Document gar0abdwwooNBrwGYnb772NoL

U BQB Q0 S fOM TIW nil Of TMl WOK UBOIUTOHT z yt. PROGRESS REPORT PL AMT TECHNICAL A V 1C OKPT.-W. A. KHUMMMICH PLANT .PlEASt RE1 91370:1716 #64 7 ^9/64 W. Q. KRUMMRICM PLANT RESEARCH GENERAL OFFICE OTHERS K C. CARDER 13 E.E.Martin 13 J .D.Sul 11 van * 5J O. B. HOSMER 10. IMP.-------------- E ' J. HOLZAPFCL . T. W. DALTON P. E. HEISLER J, K RULLENOORE tS V. Brawley T5 R.W.Bucknell Qt) M. L. MINCKLER 3 D.C.Armstror ; * O J* r- TTICKLEY L.G.Cole fy] c. El AMAOnOPTOPOLOUE 3 L. E. KLEIN *_E_ J* *MITMW|QTM O w. a, HINCHCLIFF Anmiiton O J` C. LARKIN M. ft. PATRICK f3 D.Middleton 12 D.Danna A ON . I 1 KpKlLinoson R. E. SOOEN J.A.Morgan OFFICE SERVICES 2 five extra *\X] L.C .Fuhr- melster * Molloy LL CONFIDENTIAL titli! Process Improvement Plan - Aroclor, Pydrauls, and Pyranols puiohniliW, B. Johnson, L. G. Cole, D. C. Armstrong, E. E. Martin (j.R.Savage) psosLiMi Present a specific plan with short range and long range objectives for Improving Aroclor rates, quality, yields, costs. Pollution con trol, corrosion control, safety and other studies. SUMMARYt Spec, or 1963 or IMMEDIATE LONG RANGE Std.Historical Present TARGETTarget (lQ,^ Rate 20.4M lb/yr. Yields (Biphenyl) 93.49)8 Prooess Efficiency Manufacturing Costa 7.112/cwt Total Savings 23.8H 28.6M lb/yr .OH lb/yr 97.0)8 97.5)8 _ .0)8 92.05)8 92.5)8 .93.0).8 6.451 6.101/cwt 5.983/cwt IIIO.OmZyV^ 1201 ,'0D0/yr Most of the savings claimed result from Increased divisor by virtue of in creased rate and are dependent on sales. The Aroclor quality objective of meeting Anniston's quality by 8-1-64 has been met as far as resistivity Is concerned, but has not been as far as stability Is concerned. The plan to meet this goal Is contained herein. Specific projects have been Installed within the last 3 months to reduce air and stream pollution, reduce corrosion, and Improve department safety. /me 91370:1716 (64) -2- July 29, 1964 DETAILS Background Liquid Aroclors are chlorinated diphenyl and are manufactured at WGK and Anniston by Monsanto. Diphenyl is obtained from Anniston and the following operations are performed to produce Aroclors. 1. Chlorination 2. Aeration 3. Distillation 4. Blending 5. Storing Aroclors are designated by a four digit number such as 1142 and 1242. Any Aroclor in the 1100 series indicates crude Aroclor that has not been refined by distillation. The 1200 series indicates refined Aroclor. The last two digits, 42 in thiB example. Indicates the degree of chlorination. Aroclor 1242 has 42JC chlorine by weight, and at WOK only 1242, 1248, 1254, and 1260 liquid Aroclors are produced. Monsanto is the sole national producer of Aroclors. Electrical and non electrical grades of Aroclors are produced at WOK. The national sales for electrical grade Aroclors for 1963 is estimated at 26M lbs. Sales forecasts Indicate 355* increase in sales of electrical grade Aroclor within the next 3-5 years. I. Aroclors A. Rate Summary ST37 Avg. Prod. Rate W lb/yr --purr Downtime n 8 ,u1% Remarks 2$6 Mechanical, 2% Process, and 456 other downtime 1963 19.1 15 Reduced avg. prod, rate resulted from scheduled or Inventory downtime due to lack of sales or storage. Inv. downtime was 8.45$, Mechanical downtime 2.785$, Process downtime 1.55$, and Other downtime 2.34^ Present Immed. Target 23.8 28.6 6.875* log HONS 060277 Phase I of the Aroclor expansion will be mostly completed by August 12, 1964. At least a 405$ rate increase will result. N.F.C. = $101,000. See items 13 and 14 of the Job List in the Appendix. Long Range 39.0 (1-3 yrs) 8)6 Phase II of the Aroclor expansion will be initiated by parts as needed. N.F.C. = $120,000. See Item 15 of the Job List In the Appendix 91370:1716 (64) -3- July 29, 1964 Expansion, Phase I, Chlorination The Phase I expansion will be completed by 8-12-64. The actual capacity of the ohlorlnation step will be at least 4c# greater. The following items will be Installed: a. 4 air-cooled heat exchangers (l.lH BTU/hr.) b. 4 larger Mark II Durco circulation pumps (250 gpm at 100' head) c. Chlorine feed control (by batch temperature) d. Chlorine feed totalizer for each chlorinator e. Radiation Specific Gravity recorder for #4 chlorinator (to be Installed by 9-1-64). See Item 13 of the Job List in the Appendix. Expansion, Phase I, Distillation An Integral part of the Phase I expansion consists of three separate projects as follows: a. Convert the present 3-stage Jets from condensing to 2-stage non-condensing This will eliminate a costly production problem and help avoid an increase in work force. This project will be completed by 8-15-64. See item 10 of the Job List in the Appendix. b. Project 8731 has been approved to Install a larger pump (250 gpm 120' head) and a larger coil (3") in #2 still system by 9-10-64. The pur pose of this project is to eliminate a maintenance problem and downtime. The still capacity will also be Increased. #1 still will be similarly converted at a later date as the need dictates. See item 12 of the Job List in the Appendix. c. A Job will be taken out to evaluate the need for improved earth filtering facilities. If Justified, the present facilities will be redesigned. This will be done by 10-1-64. See item 13 of the Job LlBt in the Appendix Expansion, Phase I, Handling & Storage A. feree 20,000 gal. finished product tanks will be installed by 9-15-64 as replacements for 5--15,000 gal. underground storage tanks at a cost of $92,000. Hie additional storage volume will be sufficient for a 40jtf Increase. The following projects listed below will eliminate some of the time consuming operations of the "B" operator and packer. They will also help minimize any overtime work required to handle the Increased capacity. a. Install high-speed drum-off facilities. b. Improve loading facilities at the docks. . c. Install metering and control equipment to up-grade blending facilities. Design packages will go to P & S by 10-15-64 pre suming the estimates are approved. See item 14 of the Job List in the Appendix. Expansion, Phase II MOMS 060278 A radiation specific gravity recording and controlling Instrument will be 9X370:1716 (64) -4- July 29, 1964 Installed by 9-1-64 on #4 chlorinator as an experimental unit. Closed loop chlorlnatlon-level control should be a reality by about January, 1965. Phase II of the expansion program can then be Initiated aa the need dictates to Increase the rate by 10.4M lb./yr. for a total average Aroclor rate of 39M lb./yr. The following Items are part of the Phase II proposal: a. Put 4 chlorlnatOrs on continuous chlorination: (see explanations below) The obstaole involved In putting 4 chlorlnators on continuous cascade opera tion Is that 1242, 1248, 1254, and 1260 Aroclor are produced at WOK In about equal portions. Changing products In the chlorlnators with continuous opera tion Is no problem In going up scale from 1242 to 1248, etc. However, coming down scale produces about 600 gal. of crude Aroclor mixtures. No. 5 chlori nator can be operated batch-wise to produce 1260 Aroclor out of this mixture. A small biphenyl mix tank, a charge tank, and piping changes are all that wiil be necessary to convert to continuous chlorination. The radiation Instrument will be used to control chlorination level (sp. gr.) In a closed loop system comparable to Anniston's Installation. See Item 15 of the Appendix. b. Increase still capacity: The #1 still can be converted to a larger pump and furnace coll, the same as #2. Larger burners.will also be Installed If more capacity Is needed, c. Increase Intermediate and final storage capacity: Storage capacity will be critical and two more 20,000 gal. final product storage tanks will be needed. Two intermediate storage tanks, 15,000 gal. each, will also be needed and can be used for aging the crude product. d. Improve loading facilities: A new loading dock station may also be needed aB the trailer business In creases. The chlorine supply line will have to be cleaned or renewed, and the biphenyl unloading operation will have to be improved time-wise. B. Quality Summary Test 1. Resistivity (ohm-cm) 2. Tower Factor 3. Hydrolysis Stability (ppm Cl") 4. Monsanto Stability (ppm Cl-) 5. Thermal Chem. Chloride Stability (ppm Cl-) 1242 Electrical Orade Aroclor Spec, or Std, 1563 or Historical Present 500 x 109 570 x 109 2700 x 109 None 1.0 0.41 0.41 0.14 0.51 0.40 0.31 0.29 0.75 0.70 0.55 Target 1110 x 10 0.10 0.25 0.15 0.40 Aroclor specs, are generally very high and often difficult to attain. There HONS 060279 91370:1716 (64) -5- July 29, 1964 are Indications that Monsanto customers would prefer even high quality Aroclor. It appears that Aroclor with higher stability and power factor will be needed. Aroclor presently produced at WGK meets specs, but Anniston's Aroclor appears to be more stable by Munch and Hydrolysis stability tests. Results of thermal chemical chloride stability tests and Power Factor testB appear to differ be tween the two laboratories. All other quality tests Indicate WOK Is producing Aroclor comparable to Anniston, with a possible advantage to WGK In resistivity WOK Aroclor stability will be Improved to meet Anniston's quality by 10-1-64. The lab Is working to resolve analytical discrepancies to help pln-polnt what changes In operations are needed. Aroclor stability can be affected by: a. Chlorination temperature. b. Catalyst suspension, concentration and depletion. c. Circulation and/or agitation. d. Sulfate impurities In chlorine feed. e. Crude Aroclor aging. f. Cleanliness of chlorinator (also affects mixing). g. Distillation boll down and entrainment. Hydrogen Chloride Quality Brink Mist EllmlnatorB were Installed In the off-gas off each Chlorinator on June 10, 1964 to prevent Aroclor carryover. The Aroclor carryover was eliminated, but the HC1 off-gaB Is still contaminated with biphenyl, A cooler and scrubbing system haB been designed to solve this problem. The total cost Is $10,000. A savings of $5,000/yr. will result plus the savings of reduced downtime for Dept. F-218. Improvement Plans The following is a plan for Improving Aroclor quality In general and speci fically stabilities by 10-15-64: 1, At the completion of the expansion Installation on 8-12-64 samples will be taken to check catalyst concentration (0.03# minimum) at different times during a chlorination cycle. If a problem Is found to exist it will be solved as follows: a. Write an amendment to add extra catalyst. b. Use a different method to slurry and suspend the catalyst In the charge e. Use the same chlorinator packing Anniston uses. d. Evaluate any differences In catalyst produced by different manufactures 2, Compare temperature profiles of WGK's and Anniston's ehlorlnators, and evaluate differences by 10-1-64. 3, Evaluate the degree of boll-down of the stills and entrainment compared with Anniston. This can be done by analyzing the montars from the stills. Correlate these results relative to Aroclor stabilities by 10-15-64. Also run a profile study of stabilities on still fractions. 4, If the Aroclor quality has not been significantly improved to meet the ob jectives by this time a lab testing program will be Bet-up to study the MOWS Q6G280 91570:1716 (64) -6- July 29, 1964 following variables affecting Aroclor quality in the plant; a. Chlorlnator circulation rate, basket design, packing and sparger design, b. Aging of crude Aroclor. o. Present filtering techniques. d. A study to determine If raw biphenyl, low or high boilers, and special Isomers are related to Aroclor stability. C. Yields Standard Aroclor yields are set at 95.495^ of theory on Biphenyl. The % of theory on Biphenyl wa3 96.55* for 1965. The YTD yield as of May, 1964 Is 97.4j*. The yield target has been set for 97.55* for 1964, for a yield increase of 1J*. This Increase will come primarily from the Installation of mist elimi nators in the chlorlnator off-gas lines (Item 5 In the Appendix). This project was Installed 6-15-64. A study will be made to determine whether reject sam ples and line flush out material can be used for non-electrical grade Aroclors. Process Efficiency is defined as - lbs. Aroclor Produced + lbs, HC1 Produced x 100 lbs. Biphenyl Used, + lbs. Cla Used Efficiency This Is a very good oyerall measure of the yields of products and raw materials. The P.E. for 1962 was 87.615*, 1965 was 85.495*, and currently is running 92.055*. The target for 1964 was set for 92.55* and the long range target was set at 95.0f for P.E. D. Costs 1. Aroclor cost was $7.048/owt In 1962, $6.884/ewt in 1965 and $6.451/cwt In 1964 through June. The cost will be further reduced to 6.101/cwt at a production rate of 28.6M lbs./yr. Tor a total savings of $100,000/yr. by 8-5-64, making a savings of $.550/ewt. (item 15 In the Appendix). The Capacity Increase savings. Phase I and Phase II, are predicated on sales equalling production capacity. Phase II will be completed by August, 1965, If approved, and a production rate of at least 59.OM lbs./yr. of Aroclor will be possible. This rate will reduce Aroclor costs to 5.844/cwt and save $100,000/yr. A grand total of $210,000 can be reallzd at the completion of Phase I & Phase II of the capacity Increase of the short and long range Process Improvement Plan, presuming capacity sales. 2. The Brink Mist Eliminators on top of the Chlorlnators, part of Phase I, have been Installed. This Item is a part of the Cost Improvement Plan and produces savings of $10,000/yr. See Item 5 of the Appendix. 5. The design package to revise the still Jets was Issued on 6-11-64. This project will save $5,000/yr. in steam usage and rate Improvement ard is a part of Phase I as well as a part of the Cost Improvement Plan. See item 10 of the Appendix. HONS 060281 91370:1716 #64 -7- July 29, 1964 4. Increased chlorlnator circulation and cooling ie a CIP item and will pro duce rate savings of about $100,000/yr. This phase I project will be in stalled by August 12, 1964. See item 13 of the Appendix. V. Pollution te Corrosion 1. A project was Installed in 1959 to eliminate the HC1 air pollution origina ting in the blow tanks. It has not been made to work up to April, 1964. This project was repaired and made operative by 4-15-64. 2. A study will be made of the Aroclor vapor and biphenyl vapor losses from tank vents. These fumes could contribute to air pollution and corrosion problems. Most of these vapors can be eliminated at a small cost. F. Safety 1. A design package was out by 3-1-64 to install a Chlorine superheater to in sure that no liquid Chlorine will get into the Chlorlnators. This project was Installed by 4-24-64 and 1b operating. Many safety features will be Included in the Phase I & II expansions to protect equipment and personnel. The dept, has not had a lost time accident since January 28, 1948. 0. Long Range Plans & Studies 1. As part of the Long Range Plan the possibility of a rate Increase by new chlorlnator designs should be investigated. It is recommended that contin uous stirred reactors, multlsectloned stirred reactors, and tubular reactors be investigated. A substantial rate Increase and cost reduction could re sult from a new design'of the distillation*system with controlled skin or boundry temperatures to prevent product decomposition. 2. --*r a. b. c. d. afsj *** lhe R ft D Section recommends an evaluation of the following to increase rate and Improve quality: p*a. ttJtSMb . Chlorination wlth-a new catalyst that will yield a product of higher quality, Vapor phase chlorination reactions. This could lead to tubular reactors with higher quality and rates. Liquid Chlorine use In chlorination reaction. Better quality will be Investigated. A column for earth-treating Aroclor. Evaluation of better methods of earth-treating la needed. Exchange samples of Aroclor with Anniston on a regular routine basis to check analytical results. 3. Other studies that are further recommended are: a. Elimination of air blowing. (Bv Longer residence time for crude Aroclor at elevated temperatures in the ^ presence of HC1 and catalyst. c. Addition of lime to blow tanks Instead of the stills. d. VPC methods of Aroclor analysis and Isomer identification. e. Studies to determine how Aroclor quality, rate and costs are affected by higher pressure and temperature chlorinations. HONS 060282 91370:1716 #64 -8- July 29, 1964 f. Air-cooled condensers In the still system. g. Studies to determine the need for a column In Aroclor distillation for Isomer selection. II. PYDRAULS AND PYRANOLS A. Pydrauls and Pyranols are mixes of Aroclor and other components. The major part of the mix Is Aroclor in most cases; therefore, rate, quality, yields, costs, etc. have been covered under Aroclors. A study *111 be made of mixing, blending, earth treating, and filtering to up-grade the technique, quality and rate. The blending of Pyranols Is a Cost Improve ment Item. An estimated $6,000/yr. can be saved by a close control of the sp. gr. of the Aroclor, TCB and TTCB used in the Product. See Item 16 in the Appendix. Automatic control equipment to meter the components that comprise the product mix will be Installed by December, 1964. This will release an operator to assist In other work to Increase the dept. rate. See Item 14 of the Appendix. W, B, Johnson Plant Technical Services /me MCNS 060283 rrg?Dlx hi Priority PTS Job Xo. JOT? TITLE 1 313* Inert Finished Product Tank DEScairciox r I is tall Nitrogen oyster 2 3203 Install Oven Electric Oven to heat-treat Atcapuigus earth. SPECIFIC OBJECTIVE Maintain high Sleet. Grade Quality Ly pre venting Product de grading . Quality improvenettt by activating eartn. ' 3 3202 Install Brink Mist Filter system to Improve Quality by Eliminator in Cls Line eliminate impuri Impurity elimination. ties in Cls system. 4 3205 Install Cls Vaporize*' 4" Chlorine vapo Safety protection tpr riser m Cls Line. ehlorlnators 5 3126 Improve HCi Cff-Gas Quality Pllter impurities out of off-gas. Stop blj.henyl and Aroclor carryover. 6 3189 Redesign Chlorlnator Change size of Improve quality by Catalyse Basitct chlorlnator basket. improved Chlorlnator circulation. 7 3166 Prepare Tank layout layout, no. tanks, Plan for an organized size, and material ,, department layout of construction. 8 3215 Redesign Chlorine Sparger Stainless steel. Improve ..uallty. Sch. 60 ring sparger. 9 3222 Replace 3 Product Tanks 3-15,000 gal. product tanks Rate increase by extra storage capacity being replaced by 3-20,000 gal. 10 3251 Replace Still Jets Alter 3-3tace cond. Rate improvement by Jets to 2-stage eliminating operating non-condonslng problem and downtime. u . 12 3198 Improve E.Q. Aroclor Quality 3229 Replace Still Coll Isolate stability Quality improvement problcn and solve. Replace 2" coil Rato increase and with p" coll to eliminate downtime. natch new in- 3 filiation cf larger lump project ci731 S.D.C. - 9-10-64 .Tob Status fc Remarks Est. Net $ Savings Project cor-^ Quality plctod 5-16-6* Ca| '.tal i Required 600 s.n.c. FT? Rar-davs *C7'd. 10 Project com Quality pleted 2-20-64 Project com $5000 pleted 4-2-6* Quality 2000 2600 5 10 Project com Safety pleted 4-24-64 Installation started 6-6-64 Package to P & S 6-5-64 10,000 Quality Quality 3800 10 12,400 3-12-64 47 Earnings 5-1-6* Expense 2300 15 Completed 4-25-64 To be .* determined. 0 10 Package to Quality P & S 7-17-6* 300 Construction started 7-13-64 Equipment 92,000 Replacement, 9-1-64 5 9-15-64 30 Pkg. to 5,000 P 4 S 6-11-64 Job agpr'd 3000 Earnings Expense Pkg. to P & S To be 4-16-64 determined. 2600 Earnings Expense 9-1-6* 10 0-1-64 23 9-10-64 1<* Props bl or Suceese 95* 75* 95i 99* 90^ bO* 904 90* 99* V 90V c0> 904 HONS 0 6 0 2 8 4 t * 13 *-510 Increase Arcelor O.E. rapacity phase I Install: * air- Rate Increase cooled heat exw from 20.`R lb./yr. changers on Coat Improvement chlorlnatore, 4-10 H.P. pinpa _ 250 gpm 100' head, Radiation Sp. Or. recorder. Chlorine con trol valves (5) and inte grator. etc. Under 100*000 Construction 95,000 8-12-6* 20 99# S 9 7 0 9 0 SNOW 1* Improve mixing* fil 1. Shut-off con- Insure rate in Eat. will To be 6,000 11-30-6* 15 tering and loading tro1 valves at crease without addt`1. be about determined facilities. dnan-off and 10-1-64 loading stations. 2. Metering and control equipment at Pyranol mixing stations. 3. Replace 30" Sparkler I filter. Increase Aroclor Capacity Phase II 1. Alter piping Rate Increase to put 4 chlorl- Cost Inproyemeht nators on series continuous Operation. 2. Install biphenyl head tank, mix tank and metering system. . 3. Increase still capacity on #1 still, (Same as #2) *. Improve drum-off fac. 5. Add line to blow tank. 6. install 2-15,000 gal. ac-ng tanks. 7. Install 2-20,000 gal. stg. tanks. Est. will be 100,000 out by 2-1-65 120,000 5 mo. 30 After approv'd 90# % 16 Alter Pyranol Mix Control component 0oat lajjroveadftt Open Job 6,000 Procedure ap.gr. more closely by 8-15-64 9-1-64 10 85* 17 Evaluation of rate variables 1. Lab RAD will Rate and duality , evaluate catalysts, vapor phase reaction, liquid'phase reactions, ' and column earth treating. Job will be opened by 12-1-6* To be determined 15,000 6-1-65 10 * 70* Evaluate design changes of chlorlnators and the ^ts- 1. Evaluate stirred Rate and Quality reactors and tubula^ reactors, etc. * 2. Consider designs to avoid high skin temperatures and product degradation. Long Range To be next 2-3 yrs. determined To be 1966 determined 30 30?