Document VGQznev53NXw84R5kzYVYZvKq

MONSANTO COMPANY Organic Chemicals Division Standard Manufacturing process For AROCLORS Department g46 Supersedes: Process description for the manufacture of Aroolors,. Dated: December 17, 1962. Prepared by: L. 0. Cole, f.T.S. Engineer CONFIDENTIAL INFORMATION 'This frooess Is the property of Monsanto Company, and the recipient is responsible for its safekeeping. It contains confidential information of Monsanto company whloh must not be reproduced, revealed to unauthorized 'persons or sent outside the company without proper authorization. Either retain in a Beoure file or return to the Offloe Services Department. HONS 05*760 MONSANTO COMPANY Monsanto, Illinois SAFETY REVIEW COMMITTEE Uft\lc 3-us- -(' March 10, 1965 Messrs: P. E, Heielcr - WGK H. C, Carder - WCK Process Holders Title; *JR Bucfenftlln - Org. Res, 'll, LV'Clobbard - Org, Res. Tentative Amendment No. MAM Tentative Amendment No. "A" to the Standard Manufacturing Process for Aroclor (Dept. 246, WOK) dated 7/20/64, Objective; Alter present plant distillation system and operations for a plant test. Plant test will indicate equipment needs and ability to produce improved quality (stable) Aroclor. Present Practice; Two Aroclor Distillation Systems are run in parallel. The two systems are continuous ly fed crude Aroclor from the 42 Blow Tank, The distillation is a straight take-over operation. When a run of one type (1242, 1248, e.tc,) is completed (80, 000-500, 000#) a final boil down is conducted in No, 2 still and the bottoms are dropped. The boil down material is combined with the previously distilled material and pro cessed to finished product. The bottoms are drawn off and sold as Montar or discarded. Following the boil down and bottom's drop the stills are ready for the next product run. Proposed Procedure; Run the two stills in series. Continuously feed the No.l still with crude Aroclor and use this system to pre-heat the entire feed and to distill off a low-boiler fraction (up to 10% of feed). Continously feed the No. 2 still from No.l still pot. Collect the intermediate fraction in No. 2 receiver and process as in normal operation. At the end of the run (4-5 days) boil down and drop bottoms. Do not combine the boil down (high-boiler6) with the intermediate fraction. The low boilers from No.l receiver and the high boilers from the boil-down will be isolated in a storage tank, if possible. HONS 054761 Tentative Amendment "A" March 10, 1965 If they pass non-electrical Aroclor specifications, they can be used as such. If the total amount has to be discarded because no storage is available, or because t hey are out of specification, the cost would be $3, 000 based on total product costs. Specific operating conditions for the stills will have to be determine d in the field by cut and try methods. Justification: Foreign competition appears to be capable of producing Aroclor which is more stable than that presently made by Monsanto. An improvement of product stability is necessary to protect our market position, Laboratory data* indicates that the distillation operation has a significant effect on product stability. These data indicate that product stability can be improved by: 1. Removing an unstable low-boil fraction 2. Preventing entrainment 3. Preventing contamination by high-boilers or 'bbil down This test will evaluate our ability to control the plant distillation in the three areas mentioned above, with existing equipment. Failure of the test will indicate that more drastic revisions to the existing equipment will be needed b approximate laboratory conditions. Comments: The production rate will be limi ted by maximum vapor and heat loads that can be sustained in the entrainment and condenser systems on No. 2 still. In the past 55,000tf/day have been attained in these systems. The upper limit is not presently known. Duration: The test duration will be 4-5 days. If desired operation conditions cannot be obtained during this interval the te6t will be cancelled or revised. Prepared by: *WGK PR&D Reports J-62, 2/15/65 and J-78, 3/ 8/65 D. R. Middleton MONS 054762 Tentative Amendment "A" Approvals: P. E. HeiBler vmd 4 A. Mullendore 3 March 10, 1965 HONS 054763 MONSANTO COMPANY Monsanto, Illinois July 12, 1965 Messrs: P, E. Heisler - WGK H, C, Carder - WGK Process Holders R. W. Bucknell - Org. Res. H, L. Hubbard * Org. Res. Tentative Amendment No, nBH TITLE; Tentative Amendment No. nBM to the Standard Manufacturing Process for Aroclor (Dept. 246, WGK) dated 7/20/64, OBJECTIVE: Run two plant tests using revaporised Cl2 and dilute (25 mole %) C)2, as feed stock for Aroclor 1242 production. PRESENT PRACTICE: The Dept, 246 Chlorinators are batch charged with biphenyl (Bid)). The Bi0 is then chlorinated by continuously feeding "Snift" gas to the chlorinator mass until the desired specific gravity is reached. The "Snift" Gas is a mixture of CI2 (from DeNora & Hooker Cells) Hz, N2, 02, CO? and trace amounts of organic impurities. The Cl2 concentration is in the. range of 75 * 95 mole % and varies with operations in the Cl2 depart* menle. PROPOSED PRACTICE (Two Plant Tests, 1242 Aroclor) 1. A plant chlorination test will be run using revaporized Cl2 from Dept. 232 as the Cl2 feed stock. Due to limited capacity of the revaporizing facilities in Dept. 232, we will probably be able to run only two chlorinators at a time, making a total of 5 - 6 chlorinator batches and processing through the remainder of the system as normal. Necessary samples and measurements will be taken to determine effect of concentrated and impurity free Cl2 on Aro clor stability. This material will be treated as normal production as it passes the routine plant controls. 2. A plant chlorination test will be run using revaporized Cl2 diluted to 25 mole % with dry air as Cl2 feed stock. This test will be limited to 2 chlorinators due to dry air capacity, making a total of 5-6 chlorinator batches and processing through the remainder of the system as normal. Necessary samples and measurements will, be taken to determine effect of dilute and impurity free Cl2 on Aro clor stability, This material will be segregated from normal electri* cal grade 1242 Aroclor, It will be used for non-electrical 1242 if it passes specification. MOWS 054764 Tentative Amendment No. "B", JUSTIFICATION: Foreign competition appears to be capable of producing Aroclor which is more stable than that presently made by Monsanto. An improvement of product stability iB necessary to protect our present U..S. market position and for possible expansion of foreign sales. These tests will provide information a6 to the effect of contaminants in chlorine, and the possibility of local overchlorination due to concentration effects, COMMENTS: For the revaporised Cl2 test the production rate will be limited to about 32, 000#/day for a duration of 1 - 1 1/2 days. For the dilute Cl* test the rate will be limited to about 11,000#/day for a duration of 3 days. SAFETY: No increase in safety hazards is forseen in these two test runs. APPROVALS: Prepared by: .9 /P. IJullLltZ D. R. Middleton "P, E. Heisler D, E, Harris 7-a-tS- jj jvMiiisf'cJtfVC- iMtf SAFETY REVIEW COMMITTEE: HONS 054765 MONSANTO COMPANY Monsanto, Illinois September 1, 1965 Messrs: P. E. Heisler - WGK H. C. Carder - WGK Process Holders R. W, Bucknell - Org. Res. H. L. Hubbard - Org. Res. Tentative Amendment No. __ C TITLE: Tentative Amendment No. C to the Standard Manufacturing Process (Dept. 246, WGK) dated 7/20/64. OBJECTIVE: Run plant test using chlorinator without catalyst basket, PRESENT PRACTICE: The Dept. 246 batch chlorinators (31 diam. x 16' high) are batch charged with biphenyl, which is chlorinated with snift gas. At the present, each chlorinator has a catalyst bed. The catalyst bed is 2'3" in diam, and 8' high and consists of 1 1/2" pipe nipples, 2" long. PROPOSED PROCESS (1242 and 1260 Aroclor) Remove the catalyst bed from one chlorinator and run three to five 1242 and three to five 1260 batches in that chlorinator following standard operate ing procedures, except without the catalyst bed. The test material will be kept separate from other production and will be used only if it is equivalent to normal production aroclor, according to routine analyses. During the test batches the chlorinator off-gas will be sampled and analysed for chlorine,, to check chlorine utilization of the chlorinators without the bed. The purpose of the catalyst bed is to provide iron, which is chlorinated to ferric chloride, the reaction catalyst, It is standard operating procedure to charge 0.05% by weight ferric chloride to each batch. Ferric chloride will, of course, be added to the test batches, JUSTIFICATION: During operation the catalyst becomes plugged with tars and ferric chloride and it is probable that only a small portion of the iron of the bed is available for utilization, Also, the plugged bed hinders chlorinator circulation and probably leads to hot spots in the chlorinator. There is a problem of cross contamination from batch to batch with the bed, which results in an excessive amount of overchlorinated products. HONS 054766 Tentative Amendment C 2 JUSTIFICATION*. (Pont'd.) During 1956 there were severe problems with aroclor stability. One of the problems was a lack of a consistent analytical method for checking stability. Previous to that time the catalyst bed was relied upon to supply ferric chloride and ferric chloride, per se, was not added. One of the results of the stability problem was the addition of ferric chloride to each chlorinator batch, to assure that sufficient catalyst was available. Since that time analytical methods have improved and any unstable aroclor produced would be detected immediately. The removal of the catalyst bed, then, improves chlorinator operation by increased circulation, elimination of hot spots, and prevention of contamina tion. The addition of ferric chloride provides sufficient catalyst. Any unstable aroclor produced would be detected immediately by the present routine analyses. SUPPORTING DATA : It is reported in St. Louis Research Report Nos. 1640 and 2072 that a minimum level of 0, 03% FeClj is necessary to produce stable aroclor, No mention is made of the need for iron, and none was used in the lab chlorinators, SAFETY: No increase in safety hazards is anticipated. QUALITY: Work is in progress to improve aroclor quality (stability). It is anticipated that the removal of the basket will not harm quality but, if anything, will improve it due to improved circulation,, elimination of hot spots in the chlorinators, and elimination of cross-contamination from batch to batch. DURATION OF TEST Three to five 1242 and three to five 2260 batches will be made without the catalyat bed, If this material is equivalent to normal production material, according to routine analyses, the chlorinator without the catalyst bed will be used for normal operations, and this amendment incorporated As a process revision. If the test material is not equivalent to normal production the bed will be replaced. MONS 054767 Tentative Amendment No, C 3 COMMENTS: This plant lest wbuld normally involve some loss of production. The pre sent aroclor stock position is such that it is anticipated that it will be nec essary to run only three of the five chlorinators during September, Also, some repairs to be made during September will require removal of the catalyst bed from the No. 3 chlorinator. September, then, is an ideal time to run this test. Prepared by: n^<- . W. G. KVamp/r APPROVALS: )4 __ _______ (j, A, MuTlendore ef~ 7 Date emc SAFETY REVIEW COMMITTEE J&i -iS 9-3 HOWS 054768 MONSANTO COMPANY Monsanto, Illinois SAFETY REVIEW COMMITTEE m'ZA-65 S'jO'-y /o-v-L~ October 20, 1965 Messrs: P. E. Helsler - WOK H. C. Carder - WOK Process Holders R. W. Bueknell - Org. Res. H. L. Hubbard - Org. Res. Tentative Amendment No. "D" Title: Tentative Amendment No. "D" to the Standard Manufacturing Process for Aroclor (Dept. 246, WOK) dated 7/20/64. Objective: Evaluate potassium carbonate as a replacement for lime In the Aroclor distillation system. Present Practice: Aroclor Is distilled In two parallel systems, continuously fed from the No. S blow tank. At the start of a run (1242, 1248, etc.) 200 lbs. of lime (calcium hydroxide) Is added to each still pot. At the end of a run (260,000-500,000 lbs.) bottoms are dropped and the cycle Is repeated. Proposed Procedure: Segregate the two distillation systems at the Btart of a 1242 run, To one system, add the normal amount of lime to the still pot and proceed normally throughout the run. To the second system, substi tute 200 pounds of anhydrous potassium oarbonate for the lime. Dis till away from the potassium carbonate for a minimum of two days. The product distilled from the potassium carbonate will be analyzed by routine tests before It Is combined with normal production material. If the product deviates fy&m norafil In any adverse >Way, "It will be/lso^ted ahd will/not be/sold as electrucal eyadev sH* MONS 054769 Tentative Amendment "D" October 20, 1969 Justification: The presence of a baBe during distillation serves two known purposes: It neutralizes free acid, and it reacts with the PeCls present. It is also thought that the base can react with some unstable Aroclors, converting them to a more stable form. Recent WOK PRfcD laboratory data indicates that distillation from K2C03 increases the stability of the high boiling fractions of Aroclor 1242 (low boil and mid fractions are essentially unaffected). If this proves to be the ease, it would indicate that using K2C03 and making a simple low boll cut may be a practical way of making a stable Aroolor. Safety: No increase in safety hazard is anticipated. No unusual effect was seen in laboratory distillations using K2C03. Comments: No production Iobs will be involved since WOK Dept. 246 is presently running at only 75# of demonstrated oapaclty. Prepared by: APPROVALS: \ E. Heieler k WTjBuc kn e 11 7f . A, Mullendore Date Date HONS 054770 Date /V .. Jatt/tn-' MONSANTO COMPANY Monsanto, Illinois December 3, 1965 Messr P. E. Heisler - WGK H. C. Carder - WGK Process Holders cc. R. W. Bucknell - Org. Res H. L. Hubbard -Org. ReB Tentative Amendment No. MEn TITLE Tentative Amendment No. ME" to the Standard Manufacturing Process for Aroclor (Dept. 246, WGK) dated 7/20/64, OBJECTIVE Produce more stable Aroclor 1242 by chlorinating without a catalyst basket in the chlorinator and processing as normal. Produce more stable Aroclor 1242 by chlorinating without a catalyst basket in the chlorinator and processing it through the still system with potassium hydroxide added in place of the normally used lime (calcium hydroxide). Provide sufficient product, produced as above, for testing by customers, PRESENT PRACTICE Biphenyl (Bi0) is chlorinated in the chlorinators which contain catalyst baskets. Previously the basket furnished FeClj catalyst for the reaction. Presently (Bince 1957) sufficient amount of catalyst, needed to produce stable Aroclor, is added to each chlorinator when batch charged. At the beginning of a product (1242, 1240, etc.) run 200 pounds of lime . is added to each still. The purpose of the lime is to tie up FeClj and neutralize HC1 in the crude. PROPOSED PROCEDURE Produce 8 - 9 batches of 1142 in No, 5 chlorinator with the catalyst basket removed. This has been done previously as per Tentative Amend ment No. MC". Process half of this crude material through the remainder of the system as normal, and drum it off from the finished product tank. Process the other half through No. 1 still system, but substitute potassium hydroxide (0. 06% of crude charge) for the lime in the still. Drum this . material off from the finished product tank, thus producing approximately . 1, 000 gallons of each type of test material to be used as samples for evaluation by electrical grade customers. Any excess test material will M0NS 054771 , PROPOSED PROCEDURE (Cont'd.) be sold as non-electrical grade 1242 providing it passes all specifications. JUSTIFICATION From previous plant tests, the Aroclor produced in a chlorinator without the catalyst basket was equivalent or better than normal material. By removing the baskets, hold-up and cross-contamination are reduced. Results of PR fe D laboratory studies indicate more stable Aroclor (i.e. 0. IS ppm Cl by thermal chemical chlorides) can be made by addition of KOH to the still pot and stripping off the first 1.2% of the low boilers. Plant equipment will not permit this type of fractionation, but an improve ment over normal production is expected. SAFETY____ No increase in safety haaaards is anticipated. No unusual effects were seen in the laboratory distillation using KOH, Normal precautions in handling KOH will be followed. APPROVALS: D, R. Middleton P. E. HeiIer . A. Mullendore fr o^uxj'i ^ i Prepared by: D. R, Middleton ' '.w<r Date t rihf q&te D. E. Harris P.u/. R, W, Bucknell Date Date ' A&AvTT'^'' V.... SAFFEETY REVIEW COMMITTEE \ &&& -x----f--/*T*' 7*s*---r- f---r- / / /, J L.if~ .... <aUM________ mA MOWS 054772 Monsanto, Illinois .May 10, 1965 'AMENDMENT DISPOSITION .Tentative Amendment No. "A" to the Standard Manufacturing Process for Aroclor(Dept.246, WOK) dated 7/20/64, Tentative Amendment No.''A" is dated 3/10/65. .TO; Messrs: P. E. Helsler - WOK H. C. Carder - WOK D. E. Harris - WOK J. J. Luecken - WOK R. W. Bucknell - Org. Res, H. L. Hubbard - Org. Res. J. A. Mullendore - Oen. Off. Process Holders - e/o P. J. Prader - WOK This memo 1b to Berve as a disposition of the subject tentative process amendment. The purpose of the amendment was to alter the present plant distillation system and operations for the duration of a plant test, The purpose of the plant test was to indicate equipment needs and ability to produce Improved quality (stable) Aroclor, No improvement In stability was realised and the need for fractionation was demonstrated.* The distillation system was returned to normal operation as specified in the Standard Manufacturing Process. The subject amendment should be recorded in the Standard Manufacturing Process, but not incorporated as a process revision. 08.0, D. R. Middleton Technical Services Dept. vmd *WGK TSD Report - Aroclor: Improve Electrical Grade Quality, 91370:3193, Report No.l, dated 4/14/65. HONS 054773 DISTRIBUTION SHEET 3, Technical Information Center St. Louie Reeearch 2. Technical information Center St. LouIb Researoh >, Security Pile (Records Center, St. Louis Oeneral Offloes) 1). Director of Manufacturing/Technical Production Manager Organic Engineering 5. Production Oeneral Superintendent/Production Supervisor - W.O.K. C. Plant Technical Services 7. Extra <? P, 8. Extra 9. Extra ($? 10. Extra Copy MONS 054774 1. II, III, IV. TABLE of CONTENTS Page SYNOPSIS OF PROCESS........................................................................................1-2 FLOW SHEETS............................................................................................................ 3 A. COMPLETE PROCESS FLOW SHEET B. CHLORINATION REACTION STEP C. AERATION AND DISTILLATION C, BLENDING, FILTRATION AND STORAGE PROCESS IN DETAIL ................................................. A. NOMENCLATURE AND BATCH DATA B. CHLORINATION REACTION STEP C. AERATION AND DISTILLATION D. BLENDING,FILTRATION AND STORAGE E. BY-PRODUCT HYDROGEN CHLORIDE H 5-6 7 7-6 8 COMMENTS ON PROCESS...................................................................................... 9-12 A, CHLORINATION STEP B, AERATION & DISTILLATION C, BLENDING & FILTRATION D, GENERAL APPENDIX A - EQUIPMENT LIST............................................................... 13-21 APPENDIX B - FINISHED GOODS AND RAW........................................... 22 MATERIAL SPECIFICATIONS APPENDIX C - PHYSICAL AND CHEMICAL DATA....................................23-29 APPENDIX D - UTILITIES...............................................................................30- APPENDIX E - PERSONNEL.....................'.....................................................33-36 APPENDIX F - PACKAGING AND SHIPPING..............................................37-38 APPENDIX G - MATERIAL BALANCE.............................................................39-1)1 APPENDIX H - ATMOSPHERIC DISCHARGE AND .......................... . . . MS WASTE DISPOSAL APPENDIX I - PROCESS CONTROL PROCEDURES................................. .1)3 APPENDIX J - SAFETY AND TOXICITY DATA...................................... M APPENDIX K - BACKGROUND......................................................................... 51 APPENDIX L - TIME CYCLES......................................................................... 52 APPENDIX M - QUALITY CONSIDERATIONS ........................................... 53-59 APPENDIX N - MISCELLANEOUS.................................................................... 60-63 HONS Dept. 246 - Process DescrJ.ptJ.on AROCLOR 1, SECTION I SYNOPSIS OF PROCESS Aroolor 1b a trade name used to designate ohlorlnation products of biphenyl, biphenyl high boilers, or mixtures of the two. Liquid Aroolors are produced by chlorinating biphenyl to 21, 52, 42, 48, 54, 60, and 62)6 chlorine content. Chlorination above 65# yields a solid product at normal temperatures. Liquid Aroclors are Identified by four digit numbers: The last two digit numbers represent the chlorine content (percentage by weight), and the first two numbers represent the Aroclor condition (orude or distilled). Crude Aroclors Btart with the prefix 11 whereas distilled Aroclors start with the prefix 12. For example, Aroclor 1242 Is a dlBtilled chlorinated biphenyl containing 42$6 chlorine. The first process step in the manufacture of Aroclors Is a chlorina tion reaction. Biphenyl ( 0-0) and chlorine (Cl*) gas In the presence of a Ferric Chloride (FeCls) catalyst are reacted to form a chlorinated aromatic compound. Hydrogen chloride (HC1) gas Is liberated during this reaction and piped to the muriatic acid department. The exact chemistry of biphenyl chlorination Is unknown. 'Many isomers are formed. A schematic representation of biphenyl chlorination 1b as follows: n varies 5.05--> 6.75 120-170C. t n Cle Fedls Cln ,VV n HC1 + -/56.200 n Btu. BIPHENYL M.V). - 154 CHLORINE M.W. >= 71 AROCLOR HYDROOEN M.W.-(257.1- CHLORIDE 595.6) M.W. = 56.5 HONS 054776 Dept, 246 - Process Description 2- AROCLOR SECTION I SYNOPSIS OF PROCESS The second process step is the aeration and distillation of the crude Aroclor. Dry air is blown through the crude Aroclor for a period of two hours or more. Aeration removes most of the free hydrogen chloride. Distillation of crude Aroclors is done under vacuum auto matically controlled with the controller pre-set between 30 - 50 mm Hg. abs, to obtain the best performance. Distillation of crude Aroclor separates residue*lime, ferric chloride, and tars from the finished product, The third process step includes blending, filtration, and storage of Aroclors. Approximately 0,1 - 0.2% by weight of Attapulgus earth is added to the distilled Aroclor, The mixture is agitated and filtered to the finished product tank. The purpose of the Attapulgus earth is to absorb moisture and chloride ion to improve the electrical properties of the Aroclor, During the filtration of distilled Aroclor, 2-16 oz, samples of the finished product are taken to the laboratory for control analyses. If the control analyses pass specifications, the batch is transferred to a storage tank. This process description will describe the production of Aroclors 1242, 1248, 1254, 1260, 1254 Hyiene mix, and 1262. . MONS 05477? Dept. Z46 * Process Description ( AROCLOK SECTION II FLOW SHEETS This section contains the following flow sheets, 1, Complete process flow sheet. I, Chlorination Reaction Step 3, Aeration and Distillation 4, Blending, Filtration and Storage, < MONS 054778 HONS 054779 whs ' nnwi 0*9 1 FSI0- AERATION Ao DISTILLATION HONS 054780 k w HONS 054781 Dept, 246 - Process Description H. AROCLOR SECTION III PROCESS IN DETAIL A, Nomenclature and Batch Data Aroclor is a trade name used to designate chlorination products of biphenyl, biphenyl high boilers, or a mixture of the two. The physical properties vary from light free flowing liquids to crystalline and non crystalline solids, depending upon the degree of chlorination and the * composition of the raw materials. Chlorinated biphenyl yields a liquid product of increasing viscosity up to and including 63% chlorine. Chlo rination above 63% yields a solid product at normal temperatures. A numerical system of nomenclature, consisting of four digits, has been developed for identifying the various Aroclors. The first digit denotes the aromatic raw material used in the chlorination step, The figure 1--- indicates 100% technical grade biphenyl. The second digit denotes whether or not the product is distilled. The figure -1- indicates undistilled product, and the figure -2-- indicates a distilled product. The last two digits of the nomenclature system denote the approximate percent age by weight of chlorine contained in the finished product. For example, Aroclor 1242 is a distilled chlorinated biphenyl containing 42% chlorine. Manufacture of all liquid Aroclors is essentially the same. Batch data are listed below: Type Aroclor 1242 1248 1254 1260 1262 Biphenyl Charge 4000# 4000# 4000# 4000# 4000# Chlorination Time 10 - 12 hr. 10-12 hr. 14-17 hr. 16-20 hr. 16-22 hr. Specific Gravity of Crude Weight of Crude Batch . 1.349-58 at 65*C 6670# 1.408-18 1.498-508 1.558-69 1. 580-90 at 65*C at 65 "C at 90'C at 90 'C 7580# 8450# 9600# 10,600# Weight of Distilled Batch 6330# 7200# 8040# 9100# 9850# Tons of 100% by-product HC1 per Batch 1.24 1.43 2.27 2.47 2.70 Theoretical Molecular Weight 257.7 292.6 326.6 369.5 395.6 t MONS 054782 Dept, 246 - Process Description AROCLOR__ 5. SECTION III PROCESS IN DETAIL B, Chlorination Reaction Step Chlorination of biphenyl is the only process step where a chemical reaction takes place. All other Aroclor process operations are mechanical. The starting raw materials for Aroclor production are biphenyl and chlorine gas. Biphenyl is received in 6, 000 and 10, 000 gallon tank cars from Anniston, Alabama, The biphenyl in the tank cars Is a solid mass because the crystallising point of biphenyl is 68.7*C. Steam must be applied to the tank car coils to melt the biphenyl. It is necessary to melt a vent hole through the solid mass of biphenyl by insertion oC a hairpin steam coil through the tank car dome before applying steam to the tank car coils. The vent hole avoids a pressure bulld-up in the bottom of the tank car and possible damage to the car. When the biphenyl is completely melted, it is sampled for crystallising point and moisture content and unloaded through the tank car standpipe by air pressure to the 25, 000 gallon storage tank. Dry air is used to unload the biphenyl cars to keep the biphenyl free from moisture. The flash point of biphenyl is 112*C, Chlorine gas is received in a 4 inch pipeline from the chlorine depart ment. In order to facilitate operation of the chlorine liquefaction system, MeniftM gas with a purity of 75-95% (the remainder being air) is transferred from the chlorine department. The normal pressure of the chlorine gas in Department 246 is 20-25 psig. Biphenyl (4000#) is charged into each chlorinator from the measuring tank. The biphenyl charge in the measuring tank can be regulated by valves at different overflow levels. The fotir overflow levels on the measuring tank permit biphenyl charges of 1800, 2800, 3600, and 4000 ^pounds. The measuring tank is equipped with an agitator and circulating pump. Two pounds of ferric chloride (0.05% of charge) are charged into the measuring tank for each batch. The charge from the measuring tank is pumped through the circulating line to the chlorinators. Chlorination is carried out in five chlorinators . Each chlorinator i6 three feet in diameter by sixteen feet high, and constructed of steel. Each chlorinator has a catalyst bed which is 21 3" in diameter by 8 feet high. The catalyst bed consists of 1 1/2 inch diameter by 2 inches long pieces of pipe which are similar in nature to raschig rings. The biphenyl charge is heated to 120*C. or higher before chlorination is started. After charging the chlorinator, circulation of the charge is started before the chlorine feed is begun to maintain an even distribution of the ferric chloride catalyst. M0NS 054763 Dept, 246 AROCLOR ProceBS Description 6. SECTION III PROCESS IN DETAIL B. Chlorine gas from the chlorine department passes through a Brink mi6t eliminator and evaporator before entering the chlorinator. The . mist eliminator removes most of the impurities, and the vaporator insures that all of the chlorine is gaseous. The purified chlorine gas is admitted to the bottom of the chlorinator through a distributor plate (Sparger) and passes through the catalyst bed. A chlorinator temperature less than 170*C. should be maintained during the chlorination reaction to avoid sublimation and subsequent condensation of biphenyl in the off-gas system. Each chlorinator is equipped with a Brink mist eliminator. The purpose of the off-gas mist eliminators is to trap entrained particles of Aroclor and biphenyl. The chlorination temperature in the chlorinators is controlled by auto matic chlorine gas flow regulation to hold the temperature within + 5*C, The chlorination temperature must be at least 120*C. at the beginning of the batch and no more than 170*C. to finish off a batch. The normal batch temperature is 150*C. The louvers of the air-cooled heat exchanger located in the external circulating line of the chlorinator are positioned ( such that the batch temperature will remain between 120*C. and 170*C. The exact batch temperature will depend on the chlorine flow rate which will fluctuate to maintain a batch temperature of 150*C, The louver adjustment is manually controlled by a hand valve located in the control room. The temperature of the batch is recorded at four different points: (1) in the center of the chlorinator, (2) just above the chlorine Bparger in the chlorinator, (3) at the discharge of the chlorinator pump, and ^ (4) at the discharge of the air-cooled heat exchanger. Point 1 is alarmed for high temperatures, and point 4 is alarmed for low temperatures. As a safety device, a high temperature sensing element is positioned at point 2 to shut off the chlorine gas flow if the reaction temperature exceeds 190*C. The batches are continuously circulated at an average flow rate of 200-220 GPM from the bottom of the chlorinator, up through the air-c&a>led heat exchanger, and back into the top of the chlorinator over the catalyst bed. Chlorine feed up to a maximum of 1500 pounds per hour i6 fed into each chlorinator through a flow recorder-integrator which is alarmed. The aero return integrator measures the total amount of chlorine gas flow per batch at any given time and will shut off the gas flow when the desired pre-set pounds of chlorine has entered the reactor. The average chlorine feed rate is 1000 pounds per hour. Progress of the chlorination reaction is checked periodically as needed after a pre-set amount of chlofine gas as measured by the recorder-inte^ grator passes into the chlorinator. The degree of chlorination is measured by determining the specific gravity of a sample taken from the circulating line. More frequent gravity checks are made when approaching the end of chlorination. HONS 05*784 Dept, 246 - Process Description '( AROCLOR SECTION III PROCESS IN DETAIL C. Aeration and Distillation When chlorination Is complete, the crude Aroclor Is pumped Into number two blow tank (Capacity 2000 gallons). The crude Aroclor Is aerated in the #2 blow tank for two hours or more with dry air. Aeration of crude Aroclor removes most of the free hydrogen chloride. Crude aerated Aroolor is tmrusferred from the i^2 blow tank to the #1 blow tank. The #1 blow tank is used as a crude Aroclor feed tank to the stills. Crude aerated. Aroclor Is transferred from the #1 blow tank to vacuum stlllB through an automatic control valve which maintains a constant level In the stills. Under normal conditions the automatic feed to the stills Is shut off after distilling about 75,000 pounds of Aroclor. (This Is equivalent to filling 7 still receivers). The still is then boiled down until a temperature 0 difference between the still coll inlet and outlet approaches 40 C. At this point distillation Is discontinued and all but a small heel of the residue is drawn off to drums and discarded or sold as Montar. The still Is Immediately recharged with crude Aroclor and 200 pounds of lime Is added directly to the still pot. Hydrated lime is received in 50 pound bags. The lime neutralizes any residual HC1 In the still liquor and prevents sublimation of ferric chloride during the distillation period. Distillation of Aroclors Is done under vacuum automatically controlled. The best performance Is obtained at a steady vacuum which can be pre-set by a controller between 50-50 mm Hg. Abs. Natural gas is used to heat the coll of the Aroclor still furnaces. The pressure of the gas burner ('eclipse, st. 108.5, 2", #568, 600,000 BTU/uir. ) Is adjusted as needed for production requirements. The normal gas pressure Is 2-5 pslg. - D. Blending, Filtration, and Storage When the still reoelver Is filled, the distilled Aroclor Is pumped to the blend tank (2000 gallon capacity). After two fillings of the receiver tank have been pumped to the blend tank, approximately *10 pounds of attapulgus earth Is added to the distilled 1242 Aroclor. All other Aroclors are earth-treated with 20 pounds of Attapulgus earth. Regular Attapulgus earth Is received in 50 pound bags. The mixture Is agitated and filtered to the finished product tank (2000 gallon capacity) through a 56 Inch stainless steel Sparkler Kilter. The Attapulgus earth 1b roasted at 250C. for a minimum of four hours In a Grleve-Hendry drying oven before addition to the blend tank. The purpose of earth heat treatment Is to remove any moisture In the earth and activate It. The Attapulgus earth absorbs water and . Ionic Impurities. This Improves the electrical-quality properties of the Aroclor. HONS 054785 Dept, 246 - Process Description 8. AROCLOR SECTION III PROCESS IN DETAIL D, Blending, Filtration, and Storage (Cont'd,) The filter press is cleaned after about 5-7 batches or as needed. During the filtration, 2-16 oz. samples are taken to the laboratory for control analyses. If the control analyses pass specifications, the batch is trans ferred from the product tank to a storage tank. After several batches have accumulated in the storage tank, the contents of the tank are mixed, and composite samples are taken for lot analyses. Three underground (15, 000 gallon) tanks and fi ve above-surface (each 20, 000 gallons) are available for storage of the finished products. The blend tanks, finished product tanks, and Aroclor 1242 and 1254 storage tanks are blanketed with nitrogen. The pressure of the nitrogen gas is 10 psig. Nitrogen blanketing maintains the electrical properties of the Aroclors, 'The Aroc.lorB from the storage tanks *re drummed, pptnped to tank oars, pumped to tank trucks; oV transferred to Department A**246 or B-246 mixing tanks for the production' of Pyranole, Interteens, or Pydraul A-200. Batches of Aroclor 1254-mix are mixed in the #1 blend tank. This opera tion consists of a mi/ of 10% xylene,and 90% Aroclor 1254. Xylene is received in 55 gallon drums. The flash point of xylene is 85*F, Mixing, sampling and drumming of 1254-mix is accomplished directly from the blend tanks. After the blending operation, the blend tank must be cleaned, The bottom outlet of the tank is opened and the tank is cleaned out with live steam and then blown with air. E, By-product Hydrogen Chloride The by-product hydrogen from the chlorinators is collected in a common pipeline header and flows to the central HC1 absorption unit to manufacture Muriatic Acid in Department F-218, If Department F-218 is unable to handle the off-gas, it may be sewered at Department 246 by passing through a Haveg S-K drowning jet. The removal of HC1 from the off-gas concentrates the original quantity of hydrogen and air to a point well with in the explosive limit. Therefore, it is essential to either dilute thi$ gas going up the vent stack or increase its velocity past the flame propogation rate (15 ft,/sec.). This is accomplished by introducing a sufficient quantity of steam into the vent stack. HONS 054786 Dept, 246 - Process Description AROCLOR SECTION IV COMMENTS ON PROCESS CHLORINATION STEP A, Raw Material Yields Biphenyl and chlorine are reacted to form a chlorinated biphenyl called Aroclor. The yields on biphenyl and chlorine vary with the type of Aroclors produced. Each particular type of Aroclor has its own standard yield factors. Yields are not reported for the individual type on Aroclor each month. An average yield is reported monthly and compared with standard and theoretical yields which are calculated according to the quantities of the various Aroclors produced during the month. Standard and theoretical conversion factors used in computing Chlorine and biphenyl yields are listed below. STANDARD CONVERSION FACTORS AROCLOR CHLORINE H/H Product BIPHENYL #/# Product 1242 1248 1254 1260 1262 1232 1254 Xylene . 9032 1. 0323 1.6130 1. 2903 1.3333 0.6882 1.0452 0.6180 0.5580 0.4978 0.4368 . 0.4163 0.7216 0.4480 THEORETICAL CONVERSION FACTORS AROCLOR CHLORINE H/4 Product BIPHENYL #/# Product 1132 - 1232 1142 - 1242 1148 - 1248 1154 - 1254 1160 - 1260 1162 - 1262 1254 - 10% Xyle ne 0, 6400 0.8400 0.9600 1.0800 1.2000 1,2400 0.9720 0.6891 0.5919 0.5357 , . . 0.4754 0. 4147 0.3976 0.4279 MONS 05476? Dept, lib - Process Description 10. AROCLOR SECTION IV COMMENTS ON PROCESS CHLORINATION STEP B, Capacity The monthly production capacity of Department 246 is 1,700, 000 pounds {l, 400, 000 pounds is expected by August 1, 1964) of Aroclors on a 7 day per week basis. The capacity of the chlorinators is a function of the following variables. * 1, Batch Cooling Rate - Chlprination of biphenyl is an exothermic reaction which produces 510 BTUS per pound of chlorine gas unde rgoing a reaction with biphenyl. Biphenyl can be chlorinated as fast as the exothermic heat can be removed from the batch and maintain a batch temperature of 150*C. 2, Chlorine Flow Rate - the reaction time decreases as the Chlorine flow rate increases. The chlorine flow Tate is approximately 1000 pounds per hour per chlorinator, A maximum chlorine flow rate of 1500 pounds per hour per chlorinator can be attained if desired. The ( concentration of chlorine in the Msnift" gas is another factor control ling the rate of chlorination. 3, Catalyst - The chlorination rate increases when ferric chloride catalyst is added to the charge. The best results are obtained when the biphenyl charge contains ,05% ferric chloride catalyst. C. Quality Some of the factors which affect Aroclor quality are as follows: 1. Temperature According to research experimental results, the chlorinator temperature must be greater than 120C. at the beginning of the chlorination reaction to produce stable Aroclors,2 2, Catalyst - Good contact is necessary to produce stable Aroclors, It is suspected that agitation and circulation of the reactants improve the effectiveness of the catalyst. The catalyst is also responsible for the chlorine positioning on the biphenyl molecule. Ferric chloride catalyst may be responsible for producing the desired end product, Results of research work concerning catalyst and isomeric distribution are given in Appendix N. ( HONS 05<i788 Dept, 246 - Process Description n. AROCLOR SECTION IV COMMENTS ON PROCESS CHLORINATION STEP C, Quality (Cont'd.) 3, Raw Material Purity - The purity of raw materials can affect the quality of Aroclore Doth directly and indirectly. In a direct manner, impurities which are ionic lessen the resistivity of Aroclors. Dis tillation of crude Aroclor separates most of the ionic impurities; however, minute impurities can be carried over to the receiver tanks. Attapulgus earth can remove the remaining impurities in most instances. If any ionic impurities remain after the earth treatment, the resistivity of the Aroclors will be low because such impurities will conduct electricity even in minute concentrations. In an indirect sense, impurities such as sulfates in the chlorine gas, will poison the ferric chloride catalyst and thus unstable Aroclors will be produced. The chemistry and mechanism of the catalyst poisoning are not known for certain. ( AERATION AND DISTILLATION Steam is not applied to the coils of the blow tanks when aerating Aroclors 1142 and 1146. This prevents the loss of Aroclor vapors. Eighty.psig steam is applied to the coils when aerating other Aroclors. High moisture may be removed effectively by blowing the crude Aroclor with dry air. Vacuum trouble on the stills is usually caused by flashing of product, air leaks, plugged vacuum line6, or improper functioning of the vacuum jet6. Flashing can usually be stopped by operating the still at a slower rate or increasing the flow of cooling water to the vapor condenser. Vacuum trouble can be traced systematically from the jets and usually isolated. High color and entrainment will result from overheating (around 25*C. . above normal distillation temperature) Aroclor, faulty operation of the distillation step, or boiling down the still too far. (Tars will carry over). The "tail - end" still fraction (tars) is a possible source of unstable Aroclors, ( HONS 054789 Dept, Z4fe - Process Description 12. AROCLOR SECTION IV COMMENTS ON PROCESS BLENDING AND FILTRATION Attapulgus Earth is added in the blend tanka to reduce moisture and inorganic chlorides as well as improve electrical properties. If batches do not meet specification (See Appendix B), redistillation may be necessary. The Attapulgus Earth is roasted for 4 hours at 250*C. before addition to the blend tanks, HONS 054790 Dept, 246 - Process Dc.cription 1?. I AROCLOR APPENDIX A EQUIPMENT LIST This section contains an equipment list with each piece of equipment listed by Item Numbers in a consecutive numerical sequence. Miscellaneous items of Dept, 24b such as Instruments have not been assigned Item Num bers. Equipment without Item Numbers is not included in this equipment list. All equipment of Dept. 24b will have Item Numbers assigned some time in the future. This equipment list should be expanded as additional Item Numbers are assigned. Item No. Equipment Name Equipment Number Description 101 Biphenyl Transfer 19-0582 Pump 66-3930 Taber vertical submerged cent, pump, size C-3, 2 1/2M inlet, 2" outlet. Connection bronze except shaft which is monel. Motor is 3 HP, 1800 RPM. 102 Biphenyl Storage 21-2210 Tank ( Tank purchased from Rogers and Wrigler. Capacity is 25,000 gallons. 10" 6" DIA x 40' 6" long. 3/8" plate shell, Design pressure is 50psi, 103 Biphenyl Head 21-0767 Tank 16-7225 Tank made by Graver. Dwg. C-799. Steel tank 4' 6" ID x 5' 6" str. side, dished heads, shell 3/8", top head 3/8", and bottom head 3/4" with 1/2" jacket over it and ending 9" up on tank side. Welded throughout. Test of tank is 60# and jacket i6 105# hydro, pressure. Mixer is Mixco Model N33G75, gear driven propeller. Motor is 440/3/60 TEFC, 1725 RPM. 104 Biphenyl Feed 66-7224 Durco Horiz. Cent' pump. 2" inlet, 2" outlet. Cap. 100 GPM Motor is 7 1/2 HP, 1760 RPM 105 Chlorinator #1 21-3261 ( 106 Chlorinator #2 21-3245 Tank made by Nooter, Dwg. E-880. 3' ID x 16' long with pig. head, Shell 3/8" and head 7/16" thick. 3/16" jacket over lower half of tank. . Same as Item No. 105. MONS 054791 Dept. 8*t6 - Process Description 1*). ARPOLOR APPENDIX A E&UIPMENT LIST (Cont1d) Item No. 107 108 Equipment Name Equipment Number Chlorlnator 21-3251 HZ> Chlorlnator 21-188? Description Tank made by Leader Iron Works. Otherwise, (Same as Item No. 105. Same as Item No. 107. 109 Chlorlnator 21-1*132 Same as Item No. 107 no $1 Mist Eliminator 15-0581 ill 118 113 n't 115 #8 Mist Eliminator Mist Eliminator f"t Mist Eliminator Mist Eliminator Chlorine ~ Mist Eliminator 15-0582 15-058? 15-058*1 15-0586 81-*I0*I2 116 Chlorine 38-5*187 Vaporizer 180 181 Knookout Chlorlnator 19-*t305 (S'! Pump 66-8109 Tank made of carbon steel. Element made of carbon steel. Design pressure is 50 pslg. and design temperature is 300F. Same as Item No. 110. Same as Item No. 110. Same as Item No. 110. Same as Item No, 110. Tank made by Alpha. Carbon steel construction. Coded tank. Element ?16 stainless steel. 15" Dla, glass fiber inverted type. Design pressure is 50 pslg and design temperature is ?00F. Chlorine vaporizer made by Armstrong Company. 8 5/8" OD x 11' long. Carbon steel construction. Chlorine side designed for 250 pslg. at *)00F. Steam side designed for 100 pslg at *l00oF. Steel vertical 60 gal, tank. Durco Mark 11 horlz. cent. pump. Inlet is ?" and outlet is 2", ductile iron, with Durametallic seal and Manzel lubricator. Rate 1b 200 QPM at 23' static head Sp. Or, of 1,5* Motor Is 10 HP, 1800 RPM. HONS 054792 Dept. 246 - Process Description 15. AROCLOR APPENDIX A EQUIPMENT LIST (Cont'd.) Item No. Equipment Name Equipment Number Description 122 Chlorlnator 19-4506 #2 Pump 66-8110 Same as Item No. 121. 125 Chlorlnator 19-4507 #5 Pump 66-8111 Same as Item No. 121. 124 Chlorlnator 19-4508 #4 Pump 66-8112 Same as Item No. 121. 125 Chlorlnator 69-5892 #5 Pump 66-6509 Same as Item No.121. 126 Blow Tank 21-2086 #2 Tank made by Qraver. Dwg. E-865. 71 Dia. x 7' etr. sides, dished heads 1/2", Shell 5/8", 5 turn coll of 2" pipe sup ported on brackets welded. 127 Blow Tank 66-2956 #2 Pump 69-0577 Taber horlz. cent. pump. Type L-2. 2ff" x 2". Semi-steel with monel shaft and water Jacketed stuffing box. At 20' static head, rate Is 80 0PM, 1.5 Sp. Or. at 500F. Motor Is 5 HP, 1800 RPM. 128 Air Dryer 14-0104 Anders likens Corp. Air dehydrator. Two code welded tanks filled with 55 lbs. activated alumina. Dwg. #6456. 129 Blow Tank 19-0629 Hi Pump 66-9080 Same as Item No. 127. 150 Still Hi 20-0045 151 Furnaoe Hi 27-0045 152 still Hi Pump 19-0594 66-4891 Vacuum still purchased from Oraver. Dwg. C-609. Size 6' Dla. x 5'6" lg. on str. side, i" Bholl, dished head 5/8". 60H hydro, pressure test. Steel heater furnace. Steel shell 5/16" x 5'9" Dla. x 4' 10*" lg. lined with insulating fire brlok. One ooll 2" xHy pipe, 12 turns formed into a 2' Dla ooll with spare blocks and legs. Dwg. E-886. Taber vert. sub. oent. pump, type L-2. Casing, yoke, and Impeller made of steel. 2" Inlet and 2" outlet. Length 7' 9". Capacity Is 75 0PM., static head 15', Sp. Or. 1.8 at 700F. Motor is 5 HP., 1750 RPM. MONS 054793 10. Dept. 246 - Proceaa Description l AR0C1.0R APPENDIX A Item No. Equipment Name 1 33 sun n EQUIPMENT LIST (Cont'd.) Equipment Numbe r Description 20-0062 Vacuum still purchased from Noote r. Dwg, 6944. 6* ID x 11* 10" str, shell, internal pipes, standard dished heads. Glass wool insulation 3" with 1/2" finished coat. 134 Furnace #2 135 Still HZ Pump 20-0066 66-1759 69-1277 Same as Item No. 131, Taber vertical sub. cent. pump. Type CL-4, 2 1/2 X 2", size 384, Pump is dynamo steel. Capacity is 75 CPM at 25' static head, Sp. Gr, 1,8. Motor is 7 1/2 HP, 1750 RPM. 136 Condenser #1 38-0770 Heat exchanger made by Nooter, Dwg. B-651, 12m DIA S' long having nineteen 2" O, D. 11 ga, monel tubes, monel tube sheets, monel reducer, and carbon steel jacket and back up rings on flanges, 137 Condenser HZ 38-1378 Same as Item No. 136. 138 Receiver Tank #1 21-0771 Vacuum receiver tank made by Nooter. Dwg. C`795. Size is 5'6" DIA x 5* 6" str, side, 3/8" shell, 1/2" bottom and removable head. 2" IP, size xHy monel coil with 2" inlet and 1" outlet. 3 turns, S' DIA along side and 3 turns spiral on bottom. 60# hydro, pressure test on tank and 300# on coil. 139 Receiver Tank HZ 21-1377 Tank made by Nooter. Dwg. 0795. Same as Item No. 138. 140 Receiver Pump #1 66-9067 Blackmer pump. Type PA-50L, bronze 69-0565 rotary pump, monel shaft, C.l. base. Capacity is 50 GPM, 1,65 Sp, Gr. , 350 to 500 *F. Motor is 2 HP, 1740 RPM. 141 Receiver Pump KZ 66-5670 Same as Item No. 140. 69-1258 ( HONS 054794 Dept, 246 - Process Description 17. AROCLOR ( APPENDIX A EQUIPMENT LIST (Oont'd.) Item No. Equipment Name Equipment Number Description 142 Blend Tank *?3 21-0779 Tank made by Qraver. Dwg. E-862. Welded steel tank, 71 Dla. x 71 high, dished heads ", shell 5/8". All sur faces sprayed with .005" zinc then .005' tin. 2" xHy pipe coll and supports. Cape bronze stirrer and bronze shaft. Test of tank Is 60# and coll Is 500# hydro, pressure. 145 Blend Tank |P2 21-1599 66-0217 Same as Item No. 142. Blend Tank Pump itmi Taber Horiz. Centrifugal pump. 504 s.s. 2" x lir" capacity 60 0PM, 100' head. Motor is 10.0 HP, 1800 RPM. 1*5 56" Sparkler 15-0258 Filter Filter made by Sparkler Mfg. Co., 55-D12 horizontal plate filter. Type 504 s.s. Jaoket tested for pressure of 50 psl. 146 Finished Produot Tank tfl 21-0780 Filtrate receiver tank. Dwg. E-862. Same as Item No. 142. 14? Finished Product Tank 4S. 21-1400 Tank made by Nooter. Otherwise, same as Item No. 142. 140 Storage Tank (75 21-0768 Tank made by Qraver. Dwg. C-609. Horizontal steel, 10' Dla. x 26' long on str. side, dished heads, shell head 9/16". Test of tank Is 60# and coil is 500it hydro, pressure. All coils, supports, Inside surface sprayed with .005" zinc and .005" tin. 149 Storage Transfer Pump #5 19-0585 66-0855 Taber Vert. Sub. pump. Dwg. A-587. Type C-5, 2" x 2", C.I, body, length 11'6". Cap. 50 0PM, 60' static head, Sp. Or. 1.18 at 170F. Motor Is 5 HP, 1800 RPM. 150 Storage Tunk 7/4 21-0769 Same as Item No. 148, 153 Storage Transfer Pump H'\ 19-0584 66-1501 Taber Vert. Sub. Pump. Type L-2. Si" x 2". Length 11'6". Cap 50 0PM at 40' static head. Motor is 5 HP, 1800 RPM NONS 054795 Dept, 246 - Process Description l8. AROCLOR APPENDIX A EO.UIPMENT LIST (Cont'd.) Item No. Equipment Name Equipment Number Description 152 Storage Tank ff5 21-1310 Tank made by Leader Iron Works. Dwg. C-609. 10' OD x 26' Long on str. shell Same as Item No. 148 for other oharaoteristlCB. 153 Storage Transfer Pump #5 19-0929 66-0856 Same bb Item No. 151, except length is 4'7". 154 Storage Tank #3 21-3528 Alpha tank 12'6" Dla. x 221 high. 20,000 gallon storage capacity. Aluminum constructed Dwg. TS-D-3011. 155 Storage Transfer Pump ^8 19-3172 66-2651 Durco pump, model WK2 Alloy constr. 2" x 14", 8" Impeller. Cap. 160 QPM at 55' head. Motor is 7$ HP, 1740 RPM. 156 Storage Tank ffl 21-2404 Slpha tanlc, 13' O.D. x 20' high. Vertical tank, constructed of 3/8" mile steel. Capacity Is 20,000 gallons, 157 Storage Transfer Pump in 19-2077 66-1691 Pump made by Blackmer. Monel shaft, Zi" x 2$". Cap. 90 0PM, 15' head. Motor Is 3 HP, 1750 RPM. 158 Scales 24-0246 24-0187 Made by Toledo Scale Co. 800^ capacity, dial type scale. 187 Blow Tank 21-0750 m Tank.made by graver. Dwg. E-B63. 7' Dla. x 7' str. side, dished heads shell 3/8". 5 turn coil of 2" xHV pipe. 169 Surge Tank 22-0751 Cyclone collector made by Graver. Dwg. B-695. 48" Dla. x 27" on str. side, 3' 6" long and tangential inlet near top of side. 3/16" steel throughout of welded construction. 170 City Water 69-1083 Pump Hi 66-3365 Taber Horlz. pump, Model CB5, 3" x 2s" 9" Impeller. Cap. 180 QPM, 50' head. Motor is 7i HP, 1800 RPM. 171 City Water 69-2078 Pump Hz 66-1796 Same as Item No. 170 180 Exhaust Blower 11-0265 Made by American Blower Co. Type 450E. Capacity is 6408 SCEM at 1310 RPM. Dwg. E-IO699. Motor is 15 HP. HONS 054796 Dept. 246 - Prooees Description 19. AROCLOR APPENDIX A EQUIPMENT LIST (Cont'd.) Item No. Equipment Name Equipment Number Description 185 Coke Sorubber in 21-0756 Scrubber liquor tank made by Graver. Dwg. C-800. 4'6" Dia. x 5*6" on Str. Side. Coil 3 turns of l" xHY pipe. 186 Coke 21-1396 Scrubber Ife Same as Item No. 185, 200 Cyclone Separator 21-1413 Separator made by Helntz Steel. 3' Id x 6' high tangential separator with Integral vapor pipe complete. 201 Air-oooled Heat Exohanger 38-5?28 Air-cooled heat exchanger made by Disler. Cooling oapacity is 1,200,000 Btu/hr. Steel construction except for aluminum fins. Fan motor is 2 HP, 1150 RPM. 205 Steam Vacuum Jet #l ?5-?523 #2 $ Worthington 3*Btage vacuum Jet. 264 Steam Vaouum 35-1686 Jet #2 Same as Item No. 203. 205 Steam Vaouum 35-553? Jet #3 3-Btage porcelain Kubatl vacuum ejectoi with 10" ID porcelain oondenser. Jet has a oapacity of 10#/hr. air at standard conditions. Jet designed for 150# steam and 2 mm Hg absolute. 206 Off-gas Drowning Jet 35-4756 Made by Sohutte-Koertlg. 8" Haveg fume sorubber. Complete with standard nozzle. 207 Drying Otfen 14-0138 Orleve Hendry drying oven, 440 V., 3 phase, 60 cycle, manual reset temp, controller range 0-400C. 210 Air-oooled Heat Ex ohanger 1 38-5564 66-8113 Same as Item No. 201. 211 Air-cooled Heat Ex changer Same as Item No. 201. 212 21? Air-cooled Heat Ex changer in Air-cooled Heat Ex changer #4 38-5566 66-8115 m Same as Item No. 201. Same as Item No. 201. HONS 05*797 Dept. 246 - Process Description so. AROCLOR APPENDIX A Item No. Equipment Name None Chlorine Pressure Reoorder None #b Chlorlnator Flow Reoorder EQUIPMENT LIST (Cont'd.) Equipment Number Description 29-1547 Made by Taylor Instrument Co. Pressure Recorder with 2 pens. Cat. No. X176JF235. Range 0-100 29-2019 Made by Taylor instrument Co. Flow Recorder - Controller. Cat. No. 137RF135. 12" chart, 0 to 10 Sq. root ohart. None None Water Meter 29-2486 #1 Still Tempera ture Reoorder 29-?885 Made by Worthington Corporation. 3" model IH turbine type water meter. ' Made by Leeds & Northrup Co. Temperature Recorder. Range 0 - 400C. None Hi Still Absolute 29-1170 Pressure Controller Made by Taylor Instrument Co. Absolute pressure Recorder - Controller. None None 200# Steam Flow Reoorder 29-0835 #2 Still Absolute 29-3353 Pressure Controller Made by Bailey Meter Company. Flow .Recorder. Made by Taylor Instrument Co. Absolute Pressure Recorder Controller. None #2 Still 29-0244 Temperature Reoorder Made by Leeds 4c Northrup Co. 6 point Temperature Recorder. None #2 Still Level Controller 29-1463 Made by Taylor Instrument Co. Liquid Level Recorder - Controller. None None Chlorlnator 29-0288 Temperature Reoorder #1 Blow Tank 29-2916 Temperature Recorder Made by Leeds & Northrup Co. 12 point Temperature Recorder. Made by Taylor Instrument Co. Temperature Reoorder Controller Adjusts 200H steam to Hi Blow Tank cat. #66 rm4>i85-12. HONS 054796 Dept. 246 - Process Description 21. AROCLOR APPENDIX A Item No. Equipment Name None Bo# Steam Flow Recorder None 200# Steam Flow Recorder EQUIPMENT LIST (Cont'd.) Equipment Number_______ ,r Description 29-5452 Made by Foxboro Company. Type T37, recording flow meter with Integrator and Indicator. Meter body ?l6 S.S. integrator for 80#, 400F. Steam. 29-5453 Made by Foxboro Company. Type T37 Recording Flow meter with integrator and Indicator. Meter body 316 S.S. Integrator for 200#, 510F. Steam. HONS 054799 Dept. g^6 - ProceBB Description AROCLOR APPENDIX B SPECIFICATIONS The folllwlng 1b a list of the raw materials used for the manufacture of Aroclors. Specification sheets are Included w-ere they exist. Material Code Raw Material 62601 .................................................................. Biphenyl ' >3500 .................................................................. Ferric Chloride 38800.................................................................. Dime 19400.................................................................. Attapulgus Earth 81059......................................................... Chlorine 43099 .................................................................. Nitrogen The following Is a list of the finished produots manufactured In department 246. Specification sneets are Included where they exist. Product Code Product MCS 295 Aroclor 1254-10# Xylene Aroclor 1232 81101 Electrical te Non-Electrical) Aroclor 1242 81102 Eleotrloal & Non-Eleotrloalj Aroclor 12^8 ( 81103 Eleotrloal & Non-Electrical) Aroclor 1254 81105 Electrical & Non-Electrlca)J Aroclor 1260 81107 Aroclor 1262 81101-81102 (Mix) 12*12 - 121(8 Mix ' 82868 Montars 1,2,3 and 4. MONS 054800 MONSANTO CHEMICAL COMPANY OROANIC CMIMICALS DIVISION SPECIFICATION MATtRIAL DIPHENYL (BIPHENYL) CHCMICAW FORMULA MAT SRIAk COOK 82601 UltNO DIRTS. 246 ANNISTON PLANT MOt ,,t. 15'l.20 UFIRIIDEI (MCI OF V6/51 C3 SAMRLI FOR ANALYSIS 2 x 16 oz. W.M.Bottles UNRESTRICTED INFORMATION Routine Tests property Appearance and Color Crystallizing Point GENERAL INFORMATION Distillation Range: First Drop to Dry point Specification Light Yellow Cryst. Solid 68.7C, min. 2.5C, max. Must lnolude 255*C within Range Issued 6/9/61 W.O.Krummrich Plant By ">f i^d.' Method Number 10,252 10,298 10,299 I This specification is the property of Monsanto Chemical Company and is for internal use only. (T) IN*# <AV. */#) HONS 054801 t MONSANTO CHEMICAL COMPANY ORGANIC CKIMICAU DIVIIION W. 0. Krummrlch Plant FINISHED PRODUCT SPECIFICATIO1N1,_ PRODUCT CODI 81059 ut Internal VALCf CODE IOBI>T. ON JOB ZbZ TVM . _Ch 1 or In? . (Sn 1 f t. .Qa s)._________ _____ __ NNODUCT (CFwmfMf TVM CMIMIC AV. FORMULA Mlxture MOL WT.________________________________________ _________________ _ URRRIIOII1RCCI OP IAMRLR ROR ANACYI New_________________ _______ 100 o.o. Qaa Burette Issued DEC 23 TO W. 0KJfrummrjoh Plant RAW MATERiAL Date /ipP'OrtdP.^P. for Deptfi&s&t/iszxi- UNCLASSIFIED INFORMATION General Tests (made only on request) property Typical Analyses Chlorine (Cl*) 86$ By Volume Oxygen (0B) >$ " " Carbon Dioxide (C0B) 1.5$ " " Carbon Monoxide (CO) 0.1$ " " Hydrogen (HB) 1.0$ " 11 Inert Gases (By difference) 8.4$ " " MolBture (He0) @ Std. Conditions 2-4 fAJe^?-/ft- Direct pipeline transfers to using Depts. 2>6, 257, 246 This specification is for internal use at WGK Plant only. Method`Number mN 14 imv, U/B4I MOWS 054802 MONSANTO CHEMICAL COMPANY. VI Q.,, OF.J.MC CH.M1C.IJ W.IIIJH . KrummrToh Plant. RAW MATERIA! SPECIFICATION MAtlMMAL CODE *58800 MINE DEPT*. .222* 246 UPPUER .................... MAtlMAl fivdratad-------------------__--------------------------------- ;-- tHVMlCAt POEMVUA ----------- ;---------------------------- iBBued 6/go/6^ W. Q. Krummrleh Plaint By M. D. Dealv Ca (OH)a mol vr. IVMMRMMHCI OP 6/5A7. AMPLE POE AMALVEII ____1 *_16 RQfcfctPt________ UNCLASSIFIED INFORMATION Oenaral Teats (made only on request) . Property ' Specification - Appearanoe Fine white or slightly gray powder, free from lumps or gritty material Assay (Ca(OH)s) '92,'OOJf, min. Carbonates as (CaOO*) ' J.OOj(, max, Magnesium 0.50J&, max. Sulfates (as SO*) . 0,50j(, max. Method Number 10,188 10,191 10,195 10,192 10,189 nuai>ii.aau ^_/ HONS OSA803 UNRESTRICTED INFORMATION General Tests (made only on request) Fropcrty Specification Appearance Black ponder or granules ASBay 97.0S6, min. Sulfates 0.0556, max. FerrouB Salts Trace, max. Solubility: 10:10 of Water Complete to slightly turbid, max. 30:10 of Formula >0 alcohol Complete to slightly turbid, max. J.F.Q. Method No. 16-A 22-570 120-570 S-570-1 ii?-n rr? inm <**. MONS 05A80A VNRBSraiCTED'INFORMATION Routine Teete ; Property ... Volatile Matter (at 950*c) M0'm> te.at: " . .' . : .tfhroueh USS 525 ,. .' Specification 6 . 8jt. . ' , ' 90#, min. . Method Number V., -. vv. Thle material le not aooepted without the supplier >e analysis of the above properties,! - , ?: O IN W Huy. M/M) MONS 054805 i u I MONSANTO CHEMICAL COMPANY PRODUCT CODE 81115 ORGANIC CHEMICALS DIVISION use W. Q. Krumrarlch Plan ' internal FINISHED PRODUCT SALES CODE SPECIFICATION [DEPT. OR JOB | 2n6 J.F.O. PRODUCT <?>! N**) Aroclor 1232 PROOUCT (OhMitMl Nttnt) J>H Chlorinated C MIMIC At FORMULA Biphenyl TVP* (MCS - 236) TYPE Wis.su%edKAPR^^7 1a964nt MOL WT. SUPERSEDES SPICl'OP - -JiftW-- " '1 AMPLE PON ANALYSIS * ____________ 2 x 16 os. vi. M. Bottles______________ - Routine Tests Appearance Sp. Or. 25/l5.5C Add Number Color, APHA He0 Oeneral TestB Chlorine Specification Clear Liquid 1.266 - 1.276 0.01A mg. KOH/grm. max. 100, max. J5 ppm., max. 31.5 - 52.5* Method No. 10,114 10,087 10,084 10,620 This specification Is for Internal use only. C3|N M iv. MONS 054606 MONSANTO CHEMICAL COMPANY OR9AN1C CHIMCAL* OWIIION ANN1fs,TN,yENDDpKRTOCH SPECIPICATION PRODUCT Urn*) AROCLOR 1142 PRODUCT (OMmImF PRODUCT CODE U SALES ALB* COOt l"** Alston 1246 - WOK Issued 1/24/6? W.O.Krummrlch Plant by E.O. Martin 1040-130-04/11/16-03/09------------TVf* CRUDE COMMERCIAL TVFI CMIMICAL FORMULA MIXTURE MOLWT. - - - ftAMPLI FOR ANALVBII . 3/2B/5B---------------------------- 1 Qt. Bottle Annistoni2xl6 ct.-il.M.Bottle WOK_____ UNRESTRICTED INFORMATION Routine Teste Property Specification Method Number Appearance and Color Brown to black oily liquid Anniston .... WOK 10,084 Specific Gravity 2!>Vl!>.5'>C 1.J84 - I.394 14-49-54 10,114 Acid Number (mg. KOH/g.) RESTRICTED INFORMATION 0.7, max. 14-46-54 11,532 Acid Number or the crude, which Is stored In non-lacquered metal containers Bhall be 0.2mg. KOR/g. max. 3 IN M INHV. Il/lll HONS 054607 MONSANTO CHEMICAL COMPANY OAOANIC CHEMICAL* DIVIIIOH KUUMMHICH end ANNISTON FINISHED PRODUCT SPECIFICATION rmvmK 82612 ANN. J__ 27L ANN . Soles ALE* CODE 1040-240-04/ll/l6-03/09 AROCLOR 1242 ELECTRICAL ORADE (PYRANOL 1499) `r*OUVci'(6himM~iimnf ~~ TVrt CHEMICAL FORMULA Mixture Issued 4/3>/62 W.0*Krummrich Plant By. An?. >nt~<L tUMWIDII IUCI OF 4/17/61 AMFLf FOR AMALYI 5 x 5 pt. Amber Bottles UNRESTRICTED INFORMATION Routine TeBts Property Specification Color (APHA) Condition Sp. Or. @ 25/15-5'C Acidity (mg. KOH/g.) Moisture (HeO) Refractive Index 25"C Inorganic (Free) Chlorides Pour Point Dielectric constant (1000 cycles @ 100C) Resistivity (500 VDC 0 100C 0.1" OAP) AS OHM-CM x 109 Hydrolysis Stability Test (As Chlorides) Monsanto Stability Test (As Chlorides) Distillation Range (ASTM D-gO, Corrected) 1C# Distilled by wt, 90% Distilled by wt. 50, max. Clear 1.281-1.392 0.010, max. 35 ppm., max. 1.6260-1.6260 O.05 ppm., max. -14'c or Lower . 70-R. 90 500, min. 1.0 ppm., max. 0.4 ppm., max. 325<'C, min. 360c, max. GENERAL TESTS (Made only on requesitt)) Sulfates Dielectric Strength @ 25C Flash Point ("F) Fire Point Viscosity @ 100F (SUS) Corrosion TeBt (6 hrs @ 210C with bright aluminum foil) Change In wt. of AL (#) None . 35 KV, min. 358-392 None 82-92 0.0 (Over) 7 IN *4 IAEV. It/**) Method Number WOK ANNISTON 10,084 10,084 10,114 10,087 10,620 10,125 T-2092 10,115 11,608 14-44-54 0-1 14-49-54 14-42-54 14-53-54 14-34-54 014 14-47-54 14-36-54 11,607 14-35-57 T-2087 11,503 10,117 010 14-61-57 14-31-54 12,169 11,605 10,123 10,123 10,086 10,126 043 14-28-54 14-28-54 14-4-52 14-55-57 MOMS 054806 A.C. Color (APHA) A.C. Condition A.C. Acidity (mg. KOH/g.) A.C. Inorganic(Free)Chlorides GENERAL INFORMATION Specific Heat 0 25C Coefficient of Expansion (25-65"C) Fixed Chlorine SPECIAL CUSTOMER REQUIREMENT General Electrlo HydrolyslB Stability Teat (As Chlorides) Thermal Chemical Chlorides 60, max. Clear 0.010, max. 0.05 ppm,, max. O.JO 0.00068 oo/c 42.5-45.5?6 0.5 ppm., max. 0.75 ppm., max. 10,084 10,084 10,087 T-2092 . T-2087 12,722 14- 44-54 0-1 14- 42-54 014 010 HONS 054809 MONSANTO CHEMICAL COMPANY OROANIC CHIMCAL* DIVISION Krummrioh and Anniston FINISHED PRODUCT SPECIFICATION PRODUCT PROADrUoCTo(Qlohrmlw1l2K4w8h) PRODUCT CODI |DtPT. OR AO* 81102 - 82641 IwOK 246-Ann.27 luod JUL 1 5 1964 UIK w. u. Krummrlch Plant IALCI cobs Sales By. >i T>0 1040-260-04/ll/l6-03/09 TYP Non-Electrical Orade TYP CHKMICAL FORMULA Mixture MOL PY. ' tAMPLC FOR ANALY8J) . _5r.4-fo______________ ____ 3 -X 16. 02. W. M. Bottle a_______________________________ UNRESTRICTED INFORMATION Routine Testa Appearance Condition Color, APHA Sp. Or. 865/15.5*0 Aoldlty (mg. KOH/g.) Moisture (H*0) (ppm.) Vlsooslty 8130*F (SUS) Oeneral Tests Flash Point (*F) Specification Colorless to light yellow-green liquid Clear 100 max. 1.405 - 1.415 0.010, max. 50, max. 73-80 WOK Anniston Me thod No. 10084 0-1 10084 10084 10114 10087 10620 10086 0-1 046 052 050 047 049 370, min. 10123 14-28-54 HONS 054610 M0MANT0 CHEMICAL COMPANY Mt#AMC CHCMCAU UV1MON moMiev COM 81102 Sales |<*|,e46^FOK | 27 Ann. SPECIFICATION 1040-260-04/11/16-03/09 IMIOOIACV (TMMls JNV *** Aroolor 1248 Eleotrloal Orade (Pvranol 1498) PAODUC7 (OA--Asm> TTTI jCMMCAL FOfNftlLA Issued 1/10/64 Corrected 2-16-64 Mixture #ftOL WT. -...foJjgi&L-_______________ ____ 3 x 5 Pt. Amber Bottles____________________ _ UNRESTRICTED INFORMATION Routing Tests Specification Method No's. WOK Anniston Color, APHA Condition Sp. Or. #65/15.5*0 % Apldity (me. KOH/gm.) Moisture Refraotlve Index #25*C Inorganlos (Free) Chlorides ( Pour Point Dieleotrio Constant (1000 cycles #100*C) Resistivity (500 VDC #100*0.0.1" CAP) as OHM-OM x 10? Hydrolysis Stability Test (as chlorides) Monsanto Stability Test (as Chlorides) iDlstlllatlon Range ' (ASTM D-20, correoted) 10J{ Distilled by (ft. 9056 Distilled by Wt. 50, max. Clear 1.405 - 1.415 0.010, max. 35 ppm., max. 1.6285 - 1.6305 0.05 ppm., max. 0*c, max. 4.5 - 4.7 500, min. 1,0 ppm., max. 0.5 ppm., max. 345*0, min. 385*0, max, 10,084 14-44-54 ' 10,084 0-1 10.114 14-49-54 10,087 14-42-54 10,620 14-53-54 10,125 14-34-54 T-2092 014 10.115 14-27-54 11,608 14-36-54 11,607 14-35-57 T-2087 010 11,503 l4-6l-57 , 10,117 14-31-54 IQeneral Tests (made only on request) Sulfates Dleleotrlo Strength #25*C Fire Point Vlsooslty #54,4*0 (SUS) Corrosion Test (6 hrs. #210*C with bright aluminum foil) Change In wt. of A1 (3C) ( None =55 KV, min. None to boiling point 73-80 0.0 12,169 - - 11,605 0*13 10,123 14-28-54 10,086 14-4-52 10,126 14-55-57 (over) MONS 054811 !0 *N W (MV. U,M A. C. Color, APHA A. C. Condition A. C. Aoldlty (mg. KOH, 'g.) A. C. inorganic (Free) Chloride* 6o, max. Clear 0.010, max. 0.05 ppm., max. OBNBRAL INFORMATION Speciflo Heat 25'C Fixed Chlorine 0.27 47.5 - 48.5# 10,084 14-44-54 10,084 o-l HONS 054812 MONSANTO CHEMICAL COMPANY OROAHIC CHEMICALS DIVISION Krummrloh and Anniston FINISHED PRODUCT SPECIFICATION PRODUCT N*m*> Aroolor 195^ 'PRODUCT Nmr*) JUL 1 5 1964PRODUCT COO* (DEFT. OR JO* 81103 - 82613 IW0K-246-Ann.27 Issued use W. 0. Krummrloti Plant Sales By .'Wl T3.5} i JiU SALESCODE 1040-280-04/11/16-03/09 TtPI Non-Electrioal Grade TYFI CHEMICAL FORMULA Mixture MOL VT. IVMHUNI mci OF 5" *l-6a SAMPLE FOR ANALYSIS 3 x 16 pz, w, M. Bottles________________________________ UNRESTRICTED INFORMATION Routine Tests Color, APHA Sp. Or. *65/15.5*C Acidity (mg. KOH/g.) Moisture (HgO) (ppm.) General Tests Flash Point Visooslty 210*F (SUS) Specification 100, max. 1.495 - 1.505 0.010, max. 50, max. None 44-48 . WOK AnnlBton Method no. 10084 10114 10087 10620 046 052 050 047 10123 10086 14-28-54 049 ( HONS 054613 KMSAKTO CMDHCM. COMfMVY MAWC CMOACAU MVWON 3wr>L.rwi Sales SPECIFICATION AkM CAM ' 1040-280-04/11/16-05/09 'ntOOUCT V _____ TTTrFMT" AROOLOR 1254 ELECTRICAL ORADB (PTRANOL 1476) HbOPUCtfdtmtmi WmmJ CMIMICAL rOfUMLA Issued k/Y}/62 W. 0. Krumwleh Plant ByB. 0. Martin Mixture MOL Vt. Nnmwinnor 10/10/61 MMVLM MOM AMALYW, 3 x 5 Pt. Amber Bottlss ONRBSTRICTED INFORMATION Routine 'Tss'ts Property .. 8peoi?ioaH6h Color, APHA . Condition Bp. Or. 65/15.5*0 , Acidity (ng. KOH/gm.) Moisture (H*0) Refraotlve Index 25*C Inorganlo (Free) Ohlorldes pour Point Dleleotrlo Constant (1000 oyoles 100*C) Resistivity ' (500 VDC b 100*fi 0.1* OAP) as OHM-CM x 10 Hydrolysis Stability Test (As Chlorides) Monsanto Stability Test (As Ohlorldes) Distillation Range (ASTM D-20, Correo tea) fto* Distilled by Ht. 0* Distilled by-Wt. 90# Distilled by Ht. 50,Max. Clear 1.495-1.505 0;010, max. 55 ppm, max. I.657O-I.659O 0.05 ppm., max. 7-12*0 4.15-4.55 500, min. 1.0 Pin., mx. 0.5 ppm., max. 366-578*0 571-365*0 379-394*0 GENERAL TESTS (Made only on request) K' Sulfates ' None Dleleotrlo Strength 25*0 FZbsh Point 35 tv, win. None Fire Point Vlsooolty 210*F (SOS) Corrosion Test None 44-48 (9 hrs 210*0 with bright .Aluminum foil) Ctjange In wt. of Al (#) 0.0 (Over) HOK 10,084 10,084 10,114 10,087 10,620 10,125 T-2092 11,607 T-2087 11,505 10,117 Humber AHHI8TQN 14-44-54 0-1 14-49-54 14-42-54 14-53-54 14-34-54 014 14-27-54 14-36-54 14-35-57 010 14-61-57 14-31-54 12,169 11,605 10,123 10,126 043 '<! 14-28-54 14.28,54 14-4-52 14-55-57 HONS oseai* A.C. Color, APHA A.C. Condition A.C. Aoldlty (mg. KOH/g.) A.C. Xnorganlo(Free)Chlorldes EXTERNAL SPECIFICATION Cornell - Dublller Resistivity (500 VDC 9 100!c 0.1" CAP KB OHM-CM x 109) GENERAL INFORMATION Speolflo Heat 0 85*0 Coefficient of Expansion (85-65*0) Fixed Chlorine 60, max. Clear . O.OlOJttax, 0.05 ppm,, max. 1500, min. o.er- - 0.00066 oo/*C 54.5-55.5X 10,084 10,084 10,087 10,ll6 14-44-54 0-1 14-42-54 010 11,607 14-55-54 HONS 054815 MONSANTO CHEMICAL COMPANY OROAMIC CHEMICAL* DIVISION SPECIFICATION PRODUCT Nmf) AROni.OR 1160 PRODUCT (Oh**\lt*1 Ntmf) PIRfOfDUiC&T COgDE- |I DgEPST. OMR JOBlBton USE SALES ALE* COOK lQAp-i70-04/ii/i6-nVr>Q TYPE CRUDE COMMERCTAT, TYPE CHEMICAL PORMULA MIXTURE ' issued 1/24/62 } .0 .Krummrich Plant ay P. O.'Me^. MOL VT. - SUPCRSCDS* SPECS OP 3/28/56_______ SAMPLE POR ANALYSIS 1 pt- can Anolstom x 16 oz H.M. Rottlea UflK UNRESTRICTED INFORMATION Routine TeBts Property Appearance and Color Specific dravlty 90"/l5.5'C Acid Number (mg. KOH/g.) Specification Brown to black viscous sticky mass 1.558 - 1.569 0.7, max. Method Number Anniston WOK 10,084 34.49-54 111-146-5^ 10,m 11,532 RESTRICTED INFORMATION Acid Number of the cn>de, which ie stored In non-lacquered metal containers shall be 0.2 mg. KOH/g., max. I CD IN M IftIV. II/MI HONS 064816 MONSANTO CHEMICAL COMPANY ORGANIC CHEMICAL! DIVISION Krummrlch and Anniston FINISHED PRODUCT SPECIFICATION RRODVCT`?Pi2C7lFm.,l _.Aros PRODUCT 6 Q.. Hmr>) PRODUCT CODE lOEPT. ORJOR 81105 - 82614 I WOK 246 Ann. 21 _SaleA_ IAL(P CODE 1040-g90-04/ll/l6-03/09 Non-Electric Grade Issued JUL 1 5 1964 W. 0. KrutwicY/fiant By yy,lT7)*J^ CHS MIC AL FORMULA Mixture -5-itril- SAMFLE FOR ANALYSIS UNRESTRICTED INFORMATION Routine Tests Condition Color, APHA Sp. Or. 690/15.5'C Acidity (mg. KOH/g.) Moisture (HeO) (ppm.) Viscosity 6210*F (SUS) General Tests Flash Point Fire point Specification Clear 150, max. 1.555 - 1.566 0.014, max. 50, max. 72-78 None None WOK AnnlBton MethodHTo. -- 10084 10084 10114 10087 10620 10086 0-1 046 052 050 047 049 10123 10123 14-28-54 14-28-54 MONS 054817 MONSANTO CHEMICAL COMPANY OftOAMC CHRMCAL4 DIVUION Anniston snd Krummrloh Plants FINISHED PRODUCT mprvtxm. >1105 - WOK I 2A6 - Sales SPECIFICATION IALII COOt ~' 1040-290-04/ll/l6/-03/09 yssoZFnttntt------------------------- tVFt AROCLOR 1260 ELECTRICAL ORADE_________ rAOPUCTfOAa-jia/Wa**,)' " (raANOir*4B2) CHtMICAL FORMULA Mixture Issued 2/7/62 BWy.O,/..KrQum.mhrl<eh^Plant MOL WT. UFIRIBPIIIPICI -?/W58 iAMPLt POA ANALVtll 1 ? x 5 pt. Amber Bottles UNRESTRICTED INFORMATION Routine Tests Property Specification Color (APHA) Condition Speolflo Gravity 8 90/15.5'c Aoldlty (mg KOH/g.) Moisture (H*0) (ppm.) Vlsooslty 8 210*F (SUS) Refractive Index 8 25'C Inorganlo (Free) Chlorides Pour Point (*c) Distillation Range (ASTM D-20,, Corrected) 10# Distilled by wt. 50J{ Distilled by wt. 90% Distilled by wt. Corrosion Test (6 hre. 8 210*0 with bright aluminum foil) Change In weight of A1 (jf) A.C. Color (APHA) A.C. Condition ' A.C. Aoldlty (mg.KOH/g.) A.C. Inorganlo (Free) Chlorides 150, max. Clear 1.553-1.566 0.014, max. 35, max. 72-78 1.6455-1.6470 No detectable amt. 25-34 385-398*0 390-404*C 400-420*0 0.0 , 150, max. Clear 0.014, max. No detectable amt. Method No. WOK ----- Anniston 10,084 10,084 10,114 10,087 10,620 10,086 10,125 10,118 10,115 10,117 14-44-54 14-49-54 14-42-54 14-53-54 14- 4.52 14-34-54 14-48-57 14-47-54 14-31-54 10,126 14-55-57 10,084 10,084 10,087 10,118 14-44-54 14-42-54 14-48-57 (Over) Qinm (MRV. ib,,,> HONS 054818 UNRESTRICTED INFORMATION (oont'd) Property Speolfloatlon general Tests (made only on requesitt)) Flash Point Fire Point Fixed Chlorine () Dleleotrlo Strength 9 50*C Resistivity None None 59-5-60.5 50 K.V., min. 500, min. (500 VDC 100*0.0.1" gap as ohn-on. x 10") Dleleotrlo Constant 1000 oyoles, 100'C 5.6-5.6 Method Number WOK Anniston 10,125 10,125 10,088 11,605 11,607 14-26-54 14-28-54 14-15-54 14-55-57 ll,6o8 14-56-45 RESTRICTED INFORMATION Monsanto Stability Test (As Chlorides In ppm.) 0.7, max. 11,505 14-61-57 OKNERAL INFORMATION Evaporation Loss after 6 hrs. 0 100*0 flf) 0.2, max. 10,116 14-52-54 Stability-test - after >0 daps at 100*C In glass sealed In air No liberation of ohlorlne or ohlorldes HONS 054819 MONSANTO CHEMICAL COMPANY OROAMC CHRMICAU DIVIIION SPECIFICATION PRODUCT Hmt) aroot,or ji6r PRODUCT Ntm*) MO&UCT COOt | DIPT. OR JO* UR SALES IALU COOK Issued 1/24/62 W.Q.Krummrlch Plant 1040-170-04/11/16-05/00 TVM ____ CRUDE COMmrRCTAT._____________ TVPR C MIMICAL FORMULA MIXTURE MOL WT, - > 5/28/58 AMPL1 POR ANALV0I0 1 pt. can, Anniston; 2 x 16 og, W.M. Bottles WOK UNRESTRICTED INFORMATION Routine Tests Property Appearance Color Speoifio Gravity 090/15.5C Aold No. (mg. KOH/g.) Specification Viscous liquid Brown to black 1.577 - 1.587 0.7> max. Method Number Anniston .... .... WOK 10,084 10,084 14-49-54 10,114 14-46-54 11,532 RESTRICTED INFORMATION Aold No. of the orude which la atored In non-laoquered containers shall be 0.2 mg. KOH/g., max. MOMS 054820 MONSANTO CHEMICAL COMPANY OROAMC CHIMCAU DIVIIION ANNISTON AND KRUMMRICH FINISHED PRODUCT SPECIFICATION PRODUCT Nam) AROCLOR DISTILLED PRODUCT <*) CHRMICAk PORMUkA mmt UH mm Issued 1/24/62 W.G.Krunmrlch Plant by E,0. Martin UkU COOK 1040-300-04/11/16-03-09_______ TVPK 1262 TVP1 MOk*T. KIPIRIKOIIIPBCI OP 5/28/58 MIXTURE . AMPkK POP AHAkVtl* 2 x 16 oz. W. M. Bottles_________________________________ UNRESTRICTED INFORMATION Routine TestB Property Appearance Color Speolflo Gravity 8 90/15.5'C Acid No. (mg. KOH/g.) Viscosity @ 210'F Specification Viscous liquid APHA 150, max. 1.572 - 1.585 0.014, max. 86 - 100 SUS Method Number 10,084 10,084 10,114 10,087 10,086 GENERAL INFORMATION Pour Point (ASTM) Distilling Range Total Chlorine Speclflo Gravity t ooeff (85 - 150C) 55 - 58'C 590 - 425"c 61.5 - 62.5# 0.001/C CD INM tRiV, It/Ml H0NS 054821 MONSANTO CHEMICAL COMPANY OROANIC CHEMICAL! DIVISION Krummrloh and Anniston FINISHED PRODUCT SPECIFICATION PRODUCT CODE 82868 UIE ALfel CODE See PRODUCT (TYRE* Montars 1 and 2 PRODUCT (C*>elc*! KneJ Polychlorinated PolyDhenvls CHEMICAL FORMULA 1 DEPT, OR JOE IwOK 246 Ann. Sales Below TYPE TYPE 2' Issued .Nil. 1 5 1964 W. Oi Krummrlcn j>iant By Mixture MOL _________ iopkrrioei inti of 6-15-6] (AMPLE POP ANAlYtlt g.x W. .M. BotUea UNRESTRICTED INFORMATION Routine Tests Specification Anniston WOK Method No. Appearanoe Oeneral Information Black Solid 14-17-52 11521 Physical Properties (Typical Values) Montar 1 Montar 2 Softening Point (ASTM E-28-51T) 54-l6o*C 70-170`C Acidity Chlorine Content Slightly Basle 56-42* Slightly Basic 44-48* CaO Fe Benzene Insoluble Flash Point 5-15* 0.5-1.0* ---500-620`F 5-15* 0.5-1.0* 12.5* .... RESTRICTED INFORMATION Montars 1 and 2 are the still residues from distillation of Aroclors 1242 and 1248 respectively. Composition of these Montars 1b not controlled, being entirely dependent on conditions required to make aooeptable distilled product. SaleB Code Nos. Montar 1 6405 - 001 - 04 - 0J/09 Montar 2 6405 - 002 - 04 - 05/09 CD< M '"tVi > HONS 054822 MONSANTO CHEMICAL COMPANY OROANIC CHKMICAkl DIVII10N Krummrlch and Anniston FINISHED PRODUCT SPECIFICATION PRODUCT CODR 1 DEPT. OR .101 ISBued JUL151964 82866 IWOK 2**6 Ann.27 W. 0. krummrieh PiAnt1 UIC By Ifa .6 iS Sales AkCICODI See Below PRODUCT (YvmM TVPC Montars 3 and ^ PRODUCT {OAmHmI limn*) TTPR Polyohlorlnated Polyphenyls CNIMICAk FORMULA MOL TFT.__________ UP!AIIOII IPtCl 6-13-61 Mixture ItAMPkt FOR ANALVMI 2 x 16 oz. V, H. Bottles UNRESTRICTED INFORMATION Routine Teete Specification Anniston WOK toetho? No. Appearance Black Solid 14-17-5? 11521 General Information PhyBloal Properties (Typical Values) Montar p Montar 4 Softening Point (Method ASTM E28-51T) 86-l68*C 92-206`C Acidity Slightly Baslo Slightly Basic Chlorine Content 50-58* 54-56* CaO 5-10* 5-10* Fe 0.5-0.6* 0.5-1.0* RESTRICTED INFORMATION Montars 5 and 4 are the still residues from distillation of Aroclors 1254 and 1260 respectively. Composition of these Montars is not controlled, being entirely dependent on conditions required to make acceptable dis tilled produot, . Sales Code Nos. Montar 5 6405 - 005 - 04 - 05/09 Montar 4 6405 - 004 - 04 - 05/09 MONS 054i823 Uept. 2^6 - Process Description AROCLOR APPENDIX C PHYSICAL AND CHEMICAL DATA 2}. HONS 054824 Dept. 246 - Process Description AROCLOR APPENDIX C PHYSICAL CONSTANTS 24. GENERAL PHYSICAL PROPERTIES OF AROCLORS Form......................................................................... Color......................................................................... Aroclor 1242 Practically colorless mobile oil 100 Max. (APHA> Aroclor 1248 Yellow tinted mobile oil Aroclor 1254 Light yellow viscous oil 100 Max. (APHA) 150 Max. <A1HA) Aroclor 1260 Light yellow soft sticky resin 150 Max. <APHA) Aroclor 1262 Light yellow sticky dear resin 150 Max. (APHA) Acidity-Maximum (Mgm. KOH per Gm) 0.015 0. 015% 0.015 0. 015 0. 02 Average Coefficient of 0 00068 (25*-64*C> Typical Density Specific Gravity 25*/25*C (77*/77^1. 380 Pounds per Gal. -25*C (77*F) 11. 50 Distillation Range-ASTM D-ZQ(Mod) c ........................................ 325'-360" Evaporation Loss-%-ASTM D-6Mod. 163*C................................................ 5 hrs. 3. 0 to 3. 6 100'C................................................... 6 hrs. 0. 0 to 0.4 Flash Point-Cleveland Open Cup. .*C 176* -180* *F 348'-356* 0.00070 (25*-65*C) 1.445 12. 04 340*-375* 3. 0 to 4. 0 0. 0 to 0. 3 193"-196" 379*-384* 0.00066 (25*-65*C) 1.538 12. 82 365*-390* 1.1 to 1. 3 0. 0 to 0. 2 None 0.00067 (20*-100*C) 0.00064 (25*-65*C) 1. 620 13. 50 1.646 13.72 385*-420* 400*-430* 0. 5 to 0.8 0. 0 to 0.1 None 0.5 to 0.6 0. 0 to 0.1 None Fire Point-Cl eve. Open Cup. . . .*C None* *F Four Point-ASTM D-97.............. *C -19* *F 2* Softening Point-ASTM E-Z8 *C _ _ F - - None -7* 19-4* ._ -- None 10* 50* __ _- None 31* 88* __ __ None 37* 99" -_ . _ HONS 0 5 4 8 2 $ Dept. 246 - Process Description AROCLOR APPENDIX C PHYSICAL CONSTANTS (Cont'd.) 25- GENERAL PHYSICAL PROPERTIES OR AROCLORS (Cont'd.) Form Fefractive Index-D-line 20*C Aroclor 1242 Practically colorless mobile oil Aroclor 1248 Yellow tinted mobile oil Aroclor 1254 Light yellow viscous oil Aroclor 1260 Light yellow soft sticky resin Aroclor 1262 Light yellow sticky clear resin 1.627-1.629 1.630-1631 1.639-1.641 1.647-1.649 1.6501-1.6517 Viscosity-Saybolt Universal 210"F (98. 9 * 0 34-35 36-37 Sec.(ASTM)-D-88) 130"F (54.4" C) 49-56 69-78 100*F (37.8'C) 80-93 185-240 44-48 260-340 ' 1800-2500 72-78 3200-4500 --- 90-103 600-103 (160" F or 71" C) HONS 0 5 4 6 2 6 Dept. 246 - process Description ftROCLOR APPENDIX C PHYSICAL CONSTANTS (Cont'd.) PHYSICAL AND CHEMICAL DATA Diphenyl Spoolflc Gravity: 0.992 at 75C/4c. The swann chemical company bulletin of 1950 gave thermal data on diphenyl. Viscosity of plphenyl (from Anniston piles) p. centlpolsea XbO rn?91 170 1.509 180 1.208 190 1.114 200 1.054 220 0.901 250 0.752 500 0.574 550 0.459 400 0.574 450 0.515 482 0.285 Iflc Heat (from Anniston Files) P. B.T.U./lb. 200 too 400 500 600 700 800 900 1000 0.416 0.470 0.547 0.616 O.658 0.679 0.686 0.690 0.696 . 26. HONS 05482? pept. 246 - process Description 27. AROCLOR APPENDIX C PHYSICAL AND CHEMICAL DATA (cont'd.) Diphenyl (cont'd.) Another record gives the following values for liquid diphenyl: C. sp. Heat cals./gram 100 0.360 150 0.380 200 0.412 250 0.460 300 0.518 350 0.575 400 0.610 450 0.625 Vapour CP - 0.460 25UE. 0.625 45UC. (D. A. Roper Density of Liquid Diphenyl (from Anniston fileB) prams./ee 75 0.9885 100 0.9895 150 0.9294 200 0.8885 250 0.8470 300 0.8010 350 0.7510 400 0.6918 450 0.6180 Heat of vaporization: 65,4 g, oal./g. at 258.5C. HONS 054828 pept. 246 - process Description AROCLOR APPENDIX 0 PHYSICAL AND CHEMICAL DATA (Cont'd.) 28. Speoiflo aravlty of Aroclors Various temperatures' For 1242 Temp, c. 60 65 70 1248 12511 or OE 1*176 1260 or 0E 1*182 85 90 95 100 60 65 70 ll 85 90 95 100 60 65 70 ll 85 90 95 100 60 65 70 ll 85 90 95 100 Sp. Qr, 1.5*17 1.54*1 1.558 1.555 1.552 1.52? 1.524 1.519 1.515 1.415 1.410 1.405 1.400 1.597 1.594 !.5? 1.585 1.581 1.505 1.500 1.495 1.490 1.485 1.480 1.475 1.470 1.465 1.584 1.580 1.575 1.!>70 1.!165 1.560 1.555 1.550 1.545 Lbs, per gallon (US) 11.25 11.20 11.16 11.15 11.10 11.07 11.05 11.00 10.96 11.78 11.75 11.71 11.68 11.65 11.62 11.58 11.55 11.51 12.55 12- 50 12.46 12.42 12.58 12.54 12.50 12.26 12.21 15.21 15.17 15.15 15.09 15.05 15.01 12.96 12.Q2 12.88 HONS 054829 pept. 246 - process Description AROCLOR APPENDIX C PHYSICAL AND CHEMICAL DATA (COnt'd.) 29. Specific Gravity of Aroclors Various Temperatures fcont!d) For Temp. q. SP. Or. Lba. per palIon (us) 60 1.604 65 1.600 70 1.597 75 1.593 80 1.588 85 1.582 90 1.577 95 1.572 100 1.508 13.40 13.36 13.32 13.28 13.24 13.19 - 13.15 13.11 13.07 Heat capacity of Aroolora at various Temperatures (cal/gmc.) '^Temperature ArocloP^-l^' 0 50 100 125 150 175 200 250 300 1242 1248 1254 1260 Aroclor 1242 1248 1254 1260 .280 .270 .255 .220 .300 .280 .265 .235 .320 .295 .275 .250 .330 .305 .285 .260 .335 .315 .295 .265 .340 .320 .300 .270 Latent Heat of vaporization of Aroclora .350 .330 .310 .280 .365 .340 325 .290 .380 355 .340 .305 Temp Range Latent Heat of vaporization 300 -310"c. ?00-330C. 300-350C. 30C-370C. 6l cal/gm 54 cal/gm 50 cal/gm 48 cal/gm HONS 054830 a.... PHYSICAL CONSTANTS DATA AROCLOR 1142 (Technical) 'O-Q TOT^aTu rr --" Rev. Bv A. M. Ellenburg DirrrWT' IL.ILV.57, . Civ Fomiili_______ C. .H.C1, KkcsU!.*suw.. -... .13!. ZZ_I tournee. _____ mitt t tut.. Total Cl-41. 5 - 42. 55& Senses. 12x21.54. 1 Brown to black oily Haul? 'SFec~s~lT-H-~54 MlJiIlsiitJLKO.iP____________ Boiling EmjLjL_tun______ , toiliMPflinLt___sun________ ____ WmfJilMJl___wi____________ !H!illiiim Point tfcUuit FM_a_-------- -------------- SsWlBiMLtails,fiutilyj.____ ________________ SpMIc GtivUne. __ 2SjJlS.A?C___ Poundi pel Gl. zs *C_____________ Coefficient ol Fipyicion__________________ Reflective Indexn 3______________ _____ lnli Rftjjpecifoe //?fjir.rvc.i____________ 1.346-1.360 10 >_________ -Seess ili2!,:.H. miiVitiet teidmtfflrfoMwi ___ _____ yikttitit..J IfiKUity.t.----------- ------------------------SudKJ.lMliWL------- ------------------------ SslitllilYj Met_____________ ________ StlJllIllty.llL.------------------------------ :-- Solubility in_____________ Sp.r. Tepp. C.oeH.45fi-_Uli!.Ci-- o. oooarc _Spnej.12-.2L--.54. FlnhPolel1 Flu PoTitT'C Uulsl.totttuHtei________ HlHSLfjfffiiibD________ TM(!(.a*ii Ubr .fwLAfc!ftiJ.. LUenl Beil cl Fjtstw______ Util.HlH.il .yjc._______ tails..Hi*-----------:-------Jinsauliin______ _ CilticH Pmim tiiuisiiywLCaaUrt. llteu6_ -Aroclor feiflL.QP.tJI q i,.!\4 HONS 054631 Tonicity (Givt Rt/tltnctJ NOTE: Tkett dote ikeuld net SehwariV U. S. Pub. Healli Service Bull. >32rJ I f.>3ij and Solvents" bv ,\f. L. r rt/teitd tyU (tionol iktttt if ntttttary. T>(f> m m PHYSICAL CONSTANTS DATA (Technical) TriucNvwfct foamulT Swsr 47? d Se> Ttmrirrt!nr;--T..............~ ` '----H, v. 11v A M. Ellenburj , 7/5/57 'f Fpimuli___________f.,HnCl Molaculfci.'Naight______ ______ toemact____________________ 65l)i!!tPAi!J jl?66jj____________ Boiling Poiit il mm_______ ____ (lailiotAiillg___Ml___________ Boiling Poinl &___ mf___________ Ciysialliiim Point________ :______ MfiUiUI Pfiinl,____________ ______ Solulion Poinl___________ _______ Soocilic Gnvilv*65/15. 5 Specilic Gravity . _________ Pounds ptHTtl. t jf,' ^0 ____ CmIIicIciH ol CiMnsion Relncliun Index t__________pj_________ Infia Rad Spectrum iRtltrtnct)_____________ Uft'ayiOlel^CUu^/fie/^<re/__________ yjjsMiu.fi___________________ __ _ yisifisilyj.. ...... ........j-...._. Suteltaslao...__________ :________ SsllfeililKJttKJI-_______________ ___ SdWHlilyJn_______________________ Total Cl3 H. 5 - 48. 5 dlT 1.410-1.420 ____ .U*.- 1 Te mo: CieTClTo-m*T'1'<rm57*C~~ Cl. --_JSiia*jLait. -Saecs^l/.U/.jQ.. Specs. (T\'l75?i . j>L__i/lU5s_ FllUi/oIrrt FjjiLoLnc.... Hell f Contull'iMi Hs#j! foijaMion_________________ XlJP.Wlfl_5t|l)ll!t)f (ML/)itJliU_______ Uepl.HMl.oi fiaiM_____________ Usd Hut O*.: SaKilitJfPl______ ____________ Cnlicil Tempentuio Cillinl Piesiure CllSMilUaa Cstm*t_ 382 l-Noue_______ Aroclor Bullet in OP * i lj> _______ I'.-VTi.iiM: note, n... 2.,. .J n.,7^1/-I Ift HONS 054632 3ull.23P____ ^ if Mt*f Ul> gw XU UJN fit PHYSICAL CONSTANTS DATA ................... "' TNUCTUKAL POftMULA jtfcrW y.^%0 roomTD rv TTT"-------------------- 5TTr1947 ~ Hcv. liv A. Vi. hnt>urg oimuj__ ____ MDjecuJaj Wwj^i _ --I Tfotal ci3 59.5-60,5% 1-kv.pci _____ ~SP&~~12ji2J---5A_ ADPcatance_________ BiiCLWiilQ-lPlacK Sticky mods. Specs 12:2l-54 Ml*M* AJfifijaBoilint Pom M mm fiftllia| EfiloLt__ Boilim Point < EMULIiMMilIklUmfomL____ Solution Polnl SpSjUsJLtj)dl)f_#.____ ??ZT5Z5I SpecjlicGnvity^___ _____ ____ PoundVpeT6l.~~gS "^C CocHncienl o' t.osoiion Reliicliw Index !" & Inlij Red Speclmm /Rtfrnnrtt__ .ll^5S9--.LA7g . Specs.12*21 - 5 A y!i,.v,oid Sfdclivs.f?!/*'""/..__________ 11____ * ___ ____ ______ _________________ YittStlOj1_______________ ,,___________ Suilitt.Tmsida... ___ -______________ __ $piMiy.Js.*te ______________ .___ ___ SsUfciltoJo. '__________________ _____ ----------- ^ yGr~T?^p rcoerr. T75 n 35^01" ;o;otHP7c------------- .Specs . Qsh Polnt^F/A/>&_ Fin Point C .___ hMLRl CmOhiUm____ HtH l Fwi<ion_____ ftewljtWUly MAj/MlL)__________ UUM tl.Fisi*____________ UttMbjJl.tli*..- SmuDc. Util_ Mft n_ None. HOT 6 t Ihttt dolo ihould not It rthatod outtti Company, Ui$ addiiicnoi tKttU if ntet 1 >o'y Hi PHYSICAL CONSTANTS DATA Jysr 47? Tusmwfir"" 1t*WCTWfALPOHMWt* _____ AROC.LOR 1154 (Technical) (X? r_TST!------- i 7/5/5 7 __________________ i. _ ___name FoimyU______ Mbleculaj,Weight ... totiunct_________ ____ -- Bail.idj PpinLJl.?II,__________ Boiiiu Suit A --ffim__________ ToialTlj 53.'5 - 54.b4T brownJo oiack oily Itemictl _ Jil*. iil3A SoliUuJ'imL* . -M-------------- _. ftoilim Pont t__ rm__________ Erysliillilifll.W_____________ Uilluit Paul ______________ SpJlAiac.PsiflL___ ___________ Setsili! ____ fii, ii. Sptcilic Guvity____ ______ 25 C_______ Coellicieni ol Enpantion uJ5s.raJui_ IOZ-lX_I Rtiiadive Indeii *_______ JU_ Rfd.SpCClfU$ (RtfrjfRCtl__ _________ ._.. Wt* Visijt Smln (*st?at__________ YisuHly.*________________________________ - . bufjcclsnsion_________ ------------- SPMiliJjR.fil*.... ----------------------------SpMUlt>'it...j- ______________________ SuMUttf.iS----------------- ---------------- 0 . Sip.,.0.'^ If iRPi Uaf.tLi&5di.Q5L_i. 0. 0.00857^' Flash. Point (F lUaMl___1______ Fjie. oi_n\_^C____ 1_____________ KHttUfeifraUw.____ ________ H{|| o.l Foingljn_______________ ..... . lint Rertsl Eww____ ________ UsnLHtJl.tl !t*>.______ _____ Swcitit Ht< _______ _________ C.ijiie*! JjwmiKt_______________ ciiiisii-PitMitt - Norte ,NOQ__ Tomcily (Civt Riftnncti Schwaytz, U.S.________ ... _ ull. *22" Industrial Poisons, Vol, ,-463-364 14 t , NOT E t Tkttt rfoia thouli nA( tr utteutd;,,MzJ}v&aaJi M; ............... Sy S7f7f PHYSICAL CONSTANTS DATA AROCLOR 1162 (Technical) V . - - ....... '---- ' tiU (S47 wrerci; O-Q Rev.1 13v A. M. Bllenbure 7/5/47 -_.c.uHalv MolecuHt Weight Total Cl7 61,5 -62,5% IQUJICe t PATE -SpfiCfm--lr.11^55____ toMIJOM._____________ ___._ BrjiwiU-OijlaciiJ.tistkT-jns. s3pfi4.i-.Lli5;:.. _ ' BciliM MU ________ ei<j!* EouuJ-.m___________ BiuliatPoiiili-- Jim.__________ BsillDLPJlSLJl___ ...___ -____ Cnrslillitiiu Point______________ Udlint Paifil..,, ..____________ SolUion Point__________________ $eSii.'t-CnLi&l____ 9C/Ji^5,, Spetilic Cnvily*_____________ Pounds per Sil i>s ~^C____ Coctliciont d tnponsion ________ ReTiKlive index _____ n & J..S7.7.- 1., 58?"T -3pcfi.lmLl-.SA.. !P*' R.t<LSfi*Sfl!T-tf/"rl!-!_ Ul t' i VioIri Sped(Cn/Rtjt'inctt_______ movit-t.------- ----------------------- YiKtulyy_____,........................ Sudsu Tension_______________ So!)ility ip. _______________ ScJittlilm___________________ ________________ _____________ _________ _i------------------ aji^ar. Temp.Cecil. 4ba-.UQSj-Ji-o --Spec. 1:1L: AA FIlstLPomt^F IHtiMl Ftis Point 1*c' itii'Coitf)iiaicf......... ... Heit oj foiiMlipn______ _____ LjtM Hmipi.ficum .......... . IjM He>Ul,y., wat.ii.wL;___________ CJiHLIWTOiiat_________ Dissoculion ConstKit Npnft i~Nene-- s9 __ gr Tonicity Avt Rtt'trrKt) RONS 051835 * PHYSICAL CONSTANTS DATA rotfrllTeY0 ARt>CL.OR .242 ifAvctumal roliMui a'* ~ Sysr nf ,580 pttr & rwamin av" ___A. M. Ki.'.y burg OaTi "----M-25-5? V.._. / Foimuli __ ___ _________ Wbicculat Weight________ .___ C12 h7 c: > . *257 .'. _________ sasiKLi oils _ fiBPMIMCe _.Z___ WIHI Pilinl ft ;jm_ .R&r.]lv_ Doj ling Pftjt. it 3. ML__ 11____ -iJsJiiritAS-Mcfc-.r 0:,. ~ ~ U5 R-JL'C, _ ._ _ ii<mc: ~ .... ftu.1DP J ..-7 Boiling Point-* -Offl Bpjlij* Pjynl.lt__mm_________ CrystiNi/lng Point ___ ____ Nn- - y rys' a;!\l\' e. . Heiliug Point._____________ fcWWlPMM______ r...______ Jpptiiic.tiiixtly.a_ ..C,__ 1. HQ___________________ Specific Giavjty i S ._5_C. t ,28 l - 1. _ Poundsjw till. __ n so. _____ _M.J}__ DPai,? Coefhcient ol tynsiOfi__JSj65 C_ ,Jui0(fe&. .etJetJJJ_______ RIngtifi1>_RcetidvoSlnpdMcUiwduhKf/Cmi>w_/ 1` 1`1 -l.tidi.: _______ .jt.l .<> Ultra.VjOlrt Spectrum 'Af/jftrc/__________ yiscputy*:. ,, 10 F, ____________ .-\ir..\S. Si!S___________ 1 .u-.n..sv.sywwm._.!.oA.*a______ _________________ __________ suitKt untiML. ...t>y; tfi?saJ_42lQi._4 .4i.)__________ _____ Jol^il.itymWX?________________ ]r.s-' .bjf* ___ _ fcMtilKyji.. ?A a; .& JSiiL. iUuZi Sc-cxTI I'Ll SoJifciilyia_Pxr:.&r.t__& >Q*c. iil.lj.JlSS.es______ II \q. .C.llaJ... S', it .** . 1*T, Flash Poinl'^Kytiatof,) c . o. c, Etififfli??________..c...o....c,... Meif .0f. Form|(lpn__________ fh!4L^*i.Ul>k*lAsfc!*",".t ___ _____ UMl HtJtSl iJ.JliLl'Si SpjcjiicHuL .3JJ.S.J. _____ Quiifi.LT.wnutet___________ 55ClUiuLEussii- Diatociilipn------a-- ---------- __ Spgc ):c Heat ^ iQQ'Cl Po-r pr;rV T'onna Crv.ducMviiy, cal / ' * cm/' l/e D.e cc' r:c CorsiarV 100 C. 60 cy. .4--------180 C.______ None _6J 0,20 1 0.i*0________ l 4 'C nr lou er 24. 0~~3 28 fc. 4.-, - 0.0 Ca^xulAtpri .. . To _be-p bV tjL. jsZZbIZqEZIsL MOMS 06*836 TomC|ly (<Htt Reftrtncr/ Contact Medea Pep* ISIlBliaEZLLv II Z 1 NOTE; 7 An# 4ota iKouiti Ml A* rtlttutj euttiit of Mo/itoMo ChtmitoJ Company. (Jte additional i Arli if ntctt'jr> -pctTW ' ' . ' ' S(jiT47T a.... PHYSICAL CONSTANTS DATA .......... "......... 1" J^^io Dtp? .-ABQCLQB.-1218. f r6WFTV10TT" A, M. Ellenburg 5TT1--------------- 4-25-57 .EsiTMd.i _ k>Jecu|ij_WeiM_______ C12 HB Cld talMieate.________ Boilint PniiA M 760 imi Range Boiling Ppm a 3 m_____ BeilingEejUJ___ml. gsijiEjloiitil__ SSL: Cryslilliiisi Point______ Jidlinfc.Point _____ .____ Spijiien-EeinL__ StKifein't.ilyxL 25./251C.... Specllit Gravity ^ 65/15.8 C. Founds pe< Sel. 25 C Coefticient of Expansion 25.fi6c. Reludive Indpn y 2 F.u pH l Inti* Rail Sptclnro rKrlttenct) WliI Violet Spectfum 'KrfrtMtj _ YliSiHit#____ _ I30PF. -IJUS_L4D5J..ii5______ 02.64.. 1.6285-1.6305 KiiPSl'IJt. . SurfeoJensiM___ EUmi SoiutHlitv In W<__ _____________ ____ Insoluble toifeilitniii. .lA-Alsfthol B.aSliL--{...15 g./10Q ac jolUfriUty in Pyridine__ g."'1 ^ LSfijte. - wvhctJLtmx. -SpetlfiSfiUsos. 91.9.5T . ......... . Specification 97t).'64~'~ .cau. scix.7^mii,9?.;- Jl.fi. OP-115___________ Flash f>olnl"6K/wwj c o, c. Fire Poml^C ____ c. q. e. toUK-Catoiilten.'___________ -........ HjS el Feimgiwi_________________ TtSISSlMUItir iMUtosW_________ UmiJBeK.sl.EMiM_______ _______ UeiUMeiisI**... xal/gUL_____ totliit.HtX.aiSX;______________ CiBiiiJltfsituteX________________ Ciiliml fiMirn. Diisoci ilion Comer! 196r .Noae. _54.._ -JL221 0. 356 "Pour Point ~ Tfce'rmar Conductivmity,.cI7~ -0L ..er lower 23.6 @ 2Bt)r. 4,5-4.7 ..CjlsuUicd___ JUL-OP.- US.. To be published HONS 054637 TOXICity (Gw* Rtfrrtntt) Colftact Medical Dept. M.B. OP-115 HOT E r Tkttt dota should Mt bi nlttii/ PMOirfi /Monsanto Cktmieol Company, Vtt additional tkettt if nttmary VffT > ra.... PHYSICAL CONSTANTS DATA TwmriKt! 11 -------------------------- |,vucT5Tfn=f5tssti __ A ROC LOR 12^4 ___________________________________ Sfr 47<? X~SS6 TOFTrtO`T-------------- A . M. Kl.erbjrg rp(nwl8_..a__________ ,,______ Wtoie_culaMeitM ___ ________ tepuiwce_________ 1-------------- Bullitt P!B X M.M___ &$-'|P!lirt ?fiJDl Jd X.HUD_____ 1____ Bailing i-oml A _ Boiimi Poml __ jm________________ __________________ A. Uclliug Pwijl----------- --------------------- Sol.VfijQ.Pojn!.......----------------------------- totii'ti.iw.'ly.j. &._*------------ Specilic Ctvi(yj._ 65- 1>. ^ C'._____ ... i.'i,,iL__ __ ___ ColHicienl of Emulsion : ~ 6VPC. __ Reii'acjlvjJwlE!.'?__ _J?iPCli________ ln[l J Rfd Spfc|!L^ lJUJr'tnitj____________ Ultra Violet SfOJ(Atfr<E^_____ ___ Umiu\__ ______ 21.0.X _____ _ yj>c8s]ly *.... ... _________ ,_______ Sul ret. lotion______ BlCifcSLtm___ jmiCiiiiK.it.Me.' ------- SolltilkiJi. J A A l co'. pJ. 2 _ _C__ tooijiiy.i!!.J?i L.dj-.e. -H.-CL_ 4-7'? 4.' clliu.ci 0^0 jounce t date , Palo. Yellfltt--anon .nil...]. Mfir.sa.-.QjjjL OP. Ill'll 9_i'f _Mi.4JLC_____________ " ?j.an_____________ Nor grvs-al-i.-il c____ _;____ .4fl-.:-l---i2-'_____ JUmOfifi .I 1.637Q 1.6390 S|.r;Cjl.^r:.'a)-. - ? 1 t.i _Mli_QR.ll'. .. . . t -JliM-SMS_____ __ MH OP 11? .5JL3.fejCL,.. 1.V0..Q 100_D. JhiafaMe______i______________ IfilJ4.5!Lt__^_____ il-kJL.IlPJ 9 - oftttfttLMiMt__ f'ttfWtS.-....... ........ft..(L.tu.... 'Otsi.e* CpmfcH|l'BO........ _.......... ............... HeX.ol fmXion ....____ ___________ Slatji l|ty (cai1/Va/mi_nJ_________ UekilJJl-0.l.flW! SltSiUt-Heal______________ < 2L.XL Cf8(CII.Ts!!iKfjl|KL. Cnlicil I'mitfl arnmato JaMUil o--. ;-ilaiii-Eau.___ ;______________ ^ r rrul Co- duel Ivl'.v. Cal Cl imZRClSuLl Nrr-f L-Noie____ 50 . Jl261.. JLJlIP ~Trc7 S3. 9 e 2A.C.. i "Tvi.>"n r;c Co- .-arTTo^O 4. IT 4,3: _____________ C t. iCul c^ ''d LMP-OP-Ui Jfi.faLBjb.illtE.lL MB OP-11' HONS 084838 TtBlClty (Vnt RtferrHctJ I Midi; j_l>CE....___ LMJ3 NOTE: J Am# doto tSodd net rt/u4 ouitidt of Hontofdo CA#ufd Cotnpony. {'* oddiitonol ihetli if ntcn SyCTiyf PI PHYSICAL CONSTANTS DATA AHOCLOH J_260_ STRUCTURAL"frORMUuiLA rottmio"* v NAME Enfmma............ ........ .... . _________ Moiccutat Weight _ ta>U'U................ . ................. -- lie!tic* Poire aWIjO rntr itur *< .......... Ootlihg Cmit .4 }.m____ V.................... DfilJmi PfiUK - oim..~.............. * - ... Ooi ting Point. A.... mm... .................. ....... fyel*l,!*i.ni Po|nL ______. _______ .. Melting Point .<.......... .............-............. Sflutioil Will ............. .......... 0........ 5psi'.(nti.Ui. - ...-- tet'te S'fiir..e. .- .. ,!>0t, 1 V .V C. PoirnJs pef Gaf ...^ *C........ ....... . .Coeflcieni..ot.tp.inon. ; o .iO.'XYi.... Rfliactwc index _ .. _______ MjaRtdSpcctfUfnpA'^r/pnfpy______ .... . Uliia Violet SpwUum (Rfjt**neti ............. Viftosay .... . Visqosity r................. ..................... ^ Suilice Tmioo ....... ........ - . ___ - . JolU)ili|yjn WMw ._______ 4 . ..... .. Soivfriifty. ... ... JolubjlLty.ift............................. ._______ * jrt------- Cl I. i' _____source t oK .... _ Uil^Ai'/' i.... ..... ..... .___ _ . 1 L'l'.Yjiti0sfi[L iii.ckA iiiisli _____ __ ioa-^irc____ 1.-- ...... - .MivivltLo Jti'i... Ci' * 11 ,i..v : __________ -i.......................... .J.&pL'LlllCu'.-V*. _________ 1 Ct, St. L._______ ....... .... ......... . L..V.-U i:_______... . _S^L- ;a.' SCA.'..Li s................. .. .. .------- _ ... LMB D1MJ: )' f.----------------- _ . Flash_Po\l ________ r"(te j>nl p" _ ...... Cx-O..C. ._....... . .. Mjit pi QfntyiMw.......................... .......... HeM of.fyml.ipn. .. _v .. __.______ fM^i.StAjlily (cl.'kt-'n'in.) .. . ................ . (jtpni Hc?l ol r.usi.on............................. IjUOl Mpai pJ.Yiip. _____ Ciij&m_____ .. ^cl'c. Hpjt*......... _ 6 _______ CrJiitji Tfnp.eta^ure_____________________ Ckcilltftttft________________________ ____DiiiMWiM .CODSUOL___ __------------------ No >'av\ A /_ . lii . V.22- - ....................... - ...Lru'ii^i.ij' .. AI>'i OP, 11 ~--------------------*------------------------------------- :--------------------- i --.... ....A___________ ___________ -- ic: Mca.o Dc pi. MONS 054839 1 . MB OP 1 I S___ KOTE: Thttt dnio tknuld mi bt ttlto* td outndt of Mont onto C/M*ueo/ Company. ('<e additional them tf ner< V'-* Sy.ST*79 in.. PHYSICAL CONSTANTS DATA V 5? tool'll ID TT---- &Xfl------- -..7MA1 foimuii___________ MojeurijJ|fc|ihl__ _ _ _ Swiiioct__________ Syrupy liquid MwMiULMm.fiufll_H m aDliint^Uflt ft.__JUL. foiling Point < m toiilll'-liUifiinJ_____________________ Mgllint PfliRl______________________ SaluLisnftiai----------------------j-- 5Mt'i'J!(lllY t____ 407-15. j-C____ Smcilic Gravity t _____________ ;___ Fyjjnds pei fill. * >; CC__________ L Coellicitnl ol Enpantion Rctuctivc InOcx .___________Q g JU4.T5^L.4ai. 12-5________ hl(i M$K\mjKtltrtr,'t)____ Ulti. Violet Sferttii* _______ --____ ViKoiiiji_____:Liqde..... L5.Q.2 xs. (232 SUSJ-. yiKSJELO <t___ ___ -21fllF______:_____ J3.8.SUSJ __ SiulKt IeoiiM_______ ' WHtiliBJlM?-______ Soiitilitv m . ___ SolubititY m__________ Mixture by Weigh*. 90% - Aroclor 1260 10% Toluol Sptca.4jijs>5- JM1KJUU! 1 By i.. EllSiSsa'ltvstiil.TaeJtseiLSsip-- fiitfoiCF" ^ HMUi-CstofeulTisti....... ....... :-------------HfeLOl.Formiiai___________ /_______ ItewLSlit'iilty.Mj'liiitiD.l__.7______ Usnt tiWl OlfBiM_____ ___________ ucMiiut-i!i y.------------------- _-- $MCi!it.!iul_______________ ----- OffllHl-TwattHI. ___ --_________ 5_ UD_ WfiK Lab. \ ____ Toxicity CCtvt Rtlrrtm) HONS 064840 NOTE: TAn* rfolo ihould mi t rot**rod oui$id of Mo**omo C^tmitoi Company. Vn oddiiionot ihtoit if n PHYSICAL CONSTANTS DATA ^^wtvmr=^, 1T...... ................ T 1 .. . AKOCJ.OH 1262 * TAUCtVAAL POAMUtA ' ~' ' .... . t, roi Tin------------------ ___ A. M. Ellenbjrg_________________ ___ T/3/5'? NAME For mule CfH3Cl7 .... m culu WeiiM Afiaeirenci ___ ' 305 Li?ht veil, stickv Resin Bel imfnjiijlI66jiiir-. 3B0-425C 6sL !5j EiilmL L _JWn________ Bui hy Point M __m,, 62! ini Point it .jdjti SOURCE * OATS ,, " ----- . (1958 ' fcl 52Uion Point ,, SMI ilicGrovitvi 90/15. 5WC Spei ilic Gfivitv' 25/25vC Poundi mi Gil. j C CotNiciam ol Expansion 25-65C Refieclive Intfe* t 3fir nA Infi Rod Soectfuw Wt/iitncrl Ultr I Violet Specttom mi/rnci) 1.5^-1.587 '1.846 13.72 , 0. 00064 cc/cc/UC * ' _1. 648rl. 650 . Specs. 4/11/55 mw rP.i i * ." " mMill!____ _____ JJLQ^E------------------ flfiolOOSUS __________ -Sftec&^_i/-n/.5i._....... .......... .t luff Solubility In * tolifcllltv in ..........,............ * ' Solubliltv In 4 1= r | Fla h Point F iMtiMl Fl Point C Hul ol Confuiallon Ni< of gormStlon . IM mil fiUittltv Icil./ki/inln.l LI ml Hut ol Fution Utimt Hut ol Vm. Sol :111c Hut . Cilllul TnooniUnn CrilieM Pimuri Pour Pbtnt _ None None 11 . ^> * "55-38C------------------------- l 0i t 1 O TOXIClty fdvt Reftrtnct) t ,. Contact Med. De|t. MB QP-115______________ NOTE \ Thttt duo iKoutd Mt 4 tUtud ttuldt /UoruMtP Chtmtttl CUtt diitienai *( if *#*/>. 1K-J>t. - process Description AROCLOR APPENDIX D UTILITIES Tne utility calculations are based on design calculations for a 28.8 million pounds per year production rate. The breakdown of utility usage by individual equipment Is only on estimate. The estimates of utility usage are average values in most Instances as It Is difficult to measure the operating time and load for a particular piece of equipment with great accuracy. The total usage of each utility was taken from the cost sheets. Estimates of Individual operating time and percentage of the total load were made to calculate the distribution of utilities as given In the following pages of this section. HONS 054842 Dept. 246 - Process Description AROCLOR APPENDIX D UTILITIES (Cont'd/) 1. Power Consumption A. Electricity - 440 V., 3 phase , 6o cycle Peak Item Equipment Motor Load No. Motor HP KW 101 Biphenyl transfer 3.00 pump 103 Biphenyl head tank .75 104 Biphenyl feed pump 7-50 2.6 0.7 6.6 121 #5 Chlorlnator pump 10.00 122 #4 Chlorlnator pump 10.00 8.8 8.8 123 lf(3 Chlorlnator pump 10.00 124 #2 Chlorlnator pump 10.00 8.8 8.8 125 i1 Chlorlnator pump 10.00 127 #2 Blow tank pump 5.00 129 #1 Blow tank pump 5.00 132 #1 Still pump 5.00 135 ' #2 Still pump 7.50 140 fpl Receiver pump 2,00 141 #2 Reoelver pump 2.00 144 Blend tank pump 3.00 6.8 4.4 4.4 4.4 6.6 1.7 1.7 2.6 149 0 Storage transfer 3.00 pump 151 ff4 storage transfer 3.00 pump 153 if*5 Storage transfer 3.00 pump 155 #8 storage transfer ?.oo pump 157 #1 Storage transfer 3.00 pump 170 #1 City water pump 7.50 171 #2 City water pump 7.50 180 Exhaust blower 15.00 2.6 2.6 2.6 2.6 2.6 6.6 6.6 13.0 Miscellaneous Totals 17^75 0.9 TT978 31. Month: Usage KWH 80 24 0 1980 3040 3040 3040 3040 3040 200 1580 1580 2340 20 20 200 160 240 200 80 80 2340 0 0 >.0 267800 MONS 054843 Dopt, 246 - Process Description AROCLOR 32. APPENDIX D UTILITIES (Cont'd.) 1. Power Consumption (Cont'd.) B. Electricity - 110 V., one phase, 60 cycle Peak Load Equipment KW Monthly Usage KWH Lighting 15 5600 Instrumentation 2 1440 Miscellaneous Totals -&r 2150 7TW 2. Natural oas Item No. Using Equipment Normal Use SCPH Peak Use SCFH Monthly Usage MSCF 151 #1 Furnace 1200 2400 4 50 152 HZ Furnace 1200 Totals ' 240o 2400 "4B0TS" 4?0 ror 5. Compressed (plant) Air Item No. Using Equipment Normal Use SCFM 12Y HZ Blow tank 60 146 #5 Storage tank 60 150' #4 storage tank 60 152 #5 Storage tank 60 154 ff Storage tank 60 156 Hi Storage tank 60 Miscellaneous 10 Totals 3?0 Peak Use SCFM 200 200 200 200 200 200 200 TTOT Monthly Usage MSCP 2590 90 90 90 90 90 >50 3TOT MOMS 0S4844 Dept. 246 - process Description 55. AROOLOn APPENDIX D UTILITIES (Cont'd. 4. Nitrogen Using Equipment Normal Use SCPH Peak Use SCFH Monthly Usage SCF #1 Blend TanK /fi Blend Tank #1 Product Tank //2 Product Tank ti/> Storage Tank ff4 Storage Tank #5 Storage Tank Totals 5 5 5 5 5 5 5 51" 4 4 4 4 ,,4 4 4 S8~ 2l4o 2140 2140 2140 2140 2140 2140 14,980 5. Purchased Water Item No. Using Equipment Normal Use a pm - Peak Use 0PM Monthly Usage M. Oal. 150 #1 Still 5 151 #2 Still 5 205 til Vaouum jet 20 204 #2 Vacuum Jet 18 205 ti/> Vacuum Jet 15 206 S-K Drowning Je ; 25 Miscellaneous 2 Totals "BE- 5 5 20 20 20 50 10 no- 160 150 870 770 650 120 100 SBTTT 6. High Pressure Steam "~WTSIg Vf Item No. Using Equipment Normal Use Lb./hr. Peak Use Lb./hr. Monthly Usage M. Lb 167 //1 Blow Tank 210 205 til Vaouum Jet 450 204 #2 Vaouum Jet 400 205 ifi Vacuum Jet Totals TJB 7. Low Pressure Steam SO TS1Q av 5g&uF. Item No Using Equipment Normal Use Lb ,/nr. 510 670 616 500 mr 160 520 290 240 wr Peak UBe Lb,/hr. Monthly Usage M. Lb, 102 Blpnenyl Storage 700 Tank 158 f^l Reoelver Tank 700 159 #2 Receiver Tank 700 142 f/1 Blend Tank 200 145 #2 Blend Tank 200 146 ii Finished Produfc200 Tank Totals 2755 900 900 900 500 500 500 56750 500 500 500 150 160 150 1550 HONS 054645 Dept. 2*t6 - Process Description___________ AROCLOR APPENDIX D UTILITIES (Cont'd.) V Low Pressure Steam (Cont'd.) Item No. Using Equipment Normal Use Lb./hr. Peuk Use Lb./hr. 1*47 #2 Finished 200 Product Tank 500 I -- .fcCO #5 Storage Tank 700 900 150 #4 Storage Tank 700 900 15? lf5 Storage Tank 700 900 15*4 jf Storage Tank 700 900 156 #7 Storage Tank 700 900 Miscellaneous 1*100 Totals "78130' 2800 i0,5oo ^. Monthly Usage M. Lb; 150 500 500 500 500 500 1000 "5800" MONS 054846 Dept. ^6 - Prooess Description AROCLOR ' APPENDIX E PERSONNEL Departments 246, A-246, B-246 and C-246 are closely related. Operating personnel may work In all of the departments In a given day. For this reason, the description of operating classifications and assignments for departments 246, a-246, b-246 and C-246 1b given as though all four of the departments are Just one department. . Operating Classifications Job Premium Operator Standard Operator Repairman Packer Porter Swlngman Total .Number of Men 7 day/Wek Soheduie 1 10 ie 4 Soheduie 45 45 11 22 4i 10 12* 9* The BWingman works two shifts per week (Saturday and Sunday) as a relief foreman, two shifts as a repairman, and one shift operating the premium Job. There Is an open shift on t.ie standard operator Job that is oovered by overtime. The premium operator and standard operator cover three shifts each day. The repairman works the day shift, and with the swlngman, there is 7 days per week repairman coverage. Packers work the day and middle shift 5 days per week. The porter works half time In department 246 and half time In department 24J. The premium operator has lead responsibility for his shift. The work force works all three departments Aroclor, Pyranol and Pydraul as one coordinated operation. The assignment of time Is 70# to Aroclors, 15# to Pyranol and 15# to Pydraul. Operating Assignments: Premium Operator: Has overall responsibility and operates 5 chlorlnators S Btllls and covers the necessary absences of the standard operator. Standard Operator; Operates.2 blend tanks filter, 2 finished product tanke, Btorage tankB, makes pyranol and pydraul mixes, loads trailer, and tank cars, charges chlorlnators and transfers receivers and also belongs to the Fire Brigade. Repairman; Unloads oars and trailers of Biphenyl, Trichlorobenzene and Te tra-Trlch1orobenzene and finished product, makes weekly safety Inspections and department minor repair work. HONS 054847 Dept. g*t6 - ProceBB Description AROCLOR APPENDIX E PERSONNEL (Cont'd.) Packer; Fills, stencils and labels 5 gallon, 30 and 55 gallon drums and clcan~p assignments when not drumming. Porter; Cleans office, control room, repair room, wash room and smoking shelter. Swlngman; WorkB one day per week as premium operator, two days as repair man and two days as relief foreman. As relief foreman takes overall supervision and day shift on weekends Including arranging for maintenance night sheets and line-up of work. MOMS 054648 Dept. 2*6 - Process Description AROCLOR APPENDIX F PACKAQINQ 8e SHIPPING! Aroolor, pyranol & Pydraul are filled about half In drums and half In tank oars or tank trucks. A substantial amount (about ^056) of Aroolor Is used to make Pyranol and Pydraul. Sales are largely directly to the customer. The remainder Is In bulk shipments to the J. F. Queeny Plant. All electrical grade tank truck shipments are made in the customers trucks which are Btainless steel. Non-eleotrlcal Aroclore are shipped in leased trucks and may be Iron although other materials of construction are suitable Pydraul Is Bhlpped in steel tank trucks. Electrical grade Aroolor and Pyranols are shipped In lined tank cars either *,000 or 8,000 gallons In oapaolty. The lining is either tin, zinc or aluminum spray beoause Iron contamination Is detrimental to the electrical properties. Electrical grade cars are either owned by Monsanto or on a long term lease. Non-Electrical grade Aroclor Is shipped In steel care. All electrical grade lots and bulk shipments of non-electrlcal material are sampled from the final container. That Is all tank cars and tank truoks are sampled and analyzed after loading. All electrical grade drums are sampled from one of the drums. Tank oars and tank trucks are inspected to be Bure they are free of dirt and water or other foreign material before loading. Heels are drained before loading some materials. Car washing when necessary is done by the repair track. Tank cars are sealed with a numbered aluminum seal Lacquer lined drums are used for Aroclor and Pyranol and plain Bteel drums are used for Pydrauls. A summary of products, weights and containers current use Is as follows: Product 1232 12*? 12*8 120* 1251! Xylene 1260 1262 MCS295 5 Oal. -' 60 60 60 60 60 .- Weights and Containers 30 Oal. 50 Oal. - 600# - 600# ' - 600# - 600# - 600# - 600# - 600# - 6*5# 21 - Yes Yes Yes Yes - TC . Yes Yes Yes - Yes " Pyranol 1*60 Pyranol l*8l - 675# - 675# HONS 05*8*9 Dept. 24b - Process Description AROCLOR APPENDIX F PACKAOINQ k SHIPPINO (Cont'd.) Product Pyranol A-15B3B Inerteen PPO Pydraul a-200 Pydraul SBo 5 Qal. P 65 59 - Weights and Containers 50 Qal. --5TB5Y:' >60# ?60# Uii 64^ - ' 625# TT - Yes - TC 4000 Oal. 4000 Oal. k 8000 Oal. - HONS 054850 Dept. 246 - Process Description AROCLOR APPENDIX 0 . MATERIAL BALANCE jg. The material balance on Dept. 246 was made with a minimum of field measurements. Most of the estimates on the following page check fairly close with actual raw material usages that can be readily measured. The exact composition of some of the Intermediate process streams Is uncertain HONS 054851 1 2 CftLOfUMTORS | ULt ATWI*L PSR 100 U5. AflOCLOR Dept, 2A6 - Process Description AROCLOR APPENDIX 0 Ho. SUMMARY OP MATERIAL BALANCE RESULTS AROCLOR 12A2 Raw Material & cost (t/lb.) Biphenyl (,066) Usages - Lbs./lOO lbs. product Theory Material Balance 58 65 Material Balance Usages lbs/100 lbs. 58 Finished Prod. 1 Filter Cake 5.5 Still Bottoms .5 Off-Oas HC1 8505 Chlorine (.0217) 8A 91.8 A2 Finished Prod. 1.5 Filter Cake .05 Vaouum Jet 2.8 Still Bottoms .95 Alr-HCl Mix ture AH.50 Off-Oas HC1 91'.'TO Ferric Chloride 1;.129) Attapulgus Earth |1.0502) Air (.00055) Lime (.0100) 0.05 15 5 0.5 .05 .15 5 0.5 .05 .15 5.0 0.5 Biphenyl (.0662) Chlorine (.0217) AROCLOR 12A8 52 56.5 96 105.2 52 Finish Product 1 Filter Cake 5 Still Bottoms .5 Off-Oas HC1 5875 ^8 Flni$hed ProU. 1.5 Filter Cake .05 Vacuum Jet .55 Still Bottoms .95 Alr-HCl Mix ture 50.15 Off-Oas HC1 105.20 These raw materials are the same for production of all Aroclors. MONS 054853 Dept. 246 - Process Description AROCLOR 4l. APPENDIX 0 SUMMARY OF MATERIAL BALANCE RESULTS (Cont'd.) Raw Material & Cost ($/lb.) Biphenyl (.0662) Chlorine (.0217) AROCLOR 1254 Usages - Lbs./lOO lbs. product Theory Material Balanoe 46 49.6 108 117.5 Material Balance UBages Lbs./100 lbs. 46 0.5 2.8 0.5 *T5T& Finished Product Filter Cake Still Bottoms Off-Oas HC1 54 Finished Product 1 Filter Cake O.05 Vacuum Jet 6.8 Still Bottoms 0.95 Alr-HCl Mixture 54.7 Off-Gas HC1 TTT30' Biphenyl (.0662) AROCLOR 1260 ^40 4J.4 4o 0.9 2.0 Finished Product Filter Cake Still Bottoms Off-Oas HC1 Chlorine (.0217) 120 128.8 60 Finished Product .5 Filter Cake 0.05 Vacuum Jet 4.8 Still Bottoms O.95 Alr-HCl Mixture 62.50 Off-Oas HC1 T2B.BC) MONS 054854 Dept, 6 - Process Description AROCLOR____ 42. APPENDIX H__ ATMOSPHERIC DISCHARGE - WASTE DISPOSAL Discharge to Atmosphere Lbs. per C Lbs. of Aroclor Produced Total Lbs./Yr. based on Prod. Rate 28.6^1^ 1. HC1 fumes from blow tanks 0.01 . 2)000. 2. HC1 fumes from other tankB vented to atmosphere 0.01 2,000 >. Chlorine gas from chlorinator vented to blow tank unknown .Unknown 4. Aroclor c Biphenyl vapors of tanks vented to atmosphere Unknown Unknown Discharge to Sewers 1. HC1 from chlorlnators 2.5* 500,000* 2. Cie from ohlorlnators 2.0* >0,000* Discharge to Waste Disposal 1. Montar 0.0176* 5,000* 2, Aroclor .* 95,000* ^Estimated MONS 05*855 Dept 2*16 - :Process Description AROCLOR APPENDIX 1 Sampling Point Chlorinators Blend Tanks Storage Tank Composite Tank Cars & Tra)lers PROCESS CONTROL Frequency Reason for Sample ****Normal Range Method Number 2-J tlmeB per batch Specific Gravity .011 > times each day Every 1-2 dayB Color (APHA) - Sp.Gr. at 25/15-5 C. 50-150 Max. 10,08*1 .011 10,11** Acidity (mg. KOH/g.) "Moisture (HeO) (PPM) .01*1 Max. 10,087 >5 PPM Max. 10,620 "Refractive Index at 25C. "Inorganic (free)Chlorldes1 .0020 .05PPM 10,125 "Dleleotrio Constant Max. .20 T-2092 11,608 "Resistivity (500 VDC at 100C. 500,Min. 11,607 0.1" GAP as ohm-cm X 10y "Hydrolysis Stability 1.0 PPM Test (as Chlorides) Max. T-2087 "Monsanto Stability Test (As Chlorides) 0.5 PPM Max. 11,50? ""Sulfates None ""Dlgleotric Strength at 12,169 J5 KV Min. 11,605 ""Visoosity at lOOuF.(SuS) 10 10,086 """Thermal Chemical Chlorid- 0.75 PPM es Max. 12,722 Same as blend tanks Every Load Same as blend tanks "Tests made on electrical grade Aroclors only. ""Tests made on request only. """Special customer test. """"Maximum range for all Aroclors Including electrical and non-electrlcal grades. HONS 054856 Dept, 2A6 - Process Description__________ ^ AROCLOR____ APPENDIX J SAFETY te TOXICITY DATA Safety Equipment The following is a list of safety equipment (personal and departmental) required in department 246. 1. Fire extinguishers: A. Dry Chemical (}) - Southwest corner Bldg. CR - Main Floor. - West wall at top of stairs of Second Floor. B. carbon Dioxide Snow - Southwest corner of Bldg. CR, ground level. 2. Chlorine Qas Masks (4) - Southwest oorner, second floor - Control room, seoond floor - East side, outside control room - Wall, Southwest oorner of Bprinkler house, main floor. J, Soott Air Masks - West of Lean-To A. Safety Showers (2) - Southeast corner of Bldg. CR, ground level. - Southeast oorner of Bldg. CR, 2nd Floor. 5. Davis Vapotester 6. Eye Baths 7. Sprinkler System Safety Precautions The folliwlng are safety precautions followed in the operation of department 246.1 1. Safety Equipment of Employee Each employee has the following safety equipment: (1) Hard hat (2) Safety glasses (5) Goggles (4) Rubber and canvas gloves (5) Rubber overshoes. Special equipment may be issued as neoessary for performing a particular job in a safe manner. MONS 054657 Dept, 246 - Process Description__________ A5, AROCLOR APPENDIX J SAFETY 8c TOXICITY DATA (Cont'd.) Safety Precautions (Cont'd.) 2. Sampling of crude Aroolor The samples of Aroolor taken during the ohlorlnatlon reaction are hot (170C.). Precaution muBt be taken to avoid skin contact of samples and Inhalation of Hydrogen Chloride, Chlorine and Aroclor vaporB. J. Fires Fires may result from the Ignition of leaking gas, Xylene, Diphenyl, rags, paper, wood, etc. Automatic fire extinguishers and sprinklers have been installed to combat fires. A. ExplOBlonB ' Explosions may be caused from accumulated pockets of natural gas or a rapid burning of Diphenyl In a closed container such as a Chlorinator. Chlorlnators are equipped with a 10" diameter pressure relief line with a rupture disc made to burst at 22 psl In case Diphenyl within the Chlorinator Ignites. 5. Toxicity Toxlolty does not present a serious problem. However, a complete dally change of clean clothes Is supplied to each person and time Is allotted at the end of eaoh shift to take a bath, instructions are also Issued to avoid actual skin contact with Biphenyl and Aroclor as much as possible and to wash handB and faoe before eating. 6. Miscellaneous There are many aocidents that oan occur that may be classified as health and safety hazards. These aocidents may result from such things as broken process lines, acid leaks, steam leaks, etc. The worst Inherent hazards are as follows: . 1. Free Chlorine from ruptured line or major leak. 2. HCl Oas from ruptured line or m?Jor leak. 3. Dropping bottoms from stills. 4. Hot Aroclor it Diphenyl. Safety Record The last lost-time Injury In Dept. 246 was January 28, 1948. The frequency of minor Injuries Is low, around one per month. Toxlolty: This material is a liquid under normal conditions and has a medium toxicity range for liquid Ingestion and high toxicity for vapor Inhalation. The maximum allowable concentration (M.A.C.) Is 1 mg/cublc meter. Fire Hazard: There Is no fire hazard under normal conditions. Aroclor mixes (Xylene, Toluene, Butyl Acetate, etc.) may burn and explose at high temperatures when exposed to flames. MONS 054858 Dept, gA6 - Process Description AR0CL0R APPENDIX J *10. SAFETY & TOXICITY DATA (Cont'd.) Other Hazards: ThlB material can cause dermatitis, systemic poisoning prom tne l'umes, and yellow atrophy or the liver. There are Bkln, mucouB membranes and eye hazards encountered in handling this material. Treatment and Antidotes: Call a physician and remove patient from fumes. Storage and Handling: Proteot the skin, lungs, and eyes by wearing approved protective clothing, respirator, and goggles. People who handle this material at elevated temperatures should have medical supervision, undthe air should be sampled to insure compliance with M.A.C. There are no special storage restrictions under normal conditions except store In a ventilated area. Shlpplng: There are no special shipping restrictions. FERRIC CHLORIDE (PeCls) Toxiolty: This material 1b a solid under normal conditions and is nonloxlc or has a rating as low. Fire Hazard: There Is no fire hazard under normal conditions, but It will emit toxic fumes at high temperatures. Other Hazards: Some people are allergic to this material and may develop skin rash, and there Is an eye hazard. Treatment and Antidotes: Call a physician. Storage and Handling: Protect the sxln with approved protective clothing, avoid the breathing of FeCls dust, wear approved respirator with adequate cartridge, and proteot the cye3 wltn approved goggles. There are no storugc regulations. Shlpplng: There are no shipping restrictions. DIPHENYL (CfeHsCftHc.) Toxicity: This material Is a solid at normal conditions and 1b medium loxlcT The M.A.C. of vapor Is 2 mg/cublc meter of air. if Ingested, the lethal uoue Is 2.A g/Kg of body weight. The fumes are not dangerously deadly, but'they are poisonous over a prolonged time. Fire Hazard: Diphenyl is very flammable and will burn when exposed to heat or flame or oxidizing materials. Other Hazards: Diphenyl Is not too corrosive to skin, but it will affect the' eyes. HONS 054659 Dept. 46 - process Description AROCLOR 47. APPENDIX J__ SAFETY 8c TOXICITY DATA (Cont'd.) DIPHENYL (C6H5C6H5) (Cont'd. ) Treatment and Antluotes ! WaBh eyes with water and get the patient to fresh" a Ir. Try to ";er~patlent to vomit, and call a physician. Storage and Handling! This material can be Btored In steel containers away from fire hazards and oxidizing agents. Wear suitable clothes and approved goggles when handling diphenyl. Shipping: Ship In oars or other suitable oontalnerB with a red warning label of flammability. XYLENE (C6Hl((CH3)* ' Toxicity: This material is a liquid under normal conditions and Is very toxio In liquid or gaseous form, but It Is less toxic than toluene. The M.A ,C. Is 00 ppm. Fire Hazard; This material is very flammable and the limiting explosive concentration Is 1-5.yf, by volume in air. It will also react with oxldlzing agents. Other Hazards: This material will cause neorosls If enough Is Inhaled, and is hazardous to eyes, mucous membranes, and the skin. Treatment and Antidotes: Oet patient to fresh air, and call a physician If Injested, get patient to vomit. Wash eyes and skin with water. Storage and Handling: This material should be stored In a cool wellventilated area away from fire hazards or strong oxidizing agents. The material for storage can be steel cars or tanks. Wear approved protective clothing, respirator, and goggles. Shipping: Ship In containers of steel or appropriate material with a red label. TRICHLOROBENZENE: Toxicity: This material Is a solid at room temperature and the vapors are quite toxic. The solid is poison If Ingested. The M.A.C. Is 50 ppm Fire Hazard: This solid Is flammable but is listed only as a moderate fire hazard. Will burn at 420C. or above. Other Hazards: This material will affect the liver, eyes, and mucouB membranes. Treatment and AntldoteB; Wash eyes with water, and get patient to fresh air. Can a physician. HONS 064860 Dept. g^6 - process Description 46. AROCLOR APPENDIX J SAFETY 8e TOXICITY DATA (Cont'd.) TH1CHLOROBENZENE fCont'd.) Storuge and Handling: Store this material In cool, well-ventilated area uwuy l'rom hazards anu oxidizing agents. Wear protective clothing, chemical safe goggles and approved respirator. Shipping: Ship In steel containers like care on tanks with red label. TETRA-TRI-CHLOROBBNZENB Toxicity: This material Is a solid at normal temperatures and Is medium toxic.The M.A.C. of vapor is 50-75 ppm. Fire Hazard: This material Is not a very great fire hazard, but it will burn at high temperatures and will decompose and emit chlorine. Other Hazards: This material will affect the eyes, skin, and mucouB membraneb. Treatment and Handling: Wash eyes and skin with water and get patient to fresh air. can a physician. Storage and Handling: Store this material In a cool place away from fire hazards and strong oxidizing agents. This material can be stored In steel cars, tanks, or eto. Wear protective clothing, approved respirator, and chemloal safe goggles when handling this material. Shipping: Ship this material In containers marked with a red label. LIME Ca(0H)e Toxicity: Lime Is not dangerously toxlo, and It is regarded as more of a nuisance. This material is a solid or slurry. Fire Hazard: This material Is not flammable. Other Hazards: Lime Is very hazardous to the eyes. It will burn the skin alBO, and the dust will affect the muoous membranes. Treatment and Antidotes: Flood eyes and skin with large quantities of witer. If lime is Ingested, get patient to vomit and call physician. Storage and Handling: Lime can be stored in steel containers, and people should wear protective clothing, respirators, and rubber or chemical Bafe goggles when handling lime. Shipping; There are no special restrictions for shipping, but the containers should have a white label, a caustic warning. HONS 054861 Dept. 2^6 - Process Description A ROC LOR ___ APPENDIX J *9. SAFETY 8e TOXICITY DATA (Cont'd.) ATTAPULOUS EARTH: Toxicityi This earth le not toxlo In general. Fire Hazard; There le no fire hazard. Other HazardB: Attapulgus earth can create a duet hazard almllar to other duets that contain silica. Treatment and AntldoteBi Consult a physician. Storage and Handling: Attapulsug earth presents no special storage problem and should be handled by persons wearing an approved respirator. Shipping: There are no special restrictions on shipping. HYDROOEN CHLORIDE (HC1) Toxicity: This material le a gas under normal conditions and Is very toxic." The M.A.C. Is 5-10 ppm and a concentration of 1500-2000 ppm would be fatal to humans In a few minutes. Fire Hazard: There Is no fire hazard under normal conditions, but wet gas reacts with some metals to form hazardous hydrogen. Other Hazards: ThlB material Is hazardous to teeth, skin, eyes, and mucous membranes. Treatment and Antidotes: WaBh profusely with water, If lnjested, eat chalk, magnesium hydroxide, egg whites, and milk, and also administer oxygen. Call a physician. Storage and Handling: This material should be stored In a cool, well Ventilated area away from oxidizing agents. This material can be Btored In rubber lined, glass, or tantalum vessels. People handling this material should wear suitable clothing like rubber aprons, shoes, and gloves. Also rubber goggles or ohemloal safe grades and approved pack or canister gas masks. Shipping: Shipping containers must have a white warning label and a non-flammable label. Ship In appropriate containers such as rail car or carboy. CHLORINE (Cle) Toxicity: This material Is a gas under normal conditions and Is very toxlc"^ The M.A.C. Is .55 to 2 ppm. A concentration of 1000 ppm would be rapidly fatal. Least concentration with detectable odor Is 5-5 ppm HONS 05*862 Dept. g'<6 - Process Description DO. AROCLOR___ APPENDIX J SAFETY & TOXICITY DATA (Cont'd.) CHLORINE (Cl.) (Cont'd. ) Fire Hazard! There 1b no fire hazard under nomal conditions, but there is an explosion hazard If chlorine 1b mixed with a strong reducing agent such as hydrogen or hydrocarbons at high temperature. Other Hazards: ThlB material causes eye, skin, and mucous membrane Irritation. Treatment and Antidotes: The patient should be given oxygen Immediately and treated Tor shock". Call a physician. Storage and Handling: This material should be Btored In a ventilated and cool" place away from fire hazardB. When handling, wear a gas mask or approved respirator, clothing and rubber or chemical safe goggles. In strong chlorine concentrations, wear canister gas masks, Scott air pack, or oxygen breathing apparatus. Shipping: The shipping containers must have a green gas label and a non flammable label on. Ship In steel cars or cylinders. HONS 054863 lieot 246 - ProcesR non cript-lon AROCLOR APPENDIX K BACK 0ROUND INFORMATION 51. The manufacture of Aroclore was developed quite by chance. The Indian Refining Company, in the latter part of 1926, approached the Swann Chemical Company located in Anniston, Alabama, regarding the production of Biphenyl which the Indian Refining Company wanted to UBe as a heat transfer medium. The Swann Chemical Company agreed to produoe Biphenyl, but first a process had to be developed. Two years later, In 1928, a pilot plant for producing Biphenyl became operative. However, In the meantime, the Indian Refining Company dropped all interest in Biphenyl. Since a prooess had been developed for manufacturing Biphenyl, the Swann Chemical Company started looking for other outlets for this material. The simplest outlet was in the form of Chlorinated Biphenyls which were produced In the laboratory In 1929. The Chlorinated Biphenyls produced exhibited good electrical properties. This was reported to the Qeneral Electric Company who immediately became Interested In the product which ultimately developed Into large Beale consumption In electrloal transformers and oapacltors. The trade name "Aroclore" was adopted for the Chlorinated Biphenyl produots. The properties of Aroclore vary from mobile oily liquids to fine white crystals and hard transparent resins. The excellent electrical properties, fire reslBtanoe and Inertness of the Aroclore make them useful for many applications. Plant equipment was Installed to produoe Aroolors at a rate of 5000 poundB per day or 1 million pounds per year. In the following years, this production rate was Insufficient to meet the Increased sales requirements. The Swann Chemical Company was purchased by the Monsanto company In 1955. ThlB purchase gave'Monsanto aocess to the patent rights for the production of Aroclore. Production Capacity needed to be expanded, and since Monsanto had a Chlorine Plant at Plant"B" (now oalled the W. 0. Krummrlch Plant), the Aroclor production was transferred from the Anniston Plant to the Monsanto, Illinois Plant, where operations at an Increased productive capacity started In September, 1956. By 19*10, the Krummrlch Plant production capacity wbb Inadequate, and In 19*11, a similar production unit was installed in the Anniston Plant. MONS 054664 Mon3unto Company Monsanto, Illinois Accepted by production WBJ Messrs: P. E. Helsler - WOK E. E. Martin - WOK R. W. Bucknell - Org. Ros. SAFETY REVIEW COMMITTEE Original signed by; CWR 2-19-64 0D0 2-20-64 HBP 2-10-61 January 17, 1964 K. L. McHugh - Org. Res. Process Holders TENTATIVE AMENDMENT NO. "A" TITLE; Aroclor Standard Manufacturing Process of Dec 811.01 - 811 07 17. 1962 OBJECTIVE; Increase amount of Ferric Chloride Catalyst added to the Biphenyl In Dept. 246, Aroclor. PRESENT PRACTICE; Presently 1 lb. of ferric chloride Is added to the biphenyl charge tank to A000 lbs. of biphenyl. It Is suggested that this amount be Increased to 2 lbs. of ferrlo chloride per 4000 lbs. oharge of biphenyl added to the charge tank. It haB been shown In the St. Louis Research ReportB Nos. 1640 and 2072 that a minimum level of Fe Cla catalyst 1b 0.03$ to produce stable Aroclors. Aroclore manufactured at the W 0. Krummrlch plant do not meet specs. by as comfortable a margin as Anniston's Aroclors do. if we are to retain our customers for electrical-grade Aroclors at W.O.K., the quality must be Improved. Safety will not be affected in any way. This will be a permanent procedure change. W. B. Johnson MONS 054865 Tentative Amendment No. "A"(Cont'd. APPROVAL: orl1nal signed by; ---------------- E. E. Martin F.'TJarlTn -'VoY.-------------------------- --------------- r. ) DATE:. Date reS^- mxw- /19/6A Date MONS 054666 DISTRIBUTION LIST: 1, 2. J, 5. 9-6. 7, 0. 9. 10, 11, 12, 13-lA, 19-16, H. L. Mlnckler/R. S. WobuB - Qen. Offices R- E. Soden - WQK T. W. Dalton - WOK J. R. Kellogg - WOK St. Louis Research Vital Records Center WOK Standards Department WOK Technical Services vault Copy Englahd England Anniston - R. 0 Moody Extra May 9, 196} TENTATIVE AMENDMENT NO. A PROCESS DESCRIPTION FOR THE MANUFACTURE OF AROCLOR IN DEPT. 2A6 5fr' KBCEMBER 17.' 196? -"W. KMmmrkSh plaNt, HoH&anto, Illinois SUB-TITLE: Preparation of Aroclor 1232 by the direct chlorination process oommon to Aroclor 12A2, 121)8, 1254, 1260 and 1262. PRESENT PROCESS: Aroolors are the reaotlon produots formed by the chlorination olJ diphenyl In the presence of Iron ohlorlde catalyst. The crude Aroclor, produced in the ehlorlnator, 1b air blown, distilled over oalclum oxide treated with Attapulgus earth, filtered, and transferred to storage PROPOSED CHANGE: Amend the existing manufacturing process to Include the production of Aroclor 1232, whioh contains high percentages of dichloroblphenyl, to be UBed In the large scale preparation of MCS 177, a 700-80CrF. heat transfer fluid. Aroclor 1232 1b prepared by the direct chlorination of diphenyl to a specific gravity of 1.232 to 1.236 at b5/15 5C. In the presenoe of Iron chloride catalyst. The crude Aroclor 1232 Is air blown, and dlBlllled over calcium oxide prior to transfer of the product Into storage containers at 50 to oOc. Insoluble Isomers, present In this special Aroclor 1232, slowly separates out of solution upon prolonged standing at room temperatures and are very difficult to redlssolve. Since this product is a starting material for the MCS 177 process, the Attapulgus treatment and final filtration are optional but not neceBBary. MONS 054867 -2- Thls special Aroclor 1232 cannot be back-blended If the finished product 1b off on its prescribed chlorine specifications The Incorporation of excess monochloroblphenyls Into the product will Increase the volatility of the MCS 177 and the addition of trlchloro. biphenyls will drastically raise the pour point of the finished heat transfer fluid, Abnormal compositions of this Aroclor 12>2 are readily detectable by gas-llquld chromatographic analyses. Approval 1b requested to demonstrate this change as a source of the necessary starting material for Monsanto's candidate. In the lucrative field of high temperature heat transfer applications. ORIGINAL SIGNED BY; Written by J. D. Sullivan ' J. D. Sullivan ~ Date_________ 3/9/63 Approved By: Original signed by; W. R. Richard_________w. R. Richard P. E. Helsler_________p, E- HelBler E. E. Martin__________E. E. Martin Safety Review Committee: MOKS 054868 1. R. S. Wobus 2. C. Barbre 3- T H. Becker A. J. soffranko 5. St. L. Res. Lib. 6. St. L. Res. Lib. 7. Plant B 6. England 9. P. 0 Marsh 10. Plant B 11. Plant B 12. Plant B 13. H. L. Hubbard in. J. Mltoray TENTATIVE AMENDMENT AROOLOR PROCESS January 23, 1951 Dept. 46, plant B ThlB amendment provides for the addition of anhydrous Fed*, 0.3)6 by weight of biphenyl, to the chlorlnator aB fortifying catalyst for the production of Aroelor 1160 This change In proceBB operation Is a result of a complaint submitted beoause of the presence of green color In Aroelor 1260. Research work has Indicated a trend toward Improved color when anhydrous FeCla Is used either alone or In combination with plant steel catalyst. To cite an example, using 5)6 by weight plant steel catalyst, an untreated Aroolor 1260 was prepared In the laboratory having a color of 56)6 Transmission (Fisher Eleotrophotometer, filler 425b), whereas from a batch In which the Bame catalyst plus 0 3)6 by weight anhydrous FeClj was employed, an Aroelor 1260 of 72)6 Transmission wsb obtained. Extensive analyses of the Aroolor 1260, which was prepared using plant steel In conjunction with 0.3)6 by weight anhydrous FeCl, did not indloate any abnormalities or deviations from usual quality material. A complete summary of the Research work Is presented In a memorandum to Dr. R. M. Hitchens, January 24, 1951. It Is proposed to condut a plant demonstration which will comprise the production of three to four chlorination batches of Aroelor 1160 using 0.3)6 by weight of the biphenyl charge as anhydrous FeCl. Depending on the outcome of this plant trial, that is, If a color Improvement 1b observed and a normal quality product is retained, a run of longer duration will be planned to study further the effect of anhydrous Feds catalyst on the color of Aroelor 1260. This may include variations In the amount of FeCl charged to the chlorlnator. original signed by- In January 24 APPROVED; 1951 Original signed by: ....x/%tte j. p. Mltoray 3 P Mltoray HONS 054669 w.._Jj-Mj-Miltan_____ 1/25/51.. O Dalton Date ^ , h.,,B. Hosmer D. B. Hosmer 2/26/51 pate n, narbre______________ 6/25/51 C. Barbre Date ,,-Paul 0, Marsh_________ 1/26/51 . P. G. Marsh pale SAFETY REVIEW COMMITTEE Original signed by. T'.Mp.----------- - R.R.H. 10-0, *7 R.H.M.. ____ 10-Q-r,7 September 27, 1957 D1 Btrlbutlon s l)r. 0. J. Welnkauff - Research R, S. Wobus - Roberts Bldg. T. M, patrlck - Research A. M. Ellenburg - Research T. W. Dalton - WQK J R. Kellogg WQK Process Holders TENTATIVE AMENDMENT- NO. ____ B Title: Aroclor - Standard Manufacturing Prooess Objective: This amendment covers changes in the chlorination step of the Aroclor process; In particular. It suggests that the batoh of biphenyl be circulated In the ohlorlnator during the entire period of chlorination, and that a temperature of 1>0-150C., be maintained during the whole chlorination Previous Practice: In the Manufacturjng Process, no definite temperature 1b described for the start of the Chlorination. For the biphenyl measuring tank a temperature of at least 85C., Is recommended and as a "finishing temperature" a range of 120-135C is described for Aroclor 1242 and 1248, a "finishing temp erature" of 120-150C., for Aroclor 1254, 1260 and 1262. The circulation of eaoh batoh In the chlorlnator is started after the first four (4) hours of the ohlorlnatlon (approximately half of the total chlorination time of Aroclor 1242). . proposed Amendment: The biphenyl charge will be heated to at least 115-120C., In the measuring tank. After charging the chlorlnator, circulation will be started before the chlorine feed Is begun to allow distribution of the ferric chloride oatalyst. The temperature of the chlorlnator should be brought up to 1J0C., In a minimum time usually 20 to 30 minutes after the chlorine Introduction The chlorination of biphenyl to all liquid Aroclors should be carried out at a reaction temperature of 130-150C. MOMS 054870 Tentative Amendment No.__ B -2- September 27, 1957 TropoBed Amendment (Cont'd.) NOTE: In order to meohanlcally reduce losses due to sublimation and en trainment, It Is suggested that the circulating line Introducing the charge Into the top of the chlorination be extended to the surface level of the biphenyl charge. This will prevent the reaction mix ture from being Bprayed Into the exit gas stream and should ell mlnate Borne entrainment. Justification: Laboratory experiments and actual plant runs have Indicated that catalyst concentration and reaction temperature are Imperative for the production of an end product of good quality. (Final Report No. 1640, October 22, 1956 by H Merten, ProgeBS Report No. 5; Job No >428 Code IND FL, of August, 1957 by H Merten and A. M. EllBnburg. Circulating each biphenyl batch from the beginning of the chlorination should facilitate the production of a more uniform material, since a better contact of the biphenyl charge with the oatalyst at the start of each chlorl nation Is made possible. The catalyst will be distributed more evenly and hot Bpots will be eliminated, The production of Inferior Aroclor caused by too low a chlorination temp erature of deficient oatalyst distribution would be avoided by changing the present Manufacturing Process according to this amendment. In addition to the data obtained by laboratory experiments (described above) the following Table 1 Illustrates the effect of temperature changes on the quality of the end product of actual plant runs (Bhown by stability chloride values). Table II Indicates the Improvement in the stability of different Aroclors produced by circulation of the batches during the whole chlorination period compared to runs carried out with Datch circulation after the lapse of a four-hour chlorination period. TABLE I Batch No. >19 >20 >21 Temperature Low High 94 116 110 129 1 145 ^Stability Chloride ppm,/l6 hrs O.80 0.7*1 0.49 MONS 054671 Tentative Amendment No.___ B -5- September 27, 1957 TABLE II Circulation Aroclor No. after 4 hours after 4 hours entire period entire period after 4 hours after 4 hours entire period entire period 1254 1254 1254 1254 1260 1260 1260 1260 Lot No. T-631 T-632 T-635 T-636 T-1044 T-I0A5 T-1048 T-IOA9 Stability c ppm./l6 h .5 .89 45 .*5 52 .57 59 . .45. Precautions: No Increased toxicity or safety hazards will result from this prooess change Extent of Demonstrations; It Is suggested that this amendment be Incorporated In the standard Manufacturing Process as soon as possible. Original signed by; H. L. Merten . H. L. Merten Research Department In Approved: Original signed by: J. r, Kellogg ---------Z: E7 "Kellogg"' A. M. Ellenburg A. M. Ellenburg T. Dalton T. W Dalton T. M. Patrick, Jr. T. M. Patrick MOMS 06*872 Safety Review Committee ORIGINAL S10NED BY: H. L. Hubbard 3/16/57 R. H. M.__________ 3/16/5? R. E. Howard 3/16/57 March 13, 1957 Distribution: Dr. 0. J. Welnkauff - Research R. S. Wobus - Roberto Bldg. H. L. Hubbard - Researoh A. M. Ellenburg - Research T. VI Dalton - WOK J. R. Kellogg - WOK Process Holders Tentative Amendment No.__ a Title: Aroclor - Standard Manufacturing Prooess for Department 246, W. 0. Krummrlch - Revised 3/15/55 - 0. N. Schwartz. Objective: This amendment covers process changes In the chlorination step of the Aroclor Prooess, Section V Part B, concerning the Catalyst. Present Practice: The biphenyl charge Is dropped by gravity to the #1 2, 3, ^ or 5 chlorlnators. The chlorlnators are constructed of steel and are 3 feet In diameter x 16 feet In height. For catalyst, they contain an 11 foot bed of coarse Bteel turnings which have been burned free of oil and moisture over an open gas flame prior to their Introduction into the ohlorlnator. Additional catalyBi. Is added to the chlorlnators as required, Normally, this Is not necessary more than once a year. proposed Amendment; In addition to the present catalyst source, each chlorinator batch of 3600 or 1(000 pounds of biphenyl will be charged with 2 pounds of an hydrous ferric ohlorlde before the chlorination begins. Justification: Experience haB shown that various degrees of unstable Aroclor can result at times from the present method of supplying catalyst to the chlorination step. The use of FeCla has been Investigated and found to give a very Btable product when used In the suggested purportlon The complaints from Qeneral Eleotrlo Company on Aroolor 12S2 re garding the Instability of certa n material produced In July and August, 1956, make It mandatory that we maintain our Aroclor quality at Its maximum at all times. ' MONS 054873 March 13 1957 -2- Tentatlve Amendment No.A precautions: No Increased toxicity or safety hazard will result from this process change. Ferric chloride Is highly hygrosooplc and is acidic In nature, therefore care should be tanke to prevent oontact with skin or clothing. Extent of Demonstration: The process change has been demonstrated at Anniston. This amendment will be a permanent change and should be Incorporated In the next revision of the manufacturing process. Approved: Original signed by: j. r. Kellogg ------------ X'TC Kellogg" T. W. Dalton T. W. Dalton In A. M. Ellenburg Organic Research Group Leader A. M. Ellenburg A. W. Ellenburg F. B. Zlenty 3-19-57 T. M. Patrick for T. M. Patrick HONS 05<i87< Monsanto, Illinois June 8, 1959 CC: C. M. Edelblut - AnnlBton J. Clegorn - Anniston Safety Review Committee Original signed by; T.M..P. 6-13-59 R-F...H. C-lg-IQ R. H. M. 6-15-59 Messrs. J , WW . lD/na1l9to^1n1 T. M. Patrick - ReBearoh M. Ellenburg - Research H. S. Soott Process Holders PROCESS AMENDMENT - AROCLORS beptygns1 '-v'jsxrrnm-- Title Mod'fflcatlon of ohlorlnatlon temperatures for Aroolor production Purpose To provide chlorination temperature ranges that are more compatible with plant conditions Old Procedure ,, Biphenyl chlorination is performed at temperature range of 150 to 150 C. sed Procedure ' al'chTorfhatTon of Biphenyl may be Btarted at a minimum temperature of 950C. provided that l&O^C Is reached within 1/2 hour. Chlorination may be continued for the next tow hours at a temperature no less than 120C. Completion of the batch will then be controlled between 150 and 150C. Reason and Justification 0 Normal Biphenyl storage Is maintained at approximately 95 C. to keep safely below the flash point. Therefore to adhere strictly to the process would require heating of the batch to 150C. before ohlorlnatlon. This results In production delays and Increased Biphenyl pluggage In chlorlnator off gas lines. Based on plant experience most ohlorlnators are recharged while still hot from the preceedlng batch; this normally yelld6 a starting temperature In the range of 120C. However, occasionally delays cause charging to a cooler chlorlnator where the net temperature may approach 95C. This proposal would allow ohlorlnatlon to start Immediately under these conditions The batch temperature would then rise rapidly from Its own heat with water being applied later to line out the temperature somewhere Bllghtly above 120C. A lower temperature range 120 to 150C. Is needed for the flrBt two hours to reduce Biphenyl carry-over Into the off gas lines. HONS 054875 ThlB proposed process ammendment has tentative approval from Research. In Original Signed by; T. W- Dalton ____ ______ T. W. baiton A. M. EllenOurg A. M. fillenburg J. ft7 Kellogg _________J. R. Kelloge J. R Kellogg T. M. Patrick 6-12-59 tf. M Patrick HONS 054876 Dept. 246 - Process Description AROCLOR APPENDIX L____ TIME CYCLE 52. The design oapaclty of the department 1b 1,700,000 (2,400,000 after August, 1964) pounds per month, or 20,400,000 pounds per year. Figure 1 of this section Illustrates the flow pattern of the Aroclor prooesB and lists the approximate time needed to complete eaoh process Btep. The time table for the Aroclor process Is summorlzed below: Equivalent pounds Time (hours) of Finished Product Charge Chlorlnator Chlorination 1242 1248 1254 1260 Transfer to blow tanks Aeration Distillation 1242 1248 1254 1260 Blending Filtering Dropping to Storage 25 8.70 9.20 11.10 12.50 .25 2.00 1.75 1.75 1.75 1.75 2.00 2.00 2.00 6550 7200 8o4o 9100 The time required to make completed batches of the various Aroclors are tabulated below: Aroclor ' 1242 1248 1254 1260 Batch Time (hrs.) ------- IB-Sf--1-------- L 19-45 21.55 22.55 Process operations lnoludlng filter press cleaning, sampling, etc. are Independent of the batoh completion time cycle because production time Is not loBt. MONS 054677 1. ASOCtO* *'>V yp.g.ST VTT" '?';* 0 17.* AW*' qA^TS MONS 054878 52. Dept, 246 - Process Description AROCLOR APPENDIX M QUALITY CONSIDERATIONS The Aroclor compounds are among the most versatile chemically-made materials in industry, Aroclors are useful in many ways because of their outstanding inertness, Aroclors are used alone for particular physical jobs such as insulating, heat transfer, sealants, and expansion media; and they are used as com ponents or extenders in elastomers, adhesives, paints, lacquers, var nishes, pigments and waxes, Aroclors must be highly pure, with dependably minimal traces of electro lytes for use in electrical applications, Electrical grade Aroclors must pass numerous stringent specifications. The following tests determine. Aroclor quality; Hydrolysis stability Me&Bure of chemically unstable chlorine compounds. Munch or Monsanto Stability Test Measure of thermally unstable chlorine compounds at elevated temperatures. Thermal Chemical Chloride Developed by the General Electric Co. to measure chemically and thermally unstable chlorine compounds. Resistivity Measure of insul&tive properties. Power Factor Measures power loss due to current through a capacitor. Dielectric Constant Measures the capacitance of & standard such as air compared to the capacitances of Aroclor, Specific Gravity, . refractive index Measures of chlorination level. The stability and electrical properties of electrical-grade Aroclors are paramount in quality considerations. The chlorination step of the process is most critical because many properties of the final product are deter mined by the properties of the crude Aroclor, Conditions in the chlorinator needed for a good quality product are:1 1, Chlorination Temperature - The chlorination temperature must be greater than ;120*C<` lit the beginning of the chlorination reaction to \ produce stable Aroclors. Results of research tests indicate that product stability is better as the initial chlorination temperature is increased, MONS 054679 Department 14b - Proce Decription AROCLtlR APPENDIX M QUALITY CONSIDERATIONS Z, Ferric Chloride Concentration - Research has found that the ferric chloride concentration must be at least 0.03% to form stable products. Research recommends 0.05% ferric chloride. Lower catalyst ratios result in increased "addition1* chlorination as opposed to "substitution" chlorination, indicated by higher chloride values and lower yields. The isomeric distribution of the final product is a function of the type and concentration of the catalyst used in the reaction. Homogeneous suspension of the catalyst is extremely Important. Good catalyst contact can not be attained without homogeneous sus pension. Since ferric chloride does not mix well with biphenyl, the dry catalyst must not be poured into the chlorlnator. 3, Geometry of Reacting Vessel - The shape of the reactor affects the circulation and flow pattern^f the reactants, It is suspected that the chlorine gas channels through a void space, in the existing catalyst basket. This problem is presently being studied. The reactor must be designed such that circulation of reactants is rapid and homogeneous and local over-'Chlorination does not occur, 4, Cleanliness - The ferric chloride catalyst settles to the bottom of the chlorinator. Areas of the packed bed become plugged with ferric chloride and channeling of reactant flow may result, A steam clean-out of the chlorinator may be an expedient method to remove the ferric chloride. This method was tried in the department, and evidently was successful. Further tests by the laboratory will verify the effectiveness of a steam clean-out. 5. Sparging - The sparger controls the gas distribution under the cata lyst Tiofd-up plate and the site of gas bubbles. It is not known whether the catalyst basket or sparger or both are the critical factors in achieving the proper flow of gas through the reactor. It is believed that the sparger should distribute small bubbles give good gas dis tribution throughout the chlorinator. The small bubbles have a greater surface area per unit volume of gas for mass transfer,' and fhis should increase, the rda'ctidn r$te. '. 6. Raw Material Purity - The purity of raw materials can affect the quality of Aroclors, Sulfates are particularly harmful in the chlorine gas. It is suspected that sulfates poison the ferric chloride catalyst and Sulfonate some of the biphenyl. If the ferric chloride catalyst is . poisoned, the effective catalyst concentration is reduced and thus un stable aroclors will be produced, The chemistry and mechanism of catalytic poisoning are not known for certain. Sulfonated biphenyl is carried-over during distillation and is not removed by earth treating, MONS 054880 55. Dept, 246 - Process Dcscriptipn AROCLOR APPENDIX M QUALITY CONSIDERATIONS 6, Raw Material Purity (Cont'd.) Sulfonated biphenyl heB ionic properties which lower the reeie- tivity of the finished product. A Brink Mist Eliminator has been installed in Dept, 246 to eliminate the chlorine impurities, 7. Earth Treatment - The factors affecting stability also influence the electrical properties of Aroclors. An absorbent will be inef fective if the Aroclor was not prepared in a manner such that a stable product was formed during the chlorination reaction. However, research has found that absorbents are very effective for improvement of electrical properties by removing ferric chloride and tars carried-over during distillation, provided the crude Aroclor has good stability. The absorbent used in Dept, 246 (after distillation) is Attapulgus Earth the concentration should be 0,05% for Aroclor 1242 and 0,1% for other Aroclors, The earth must be heat treated at 250'C. for a minimum of 4 hours before addition to the Aroclor, Heat treatment reduces the moisture and activates the earth, 8. Lime Treatment - It is important that proper amount of lime (2$0 pounds per, still run) be added to the still to prevent sublima tion of ferric chloride. 9, The blend tanks, finished product tanks, and Aroclor 1242 and 1254 storage tanks are blanketed with nitrogen gas. Nitrogen blanketing maintains the electrical properties of the Aroclors by preventing corrosion of the equipment, , In summary, the chlorination step of the process is the most critical. A good quality Aroclor can not be produced if a stable compound is not formed during chlorination. Once a stable compound is formed, other techniques such as use of lime, absorbents, and nitrogen blanketing are used to maintain and improve electrical properties. I HONS 054881 Dept, 246 - Process Description 56. AROCLOR _.. _ QUALITY CONSIDERATIONS (Cont'd.) Absorbents Numerous absorbents have been screened in the laboratory at various contaot temperatures for their effect on resistivity of plant untreated Aroclor 1242. The most satisfactory absorbent pound for improving the resistivity of Aroolor 1242 was DVM attasorb. Table I of this section lists the laboratory results of the different absorbents used to treat Aroclor 1242, Degradation of Aroclors Degradation of Aroolors, which leads to loss in eleotrloal resistivity, is one of the short comings of UBlng Aroclor as a dielectric, especially sinoe only a very minor degradation oan cause a eerlouB breakdown in eleotrloal equipment. The thermal degradation of fraotlonated Aroolor has been measured at 250C. and the amount of Hydrogen Chloride liberated was measured. The results of these tests are listed in table II of this section. ' Aroolor 1242 has been degraded by ultravlolent light, and the decrease in eleotrloal resistivity with Irradiation time was measured. The plot of resistivity versus time of Irradiation (Figure 1 of thiB seotlon) resembles a conductivity versus concentration ourve for a weak electrolyte. It is possible to remove the oonduoting material brought about by photo-degrad ation, and restore the resistivity to its original value by passing the degraded material over activated alumina. Thermal degradation of Aroolors is minor oompared to photo ohemical degradation. Thermal treatment causes release of a small amount of hydrogen Chloride initially, but this evolution oeases after a short time. Such behavior Is attributed to thermal degradation of impurities. If Aroclor is lrrodlated, then exposed to a thermal treatment, appreciably more HC1 Is liberated. I HONS 054882 Dept. 246 - prooess Description AROCLOR APPENDIX M 57. QUALITY CONSIDERATIONS (Cont'd.) TABLE I Adsorbent ADSORBENT SCREENING! DATA Adsorbent Pretreatment Contact 0 Temperature C. Volume Resistivity - at 100C. ohm-cm x 10___ LVM Attapulgus Earth None LVM Attapulgus Earth LVM Attapulgus Earth. LVM Attapulgus Earth. Attasorb - LVM Heated at 250C.12 hours. Heated at 550C.12 hours. Heated at 350C.4 hourB. None Attaolay None Activated Alumina (Alcca Orade F-3 -325 mesh) None Voolay 525 (Western Bentonite) Panther Creek (Southern Bentonite) Flltrol Grade 1 Zeolex 7 (Zeolite) Florlte 60 mesh (Aotlvated Bauxite) Suprex L-Q (Kaolin) Attasorb - LVM Attasorb - RVM . None None None None None None Heated 550C.12 hours. None 60 80 100 120 60 80 100 120 60 80 100 120 60 80 100 120 60 80 100 120 80 100 120 60 80 100 120 80 100 120 80 100 120 80 80 100 Moo 2000 2800 2900 A 200 6400 7200 6100 9300 9000 6J00 6500 2400 5600 6000 5700 9700 12,100 13.700 17,800 10,200 5400 6000 2100 2500 2800 5100 5700 5800 9700 6200 11,500 8100 2600 7000 5600 100 4500 100 12,200 100 6,200 HONS 054883 Dept, g46 - Process Description aroclor______ APPENDIX M 60. . QUALITY CONSIDERATIONS (Cont'd.) TABLE I (Cont'd.) Adsorbent Linde Moleoular Sieve Type 4-a Laminar Alumina (Dayton) Adsorbent Pretreatment None None Contact Temperature C. 60 60 Volume Resistivity at 100C. q ohm-cm. x 10^ 2100 900 Note: 9 ReslBtlvlty of Aroclor before treatment 1 x 10 ohm-cm. 1 HONS 054884 Pept. g46 - Process Description______ arocloh APPENDIX M QUALITY CONSIDERATIONS Aroclon 1221 1252 1242 1248 1254 TABLE II THERMAL DEGRADATION OP AROCLORS AT 250C Km. of HCl/gm x 10^ 5.55 6.75 11.07 5.?1 6.42 9.81 5.96 9.58 15.00 5.61 5.44 8.48 5.45 5.?6 6.45 Heating Time 1 hr. 2 hrs. 5 hrs. 1 hr. 2 hra. 5 hrs. 1 hr 2 hrs . 5 hrs . 1 hr. 2 hrB. 5 hrs . 1 hr. 2 hrs. 5 hrs. 59. ( MONS OS4885 Rq3 l.3 t l. v lt y x lO - U orun-cni* K*S *J* ToJS iw> ** 1323 irradiation Time In Hours 60. Dept. 246 - Process Description AROCLOR APPENDIX N MISCELLANEOUS REFERENCES1 1. St. Louie Report No, 2694, Job No. 171-1028, February 15, 1952. Title: Operation of Aroclor Stills At Increased Pressure For Increased Rates Summary: Distillation runs were made at 20 to 30 mm Hg. The rate of Distillation of 1200 series Aroclors increases with pressure, 2. St. Louis Report No. 2755, Job No. 2-02-760.01 - 3948-3 March 6, 1961. . Title: Improved Aroclor 1242 Studies Summary: Studies were carried out to determine the effect of temperature, chlorine content, and catalyst concen-' tration in chlorinated biphenyl mixtures. 2, 4-dichlorobiphenyl is the percursor of the high dielectric constant, trichlorinated components, 3. St. Louis Report No. 2072, Job No. 2-02-750. 01-3428, May 4, 1958. ' Title; Final Report on Aroclor Process Studies. Summary: Purity of raw materials, catalyst concentration, reaction temperature and rate of chlorination were the variables studied with respect to their influence on the stability of the finished product. 4. St, Louis Report No. 2540, Job No, 171-616, December 28, 1958, Title: The Effect of Prolonged Heat on the Electrical Properties of Aroclors. Summary: Aroclors 1232, 1242, 1246 and 1254 were held at HO'C, The power factor was periodically measured. 5. St. Louis Report No. 2234, Job No. 171-451, June 14, 1956. Title: Evaporation Losb of Aroclors. Summary: The evaporation loss of Aroclors was determined at 100*C. under static conditions, HONS 054887 61. Dept, 246 - Process Description AROCLOR APPENDIX N MISCELLANEOUS REFERENCES 6. St,.Louis Report No. 2790, Job No. 171-1028, July 3, 1952. Title: Increased Production of Aroclors by More Rapid Rate of Chlorination. Summary: Chlorination rate was increased from 400 pounds per hour to 770 pounds per hour, Aroclors produced at increased rate was within specifications, 7. St. Louis Report No, 1842, Job No. 2-02-750.01-3368 July 12, 1957. Title: Use of Ferric Chloride as Catalyst for Production of Aroclor 1242. Summary: The Comparison of stability chloride values revealed no difference between the product made with iron turnings as catalyst and ferric chloride as catalyst. 8. St. Louis Report No, 2096, Job No. 2-02-750,01-3202, June 6, 1958, Title: Resistivity Improvement of Aroclor 1242. Summary: Numerous absorbents were screened at various contact temperatures for their effect on resistivity of plant untreated Aroclor 1242. Heat activation of Attapulgus Earth was also studied. 9. E. E. Martin, OPERATING INSTRUCTIONS FOR DEPT. 246. W, G. Krummrich Plant, 1961. [ 10, E. E. Martin, PROCESS DESCRIPTION FOR MANUFACTURE' OF AROCLORS', 11. E. Mather, PROCESS DESCRIPTION FOR MANUFACTURE OF AROCL&RS, ^ MOMS 054886 Dept. 246 - Process Description AROCLOR APPENDIX N MISCELLANEOUS 6?. The following table shows the results of tests which measured the evaporation losses of the various Aroolors. Aroclor Evaporation Rate gms./cm?/hr./100pC. Aroclor 1221 . .00174 Aroclor 1232 Aroolor 1242 .000874 .000338 Aroclor 1248 .000152 Aroolor 1254 ,000053 Aroclor 1260 .0000088 Aroclor 1262 .0000132 Prom the above results, the evaporation rate for Aroclor 1262 Is greater than that of Aroclor 1260. This unexpected result may be explained by some difference In the conditions of which the two lots were prepared, The reaction produots in Biphenyl Chlorination differ with the type of oatalyst used. Results of research investigations are listed below i _ Catalyst Isomer Distribution of Aroclor 1232 2 - 'T':~ 2771 - HE" 27TT 4,4' trl FC Cl 3 Sb Cls Tl Cl Sn Cl 15* 11 11 . 24 7* 15# 0.7 20 0 20 l 16 6* 38* 3.6 ?8 2.2 46 2.3 38 9* 18 9 14 7 18 1.3 HONS 054669 Dept 246 - ProoeBB Description aroclor APPENDIX N___ _ MISCELLANEOUS (Cont'd ) 65. Some of the typloal operating dlff culties In department P46 and possible remedies are given below: CHLORINATORS Trouble Chlorlnators operating against too much back pressure. Cause Plugged off-gaB lines Remedy Open lines and steam them out. Dry out lines with air before resuming operation. Chlorlnator slow In picking up gravity 1. Low Chlorine pres 1. Call Chlorine Dept, sure or low ohlorlne for more gas gas concentration 2. Cheok Biphenyl 2. Wet Biphenyl storage tanks for moisture. BLOW TANKS Blow tanks staoklng off Operating Chlorlnators Close chlorinator vent; with vent open. possibly reduce air to blow tankB STILLS Not enough vacuum 1. Ejectors not pull . lng properly 2. Coke scrubber Contains water 1. Check Ejectors 2. Drain Coke scrubber Foreign material In filtrate samples ' ?6" SPARKLER FILTER Dirty filter or broken paper Clean & re-paper press HONS 054890 "hEm* Y*W on Mb Mr RROOUCTIOlROUANTIT V BKRBHBBOAMOUNT MATERIAL COBT BTRAM BLICTRICIYV COMRRBBBBO AIR WATRR.RURCMABBD WATCR.RLANT RRRRIBBRATION RABB \ OR \ _____ ::______________ Tsyto.______ w__________________________ Pred.t.odt %\\ 00 Ttaor. Thory* *Th.or/Std KThBwy/M Co.oclt.VAOO Oo Cwt Unit Irt. Unit Com _ 1KRO MfP. INVENTORY VALUBACAR OT MIR OR IR AT IMB BRACRBT* R BRACRBT i . BRACRBT B BRACRBT B OR NON* V AMOUNT V\o. loo VHIt COBT AMOUNT ____ cap________________ UNIT COBT AMOUNT UNIT COBT AMOUNT Tl\L g\w> \l< \wa.u f <U \A OM Ap\ <1 1 VP* V 3A 5A> \9>< caA Hk j A<\ ^1 P\i LAB OR*MAN UR ACT UR1 MO BALARIBB RAYROLL`OVIRHBAO f ACTORV BURRLIBB laboratory CLOTHIMO B LAUNORV RROD. DBRT. eONT. BAR. TBCHNICAL BBRVICB MBCH. BAR. Y Y, f * f B S^avT 4o ^oO V<N oA? AML \V-L 4tb &41 V iic&c Mi _________ iCLS Sul 4jSL m Wxv. PAY lo _______ \ Vha _________ asa >A, PmbI t>tntl Cmr*nim OIRRBCIATIOM B B r(M MJmr C*Rrtr*ln ft9t PmBuCJ 0BI Cowv *s_& CKRCNBR'OUANTITY UNIT UNIT RR LABOR LABOR RAT* HOUR* ARK KXN KXX LABOR MBN RKK BTIAM RLBCTRICITV M LOB. iUt KWH .tau> f^MRRBBBBD AIR WAT IRoRURCHABBO M CR M B AL. AAA WAYBR.RLANT f UBLB AB RUBL'OIL tei LAB. LMOR *TMBV BMW M BAL. M CR BAL. TON BLKB. man/hrb AKA yfe-v aIl* ALASiL \ v\^ VfiA \*W \<AA\ \LVSl TpAV \ V \ JoS \tLA-o \fr _____ oVov \ YPS OrYWA ^oiov OUANTIT V \s\ OUANTIT V QUANTITY SATA VfO Vi ____________---- ____________________ %JtS. ______________________ il_ \v" *&& JAvV >&A-a "1*A XML . . .......... \l> ^AaX 0UANT.TT \3-v <LL ____________xuk _________ m m*~ n Vila XXRK KKXX AAA, 9 NUMB BR OR UNITS BOUIRkMMT UBIOl ORRT. NO. d.t. no. Lwbo . Lv.i ORRT. NO. * \oo * _______________ \OQ -*- B /far Nor % --Vq-^ * -----------; Y HONS OS4S91 DAT* MlfT# i/#e KXN NRK ` Se _______~ i1 -------- ----------------- PRODUCTION COST STANDARD V or V ***>**______ _____________________________________ _____ _________ _1 PERT. HO,_________________ _______________ THEORY TO ITO. ON <KiC CAPACITY \^00 6IM3 P.CCTIV. V V^teA THEORY TO ITO. ON ... __________ MATERIAL coot NAMC . CO*T UNIT Ou*ntiyv hca unit THEORY TANOARO INV. UNIT COIT UNIT COIT ^ VAo' 5?) Loo - - VvH.t ______ <( frlXrfL'Vt . A. VIAL *\\ 0* ... If* >*>T Oc>f \09o C>o^ a 5. \X.ts oo^ T_ i_ vo\ <% Wlif-N <2*lQjS__ ___TQ*t <^o._______ ^OIaov ^vOOk>> V- S*k-\ 1 O.N. ,1 vA M ^\ 0O ww' U^i <lftu r>\ Vi* 1-4 CL^Va-i.-C ... ... \% V* Av \*o Ob . K.oii p- svvi 4\\o-\ C^Iaca. L\.Vlv*t \W1 . 4\\ \< 4fcUbS SU*%A>V Avt*v - 14 9* U av_ V.A SU 43.0 Si a* .. *A 14.0 \'to 1% 0 a* \*l 03 fc ' AV Vi. V55I *YO \\.o VS Lvo WA9.0 nt5a^ OtAU> ovAi-o 6ML& 0\v>t, O'.tii *'4>k A i'a t. \ ^0*0 \ 5 1 o^K J.'LOv A pvelWV i \ VxT~ MN ,. vvc* LA *.>! 4w\v \w BAvWl vvt^ V*.,f 1 A4*i tie \ t> ii__ Ac ^o 0 \s> t* 0 AL U. <kl ** RAW MATERIAL VAREHOUIINO I HANDLINO OROIV TOTAL MATERIAL! BYPRODUCT! 9.14.,is ftt-V vi>w'w. A. jvt.| -- W<VmX tV LiXvV..< TOTAL BYPRODUCT! NET TOTAL MATERIAL! , ' CQIT ftf IHUTCQWN lO>t or >iARTur cnT Ql CHAMOEOVER t ** -V. XiLa.a. Ai CLAHiriCATION (Cmttg.) COIT or ITANP-BT COIt TO WOVI A MAN ITAND-BY LABOR NO. Or MEN 0D*\. MOKS 0 5 4 8 9 2 WOpyCTtON CQP1 w. ii.'m v% S\vo\ ^ f-'-VAv * .1ft' 'Aval______ JialAi________ v. <>. AV t>< gaw.&.. Av<\ . ot>* \ t w .\k 4\\. w imvi . R *1 j ,-OiitSL Coif V9*> y