full capacity Increase
Capacity of Dept. 246 la 3.0M#/mo. If sales are available.
Work la being done by TSD Mechanical Group
Capacity increase from 3287 cannot be realized without this Job.
Safety - Pume inhalation
MONS 06027*1
LIST OP CURRENT AMD PROPOSED JOBS (Coat'd)
Pg. 2 9/17/65
TITLE, OBJECTIVE
SAVINGS BENEFITS
CAPITAL
TSD TIME TO COMFITION MAN-MONTHS
EDC
TECHNICAL
SUCCESS
FACTOR
STATIC. COMMENTS
Pyranols: Investigate high power factor problems
Needed to meet the industries future requirement
Aroclor: Increase safety of still bottoms dropping operation
Safety
Pyranols: Determine suitable material for shlpnent of Transformer
Blends
$10-$20,OOO/year customer reimbursement
1/2 1/3
1/66 9056 10/66 90)6
TSD Materials Section presently working on.
MGNS 060275