Document JNVQb0Y1mNY1Egz07jnQX49LX

Sauget, Illinois June 11, 1968 COMPANY CONFIDENTIAL PROGRESS REPORT Aroclor Expansion (CEA 1800) W. G. Krummrlch Plant Dept. 246 DISTRIBUTION: ORGANIC OTvTSION D. cV\Armstronaf - WGK T. W. Dalton /WGK M. S. F&Ld -/WGK T. E. Greeptoan - WGK W. A. KuhrfV'tS.O. J. R.^JjfClaiM - WGK CENTRAL ENGINEERING R. S. Yates R. P. Stevens REPORT OBJECTIVE To communicate to Organic Management the Aroclor Expansion project/start-up status and timing and the status/plans of the Aroclor Quality Improvement Program. REPORT SCOPE The report is a brief resume1 of major events thru 5/31/68. Prepared by: H. F. Ray Manufacturing Representative Approved by: T. W. Dalton General Superintendent mh 00t70^ TOWOLDMONOQ45122 -2 I PHASE I - AROCLOR FINISHED PRODUCT STORAGE Field construction is nearing completion. Actual completion date of Phase I may be delayed from 7/1 to 7/15 due to a priority shift toward completion of the manufacturing area. If this delay is encountered, no effect on current department operations or the overall expansion program will result. The Article 10 discussion with Local 12 concerning implementation of Phase I is scheduled for 6/13. No additions to the workforce will be made at this time. Provided that sufficient biphenyl is available the new 100M gallon biphenyl storage tank will be placed in service during the week of 6/17. The new motor control center and foreman's office are virtually complete except for lighting and heating. Air conditioning for the foreman's office will be provided as part of approved WGK Project 6350 - "Upgrade Control Room - Bldg. CR". The formal start-up budget for both Phase I and II will be issued by 7/1. PHASE II - 40M#/yr. AROCLOR MANUFACTURING FACILITIES Process piping isometrics for the manufacturing area are complete and have been issued for construction. Steam tracing and Utility piping details are being developed. Installation of the new 8" HC1 line is 90# complete. Steel erection is complete except for some of the pipe bridges. The two still pots along with the tangential separators and two absorber finished product surge tanks have been installed in the new structure. The intermediate storage tank has also been installed north of the new structure. Plant air, city water and electrical tie-ins have all been completed. Foundations for the blow tank and therminol systems have been installed leaving only minor foundation work(off-gas jet, stairs, etc.) to be completed. Workforce plans(both hourly and salary) for Phase II will be finalized by 7/1. Effective 7/1 a start-up foreman will begin training in Dept. 246 to allow the regular department foreman, Virgil Brawley, to assist in the expansion start-up details full time. Based on current progress and equipment deli- _ _ _ t start-up date has officially been moved up from December 2 to October l4J AROCLOR QUALITY IMPROVEMENT PROGRAM The initial plant test(2 batches) utilizing iodine in conjunction with ferric chloride as a chlorination catalyst was completed. Results indicated no Improvement over normal stability. Further investigation work in the laboratory has pinpointed the problem as chlorination (in the absence of ferric chloride) of the material trapped in the chlorinator off-gas mist eliminator. Alternatives for resolving this problem in the plant include the following: 00$7p<4 TOWOLDMONOQ45123 f1-^Run a longer series of batches with iodine present as the iodine apparently cleans out the trapped product. Remove the off-gas mist eliminators so that no material is trapped ' and returned to the chlorinator. Wet down mist eliminators with crude Aroclor which contains ferric chloride. The next plant test will involve alternative 1. EDC is 7/1. Future work will be based on the results attained in this test. During the initial plant test the HC1 generated was sewered to avoid any problems in using departments due to iodine/iodine compound contamination. Off-gas samples taken during the run(one chlorinator on iodine test, four others on normal-operation), however, indicated the contamination level to be onlycT ppm iodine^ PR&D is now attempting to obtain approval to perform future pT&nx demonstrations without sewering the HC1 gas to avoid the potential $1000/day loss. 0057095 TOWOLDMONOQ45124