Document JvE2OnOk3zDRy8Vp2B0mKk3Ov

Monsanto PROM iNAMC ft LOCATIONl 9ATC SUftJCCT NCI TO R. M. McCutchan WGK, Sauget, Illinois July 26, 1971 CEA 2417 - Aroclor Column Objectives and Key Premises Revision No. 2 D. R. Cova A. J. Heinze A. E. Leisy R. H. Munch J. R. Savage N. B. Wolk ' ec: P. B. Beriignus V. Brawley C. Buckley W. C. Engmaryf^*'*' R. M. Kountz W. Krull W. R. Richard A. Zavadil Previous objectives*were issued as follows: 12/10/70 - Original ' ' *2/4/71 - Revision No. 1 This Revision No.' 2 of the objectives and key premises is for two purposes. First, it adds objectives and premises to include monochloro- biphenyl (MCS-1109). This product was not being considered at the time of Revision No.l. Second,''current status and appropriate comments are included on some of the objectives. *R. M. McCu'tchan hra DSW 296578 STLCOPCB4066491 SECTION III. PROJECT OBJECTIVES AND PREMISES I. CEA 2417 OBJECTIVES The following objectives will be demonstrated: STATUS/COMMENTS . 1. Meet the CEA 2417 time schedule. 1. The original start-up date was 6/1, but was changed to 8/1 when MCS-1109 was added to the scope. 2. Stay within budgets on construe tion and start-up costs: CEA 2417 Capital CEA 2417 Expense Start-up expense $830 M 95 M 100 M 2. The 2417 budgets include Variance No. 1 which ' allowed for facilities to produce MCS-1109. It appears that both capital and expense will be within budget. . 3. Demonstrate design capacity: Aroclor 1016 MCS-1109 54 M#/yr. 18 W/yr. 3. Underwriter Laboratories accepted Aroclor 1016 as being equivalent to 1242. If a forecut had been necessary, capacity would have been lower on 1016. 4. Meet specification qualities on all products. Those affected by CEA 2417 are: '. Aroclor 1016 MCS-1109 Aroclor 1254 Aroclor 1260 Aroclor 1221 5. No increase in PCS's leaving Dept. 246 via sewers and no more than 1.0 lbs./day additional to atmosphere. 5. During the first run (only) of MCS-1109, 3-5 lbs./day of monochlorobiphenyl will besdischarged to the sewer. 6. No significant change in department biphenyl yield. DSW 296579 STLCOPCB4066492 SECTION III. PROJECT OBJECTIVES AND PREMISES (contd.) II. KEY DESIGN PREMISES STATUS/COMMENTS 1 Any remaining phthalic anhydride 1. The first run will be a in .column can he flushed out in "half-size" run of initial startup. . Aroclor 1016. Assuming acceptable quality, this production will be used for Therminol FR-1. 2. Volumetric control is adequate . 2. "End of forward flow" on for determining: MCS-1109 can also be _ determined by C,P. . \ a. change in reflux ratio ' "End of forecut" on * . b. end of crude feed MCS-1109 can also be c. end of forward flow estimated by # Biphenyl ^ d. end of forecut for MCS-1109 in forward flow. Volume control within 250 gal. is necessary on the above' determinai . tions and can be achieved.- 3. ;Still pot pressure can be control; i-led such that the furnace outlet [temperature will be a maximum of 300C., and the temperature differential on the furnace, a maximum of 10C. 4. .Still pot bottoms from Aroclor 1016 will be 50# Cl2 or less. . -5* The C. B. 5+ level will not exceed 0.4# in the finished Aroclor 1016. 6. The C. B. 2+ level will not exceed 1.0# in the finished MCS-1109. - * . 7 PCB discharge to the atmosphere 7 will be an estimated 1.0#/day or less from the vacuum jet. There will be no significant PCB loss to the sewer from this project, and none from the vacuum jet. 9 All sewers will pass through a settling basin. During the first run (only) of MCS-1109, 3-5 lbs./day of monochlorobiphenyl will be discharged to the sewer. 8. The severity of potential -- hazards in Dept. 246 will not 1 be increased by CEA 2417. 9. Stainless steel is a suitable' material of construction for the Aroclor fractionating oSnN **58 STLCOPCB4066493 SECTION III. PROJECT OBJECTIVES AND PREMISES (contd.) II. KEY DESIGN PREMISES (contd.) ' STATUS/COMMENTS 10. WGK will be the only. MCS-1016 supplier and will be reliable. 11. Cross-contamination between Aroclor 1016 and MCS-1109 can be held to an acceptable level. 12. The isomer distribution of crude for MCS-1109 (5.0# Cl2) that will be produced in the continuous chlorinators will be adequate for the process which was based on batchproduced crude. . III. OPERATIONAL PREMISES 1. Chlorine and biphenyl will be available in adequate quantities and proper quality. 2. WGK will produce Aroclor 1016; MCS-1109; Aroclors 1232, 1242/ 1248, 1254, 1260, 1262, and 1221; blends Iperteen PPO, Inerteen 70/30, Inerteen 54201 CM, Pyranol A1333B, Therminol PR-0, and FR-Low Temp, (or their equivalent by other names); Therminol PR-1, and MCS-1023. 3. WGK will not produce Therminol PR-II or PR-3, or Pydraulsafter Antwerp is in.Pydraul operation. 4. WGK will rework reclaimable scrap Aroclors or blends. #, 5. Therminol PR-1 will utilize Aroclor 1016 and ' Inerteen 54201 CM will use Aroclor 1242. 6. The 100# column capacity for Aroclor 1016 will be 54Jy/yr., and 18 ffis?/yr. for MCS-1109. Based on the 1971 forecast there will be 2.0-2.5 months of idle time. 7. The capacity,for continuously, chlorinated Aroclor - .1142 (crude)-will'be approximately 54 M#/yr. This' provides a surge capacity-of 5-10# over expected 1971 demand. ' DSW 296581 STLCOPCB4066494 SECTION III. PROJECT OBJECTIVES AND PREMISES (contd.) III. OPERATIONAL PREMISES (contd.) 8. The sales and use forecast used in designing this project is: . Aroclor 1221/focS-1109 1232 1242/foCS-10l6 1248 1254 1260 1971 * ' ' 23' M' 0.1 1[approx.) 40.3 1[about 5.0 M of 1242) r.4 8.4 - ` 2.7 9. Dept. 246 will have the following delivery capability (bulk): . Necessary Lead -Time Aroclor 1016 & PR-1 MCS-1109 . Aroclor 1254 Aroclor 1260 Aroclor 1232 Inerteen 70/30 All other blends Anytime 5 days 1 day 2 days 10 days Anytime (assuming installa tion of 70/30 tank) 3 days - 8056 confidence 5 days - 95# confidence Aroclor 1221 and 1242 2 days When possible cars will i loaded prior to the receipt of an order. 10. All- products will be available in drums and" tank cars. Commercial trailers can be loaded with non electrical grade products. Electrical grade products can be loaded into trailers reserved for this service. 11. Aroclor 1016 and MCS-1109 column bottoms will be distilled and further chlorinated to Aroclor 1254 or 1260. If there Is an excess of still bottoms; it will be incinerated51. If more 1254 or 1260 Is needed, it will be batch chlorinated from biphenyl. 12. Off-gas condensate will be further chlorinated to Aroclor 1254. 13. The operation of the Aroclor incinerator will not be an integral part of the Aroclor production department. DSW 296582 STLCOPCB4066495 SECTION III. PROJECT OBJECTIVES AND PREMISES (c'ontd.) III. OPERATIONAL PREMISES (contd.) 14. There can be blending of finished lots of * Aroclor 1016 as long as each lot is a complete batch distillation.' 15. Construction and tie-in of this project will not interrupt normal production, other than brief shutdowns for piping tie-ins (8-48 hours). 16. .Customer acceptance of Aroclpr 1016 will be . such that there will not be-parallel production of Aroclor 1016 and Aroclor 1242 for capacitor use. OSXN W6581 STLCOPCB4066496