Document X7j42NzY8L82BKZOebzpO6KJB

INTER-OFFICL memo TENNECO CHEMICALS, INC. To W. Miringoff at Burl ington j. V/. Poarch From . Burlington PROCESSING ENGINEERING MONTHLY REPORT Subject APRIL, 1975 BURLINGTON Date April 30, 1975 H. B. Carr W.Copy to C. Champion W* F* Gabe 1 Dr. R. T. Gottesman Dr. L. Gross Dr. P. A. Lobo R. S. Miller Dr. M. Rosen G. I. Rozand P. R. Scarito A. C. Siegel J. T. Sweeney C. G. Thompson T. T. Zuhl J. J # Zullo P. E. Burlington Pilot Plant - Flemington 1 le A. Dispersion Resin 1. Testing of Fryma Equipment for VCM Stripping (J.W. Poarch) Tests were conducted in Rhinefelden, Switzerland on the Fryma deaeration machine using Wacker prepared latex during the weeks of April lh and 21. Using this equipment it was possible to remove Vinyl Chloride from latex containing 9,000 to 13,000 PPM VCM down to levels below 500ppm. A complete report is being assembled and will be issued by May 5. 2. Dispersion Stripping Trials, Burlington Plant (L. Schappell) Table I contains a summary of stripping conducted during the month. The last two batches shown were stripped under conditions which production adopted on April 16. Without nitrogen sparging the VCM removal rate becomes very slow after the third hour. With nitrogen sparging the rate of removal is more rapid. 3* Study of Oxygen Levels During Prolonged Stripping (R. Donovan) With the above stripping procedure of two hours at full recovery followed by three hours of steam jet evacuation, a study has been made which shows that the oxygen level in the discharge of the compressor will reach 3?4 in 3 hours at a vacuum of 26"Hg. This is primarily due to the air leakage rate at seals and flanges becoming significant at low VCM flow rates. COLORITE 010774 page two 4. B. Plant Production of 1742-LOP 1051 (R. Donovan, L. Schappell) Type 1742 resin was produced for the first time in B plant. Close attention was given to the different process conditions which exist in B plant and their effect on properties. As expected, the pressure drops across the three stages were lower in B plant (see table III) than in A plant, especially the third stage. The rheology of the base resin in B plant was significantly lower than A plant base resin, (see Table ll). After blending with tridecyl alcrhol and additive resin the 17^2 product properties show less significant reductions in rheology. 5* Additive Resin Control System ( L. Schappell) Prior to production of 1750 resin the week of 3/31/75, a new positioner was installed at the additive feed screw and the ratio control system reconnected. Also the feed screw assembly was mounted to the additive bin. The fluctuation in weight indicated was reduced from + 10-20 lbs. to + 5-10 lbs. from the actual weight. The additive data indicated that the ratio controller system could produce a product with more in-spec additive levels than if the additive feed rate were constant. The AR-gOl additive weights were analyzed for the production of 1742 between 4/11 and 4/16, Of 160 pallets bagged, 133 had additive levels of 4 - 8%. For the 1732 run that followed there were 124 pallets of 135 bagged which contained 4-8% AR-9OI. One reason for the better control during the 1732 run was the close monitoring at the start of the run to zero-in on the required set-point. Also the set-point was fixed for the entire run. 6. Trjdecanol Additive Control System ( L.A. Schappell) The ratio control system is not functioning properly. The output signal to the control valve is oscillating frequently and appears to be over shooting the desired set-point. The amounts added per pallet fluctuate 50% from the specified amount of 30 lbs. for 1732 and 1742 resins. To reduce the output response first the controller gain will be reduced. 7. VCH Material Balance - 1742 "B" Plant (R. A. Donovan) Materia] balance samples were taken for characterization of 1742 in "B" Plant. These samples were taken to see the extent of VCM removal from the blend tank through the bagger. The results obtained are as follows: Sample Point Blend Tank Cake Breaker Primary Col lector Fine Product Bin Bagger VCM Content (ppm) 4/40 3240 69 21 9-7 COLOR!TE 010775 PAGE THREE 8. Dispersion Plant Charging (R.A. Donovan) In following charging procedures of dispersion latex some insight was gained on one possible cause of sloppy latex- On one batch of 1750 the cuno filter became some what plugged thus reducing the charging rate by 2klA. The pressure drops at the orifice plates were likewise reduced and a sloppy latex resulted. B. Suspension Resin 1. Type 10.SR Special - LOP 1050 L.A. Schappell) This LOP was issued on 3/31/75 to allow the production of 250,000 lbs. of 10.5R resin for Nixon containing less than 2 ppm VCM. It was necessary to increase the stripper hold time at 210F to one hour and to increase the blend tanks hold time from two to six hours in order to meet the " less than 2ppm requirements". The resin color varied considerably from lot-to-lot. Table IV indicates the color results and process conditions per lot. The major reasons were variations in batch hold time in the reactor, hold time at 210F during stripping, mixing time in the blend tank and dryer temperature. It is essential for consistent resin color that the batch hold time in the reactor be less than two hours, and the hold time during stripping be no more than sixty minutes. To produce less than 2 ppm VCM content 10R resin, the mixing time must be six hours after addition of the fifth batch in the blend tank, the hold time during stripping must be sixty minutes and dryer outlet temperature should be 170F or higher. 2. Suspension Resin Stripping A review of suspension stripping conditions and results is attached as Table V. 3. Copolymer Type 315 - CBS Complaint (R. Donovan, L. Schappell) A review was made of the past years formulation sheets and the past months reactor data sheets in response to a complaint by CBS of a change in the quality of records pressed from Tenneco resin. After comparing quality control results of the resins in question with previously accepted resins we found no significant differences in resin quality. The problem was then found to be due to a faulty weigh scale in the CBS plant. C. Miscellaneous 1. Sand-Filtration Pilot Test (R.A. Donovan) Tests as to the feasibility of a dual media filtration column as a final treatment for the effluent water have been made. Results of the test have not been determined as of yet, the removal of total suspended solids and the effect on BOD are of prime concern. COLORITE 010776 PAGE FOUR 2* Vent Condenser (r.A, Donovan) Reading taken from VCM vent condenser for the month of April showed an average of 300 lbs* per day of VCM being vented to the atmosphere. This calculation is based on a 26% concentration of VCM in the exhaust Stream. II, FLEHINGTON A. Suspension Resin Production 1. Fiemington Plant Start-Up ( L. Medeiros) The Fiemington Copolymer Plant is now in full operation. Water to monomer ratio has been reduced to 1.46 with a 4600 gallon charge (at reaction temperature). No further changes in this area are now contemplated. To obtain a particle size distribution with Quality Control specifications, reactor rpm was reduced from 108 to 88.2. A very narrow particle size distribution was being obtained at the higher rpm, with gelatin reduced to as low as 22 lbs. Current t/315 product is processing in control at a gelatin level of 36 lbs. (All "A" type). Tenneco type 314 was introduced into the product mix. It processed with acceptable particle size control at a gelatin level of 42 lbs. Current processing problems are in the area of optimizing the total reactor cycle time and drying. Drying area breakdowns due to either the centrifuge or bulk transfer system has caused slurry back-up. Vibrators installed on the centrifuge wet cake chutes has helped alleviate pug-up problems in this area. The problem with the "A" centrifuge breaking shear pins is still being looked into. Several bulk transfer blowers on the "A" dryer system were burnt out. Modifi cations to the system appeared to have helped. These bulk transfer blowers generate air temperatures near 200F. Production is installing cooling fins on the piping after these blowers to prevent degrading the copolymer resin (especially during a plugged line situation). Burnt resin has been found in the system. Work on characterizing the total reactor cycle time is being pursued. Full catalyst loading optimization will not be possible until the refrigeration system is in service, (estimated in July). The River water temperature fluctuates daily, running to as high as the mid 50's. Production has started high pressure vJater cleaning the reactor jackets. Excessively long pressure drops were observed on T/314 polymerization. Quality Control reported Phenol inhibitor in the recovery system at acceptable levels of 40 - 50 ppm. To verify the effect of recovery on Kinetics two major batches were charged. COLOR!TE 010777 RESULTS WERE AS FOLLOWS; REACTOR 4 BATCH 258 250 241 CATALYST 19.0 19.0 18.5 RX TIME AT TEMP. 7-3 9-5 9-3 MINIMUM JACKET 85 102 RECOVERED None 1000 lbs1000 lbs. 7 259 19.0 8.3 78 None 251 18.5 9.8 90 1000 lbs. 242 18.5 9-3 90 1000 lbs. Conclusions are difficult to draw with certainty on this limited data, but it appears that recovery is having an effect on kinetics. The phenol content in the recovered monomer is being monitored closely. Production has instituted an add procedure to reduce this level below 40 ppm. Previous belief was that it would take 150 - 300 ppm inhibitor to significantly affect reaction kinetics. 2. Alternate Suppliers Evaluation for "A11 Gelatin (L. Medeiros) Processing Control history on particle size with "A" and MB" types (Atlantic and Hormel) gelatins at Burlington was researched and compared to Flemingtons use of "A" type Atlantic gelatin. Results are summarized in a memo report dated 4/25/75. Currently both plants utilize an all "A" gelatin suspension system. Atlantic is our only supplier of this gelatin. Processing history on 315 shows Flemington producing a slightly narrower particle size distribution. It is expected that the Hormel "A1* gelatin may broaden the distribution. It was recommended that the "A" type Hormel gelatin be evaluated in Flemington. An LOP will be issued for this purpose. 111. GENERAL Two days were spent by the whole process group in the Engineering Seminar April 1 and 2. JWP :.km COLORITE 010778 TABLE ! Sr er les 109 no 112 113 Type 1750 1755 1730 1742 < hr. 9000 13735 OjSPERS ION STRIPPING TRlAic 2 hr. 85 74 25210 3hrs. 654o 10770 Residua! VfM (PPM) 4 brsr. 1371 5 hrs. 6 hrs. .16165 6238 6519 10185 8 hrs. 535 Cond i f jrvne 24-26" Hg. VACv5 SCFM N2 sParge 24-26" Hg, VAC., 10 SCFM ^2 Sparge 24-26" Hg. Vac. 24-26" Hg, Vac. COLORITE 010779 ( L-A. Scbappell 4/28/75 DATE 9/24/74 11/15/74 11/25/74 DATE 4/11/75 4/14/75 4/15/75 TABLE II 1740 - "A" Side BROOK VISC 43 54 43 1740 - "B" Side BROOK VISC 33 29 31 SEVERS VISC 400 218 222 SEVERS VISC 146 155 141 R.A. Donovan 4/28/75 COLORITE 0X0780 LOT NO . 935010 935011 935012 935013 935014 935015 935016 935017 935018 TABLE III Q.C. PROPERTIES - 1742 "A11 PLANT Zip 1st Staqe 174 168 180 183 186 185 196 194 192 ZP 2nd Staqe 172 171 173 181 181 179 181 183 177 ZP3rd Staqe 203 205 203 200 108 190 188 185 182 5P 547 545 556 564 555 554 565 562 551 BROOK vise 83 62 66 55 56 62 50 46 52 SEVERS vise 82 79 . 100 84 101 103 85 78 90 ) 935022 935023 935024 935025 182 183 187 188 "B" PLANT 170 150 174 136 175 148 170 151 505 493 510 509 65 65 75 61 70 64 74 78 R.A. Donovan 4/28/75 COLOR!T 010781 JLV SPECIAL T-10R PROCESS CONDITIONS Lot Number 495012 495013 495014 495015 495016* 495017 Hold Time in Reactorj min* 0 46 187 48 72 115 Hold Time @ 210 F min 46 49 57 60 60 70 Fill Time Blend Tank, hrs 11.0 12.5 11.75 13.0 13.0 12.0 Mix Time Blend Tank, hrs 2.6 6.0 6.2 7.5 4,8 5.9 Drying Time, hrs 9,0 7.2 7.8 5.8 . 5.5 5.7 Dryer Outlet Temperature, F 163.5 164.3 17 0.0 174.7 165.6 169.6 Residual VCM, ppm 6.7 2.7 1.4 1.4 2.1 0.2 Color Lab 88.75 .16 4.16 88.2 .35 4.70 88.0 .36 5.40 88.3 .20 4.85 88.7 .14 4.80 87.6 .60 5.40 COLORITE 010782 *Time in reactor after pressure dropped below 120F mark on recording chart. L. A. Schappell 4/17/75 TABLE V BURLINGTON STRIPPING DATA 3/26-4/25 PRODUCT 175 10.5/R 250-3 BR-501 314 315 390 391 AVG. VCM PPM 340 2.9 116 2.43 66 111 57.5 57.4 315 314 53 121 60 ONE SIGMA VALVE PPM + 144 + 2*6 29 + 2.52 + 28 + 47.5 + 25.6 + 21.8 RANGE PPM 210-580 N.D.-17 70-140 N.D.-12 35-90 18-280 14-170 22-96 FLEMINGTON STRIPPING + 30 + 90 + 13 -- DATA POINTS 7 53 6 45 3 71 43 14 STRIPPING CONDITIONS 190, 300 gal. 210, 30 min. 190, 500 gal. some <P210,60 min. 165, 200 ga). 210,15 min. 190, 500 Gal. 190, 180 200 gal. 190, 180 200 gal. 190 180 200 gal. 190, 180 200 gal. 17 190, 15 min,cool 22 195, 15 evap.,cool 4 195, 15 evap.,cool J.W. Poarch 4/30/75 COLORITE 010783