Document aJmwMkznxG34wG9LGaX2xeY9Y
PROGRESS REPORT
^OB NO.
REPORT NO.
DATE
TECHNICAL SERVICES DEPT. - W. 0. KRUMMRICH PLANT
W.O..KRUMMRICH PLANT
e.L. BOEHM
SP*
0. A.
Meyer
I 1716:246
RESEARCH o. 2n0.
I 95 (Final)
GENERAL OFFICE
I 2/21/
0 R. E. BILGER
J.R."Savage
'0 V. Brawley
^ r, H. Munch '00. OANNA (4)
NITRO 0 W. R. KELLOGG
Q J. M. CONNAUGHTON
lE D. Fitzgerald 13 V. Wft jaeger 0w. P. DUNLAP
M4H18TOH
0 J. Landwehr
0T. W. DALTON *0P. C. HEISLER
fg) G. L. Bratsoh f3Qc. E. ANA6Ro5T5POULOS 0 P. W. EDWARDS Queeny
G.O.
'|T. M. Morrow 12 P.O. Deuarmo 0R. E. Howard E P.B.Benignus
0 J- R. McClain
W. L. Rice
13 J.F. Quinn
0S. A. HElNINGER
* G.R.Buchanan
. ] H. B. PATRICK
13 T.M. Patrick 0 D. B. HOSMER
* J.O.Bright
|gw. j. WILSON
g, H. C. Carder *
0DC.Armstrong
S W.A.Kuhn-G..O. g] N. L. SAMPLE
*
0H.F. Ray
TO RECEIVE DETAIL SECTION
B R.J.Stratmeyejr
AROCLOR AND AROCLOR BLENDS: PROCESS IMPROVEMENT PLAN
personnel: r. m. MeCutchan (T. E. Greenman)
problem:
The objective of this report is to present the Dept. 246 (Aroclors, Pyranols and Pydrauls) Process Improvement Plan.
Savings of $14,000 and new earnings of $45,000 (B.T.) will be realized during 1968 as a result of Increased capacity.
Ready for 1969 production will be a new continuous chlorination
plant with accompanying stills, earth treatment columns, storage
tanks, and increased blend capacity at a cost of $1.5M. Benefits
of the expansion will be:
_
1. Provide a total WGK Aroclor capacity of 70.OM lbs/yr which
will be sufficient to meet sales needs through 1972 with a
25$ excess domestically. Maximum capacity will be needed
' by 1976-77.
.
2. Protect market by achieving corporate quality goals.
J. Ability to supply all customers with Aroclor from either
Anniston or WGK.
4. Lower maintenance costs.
5. Increased profits will begin in 1970 with payout occurring
* in 1974. (See "Appendix H" for manufacturing cost details.)
An estimated 5/4 man-years of TSD process time and 5-1/2 man-years
of PR & D time will be needed 'during 1968.
ACKNOWLEDGMENTS: Thanks to D. C. Armstrong, V. Brawley, D.
Fitzgerald, J.
Gloeckner, and.H. F. Ray for their assistance
and cooperation in the gathering of data and writing of this
report. '
0198277
r. McCutchan
Technical Services Dept.
/Jd
COMPANY CONFIDENTIAL INFORMATION
This document is the property of Monsanto Company and the recipient is responsible for its safekeeping and disposition. It contains confiden
tial Information of Monsanto Company which must not be reproduced, revealed to unauthorized persons or sent outside the company without
proper authorization. Either retain in secure flies or destroy.
.
FORM WGK BOO REV-2/66
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DETAILS
. -
I. Synopsis of Process
The Aroclor process consists of the following steps: .
Chlorination - Batch chlorination of biphenyl (Bi/) with snlft gas (approximately 86 mole % Clz) at 150dC produces
Aroclor. The by-product is hydrogen chloride (HC1) gas.
Blowing - Crude Aroclor from the chlorinators is blown
with air to remove excess HC1 before distillation.
.
Distillation - Crude Aroclor which has been air blown is continuously fed to the stills. These stills are straighttake-over type with no fractionation.
Earth Treatment and Filtration - The distilled Aroclor is
earth (attapulgus) treated, filtered, and transferred to
storage.
'
Blending and Loading - The finished product from the storage
tanks is loaded into cans, drums, tank trailers, and tank
cars, or used for making blends (electrical and non
electrical).
The principal Aroclors produced at WGK are 1242, 1248, 1254, and 1260. The last two digits Indicate the % chlorine (weight) contained in the chlorinated biphenyl mixture (Aroclor).
II. Scope of Report
.This report pertains to both the existing batch chlorination
iplant and the proposed continuous chlorination plant which
is expected to be on-stream by January, 1969.
.
01.9&278
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III. TSD Process Job List
Priority
Job
1 Install heat exchanger on Project 5554 (app roved). Follow startup.
Capital $&,000
2
Coordinate quality tests
0
in conjunction with PR&D
effort.
5
Make nitrogen blanket
$1,000
system operable.
4
Determine biphenyl loss
0
es under various chlori-
nator conditions. Recom
mend conditions for 1968.
5 . Design and install fume $7,000 removal system.
6
Investigate possible blend specification change s.
0
7 Check still operation
0
at pressure lower than
40 mm.
8 Evaluate level recorder $1,500 for still #2, Install
if Justified.
9
Evaluate liquid nitro
TBD
gen supply system for
Dept. 246/254.
10 Evaluate automatic drum $200
flushing and drumming
500 M
installation with new
building.
ll
Evaluate equipping #1
$15,000
still with horizontal
pump and bolldown
facilities
Savings/Benefits
EDC
Meet 1968 sales needs, insure $25,000 rate savings in 1968.
4/1/68
Protect $5 M market
5/1/68
Quality
Quality, minimize losses
4/1/68
5/1/68
Safety
6/1/68
Increase blend capacity 5/1/68
$l,000/yr in lab costs Raw material savings
Quality
4/1/68
Process control
6/1/68
Lower nitrogen costs
4/1/68
$20,000/yr labor sav ings and quality improvement.
Increase distillation capacity by 5 M lbs/ year
1/1/70
oioe*79
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IV. Capacity
' '
A. Aroclor
.
1. Current Capacity
'
Department 246 is rated at 2.5 M lbs Aroclors/month, or 29.9 M lbs Aroclors/year. The department averaged 2.5 M lbs/month during 1967* Presently the bottle neck is chlorine availability and distillation rate.
2. Sales Forecast - WGK (H. J. Day, 9/7/67)
'
TABLE I (M Lbs)
Made In
Aroclor _i26L- 1968 .
1970
' 1971 1912
1252 1242 1248 1254
1260 1262
22
12576
5593 6615 4813
154
16107 5049
4831 6638
-_12&
19037 4596 5039 6953
--135
21484
4571 5462
7345 145
23772 4447
5957 8l4o
155
25572 4861
6257 8485
165
TOTAL
29773 32750 35760 39007 42471 45340
Dept.Cap,, 37200* -----New 40 M lbs/yr Plant -----
*Based on installation of still preheater and
increased CI2 rate.
.
3 Capacity to Meet 1968 Sales
Current department capacity is not sufficient to meet 1968 sales needs. Capacity increases are planned in both the chlorination and_distillation steps to an overall capacity of 37*2 M lbs Aroclors/year, or 3.1 M lbs/month.
a) Chlorination'
1. Project 3824 installs a 6" chlorine feed line to Dept.. 246 (EDC 3/1/68).
2. Project 4864 increases chlorine revaporization capacity (EDC 3/1/68).
3. The Brink's mist eliminator elements will be replaced to reduce yield losses in the off gas.
4. In-line specific gravity instruments are needed, and will .be installed in the continuous chlorina tion plant.
0198280
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IV. Capacity (Continued)
A. Aroclor (Cont'd)
b. Distillation '
Project 5334 installs a spiral heat exchanger to preheat the still feed (EDC 3/1/68). This gives a 10$ surge capability and insures needed production until the expansion is complete.
4. Storage Capacity, M Gal.
Product
Present Capacity, After Blending Project Complete
TABLE II
1968 -Add 5 Tanks & Remove Un'gd
1971 Add Three
Tanks
Minimum 1971 Storage Recoin. By H. J. Day,
6/67
1242 1248 1254
1260
55 20
20
30
80 140 132.0 40 40 25.2 40 40 34.4 20 20 20.2
TOTAL
125
180
240
211.8
All new tanks will be 20,000 gallon aluminum tanks with nitrogen blanket facilities.
B. Aroclor Blends
1. Current Capacity
Dept. A-246 is rated at 1.2 M lbs/month Pyranols '(14.4 M lbs/year) and B-246 at 0.575 M lbs/month Pydrauls (6.9 M lbs/year). However, the Pyranol capacity can not be achieved because of lack of mix tank capacity. During 1967 these blends were produced while operating at near capacity:
Pyranols:
1260 PPO 1254 PPO
A13B3B
Pydrauls: A-200 280
TOTAL BLENDS
1967
4,958,639 3,099,362 1.199.190 9.237.191
2,454,315 191,772
11,883,278
1920i
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IV. Capacity (Continued)
B. Aroclor Blends (Cont'd)'
t' 2. Future Capacity and Sales Forecast
Project 2844 (EDC 7/1/68) provides for changes and additions to loading and transfer lines, metering facilities, and the conversion of No. 8 storage tank to No. 5 mix tank. This will Increase mix
tank capacity from 27.5 M gal* to 47.5 M gallons, and should make possible capacities of 24.0 M lbs/ year Pyranols and 6.9 M lbs/year Pydrauls.
Aroclor Blend Sales Forecast, M Lbs.
prrmbay, 9/W67)
TABLE III
Expanded . Capacity 1968 122 1970 1971 1972
Pyranols:
Inerteen PPO (1260) Inerteen 54201 KA Pyranol A15B5B
7200 2000 1756
*
7500 1800 1800
8000 1950 1900
8700 2100 2200
9200 2100 2200
TOTAL PYRANOLS 24000 10956 11100 11850 15000 15500
Pydrauls:
Pydraul A-200 Pydraul 280
2540 197
1700 240
1600 280
1100 520
1100 550
TOTAL PYDRAULS
6900
2557 1940 1880 1420 1450
TOTAL BLENDS
50900 15475 15040 15750 14420 14950
C. Drumming 1. Current Capacity
0198282
Drumming is done on two shifts, one standard operator per shift, 5 days per week. The standard operator also helps load trailers and tank cars (25% of time). During the 12 month period, June 1, i960 - May 51, 1967, the following drums and cans were filled: (see Appendix A for detailed drumming report.)
TABLE IV
Size
55 Gal. 50 Gal. 5 Gal. Total
Aroclors Blends
TOTALS
7221 8249
15470
0 40
540
569 2148
7790 10957
2717
18727
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IV. Capacity (Continued)
C. Drumming (Cont'd)
.
1'. Current Capacity (Cont'd)
.
Grand Total: 18,727 drums and cans Average Output: 36 drums and cans/man/shlft
2. Future Drumming Needs
'
TABLE V
Total Production, M Lbs
. 1972 (Sales 1967 Forecast)
3 Year $ Increase
Aroclor Blends
29.8 11.9
45.3 14.9
52$ 25$
On the assumption that drumming requirements increase proportionally in 1972 with total production, 26,600 drums and cans will be needed. By adding one man on third shift drumming, these needs can be met with an average output of 34 drums and cans/man/shift. After 1972, a seven-day operation may be needed.
If drumming requirements increase sharply, a more auto mated drumming facility might be considered. (A rough estimate of such an installation including building is $200-300 M) Another source of justification for an automated system is the possible need of a drum flushing system for improved "as packaged" quality. Anniston TSD has the assignment of determining total company needs for maintaining Aroclor quality while packaged. Results of their studies will dictate drumming needs for future quality requirements.
D. Tank Car and Trailer Loading
The following table shows the number of tank cars and trailers loaded during June 1,' 1966 - May 31, 1967, arid the projected loadings for 1972:
Number of Trailers or Cars
Tank Cars: Aroclors Pyranols
Total
Trailers:
. 95$ Aroclors 5$ Pydrauls
6/66-5/67
72 iS
197
0198283
mi in
. 125 235 300
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IV. Capacity (Continued) D. Tank Car and Trailer Loading (Cont'd)
The existing loading facilities plus the two unloading docks included in the proposed plant expansion (CEA 1800)
will be adequate through 1972.
E. Haw Materials
The following raw materials will be needed based on sales forecast.
TABEE VII
(M lbs)
1968
1972
Biphenyl Chlorine TCB TTCB
18.0 M lbs
25.2
34.1
46.6
. 3-5 0.9
4.3 1.2
F. Expansion - Continuous Chlorination (CEA - 1800)
. 1 Scope
a) Five new 22.000 gallon aluminum storage tanks
' (EDC 7-1-68).
b) Railroad spur and two unloading docks
c) One 100,000 gallon biphenyl storage tank
d) Three existing 15,000 gallon underground tanks
will be dismantled
.
e) Separate transfer lines for each product from
day tanks to tank farm, and from tank farm to
loading or drumming areas.
f) Chain of four chlorinators with external cooling
and continuous feed tank (EDC 12-1-68)
g) Continuous blow tank and Intermediate storage tank
h) Two semi-continuous distillation systems
i) Four continuous porocel column treatment systems
J) A complete therminol heating system
k) Additions to the existing control room including
instrumentation
l) Electrical substation changes to supply power
m) Motor control center
n) Foreman's office
0198Z81!
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IV. Capacity (Continued)
F. Expansion - Continuous Chlorination (Cont'd)
2. Justification for Expansion
a) Provide a total WGK Aroclor capacity of 65.0 M
lbs/year which will be sufficient to meet
sales needs through 1972 with a 40$ excess at
WGK.
b) -Protect market by achieving corporate quality
goals as follows:
1242
1254
Resistivity, x 10^ ohm-cm 10,000
15,000
Power Factor, $
0.6$
0.3$
Thermal Chemical Chlorides, <0.1
<0.1
ppm
c) Ability to supply all customers with Aroclor
from either Anniston or WGK.
d) Lower maintenance costs.
e) Increased profits will begin in 1970 with payout
occurring during 1974. At maximum capacity in
the new plant, profits (B.T.) will be approximately
$2.0 M/year over profits at maximum capacity in
the old plant. ' If the Aroclor sales growth
pattern continues, and with only a small increase
in Anniston Aroclor capacity, maximum WGK capacity
of 70 M lbs/year will be needed by 1976-77. If
a 25$ surge capacity is required, further expansion
should be anticipated in 1972-73*
3. Capacity
After the continuous chlorination plant is on stream, all biphenyl will be chlorinated to the 1142 level in the new plant. It will then be chlorinated to the 1148, 1154, and 1160 levels in the batch plant. In 1972, based on H. J. Day's forecast of 9/7/67, the capacities and requirements of each plant will be:
a) Chlorlnator Capacity, M lbs/year
TABLE VIII
Maximum Capacity 1972 Sales Based on 1972
Forecast Product Split
For Internal Use: Continuous System
For Sales: Continuous System
(1142) (1142)
15.9 . 25.6
6.5 36.5
0198?85
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IV. Capacity (Continued)
F. Expansion - Continuous Chlorination (Cont'd)
3. Capacity (Cont'd)
Maximum Capacity 1972 Sales Based on 1972
Forecast Product Split
For Sales (Cont'd) . Batch System using 1142 as feed for 1148, 1154, and ll60
19.8
9.0
Batch System using Biphenyl as feed for 1148, 1154, 1160
Total .Aroclors For Sales
0 ____
45.4
24.5 _
70.0
b) Still Capacity, M lbs/year
Still No.
Product
TABLE IX
1972 Sales . Forecast
Maximum Capacity Based on 1972 Product Split
1
2
3 (new) 4 (new)
1260-62
8.6
Boil-down only, all aroclors
1242
25.0
1242
0.6
1248
4.9
1254
6.3
Boil-downs 20.0 25.0 10.0
6.5 8.5
Total Aroclors
45.4
70.0 .
A. Goals
The following Aroclor quality goals were set at the corporate Aroclor meeting held on May 9-10, 1967:
1242
Resistivity x 109 ohm-cm
Power Factor, % TCC, ppm
10,000 0.6 <0.1
1254
Resistivity x 109 ohm-cm
Power Factor, % TCC, ppm
15,000
0.3 <0.1
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V. Quality (Continued)
. '
B. 1967 Aroclor Quality
In December 1966 the removal of the catalyst baskets
from the chlorinators was completed at V/.G.K. No
other normal operating conditions have been changed.
During 1967 the only quality shift has been an
Improvement in the electrical properties of both 1242
and 1254 during the third quarter. This is unexplained.
Normal quality ranges have been as follows:
.
TABLE X
.
1242: 1254:
W.Q.K. - 1967 - In Plant Analysis
1907 Normal Range
0/67-II/67
Average
Spec.
Q
Resistivity x lCr ohtn-cm
Power Factor, %
TCC, pprn
1,000-10,000 0.5-3.0 0.45-0.6
6,000 0.7 0.49
500 5-0 0.65
Resistivity x 10^ ohm-cm
Power Factor, f TCC, ppm
5,000-40,000 0.2-1.0
0.6-1.0
40,000 0.2
0.8
None None None
For a complete storage tank analysis record of Aroclor
1242 and 1254, see Appendix B.
'
C. Batch Quality Studies and Recommendations
Since early in 1967 there has been a concerted effort to
improve Aroclor stability and electrical properties.
This is a corporate effort headed by D. C. Armstrong of
W. G. K., PR & D. It was initiated by the realization
that Monsanto's Aroclor was surpassed in quality by
foreign competitor's products.
.
The following quality factors have been considered and/ or investigated: (For a complete report of PR & D batch work, see J. A.' Gloeckner's progress report 91370:3794(1).)
1. Chlorination
a) Higher temperature chlorination will improve
'Aroclor qualityT Four storage tanks of 1242
have been made at 195C with an average 0.30
ppm TCC. The normal material made just prior
to the tests averaged 0.45 ppm TCC. Optimum
temperature has not been determined.
-
0198287
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V. Quality (Continued)
.'
C. Batch Quality Studies and Recommendations (Cont'd)
1. Chlorination (Cont'd)
b) Higher ferric chloride concentrations (0.2/)
are beneficial at lSO^C. At 200^C, the benefit
is doubtful.
.
c) Catalyst particle size was checked and found to
'vary considera~bly7 (fee Appendix C).Pennsalt
is the only supplier of anhydrous ferric chloride
' and they do not attempt to control particle size.
d) Biphenyl quality is an important variable under
normal conditions. At higher temperature or
catalyst level the effect of biphenyl quality is
greatly reduced.
e) Initial reaction temperature does not affect
' quality as long as it is at least 120C.
f) Bromine was added to the chlorine to a 700-800
. ppm level and used to make a storage tank of
1242. At reaction conditions of 195C and 8 lbs.
FeCls/batch, a TCC of .047 was obtained. This
material was life-tested by Electric Utilities
and approved.
g) Sparger design has been changed to give better
chlorine distribution and to prevent catalyst
settling. Resulting quality data has not been
obtained .
h) Off-gas condensate is not suitable as a raw material
for electrical grade Aroclor, but could be used
for non-electrical grade. Off-gas losses increase
by five times when increasing the reaction
temperature from 150C to 195C. Cost of yield
loss will Increase by $30,000 for production of
30 M lbs.
Conclusion: Only one change can be recommended to improve Aroclor quality in the chlorination step. A temperature of 195C should be used.
2. Filtration of Crude Aroclor
If catalyst concentrations higher than 0.05$ are used, the undlssolved ferric chloride should be removed before distillation. A centrifuge installation would cost $25-40,000.
01982 88
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V Quality (Continued)
C. Batch Quality Studies and Recommendations (Cont'd)
3'. . Distillation
'
a) A lime charge equivalent to 0.8$ of the chlorination mass should be used (present practice).
b) For good process control, a level recorder is recommended for No. 2 Still. Especially during .boll-downs, guess work risks line pluggage and considerable downtime.
4. Earth Treatment vs Porocel
In the present plant, 20 lbs. of attapulgus earth . is mixed into a blend tank of distilled Aroclor
for 30 minutes and then filtered to a finished product tank. Varying amounts of earth and porocel were tried, but no significant quality difference was noted. Power factor was measured on a temporary in line instrument.
5. Storage and Transfers
*
a) All Aroclor storage tanks should be 21-25,000 gallon aluminum tanks with a nitrogen blanket. The existing nitrogen system does not work and is being checked for modifications. It will be operable by 4/1/68.
b) Separate aluminum transfer lines should be available for each aroclor product.
D. Continuous Chlorination Recommendations
WGK PR & D recommends the following process conditions
be used in the continuous chlorination Aroclor plant
expansion:
.
1. Chlorination
a) Biphenyl
.
-i
Biphenyl will be monitored for water content. If high levels (80 ppm and above) are encountered
frequently, the biphenyl should be dried with a molecular sieve prior to chlorination.
0
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V. Quality (Continued)
'
D. Continuous Chlorination Recommendations (Cont'd)
TABLE XI
b) Temperature
Biphenyl Feed Tank Chlorinator 1 .
2 5 4
Min. Temp.
100C 140 150 170 190
Max. Temp.
120C 160
. 170 190 210
c) Catalyst
Use 0.1$ FeCl3 having a mesh size specification
of 50$ less than 15 microns and 100$ less than
50 microns. Direct addition of the catalyst to
the chlorlnators is being explored. No baskets
are to be used.
.
d) Yield Losses - Based on laboratory continuous
chlorinations, vapor losses are expected to be 2-3
times that experienced at the Anniston Plant. This
material should be used for non-electrical grade
Aroclor production.
._
e) Circulation rate should be as high as possible '
compatible with good maintenance (narrows isomer
distribution).
2. Crude Aroclor (1142) Storage
a) Temperature should be as high as possible,
150-190"C minimum.
b) Residence times should be as long as possible
with a 12 hour minimum. The new intermediate
storage tanks are sized for a 48 hour residence
time.
'.
c) The catalyst present improves stability.
<0 Agitation is recommended for optimum contact of
catalyst and. 1142. It will also minimize
catalyst build-up in the tank.
e) HC1 removal will be accomplished by maintaining
a mild vacuum (650 mm absolute) on the 1142
storage tank. Further work will determine if
this is necessary. Air blowing is not recommended.
0198290
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V. Quality (Continued)
D. Continuous Chlorination Recommendations (Cont'd)
3. Distillation
'
a) Lime charge of 0.8/ adequately handles up to 0.2$ catalyst concentration.
b) Pressure is not very critical, but the lower the better. Starting with the same crude and distilling to the same yield, pressure and TCC are related as follows:
TABLE XII
Pressure
Temperature
TCC
5 mm 40 60
190C 240 280
0.22 ppm 0.27 0.32
c) A forecut of 1$ will result in an improvement of 0.01-0.03 ppm TCC, independent of earth treatment method, chlorination conditions, or ageing. The forecut could be added to the condensate from the chlorinators and used for non-electrical Aroclors. Present plant expansion does not anticipate making this forecut. Further PR & D investigation is scheduled.
4. Earth Treatment
Use porocel columns as demonstrated at Anniston.
5. Future Work
EDC
a) Assist in plant demonstration at Anniston using 5/1/1
chlorination conditions of 190-195C in the third
chlorinator and FeCl3 added to each mix tank.
Evaluate results. (Test scheduled for 3/11/68).
b) Define where FeCl3 should be added (pending
4/l/t
Anniston demonstration).
c) Determine necessity and means of HC1 removal
3/lA
from crude.
d) Investigate effect of water and trace Impurities 9/1/'
in: biphenyl on Aroclor stability. Monitor H0
level In department biphenyl storage.
e) Monitor bromine content of department chlorine. 3/1/
f) Evaluate additional routes for Improving
9/1/
Aroclor stability.
0198291
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V. Quality (Continued)
E. Aroclor Blends
Specifications are normally met on all Aroclor blends, but sometimes with great difficulty. The following conditions hinder the production of high quality blends:
1. General
. a) .
b) c) d)
' e)
The blend tanks are'inadequate in size and TTCB
storage non-existent. Project 2884 will provide
a third blend tank (20,000 gallons). It is
recommended tlat one of the underground storage
tanks (15,000 gallons) be retained for TTCB
storage.
.
.
There is only one supplier (Hooker) of TCB and
TTCB. These raw materials have poor electrical
qualities and are difficult to clean up.
To aid in the mixing process, the blends are
blown with plant air. This is not a good
practice and an alternate method should be used.
Earth treatment of the blends does little
good, sometimes degrading the electrical
properties. During 1967 earth treatment of 1260
PPO and 1254 PPO has been stopped. Less difficulty
in meeting specifications has resulted.
The chloride scavenger harms electrical properties.
2. Specifications
a) Pydrauls - No problems b 1254 PPO - No problems c) 1260 PPO - Two causes make the specific gravity
and refractive index specification difficult to meet: (1) The specifications for the blend are
narrower than for the components. (2) The specific gravity and refractive index
specifications do not correlate well with each other. The per batch average Is three blend adjustments and eight control sample analyses. This means increased lab costs, but more importantly, delay
in shipments, below minimum drummed inventory, and poor TCB arid TTCB yields.
A program to correct this problem was set up in 1966 by Don Harris and Bill Caraway, but was - dropped after preliminary work because the dollar value was low ($10-12M/year). Completion of this work is still needed as the time factor . becomes more important and blend sales Increase.
0198292
TOWOLDMONOQ45454
91570:246(1)
Page 17
2/21/68
V. Quality (Continued)
'
E. Aroclor Blends (Cont'd) , .
.
' d) A 15 B 5 B - This biend suffers from the same
specific gravity and refractive index problems as does 1260 PPO. In addition, blends must be adjusted with 1260 since there is no TTCB storage. Finally, because of the poor quality TTCB, the electrical property specifications are difficult, and occasionally impossible to meet. Five electrical property checks and ' seven specific gravity and index analyses are made on an average batch.
VI. Yields
A. Biphenyl .
'
TABDB XIII
Year
Actual Yield
Standard
1964
1965 1966
1967
96.57/
98.59 98.66
98.50
97-0/
The yield loss is in the off-gas condensate and is worth $7,000 in 1968 when chlorinating at 150C and $57,000 when chlorinating at 195C. In the continuous chlor ination plant this material will be used in the feed stream when producing non-electrical grade Aroclor.
B. Chlorine
,
Chlorine usages are calculated by the chlorine department and therefore are not a meaningful gauge to the Aroclor Department operations.
1 TTCB
TABBE XIV
TCB TTCB
Actual Yield 1967
98.25 94.11
Standard
98.0/ 98.0
The yield losses are worth $10-12 M in 1968 and are due to lack of TTCB storage and mix tank capacity.
0198^3
TOWOLDMONOQ45455
91370:246(1)
18 2/21/68
VII. Manufacturing Costs (Year 1967)
Total cost variance on the Aroclor production and blending operation was (-) $9,298 for 1967. The following; items represent the larger cost variances:
A. Compressed Air Act $12,132 Sch $6,007 Var (-) $6,125
Compressed air is pro-rated to the using departments.
B. Supplies
Act $17,381 Sch $22,543 Var $5,162
Supply costs appear normal and are itemized in Appendix D.
C. Packing Containers
Act $120,886
Sch $113,295 Var (-) $7,591
A larger than expected percentage of Aroclor and Ardor blends are being sold in drums.
D. Laboratory
Act $35,995 Sch $31,772 Var (-) $4,223
As noted previously, many control samples are analyzed ' in achieving blend specifications.
E. TSD, Experimental, and PR & D
Act $107,635 Sch $30,79*1 Var (-) $76,841
Since early in 1967, an intensive program has been planned and pursured in an effort to improve Aroclor
quality.
F. Mechanical Expense
Act $129,008 Sch $192,778 Var $63,770
A plant expansion expected in 1967 which did not materialize causes the large positive variance.
Mechanical expenses and downtime during 1967 were above 1966, but in line with 1964-65- Other downtime results primarily from low chlorine pressure. -This should be corrected with the completion of projects 3824 and 4864.
For a summary of 1964-1967 mechanical expense and downtime, see Appendix E.
Appendix F itemizes the mechanical expenses for 1966 1967. Pumps continue to be a source of high maintenance costs. It is recommended that all new pumps installed . be equipped with mechanical seals. Replacement or modification of existing pumps to pumps with mechanical seals will be evaluated.
TOWOLDMONOQ45456
91370:246(1)
Page 19
2/21/68
VII. Manufacturing Costs (Continued)
F. Mechanical Expense (Cont'd)
Appendix G lists all projects currently pending,.or completed during 1967-
VIII. Stream and Air Pollution
The principal stream pollutants from Dept. 246 are' biphenyl and chlorinated biphenyl. These, are sewered at a rate of 700-800 lbs/aay and are not considered a pollution problem. The sewering of this material will be eliminated with the
Aroclor plant expansion by January, 1969.
The principal air pollutant is HC1 gas. This is minimized
by drowning the blow tank vapors.
TOWOLDMONOQ45457
APPENDIX "A DRUMMING OF AROCLOR & BLENDS, 6/66 - 5/67
Prod.
Type Container, Gallons
55
ti 1I
30
June 1966
5J j
1232
j
1242
1248
'!
1254
.|
1260 1262
!|
A 13 B 3 B !
1254 PPO j
1620. PPO i
PYD A-200
'\
i
PYD A-280
! ;
88 985
138 24g
196
64
1254 + 10< XYL
'
THERM 1 THERM 2 THERM 3
TOTALS
* - *Oub . O'
40
--------------------------
1696
64
* 39
! 36 I
16
91 '
55 . 30 July
302 158 510 251 7 95 22 91 203
42 104
1656 29
5
' 55
5
Aug.
- I 22 I 40 I 192
66 I 402
` 30
! 19
! 352 i
j 96
132
438
76 4
66 : 1641
162
55 30 Sept.
5.
195 20
183
' 61
297
148
155 .
377
255 ..
60
190 4
1475
320
TOWOLDMONOQ45458
Prod.
1252 1242 1248 1254 1260 1262 A 15 B 3 1254 PPO 1260 PPO PYD A-200 PYD A-280 1254 + 10% XYL THERM 1 THERM 2 THERM 3
TOTALS
APPENDIX-"A" (CONTINUED) DRUMMING OF AROCLOR & BLENDS, 6/66 - 5/67
Type Container,
Gallons
55 30
Oct. 1966
5
! 55 . 30
\
!
3
Nov.
I
150 . 345 23
216 '
366
| . 231
; 142 ;
;
12 178
; 9i 1
j 231
5
] - 55
5 . J
!.
.
i Dec.
t J _j
, 138 84 35 ' 354
1 i .. |
i !
1034
170 64 : 161
174
' 200 52
j
| ; i j
1
55
120 221 24 58 70 134
116
152
30 Jan. .
100 . 50.
5'
10 61
i 39
39
! 28
32
59 70
; 52
: 174
!i 75
1229
142 : 834
1069
1319
252 ; 1037
150 . 103
TOWOLDMONOQ45459
APPENDIX "A" (CONTINUED) DRUMMING OF AROCLOR & BLENDS, 6/66 - 5/67
Prod.
Type Container
. Gallons
! 55
5 1 55
50 5 -55
50 5 ! 55
50 5 .1 55
50
1 EEB.
|
MAR.
APRIL
!
MAY
TOTAL
1232 1242
1248 1254
1260 1262
A 13 B 3 B 1254 PPO
1260 PPO
41 176 108 134
57 2
145
; 53 ;
!
92 72 250
741
30 14
255
15
18 104 448
52 1 141
| 98
63 1560
-
201 36 ' 456
1039 71 4456 .
24 '
416
79 35 53 130 99 175 1571 453 1849
244 37' 10
151
1790 50
203
PYD A-200
22?
1i 60
224
158
2766
r\>ii
000
j 212.
1254 + 10^ XYL
39
THERM 1
16
THERM 2 O 110
THERM 3
<
CD
rvj
>D
38 .
52 90 16
112 143 16 ; 44
i 34 ; 14
' 231
480 825 130
36 34 16
TOTALS
1029 127; 969 15 16 ; 1287 35 123 1208 qg 246 55 Gal. 15, 470 30 Gal. 54 o 5 Gal. 2,717
TOWOLDMONOQ45460
7'ICAL GRADE 124 2
Spec.. v.C^ l.'jcaX
900 i;.ln.
9.0 )',<xx.
1-10., 1967 ic Mo.
TCC
Re 4istivity x 10'
iJ.F.
Comments
January
February March
April *
M&y June
July August September
October
November
KI-
liOl 0.25 1)02 0.29
405 404 .
406
0.30
0.37 C.41
40? 0.4q
4 08 0.51 411 0.45
412 0.33
415 0.59 4 1"( 0 4 0
421 0.28
422 0.34
425 0.45
42? 0.47
426 0.52
451 0.48 455 0.32
457 0.36 440 0.62
444 0.61
447 0.53
446 0.26
. 451
0.59
455 0.55 456 0.49
457 0.47 453 0.55 462 0.63
465 0.46 469 0.47
471 . 0.38
472 0.30
. 475 476
0.44 0.4l
477 0.26 480 0.50
482 0.37
.
December
January 1968 February
485 488
489 492
493 494 KK402 405 406 4o8
0.53 0.64 0.35 1.81 0.40 0.35
0.34 0.37 0.35 0.50
1830 3950 2000
600 8v0 600 1030 3200 204g 1600 960 700 680 900 1600 880 750 2150 1300 4240 2500 3250 2680 2620 20 4 0 7489 5000 2560 2610 10400 6900 22400 13600 13690 7350 13750 4000 8000
2000 1300 1450 1545 2500 2880
1320 10600
1880 1900
0.69 0.82
COS 1'6.ting conditio
1.63 2.20
1.29 2.64
4.44 0.90 0.76 1.30
unless otherv,'i.sc r.crcec (160C, 2 lbs
?eCl3)
All otiiv.'P r.:8.t erial sold as non-electrics
9. vO 3.03
2.37 3.36 1.62 3.06 1.66 0.26
3.24
*
0.66 0.84
0.85
0.81 -- (195C,8 lbs
0.80
F6CI3 )
1.39
0.31
1.56 -- (195e, 8 lbs
0.9? 0.94
F0CI3 800 ppm Br'2)
0.52 O.78 o.4o
0.36 -- (195C, 2 lbs
0.23
Fe C13 )
0.40
0.24 -- (1950, 2 lbs
1.26
FeCl3)
0.19 -- (195C, 2 lbs
O 1.74 (M 2.64
FeCla)
O' 2.96 --(195C, 2 lbs
4.41
FeCl3)
2.46 --(195C, 2 lbs
1.23
FeCl3)
S:8
1.33 2.27
TOWOLDMONOQ45461
APPeKDIX E (Continued)
Ko., 1967
a: CPKICAL COPSE 125-4
Spec. - Ko plant specifications.
Sot Ko.
TCC Resistivity x ICk
M O--1 1 1
January February March
April May
June
July
August September October
November
December
January 1968 February
6c4
605 606
607 609
613 616
618
619 621 623
625 628
631 632
633 634 636
637 KK602
605
0.60
0.65 0.68 0.69 1.00 1.07 1.00
0.99
1.19' 0.89.
0.96
0.79 .1.06
1.05 0.50 0.67 0.85 1.34 1.24 0.82
0.85 0.57
8600 510
3450 4 080 22000 1200 10400 22400 6650 5900 6400 36020 24015 43250 B00460 160000 4l60 13500 6950 8805
2650 16000
C. 6 3 4.12 1.06 0.90 0.24 2.53 0.49 O.29
0.31 0.63 0.7 o 0.14
0.15 0.23 0.11 0.20 0.31 0.43 0.76 0.70
1.44
0.31
o!-- $
Comments
Ope ' ' dit lpO o, a FeCl3.
0*9, 63Oo
TOWOLDMONOQ45462
. Ap?;y/Di,;: _c
n/an'.O
rAn/Ilhb ht ,1:
Particle sise i>r.t> Oe t?r:in "no by St. Louis Testing Laboratories, Inc.
Plant Date Reaiple Tested
Per Cent less than Per Cent less tban
Per Cent less than Per Cent less than Per Cent less than Per Cent less than
1 in.lcron a :,;.'.cron
10 iii'.oron 20 u:` cron -' ; C roV:
cron
v;cx
5/8/67
___
--
17.4 40.6 35.5 96.1
Anniston
5/25,'67
6.6
24 .5 42.5 S3.4
-- --
LGX 7/6/67
Annisto 7/6 '6?
tf\aj L
5-4 65.9 91.4
-- --
--
--
3.5 21.8
7 {
0X96301
TOWOLDMONOQ45463
APPENDIX D ; SUPPLIER.
items. over $200 bought from, the storeroom during 9 months of 1967:
Filter paper. Sparkler :
>
Glass bottles, -5 pt.
'
Oakite-cleaner
V:
Seal's (labels) v
...
Filter cartridges ' ;
:
Soaps and detergents -.
,'
16 oz. bottles and caps
:.
Kerosene .
.
Filter cartridges, Alsop
Pressure, gauges
'
Rfegs
Steam hose
:
" 5-2'' flanged tees, 4gate valves
$662,50 607*52 502.26 475.00 462.00 551.88
555*95 277.20 .272.00 245.46 244.86 221.61 240.00
The above items account for about 50& of the total supply cost. The
balance Is made up -of non-repeating -items bought through the storeroom
and through purchase orders.
.,
.
0198302
TOWOLDMONOQ45464
APPENDIX E
SUMMARY OF TRUE REPAIR, MECHANICAL
EXPENSE, AND DOWNTIME FOR 1964 - 1967
,
: V.
..
CateRory ` True Repair
12i
1966
1261
'. $80,4on $82,302 $70,450 $
Mechanical Expense
116,834 100,379 88,592
129,008
Repair D. T.
.
1.92# 2.93#
0#
5.12#
Process D. T.
5.29
2.00
0.46
4.48
Total D.T.
9.03
9.20
2.76
10.50
Ol'303
TOWOLDMONOQ45465
APPENDIX F
Category'
Pump
_
Furnace
'`
Dept, repairmen
Instrument
Ejector
Platform
Plant. Improvement
Work t.o Assist
Tank, Closed '
Piping .
Electrical
Miscellaneous
All Others
Total M.E.
MECHANICAL EXPENSES, 1966-1967 YTD (JULY)
1967
: % of
Thru July Total M.E.
'' '
$10,571 . 1,384
17.0$ 2.2
4,799
7.7
3 >539
- . 5.7:
.2,030
3.3
15,338 . ,
24.7
8,684 . . 14.0
5,702
9.2
tMl
0.9 ' 4.6
686
1.1
l> 820
2.9
4,236
6.8
$10,048 1,844 8,560 7,340 2,554
. 13,208 9,132
. 9,124
2,647 8,722
4,351 3,439 . 7,623
$62,208 ,
$88,592
' % of Total M.E
11.35S 2.1
9-7 8.3 2.9 14.9
'
10.3
10.3 3.0
9-8 4.9
3-9 8.6
*.
019830*
TOWOLDMONOQ45466
APPENDIX G PROJECTS CURRENTLY PENDING
OR COMPLETED DURING 1967
Engr. Auth. No.
Est. No. .
5534 2844
Date App.
8/gl
4/66
Description c
Install heat exchanger Blending & Loading
Facilities
Cost
$ 8,000 60,000
S-842 S-892 S-893 S-670
S-65O
5639 1138
4263 4467 4448
4871 5018
5*11 3446 3528 2698
10/67 12/66 1/67 3/67
M7
4/67 5/67 8/6J 7/66 7/66
12/65
Relocate TCB Dock
Install alarms on chlor.
Dism. gravity instrument
Replace steel & handrails
Replace vacuum Jet
Install Exp. Filter
P.M. painting steel
P.M. insulation repairs
Install safety showers
Alter shower tracing
Alter three loading docks
Dismantle & replace
lean-to
'
2,100 3,450
500 18,810
4,620 2,600 23,380
5,375 2,700 1,000 * 5,700 30,500
Upgrade control room
4,000
S-647 S-7060 M-6049 R3771 8/66
M-5034 3491 8/66. Minor
Upgrade office
Upgrade lighting
.
Relocate 6" fire
protection line
Roof over loading dock
Install mech. remote
Ram valve
Install spare #2 still
pump
6,000 8,000
Status
EDC 2/1/68 Given to CED for construction; mat'l being ordered. EDC 7/1/68
Comp. 8/67 Complete Complete Complete Complete 6/67 Complete Complete Comp. 5/67 Comp. 5/67 Complete Held up pending study of drumming required. Held up pending department expansion by CED. Est. sub. 8/67
Complete 5/67
Complete 2/67 Scheduled for December 1967 T/A Estimate submitted
0196305
TOWOLDMONOQ45467
APPENDIX H
Using the cost standard prepared by H. F. Ray for th<2 expanded
Aroclor plant operating at a maximum capacity of 70 M lbs/year,
the following manufacturing costs and net profits/year were
calculated:
-
.
Sales Forecast, lbs.
Unit Mfg. Cost
Net Profit (B.T.) FI 4
Increased Profit Compared to 1968, M $
1268 !3a. 1970 1971 1972 1976-77 32.75 35.76 39.01 42.47 45.34 70.00
46.84 47.66 47.47 47.29 47.16 46.48
1.59 1.45 1.65 1.87 2.06
3.65
-0.14 0.06 0.28 0.47
2.06
..
Payout should occur during 1974.
v.
Assumptions; '
.*
1. Average sales price of 15-0^/lb'.
2. SARE of 22$.
,' ;
;
J. Salary and wage increase of 4$ annually over 1968.
4. 1967 prices on biphenyl and ferric chloride, 1968 prices on other raw materials.
5. Depreciation based on addition of 1.5 I $ capital with
12 year life.
.' .
6. Addition of four operators, one packer, and one foreman.
7. Biphenyl yield of 97& chlorine - 93$.
OH*506
TOWOLDMONOQ45468