Document daRZvM1kGOyNJd4KYB20vLxjQ

CAUSTIC I / CHLOR - ALKALI 2 1994 REACTIVE CHEMICALS REVIEW CAUSTIC AREA - both plants Dow Confidential Information `,yj r.ONFT OFfVTT^ 09/29/94 NaOH EVAPORATOR AREA 23Sf Slum r^rA 04 7406 f NFTnFNTTAi 09/JM DOW CONFIDENTIAL NaOH CENTRIFUGES & PRIMARY COOLING AREAS 09/94 DOW CONFIDtNTIAL DO A 047407 OONFTDFNTTAL NaOH FINISHING AND STORAGE AREA 09/91 now coNfinCNTiAi DO A 047408 OONFTDFNTTA! CAUSTIC 1 EVAPORATOR AREA 236# STEAM JMBUTl F CAUSTIC 1 CENTRIFUGES/PRIMARY COOLING CAUSTIC 1 CHILLINJ/FILTERING/STORAGE 'Mill I ' CAUSTIC t/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 RAW MATERIALS/PROCESS AIDS - RAW MATERIALS Cell Effluent (8-11% NaOH, 15-17% NaCI, 72% Water) - PROCESS AIDS Steam (150# and 235#) Carrier Brine (Caustic l Only) Process Water River Water Instrument Air Plant Air nn ft 0474^ SUPPLIES HCL (Used for PH Control at Caustic 1-Does Not Contact Process) Lithium Bromide (ARU-not in Contact With Process) JMBUTLER 09/28/94 CAUSTIC l/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 RAW MATERIALS/PROCESS AIDS: SOURCE AND STORAGE - SOURCE Cell Effluent - CL2 and CA2 (Pipelines) Steam - Power I (Pipelines) Carrier Brine - CL2 (Caustic I Only-Pipeline) Process Water - Utilities (Pipeline) River Water - Plant Pumps (Caustic I Only-Pipeline) HCL - Solvents (Pipeline) Lith. Bromide - ARU (Contained Within Unit) CTW - Plant Pumps (CAII Only) - BLOCK STORAGE DO A 047413 CONFTDFNTTAl Cell Effluent - T-1 (Plant Feed), T-2 (User Feed), T-1A, T-2A, T-3, T-109 Tanks @ Caustic; D-301, D-316A @ CAI1I HCL, Steam, Carrier Brine, Process Water, River Water - No Storage: Supplied via Pipeline on Demand Lith. Bromide - Stored Within ARU jmbutler 09/28/94 CAUSTIC l/CAll REACTIVE CHEMICALS REVIEW OCTOBER, 1994 RAW MATERIAL: SPECIFICATIONS Cell Effluent Caustic (NaOH) % Iron (Fe) PPM Sodium Sulfate (Na2S04) PPM Sodium Sulfite (Na2S03) PPM Sodium Chlorate (NaCI03) % 5-15 1.0 2500 1-20 0.03 [~jO A 04741 4 CONFTDFNTTAl JMBUTLER 09/28/94 CAUSTIC l/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 PRODUCTS/BY-PRODUCTS - PRODUCT 50% Caustic (50% NaOH, 0.5% NaCI, 49.5% Water) - BY-PRODUCTS Condensate (Boiler and Non-boiler Grade) Salt Slurry Sulfate Purge OO A 047415 C": ONFTDFNTTAI. JMBUTLER 09/28/94 CAUSTIC l/CAll REACTIVE CHEMICALS REVIEW OCTOBER, 1994 i j PRODUCTS/BY-PRODUCTS: IN-PLANT DISTRIBUTION - PRODUCT Caustic - Pipelines to Storage Tanks in Plant and at Tank Farm Cell Effluent - Pipelines to Users (Backflow Protection Critical) - BY-PRODUCTS Condensate Salt Slurry Sulfate Purge - Boiler Grade Routed from Collection Tank to Power I or Used Internally - Non-Boiler Grade consumed in Process or Routed to Canal - Routed from Two Salt Columns (D-205&D-207) to CL2 or Used Internally (CAM) - Brine from CL2 Mixed with Salt to Assist in Transfer - Routed to User Feed Tank (T-2) @ Caustic DO A 04741> CONFIDFNTTAL CAUSTIC l/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 PRODUCT SPECIFICATIONS 50% CAUSTIC Caustic (NaOH) Salt (NaCI) Iron (Fe) Sodium Carbonate (Na2C03) Sodium Sulfate (Na2S04) Sodium Chlorate (NaCI03) Nickel/Copper (Ni/Cu) Arsenic (As) Mercury (Hg) Lead (Pb) Heavy Metals as Pb Silicon (Si) Manganese (Mn) % % PPM % % % PPM PPM PPM PPM PPM PPM PPM 49.0-51.0 1.0 5.0 0.2 0.025 0.15 1.0 1.5 0.5 5.0 15.0 100 1.0 00 A 047417 CONFTDFNTTAl JMBUTLER 09/28/94 DOW, CAUSTIC l/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 BY-PRODUCT SPECIFICATIONS Salt Slurry Caustic (NaOH) % Salt Settle Volume (SV) % Conductivity Hydrazine Boiler Grade Condensate MMHOS PPM 1.25 Max 5-50 10 Max 0 DO A 047418 OONFTDFNTTAI JMBUTLER 09/28/94 CAUSTIC l/CAll [ REACTIVE CHEMICALS REVIEW OCTOBER, 1994 REACTIVITY: 50% NaOH - WATER - Dilution With Water is Exothermic - Rapid Temperature Increase Can Result - Heat of Dilution: Naoh*H20+H20-*~ Na0H*2H20+175 BTU/LB - ACIDS - Reaction is Violent and/or Explosive - ORGANIC COMPOUNDS - Potential Violent Reaction - METALS /' - Rapid Reaction With Aluminum, Tin, and Zinc. . - Can React with Amphoteric Metals in Water Solutions to Generate H2 Gas - Reaction With Bronze and Brass - Flammability D0 A 047419 conftdfnttai - Not Flammable JMBUTLER 09/28/94 r CAUSTIC 1 REACTIVE CHEMICALS REVIEW OCTOBER, 1994 ftrifHriTariaJfaEEl REACTIVE CHEMICAL CONCERNS CONCERN C II Effluent DistributionBackflow From User Plants Water/NaOH Heat of Dilution PREVENTIVE MEASURES User Plants Surveyed in May, 1994 to Ensure Backflow Protection is In-place. Water is Added Throughout Process. Continuous Flow and Closed System Control Temperature Increase Near Normal and Eliminate Impact Of Boiling Action, Respectively. Utility SystemsCaustic Contamination Double Block and Bleed Used at All Cross Tie Points. Corrosion of Nickel Clad Vessels by Hypochlorites in the Cell Effluent Feed Cell Effluent Analyzed for Hypochlorites. Neutralized With Sodium Bisulfite. DO A 047400 OONFTDFNTTAL JMBUTLER 09/28/94 CAUSTIC LOADING & DISTRIBUTION POTENTIAL PROBLEMS TANK TRUCKS TANK TRUCK CONSTRUCTED OF ALUMINUM. "NON-CAUSTIC HEEL IN TANK TRUCKS FROM PREVIOUS LOAD. PREVENTIVE MEASURES 1 - T. E. D. sheet requires truck to be constructed of nickel clad, stainless steel. or lined carbon steel (MC-304, 307. 311. 312, 316). 2 - Listed on loading checklist. 1 - Tank trucks required to have completed cleaning sheet. COMPARTMENTED TANK TRUCKS CONTAINING CHEMICAL REACTIVE WITH CAUSTIC IN ADJACENT COMPARTMENT. 3 - Heel checked by chemical methods; litmus paper, mixed indicator, non-caustic heel verification tests. -/uv<y 4 - Written procedures for loading and checklist completed on each truck. 5 - Personnel training. 1- Staff approval required before loading compartmented trucks. p. i&'L 'pix/, l k1 . Dow Confidential 09/28/94 00 A 047471 O.ONF T DFNT T Al CAUSTIC LOADING & DISTRIBUTION POTENTIAL PROBLEMS PREVENTIVE MEASURES TANK CARS. NON-CAUSTIC HEEL IN TANK CAR FROM PREVIOUS LOAD OR FROM CUSTOMER CONTAMINATION. /- V 'MlI'*f * &<! BARGES NON-CAUSTIC HEEL IN BARGE FROM PREVIOUS LOAD. 1 - Dedicated fleet of tank cars. 2 - Dow-owned tank cars not stenciled "CAUSTIC" only loaded after cleaning. 3 - Visual inspection before loading each car. 4 - Heel checked by lab. procedures if necessary, 5 - Written procedures for loading and checklist completed on each car. 6 - Personnel training. 7 - Follow-up with customers in cases of car contamination. Cars cleaned before reloading. 1 - Dedicated fleet of barges. 2 - Visual inspection before loading. 3 - Heel checked by lab. Procedures, f4 'U&Mai 4 - Written procedures for loading. 5 - Personnel training. Dow Confidential (")0 A 0474?? GONF1 OFNT 7M 09/28/94 CAUSTIC LOADING & DISTRIBUTION POTENTIAL PROBLEMS SHIPS NON-CAUSTIC HEEL IN SHIP. PREVENTIVE MEASURES 1 - Ships required to be cleaned before loading. 2 - Last cargo information supplied to LAD ship coordinator and caustic plant loading coordinator. 3 - Visual inspection before loading each ship. 4 - Written procedures for loading. 5 - Personnel training. Dow Confidential 09/28/94 DO A 047423 GONFIDFNTTAI, OmMT Matrtx.XLS