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Hammond Plant SAL 0CCC1C232 PED ORIENTATION PROGRAM HAMMOND CHEMICAL PLANT HAMMOND, INDIANA The Hammond plant began production in 1969 using the new Chemithon Sulfonation Process. Operation had existed at the site using a batch process since 1958. This operation was discontinued when the new continuous process came on-stream. Throughput capability has been increased to 70 MM pounds per year from the original 30-40 MM pounds per year. The increase was achieved both through optimization of the process and through evolution of different product slates. The plant uses as feedstocks linear alkylbenzenes from Baltimore and "ALFONIC" ethoxylates from Lake Charles. Sulfur trioxide is purchased from an adjacent Stauffer Chemical Company plant. Other feedstocks include sodium hydroxide, ammonium hydroxide, ethyl alcohol, and "ALFOL" alcohols. GENERAL DESCRIPTION Sulfonation/Su1fa tion Feedstock (a 1kylbenzene, ethoxylate, or alcohol) is charged to parallel thin film reactors. Sulfur trioxide, in a carrier air stream, Is injected into the reactor also. The exothermic reaction mass is cooled by water in the reactor jackets. Reactor effluent, consisting of liquid sulfonatlon products and air, is phase separated in a cyclone. Effluent gases are normally passed through knockout drums and transferred across the fence to Stauffer Chemical Company where SO2 and SO3 mists are burned to recover the sulfur. When the Stauffer unit Is not running, the effluent gases are vented to the atmosphere through an SO2 scrubber. Crude sulfonates (alkylbenzene derivatives) from the cyclone are subjected to further contacting In "digesters11 to complete the reaction of any dissolved sulfur trioxide. Following the digestors, alkylbenzene derivatives are contacted with water In a "hydrator." This converts any anhydrides back to the .sulfonate form. The sulfonate or sulfonic acid is then sent to storage. Sulfates (alcohol or ethoxylate derivatives) are immediately neutralized to avoid chemical decomposition of the unstable sulfate. Su1fona tion/Sulfat ion Chemj stry a. Alkylbenzene Sulfonation C12 1 Q) (L) + S03(g) C12 1 (L) SAL ^ C 0 C1 c 2 3 3 b. Ethoxylated Alcohol Sulfation R-(C2Hi|0)X-CH2-0H(L) + 503(g) ---------- R-(C2Hi10)CH2"0-CH3H (L) Neutral1zatlon Neutralization is accomplished through injection of NaOH or NH3OH into the sulfonate or sulfate as it enters a centrifugal pump. The pump and downstream piping constitute the "reactor". The heat of reaction is removed in watercooled exchangers. Sodium hypochlorite is then injected to bleach the stream. Sodium xylene sulfonate may also be injected at this stage, depending on the product being made. Sodium carbonate or sodium bicarbonate is added to the ether sulfate product as a pH buffer. Neutralization Chemistry a. Alkylbenzene Sodium Sulfonate (Sulfonic Acid) C12 ; + NaOH ^S03H C12 + H20 S03Na b. Ethoxylated Alcohol Sodium Sulfate (Ether Sulfate*) R-(C2HifO)x-CH2-0-S03H+Na0H --------- R- (C2H40)x-CH2-0-S03Na + H20 PRODUCTS Sulfonates and sulfates are utilized as surface active agents (surfactants) in biodegradable laundry powders, dishwashing liquids, and shampoos. Hammond's products include: Conoco SA-597 Sulfonic Acid Conoco C-550 Slurry Conoco C-560 Slurry "ALFONIC" 1412-A "ALFONIC" 1412-S Derived from N-500 Alkylbenzene Sodium Sulfonate of SA-597 C-550 Blend with Sodium Xylene Sulfonate Ammonium Salt of Alcohol Ether Sulfate Sodium Salt of Alcohol Ether Sulfate This sheet Is CONFIDENTIAL and should not be distributed outside Continental Oil Company. Spec. No. 02-3300 CONOCO SA-597 Sulfonic Acid Special SO3 sulfonated NAUOLKHE 500 alkylate Teat Active, Wt. Z a. b. Sulfuric Add, Wt. Z Free Oil, Wt. Z (2) Unaulfonated Oil, Wt. X Water, Wt. Z Sulfur Dioxide (SO2), Wt. Z (4) Specification 96 min. 97.5 mih. ! us* 2.5 w 1,0 max 1.0 au 0.06 max Typical Property Teat Method 1.001 97.5 Calculated (1) 1.3 1.052 1.021 0.7 1.063 0.4 0.01 1.016 1.066 Acid Color, Klott (5% active acid) Iron ppm (3) W Uax 10 sx. 55 2 1.054 1.019 (1) Active, Wt. X - 1001 - (sulfuric acid, vt. Z + unaulfonated oil, wt. Z + water, vt, Z) (2) Internal specification^--not..to be used outside Conoco* (3) For E. F. Goodrich only, ' (4) For P & G only. 7-15-77 (Replaces 4-10-77) -SAL 0 000ZC235 This sheet is CONFIDENTIAL and should not he distributed outside Continental Oil Company Spec. No. 02-3351 CONOCO C-550 Slurry Special Identification: Sodium sulfonate of SA-597 Test Active, Wt. % Sodium Sulfate, Wt. X Free Oil, Wt. % .Color, Klett (5% solution) pH, 5% aqueous solution Specifications 50-53 (1) 1.3 max. 1.2 max. 1.1 max. (1) 50 max. 7-8 7.0-8.5 (1) Typical Property 52 1.05 1.1 1.05 32 7.5 _ Test Method 1.001 1.052 1.021 1.014 1.047 1.047 (1) For Gateway Only - Add buffer, 0.05%-0.1Z Sodium Bicarbonate 4-10-77 (Replaces 10-1-72) SAL 0CCC10236 This sheet is CONFIDENTIAL and. should not b distributed outside Continental Oil Company. Spec. No. 02-3353 CONOCO C-560 Slurry Special Identification: Blend of sodium sulfonate of SA-597 and sodium xylene sulfonate Test Typical Specification. Property Total Active, Wt. % (LAS + SXS> 57-60 59 Solids, Wt. Z 63.1 max 61.2 Sodium Xylene Sulfonate, Wt. Z 1 min^ C max 2 Free Oil, Wt.Z 1,6 max2 1.35 Sodium Sulfate, Wt. Z 1.5 max 1.0 pH, 5% aqueous solution 7-8 7.5 Color, Klett, 5Z active Iron, ppm 50 max . 5 max 40 3 Phosphate (as P2O5) ppm 40 max 2 Test Method Calculated^ 1.064 1.040 1.021 1.052 1.047 1.042 1.019 1.067 (1) Active-, Wt. X - Solids, Wt. X - (Sodium Sulfate, Wt. X + Free Oil, Wt. X) (2) 1.2 Max. for Colgate and Wyandotte (3) For Colgate only -- 1.5-2.5X SXS (4) For Wyandotte only -- 2.0-2.5% SXS 7-15-77 (Replaces 2-25-77) SAL 0C0C1C237 This sheet is CONFIDENTIAL and should not be distributed outside Continental Oil Company. Spec. No. 06-4560 ALFONIC 1412-A Alcohol Ether Sulfate Special Identification: Ammonium Salt of ALFONIC 1412-40 (Spec. No . 06-4360) Test Specification Typical Property Test Method Active, Wt. Z 58.0- J.O 59.2 1.009 Solids (Active + Free Oil + Salts), Wt. Z 62.0 1.5 61.0 Calculated Ethanol, Wt. Z 14.0 1.0 13.7 1.057 Unsulfated (Ethoxylate + Alcohol) 3.0 max. 2.2 1.038 Total Inorganic Salts, Wt. Z 2.5 max. <1.0 Calculated Alcohol Insoluble, Wt. Z 0.75 max. 0.3 1.052 Cl as NH4CI, Wt. % 0.25 max. <0.1 1.010 Proa, ppm 5 max. 2 1.019 Copper, ppm 0.5 max. 0.3 1.045 Peroxide Content, ppm 10.0 max. nil 1.044 pH 7.0-7.5 (1) 7.2 1.043 Color, Kletc, 52 Solution 50 max. 30 1.042 Color, Gardner (Purex) 3 max. - Corrosion Test Pass - Odor Equal to Standard - Appearance Clear to slightly viscous liquid Molecular Weight 423-444 436 Ca + Mg as CaC03 5 max. <5 Colgate Method Water, Wt. Z 20.0-29.0 25 Calculated (1) 0.22 Na2C03 as buffer 1-26-76 (Replaces 2-7-73) This sheet is CONFIDENTIAL and should not be distributed outside Continental Oil Company Spec. No. 06-4565 ALFONIC 1412-S Alcohol Ether Sulfate Special Identification: Sodium Sulfate of ALFONIC 1412-40 (Spec. No. 06-4360) Test Active, Wt. % Ethanol, Wt. % Dnsulfated (Ethoxylate + Alcohol), Wt. % Total Inorganic Salts, Wt. % Na2S04, Wt. % NaCl, Wt. % Iron, ppm Copper, ppm pH, 1% Solution Color, Klett, 5% Solution Specifications 58.0-60.0 13.0-15.0 Typical Property Test Method 1.009 1.057 3.0 max. 2.5 max. 1.0 max. 1.5 max. 5 max. 0.5 max . 8-9 (1) 50 max. 1.038 Computed 1.052 1.010 1.019 - 1.045 1.047 1.042 [I) Butler required; 0.2% to 0.3% Na2C0^ recommended 10-1-72 3Al_ 001c23. ORGANIZATIONAL CHART HAMMOi JHEMICAL PLANT J--IL ! -I .1 c? $ O St Sit NBUT&ALtZA TTOrt