Document RaG4m33mkGxo4QozMn5L2y5Q8

/> k S 'H ft. FC-143 STATUS I . OBJECTIVES I I . STATUS I I I . INTERIM PROCESSES A . ION EXCHANGE B . D IALYSIS C. THERMAL TREATMENT IV . ALTERNATE SURFACTANT V . PROGRAM %%**, --t-"* f t * P. P. BURKS, JR . 1981 SEPTEMBER 17 OOOO^v. SPR000133 EID714050 1. FC-143 OBJECTIVE ELIM INATE OR CONTROL AT SAFE LEV ELS FC-143 EXPOSURE AT SPRUANCE AND IN TRADE. ORIGINAL TIMING A . DEFINE TOXICOLOGICAL HAZARDS AND EXPOSURE L IM IT S . HASKELL 9/81 B . COMMERCIALIZE INTERIM PROCESS. R&D 4Q'81 C . COMMERCIALIZE NEW PACKING YARN (NEW SURFACTANT). PPD/R&D/MFG 4Q '8 2 STATUS A . HASKELL RECOMMENDATION DELAYED. NOW EXPECTED MID-OCTOBER. B . INTERIM PROCESS WORK IS ON SCHEDULE. ION EXCHANGE APPEARS F E A S IB L E , AND SCALEABLE AT MODERATE COST. - W ILL REQUIRE TOP PRIO RITY FOR YEAREND ADOPTION. C. PPD REPORTED PROMISING RESULTS WITH NEW SURFACTANTS. 9/17/81 000063 SPR000134 EID714051 2. IN TER IM PRO C ESS: ION EXCHANGE CONCEPT SEPARATE FC-143 FROM D ISPER SIO N , AFTER POLYMERIZATION, BY ADSORPTION ON ANION-EXCHANGE R E S IN . FC-143 NEEDED FOR POLYMERIZATION, BUT TRITON S T A B IL IZ E S DISPERSION IN U SE. TECHNOLOGY PERFLUOROOCTANOATE ANION (F C - 1 4 3 ) IS BOUND BY STRONGLY B A SIC QUATERNARY AMMONIUM GROUPS (AMBERLITE IR A -9 0 0 ) - WEAKLY BOUND HYDROXYL GROUPS DISPLACED - TEFLON P A R T IC LE S , NONIONIC TRITON NOT RETAINED (CHART 1) MACROPOROUS BEADS ALLOW SOLUTION TO REACH BINDING S I T E S , BUT TEFLON PA RTICLES EXCLUDED. (CHART 2) RESIN I S REGENERATED BY FLUSHING WITH EXCESS SODIUM HYDROXIDE. LABORATORY RESULTS APPROXIMATELY 90% FC-143 REMOVED WITH AMBERLITE R ESIN . REMOVAL INCREASED WITH COLUMN LENGTH (T A B L E I ) . - 98% REMOVAL PREDICTED WITH 80 CM COLUMN. DISPERSION S T A B IL IT Y AND SOLIDS CONTENT UNAFFECTED. 9/17/81 000070 SPR000135 EID714052 3. SCALEUP CONSIDERATIONS INTERIM PROCESS: ION EXCHANGE (C o n tin u e d ) NEED TO DEMONSTRATE REGENERATION OF RESIN FOR REUSE. - PREFERABLY WITH SODIUM HYDROXIDE - BACKUPS ARE: ( 1 ) ALTERNATE R E S IN : ALKANOL AMINE IS WEAKER B A S E , EA SIER TO REGENERATE THAN ALKYL AMINE. ( 2 ) STRONGER ELUTING AGENT: CHLORIDE HAS HIGHER A F F IN IT Y FOR R ES IN . HAVE ID E N T IFIE D COMMERCIAL ION EXCHANGE UNIT (CULLIGAN) WHICH SHOULD HANDLE DISPERSION NEEDED FOR I&T PRODUCTS. - REQUIREMENT FOR I&T IS APPROXIMATELY 4500 GALLONS/MONTH - CAPACITY OF UNIT > 2000 GALLONS OF DISPERSION BEFORE REGENE RATION NEEDED. ~ - FLOW RATE OF UNIT IS APPROXIMATELY 3X DEMAND, SO UNIT SHOULD RUN 10 DAYS/MONTH WITH 2 -3 REGENERATIONS. ESTIMATED INVESTMENT AND COSTS A R E: - $2M FOR U N IT, $ 5 -1 OM IN STALLED . - OPERATING COSTS $ 1 5-30M PER YEA R , OR $ 0 .0 2 - 0 .0 4 / L B I&T PRODUCT. CONCLUSIONS ION EXCHANGE APPEARS TO BE A TECHNICALLY F E A S IB L E ROUTE TO REMOVE FC-143 AT MODERATE COST. REMOVAL OF FC-143 TO NON-DETECTABLE LEVELS SHOULD BE ACHIEVED WITH DUAL U N ITS. MEED TO DEMONSTRATE. 9/17/81 000071 SPR000136 EID714053 4. INTERIM PROCESS: ION EXCHANGE [C o n tin u e d ] NEXT STEPS COMPLETE TECHNICAL BA SIC DATA. - REGENERATION WRITE AND APPROVE PROJECT (WITH D ESIG N ). COMPLETE INTERNAL PACKING T E S T . OBTAIN HASKELL RECOMMENDATIONS AND DECIDE TO PROCEED. ORDER EQUIPMENT. DEVELOP TRADE PROYEOUT PLAN. OBTAIN SAFETY AND PRODUCT CLEARANCES. DEVELOP ANALYTICAL AND WASTE DISPOSAL PROCEDURES. INSTALL EQUIPMENT AND CHECKOUT PROCESS. ADOPT. * DEPENDING ON P R IO R IT Y . 9/17/81 TIMING SEPTEMBER OCTOBER OCTOBER OCTOBER OCTOBER-NOVEMBER NOVEMBER NOVEMBER-DECEMBER* DECEMBER-JANUARY* DECEMBER-JANUARY* DECEMBER-FEBRUARY* 00Q072 SPR000137 EID714054 5. INTERIM PROCESS - D IA L Y S IS (U LTR A FILTR A TIO N ) CONCEPT SEPARATE FC-143 FROM DISPERSION AFTER POLYMERIZATION, BY FORCING SOLUTION THROUGH SEMI-PERMEABLE MEMBRANE. FC-143 NEEDED FOR POLYMERIZATION, BUT TRITON ADDED FOR DISPERSION STA B ILITY IN-USE. TECHNOLOGY SEMI-PERMEABLE MEMBRANE SUCH AS CELLULOSE ACETATE PASSES SOLVENT, FC-143 AND TRITONS), WHILE RETAINING TEFLON P A R T IC LE S . DISPERSION I S RECIRCULATED THROUGH MEMBRANE CELL WHICH REMOVES A FRACTION OF FC -143 IN EACH PASS. FRESH TRITON SOLUTION IS ADDED TO MAINTAIN 60X TEFLON SO LID S. STATUS ABCOR CO. RECOMMENDED BY ESD AS VENDOR T E S T S I T E . TES T BEGAN 9 / 9 . SAMPLE ANALYSIS EXPECTED BY 9 /2 5 . CONCLUSIONS D IA LY S IS (OR ULTRAFILTRATION ) APPEARS TECHNICALLY F E A S IB L E ROUTE TO REMOVE F C -1 4 3 . HIGHER C 0 5 T: $25M, OR $2.5M/M0NTH RENTAL. AND INCONVENIENCE OF ADDING TRITON SOLUTION ARE NEGATIVES V S . ION EXCHANGE. NO FURTHER WORK I S PLANNED. 9/17/81 000073 SPR000138 EID714055 6. IN TERIM PROCESS: THERMAL TREATMENT CONCEPT EVAPORATE OR DECOMPOSE FC -143 PRESENT ON IMPREGNATED PACKING YARNS. TECHNOLOGY ( 1 ) YARN PACKAGES ARE HEATED 3 -5 HOURS IN BLEACHING OVENS. ( 2 ) YARNS ARE HEATED ON-LINE WITH HOT ROLLS OR WITH RADIANT HEATING. RESULTS BOTH HEAT TREATMENTS REMOVED ALL DETECTABLE FC-143 FROM YARN. OVEN HEATING (1 9 0 C } REQUIRED < 30 MINUTES WITH YARN, BUT 3-5 HOURS WITH PACKAGES (2 - 1 / 2 HOURS REQUIRED FOR CORE TO REACH OVEN TEM PERATURE). ON-LINE HEATING FA STER, AS EXPECTED: - 99% REMOVAL IN 6 SECONDS ON 276C HOT ROLLS. - 94% REMOVAL IN 4 SECONDS USING 500C RADIANT OVEN. PROBLEMS WITH OVEN HEATED YARNS: - S TIFFN ESS CAUSED BY OVERDRYING WHICH HARDENS DISPERSION COATING. - DISCOLORATION V IA OXIDATION OF TRITON. - PACKING F A ILE D INTERNAL T E S T . (LOSS OF MECHANICAL P R O P E R T IE S .) ON-LINE HEATING PRODUCED LESS STIFFN ESS AND DISCOLORATION THAN OVEN HEATING. - REDUCED TEFLON YARN ELONGATION BY 30% EVEN AT MINIMUM WINDUP TENSION. MECHANISM LITERATU RE SUGGESTS DECARBOXYLATION OF FC-143 YIELD IN G 1 -HYDROPERFLUOROHEPTANE I S MORE L IK E L Y THAN EVAPORATION. ANALYTICAL RESEARCH WORK WITH GAS PHASE INFRARED SUPPORTS DECARBOXYLATION. - C02 AND 1-HYDRO SP EC IE S DETECTED AFTER HEATING. - NO FC-143 (CARBONYL) DETECTED IN O FF-G ASES. 9/17/81 000074 SPR000139 E ID714056 j0NT,bjINTERIM PROCESS: THERMAL TREATMENT /. CONCLUSIONS FC-143 CAN BE ELIMINATED BY HEATING YARNS. PACKAGE HEATING DOES NOT APPEAR F E A S IB L E BECAUSE LONG HEATING CHANGES PRODUCT. ON-LINE HEATING MIGHT BE WORKABLE, BUT PRODUCT CONCERNS (LOW ELONGATION) AND HIGH EQUIPMENT COST (APPROX. $100M) ARE IMPORTANT NEGATIVES. NO FURTHER WORK IS PLANNED. 9/17/81 000075 SPR000140 EID714057 8. NEW SURFACTANT CONCEPT REPLACE FC-143 WITH ALTERNATE SURFACTANT IN POLYMERIZATION R E C IP E . STATUS PRIMARY CANDIDATE IS TELOMER A SULFONATE. c F 3 (C F 2 ) n CH2 CH2 S03 H - IN IT IA L TECHNICAL TESTS PROMISING. - COMPLETION OF TECHNICAL AND EMBRYOTOXICITY TESTS EXPECTED IN OCTOBER. BACKUP IS "N EO S," JAPANESE PHENYL SULFONATE. - IN IT IA L TESTS PROMISING. - EVALUATIONS TO BE COMPLETE 4Q. CONCLUSIONS PPD O P TIM ISTIC OF ID EN TIFYIN G A REPLACEMENT IN 4Q. WE NEED TO CONTINUE INTERIM PROCESS DEVELOPMENT. 9/17/81 000076 SPR000141 EID714058 PROGRAM A . DEFINE TOXICOLOGICAL HAZARDS B . COMMERCIALIZE INTERIM PROCESS RESP. HASKELL 1. DISPERSION PURIFICATION DEFINE F E A S IB IL IT Y OF REMOVING FC-143 BY D IA L Y S IS OR ION EXCHANGE DECIDE ON SCALEUP D EFIN E TECHNICAL BA SIC DATA FOR ION EXCHANGE PREPARE PROJECT COMPLETE INTERNAL PACKING TEST AUTHORIZE PRO JECT, PURCHASE EQUIPMENT AND BEGIN INSTALLATION OBTAIN NEEDED CLEARANCES, COMPLETE TRADE PROVEOUT, AND ADOPT C . COMMERCIALIZE NEW PACKING YARNS WITH RESINS THAT HAVE NEVER CONTAINED FC-143 1 . ALTERNATE SURFACTANT (PRIMARY CANDIDATE) POLYMERIZATION, EMBRYOTOXICITY DEVELOP PROCESS TO MANUFACTURE (C&P) F IB ER S CHECKOUT COMMERCIALIZE COMMERCIALIZE BACKUP ( I F NEEDED) 2 . NON-AQUEOUS DISPERSION COATINGS DEFINE F E A S IB IL IT Y COMMERCIALIZE 3 . NON-TFE DISPERSION COATINGS DEFINE F E A S IB IL IT Y COMMERCIALIZE R&D PPD TIMING 10/81 (DELAYED) COMP. COMP. 9/81 10/81 10/81 11/81 IQ '82 4Q *81 40'81 lQ '82 MID-1982 LATE 1982 HOLD HOLD HOLD HOLD 9/ 17/81 000077 SPR000142 EID714059 10. Column H e ig h t (C o n tro l) 17 cm. 30 40 50 30 + 20 TABLE 1 F C - 143 REMOVAL BY ION EXCHANGE F C -1 4 3 , ppm* 1488 406 211 - 239 166 131 75 - 106 % FC-143 Removed -- 73 85 91 91 94 *B a se d on s o l i d s in d is p a r s io n . 9/17/81 000078 SPR000143 EID714060 CHART 1 COMPOSITION OF TEFLON DISPERSION TEFLON P A R T IC LE S , 0 .1 7 MICRONS WATER TRITON X -100 OCTYL PHENYL POLY (ETHYLENE OXIDE) FC-143 AMMONIUM PERFLUOROOCTONOATE % BY HEIGHT 60 35 5 0 .1 9/17/81 000073 SPR000144 EID714061 12. MACROPOROUS BEADS CHART 2 RESIN TECHNOLOGY TYPE I { AMBERLITE IRA -900) M ch3) 3 TYPE I I (IR A -9 1 0 ) c h 2 c h 2 oh HYDROXIDE ( R E F .) SALICYLATE NITRATE CHLORIDE BICARBONATE ACETATE 9/17/81 RELATIVE A FFIN ITIES TYPE I 1 .0 450 55 22 6 3 .2 TYPE I I 1 .0 55 8 2 .3 1 .2 0 .5 000080 SPR000145 EID714062