Document aJd16Y2EKr6jOBzp7g8gpBzEX
PROGRESS REPORT
/ lion no.
f,0, krumhhicn plant
BG.L. Bratsch B *T.W. Dalton . 0 QD.W. Jackson B
A.E. Leisy ' B
E.D. Malone ' a
*0B.W. Corlew . a
Q D,J. O'Toole a
g)R.M. McCutchan Br ID V. Brawley^ W
QW.C. Engman B TO MCIIVB DITAIL IICTION
a
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b
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'b ' J.E. Smith *
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AROCLOR: INCREASE AROCLOR CAPACITY
import no.
idati
GENERAL OFFICE
OTHERS
0J.O. Bright H.C. Carder
it13 R. L.a"iRmriese *K) * R. KILLOOO
B D. Danna (4) KJ.C. **T!an"dwehr .
P.W. Edwards
So. 2nd St.
0 D.B. Hosmer/ IS P.0. DeGarmo
F.J, Holzapfel UT.M. Patrick
0 R.E. Howard *B J.F. Quinn
W.A. ,Kuhn
0
0M.P. Lux ' *0
ffi W.R. Richard b
pipionnili W. A. Krull (T. E. Greenman)
proilim. Verify Design Capacity of Aroclor Expansion
summary
During a capacity check, the design rate of the equipment Installed in the Aroclor expansion was exceeded for about a two day period. This verifies that the Aroclor production capability at WGK is about 70 H pounds per year provided we have sufficient operator force and storage. To reach 70 H pounds, three more 22,000 gallon storage tanks and one or more operators would be needed. The 1970 cost standard indicates a capacity of 57.6 M pounds per year. The storage limitation is the lower restriction.
The 1973 and 1974 forecasts are for 55 and 59 H pounds respectively. This Indicates a need for additional storage in 1973 and that before this, no changes or additions are necessary. The capacity of the drowning Jet will be checked to see if HC1 pollution could be a problem at full rate. Quarterly capacity checks will be made to discover any restrictions that could develop due to wear.
Future Work: This Job will be closed.
W. 'A. Krull Technical Services Department
02UU63
/tm
COMPANY CONFIDENTIAL INFORMATION
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TOWOLDMONOQ45513
91370:3690 (2-Final)
-2-
5/6/70
DETAILS:
I. BACKGROUND
A. In 1968 the Aroclor Department was expanded by a CED
project, CEA 1800, which was continuous and rated at
40 M pounds/year. At the time the new facility was
added, the existlftg batch plant was rated at 30 H
pounds/year.
.
B. The sales forecast dated 2/15/70 forecasts an Aroclor production for coming years in millions of pounds per
year as follows:
1971 - 46.5
1972 - 50.9 1973 - 55.5 1974 - 59.2
C. Aroclor is presently produced using the continuous chlorinators for 1242. All other Aroclors are produced in the batch chlorinators from Biphenyl. Aroclors 1248 and 1254 are distilled in one continuous still and 1242 in the other. The two batch stills are used for other
products (#l) and boiling down still bottoms (#2). All numbers in this report were arrived at assuming this type operation would continue.
II. WORK DONE AND RESULTS
A. The actual operating capacities of the major process steps were found by running the equipment at high rates. By material balances the actual rates were compared to instrument readings and the instruments found to be correct. The rates do not reflect maxlmums in all cases.
, The still rates in particular are some unknown amount less than maximum.
B. The following table gives the rated and measured capa cities of the steps of the continuous expansion. Both figures use 93# on stream time. The #4 still actual capacity was based on the 1248-1254 product split.
ozvi06'' TOWOLDMONOQ45514
91370:3690 (2-Final) DETAILS:
-3 -
5/6/70
Equipment Chlorinators #3 Still #4 Still #1 Absorber #2 Absorber #3 Absorber #4 Absorber
COMPARISON OF RATED AND ACTUAL CAPACITIES
Product
Rated Capacity H pounds/year
Actual (H pounds/year)
(1142) '
40
46
(1242)
25
33
(1248,1254)
25 '
36
(1242)
27
53
(1254)
27
35
(1248)
27
38
(1260)
27
62
C. The expansion equipment has been demonstrated to rated capacity. In the next table a comparison between demon strated rates and forecasted requirements shows the excess capacity available. This table includes the batch plant as well as the continuous expansion.
Product 1242 1242 1242 Other Aroclor 1248,1254 1260,1262,1232 1248 1254
REQUIRED AND DEMONSTRATED CAPACITY
Process Step
Demonstrated 1971
1973
H #/year Forecast Forecast
Chlorination
46
27 33
Distillation Absorption
55 53
27 33 27 33
Chlorination
26
19 23
Distillation
22
16 19
Distillation
9
34
Absorption
38
89
Absorption
35
8 10
Forecasted % Rate in 1973
70 100
60
90
85
45
25 30
1260
Absorption
62
345
0211065
TOWOLDMONOQ45515
915700690 (2-Final)
-4 -
5/6/70
DETAILS:
II. WORK DOME AND RESULTS (Continued)
D. The production department has indicated that one or more additional operators would be necessary if a high rate is to be maintained for a longer period of time. Also, additional storage^ would be necessary to run at high rates These factors restrict the capacity to 58 M pounds/year with storage being the lowest restriction. The forecast indicates a need for additional storage in 1974.
CONCLUSIONS:
The capacity check and previous production records have shown that the department will be running at reduced rates through 1973. The 1242 still will be nearing capacity in 1973 even though the addi tional demonstrated capacity is not maximum. Storage and operators may be needed in 1973. From the data in the Appendix, it appears that the off-gas condensate rate is doubled when the continuous chlorinators are Increased from 70$ to 100$.
RECOMMENDATIONS:
1. Evaluation of drowning jet be made to determine pollution level
at full rate.
.
2. No other capacity related TSD work be done until 1973 when
storage should be evaluated, unless sales exceed the present forecast.
3. Quarterly checks be made to discover rate restrictions that occur.
APPENDIX:
The remaining pages of this report consist of data taken during capacity checks. The temperatures, pressures and levels should be typical of conditions at the various rates.
/tm Att:
W./A. Krull
'
Technical Services Department
021106b
TOWOLDMONOQ45516
0211067
APPENDIX:
Biphenyl Cat.
Feed
Mix
Bi 0
Rate
Ratio Temp
(%) Min-Sec. C
CONTINUOUS CHLORINATOR DATA
Cl2 Pres
------ DensiDensi- trol Densi-
% C12 Flow sure
Specific Gravity
trol Set
trol
r#7| MS PSIG #6 #7 1 #8 #9 Point Readins
55 6 - 7 99 44 43 53 70
1.096 1.165 I.252 1.346 80
65
6-7
100 44 55 46 60
1.092 1.191 1.275 1.355 83
1.356 1.359
65 6 - 7 96 44 55 45 64
1.092 1.190 1.270 1.352 81 1.355 1.358
75
6-7
100 45 60 47 70 25
1.082 1.186 1.266 1.339 65
1.343 1.344
75
6-7
100 45 60 50 70 27
1.088 1.184 1.258 1.343 67
1.345 1.346
85
6-7
100 50 62 59 92 27
1.088 1.182 1.258 1.345 78
1.353 1.352
85
6 - 11
99 65 71 75 68
I.O98 1.190 1.286 1.354 94
1.360 1.369
85
6 - 11
99 66 73 74 70 25
I.O96 1.186 1.279 1.340 88
1.359 1.361
100
6 - 14 100 99 100+ 99 72 26
1.124 1.217 1.248 1.358 72
1.350 1.350
100
6 - 14
99 75 70 75 83 26
1.109 1.204 I.295 1.351
1.343 1.343
100
6 - 14 101 90 90 90 71 26
1.110 1.198 1.282 1.352 68
1.345 1.348
100
6 - 14 100 90 90 85 57 27
1.116 1.222 1.306 1.347 46
1.347 1.347
TOWOLDMONOQ45517
0ZU068
APPENDIX:
Biphenyl Feed Rate
($) 55 65 65 75 75 85 85 85 100 100 100 100
Chlorinator Temp (C)
> #7 #8 #9 136 155 175 193 137 159 174 192 136 158 174 192 153 167 175 192 156 167 175 192 155 167 185 194 157 168 187 192 157 170 186 193 164 170 193 193 154 167 183 195 ^ 155 169 184 194 155 169 184 192
Off--Gas
Temp (C)
Conden
sate
Header
Tank
89 44
77 38
83 45
88 41
92 43
100 43
91 40
93 41
101 41
102 41
107 42
100 40
Int. Stor. Temp
C
174 180 174
168 168 170
184
176
175 178
180 180
Blow Tank Temp
C
145 145
115 130
145 147
148
145 160
125 120
110
6- -
TOWOLDMONOQ45518
APPENDIX:
Bi phenyl Feed Rate
(%)
#6 Air
Speed Press
55 Slow 11
Cooler Settings #7 #8
Air Speed Press Speed Press
Slow 12 Slow 12
65 Slow 10.5 Slow 12 Slow 12
65 Slow 11 Slow 12 Slow 12.5
75 Slow Close Slow 11.5 Slow 11.5
75 Slow Cld Slow 10 Slow 11
85 Slow 9.5 Slow 10.5 Slow 10
85 Slow 11 Slow 8.5 Slow
8
85 Slow 9.5 Slow Open Slow
7
100 Slow Open Fast 12.5 Slow Open
100 Fast 15 ( Fast 14 Fast 13
100 Fast 12 Fast 12.5 Fast 12.5
100 Fast 12.5 Fast 13 Fast 13
#9
Speed Press Slow 12
Slow 12.5
Slow 12.5
Slow
13
Slow
13
Slow 10
Slow 13
Slow 13.5
Slow
13
Slow
13
Slow
13
Slow
15
Cooler Outlet Temp (C)
Sparger Temp (C)
#6 #7 #8 _#2__ > #7 #8 #9 135 152 172 190 136 153 173 191 136 155 173 190 136 157 173 190 136 156 172 190 136 157 172 190 153 164 173 19.0 153 166 172 190 156 164 173 191 156 166 173 190 155 164 182 191 155 166 183 191 155 164 183 190 157 167 185 190 155 166 182 190 157 169 184 192 161 164 189 191 164 168 191 191 151 l64 180 191 154 166 181 193 152 l64 180 192 155 168 183 192 151 164 180 192 155 168 183 190
-7
0211069
TOWOLDMONOQ45519
APPENDIX:
#3 STILL DATA
Absorber Surge Peed Tank Rate level
%f
47 52
Circu-
lating
Still Still Pump Flow
Level Press Press Rate
% (mm Hg) psig
t
55 40 50 23
Therminol Temp
Set Temp Out Point To Ex Ex
C C C
265 264 235
Still Temp
C
227
Product Temp C
Condenser
Water
Out Vapor Out
Temp C
Of Into Con
Ex. Cond. denser Rec In Out
223 223 50 6l 48 54
61 43 53 40 58 70 255 253 241 231 238 225 55 65 53 60
64 48 53 42 58 73 255 256 243 233 241 226 56 64 54 61
70 46 55 39 58 40 270 270 247 235 243 228 63 71 59 68
71 51 54 42 50 40 270 268 245 233 241 228 65 73 6l 70
8- -
0211070
TOWOLDMONOQ45520
