Document VKKebY41xOZ0GxVkb4NKm3yjZ

PROGRESS REPORT .. ^ TECHNICAL SERVICES DEPT.-W. Q. KRUHMRICH PLANT I job no. | report no. [ 9^370:3690________ | 1 (Final ) idate | J , 17/68 0 0 W.O. KRUMMRICH PLANT OENERAL OFFICE OTHERS 0.D.Dressel J. M. CONNAUGHTON T. W. DALTON >9 P.J. Verna J.G.Bright J.E.Smith *0 D.C.Armstrong 0W.R. Richard EkJd. DANNA (4 ) H 0C p .E.AnagnostopUUXUo *QD. E.Cayard QP. . EDWARDS 0J R: Ravage NITRO *0 W. R. KANENLILSTOOGNG taJ.C .Landwehr * So. 2nd St. .0J,W,Molloy 'SW.A. Kuhn 0R.E.Howard 0 P.0. DeGarmo { J. R. McCLAIN . s. A. HEININOER J.F. Ouinn 0 H. B. PATRICK . *0 D. B. HOSMER *0T.M. Patrick SJD.W. Jackson H.C.Carder 1H.P. Ray 0N.L. SAMPLE *60 V. Brawley^^Sptl . EJR. J. StratmeyeiIO TO RECEIVE DETAIL SECTION INCREASE AROCLOR CAPACITY personnel? R. M. McCutchan (T. E. Greenman) PROBLEM: The Aroclor capacity is inadequate to meet 1968 sales forecast 0 SUMMARY By mid-1967 it became apparent that the Aroclor department capacity had to be increased by at least 10$ in order to meet the 1968 sales forecast of 32.75 jyf ibs/yr. The rated and actual capacity was 29*5 M lbs/yr. The following capacity improvements haye been completed: Item Date Cost OSR & Capacity Increase 1. Furnace improvement 9/67 Minor Work 2.0# 2. Six-inch Cla line 2/23/68 $32,480 2.5# 3- Still Preheater & Alterations Total 4/18/68 $9300(est) $41,780 7-0# 11.5# When the chlorination step is run at 195C for quality reasons instead of the normal 150C, the off-gas vapor losses increase with a resulting 2.5# decrease in OSR and capacity. May 1968 was run at 195C and yet production was 3,166,383 lbs, breaking the old record by 9*6#. The 1968 sales forecast will be met (15, 796, 967.lbs. thru June) The expanded Aroclor facilities are scheduled to start up on 10/14/68. The above capacity improvements result in estimated savings of $52,000 and new earnings of $158,000 before taxes. DSW 311656 COMPANY CONFIDENTIAL INFORMATION This document Is tbs property of Monsanto Company sad tbe recipient is responsible for Its safekeeping and disposition. It contains confide, tlal Information of Monsanto Company which moat not be reproduced, revealed to unauthorised persons or sent outside tbe company withov proper authorisation. Either retain in secure files or destroy. FORM wok too rtEV-2/66 STLCOPCB4071642 91570:5690 (1) -2- July 17, 1968 Future Work: EDC 1. Check preheater operation after alteration. 8/15/68 2. Monitor preheater operations for possible plugging. 10/15/68 5. Close Job. . 8/15/68 Acknowledgements The capacity improvements summarized in this report are the efforts of the Production department itself, the TSD Mechanical Design Group and the TSD Process Group. Particular thanks goes to H. F. Ray and V. Brawley. ' R. M. McCutchan Technical Services Department /tm DSW 311657 STLCOPCB4071643 SUMMARY DETAILS: I. REPORT OUTLINE BACKGROUND t' A. Capacity vs. Sales Forecast B. Production Limitations II. CAPACITY IMPROVEMENTS A. Furnaces B. Six-inch Chlorine Line C. Still Preheater D. Summary of Capacity Improvements III.CONCLUSIONS IV. FUTURE WORK APPENDIX A. B. C. Aroclor Production Timetable of Preheater Project Preheater Drawing dSVM 3AA658 STLCOPCB4071644 91370:5690 (1-Pinal) -4- July 17, 1968 DETAILS: I. BACKGROUND A. Production Capacity vs. Sales Forecast By mid-1967 it became apparent that the Aroclor production capacity was inadequate to meet the 1968 sales forecast. The rated capacity was 2.462 M lbs/mo., or 29.5 M lbs/yr. Through June 1967* the department was operating a 103.6$ of rated capacity. The sales forecast was 32.75 M lbs. of Aroclors for 1968. Department capacity had to be increased by at least 10$. B. Production Limitations 1_. Low chlorine pressure caused considerable production loss. This was being corrected by the installation of a new 6" chlorine feed line to replace the existing 4" line (Project 3824, Mechanical Design Group). 2. Distillation was a bottleneck when producing Aroclor 1242, which is about 50$ of the total Aroclor production. The distillation on stream rate (OSR) for 1242 was about 3900 lb/hr. while the chlorination OSR for 1242 was about 4300 lbs/hr. This assumes a total chlorination batch cycle of 7.5 hrs. For Aroclors 1254 and 1260, the distillation rate was not limiting. The two stills are fed continuously by vacuum. II. CAPACITY IMPROVEMENTS A. Furnaces In September 1967* the production department increased the heat supplied to the stills by decreasing the size of the furnace burner orifices and increasing the gas pressure. An overall OSR increase of about 2$ resulted. (See summary paragraph of this section of this report for actual rates.) B. Six-inch Chlorine Line A new 6" chlorine feed line (Project 3824) was activated on 2/23/68. Periods of low chlorine pressure (below 18 psl) were eliminated. Normal pressure increased from 20 psi to 25 psi. Other changes were made in the department a short time later, but it is estimated that a 2.5$ OSR increase resulted from this project. DSW 311659 STLCOPCB4071645 91570:5690 (1-Final) -5- July 17, 1968 C. Still Preheater 1. Original Project Since about 40# of the heat supplied by the furnaces to the stills was used in raising the temperature of the crude Aroclor to its boiling point, a sizeable distillation capacity increase could be achieved by preheating the still feed. A still preheater estimate for $8000 was approved, package submitted, and equipment installed under Project No. 5554 as per drawing TS-D-8555* The 150 sq. ft. spiral preheater cost $2980. The following considerations determined the project design: a. Temperature Still Feed temperature before project 110C Still Feed temperature after project (temp, of 200 # steam) 195C Boiling Pointoof Aroclor 1142 at 40 mm Hg 220C b. Flow Rate to Stills Normal Maximum 7 gpm 12 gpm c. Flow Velocity Because the still feed contains approximately 0.02$ undissolved FeCl3 catalyst, the flow velocity had to be sufficient to prevent excessive settling out. The need to avoid very low flow velocities, the need for low flow rate and a high^T, determined that a spiral heat exchanger was best suited for this purpose. The curved channel through which the Aroclor flows minimizes settling out. d. Pressure Drop Pressure drop through the heat exchanger was estimated to be 10 psi. Actually it is 12-14 psl. Before the installation of the preheater, the still feed was pulled by vacuum to the stills from the blow tanks. The Increased pre ssure drop made a pump necessary in addition to the still vacuum. A 1-1/2 x 1 x 6 Durco Mark II was chosen. qS^ STLCOPCB4071646 91570:3690 (1-Pinal) -6- July 17, 1968 2. Alterations After start-up the need for the following alterations was apparent. a. Discharge Line The spiral heat exchanger is protected against high pressures by a 100 psi carbon rupture disc. The discharge line went to sewer. If the disc ruptured while the pump was in operation, it would have been possible to lose an entire blow tank of crude Aroclor. The piping has been altered to tie the rupture di3c discharge line back into the top of the blow tank. b. Pump Impeller The 5" impeller was replaced by a 6" one. An overall demonstrated OSR increase of about 7# resulted from the installation of the still preheater. Start-up of the preheater was on 4/18/68. D. Summary of Capacity Improvements 1. Capacity Variables In order to evaluate the actions taken to increase capacity, the effect of two process variables had to be established. a. Percent Chlorination When chlorinating biphenyl to the 42-60# chlorine range, the OSR decreases approximately 8 lbs/hr for every 1% increase in final chlorine content. In other words, the OSR for Aroclor 1142 is about 50 lbs/lir greater than the OSR for Aroclor 1148. This data is based on production records for 10/1/67 to 4/17/68. b. Chlorination Temperature During most of the second quarter 1968, the chlorination temperature was 195C instead of the normal 150C. This was done to improve Aroclor stability. When operating at the higher temperature, off-gas condensate losses increase to reduce the OSR by about 100 lb/hr, or 2.5#* STLCOPCB4071647 91370:5690 (1-Pinal) -7- July 17, 1968 2. Aroclor on-stream-rates The graph on the following page relates# chlorination to OSR as it increased with -the improvements discussed in this report. The rates shown assume a chlorination temperature of 150C. If 195C is used, OSR decreases by 100 Ib/lir as noted above. 3 Aroclor Capacity Assuming full use of the preheater, 48# average chlori nation at a temperature of 150C, and a standard on-streamtime of 91#, the_predicted OSR is 4580 #/hr with a pro duction of 2.87 M lbs/mo. or 34.4 M lbs/yr. This meets the goal of 10# increase in Aroclor capacity. ! The best month to date was May, 1968 when the preheater was used all month, average chlorination was 47*55# at 195C, OST was 99*4#, resulting in an OSR of 4279 lb/hr and a production of 3,166,383 lbs. See Appendix A for 1967-8 production data. III. CONCLUSIONS Production of WGK Aroclor will be sufficient to meet the sales forecast. Preheater downtime must be kept to a minimum. At this writing the new Aroclor expansion is scheduled to start-up on 10/14/68. . IV. FUTURE WORK A. Check preheater operation after alteration. B. Monitor preheater operation for possible plugging. C. Close Job. EDC B7I5 10/15 8/15 DSW 311662 STLCOPCB4071648 * M * tk aA n .. -o 5>OMw STLCOPCB4071649 Month July 1967 August September October November December Jan. 1968 February; 4 March April May ! June 196|8 #12 51.1 48.3 49.3 48.8 46.9 50.1 49.2 47.0 46.6 48.7 47.6 48.5 OST, % 83.4 88.9 86.1 97.3 97.2 69.I 79.7 81.6 90.6 96.5 99-4 86.8 APPENDIX A OSR,lb/hr 3917 3855 3800 3866 4127 4119 3985 3942 4ll6 4063 4279 3893 Production 2,446,613 2,550,544 2,355,684 2,798,453 2,887,372 2,118,204 2,363,279 2,235,888 2,773,669 2,824,184 3,166,383 2,433,564 Comments Furnace improvements Turn-around 6"C12 line on 2/23 195C on 4/11 Preheater on 4/18 DSW 311664 STLCOPCB4071650 APPENDIX B TIMETABLE TSD Job No. 91570:5690 opened Evaluation begun Estimate 5554 ($644o) submitted Verbal approval received Equipment ordered (spiral preheater) Project package transmitted to P & S Formal approval received Revised Estimate 5554 submitted (+$1560) Equipment arrived at plant Formal approval of revision received Project installation completed Project Start-up Estimate 6621 for alterations submitted ($1500) Formal approval received Alterations completed Progress Report written Job Closed 10/7/66 7/1/67 8/1/67 8/2/67 8/11/67 8/29/67 9/29/67 10/51/67 11/7/67 11/29/67 1/15/68 4/18/68 5/6/68 5/6/68 7/1/68 7/17/68 --_ DSW 311665 STLCOPCB4071651 Appzdpn c AMERICAN HEAT RECLAIMING CORPORATION r- SPIRAL HEAT EXCHANGER SPECIFICATION SHEET customer Monsanto Co* address Kruaniich Plant PLANT LOCATION . . . YOUF JOB No youfi REFERENCE No. our inquiry no. 1-9438 DATE July 25. 1967 service of unit type i-v TOTAL SURFACE Ardor Heater No. OF exch. req'd. 150 8q. ft. One item no. connected in SURFACE PER EXCH. ' GUARANTEED PERFORMANCE ~ FLUID CIRCULATED TOTAL FLUID ENTERING VAPOR LIQUID r STEAM NON-CONDENSABLES FLUID VAPORIZED OR CONDENSED STEAM CONDENSED SPECIFIC HEAT B.T.U./# SPECIFIC GRAVITY THERMAL CONDUCTIVITY VISCOSITY LATENT HEAT - VAPORS B.T.U./# TEMPERATURE IN - F TEMPERATURE OUT OPERATING PRESSURE PRESSURE DROP F /SQ. IN. # /SQ. IN. 3 HEAT EXCHANGED - B.T.U./HR. 370*000 HOT SIDE Steam 440 /HR 440 #/HR 440 #/HR 837 338 388 200 COLD SIDE Arelor 7500 #/HR 12 GPM .... .34____________________ 1.25 .07 15 CD 232 380 LOG. M.T.D. 10 DESIGN PRESSURE /SQ. IN. TEST PRESSURE # /SQ. IN. DESIGN TEMPERATURE F SPACING IN. CHANNEL SEAL MATERIAL eflr^nr, ntP.fil gaskets connressed asbestos 3500SHIPPING WEIGHT fsnpvox. # dimensions see attached sketch REMARKS CONSTRUCTION 220 330 220 330 400 3/16" 400 3/16" Alternate Channel* Welded THICKNESS 1/4" 5/16" OUtfli.da tUCHS ` WEIGHT FULL OF WATER DSW 311666 STLCOPCB4071652 a bCd e f gh J knP rs 35" 12" 6" 24" 5" 23" 12" 49" 7".... . 1" ... -l"-- 1" 1" ?" 150SQ. FT SPIRAL HEAT EXCHANGER For . Monsanto Co. Cust. No.: Inq, No.:t,,9438 Date7/?5/67 AMERICAN HEAT RECLAIMING CORP 1270 Sixth Avenue New York 20, N.Y. STLCOPCB4071653