Document V3jkyBJLa0J5zd4DaLB5q1Vg4

Texas City, Texas THUMBNAIL SKETCH Hydrocarbons Division PRODUCTS Styrene monomer for use in the plastics, synthetic rubber and surface coating industries. Vinyl chloride and vinyl acetate monomer for use in plastics Industry as transparent sheeting for rainwear, etc., or rigid for tile or hoses. Acrylonitrile monomer for use in the plastics industry and in the synthetic fiber industry for miracle fabrics, Polyethylene polymer for use in the plastics and wire coating industries; used solid in molding and in flexible film for coverings. Methanol for use in production of radiator anti-freeze and formaldehyde. Lactic acid for use in food preparation and in manufacture of doth. PLANT IN BRIEF Acquired in 1946 by purchase from U. S. Government. Started operation in 1943 by Monsanto for U. S. Government's rubber program. No. of employees: Approximately 1,900 (1,150 hourly - 750 salaried) Best safety record: Without lost-time accident: 6,814,618 man-hours Date record ended - January 26, 1962 Unions: Texas City, Texas, Metal Trades Council, AFL-CIO Associated Guards of the United States International Union of Operating Engineers Local 347 Geographical description: 201 acres. 13 miles north of Galveston; 40 miles south of Houston; located directly on Galveston Bay on Highway 146 leading in south from Highway 75. Highway 75 connects Houston and Galveston. Texas City Disaster - April 16, 1947 - caused by the explosion of French liner "Grandcamp" loaded with 2300 tors of ammonium nitrate ot adjacent public dock . 604 employed by Monsanto 451 (approx.) on dur/ at time af disaster 145 killed over 200 hospi toll zed 123 employees of outside construction contractors on duty in the plont 227 total dead at plant $500,000 emergency relief fund appropriated by Monsanto WAR 000001 RSV0032990 r( PLANT HISTORY Monsanto Company Texas City, Texas Hydrocarbons & Polymers Division Monsanto located its plant in Texas City, Texas, to take advantage of the supply of petroleum raw materials, fuel, adequate shipping facilities, and the temperate year-round climate that affords setting up chemical units without protection from extreme weather conditions. The Texas City plant is located directly on Galveston Bay, within the city limits, on the southeast corner of the city. Other industry in the city extends back from Monsanto for several miles and Includes three other chemical companies, three oil refineries, and a tin alloy plant. The population of Texas City is now about 35,000 people -- having grown consistently with the industry of the Gulf Coast. Adjacent to the city is the residential town of La Marque. Texas City is 13 miles north of Galveston, which is directly across the bay from the Monsanto plant, and is 40 miles south of Houston. In November of 1941, Monsanto purchased a 30-acre tract of land in Texas City from the Texas 5ugar Refining Company. The tract was located on the Galveston Bay shore adjacent to the dock facilities of the Texas City Terminal Railway. Much of the land had been filled in from the bay. The site contained miscellaneous office buildings, a boiler house, machinery storage, a machine shop, warehouse and other buildings, all in a questionable state of repair. Plans were started immediately for the construction of styrene production facilities under the auspices of the Denfense Plant Corporation for the synthetic rubber program. The plant design utilized a process developed by Monsanto and actual construction of a 20,000 ton a year plant was started on March 17, 1942. In September of 1942 the government asked for expanded production facilities to produce 50,000 tons of styrene a year. In December of that year-some units were completed and start-up operations were begun. On March 13, 1943, four days less than a year after the start of con struction, the first tank car of styrene left the plant. In August, 1944, additional modification work was done to the units to produce the equivalent of 60,000 ton a year -- 10,000 tons above that requested by Rubber Reserve. Until 1946 allrof the styrene produced was earmarked for the government's synthetic rubber program. However, with the passing of VE Day andVJ Day, war requirements declined rapidly and by late 1945 the plant was operating at a reduced capacity. In mid-1946, Monsanto requested and obtained permission from the government ta utilize some af the surplus capacities of the plant to provide styrene for the expanded domestic plastics market. Throughout the rest of 1946 Monsanto was engaged in negotiating with the government on the purchase of the plant and the beginning of a styrene polymerization unit at Texas City. On October 5, 1946, Monsanto purchased the plant from the government for approximately $10 million. However, the company was still committed to supply some styrene to Rubber Reserve on a reduced schedule. Additional units were placed in operation and modifications were made on existing units, effecting a major increase in monthly styrene production. WAR 000002 RSV0032991 (( 2- - On January 1, 1947, the Texas Division was established as a separate operating unit of Monsanto. The division included 550 employees on 45 acres of land. At the same time, plans were formulafed to increase styrene production through a program to extend over several years. These plans received a material setback on April 16, 1947, at 9:12 a.m. when the French liner, "S, S. Grandcamp," looded with 2,300 tons of ammonium nitrate, exploded at the Texas City Terminal Railway dock adjacent to the plant. The explosion resulted in the total destruction of the plant with an extremely heavy toll of dead ond injured. The impact of the explosion was equivalent to 250 five-ton blockbusters; in the immediate area rhe detonation was almost equal to that of an atomic bomb. A large warehouse -- a steel and brick structure -- was flattened; not o splinter remained upright. The main power plant was similarly crushed. As the blast fanned out, walls of manufacturing buildings fell, windows of the offices and laboratories were shattered, and pipe lines carrying inflammable liquids were torn apart. The explosion's heat ignited the benzol, propane and ethylbenzene pouring out of ruptured pipes and storage tanks. At the' time of the explosion, the plant employed 604 people; approximately 451 of them were then on duty. Of this number, 145 were killed with over 200 being hospitalized with serious injuries. In addition to company casualties, 123 employees of outside contractors were working in the plant; 82 were killed, bringing the death total at the plant to 227 people -- more than one-half of the whole area's total dead. To provide for payments which were beyond the company's legal liabilities, the Board of Directors Immediately appropriated a $500,000 relief fund. This was in addition to many other benefits, financial settlements and assistances given to victims of the disaster. Two days after the explosion, the company president was asked about the future of the plant. He replied -- "We will rebuild the plant; o better plant than was destroyed." True to its word, Monsanto did rebuild . The plant was again on stream and producing ethylene in March of 1948 and the first styrene was shipped out in August. Changes apd modifications in the design made possible the production of styrene well above the original pre-blast figOres. In September of 1950 a major expansion program for Texas City was announced. The expansion included new additions to the styrene plcn.t and the construction of units for the production of vinyl chloride-and acrylonitrile. Construction was actually begun in early 1951 and completed during the latter part of 1952. On October 14, 1952, the first tank car of vinyl chloride monomer v/as shipped to the company's plant at Springfield, Massachusetts. On December 30, 1952, the first tcr.k car of acrylonitrile monomer was shipped to the Decatur, Alabama, plant of the Chemstrand Corporation where it was used in the manufacture of Acrilan, a new synthetic fiber. These events marked the beginning oF the plant's quantity production of all three of the most important monomers in industry -- styrene, vinyl chloride and acrylonitrile -- making Texos City the "Monomer Headquarters of America." Styrene production capacity, now doubled in size, mode the plant one of the world's largest producers of the basic plcstic. WAR 000003 RSV0032992 rr -3- On January 1, 1954, Monsanto reorganized its division along product lines. As a result of this reorganization, the Texas Division was made a part of the Plastics Division. Construction started in 1954 on a major addition to the research laboratories at Texas City. The new building was completed fhot year and housed 16 additional laboratories plus a wing for offices and an auditorium. The Research Department also uses a three-story structure, a part of the original plant. Further major additions to the plant were announced in 1954 with the construction of a high purity ethylene plant, a polyethylene plant, a ship dock and a methanol plant. The high purify ethylene facilities were completed late in 1954, The methanol unit also went on stream in November of 1954. The plant was a joint venture with Heyden Chemical Corpora tion and was based ot Texas City because of the large ocetylene operation there for acryloni trile production, Monsonto's first polyethylene plant went on stream in January of 1955. The new product represented the first polymer at Texas City that was being shipped directly to our customers. The polyethylene plont used existing ethylene units for its basic row material. The ship dock, originally justified on the basis of methonol shipments by Heyden, also permitted tanker shipments of styrene monomer and receipts of benzene. The dock is used by the "5. 5. Chemical Transporter" for these shipments. Construction of boiler wafer demineralizer facilities was begun in mid-1955. This facility for expanded power needs at Texas City was placed in service in December of 1955. Another major expansion wos announced in 1956 with the construction of a multi-million dollar ethylene plant to supplement existing ethylene units. The new units were completed and went on stream in April of 1957. Ethylene is a basic chemical at Texas City for the production of styrene, vinyl chloride and polyethylene. The Research Department began work in 1956 on the addition of a two-story wing to the structure finished in 1954. The new building houses laboratories, testing facilities and offices and was completed during the summer of 1957. An expansion for the divisional Engineering Department was completed In 1956 with the finishing of new office quarters in an existing structure that had been used as a wotehouse. The r new quarters include offices and conference rooms for the Engineering Department. Since 1956, styrene, vinyl chloride, acrylonitrile and polyethylene have undergone major capacity expansions. Texas City's styrene plant is now the world's largest single facility for the production of that product. In the spring of 1961, ground was broken for a huge complex at Chocolate Boyou for the production of hydrocarbons. Multiple pipelines connect that plant with Texas City. WAR 000004 RSV0032993 r { -4- Texos City, along with Chocolate Bayou and Lion Oil, became a part of the Hydrocarbons Division in October of 1961, when the company combined the operations of petroleumbased chemicals into one division. The division was reorganized in 1965 to include severalmanufacturing locations of the former Plastics Division and wos renamed Hydrocarbons and Polymers Division. Construction began in 1962 on a multi-million dollar unit that added a new product to Texas City's line. The plant makes vinyl acetate monomer. Monsanto now owns 280 acres of land at Texas City. This is broken up into 201 acres which is the plant site and 79 acres about three-quarters of a mile north of town which is used to obtain fill for construction and to dispose of sludge from water treating facilities. The plant has 120 buildings with a total floor space of approximately 538,267 square feet. Most of the production operations are of semi-open construction. Besides the manufacturing units and their service departments, Texas City also has large research and engineering deportments. The plant currently employs around 1,900 people 1,150'are hourly employees and 750 are salaried employees. Monsanto is the second largest employer in industralized Galveston County. Texas City is served by railway freight, deep water anchorage for sea-going vessels and the intra-coastal canal for barges. Other chemical industries in Texas City include Union Carbide Chemicals Company, Smith-Douglass Company and AMOCO Chemicals Corporation. The refineries are American Oil Company, Marathon Oil Company and Texas City Refining, Inc. Wah Chang Corporation, manufactures of tin alloy products, are also located in Texas City (previously the Tin Processing Corporation). Production qt Monsanto's Texas City plant is concerned primarily with the plastics and synthetics industry. The plant takes such raw materials as natural gas, petroleum by-products, air, chlorine and ammonia and processes them into colorless liquids or opaque solids. The liquids are "monomer" and include styrene, vinyl chloride and acrylonitrile.. The solid, a "polymer", is polyethylene that is shipped as tiny pellets to customers. Styrene is to the plastics industry what steel is to the auto industry. It is found in synthetic rubber, paints, waxes, polishes and tires. It turns up as a high-impact plastic in dishes, toys and boats. Styrene also goes into wall tiles, fishing rods and automobile bodies. The end uses are limitless. The end use of vinyl chloride monomer is also extremely varied. Vinyl chloride can be either a rigid or flexible plastic. It goes into transparent sheeting for rainwear, shower curtains and as upholstery Fabrics. It is also used in garden hose, floor tile and adhesives. Vinyl acetate is also produced at the Texas City plont. Vinyl acetate is used to make vinyl plastics and emulsions. Acrylonitrile monomer is primarily used in the synthetic fiber industry. From acrylonitrile is spun Acrilan by the Chemstrand Corporation, a wholly owned subsidiary. Acrilan is a soft, wooly fiber that finds its way into dresses, sweaters, blankets, suits, work clothes and rugs. The miracle fiber is resistant to wrinkles, stains, mildew, rot and acids, and is completely washable. WAR 000005 RSV0032994 f \ -5Polyethylene plastic, both high and law density, is manufactured at Texas City. Polyethylene is used widely os o wire coating and in squeeze bottles for cosmetics, etc. The soft, pliable plastic also makes safe toys and molded tableware. Used in a transparent sheet or film, it . packages frozen foods and protects products. One of the "non-plastic11 products at Texas City is methanol. It is used principally as an automobile radiator anti-freeze and in the manufacture of formaldehyde by other plants. Our newest plant at Texas City makes synthetic lactic acid -- both food and technical grade. Food grade lactic acid is used as an acidulant in green olives, dairy products, carbonated beverages and other food products, and as an ingredient in emulsifiers for baker/ products. Technical grade lactic acid is used in fanning of hides and textile finishing and as a chemical intermediate. Texas City is a highly-automated plant. The manufacturing units are run by a few operators and engineers who operate production from control houses that are a maze of control panels, dials and instruments. An idea of the degree of automation is seen with the fact that out of the 1 ,'l-40 hourly employees, approximately 440 of them are maintenance personnel who work only one shift. The other 700 hourly employees consist mainly of production personnel who work three shifts round-the-clock. This aufomatian makes moss production of chemicals and plastics possible at low market prices. Another "record" for Texas City has been its safety performance over the yea's. For faur different years the plant won the President's Safety Trophy for having the best record in the entire company, retiring it permanently at Texas City. The best record without a lost-time accident is 6,814,618 safe man-hours worked; Monsanto is a safety leader in the Galveston County area. 6-15-67 WAR 000006 RSV0032995 GENERAL INFORMATION PLANT LOCATION The plant is located at the southeast corner of Texas City. Total plant area is 358 acres of which 243 are in use for manufacturing. This total acreage includes 80 acres northeast of Texas City in the Amburn Tract, 18 acres south of the plant at Swan Lake, and 18 acres of peripheral property adjacent to the plant. The Amburn Tract property is the site of our fire training area and a lagoon used to decant river mud from the plant water treating clarifier. The Swan Lake property is used for non-hazardous waste disposal. ORGANIZATION Manufacturing operations at Texas City are administered by the Fibers and Intermediates Company, which operates the acrylonitrile and acetone cyanohydrin units, site utilities, and environmental control operations. The Polymer Products Company is a guest operator of six manufacturing units - ethylbenzene, styrene, oxo alcohol, phthalic anhydride, phthalate esters, and tertiary butylamine. The Industrial Chemicals Company is a guest operator of the acetic acid-and methanol manufacturing units. The Agriculture and Nutritional Products Company is a guest operator of the lactonitrile, lactic acid, and iminodiacetic acid manufacturing units (IOA is currently mothballed). Other Manufacturing functions at Texas City include MlSO, Accounting, Personnel , Plant Engineering and Distribution. The Personnel department includes the medical dispensary, industrial hygiene laboratory, plant security, and cafeteria. Plant. Engineering includes instrument, electrical and mechanical maintenance, project construction groups with a large central shop facility, purchasing, stores, an engineering design group for plant projects and a material /mechanical technology group. The Distribution department includes material handling, production planning and scheduling, and the quality assurance laboratory. The Technical Center at Texas City includes a process engineering group which sup ports capital project development, research and development laboratories and a CEO project support group. The Texas City plant has historically used contractors to supplement Monsanto craftsmen and to execute capital project work. For the last few years, the numoer of contractor supplement to maintenance has gone down significantly. Monsanto Maintenance now works in our Plant Capital Projects group which in the past has been total contract manpower. We have provided an average of Monsanto craftsmen per day to Capital Project work. Overall the contractor headcount has been down during 1983 and 1984 excest for turnarounds that have occurred. WAR 000007 RSV0032996 'ferX-fe. Pl/caJT- Page 2. employment The plant employs 1364 people in the following classifications: Wage 855 Salaried: Manufacturing, Exempt Non-exempt 263 101 Process Technology, Exempt Non-exempt 81 47 Corporate Engineering, Exempt Non-exempt 12 2 MPP Distribution, Exempt 3 Total 1364 Plant operating and craft wage personnel are represented by the Texas City, Texas, Metal Trades Council, an association of thirteen craft and operating unions. Cafeteria workers are represented by Local 347, International Union of Operating Engineers, AFL-CIO. Security guards are represented by the Associated Guards of the United States. MAJOR PRODUCTS The major finished products of the plant are as follows: Acrylonitrile used for fibers, nylon and structural plastics. Acetic Acid used in making cellulose acetate and vinyl acetate monomer, and for fiber and agricultural production. Acetone Cyanohydrin used for manufacturing polymethyl methacrylate plastic. Iminodiacetic Acid used as a raw material for Roundup. Synthetic Lactic Acid used in the food industry as a preservative. Methanol used m the production of anti-freeze, formaldehyde and acetic acid. Oxo Alcohol used in manufacture of phthalate esters. Phthalic Anhydride used in plasticizers, polyesters, alkyd resins,,dyes and pharmaceuticals. WAR 000008 RSV0032997 Page 3. Phthalate Esters used in food-grade plastics, floor tile, film, fabrics and adhesives. Styrene Monomer used for plastics, synthetic rubber, and surface coating matarials. Tertiary Butylamine (TBA) used as intermediate for the rubber and tire industry. TEXAS CITY PLANT HISTORY 1941 ... Thirty-acre tract purchased under auspices of Oefense Plant Corporation. 1942 ... Construction started on Styrene monomer unit and supporting Ethylene units. 1946 ... Plant purchased by Monsanto from United States Government. 1947 ... Ship explosions in harbor completely destroyed plant; reconstruction of Styrene and Ethylene units started immediately. 1951 ... Construction begun on Acrylonitrile, Hydrogen Cyanide, and Vinyl Chloride monomer units plus supporting Oxygen and Acetylene units; major expansion in Styrene. 1952 ... Started up Oxygen, Acetylene, Hydrogen Cyanide, Acrylonitrile and Vinyl Chloride monomer units. 1954 ... Construction begun on Methanol and low density Polyethylene units plus high-purity Ethylene units. 1955 ... Started up TBA unit and low density Polyethylene. 1956 ... Construction begun on new Ethylene units. 1957 ... Started up new Ethylene unit. 1959 ... Tract of 68 acres adjacent to plant acquired and filled by dredging for future plant expansion. 1962 ... Construction begun on nigh density Polyethylene unit. 1963 ... Started up Lactic Acid unit. 1969 ... 22 acres adjacent to south side of plant acquired for new deep water docking facility and product storage area. Construction started on new Methanol and Acetic Acid units. Construction begun on Phthalic Anhydride and Esters units. WAR 00000? U RSV0032998 Page 4. 1970 ... Started up new Methanol, Acetic Acid and Esters units. Acetylene, Acrylonitrile, Vinyl Acetate and old Methanol units shut down and dismantled. Construction begun on Oxo Alcohol and new Styrene units. 1971 ... Started up EVCL unit. Started up Phthalic Anhydride and Oxo Alcohol units. 1972 ... Part of low density Polyethylene shut down. Started up new Styrene unit.Started up new primary waste water treatment. 1973 ... Signed contract for secondary waste water treatment at Gulf Coast Waste Disposal Authority (GCWOA) regional treatment facility. 1974 ... Started up new Ethylbenzene unit. Construction begun on new Acrylonftrile unit. EVCL unit shut down. 1975 ... Construction started on Acetone Cyanohydrin unit. Low density Polyethylene unit shut down and dismantling started. Started up GCWDA secondary treatment facility. 1976 ... Acetone Cyanohydrin started up. Low density Polyethylene dismantling complete. 1977 ... Started up new Acrylonitrile unit. "Hydrogen Cyanide unit shut down. 1978 ... Chrome-Zinc removal project completed. Stormwater diversion project completed. 1979 ... Major energy conservation project completed. Boiler fuel conversion project completed. WAR 000010 RSV0032999 Page 5. 1980 ... Acrylonitrile Exposure Reduction project completed. Ethylene plant shut down,1 dismantling. Started up GCWDA regional disposal facility for hazardous solid waste. 1981 ... Evaluation of coal utilization. Benzene Exposure Reduction project completed. Benzene pipeline from Shell and Exxon put on line. 8.7 acres south of plant leased. CO^ line from Air Products to Methanol completed. 1982 ... AN conversion to Nitto catalyst. Demonstration of Phthalic Anhydride energy conservation project. Startup and shutdown of IDA II. High density Polyethylene shutdown. 1983 ... Install packing in EB/SM splitter column. Texas City site study. 1984 MAJOR PROJECTS Cogeneration evaluation. Acetic Acid debottlenecking. Methanol reformer rehabilitation. Complete cooling tower consolidation. cV* IT / ,/'*' WAR 000011 .L RSV0033000 6rtv PLANT WORK COOE 001 Ethylene \$0 'CP- -v-uP ial Feed: Propane Products: Hydrogen, Methane, Acetylene, Ethylene, Propylene, Cracked Oil Solvents: OimethyI fo^pmide, Freon 11 (CCI|F) 002 6 003 Alkylation Feeds tocks : Ethylene, Benzene, HCl, Ethyl Chloride, Aluminum Chloride, Aluminum Powder, Caustic {50%) Products: Benzene, Ethylbenzene, Polyethylene, Flux Oil (Heavy ends) 00i 6 005 Ethylbenzene Distil lation Feed: Alkylate Products: Benzene, Ethylbenzene, Polyethylene, Flux Oil (Heavy ends) Heat Transfer Fluid: Dow therm A (Oiphenyloxide, Diphenyl) 006 Lead Pot Cracking Feeds: Propane, Lead (Unit #6 was dehydro Products: Hydrogen, Methane, Ethylene, Acetylene, at one time) Propylene, Cracked Oil 007 6 008 Oehydro Mixture & Distillation Feed: Dehydrogenation Mixture (DM) Products: Benzene, Toluene, Ethylbenzene, Styrene, Flux Oil (Alkylation Tars) , Styrene Tar, Sulfur, tert-Butylcatechol 0)0 "i qfcc Ethylene .<> ifS"7 foi.* Oil NS I Feed: Field Condensate Pyrolysis Products: Hydrogen, Methane, Ethane, Acetylene, Ethylene, Allene, Methyl acetylene,, Propane, Propylene, Butane, Butenes, Butadiene, Pentane, Pentenes, Isoprene, Pentadienes, CyclopentadIene, Hexenes, 8enzene, Toluene, Xylenes, Styrene, Dicyclopentadiene, Methylstyrenes, Indenes, Cs Aromatics, Napthalene, Methylnaphthalenes, Pyrotysis Pitch Product Cuts: BTX, Resin Oil, Naphthalene Concentrate, Resin PR Processing Solvents: Oimethy1foramide Refrigerant: Freon II (CCljF) Cooling Tower Chemicals: Cl2, H2S0i, , NaNOj. Na2Cr207. Na^SOj, NajPQi., 3nCr0i, Feeds : 2, L-Dinitrophenol , HCl , NaOH Products: 2-Amino-4-Nitroohenol , Sodium 2,4-0 i nitrophenoxide (NSI Salt) 013 & Q\k Ethylbenzene Feeds : Ethylene, Benzene, Aluminum Powder, HCl, Ethyl Chloride, NaOH, Anhydrous AIC13 Products: Benzene,Ethylbenzene, Polyethyl benzenes, FJux Oil (Heavy Ends), Aqueous A J C13 Muriatic Acid (HCl) Cooling Tower Chemicals: Chlorine, Na2S0i, 3nCr0u WAR 000012 RSV0033001 2- - 0l5 6 016 Styrene Feeds: Ethylbenzene, Dehydrogenated Mixture, Shell 105 Iron Oxide Catalyst (Fe203+ K2C03+Cr203) Flux Oil (Alkylation Heavy Ends), Tert- Butylcatechol , 2, *#--Dtni trophenol, NaOH, HCl ' Products: Benzene, Toluene, Ethylbenzene, Styrene, Sodium 2,4-Dinitrophenoxide, 2 Amino- 4-N1trophenol, Styrene Tar (Polymer Flux Oil), Hydrogen, CO, COz, Ethylene 017 Oxygen Solvents: TricresyIphosphate, Methylene Chloride, Freon 12, Santocell, Vermiculfte 018 019 Acetylene HCN (Hydrogen Cyanide! Feed: Methane Products: Ha, C0`; Acetylene, Higher Acetylenes, Soot Solvents: Butyrolactone, N-MethyIpyrrolidone, Toluene, Diesel Oil Feed: NHj, CHi,, H2S0(,, Platium-Rhodium Gause Cooling Tov<er Chemicals: SO2, 3nCr0i,, Na2S03 020 Acrylonitrile (am--1) / J jloi1 ST SOt r^4 1 ^J. fu j^r -7 }~IO /72? Feeds: HCN, Acetylene, HCl - J catW*1 Catalyst: CuiClz, KC1, NH<,C1 Products: Acrylonitrile, NH , HCN, Acetonitrile, Crotonitrile, Croton Aldehyde, Acrolein, Methyl Acrolein, Monovinyl Acetylene, Diviny- acetylene, Cyanobutadlene, Lactonitrile, Methyl vinyl ketone, Crotonic Acid, Acetaldehyde Inhibitors : p-Nitrosodiphenylamine, p-Amino- phenol, p-Methoxyphenol, Hydroquinone 021 VCM Feeds: Acetylene, CI2, Ethylene, HCI, Styrene (Vinyl Chloride Oxide C-"10' Monomer) Catalys t: HgClj, Silica, CuClz, Alumina, 11 13/ M j 1 \^j(,q _ 'fr Ifit-iv HjPOi. (QCt P roducts: Vinyl Chloride, Ethylene Oichloride, CTrich1oroethane, Ethyl Chloride, Ethylene Vfij-r CovtfJ Dichloride, Trichloroethanes, 2 Chlorobutadiene, _- Chloronated Tars (Heavy Ends), bis(chloroethyl) ether(smal1), Chloral 02^ Waste Treatment Liquids: Acetic Acid Sump Sludge, Chlorinator' Sump Sludge, HeOH Heavy Ends, Oxo Alcohols Recycle, Acetic Acid Bottoms, HCN, Dock Collections, Vacuum Truck Skimmings, TBA Wax, Flare Sump Cleanouts, Paint Waste Solvents, Recycle Styrene. Pilot Plant EMA Waste, Lube Oil, Mob 11 therm WAR 000013 RSV0033002 025 027 029 031 033 034 035F 035P Tert-Butyl Amine (TBA) -3" Feed: HCN, Isobutylene, H2SQ1,, 50? NaOH. Llm< Products: T.-Butylalcohol. TBA. Sodium Formanl Poly Isobutylenes (TBA Wax). Lactonitrile (LN) Feeds: HCN. Acetaldehyde. NaQH. H'iPOi. Products: Lactonftrile Acetone Cyanohydrin (acy) Feeds: Acetone, HCN. NaOH, H?S0u Product: Acetone Cyanohydrin Methanol Feeds: 3n Chromite Catalyst. KMnOu. H2SOU. Pd -- AWOs Catalyst, Co, Coz, H2 Products: Dimethyl ether, Methanol, hiqher alcohol? (heavy ends) Lactic Acid (LA) Feeds: Lactonitri1e. Methanol, HCl. Methylchloride Products: Acetaldehyde, NHa. NHwCl . Methyl aceta te Lactic Acid, Methyl lactate Catalyst: ion Exchange Resin (Strong Base) Vinyl Acetate Feeds: Acetylene, Acetic Acid. Methanol, Styrene Oxide, NaoH, Hi$0<, Catalyst: Zn Acetate, H2SO1* Products: Acetaldehyde, Progenyl Acetate. Vinyl Acetate, Acetic Anhydride Inhibitors: Diphenylamlne. Hydroquinone Heat Transfer Oil: Mobil Therm High Density Polyethylene Finishing Feeds: Ethylene, Ca(0H)2 Dilaurylthiodipropionatc (DLTDP); N, N-bis(2-hydrovyethyl]-C\2-CifiAlkylamine (Armostat-34o), Polyethylene Glycol , glycerolmonostez Zinc Stearate, Diphenyl phosphite, Tetrakis [Methylene 3"(3* * 5 di-t-butyl-4 hydroxyphenyl) propionatelMethane (lrganox 110) ; N/I-bis [hydroxyethyllaurylamide (MASA); Oxylate Ester (0AE 4,4'-th5obs-(6-t-butyl-m-Cresol) (Santonox)(2, 6--01t-Butyl-p-Cresol (lonol)`Distearylpentaerythri t phosphite (Weston 618)I 2-Hydroxy-4-N-Octoxy1 benzophenone (Cyansorb UV-53H)/2,4-Dtt!5"butylphen^ 3,5-dl-t-butyl-4-hydroxyl benzoate (AM340) Product: Polyethylene High Density Polyethylene Powder Feeds: Ethylene, Hydroqen, Acetylene, Methanol, Butanol, Hexane, Ethylene Oxide, Hydroxyl amine. Lime, Butene-1 Catalyst: Dtisobutyl aluminum hydride, TiCK Product: Polyethylene WAR 000034 RSV0033003 f .- f ' 01,1 6 042 Low Density Polyethylene Feeds: Ethylene, Acetylene, propargyl aldehyde. Vinyl Acetate, Propane, Isobutylene, Propylene! Erucyl Amide, 2, 6-DI-t-butyl-p-Cresol (lonl){ 44l-thlobis- ($-tert-butyl-m-cresol (Santonox); 1, 3, 5 tr? Methyl-2 ,4,$-tris `[3,5 d i-t-buty-l- 4-hydroxy benzyl] benzene (ionol) Catalyst: Oxygen, Dl-tert-butyl peroxide, Lauryl peroxide, Benzoyl Peroxide, Oiatomaceous earth (celite 219) Product: Polyethylene 044,045,04$ Methanol 048 Qxo-Alcohol Feeds: Hethane, Hi,CO, COj, Hydrazine, NaOH, HCl, Feron 12, NaOH, Na3PQ3, NasPOi,, Ethylenediamlne * tetra acetic acid, (EDTA) ,nltri lotrlacetic acid (NTA Product: Methanol, Ethane, C3-C6 higher alcohols Catalyst: ZnO, CuO, AI2O3 Feeds: CO, (Cs, C(, Cm, 2-Olefins); Hi Products: C7, Cs, Cu, Aldehydes; C7, C9, Cu Formates; C7, C*, Cu, Alcohols, Cs, Ca, Cm Hydrocarbons; Keavyends Catalyst: CriOj, CoO 050 Acetic Acid Feeds: CO, Methanol Catalyst: Rh13, III Products: Acetic Acid, Methyl todide, Acid, Methy Acetate, Heavy Ends, [2 Propionic 051 AH-5 Feed: NH3, Propylene Catalyst 4j: CoMoOi,, NiMoOi,, BIMoQt,, K3PO3, Fe203 Products: HCN, Acyrlonitrile, Acrylic Acid, Acrolein, Crotonltrile, Acetic,Acid, Succinohitri1e Fumaronitrile, Oxazole, 3-Cyano-pyridIne, poly HCN Boiler Chemicals: ZnCrOi,, Aqueous AlCls, Na2S03 NaOH, SO2, Ka3P0h,. Sodium Hexameta phosphate Inhibi tor: HzSOn, Hydroquinone, p-Methoxylphenol (HQ,), Mercaptobenzoth i ozo 1 e 053 Phthallc Anhydride Feed: Orthoxylene -(PA) - Catalyst: ViOs on Silica, SO2 Products: Maleic Anhydride, Citraconic Anhydride, 0-Tolulc Aldehyde, Benzoic Acid, Phthalic Anhydride Tars Bo tier Chemicals: NaOH, HzSOi., NaiSO: 060 Ethylene Vinyl Feeds: Vinyl Chloride, Ethylene, Acrylamide Chloride Inhibitor: Hethoxyphenol, Butyrated Hydroxy Toluene, Fe(NHw)3 (S0,,)2, (NHJjSjOj,NaOH, Sodium Lauryl Sulfate, Tetra Hydrofuran, Ethylenediaminete Acetic acid, Soduim formaldehyde sulfoxylate Product: Ethylene-Vinyl Chloride Polymer OPo Power l2 NaiPOu, Sodium Hexameta Phosphate, Cl 2, NaCr207, NajSOi, NaOH, Muriatic Acid, ZnCr0,, Lime, HzS0u, FeS0,,, Aqueous AlC13 ,> [}.' WAR 000015 RSV0033004 P6 LI L2 L3 W1 W2 -5- Material Handling Acetic Acid, Acrylonitrile, Ammonia, AcetaldehycAcetone Cyanohydrin, Acetone, AICI3 (Anhydrous), Aluminum Powder (Scrap), C7, Ca, Cn, Alcohols, Butyrolactone, Benzene, Butanol, Butenes, Chiori' Condensate, Oi Undeaylphthalate, Oecane, Diesel Oil; Ethyl Chloride, Ethybenzene, C7-C11 Ph'thali: Esters, Hydroquinone, HCN, HiSOs, Hexane, Flux C: Light Ends (oxo alcohols), Lactic Acid, Lactonitr Anhydrous HC1, Isobutylene, N-Methyl Pyrrolldone, Diphenylamtne, p-Methoxyphenol (mq), Methanol, Mineral Oil, Naphthalene, Naphthalene Concentrate NaOH, Phenol, Propargylaldehyde, Phthalic Anhydr: Propane, Propylene, Polyethylene, SA8, -Sunnybom, Sulfur, Styrene, Tert-Butylamine, TBC, Vinylchlor Vinylacetate, o-Xylene, Toluene, Cfi, Cg-CiaOIef ir Petrochemicals Lab Solvents: CH2Cl2, ChCl3, Celt,, Trichloroethylene Acetonitrile, Pyridine, Dimethyl foraraide, Acetone Tetrahydrofuran, Dioxane, Ethyl Ether, Benzene, Toluene, Ethanol Acids: HC104, HC1, HI, HzSO^, HjPO*, HNO3, Aceti: Acid Bases: NH40H, NaOH, KOH, Na2C0j, NaHCO? Reagent Chemicals; Numerous but in small amounts with little contact. Products 5 Raw Materials: All that have been use: in the Plant Polymers Lab Solvents'. ChCl3, Hexane, Xylene Product: Polyethylene Research Process Technology Lab Main Warehouse Solvents: CH2CI1, CHCI3, CCI4, Trichloroethylene, Acetonitrile, Pyridine, Dimethylforamide, Acetone, Tetrahydrofuran, Dioxane, Ethyl Ether, Ethanol, Butanol, Methanol, Benzene, Toluene, Xylenes, Ethylbenzene Acids: HC1, Hi, HNOj, HiSou,.HiPOw, Acetic Acid Bases: NH4OH, NaOH, KoH, Na2C0j, NaHCOj Regent Chemicals: Numerous Products 6 Raw Materials: All that have been used in plant So Iven ts: MC-9, Vinyl thinner, Expoxy thinner, Kerosene, Lacquer thinner. Vacuum pump oil, Insect cide, CCl1*, Cutting Oil, Kobiltherm, Lub Oil P. E. Warehouse Raw Material Additives: Oilauryl thiodipropionate (OLTDP) N N-Bi5(2-hydroxethyl)~al Ry1 amine (Armoste 340) Polyethylene Glycol, glycerolmonostearate, Zinc Stearate, Tetrakis (Methylene 3~(31, 5 di-t" butyl-4-hydroxyphenyl) Propionate) methane (I rganc HO), Dipherlyl phosphite, N N-bis (hydorxyethyl laurylamide (MASA), Oxylate ester (OABH) , 4,4'- thobis-(6~5-butyI-m-cresoi) (Santonox), 2,6-01" t-butyl-p-cresol (lonol), 0?steary i pentaerythrityc posphite (Weston 6l8), 2-Hydroxy-4-N-octozy 1 ben- __ zophenone (Cyansorb UV-S3a) , 2,4-0 i**t=buty l pheoy^ WAR 000016 -// RSV0033005 El EZ E3 Eh N-l N-2 HOI M02 M03 H0<< HO 5 HO 6 H07 H08 HO 9 H11 Ml 2 -6- 3, 5"d5-C-butyl-k-hydroxylbenzoate (AH 340), Butanol, Erucylamlde Technical-Office General Plant Vapors Technical-Plant Unit Vaport 6 Liquids - Non-Technical-Offlee General Plant Vapors Non-Technical-Plant Unit Vapors & Liquids Non-Exempt-Off 1 ce General Plant Vapors Non-Exempt-P1 ant Unit Vapors & Liuqids Abestos Workers Abestos, Fiberglass Bollermakers Welding, MC-9 Cleaning Solvent Carpenters Butane, Trichloroethylene, Contact Cement, Acetone Electrical Workers HC-9, CCK, Methylene Chloride, Polychlorinated6, Phenyls (PCB's), Mineral oil Instrument Hen MC-9 CCK, Hehtylene Chloride, Ethanol, Benzene Ironworkers Welding, MC-g Cleaning Solvent laborers NS 1, Used Carbon, Shell 105 Iron Oxide Catalyst, Cu-CriOa Oxo Catalyst, CoO/NiO Oxo Catalyst, Zinc Oxide, Dept. 2*4 Ash & Slag, Dept. 2k Chloronator Sludge, Ion Exchange Resins, Olatomaceous Earth, Sand, Naphthal'ene Waste, Styrene Polymer, Barrier Resin Scrap, EMA Waste, Acetylene ^ Esters AN cr. Filter Cakes Cooling Tower Sump Sludge, Dept. 19-25 Suipp Sludge Dept. 513 Filter Screening, Flare sumps Machinist Cutting Oil, Kerosene, HC-9, CCl^, Welding Painters- Silica from Sandblasting, Vinyl Thinner, Epoxy Thinner. Lacouer Thinner. Kerosene, Paint Pipefitters Welding, Seal Lead, Epoxy Glue, HC-9 Truck Drivers/ Helpers Gasoline WAR 000017 RSV0033006 56 Es ters 1 K-13 Janitors CAF Cafeteria Additional Plant Work Code Feed: Phthalic Anhydride, Cj-Ci* Alchols Cata1yst: Oxalic Acid, Stannous Oxalate, Diatomaceous Earth Products: C?-Cxi Phthalic' Esters Ammonia Water, Waxes, Household Cleaners, Research and Petrochemical Laboratory Trash, Commode Cleaner (HC1, Hi PO4 n-Alkyl (C12 - C18) Dimethyl Benryl Ammonium Chloride) . Fantastik Cleaner^ Floor Disinfectant (contains Isopropyl Alcohol, Pine oil, Soap, Potassium 0-benzyl P-chlorophenate), Clorox (NaOCl), Potassium Hydroxide, DranSo (NaOH), Commode Cleaner (Hcl, H1PO4, n-Alkyl (Ci2-Ci8)0imethyl Benzyl Ammonium Chloride), Dip-It Oxygen Bleaching Agent. ' v>j; WAR 000018 (/ RSV0033007