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W. J. King April 1976 "PONSOL" SPRAY DRYER #2 Chambers Works Bldg. 743 1-1-1 Principle of Process A slurry or solution is pumped to an atomizing nozzle. Steam or pump pressure is used to atomize it. The droplets of material thus formed come in contact with a large volume of hot air. The dry product is separated from the air stream in a cyclone. The product is discharged to containers and the air stream is scrubbed to remove any remaining particles and then discharge to the atmos phere. Reaction There are no chemical reactions. N32959 W. J, King April 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER #2 SUBJECT: OPERATION: Chambers Works Bldg. 743 III-1 Flow Diagram W MU- DUP050467562 W. 0. King April 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER #2 SUBJECT: OPERATION: Chambers Works Bldg. 743 IIX-2 Gas System *~!J-j* v> Is i "v 3^ 2k ^ <o U. CL ' ) M U-nM DUP050467563 W, J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 II1-3 "PONSOL" SPRAY DRYER #2 SUBJECT: OPERATION: Dispersant Loader DUP050467564 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 III-4 SUBJECT: "PONSOL" SPRAY DRYER $2 OPERATION: Equipment List CY-1 - Dispersant Loader, an enclosed endless chain of S.S. flights driven through a gear reduction system by a 3 HP 550V. 1750 RPM" motor. CY-2 - Box elevator and dumper, a platform cage attached to an endless chain in guides. It is driven through a gear reduction system by a 7 1/2 HP 550V. 1750 rpm motor with a magnetic brake attached. D-IO - Dryer, an 8' diameter x 45f high S.S. dryer body with a conical bottom and flat top. DC-10 - Dust collector, an Aerodyne S.S. dust collector 25 3/4' high. It is ijj two functional sections joined as one unit. The upper Aerodyne - exhause-recirculation section is 6 3/4 ft. drain by 4 3/4 ft. high. The lower dust section is 5' drain x 21' high. It has a conical bottom with a rotary air lock for dis charging solids. The air lock turns at 10 RPM driven through a gear reducer by a 1/2 HP 220V. 1750 RPM motor. FN-10 - Recirculating air fan for DC-10, a 6620 c.f.m. 2375 RPM fan driven through V-belts by a 50 HP 55OV. 1750 RPM motor. FN-11 - Main exhause fan, a 10,000 c.f.m. 2300 rpm fan driven throug V-Fel'ts by a 125 HP 550V. 1750 RPM motor. FN-12 - Dispersant hopper exhaust fan, a New York Blower size 15 fan driven through V-belts by a 1/2 HP 550V, 1750 RPM motor. FR-10 - Drying air heater, propane fired Maxim heater furnishing total combustion gases for drying air at a rate of 480,000 cubic feet/hr. It can furnish approximately 10 million BTU/hr. P-10 - Feed pump, Moyno 6FGJ6SSQ 27-216 RPM driven through a verispeed drive by a 15 HP 1750 RPM 550V. motor. P-11 - Circulating pump for scrubber solution, Gould 35 GPM pump driven by a direct coupled 10 HP 550V. 1750 RPM motor. P-12 - Slurry suck-up1 pump, an air and spring driven diaphragm pump. P-13 - Booster pump for wash water, Gould high pressure 20 GPM, limited volume pump driven by a direct coupled 15 HP 550V. 1750 RPM motor. P-l4 - Slurry recirculation pump for T-10 & 12, Gould 300 GPM pump driven by a direct coupled 20 HP 550V. 1750 RPM motor. P-15 - Feed pump, Moyno special high pressure feed pump driven through a verispeed drive by 20 HP 550V. 1750 RPM motor. DUP050467565 W. J. King April 1976 OPERATING INSTRUCTIONS SUBJECT: "PONSOL" SPRAY DRYER fi2 OPERATION: Chambers Works Bldg. 743 III-5 Equipment List P-l6 - Slurry recirculation pump for T-13, Gould 300 GPM pump driven by a direct coupled 20 HP 550V. 1750 RPM motor. SB-10 - Scrubber, a 10* long 5'6T' wide x 4* high S.S. box with a 1*8" x 5*scrubber solution contact area which uses either 3" stainless steel pads or 1" S.S. bars. The exhaust 1/3 contains demister vanes for droplet removal. SC-10 - Scale, Toledo 711-2881, 0-600 lb. dial face 30 x 30 plat form with mounted rollers. T-10 & 12 - Peed tanks Identical 2,950 gal. S.S. tank with 56 RPM and 2b RPM two speed agitation driven through a gear reducer by a two speed 30 HP 550V. 1750 RPM and 15 HP 550V. 880 RPM motor. T-ll - Scrubber solution storage tank, 600 gal. S.S. no agitation. T-13 - Press cake make up tank, 2,950 gal. S.S. tank with 56 RPM and 28 RPM two speed agitation driven through a gear reducer by a two speed 30 HP 550V. 1750 RPM and 15 HP 550V. 880 RPM motor. DUP050467566 W. J. Ki ng April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 13 1-6 "PONSOL" SPRAY DRYER #2 SUBJECT: Loading Prepared Slurries 0PE8ftTI8H:_ 1. Check to be sure feed tank T-10 or T-12 is empty and all valves are closed, 2. Place screen in manway and hook-up P-12 discharge hose to screen, 3. Place tote tank or barrel in position and hook up line to unloading pump P-12. 4. Pump contents of tote tank or barrel to feed tank. When tote tank is empty, rinse with 50 lbs, of water, valve off suction to pump and turn off pump. 5. Disconnect tote tank and place another full one of the same charge in position. Pump this one also to feed tank. Con tinue pumping until charge is loaded to feed tank. 6. On last tote tank of charge, rinse with 20 gallons of water and pump this to the feed tank. This lessens dye loss by cleaning out feed line to tank. 7. Wash the empty tote tank to the ditch. Be sure they are drained and product labels removed. Set empty, clean tote tanks aside for return to the area. Be certain that the discharge valves are closed and caps are fitted on the quick couplings. 8. After last tank has been disconnected, remove discharge hose from screen and remove screen from manway. 9. Clean up screen, unloading pump P-12, and line by flushing with water to the ditch. DUP050467567 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 III-7 "PONSOL" SPRAY DRYER #2 , SUBJECT: Dispersant Loader OPERATION: MU - ISlil H` N32959.02 ........ .................. ............ ........................... DUP050467568 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 7^3 III-8 ____ HPONSOL" SPRAY DRYER #2 SUBJECT: OPERATION' Loadins Dispersant Agents 1. Start PIT-12, ventilating fan, for the dispersant loader. 2. Start CY-1, the dispersant loader. 3. Load the Reax 85A called for by the log card into conveyor hopper. 4. Shut down CY-1, agitate the contents of the tub, and circulate using P-14 for one hour, sample to G.A.L. as a S.D, slurry for adds and wet DPT. (Sample C.) 5. Start CY-1. Add 3/4 of the Tamol SN called for by the log card while waiting results on C sample. If C adds are within 10$ of amount called for by the log card, complete the addi tions of Tamol SN as called for by the log card. If C adds are above or below 10$, contact supervision. 6. Shut down CY-1 and FN-12 after all dispersants have been added. Mix for one hour and sample to G.A.L. as a S.D. slurry for adds and wet DPT. (Sample E.) If the log card amounts of dis persants have been loaded, do not wait for the E & F results; start drying. Ku-zid nz DUP050467569 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 111 -- 9 "PONSOL" SPRAY DRYER #2 SUBJECT: Shutdown to Operation OPERATION: Unless otherwise stated, the following operations are from the panel board. 1. Set feed control FC-101 to manual and output air to 9 psig. 2. Connect feed tank T-10 or T-12 to pump P-10 or P-15. Dry dip tank (be sure agitator is off when dipping) and record on log card. 3. Connect return line to T-10 or T-12. Be sure return and feed line are connected to the same tank. 4. Open bottom valve on T-10 or T-12 and start up feed pump, P-10 or P-15. Running light should come on. Be sure both feed line and return line are con nected before starting pump. 5. Check tank to be sure slurry is returning to tank. It should take about 6 minutes for slurry to return after starting with empty lines if output is set at 9 psig. 6. Start P-ll scrubber circulating pump. Prior to starting, water level in scrubber water tank T-ll should be 1/2 way up in the middle sightglass. Running light should come on when pump is started. Flow should be 6.25 on the meter (250 gpm) or better. 7. Start main fan FN-11. Running light should come on. * 8. Start sec. fan FN-10. Running light should come on. 9. Place barrel on scale SC-10. Weigh and record tare weight. 10. Start air lock. Running light should come on. 11. Set temperature control TC-116 to 4 psig output - automatic mode and set point at required temperature (see log card). 12. During this time, the main power light should come on, the system will purge and 3 minutes after the power light is on the purge light will come on. If it does not, see interlock list for prpbable cause and correct it. 13. Check to be sure gas valves (SV-1, GV-2, GV-3) are open. These valves are located on the fourth floor platform beside the main burner. im u - 2 3f, i r? DUP050467570 W. J. Kin; April 197 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 III-10 SUBJECT: "PONSOL" SPRAY DRYER #2 OPERATION' Shutdown to Operation 14. Q)en propane feed valve. Light should come on. 15. Depress the pilot start switch and hold in until pilot light lights. The following automatic series will take place. Valves SV-108A, SV-108B will open as valve SV-108C closed. This allows gas to be fed into the pilot burner. A spark plug will be activated to light this gas. When the pilot is ignited, the "Pilot on" light goes on. If the pilot does not light, the alarm will sound and SV-108A and B will close and SV-108C will open. If pilot does not start, see Page III-18. .16 When it is decided to light the main burner, depress valve open switch and hold down until "burner on" light comes on. ..If the flame is not established, repeat Steps 14, 15, and 16 17. After burner is lit, allow outlet temperature to rise to 75-100F. Slowly raise air pressure to maximum of 9 psig and then set controller to automatic position. When air to control valve starts to decrease, set pressure to 18 psig or above. .18 Set the external steam controller, PC-120, and the internal steam controller, PC-151, to zero. 19, Open main steam valve (HV-130). Light should go on. .20 Raise pressure of external steam to set point by using PC-120 In manual. t .21 Raise pressure of internal steam to set point by using PC-151 in manual mode. .22 Set the feed controller, PC-101, to manual and 0 psig output. 23. Open 3-way feed valve to dryer. This will allow feed to go to dryer. 24. Depress and hold wash flush, PB-132, for 45 seconds. This will clean out return line to tank. 25. The outlet temperature of the dryer will drop. As the outlet temperature-approaches its set point, raise the output of the feed controller PC-101 until the recorder gpm is at 5 gpm. Set point to 5 gpm and switch to automatic. 1 DUP050467571 W. J. King April 1976 OPERATING INSTRUCTIONS SUBJECT: "PONSOL" SPRAY DRYER #2 OPERATION: Chambers Works Bldg. 7^3 III-ll Normal Operations 1. Follow instructionI s given on the instruction sheet. See also the product sheet. This sheet will indicate any hazards involved in handling individual products. 2. Maintain temperature on the dryer as instructed. Check log card and list of Drying Control Set Points. 3. Check periodically for dust losses at the stack. The dryer should be shut down when a dust loss is evident. All of the dyes are very expensive. Dust loses also cause atmospheric pollution. '4. Keep a check on the instruments to be sure the dryer is operating properly. 5. Replace the drum on scale when it is full. 6. Label, tag, and head each drum immediately. Include on barrel label, net weight, code number of product, name of product, barrel number and charge number. Use plastic drum liners when drying dyes. 7. Maintain an adequate supply of clean dry drums. J Be sure the drums are stored in a safe manner. Do not use wet drums. Do not use 2 wash drums (drums with 6" dia yellow circle stenciled on side of drum). 8. Maintain the Prqduee and Ship ticket up to date. 9. When putting drums on pallets, make certain stenciling on barrels face outside so that the material can be identified without having to move drums on pallet. 10. At the beginning and end of the shift, record the events of the shift 0n the shift log sheet. Dry dip the tanks and record. Continued M U -2 38 | RZ DUP050467572 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 III-12 SUBJECT: "PONSOL" SPRAY DRYER #2 OPERATION: Normal Operations 10. Continued Be sure agitator is off when dipping tanks. Be sure to note unusual occurences in detail. Leave information on needed repairs, malfunc tioning equipment, etc. Record any down time and reasons for down time. 11. Keep the area clean and trash picked up. The panel board and control room must be kept clean and dry at all times. DO NOT USE ANY WATER IN THE CONTROL ROOMS. > DUP050467573 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 111-13 "PONSOL" SPRAY DRYER #2 SUBJECT: Operation to Shutdown OPERATION: 1. When the feed stock level is within l-1nch of the feed tank's outlet, wash down the tank using less than 200 lbs. of water. This will clean the tank and lessen the product loss. 2. Repeat Step 1 using up to 1,000 lbs. of water. Be sure tank walls are clean. 3. As the output of slurry controller decreases and inlet tem perature increases, turn off flame by pressing pilot flame stop button. This should turn off all gas to the burner and cause the flame out alarm to sound. When the burner is not lit, the feed is directed back to the feed tank auto matically. 4. Allow FN-10, FN-11 and P-11 to run to cool down the unit. Shut off P-10 or P-15 if feed tank is empty. DO NOT RUN P-10 OR P-15 DRY. 5. After the unit has cooled down, inlet air below 200F, check barrel on scale to be sure it will hold any hangups. Turn off the following in order: a) Air lock b) FN-10 sec. fan c) FN-11 main fan Don't turn off P-11 scrubber pump. 6. Turn on air lock and pack out all product. 7. Turn off air lock, lock out FN-11. Inspect unit for hangups by opening duct to dust collector and looking into the dryer and lower part of dust collector. (Pack out amount). 8. Turn off P-11. (P-ll must always be running before FN-11 main fan is started). m 11 ? * r. r r DUP050467574 W. J. Kins April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 III-14 SUBJECT: "P0NS0L,, SPRAY DRYER #2 OPERATION' cleaninS Peed System 1. Disconnect return line from tank (T-10 or T-12). 2. Drain feed line by opening valve next to control room, 3. Drain pump (P-10 or P-15) by allowing it to run for two minutes. DO NOT RUN PUMP (P-10 or P-15) DRY. 4. Valve off T-10 or T-12 and remove suction line from P-10 or P-15. 5. Place hose under T-10 or T-12 and route to ditch. 6. Place water hose into suction of P-10 or P-15. 7. Start P-10 or P-15 allowing it to flush the feed line and the return line to the 2nd floor drain. 8. Continue flushing until no color is seen in discharge at 2nd floor. 9. Wash T-10 or T-12 with water from Pick heater until no color is visible. Be sure top of tank and baffles are clean. 10. Close valve under T-10 or T-12 and fill with water, agitate and then open and close three times T-lO's or T-12's drop valve. (This will clean seat). 11. Drop this wash water to the ditch and rinse tank. 12. Close T-10 or T-12 drop valve. Tank is ready for inspection MV-lltl R DUP050467575 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 III-15 SUBJECT: "PONSOL" SPRAY DRYER #2 OPERATION: Clean Dryer Dust Collector DO NOT turn off P-11 scrubber pump until all of the systems are clean except the scrubbing system. 1. Inspect the dryer for large hangup. If any are found, start FN-11 and FN-10 and remove as much as possible by brushing. Do not remove with water. Turn off FN-10 and FN-11 after Brushing. 2. Be sure FN-11 Is locked out then remove lower plates from DC-10 (aerodyne). Start air lock motor. Be sure barrel Is in place and sweep material into air lock. When as much dust is removed as possible, replace lower plate. Remove the barrel. 3. Start up FN-11, FN-10. 4. Place water hose Into P-10 or P-15 and start to circuulate water from pump to 2nd floor. Do not have recycle line connected to tank. 5. Be sure air lock is running and duct valve is open.' Open drains on DC-10, FN-10, FN-11 and place water hoses into duct opening. 6. Turn on water to hoses, 7. Set controller to feed 50 lbs. steam to dryer and turn on slurry bypass. Open and close 3-way valve about three times to clean seats and then leave it open so that water Is pumped to the dryer. 8. Allow water to run until no color is observed in the air lock discharge. Then turn off water, steam, FN-10 and FN-11. 9. Inspect dryer and DC-10, Wash if necessary. 10. Turn off P-11. Drain pump and T-ll to ditch. 11. Wash SB-10 to ditch via T-ll. 12. Close ditch valve. Fill T-ll 1/2 full with water and circulate to SB-10, for 15 minutes then drain to ditch. 13. Refill T-ll to overflowing and drain to ditch until color is no longer visible in draining. 14. After T-ll 'i,s clear, shut drain valves and open valves to P-ll, MU-- 2301 R 2 DUP050467576 W. 0. King April 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER #2 SUBJECT: Point Mame PS 106 Gas Pressure PS 112 Gas Pressure TS 114 Inlet Tempera ture to Dryer FS 115 Drying Air Flow PS 11 9 Dryer Vacuum TS 121 Dryer Discharge Temperature PS 124 Instrument Air Pressure FS 1 27 Scrubber Water FI ow PS 129 Sec. Air Pressure Access doors OPERATION: Alarms ON Low Pressure High Pressure High Temperature Low Flow High Vacuum High Temperature Low Pressure Low Flow Low Pressure Doors Open Chambers Works Bldg. 743 III-16 Interlocks Action Shuts Off Burner* Shuts Off Burner* Shuts off Burner* Shuts Off Burner* Shuts Off Main Fan Shuts Off Burner* Shuts Off Burner* Shuts Off Burner* Shuts Off Burner* Shuts Off Burner* *HOTE: Whenever the burner shuts down or if burner is not lit, HV-V32, 3-way slurry feed valve, directs the feed back to the feed tank. DUP050467577 W. J. King April 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER #2 SUBJECT: OPERATION: Chambers Works Bldg. 743 HI "17 Trouble Sheet 1. Main fan, FN-11 , will not run (PB-125). Check electrical. 2. Main fan, FN-11, running but shuts down. Check electrical. Interlock Hi Vacuum (PS-119). Too much pressure drop on system. 3. P-ll water scrubber pump will not run. Electrical trouble. No interlocks. 4. Second fan, FN-10, will not run. Electrical trouble. Main fan not running. 5. Power light does not go on. "> Light burned out or one of the following: Low water flow, less than 6.25 (250 gpm) (FS in scrubber system) P-ll. Low Sec. air pressure (PS-129) FN-10 Low drying air flow (PS 115) High discharge temperature to dryer (TS-121) High inlet temperature to dryer (TS 114) Low instrument air pressure (PS 124) Low gas pressure (PS 112) Door (s) to, unit open 6. Pilot will not start. Power not to unit (see power light). Purge not complete. PB-133, field switch, left in off position. Electronic failure on safety guard unit. No fuel. 7. Main burner will not light. Manual gas valve closed GV 1 and/or GV 2. Pilot'pot lit. Note: If main burner does not light; in order to try again, the pilot must be re-established. DUP050467578 W. J. Kini April 1971 OPERATING INSTRUCTIONS SUBJECT: 8. h c\j ro-=r "PONSOL" SPRAY DRYER #2 OPERATION: Peed will not go to dryer. Burner not running. Pump not running or failed. Plugged line or 3-way valve failed. Low air pressure to 3-way valve. Chambers Works Bldg. 7^3 III-18 Trouble Sheet M U --S3 t R 2 DUP050467579 W. J. King April 1976 OPERATING INSTRUCTIONS "PONSOL" SPRAY DRYER #2 SUBJECT: ____________ ______________8PERATI0H: Chambers Works Bldg. 743 II1-19 "These Ope rating In struct! ons hav e been issued aft er complete r ev i ew of current techno logy and conform to current recorded C. i n W. Proce TA's an ss d and TC's. sII ubsequ ent recommendatio ns U J. (A uthor's signa tu Buildinq Supervisor 6(J-J- Date Y/Z//7C Senior Supervisor ' Date Chief Supervisor, Operations ^ Date Chief Supervisor, Tech, or Plant Assist. ^L ftj'^th-K****-^***-- ^ Date ----------- ------------------------------------ /lec /ab #4751 * DUP050467580 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 7^3 IV-1 SUBJECT: "PONSOL" SPRAY DRYER #2 nDCDjmnu- Sampling and Operating UrtBAIIUH. proce^Uie fop "Latyl" Colors 1. Load Reax 85A, water and slurry. 2. Sample to G.A.L. for adds and wet DPT. Add 3/^ of the Tamol SN called for on the log card while waiting results from lab, 3. If adds called for by G.A.L. are within 10% of those called ' for on the log card, complete the addition of the Tamol as called for by analysis. If adds are above or below 10%, con tact supervision. If solids calc, exceed percent gross solids, check for 100$ present. If that is within 10$ of the 100% shown at bottom of log card, proceed with Tamol as above. 4. Whenever additional dispersant above that called for on the log card is added to the slurry, add an equivalent amount of h 2o . 5. After all dispersants have been added and mixed, resample to G.A.L. for adds. Record all results on log card. Do not wait for E&F results before starting dryer if dispersants added are log card amounts. 6. Run with outlet temp, as instructed usually between 175-l85F. Do not let inlet temperature go above 600P. 7. Start dryer at 5 GPM feed rate. Dry 3 bbls. and sample'to G.A.L. for dry DPT. Reduce feed rate to 3 GPM while waiting results. 8. When DPT on bbl. 3 comes back from lab., make following adjust ments on feed: If DPT on bbl.' 3 is under 15 sec. between 15-25 sec. between 25-35 sec. between 35-60 sec. over 60 sec. set feed at 6 GPM, 5 GPM. 4 GPM. 3 GPM. shut down and wait for results for DPT at 3 GPM. 9. After adjustments in feed rate have been made (Step 8), sample last barrel off at 3 GPM to G.A.L. for DPT. Record results on log card. If DPT at 3 GPM is over 60 sec., shut down and contact super vision. 10. Also, after adjustments In feed rate have been made (Step 8), run for 3 barrels and sample to G.A.L. for DPT. Do not change -J feed setting until results are back from G.A.L. but, upon receipt of these results. If DPT is over 40 sec,, reduce feed rate by 1 GPM and resample. Record all DPT's and barrel num bers on log cards. MU- 2 36 1 R 2 DUP050467581 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 7^3 IV-2 "PONSOL" SPRAY DRYER #2 SUBJECT: Sampling and Operating OPERATION: Procedure for "Latyl" Colors SAMPLES: Slurry - One 8 oz. for C sample from tank after water. Reax and slurry. One 8 os. for E sample from tank after adding Tamol. Dry - Two 8 oz. from bbls. 3, 10, 20 and last. On last bbl. one is for D.P.T., cloth test and A.I. The other one mark Final - File Only. One quart composite - C. E. Childs Wash water - One 8 oz. for % A.I. J MU-23 R2 V DUP050467582 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 7^3 V-l SUBJECT: "PONSOL" SPRAY DRYER #2 nOoPcEoRmATnIOiiN' . tLnoa,rdhin^g PressTi]hCsake- 1. Check T-13 and lines for cleanliness. Close valve at bottom of T-13. 2. Add water to cover lower agitator blade. 3. Turn on agitation to low speed. 4. Open the gate to CY-2 using the air cylinder control. If CY-2 platform is not in the full down position, an interlock will prevent gate from opening. 5. Load a box of wet press cake on CY-2 platform. If the wet press cake is in a white plastic box, use the special adapter for the platform of CY-2. 6. Close the gate to CY-2 using the air cylinder control valve. If the gate Is not completely closed, an Interlock will not allow CY-2 motor to operate. 7. Raise CY-2 platform to the full up or 'dump pos'itlon. If press cake does not come out of box, lower platform part way. Stop, Then raise to full up position. Repeat as necessary. 3. Add the minimum amount of water necessary to keep the slurry stirrable and pumpable. 9. Return CY-2 platform to the full (Sown position. < 10. Load the remaining press calce and other ingredients called for by the log card. Record weights. Remove tags from empty containers. 11. Set the valves In the discharge line of P-16 to recirculate the slurry to T-13. 12. Open the valve at the bottom of T-13. 13. Start P-lG. Circulate the slurry until it Is free of lumps. A pint of slurry should pass completely through a 10 mesh screen. 14. When the slurry passes the screen test, connect the flexible hose on pump up line from P-16 to either T-10 or T-12, Pass the slurry through the manhole screen. HwI . M U-23 1 R2 N32959.03 DUP050467583 W. J. King April 1976 II PONSOL" SUBJECT: SPRAY OPERATING DRYER #2 INSTRUCTIONS Chambers Works Bldg. 743 V-2 Loading Press Cake OPERATION: to The Feed Tubs 15. Open the valve to the line for the second floor and close the valve which recirculates to T-13. 16. When the charge has been pumped over rinse T-13 with 600 lbs. of water and pump this to the feed tub. 17. Shut down P-16 and the agitation for T-13 for either another charge of the same material or for the clean up procedure. DUP050467584 W. J. King April 197? 0PERATIN6 INSTRUCTIONS SUBJECT: "PONSOL" SPRAY DRYER #2 OPEBATiBN: Chambers Works Bldg. 743 VI-1 Process change for Dustless Beads - Mechanical Items Locking & Tagging: Lockout FN-11, P-15> and AL-10. Tag main propane valves to FR-10. Tag steam & process lines to D-10 nozzle. D-10: Change thermowell location from bottom outlet ductwork to outlet beside bottom door. Remove frying pan blank in ductwork below bottom door. Change nozzle, as required by operations, at top of dryer. Operations to change vanes at top of dryer as required. FR-10: Remove entrance panel of sheet metal on south side of furnace under main propane feed line. Inside furnace, remove 2 s/s center panels also the North and East s/s air baffle panel. Install fabricated replacement panels so clearances are 1/2" or less. DC-10: Place Sweco separator under AL-10 and hookup. (Operations and Mechanic 1s). SB-10: Operations remove scrubber pads in inlet duct and Install pipe baffles. (Operations) Changing back: Just reverse all operations to original positions. FR-10: Original panels set to 1-1/2". O N32959.04 DUP050467585 W. J. King April 1976 OPERATING in s t r u c t io n s SUBIECT: "PONSOL" SPRAY DRYER #2 OPERATION: Drying Control Set Points Chambers Works Bldg. 7 43 VII-1 Latyl's Internal steam pressure, psi External steam flow, lb./hr. Slurry flow, gpm Inlet temp., max., P. Outlet temp., F. 65 1,500 Note 2 450 175-180 Special Latylfs (Note 1) 65 1,500 3 350 175-180 Sevron's 80 1,500 3-5 750 165-170 Inter mediates 80 1,500 5 750 19-4-202 Note 1 - Special Latyl'b include: Latyl Brick Red EV, Latyl Bright Yellow 6GFS, Latyl Navy EFSN and Latyl Orange 3YFS. . 4^ Note 2 - See section entitled "Sampling Procedures'". MU -- 2361 RZ N32959.05 DUP050467586 W. J. King April 1976 OPERATING INSTRUCTIONS SUBJECT: "PONSOL" SPRAY DRYER 2 OPERATION: Chambers Works Bldg. 7^3 VII-2 Hazard Key SIRI CYAN CORR FLAM TOX Identification of Hazardous Materials Skin irritant or respiratory Irritant Cyanotic Corrosive Flammable Toxic Name of Material Acetic Acid* Glacial Ammonia, Aqua Boric Acid l,^-Diamino-2,3"Diehloro Aq. Dowicide G ''Dybln" Crude Hydrochloric Acid, 30$ "Latyl" Crudes Leuco-1,4-diamino Aq. Lignosols Maracarl N-l Marasperse CB Nalco 71-D-5 Natural Gas PC-269 Polyfon 0 "Ponsol" Crudes Potash Caustic Propane Reax 85A < "Bevron11 Crudes Soda Ash Soda Caustic, Liquid or Flake Sodium Siluofluoride Tamol N and SN Hazard FLAM - SIRI SIRI - CORR SIRI SIRI SIRI - TOX SIRI SIRI - CORR SIRI SIRI SIRI SIRI SIRI FLAM - SIRI FLAM SIRI SIRI SIRI SIRI - CORR FLAM SIRI SIRI SIRI SIRI - CORR TOX SIRI - TOX CORR TOX TOX M U --Z3 | R2 DUP050467587 W. J. King April 1976 OPERATING INSTRUCTIONS Chambers Works Bldg. 743 VII-3 PONSOL" SPRAY DRYER #2 SUBJECT: Latyl" Dyes Controlled OPERATION: by "DPT" The following disperse dyes must pass "DPT" to be "01 SHIP". If any lots do not pass, they will be released as "02" quality, no good "DPT". "Latyl" Blue GFE Blue 4-GFS Bordeaux B Brick Red EV Bright Yellow 6-GFS Brilliant Blue BGA Bril 1iant Blue BGN Brown 8-RFS Cerise NSN Cerise YLN Navy EFS Orange 4-RFS Orange 3-YFS Rubine BFS Yellow GFSW Yellow 3G Yellow 3GB Yellow 5R Violet 2R 3-31-75 from a letter by J. A. Oscar DUP050467588