Document KJe80ZmM0JvgJ3eGVpyyMBgYr
May 15, 1990
DOW CHEMICAL U.S.A.
LOUISIANA RESEARCH & DEVELOPMENT P.O. BOX 400
PLAOUEMINE. LA 70765-0400 504-389-6000
Buck Bailey Jack Gathers Don Jones Dave Mihalik Mark Mitchell John Monroe' Art Royals Gerald Vagener Doug Valker Brian Vitt
3301V 2511 4701T 3701 3601 3301V 4701T 2503 3301E 2505
cc: Maurice Oubre Larry Hebert Rick Vittmann Eddie Supple E.J. Brown
6650 2511 3701 4601 2511
David Vest Barry Young Ken Mall Stan Kirsch
2511 1601 4601T 4601T
REACTIVE CHEMICALS COMMITTEE REVISE - METHANES
A Reactive Chemicals review is scheduled for Tuesday, May 22, 1990 at 8:30 a.m. in 4601T project team trailer for Chlorinated Methanes Liquid Process Injection process change.
If you are unable to attend please have someone substitute for you and notify Robbie Bagaley (1805) of your replacement.
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Gerald Vagener REACTIVE CHEMICALS COMMITTEE
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NOTE TO COMMITTEE MEMBERS: A copy of the presentation packet Is enclosed.
`HF.MlCAL COMPANY
cNFrr>F-NTI(5( 00 006785
;iHY-lb-*90 'JED 09:i4 ID:DOW lMP DIET *1852 TEL NO:409-238-45S7
04S6 PQl
DOW CHEMICAL U.S.A.
ftMS OPERATIONS FREEPORT,! U.AS77J41
September 27, .1988
Ron Kendrick A*1880
REACTIVE CHEMICAL/LOSS PREVENTION MINI REVIEW - LIQUID M, INJECTION -
SEPTEHJER 22, 1988
1
Present:
Process - Ron Kendrick, Larry Hebert (LaSTL), Joe Repman, Kristi Wooley, Ron Jones, Gordon Guy, Duke Dotson, Mark Moran, and William Miller
Committee - Jan Seth, Mitch White, Walt Hoffman, and John Slayers
The only recormendat ion made was to provide a low pressure alarm and shut down on the liquid feed to the reactor.
Your response within a month will be appreciated.
KJ, A. Biggers Safety ana Loss Prevention
1 ke
Post-It"' brand fax transmittal memo 7071 po (
Co /s SET F*> . **
""ftML Co.
khono#
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CONFTDFNT1AL DO 006786
May 25, 1990
DOW CHEMICAL U.S.A.
LOUISIANA RESEARCH & DEVELOPMENT p o box
PLAOUEMlNE LA 70765 U*SC0 504 239 nOCL
Stan Kirsch Chlorinated Methanes 4601 Bldg.
REACTIVE CHEMICALS COMMITTEE REVIEW - MAT 22, 1990
PROJECT; Methanes Liquid Methyl Chloride Injection into R-300
PROJECT REP; Stan Kirsch
ATTENDEES: Gerald Wagener, Mark Mitchell, Barry Young, Emmett Brown, Larry Hebert, James Vatkins, Maurice Oubre, Ron Gast, David West, Stan Kirsch, Ken Mall, Don Jones, Eddie Supple
CONCERNS:
1. Consider updating reactor start-up checklist to include items which will assure that all instrument work errors are identified and corrected before attempting start-up. An incident occurred on May 7, 1990 at Solvents/EDC (RID reactor) which was a direct result of this condition.
2. Update procedures to assure that vessels/piping containing methyl chloride are not blocked-in "liquid full".
Please respond in writing to the Committee Chairman within one month as to action taken or planned in regard to these considerations.
Gerald Wagener REACTIVE CHEMICALS COMMITTEE
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CONFl^Tt* DO 006787
June 6/ 1990 Gerald Wagner Analytical Labs - Reactive Chemicals Committee 25-03 blog
The concerns of the Reactive Chemicals Committee on the Liquid Methyl Chloride Injection into R-700; from the May 22* 1990 review have been recieved and noted. The plant will address these concerns through the olant's Mod 5 policies* procedures and checklists. Enclosed is a copy of the existing policies* procedures and checklists that relate to the review's first concern. The plant does not believe that the review's second concern is a problem for this specfic jystem. l;owever* a orocedure will be written before this line is put into service to assure that the liquid methyl chlorine line to R-300 is not be hlockel in " liquid full". Please contact me if there are any questions.
Stan Kir sc h Chlorinated ''ethanes
CONFTDFNTTAI 00 006788
5/2 2/90 REACTIVE CHEHICAL REVIEJ LIQUID Ml INJECTION INTO R-300 INFORMATION PACKAGE TABLE OF CONTENTS 1. AGENDA - SCOPE 2. ' BRIEF PROCESS/PROJECT DESCRIPTION AND CHEMISTRY 3. REACTIVE CHEMICAL DATA 4. CRITICAL INSTRUMENT LIST 5- REACTIVE CHEMICAL CONCERNS AND SOLUTIONS 6. HEAT AND MASS BALANCE 7. MOD V GRAPHICS AND ALARMS LIST
CONFTDFNTTAl DO 006789
REACTIVE CHEMICAL REVIEW
LIQUID Ml INJECTION INTO -300
5/22/90
Ok
STARTS AT 8:30 AM * CMP PROJECT TRAILER CONFERENCE ROOM.
conftdfntiai
DO 006790
AGENDA 1. SCOPE AND QUESTIONS The scope of this review is the liquid M1 injection system as it relates to R-300 but not R-30 0. The R-300 control s ys te ml TDC ) has been converted to Mod V and is awaiting a shutdown to tie the Nod V in. Liquid Ml injection is part of this Mod V conversion. The liquid injection technology was developed here by Larry Hebert and David West. The pilot plant was installed and the technology proved in the LAD CMP. Texas and Stade CMP plants have implemented liquid injection.
2. BRIEF PRD CESS/PROJECT DESCRIPTION AND CHEMISTRY 3. REACTIVE CHEMICAL DATA 4. CRITICAL INSTRUMENT LIST 5. REACTIVE CHEMICAL CONCERNS AND SOLUTIONS 6. HEAT AND MASS BALANCE 7. MOD V GRAPHICS AND ALARMS LIST
CONFIDENTIAL DO 006791
{ 2. 3RIEF PROCESS/PROJECT DESCRIPTION AMD
OONFTDFNTTAt DO 00679?
1989 ENERGY/YIELD/MAINTENANCE CONTEST ENTRY
PLANT: __ Chlorinated Methanes Plant
DATE: ___December 14, 1988
DESCRIPTION OF PROJECT: Methylene chloride and chloroform are produced in the Chloromethanes plant by vapor-phase chlorination of a mixture of methyl chloride and methylene chloride. Market projections indicate that chloroform demand will exceed capacity in 1990, accompanied by a gradual decrease in methylene chloride demand. Plant capacity is partly limited by the relatively low reactant conversion in the thermal chlorination reactor.
The purpose of this project is to increase the chloroform yield and capacity in the existing Chlorome thanes plant by injecting part of the normal gas feed as a liquid directly into the thermal chlorination reactor. Evaporation of the liquid inside the reactor allows an increase in the chlorine feed concentration, thus increasing the per-pass conversion and reducing the amount of recycle compared to present operation. Preliminary results obtained in the miniplant have demonstrated the basic feasibility of liquid feed injection.
All the economics and chloroform production increases are based up our best computer simulations of the plant. We expect to get an additional 21 million pounds of chloroform production per year from this project.
SUBMITTED BY: Stan Klrsch. Larrv Hebert, David West, and Ken Mall
PHONE; 8798
Attach any other pertinent Information and mail complet d project package to Ken Nelson, Building 3301W, as soon as it's ready. Final deadline is October 28, 1988. If a project n ds to be authorized this year, it can be reviewed at any tim and recognized as a 1989 Contest entry.
CONFI^1*1 DO 006793
CMP OVERVIEW
OONFTDFNTT Al
DO 0 0 6 7 9 4
HCL, HjjO
HVDROCHLORMATION REACTIONS
II MEOH 4 HCL
M| 4 M20
21 2 MEOH 31 DME + 2HCL
OWE 4 H2O -- 2M, + H20
THERMAL CHLORINATION REACTIONS
M| + CL2 ----- -----> M2 4 HCL
m2 + M3 + cl2
---- Mj 4 HCL
---- M4 4
HCL
*
PROCESS SKETCH BEFORE PROJECT: M*l M'fc VAP VAf
VAf
PROCESS SKETCH AFTER PROJECT:
VAf '
OONFTDf NTT Al D0 006795
THERMAL CHLORINATION OP METHYL CHLORIDE (Ml)
A. Primary reaction
CH3CI + ci2------ > CH2C12 + HC1
298 " -24.20 Kcal/mole
298 AHrjqj " -24.23 Kcal/mole
CH2C12 + Cl2 ------- CHCI3 + HCl
298
^GRXn " -22.69 Kcal/mole 298
-21.86 Kcal/mole
CHCI3 + Cl2 ______ >. CCI4 + HCl
298 AGRxn * -20.31 Kcal/mole
298 AHRxn " --21.86 Kcal/mole
DOW CONFIDENTIAL INFORMATION
1 A\
DO 00&796
3 REACTIVE CHEHICAL DATA
CONFIDENTIAL DO 006797
JU___ INTRODUCTION
Chlorinated methanes are currently produced by the adiabatic thermal chlorination of methyl chloride and methylene chloride. Since both methyl and methylene chloride can form explosive mixtures with chlorine, it is critically important that th flammability limits of the system be known so that pre-ignitions, deflagrations, and detonations can be avoided in the mixed feed line to the reactor. A detailed study of the explosibility of chlorinated methanes with chlorine was performed by Rimato and Smith1 in which the flammable limits of chlorine were defined in pure methyl chloride, methylene chloride, and chloroform over a wide range of temperatures and pressures. However, experiments were not performed to define the flammable limit in organic mixtures. Since the organic feed to the chloromethanes reactor typically is a mixture of chlorinated methanes, a subsequent study was performed by O'Shaughnessey2 to define flammable limits in methyl and methylene chloride mixtures. A summary of this data is shown in Table I. The study was done at a constant temperature of 60 C and over a small range of pressures.
The purpose of the present study is to combine the data from O'Shaughnessey with that of Rimato and Smith in order to develop an empirical model to define the chlorine flammability limit as a function of temperature, pressure and organic composition which would be accurate over the range of typical plant operating conditions. This model could then be programmed into the plant control system to continuously monitor the flammability approach in the reactor feed.
II. MODEL DEVELOPMENT
The data from the two previous studies were combined and analyzed using the SAS (Statistical Analysis System) computer program. An uncertainty of 1 mole% was assumed for the data of Rimato and Smith. The following linear model was developed:
Xfiam - 33.01 - .06726T - .03804P + .1997XM2 - .001194(XM2)2
where Xflagj
P 'M2
chlorine flammability limit (mole %), temperature (C), pressure (psig), and organic M2 concentration (mole %).
The R-square value for this model was 0.9. A comparison of observed and predicted flammable limits is given in Table II. Maximum deviation between the observed data and the model is approximately 5% ( 1.3 mole%). Combining this with an
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CONFTDFNTTAL
DO 006798
-2-
uncertainty of l molet in the observed data, the model should predict flammability to * 10% ( 2.3 mole%) over a temperatur range of 25 to 100 c, a pressure range of 0 to 75 psig, and over the full range of methyl and methylene chloride concentrations.
11L___RECOMMENDATIONS It is recommended that the above empirical model be used t predict the chlorine flammability limit in the feed to the chloromethanes thermal chlorination reactor. A meeting was h Id between research, manufacturing, and the technology center to review the flammability data. It was decided that the design sparger chlorine concentration during liquid injection in the Texas process be less than 90% of the predicted flammable limit. An alarm limit of 95% and an automatic shutdown limit of 100% of the flammable limit were adopted. It was felt that since the chlorine and organic feeds in the Texas process are not mixed until they are actually introduced into the reactor, a close approach to flammability would be acceptable.
IV. REFERENCES 1. C. J. Rimato and R. A. Smith, "Explosibility of Chlorine with
Methane, Methyl Chloride, Methylene Chloride, and Chloroform", Dow CRI TC-818, March 1980. 2. D. M. O'Shaughnessey, Dow CRI ML-AL88-020096.
r.ONFlWN-"*' 00 006799
i
TABLE I CHLORINE FLAMMABILITY DATA ON MIXTURES OF
METHYL CHLORIDE AND METHYLENE CHLORIDE
METHYL CHLORIDE M2 - METHYLENE CHLORIDE
-3-
1. BINARY MIXTURES AT 60 C m2 / ci2. 1 ATM Mi / Cl2, 35 PSIG
2. TERNARY MIXTURES AT 60 C 2 (Mi) : l (M2) / cl2. 35 PSIG 2 (Mi) : 1 <m2) / cl2 , 50 PSIG 6 (Mx) : 1 (w2> / cl2/ 35 PSIG 6 (Mi) : 1 (M2) / cl2, 50 PSIG
in
o
FLAMMABILITY (MOLE % Cl2)
36.3 0.8% 27.0 1.0%
33.4 * 0.5% 33.3 0.5% 28.9 0.5% 28.5
Data by Dan 0`Shaughnessey (ML-AL88-020096)
CONFIDFNTIAI Vj i 1
DO 006800
-4
TABLE II COMPARISON OP OBSERVED AND PREDICTED PZiAMMABLE LIMITS
xflaa " 33.01 - .06726T - .03804P + .1997XM2 - .001194 <XM2>2
Source of Data
0 R&S R&S R&S R&S R&S R&S
0 0 0 0 R&S R&S R&S 0
Temp (C)
60 25 25 25 100 100 100 60 60 60 60 100 100 100 60
Press (psig)
35 0
25 75
0 25 75 50 35 50 35
0 25 75
0
M2 Cone (mole %)
0.0 0.0 0.0 0.0 0.0 0.0 0.0 33.3 33.3 14.3 14.3 100.0 100.0 100.0 100.0
Cl, Flammable Limit
Observed
Predict*
(mole %)
(mol %
27.0 32.5 29.5 29.5 27.6 24.0 24.0 33.3 33.4 28.9 28.5 35.0 33.2 31.5 36.3
27.6 31.3 30.3 28.5 26.3 25.3 23.4 32.4 32.9 30.2 29.6 34.3 33.4 31.5 37.0
Source of Data: 0 O'Shaughnessey, R&S - Rimato and Smith.
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CONFIDENTIAL
MO * i * Jiiiimtm'tJ
>
DO 006801
-5-
TABLE HZ COMPARISON OP PLAMMABItITY APPROACH IN REACTOR AND SPARSER
Mole % Liquid in Total Org. Feed
10 10 10 10 20 20 20 20 30 30 30 30
Mole% M, in Vapor Peed
0 20 40 60
0 20 40 60
0 20 40 60
% Flammability in Sparger
86.3 79.7 76.9 76.1 96.5 90.7 87.2 86.1 106.7 103.2 99.0 97.5
% Flammability in Reactor
79.8 74.4 72.0 71.1 82.0 78.7 76.3 75.2 82.7 83.0 80.7 79.5
Basis:
Reactor Outlet Temperature = 475 c.
Feed Temperature * 5 C superheat over dew point. Reactor Pressure * 45 psig. Liquid Injected * Methyl chloride.
CONFIDENTIAL
OONFTDFK/TTAL DO 006>802
Detonation ranges (vol.X) for common hydrocarbons and chlorinated hydrocarbons (1 atm., at or near 25 deg. C). Compiled by DHV A/90
hydrogen methane ethane
air 18.2-58.9 6.3-13.5
oxygen 9-95.3 6.7-56
chlorine 17.5-83 15-45
ethylene
acetylene
4.2-50 4 - 51
[cj [a]
3-93 [b]
propane
3-7
[c]
propylene
3.5-8.5 [c]
methyl chloride methylene chloride
? - 17.3
10.5-63 11.5-75.8
12.5-55
REFERENCES
Except where noted data are from: Dokter, T., Journal of Hazardous Materials, 1985, 10, 73-87.
a. Breton, J., Ann. Combust. Liq., 1936, 11, 487. b. Kistiakovsky, G. B.; Knight, H. T.; Malin, H. E., J. Chem. Phys.,
1952, 20, 884. c. Stull, D. R., Fundamentals of Fire and Explosion, AIChE Monograph
Series, 1977, 73(10), 76.
OONFTDFN'nAl DO 006803
CRITICAL INSTRUMENT LIST: - CL 2 small 8 big flow meters. Aid 30, <114) 8 AI (1 24 ) , Cl 44 ) - Ml small & big flow meters, AI1135) 8 A I (12 5) ,< 14 5) - M2 flow meters, AI (1 26 ), (146) - Liq Ml flow meters, AI <10 5) , < 115) - R-300 outlet temperatures, AI <171), < 173 ), <1 81) - R-300 intlet temperatures, AI <175 ), <176), <1 85 )
1 co^
006804 DO
REACTIVE CHEMICAL CONCERNS AND SOLUTIONS
OONFTDFNTTAL DO 006805
REACTIVE CONCERNS 1. Exceeding tn e CL2 S flammability limit. 2. Reverse flow of R-300 contents into liquid Ml line. 3. Unstable/inaccurate liquid Ml flow. A. Unstable control of the liquid injection mass ratio
( lbs CL 2/ lb s liq Ml).
V
CONFTDFNTIAI. DO 006806
REACTIVE CONCERNS AND SOLUTIONS
1. Exceeding the CL2 % flammability limit.
- This is the worst case scenario. Exceeding the CL 2 f; flammability limit and having an ignition source thus resulting in a deflagration in the inlet line or far exceeding the CL2 5; flammability limit by going into the detonation range and having an ignition source resulting in a detonation in the inlet line. A deflagration or detonation in R-300 itself is not likely since* liquid injection can only oe started after R-300 in up and running.
The list of ways exceeding the CL2 % flammability oroblem is addressed begins with liquid injection permissives the list is as f ol tows. A. Liquid Injection Permissives
1. Is the C12 `-i flammability below - 80 %
2- Is the C12 load above - 29* 000.0 Lbs/hr
3- Is the Liq Ml and Small C12 FCV closed
4- Is the Liq Ml line pressure above 175 psig (R-3 00 pressure is about 40 psig) and not failed or in manual.
5. Is at least one Liq Ml and one small Cl 2 flow meter of the two pairs of flow meters not failed or in manual.
6. Is R-300 outlet temp stable* not more than one degree below its setpoint.
Once these permissives are met and liquid injection is desired the liquid Ml flow may be started.
Liquid injection will be ratio controlled. The CL2 thru AO (101) will be ratio controlled to the liquid Ml flow thru A0(123).
rONFTDFNTTAI, DO 006807
B, The Hod has a high C12 flammability and high inlet line temperature shutdowns and alarms. The Mod will automatically ramp the liquid Ml flow down if the High % C12 flammability alarm becomes true# it is set at 9 0S, until the alarm clears and will not ramp it up until a new li q Ml flow setpont is entered. The Mod will shutdown liquid injection if the % CL2 flammability exceeds 955:* R-300 will shutdown if it reaches 995s. The Mod will alarm if the inlet line temperature exceeds 75 deg C. It should be noted here that the inlet line temperature will be triplicated for redundancy. The Mod will shutdown R-300 if the inlet line temperature exceeds 90 deg C.
CONFIDENTIAL DO 006808
Note:
If two of the any three thermocouples fail the plant policy
shall be to get the failed thermocouples fixed as soon as possible# emergency. That is call out a instrument man to r epai r it .
If one of the any three thermocouples fails the plant policy shall be to get the failed thermocouple fixed but not as an emergency but as a high priority.
The accuracy of a single thermocouple can be verified by checking the history logged temperature values for the thermocouple in question.
C. The Mod has redundant flow meters on all flows that go into the CL2 % flammability calculations# except the small vaoor Ml flow since it is only used during start up of R-300.
All of the flow meters are temp and pressure compensated# except the li quid Ml.
If at anytime during liquid injection a pair of flow meters for a flow are lost or the liquid Ml line and or R-30 0 pressur transmitter has failed or is put into manual liquid injection will shutdown. R-300 will not shutdown.
Also if at anytime while operating R-300 with or without liquid injection and a pair of R-300 feed flow meters (other than the liquid injection flows) are lost R-300 will shutdown. Liquid injection is shutdown whenever R-300 shuts down.
Note: If one of the any pair of flow meters fails the plant policy shall be to get the failed meter fixed as soon as possiole# emergency. That is call out a instrument man to repair it.
The accuracy of the single flow meter can be verified checking the history logged control valve output file or checking the history logged flows for the flow meter in question.
In the case of the C12 meters they can be compared to the C 12 pay me te r.
>>>>>>>>>>>>>>>>>>>>>>>
The control design logic is to err on the safe side.
The highest CL2 flow meter is used in the % CL2 flammability calculation if the two working meters deviate significantly.
The lowest organi c( Ml#H2) flow meter is used in the % CL 2
flammability calculation if the two working meters
deviate s igni f i cant ly.
CONFIDENTIAL
The inlet temperature uses the mid value if all three are working and the high if only two are working.
the outlet temperature us s the mid value if all three are working and the high if nly two are working.
DO 00680*9
D. The Hod has redundant computers and a whole array of self di agnost ic s-
(
CONFTOFNTTAl DO 006810
2. R verse flow of R-300 contents into liquid Ml line. This is addressed by a low diff- pressure alarm and liquid injection shutdown alarm across the liquid Ml FCV. And a check valve.
The alarm setpoint is 125 Dsi. The shutdown setpoint is 75 psi or loss of the Liquid Ml and or R-300 pressure transmitter.
3. Unst ab le/i na ccurat e liquid Ml flow.
This is addressed by low liquid Ml flow alarm and shutdown. The Liquid Ml flow setpoint must be large enough for the FCV to be off its seat before it can control properly and the liquid Ml can be accuractly metered.
When a liquid Ml flow setpoint is first entered it must be larger than 5000 Lbs/hr or the FCV will not become enabled. If now the Liquid Ml flow drops below its low flow setpoint the alarm will ring# if it drops further liquid injection will be shutdown.
The alarm setpoint is 3500. 0 Lbs/hr. The shutdown setpoint 3000. 0 Lbs/hr.
4. Unstable control of the liquid injection mass ratio ( lbs CL2/lbs liq Ml).
This is addressed by a mass ratio control problem alarm. This alarm looks at the mass ratio setpoint and compares it to the actual mass ratio. If the mass ratio deviations from its setpoint an alarm is sounded.
The allowable mass ratio deviation must be less than 0.05.
The plant policy is that the boardman will decide if he should continue or shutdown liquid injection should this alarm come on.
5. The Mod is equipped with a manual shutdown switch for the liquid injection system and the R-300 system.
CONFTOFNTTAL
DO 006811
6 HEAT AND MASS BALANCE
CONFTDFNTIAI DO 006812
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THE DOW CHEMICAL COMPAmiMT
MATERIAL & HEAT BALANCE frs L?oo . 'Mm it**' *> CONFIDENTIAL
DO 006813
l 7- MOO V GRAPHICS AND ALARMS LIST
fr-
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T he Mod graphics are given instead of the P&ID*s. The graohic c onta ins the same information as the PSID*$ in a condensed form.
CONFTDFNTIAl 00 006815
AO'S USED FOR STRIP CM
'1-i' CAM Battery
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CONFIDENTIAL DO 006818