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CT- 1699 UNION CARBIDE INTERNAL CORRESPONDENCE PLASTICS DIVISION To {Homo) Company lo,, Mr. J. H. Field TEXAS CITY PLANT P. 0. BOX 471, TEXAS CITY, TEXAS March 21, 1966 Data Copy I* See Distribution List at End of Report Status Report, Initial Production Run, QXOS-7 In the attached report Mr. H. H. Savage presents the detailed work done on the recent initial commercial-sized production run of QXOS-7, produced for the calendering and extrusion markets. Approximately 300M pounds of resin was produced with an ethylene concentration range of 1.53% to 2.06%. This was a fine piece of work. Process Development and Laboratory Groups are to be commended for their valuable and timely assistance. NAG: sh Attachment N. A. Gimber ucc 039573 SUSPENSION VINYL RESINS TEXAS CITY PLANT Status Report Initial Production Run, QXOS-7 Author: H. H. Savage Date: March 21, 1966 Summary The initial production run of QXOS-7 has been completed--producing 298,280 pounds of resin. The maximum ethylene content attainable with existing equip ment is 1.6%. Pending customer acceptance, this resin could be produced at reasonably good rates. Substantial equipment additions would be required to produce QXOS-7 at the 2% ethylene level. Discussion The QXOS-7 run was started on March 4 and completed on March 10. Produc tion loss caused by this experiment amounted to 270, 000 pounds. Four blends totaling 298,280 pounds were produced. Blend analyses are shown in Table I. The first 21 autoclave batches were included in B-l and B-2, These batches were made with an ethylene charge that resulted in a final pressure requiring significant autoclave venting at the end of the reaction. The ethylene content was 1. 7%. In an effort to increase the ethylene content to the desired 2%, the autoclav charge (except for ethylene) was reduced for the five batches in B-3, This blend contained only 1. 5% ethylene. This was caused by a difference in the proportion of the ethylene in the vapor and liquid phases. The final pressures of these batches averaged 290 psig and no venting was required. The last five batches were charged with a 1/3 increase in the ethylene charge and were recovered as B-4. This blend contained 2.1% ethylene, but the auto claves required a considerable amount of venting. In two cases the amount of venting was so great that foaming plugged the 1/2" valve being used, and it was necessary to crack the hand vent valve to keep the pressure under control. Recipes used during the run and the recommended recipe for any future run at 1.6% ethylene are attached as Table II, Other than obtaining the desired level of ethylene content in the resin, the only difficulty encountered was in attaining a reasonable reaction time at the v ry low reaction temperature of 41 *C. Fifteen pounds of IPP (75 lb. of solution) ucc 039574 Status Report on QXOS-7 2. were used per batch. This is more than a reasonable amount for the manual operation presently employed. Incidentally, the usage during full scale pro duction would be about 50% of the Non-Solvent usage. As in the case of the QXOM-7, the resin particle size was rather large, the dry blending times were excellent, and the bulk densities lower than the com parable homopolymer. Fisheye ratings were good except for B-3 which was unaccountably high. ICMT color was good and ASTM conductance very poor. Melt viscosity results are not yet available. The work of the Development Department in preparing the individual autoclave samples, and the many extra hours of analytical effort by the Resins Laboratory are gratefully acknowledged. Recommendations QXOS-7 cannot be considered satisfactorily scaled-up since the ethylene con tent that can be attained in the present system is less than the aim of 2%. For routine production, 1.6% is the maximum that can be promised. The South line is the only line on which QXOS-7 can be produced. If full scale production at the 1. 6% ethylene level is contemplated, a charging system for the IPP catalyst system will be required. A batch charging met r and an extension of the Non-Solvent IPP circulating system would be required. Production of QXOS-7 at the 2% level would require facilities for handling the vented ethylene and instrumentation for controlling the venting. ucc 039575 TABLE I QXOS-7 BLEND ANALYSES B -1 B-2 B-3 Pounds Ethylene, % Total Solids, % Inherent Viscosity Screens, 40 mesh 60 mesh 80 me sh 100 mesh 140 mesh ZOO mesh Median Particle Size ICMT Color 94,480 1. 74 99.6 1. 34 100 97 32 11 5 2 194 112 118,540 1.72 99.5 1.32 100 98 32 12 2 0 195 110 43, 520 1.53 99.4 1.28 100 90 29 15 4 0 205 115 Contamination Respro 17.5 Mil/10 Mil 3 0/52 1 0/53 1 6/1792 Bulk Density ASTM Absorption Clear HRP 27.0 112 3 27.0 118 2 29 108 3 Dry Blend, Min. /Temp. 2.4/78 2.8/78 2.3/79 ASTM Conductance 1.45 1.85 1.00 Melt Viscosity -- Not Available -- 3. B-4 41,740 2. 06 99.4 1. 31 100 82 32 22 5 2 215 114 2 0/83 27 115 2 2.0/77 2. 10 ucc 039576 a TABLE II QXOS-7 RECIPES 3-21 Batches 22-26 27-31 Water, Gal, 2, 800 2,400 2,400 Methocel-15, Lb. 6. 0 5.2 5.2 Cellosize WP-300, Lb. 18.0 15.5 15.5 Sodium Bicarbonate, Lb. 13.0 11.2 11.2 Vinyl Chloride, Lb. 10,850 9, 310 9, 310 Ethylene, Lb, 625 600 800 IPP, Lb. 15 13 14 Termination Press Drop, psi 25 25 25 Reaction Temp. , *C. 41 41 41 4. Future 2, 800 6.0 18.0 13.0 10,850 575 16 25 41 4 ucc 039577 5. Status Report on QXOS-7 DISTRIBUTION LIST Texas City Mr. W. D. Bush Mr. O. T. Carlisle Mr. M. E. Eisenhour Mr. J. F. Erdmann Mr. J. H. Field Mr. A. P. Fisher Mr. N. A. Gimber Mr. G. G. Harkreader Mr. J. L. Hockersmith Mr. O. A. Holt Mr. D. E. Richardson Mr. J. C. Schlichter Tarrytown Mr. P. T. McCoy Food Products Division, Chicago Mr. DonTijunelis New York Office Mr. A. A. Boehm Mr. W. J. Canavan Mr. F. D. Dexter Mr. C. R. Field Mr. W. H. Joyce Mr. J. R. Wilkinson Bound Brook Mr. N. H. Barton Mr. Ed Bell Mr. A. J. Costantin Mr. F. A. DeMelio Mr. G. G. Himmler Mr. A. P. Mazzuchelli Mr. K. V. McCullough Mr. H. J. Rutherford Technical Center Dr. F. E. Bailey, Jr. Dr. J. J. Brezinski Mr. D. L. Engle Mr. J, W. Fields Dr. J. E. Glass Mr. W. S. Lanier Dr. W. R. Manning Mr. M. E. Sutherland ucc 039578