Document kD97J29w96B16LmbrnjMJEb0b

MONSANTO COMPANY ANNISTON PLANT STANDARD MANUFACTURING PROCESS FOR AROCLORS July 1969 DEFENDANT'S EXHIBIT IS DSW 543174 WATER PCB-SD0000051187 COMPANY CONFIDENTIAL Distribution: Technical Information Center - St.L (2) Security File - St. Louis \ J. E. Smith - St. Louis G. L. Jessee J. L. Corder G. W. Miller H. E. Schulte Technical Services (3) D. Danna - St. Louis (3) Plant Standards Dept. (Extras) APPROVAL OF SAFETY REVIEW COMMITTEE H. E. Schulte jzyrld. T. w. Lawrence J. C. Landwehr MONSANTO COMPANY ANNISTON PLANT 13 JAN 71 TENTATIVE AMENDMENT "F" TO AROCLOR STANDARD MANUFACTURING PROCESS Dated Jul 69 TITLE: PRODUCE AROCLOR 5068 OBJECTIVE: To produce Aroclor 5068 in the existing solid Aroclor system. PRESENT PROCEDURE: Aroclor 5068 has not been produced in plant equipment before and there has been no previously established procedure to follow. PROPOSED AMENDMENT: Make a test batch of Aroclor 5068 in existing solid Aroclor equipment. The process changes will be conducted as follows: a. Approximately 8500 pounds Santowax R will be chlorinated to 60% by weight chlorine by standard operating procedures. b. At approximately 60% chlorine, 5 pounds more catalyst will be added to the chlorinator to increase chlorine efficiency. As the batch proceeds, this procedure may be repeated to keep chlorine efficiency at an acceptable level. DSW 543175 WATER PCB-SD0000051188 Tentative Amendment "F" Aroclor Standard Mfg. Process Dated Jul 69 2. PROPOSED AMENDMENT; continued c. Chlorine feed rates will be controlled so that the temperature of the batch remains approximately 260C. to 280C. and free chlorine in the off-gas is kept at a minimum. d. At approximately 65% chlorine by weight and a softening point of 130*C., three or four 50-gallon drums of material will be removed from the chlorinator to be used in pro ducing 5465. e. Throughout the batch from 60% chlorine to 68% chlorine, hourly samples of off-gas and product will be taken to assist in design of a full production system. f. When the softening point of the batch reaches 150C. to 160C., the chlorine feed will be stopped. g. The batch will be transferred to the blow tank and air blown before being drummed out of the blow tank. h. The product will be allowed to solidify and then will be ground to a powder for shipment to potential customers. SOURCE OF DATA: Anniston PR&D work (letter from G. L. Arnett to Aroclor 5068 file dated 1/11/71). SAFETY: There is one main potential safety problem created by this test. As the weight per cent chlorine increases, the rate of reaction will decrease and free chlorine will be released in the off gas. This free chlorine poses two potential problems: ' 1. The possibility of chlorine and steel combustion at temperatures above 250C. in the off gas lines. To cope with this problem, temperatures will be watched closely and water will be sprayed on the lines to cool the steel if needed. 2. The possibility of too much free chlorine being released to the atmos phere. All process variables will be closely watched and controlled to keep the free chlorine released to the atmosphere at a minimum. However, if the free chlorine released to the atmosphere reaches an intolerable amount, the test will be discontinued. QUALITY: This material is requested by the Textiles Division and they require a softening point of 150C, and that no lime be added to neutralize any entrained HC1, DSW 543176 WATER PCB-SD0000051189 Tentative Amendment "F" Aroclor Standard Mfg. Process Dated Jul 69 3. EXTENT OF TRIAL; A plant test batch will be made the week of January 25, 1971 and the data from this test will be evaluated before any further tests are made. DSW 543177 WATER PCB-SD0000051190 Tentative Amendment "F" Aroclor Standard Mfg. Process Dated Jul 69 4. APPROVALS: Department Supervisor Production Superintends! Plant Manager G/S*-. Miller . L. Corder PRfiD Group Leader: 7/ J. L. Brown Research Group Leader: Master copy signed by J. W. Baker J. VI. Baker Mgr. of Research & Dev.: Master copy signed by W. R. Richard W. R. Richard Manufacturing Manager: Master copy signed by J. R. Savage J. R. Savage 77^-7; Date ) Date Date I-/V-7/ Date 1-20-71 Date 1-20-71 Date 1-18-71 Date DSW 543178 WATER PCB-SD0000051191 COMPANY CONFIDENTIAL Distribution: APPROVAL OF SAFETY REVIEW COMMITTEE Technical Information Center - St. L (2) Security File - St. L . E. Smith - St. L G. L. Jessee . L. Corder . W. Miller H. E. Schulte Technical Services (3) D. Danna - St. L (3) Plant Standards Dept. (Extras) _________signed by H. E. Schulte H. E. Schulte ________Signed by T. W. Lawrence T. W. Lawrence ________Signed by J. C. Landwehr J. C. Landwehr MONSANTO COMPANY ANNISTON PLANT 28 Apr 71 TENTATIVE AMENDMENT "G" AROCLOR STANDARD MANUFACTURING PROCESS Dated July 69 TITLE: PRODUCE AROCLOR 5465 OBJECTIVE: To produce Aroclor 5465 in the existing solid Aroclor system PRESENT PROCEDURE: Aroclor 5465 has not been produced in plant equipment before and there has been no previously established procedure to follow. PROPOSED AMENDMENT: Make a test run of Aroclor 5465 in existing solid Aroclor equipment The proposed process changes are as follows: 1. Aroclor 5065 will be produced in #9 chlorinator as described in Tentative Amendment "F" dated 1/13/71. 2. Each A-5065 batch in the chlorinator will be followed immediately by an A-5032 charge preheated in the blow tank. (Similar pre cautions as used when producing A-1168 will be used to minimize line pluggage.) The A-5032 will then be chlorinated to A-5065. DSW 543179 WATER PCB-SD0000051192 Tentative Amendment "G" Aroclor Standard Mfg. Process Dated July 69 Page 2 PROPOSED AMENDMENT: (cont'd.) 3. The distillation will be carried out as normal with A-5460 and within the standard process limits (5-20 mm Hg absolute pressure and 340400C). 400C will be considered the maximum allowed temperature cut-off for the distillation of A-5465. The still vacuum system will be checked for its ability to reach 10 mm Hg prior to starting the test batch. 4. The distilled product will be flaked and packaged in bags or drums for evaluation purposes. For a plant run of A-5465, the following schedule is proposed to reduce #9 chlorinator cycle and to keep the chlorinator system flushed out: 1. 1st Batch a. Produce A-5065 in #9 chlorinator, starting as normal. b. Transfer directly to #4 still as in A-1268 production. c. Distill under normal A-5460 conditions after vacuum degasing and lime addition. Maximum tenperature, 400C. d. Draw bottoms at end of distillation. 2. 2nd Batch a. Produce A-5032 in any other chlorinator (#2, #4, #10, #11). b. Transfer to #2 blow tank and hold hot. c. Follow first batch A-5065 in #9 chlorinator with hot A-5032 from #2 blow tank. d. Chlorinate A-5032 to A-5065. e. Transfer directly to #4 still and complete as in first batch. 3. 3rd, 4th, etc. Batches Same as 2nd batch. 4. Last batch of a A-5465 run a. Follow with A-5032 as in second batch. b. Chlorinate to 5060. c. Follow last still batch of A-5465 with A-5060. d. Distill as normal and finish through system to flush out. DSW 543180 WATER PCB-SD0000051193 Tentative Amendment "G" Aroclor Standard Mfg. Process Dated July 69 Page 3 SOURCE OF DATA: Anniston PR&D work, 1. Letter from G. L. Arnett to A-5068 file, dated 1/11/71. 2. Mid-month report - G. L. Arnett (J. L. Brown) to J. C. Landwehr, dated 3/16/71. (See attached sheet.) SAFETY: There is only one main potential safety problem created by this test. Near the end of the chlorination, the rate of reaction decreases and the potential for higher free Cl^ in the off gases will exist (discussed in Tentative Amendment "F" issued for the production of Aroclor 5068). During the plant run of A-5068 the free chlorine level in the off gas was kept low by addition of extra catalyst at the 60% chlorination level. The previous precautions will be repeated for production of A-5065. No safety changes are expected in the distillation area due to using existing temperature limits. JUSTIFICATION: A plant run of Aroclor 5465 is necessary to obtain quantities sufficient to develop market feasibility and obtain operating experience to develop production economics. A potential magnitude of justification should be obtained from Marketing if necessary for initial plant tests. Some sample orders have been filled with lab produced A-5465 but numerous sample orders are now being held for lack of material. QUALITY: The following properties will be monitored during chlorination and distilla tion : 1. Crude Aroclor softening point (130 - 135C at end of chlorination) 2. Distilled Aroclor softening point (121 - 129C) 3. Distilled Aroclor 5465 color (2.5 NPA Max.) Exact specs will not be set until after plant demonstration. The above data is based on the tentative specs issued from initial lab data. OPERATIONS: There are two known potential operating problems, both of which could add to downtime and mechanical expense. DSW 543181 WATER PCB-SD0000051194 Tentative Amendment "G" Aroclor Standard Mfg. Process Dated July 69 Page 4 OPERATIONS: (cont'd.) 1. Pluggage of piping and equipment associated with #9 chlorinator system Following the plant batch of Aroclor 5068, the chlorinator cooler, pumps and piping were plugged solid and required complete dismantling for cleaning. An attempt to flush the chlorinator system with a small volume of liquid Aroclor apparently failed. The system was shut down for four days following the A-5068 run and prior to discovering the pluggage. By immediately following any future batch of A-5065 or A-5068 with a preheated charge of A-5032, we hope to solve the chlorinator pluggage problems. 2. Thicker Montar following A-5465 distillation Although lab data indicates no adverse Montar conditions, it is felt that decomposition during distillation is much more significant in the plant and that thicker Montars are highly probable. Likewise, a higher potential for plugging the still pump, coil or piping will exist. EXTENT OF TRIAL; Three to five plant batches should be produced to prove or disprove a plant process. Plant tests will be scheduled upon approval of this tentative amend ment and the ability of Anniston Production to fit into current requirements. Originated by: /dp Att: Lab distillation data DSW 543182 WATER PCB-SD0000051195 PRSD LABORATORY ANNISTON PLANT Pag* 5 Distillation No. 1 *Aroclor 5065 (S.P. 130C) Vacuum (mm) Pot Temp. C 1st Drop Approx. 65* Dist. Completed 9 9 9 354 376 400 Distillation Yield - 85.8* (5465) Softening Point of Aroclor 5465 - 123C Color b 2.0 NPA Softening Point of Montar (Dist. Bottoms) * 208C Head Temp. C 300 340 345 Distillation No. 2 `Aroclor 5065 (S.P. 130C) Vacuum (mm) Pot Temp. C Head Temp. 8C 1st Drop Dist. Completed 20 20 365 325 400 355 Distillation Yield = 85.8* (5465) Softening Point of Aroclor 5465 = 123C Color = 2.0 NPA Bottoms from this distillation were left in still and mixed with distillation No. 3 to duplicate plant conditions. Distillation No. 3 `Aroclor 5065 (S.P. 130C) 1st Drop Last Portion Over Vacuum (mm) 5 5 Pot Temp. C 332 380 Head Temp. C 285 335 Distillation was stopped at 380C pot temperature due to distillate turning black. Distillation Yield = 88.1* (5465) Softening Point of Aroclor 5465 * 123 Color * 2.0 NPA Softening Point of Montar (comp, of 2 and 3) 202C Distillation No. 4 `Aroclor 5065 (S.P. 130C) Vacuum (mm) Pot Temp C Head Temp. C ' 1st Drop Dist. Complete 15 15 360 400 Distillation Yield =* 84.8* (5465) Softening Point of Aroclor 5465 = 123C Softening Point of Montar 210C Color = 2.0 NPA 325 365 `All Aroclor 5065 material was obtained from the plant chlorination run of Aroclor 5068 (chlorination was stopped at a softening point of 130C to obtain two drums for experimental purposes). DSW 543183 WATER PCB-SD0000051196 Tentative Amendment "G" Aroclor Standard Mfg. Process Dated July 69 APPROVALS: Department Supervisor Original signed bv G. W. Miller G. W. Miller Production Superintendent Original signed by Jesse L. Corder J. L. Corder Plant Manager Original signed by G. L. Jessee G. L. Jessee PR&D Group Leader Original signed by J. L. Brown J. L. Brown Research Group Leader Original signed by Q. E. Thompson Q. E. Thompson Manaqer of Res. and Dev. Original signed bv W. R. Richard W. R. Richard Manufacturing Manager Original signed bv J. R. Savage J, R. Savage Page 6 5/10/71 Date 5/19/71 Date 5/21/71 Date 5/24/71 Date 5/25/71 Date 5/25/71 Date 5/26/71 Date DSW 543184 WATER PCB-SD0000051197 COMPANY CONFIDENTIAL Distribution: Technical Information Center - St.L (2) Security File - St. Louis J. E. Smith - St. Louis }G. L. Jessee *\J. L. Corder S. W. Miller H.E. Schulte Technical Services (3) D. Danna - St. Louis (3) Plant Standards Dept. (Extras) APPROVAL OF SAFETY REVIEW COMMITTEE Master signed by H. E. Schulte H. E. Schulte Master signed by T. W. Lawrence, Jr. T. W. Lawrence Master signed by J. C. Landwehr J. C. Landwehr MONSANTO COMPANY ANNISTON PLANT 13 OCT 70 TENTATIVE AMENDMENT "E" TO AROCLOR STANDARD MANUFACTURING PROCESS Dated Jul 69 TITLE: INCREASE CHLORINATION EFFICIENCY IN THE PRODUCTION OF SOLID AROCLOR 5060 BY USING ALUMINUM CHLORIDE AND/OR POWDERED ALUMINUM METAL AS THE CATALYST. OBJECTIVE: To increase the efficiency of the Aroclor 5060 chlorination to alleviate free chlorine in the by-product hydrogen chloride gas. PRESENT PROCEDURE: Santowax R is preheated to 150C., mixed with 0.05% ferric chloride, and charged to a batch chlorinator from a weigh tank. Chlorine gas is added until the desired softening point is attained. Both chlorine flow and reaction mass temperature are closely controlled at 3000 #/hr. maix. and 250C. max. respectively. It is then transferred to an air blowing tank to remove the hydrogen chloride gas before charging to the still. Vacuum distillation is carried out in the presence of 0.5% lime and then the product is flaked, bagged and drummed for storage before sales. DSW 543185 WATER PCB-SD0000051198 Tentative Amendment "E" Aroclor Standard Mfg. Process Dated Jul 69 2. PROPOSED AMENDMENT: Santowax R will be chlorinated using 0.05% aluminum chloride and/or powdered aluminum as the catalyst. The test will be carried out on normal plant batch chlorinations. The process changes will be conducted as follows: a) 0.05% (approximately 5.5 pounds) of aluminum chloride and/or powdered aluminum will be added to the Santowax R in the charge tank. b) After proceeding with the batch as a normal chlorination batch, immediate improvement in the amount of free chlorine in the product hydrogen chloride off gas should be noted. SOURCE OF DATA: Anniston PR&D Report No. 1 of Job No. 446-507, 1-22-69. SAFETY: Aluminum chloride must be handled so as not to contaminate it with water, because HC1 will be liberated. Powdered aluminum does burn, but under plant conditions will not cause any new safety problems. QUALITY: Chlorinations using aluminum chloride and/or aluminum metal does slightly change the isomer content of the product. This does not change the final material specifications of the product. However, this slight change in isomer content makes Aroclor 5460 more closely resemble the isomer content of our foreign competi tors, Bayer and Kanegafuchi, and therefore doesn't change any desired properties of our Aroclor 5460. EXTENT OF TRIAL: A drop in the free chlorine should be immediately noticeable; however, the normal six month trial period is requested to assure sufficient; time to run further tests after evaluating the first. DSW 543186 WATER PCB-SD0000051199 Tentative Amendment "E" Aroclor Standard Mfg. Process Dated Jul 69 3. APPROVALS : Department Supervisor: Master signed by G. W. Miller___________________ G. W. Miller 10/14/70 Date Production Superintendent:Master signed by J. L. Corder J. L. Corder 10/14/70 Date Plant Manager:Master signed by G. L. Jessee__________________________________ G. L. Jessee 10/14/70 Date PR&D Group Leader:Master signed by J. L. Brown_____________________________ J. L. Brown 10/14/70__ Date Research Group Leader: Master signed by J. W. Baker___________________ J. W. Baker 10/27/70 Date Mgr. of Research & Dev. :Master signed by M. W. Farrar___________________ M. W. Farrar 10/28/70 Date Manufacturing Manager:Master signed by J. R. Savage______________________ J. R. Savage 10/29/70____ Date I DSW 543187 WATER PCB-SD0000051200 COMPANY CONFIDENTIAL Distribution: Technical Information Center - Security File - St. Louis J. E. Smith - St. Louis G. L. Jessee v. J. L. Corder ^G. W. Miller St. L(2) H. E. Schulte Technical Services (3) D. Danna - St. Louis (3) Plant Standards Dept. (Extras) APPROVAL OF SAFETY REVIEW COMMITTEE Master copy signed by H. B. Schulte H. E. Schulte Master copy signed by P. K. Ward P. K. Ward Master copy signed for J.C.Landwehr J. C. Landwehr by V.R.H. MONSANTO COMPANY ANNISTON PLANT 17 Jul 70 TITLE: TENTATIVE AMENDMENT "D" TO AROCLOR STANDARD MANUFACTURING PROCESS Dated Jul 69 PRODUCTION OF AROCLOR 5432 OBJECTIVE: - To produce Aroclor 5432 in the existing Solid Aroclor system PRESENT PROCEDURE: Aroclor 5432 has not been produced in plant equipment before and there has been no previously established procedure to follow. PROPOSED AMENDMENT: Follow the standard operating instructions for producing Aroclor 5442 with the following exceptions. Chlorina tion level can be monitored by checking product specific gravity at 90C. To produce a final distilled product within the specified 1.263-1.290 gravity range (30.5-33% chlorine), the chlorinators should be finished between 1.273-1.300 gravity units. DSW 543188 WATER PCB-SD0000051201 Tentative Amendment "D" Aroclor Standard Mfg. Process Dated Jul 69 2. SOURCE OF DATE; a) Anniston PR&D Report No. 1 of Job No. 446-515, 5-26-70 b) Letter P. D. Fowlkes to G. L. Arnett on Aroclor 5432 specs 7-15-70 SAFETY: The amended process has no effect on safety of operation. department safety practices will be followed. Normal QUALITY: The following properties will be monitored during chlorination and distillation: a) Crude Aroclor specific gravity, 1.273-1.300 gravity units at 90C. b) Distilled Aroclor specific gravity, 1.263-1.290 gravity units at 90C. c) Distilled Aroclor color,--2 NPA EXTENT OF TRIAL: r An initial plant demonstration run will be made the last week of Jul '70. The normal six month trial period is needed to make any minor spec, changes to assure compatibility of Aroclor 5432 with the components of the various Aroclor blends Aroclor 5432 will be used to make. :kd Originated by: C'R.. yYlc. C. R. Mcllwain and DSW 543189 WATER PCB-SD0000051202 Tentative Amendment "D" Aroclor Standard Mfg. Process Dated Jul 69 3. APPROVALS: Department Supervisor Master copy signed by G. W. Miller G. W. Miller 7/20/70 Date Production SuperintendentMaster copy signed byH. L. Williams H. L. Williams 7/20/70 Date Plant ManagerMaster copy signed for G.L. Jessee by L.C.L. G. L. Jessee 7/20/70 Date PR&D Group Leader Master copy signed by J. L. Brown___________ J. L. Brown 7/20/70 Date Research Group Leader: Master copy signed by J. w. Baker J. W. Baker Mgr. of Research &Dev.: ManufacturingManager: Master copy signed by M. W. Farrar M. W. Farrar Master copy signed by J. E. Smith J. E. Smith 7/29/70 Date 7/30/70 Date 7/22/70 Date DSW 543190 WATER PCB-SD0000051203 COMPANY CONFIDENTIAL Distribution: Technical Information Center - St.L(2) Security File - St. Louis J. E. Smith - St. Louis G. L. Jessee J. L. Corder W. Miller H. E. Schulte Technical Services (3) D. Danna - St. Louis (3) Plant Standards Dept. (Extras) APPROVAL OF SAFETY REVIEW COMMITTEE Master copy signed by H. E. Schulte H. E. Schulte Master copy signed by P. K. Ward P. K. Ward Master copy signed by V.R.H. for Landwehr J. C. Landwehr MONSANTO COMPANY ANNISTON PLANT 14 Jul 70 TENTATIVE AMENDMENT "C" TO AROCLOR STANDARD MANUFACTURING PROCESS Dated Jul 69 TITLE: USE SODIUM HYDROXIDE TO PRODUCE LOW COLOR SOLID AROCLOR 5460 OBJECTIVE: To produce Aroclor 5460 with a color less than 1.25 NPA PRESENT PROCEDURE: Santowax R'is preheated to 150C., mixed with 0.05% ferric chloride, and charged to a batch chlorinator from a weigh tank. Chlorine gas is added until the desired softening point is attained. Both chlorine flow and reaction mass temperature are closely controlled at 3000 #/hr. max. and 250C. max. respectively. It is then transferred to an air blowing tank to remove the hydrogen chloride gas before charging to the still. Vacuum distillation is carried out in the presence of 0.5% lime and then the product is flaked, bagged and drummed for storage before sales. DSW 543191 WATER PCB-SD0000051204 Tentative Amendment C Aroclor Std. Mfg. Process Dated Jul 69 2. PROPOSED AMENDMENT: Aroclor 5460 will be vacuum distilled in the presence of 0.5% lime and up to 2.5% sodium hydroxide. The test will be carried out on the smaller still (No. 4) to minimize the pounds of intermediate color Aroclor 5460 and to minimize the risk (loss of production) of corrosion of caustic on the steel equipment. The distillation step will be modified as follows: a) Air blow 5060 for a minimum of 1 hour b) Charge still and pull vacuum before adding lime and sodium hydroxide c) Vent still and add 250 lbs. of lime and 250 lbs. of flaked sodium hydroxide d) Begin heatup. When temperature reaches 318C. (melting point of sodium hydroxide) in the still, hold temperature for 10 minutes e) After 10 minute hold period, follow normal operating procedure until distillation is complete f) Draw bottoms immediately after every batch. Solidification of sodium hydroxide begins at 318C. g) Repeat steps a-f using 2.5% (625 lbs.) sodium hydroxide. The system should now be flushed out h) Intermediate color 5460 produced during flushing operation will be segregated from normal and low color 5460. It will be blended with darker 5460 to prevent regular customers from receiving this improved color product i) Run up to 10 batches using 625 lbs. of sodium hydroxide. SOURCE OF DATA: a) Anniston PR&D Report No. 2 of Job No. 446-507, 9-30-69. b) Teletype from O. Siebert indicates no corrosion problems encountered using sodium hydroxide; dated 5 Dec '69. SAFETY: Bottoms will contain hot caustic. Faceshield must be worn when drawing bottoms. Discard drums at plant dump. Standard safety procedures will be used in handling the anhydrous sodium hydroxide. Caustic left in an opened drum after a still has been charged will not be used in the next charge. Wet caustic will not be used at any time during the test to prevent the instantaneous formation of steam upon addition to the still batch (240C.). .. DSW 543192 WATER PCB-SD0000051205 Tentative Amendment C Aroclor Std. Mfg. Process Dated Jul 69 3. QUALITY: The color and other properties of Aroclor 5460 will be monitored closely during the test. All intermediate color 5460 will be segregated. Montar 5 (bottoms) produced will be checked for alkalinity. Samples of the Santowax R and resultant Aroclor 5460 will be analyzed for effect on caustic treatment on the biphenyl, PCB contents. EXTENT OF TRIAL: Color improvement should be noticeable almost immediately. A one to two week trial should be sufficient to determine whether any further work is required. However, the normal six month trial period is needed to assure sufficient time to run further tests depending on the results of the first test. Master copy signed by Originated by: c- R- Mcllwain_________V. R. Haupt C. R. Mcllwain and V. R. Haupt APPROVALS: Department Supervisor Master copy signed by: G. W. Miller G. W. Miller Production Superintendent J . L. Corder J. L. Corder Plant Manager G. L. Jessee bv L.C.L. G. L. Jessee PRSD Group Leader J. L. Brown J. L. Brown Research Group Leader J. W. Baker J. W. Baker Mqr. of Research s Dev. M. W. Farrar M. W. Farrar Manufacturing Manager J. E. Smith J. E. Smith 7/23/70 Date 7/29/70 Date . 7/23/70 Date 7/23/70 Date 8/24/70 Date 8/24/70 Date 8/26/70 Date DSW 543193 WATER PCB-SD0000051206 Distribution: Technical Information Center - St. Louis Security File - St. Louis W. A. Kuhn - St. Louis W. B. Papageorge H. L. Williams R. A. Haydel C. K. Eastman Technical Services (5) D. Danna (5) Plant Standards Department (Extras) (2) Approval Of Safety Review Committee MONSANTO COMPANY ANNISTON PLANT April 29, 1969 TENTATIVE AMENDMENT *'B" TO AROCLOR STANDARD MANUFACTURING PROCESS Dated: October, 1968 TITLE: Reduce lime concentration in Liquid Aroclor stills to increase yields OBJECTIVE: To increase the Liquid Aroclor yield to 98% by changing the distillation procedure. PRESENT PROCEDURE: Liquid Aroclors are produced by semi-continuous distillation of the crude material. A batch is considered to be 1,000 gallons of distilled product. The present procedure is to add 250 lbs. of lime to the first batch of each run. The still is then operated with continuous feed for five batches. At this point 250 lbs. of lime is again added to the still. The distillation run is then continued until the tenth batch. Then the feed is discontinued and the level in the still is boiled down to a 20% still level before the bottoms are discarded. DSW 543194 WATER PCB-SD0000051207 2- - PROPOSED AMENDMENT: The W. G. Krummrich Plant presently adds 150 lbs. for each 15 batches and runs for 3O batches before dropping bottoms. Anniston Plant PR&D work indicates that it is possible to reduce the lime addition even further than this. It is proposed that a plant test be conducted to determine how many batches can be distilled before lack of lime effects the product. In this test 150 lbs. of lime will be added to the still and product dis tilled until a degradation of color, thermal chlorides, or electrical properties develops. Then 150 lbs. of additional lime will be added and the test continued until product quality begins to deteriorate or until the still bottoms become too viscous as noted by increased still pump current. SOURCE OF DATA: Anniston PR&D Report No. 1 of Job No. 913.70: 446506; 3/17/69. SAFETY: The amended process has no effect on safety of operation- QUALITY: The quality of Aroclor produced will be monitored closely. No off-grade material will be allowed in the storage tanks. EXTENT OF TRIAL: The proposed lime concentration will be maintained until the effects are noted. Two or three runs should be sufficient to determine the maximum number of batches possible without additional lime. The test will run for the normal 6 month trial period; however, to determine long range effects. Originated by jw DSW 543195 WATER PCB-SD0000051208 -3- APPROVAL Department Supervisor Production Superintendent Plant Manager Research Group Leader Research Manager Technical Production Manager R. A. Haydel H. L. Williams (P, W. B. Papageorge M. E. Gibbs 7aJ> W. R. Richards Af W. A. Kuhn Date s/r/49 D^te Date t>/AL'/io'j Date s/asJl9 Date Date DSW 543196 WATER PCB-SD0000051209 COMPANY CONFIDENTIAL Distribution: Technical Information Center - St. Louis (2) Security File - St. Louis W. A. Kuhn - St. Louis W. B. Papageorge H. L. Williams R. A. Haydel C. K. Eastman Technical Services (3) Plant Standards Dept. (Extras) MONSANTO COMPANY ANNISTON PLANT October 28, 1969 FINAL AMENDMENT TO AROCLOR STANDARD MANUFACTURING PROCESS Dated August 1969 TITLE: Discontinue Earth Treatment of Non-Electrical Grade Aroclors 1221, 1248, 1262. BACKGROUND: Treatment of electrical Aroclors is done in order to remove ionic impurities from the Aroclors and upgrade electrical properties. Historically, non-electrical Aroclors have likewise been treated at Anniston due to the fact that all Aroclors shared common lines and tanks and possibility of contamination was quite high. Recent additions to Aroclor Department, a tank farm and porocel treatment facilities, have effectively segregated individual Aroclors down stream of the treatment facilities making it unnecessary to treat non-electrical Aroclors. DSW 543197 WATER PCB-SD0000051210 -2- PRESENT SITUATION: Earth treatment of non-electrical Aroclors (Aroclors 1221, 1248, 1262) is discontinued. Electrical Aroclors (Aroclors 1242, 1254, 1260) are treated by passage through columns packed with porocel (activated bauxite). -' SOURCE OF DATA; 1) Memo - L. R. Stark to R. A. Haydel on October 3, 1969, stating that applications tests of untreated Aroclor 1248 in Pydraul fluids indicated no diverse effect. 2) Memo - N. W. Touchette to Cumming Paton on September 30, 1969, stating that applications testing of untreated Aroclors 1248 and 1262 in polysulfide formulations showed the material to be acceptable for use in the formulations. 3) Memo - C. Paton to J. E. Smith on September 15, 1969, stating that untreated Aroclor 1221 was acceptable. SAFETY: This process change has no effect on the safety of the operations. QUALITY: Applications testing of the untreated Aroclors disclosed no quality problems. Department Supervisor DSW 543198 WATER PCB-SD0000051211 DSW 543199 WATER PCB-SD0000051212 MONSANTO COMPANY ORGANIC CHEMICALS DIVISION ANNISTON, ALABAMA STANDARD MANUFACTURING PROCESS FOR AROCLORS Revised by: R. A. Haydel Prod. Supervisor Approved by: H. L. Williams Prod. Superintendent Issued: July 1969 COPY NO. Supersedes - Standard Manufacturing Process for . Aroclors issued September 1966 CONFIDENTIAL INFORMATION This process is the property of Monsanto Company and the recipient is responsible for its safekeeping. It contains confidential information of Monsanto Company which must not be reproduced, revealed to unauthorized persons, or sent outside the Company without proper authorization. Either retain in a secure file or return to the Standards Department. DSW 543200 WATER PCB-SD0000051213 STANDARD MANUFACTURING PROCESS FOR AROCLORS DISTRIBUTION Plant Manager Production Superintendent Production. Supervisor Maintenance Superintendent Technical Production Manager Organic Division Mgr. Foreign Manuf. (on common products only) Technical Information Center Security File Technical Services Department Plant Standards Department Copy Number 1 2 3 A 5 6, 7, 8 9, 10 11 12, 13, 14 Extras Copies DSW 543201 WATER PCB-SD0000051214 STANDARD MANUFACTURING PROCESS FOR AROCLORS SECTION I SECTION II SECTION III SECTION IV APPENDICES , TABLE OF CONTENTS SYNOPSIS OF PROCESS FLOW SHEETS PROCESS IN DETAIL A. Batch Liquid Chlorinators B. Continuous Chlorinators C. Biphenyl Mix Tank and Feed Tank D. Solid Batch Chlorinator E. Blowing Tank Operation F. Liquid Stills G. Earth Treatment and Filtration H. Porocel Column I. Solid Still J; Packaging COMMENTS ON THE PROCESS A. Equipment List B. Finished Good, By-Product, & Raw Material Specifications C. Physical Constants for Finished Goods, Intermediates, and Major Raw Materials D. Utilities E. Personnel F. Packaging and Shipping G. Material Balances H. Atmospheric & Stream Discharge & Waste Disposal I. Process Control Procedures J. Safety and Toxicity Data & Accident Reports K. Background Information L. Time Cycles M. Quality Considerations N. Miscellaneous DSW 543202 WATER PCB-SD0000051215 STANDARD MANUFACTURING PROCESS FOR AROCLORS AMENDING RECORD SHEET AMENDMENT NO. A. B. B. TITLE OR DESCRIPTION Packed Bed Treatment of Electrical Grade Aroclors High Temperature Chlorination Reduce Lime Concentration in Liquid Aroclor Stills to Increase Yields DATE 5/18/67 12/27/67 10/1968 DISPOSITION Accepted Never Tried DSW 543203 WATER PCB-SD0000051216 TO r> J DSW 543204 WATER PCB-SD0000051217 STANDARD MANUFACTURING PROCESS FOR AROCLORS SYNOPSIS OF PROCESS Aroclors are the reaction products formed by chlorination of Biphenyl and/or Terphenyls using Ferric Chloride Catalyst. The by-product HC1 gas produced is absorbed in water to produce Muriatic Acid. Crude Aroclors are produced in the chlorinators, air blown, distilled, earth or Bauxite treated, filtered and loaded for shipment. Aroclor is a trade name used to designate chlorination products of Biphenyl, Terphenyls, or mixtures of the two. The physical properties vary from light free-flowing liquids to crystalline and non-crystalline solids. Depending on the degree of chlorination and the composition of the raw materials, Santowax R, and mixtures of Biphenyl and Santowax R, or Biphenyl and Santowax C, yield products of increasing viscosity up to non-crystalline resins. A numerical system of nomenclature, consisting of four digits, has been developed for identifying the Aroclors. The thousands digit denotes the raw material used in the chlorination. The figure 1--- indicates 1007. technical grade Biphenyl. The hundreds digit denotes whether or not the product is distilled. The -1-- indicates undistilled, and the figure -2-- indicates distilled. The tens and units digit denote the approximate percentage of chlorine contained in the finished product. For example, 1260 is a distilled chlorinated Biphenyl containing 60% chlorine. There are deviations from the above nomenclature when Solid Aroclors are produced. These are listed below: 1. Aroclors 4065 and 4465 Aroclor 4065 is the crude and 4465 is obtained by distillation. The starting raw material contains 40% Santowax R and 60% technical Biphenyl. This is chlorinated to 65%. Since January 1969, this product is now produced by blending Aroclor 1262 and Aroclor 5460 in approximately equal proportions. 2. Aroclors 5060 and 5460 - Aroclor 5060 is the crude from which Aroclor 5460 is distilled. The starting raw material is 100% Santowax R which is chlorinated to 60%. 3. Aroclor 5042 and 5442 Aroclor 5042 is the crude from which Aroclor 5442 is distilled. The starting raw material is 100% Santowax R which is chlori nated to 42%. DS\N 543205 WATER PCB-SD0000051218 Aroclor Manufacturing Process Synopsis of Process ' 2 4. Aroclor 2565 This is an undistilled product. The starting raw material consists of 257. Santowax C and 75% technical Biphenyl. This is chlorinated to 65%. Chlorinator Area There are four batch operated liquid chlorinators, one batch operated solid chlorinator, and one continuous operated chlorinator system. The continuous system consists of four batch chlorinators cascaded with overflow from one unit to the next. The product from the last stage is the finished crude Aroclor. Batch operated liquid chlorinators are charged with 3,000 pounds of Biphenyl with 1-1/2 pounds of Ferric Chloride Catalyst. Charges for the solid chlorinator vary dependent upon the Aroclor to be produced. Chlorine gas added through a distributor plate reacts with the raw material to release HC1 and heat. The HC1 gas goes to the Muriatic Acid Department. Heat is taken away by use of external air cooled heat exchangers. The specific gravity of the crude is checked after chlorine feed has been on for four hours, again when 80% chlorinated, as indicated by alarm, and as needed thereafter. In the continuous chlorination system. Biphenyl is fed to the first stage and chlorinated. Crude Aroclor overflows to the second stage, etc., until the final product overflows from the last stage. Each chlorinator is held at a different level of chlorination with the last stage being the final crude Aroclor desired. Normally, Aroclor 1142 is produced in this system. Crude Aroclors from the batch chlorinators and the continuous system are transferred to a blowing tank to be air blown for one (1) hour minimum before distillation. Still Area . Liquid Aroclors Aerated Aroclors from a blowing tank or a feed tank are charged to a still, hydrated lime is added, a vacuum of 720 mm Hg (40 mm Hg absolute) is applied, the still furnace is fired, and the Aroclor is distilled into a receiver. The distillation is semi-continuous, since up to ten (IP) receivers are distilled prior to drawing bottoms or residue from the still. Every two receivers (or approximately 2,000 gallons) are treated with 40 lbs. of earth for two hours and then filtered. The finished product is transferred to storage tanks prior to loading into drums or tank cars. OS\N 543206 WATER PCB-SD0000051219 Aroclor Manufacturing Process Synopsis of Process 3. In 1967, an experimental absorption column was installed to treat Aroclor 1242 by passage through a bauxite bed to improve electrical qualities. This was designed as an alternate to earth treating the Aroclors. The column proved successful on 1242 and the bauxite column treatment is expected to replace earth treatment in the near future. Solid Aroclors Solid Aroclors are distilled in a similar manner to Liquid Aroclors except for 1168. Aroclor 1168 is not air blown and is charged directly to the still from the chlorinator. A vacuum of 4 mm Hg absolute is applied for distillation. Solid Aroclors have one to four receivers distilled prior to drawing bottoms in the still. This is dependent upon the particular Aroclor being produced and also on which still system (No. 4 or 1) is being used. Solid Aroclors are not earth treated or filtered. They are drummed directly from the flaker hold tank or are flaked (Aroclors 1268 and 5460). Chemical Equations Liquid Aroclors The general equation for the chlorination of biphenyl to produce liquid Aroclors is as follows: Biphenyl 154.2 +n[ci2} Chlorine 70.9 Where h varies from 1.15 for Aroclor 1221 to 6.8 for Aroclor 1262 Aroclors 1221, 1232, 1242, 1248, 1254, 1260, and 1262 are produced in Anniston's liquid Aroclor systems. O WATER PCB-SD0000051220 Aroclor Manufacturing Process Synopsis of Process 4. .. Solid Aroclors Following are equations for Biphenyl and Santowax R based Solid Aroclors: Biphenyl based Aroclor - 1268 8.72 Chlorine 70.9 8.72 Cl Aroclor 1268 453.9 Chloride 36.5 Santowax R based Aroclor-5442 & 5460 Aroclor (389.3-552.5) n = 4.63 for 5442 and 9.4 for 5460 Also produced at Anniston are 2565 - a. chlorinated mixture of Biphenyl and Santowax C, and 4465 - a blend of Aroclor 1262 and Aroclor 5460. - . OS\N 543208 WATER PCB-SD0000051221 C T ig u c 0S 5209 WATER PCB-SD0000051222 STANDARD MANUFACTURING PROCESS ' FOR AROCLORS II. FLOW SHEETS c f DSNN 54321 WATER PCB-SD0000051223 WATER PCB-SD0000051224 WATER PCB-SD0000051225 WATER PCB-SD0000051226 DSW 543214 WATER PCB-SD0000051227 ,11 CXO * ! (p\b ' FniMCi !; r 11 * ^ (w> r--ifL- fe'5 * tA ---------------------------------1 -----1 .i)__^ - - -i\ ? St .. titi'rti 6 20 -- i _____ j 10 i> 3 Z. M'tLL 1---------------- - COMPANY CONFIDENTIAL This paq prwBf> el n Mite Com be eeoaeiM In for metion jMscaaMooialantffveflt n^tov^preaicedi Basis! ^vmoj Pea Batm Of 54 60 M W. 1 2 C|H,, 230.3 u,oe 3 4 5 T~ n ~5~ q- lO II : *2. 4U FiCl, IC1.1 5 C-wOUlNE AiA Cl, ")0.9 2^ 3*2 31 ee 20 20 33e 33oo loo 3oo MvetoGCN 1 2 Cftuot 5060 eV'ia- 574-1 KrM*M C-*A>0I HCt 3fr.S 35 3S 35 lUio ISO 15 310 15310 25,2'0 150 LimI 5440 Month*. 5 74.1 t,K.O. S74.I 1 250 M SI S ir sis n<s| DSW543215 WATER PCB-SD0000051228 PROCESS IN DETAIL I f -ft I fl 1 i > OS\N 543216 WATER PCB-SD0000051229 STANDARD MANUFACTURING PROCESS FOR AROCLOR . III. PROCESS IN DETAIL A. Batch Liquid Chlorinators Crude Liquid Aroclors are produced by batch chlorination in a vertical vessel. The reaction is cooled by external air cooled heat exchangers and agitated by a circulating pump. Biphenyl is chlorinated with chlorine gas added at the bottom of the vessel. HC1 gas vented at the top of the chlorinator is a by-product which is recovered in the Muriatic Acid Department. Crude Aroclor produced in batch chlorinators is trans ferred to the blowing operation when the chlorination is completed. Chlorine gas is fed to the chlorinators from tank cars. A chlorinator charge (3,000 lbs.) of specification grade Biphenyl is pumped to the chlorinator charge tank from a Biphenyl storage tank. One and one-half (1-1/2) pounds of Ferric Chloride is slurried in Aroclor and dumped into the charge tank with each chlorinator charge. The Biphenyl and Ferric Chloride is agitated for a minimum of 15 minutes and then transferred to the chlorinator. Aroclor 1142 can be used to charge a batch chlorinator for the pro duction of 1148, 1154, 1160, or 1162. When 1142 is used for a chlori nator charge no Ferric Chloride is added. After the chlorinator has been charged, the circulating pump is started and the chlorine feed is put on the chlorinator. Chlorine feed rates range between 400-800 pounds per hour. Normal reaction temperatures are between 140-170C. This temperature is automatically controlled by circulating the reaction mass through the external air-cooled exchangers throughout the chlorination cycle. The reaction temperature is alarmed both high and low. The operator checks the specific gravity of the material at intervals throughout the chlorination to determine the degree of completion of reaction. An alarm sounds when the chlorination is 80% complete. When the gravity of the chlorinated mass indicates it is finished, it is transferred to a blowing tank. B. Continuous Chlorinator Operation The continuous chlorinator operation consists of four cascade flow chlorinators in series where specific levels of chlorination occur. Biphenyl, with Ferric Chloride added, is fed continuously into the first chlorinator where the material is chlorinated and overflows to the second chlorinator. The finished product comes off the final unit, flows into a catch tank and is pumped to a continuous blow tank. The material is pumped from this blow tank to another blow tank for additional blowing. Chlorine is fed to each chlorinator continuously. The HC1 gas evolved is recovered in the Muriatic Acid Department. DSW 543217 WATER PCB-SD0000051230 Aroclor Manufacturing Process Process in Detail 2. B. Continuous Chlorinator Operation (Contd.) This chlorination system can be reduced to three (3) chlorinators in series in case problems occur with one unit. Normally 1142 is the only Aroclor produced on the continuous system, however, other liquid Aroclors can also be produced with the chlorinators set for different levels of chlorination. The Biphenyl feed rate to the continuous system varies between 3 to 6 gallons per minute dependent on production rate desired. Chlorine feed rates also are dependent on production rates and can vary widely. Normally, the chlorine rate to each chlorinator will vary between 600 to 1,200 pounds per hour. As in the batch system, the reaction tem perature of each chlorinator is controlled between 140-170C by cir culation through external, air cooled exchangers. The second and fourth chlorinators in the four chlorinator system are equipped with Accuray density controllers. These automatically control degree of chlorination to a predetermined level by controlling chlorine feed to the chlorinators. The operator also spot checks specific gravity periodically to insure proper degree of chlorination. In the case of Aroclor 1142, the specific gravity of the material from the final chlorinator is kept in the range of 1.344 to 1.357 measured at 65C. C. Biphenyl Mix Tank and Feed Tank When Biphenyl is needed for the continuous chlorinator operation, a charge of about 5,500 pounds is pumped from a Biphenyl storage tank to the mix tank. Two and two-tenths (2.2) pounds of Ferric Chloride is added to the tank. The agitator in the tank is started and the Biphenyl and Ferric Chloride is agitated until a charge is needed for the Biphenyl feed tank. The feed tank is located under the mix tank. The feed tank low level alarm sounds the annunciator system at 257. full, at which time the mix tank batch is dropped into the feed tank. This will allow a minimum of one hour agitation in the mix tank. The agitator in the feed tank runs continuously while Biphenyl is,being fed to the first stage of the continuous chlorinator operation. D. Batch Solid Chlorinator Crude Solid Aroclors are produced by batch chlorination of Biphenyl or Santowax in a vertical reaction vessel with Ferric chloride as a catalyst (5 lbs. per chlorinator charge). In the case of Aroclor 5460 (the largest volume solid Aroclor produced), 11,000 pounds of Santowax constitutes a chlorinator charge. The reaction of Santowax and Chlorine to form Aroclor 5060 takes place at a temperature of 250C. This temperature is maintained by circulation of the reaction mass through a therminol cooled exchanger. Chlorine is added to the bottom of the vessel continuously throughout the cycle at a rate of 2,500 pounds per. hour for most of the chlorination period. Aroclor 1142 can be used to charge the chlorinator for production of 1168 in which case no Ferric Chloride is added. DSW 543218 WATER PCB-SD0000051231 Aroclor Manufacturing Process Process in Detail 3. D. Batch Solid Chlorinator (Contd.) By-product HC1 gas vented at the top of the chlorinator is recovered in the Muriatic Acid Department. Crude Solid Aroclors produced in batch chlorination are transferred to the blowing tank operation when the chlorination is completed. (The only exception being 1168 which is not air blown but pumped directly from the chlorinator to the still). Chlorine gas is fed to the chlorinator from tank cars. E. Blowing Tank Operation Crude Aroclors produced in the chlorinators are air blown for a minimum of one hour, for removal of residual HC1, before the material is fed to the stills. One hundred and twenty psig (120 psig) steam is maintained on the coils of the liquid blowing tanks during this operation. Therminol heat (250-300C) is maintained on the coil in the solid blowing tank. Residual HC1 blown out of the crude Aroclor is drowned in a water ejector which pulls a slight vacuum on the blowing tanks. F. Liquid Stills Aerated crude Liquid Aroclor from a blowing tank or a roof tank is fed to one of three stills. Fifty pounds of hydrated lime is added to each equivalent still charge of Aroclor. A vacuum of 720 mm Hg (40 mm Hg absolute) is applied to the still. The Aroclor is circulated through a gas fired furnace which supplies the heat for distillation. The distilla tion takes place between 165C and 335C.dependent on which Aroclor is being distilled and also upon the exact composition of the Aroclor at a specific point in the distillation cycle. The distillation is semicontinuous, in that up to ten receiver fulls of Aroclor are accumulated prior to discharging the residue (Montar) from the still. The Aroclor vapors from the distillation pass upward through an open column through a water cooled condenser. The condensed Aroclor is collected in a re ceiver and then transferred into a blend tank. Distilled Liquid Aroclors are treated with,Attapulgus Earth in the blend tank, (or pumped through a column containing activated Bauxite) filtered, analyzed, and packaged or held in storage. Still bottoms are sold as Montars or discarded. G. Earth Treatment and Filtration Most Liquid Aroclors are treated in the blend tank with Attapulgus Earth. Forty (40) pounds of earth are used for every 2,000 gallons of Aroclor. This earth is dried in an oven for a minimum of four hours at a temperature of 210-250C. The material, with the earth added, is agitated and then pumped through the filter press and back to the blend tank. When no earth is visible in a line sample of the Aroclor, it is directed to a filtrate receiver. The filtered Aroclor is then ready for drumming or transfer to a storage tank. DSW 543219 WATER PCB-SD0000051232 Aroclor Manufacturing Process Process in Detail 4. H. Porocel Column At present, part of the Aroclor 1242 production is treated in a Polocel (activated Bauxite) column. The production from No. 3 liquid still system is pumped to the top of a column filled with 20/60 mesh Bauxite. Normal flow through the column is around 3 gpm. Optimum product tem perature for treating is around 65C for 1242. Fresh charge of Bauxite is dried by circulating hot Therminol (120C) through the column jacket and blowing nitrogen through the Bauxite until the moisture content of the charge is below 1,000 ppm. Passage through the bed results in adsorption of the ionic impurities in the Aroclor 1242 by the Bauxite. The Aroclor discharges from the bottom of the column and is sent on to storage. The column was installed in 1967 as an experimental unit designed to test the feasibility of replacing earth treatment (see G above) as a means of treating electrical grade Aroclors. The objective was higher quality Aroclors. The column proved successful and other units will be installed by September 1969 to treat other Aroclors and some raw materials used for Aroclor Blends. I. Solid Still Aerated Crude Solid Aroclor from a blowing tank is pumped to the No. 4 still. After the charge is transferred, 250 pounds of hydrated lime is added to the crude Aroclor. Vacuum is applied to the still and the Aroclor is circulated through a gas fired furnace and heated to the vaporization temperature. The dis tillation takes place under a vacuum of 10 to 20 mm Hg absolute. Vaporization temperatures range from 340-400C depending upon exact composition of material and stage of the distillation cycle. The distillation is straight take-over. The vapors pass up an open column and are condensed in a vertical therminol cooled condenser. The distilled Aroclor is collected in a receiver. If within specifi cations, solid Aroclors are either drawn out in drums or cans, or are transferred to the flaker operation for flaking into bags. Still residue or bottoms are sold as Montars or discarded. J. Packaging Solid Aroclors are packaged in fiber drums, galvanized drums, galvanized cans and in paper bags. Liquid Aroclors are packaged in steel drums and cans. These drums and cans are lacquer lined.with two coats of clear'Epoxy Phenolic lacquer. Liquid Aroclors are also loaded into tank cars and trucks. DSW 543220 WATER PCB-SD0000051233 j COMMENTS ON PROCESS 1 !> i 5^ oS'N WATER_PCB-SD0000051234 STANDARD MANUFACTURING PROCESS FOR AROCLORS COMMENTS ON THE PROCESS A. LIQUID AROCLORS 1. Chlorination a. Temperature Chlorination temperatures of 120C or lower yield a product which will not pass the stability tests on electrical grade Aroclors. A minimum of 130C has been set for the chlorinators. An upper temperature limit is not defined as critical to high quality Aroclor production. A practical limitation is governed by the increase of overhead product loss to the off-gas collection tank. The normal temperature range is between 1A0C and 170C. b. Catalyst The basket containing a bed of iron turnings in the chlorinator provides contact surface for the Chlorine and Biphenyl, 'and the iron reacts with the Chlorine forming Ferric Chloride which is the actual catalyst. Consumption of the turnings makes it necessary to inspect the chlorinator semi-annually and replenish the turnings if necessary. Ferric Chloride (anhydrous powder) in the amount of 0.05/i is added to the chlorinator charge to provide assurance of adequate catalyst at all times during the chlorination. It is imperative that the iron turnings in each chlorinator be inspected semi annually. Aroclor supplied to General Electric and Westinghouse must be produced in chlorinators containing the basket. (Prior to any shipment of Electrical Grade Aroclor being shipped to General Electric, and Westinghouse from a process where the baskets are removed. Marketing will review the process change with both customers.) The catalyst is added to the chlorinator charge tank or mix tank (continuous chlorinators) and agitated for at least 15 . minutes but usually at least an hour before charging or feeding the chlorinators. MCL and WGK Aroclor Departments do not premix the catalyst. Research has indicated the tendency to producing unstable Aroclors can be attributed to improper catalyst concentration which may be brought about by insufficient mixing prior to chlorination. DSW 543222 WATER PCB-SD0000051235 Comments on the Process Arocl^rs 2. Free Chlorine in the off-gas from an individual chlorinator or from the vent at the HC1 absorber sewer box indicates problem operation in the Aroclor Department. It can be caused by inadequate reaction of the Biphenyl and might in dicate formation of unstable Aroclor. If this situation occurs it should be corrected immediately. Take samples from the individual chlorinator off-gas and have them analyzed for free chlorine by the laboratory. Check grab samples from each chlorinator of the crude Aroclor being produced and observe it for unusual appearances. Inadequate amounts of catalyst present as Ferric Chloride or iron turnings can cause free chlorine in the off-gas line. In case this situation occurs and cannot be resolved, remove the chlorinator from operation. Contact department supervision immediately. A badly worn chlorinator distributor can also cause free chlorine in the off-gas line. c. Chlorine Problems with the chlorine vaporizer can occur which would allow liquid chlorine to be fed to the chlorinators. In case this should happen, slugs of liquid chlorine would be fed into the chlorinator possibly causing excessive reaction or excessive loss and venting of chlorine to the atmosphere. Chlorine in the HC1 off-gas pipe lines could cause extreme reactions which would generate excessive heat. This reaction can cause a pipe line to become red hot and melt the pipe line in two. This would result in chlorine gas escaping to the atmosphere. Every effort possible should be made to operate the vaporizer with the control system provided. Entrainment of Biphenyl or crude Aroclor into the HC1 lines can occur from excessive chlorine rates. This can be checked by observing the off-gas from the chlorinators in the sight glasses on top of the Brink Demister on each chlorinator. Normal oper ation of the chlorinator should be to minimize this carry-over. Low chlorine pressure can cause operating problems within the Aroclor Department. In cases of extreme low pressure, the crude Aroclor could back up in the chlorine line and begin blow-back into the chlorine header. In this case, pluggage of chlorine feed lines with crude Aroclor would most likely occur. DSW 543223 WATER PCB-SD0000051236 Comments on the Process Aroclo'jrs I' d. Chlorinator Off-Gas Collection 3. The demister on top of the liquids collection tank is used as a final knock-out for Aroclor and Biphenyl entrained droplets in the HC1 gas system. Usually this system will be operating with the steam tracing around the outer shell shut off. When the steam tracing is turned on it will allow vapors to be carried through the demister to the Muriatic Acid absorber. The sight glass on the discharge of the demister can be checked to determine if entrained droplets are being carried over. The steam is installed for use to unplug, the demister in case pluggage should occur. The trappings from this clean-up system are used to produce Aroclor 1148 and 1162 only. The reason for this is to be sure that we do not produce any unstable electrical grade Aroclor. It is extremely important that the tempered water system on the liquid HC1 off-gas condenser be drained during excessive cold weather if it is shut down. The bottom head on the condenser has drain valves at two locations. Both of these drain valves must be open to remove water from the off-gas condenser when the system is shut dovm. 2. Air Blowing of Crude Aroclors Air blowing of crude Aroclors takes place with compressed air from air blowers. Batches of crude Aroclor must be blown for a minimum of one hour. If this is not done, off-quality Aroclors (high color, high acid content) could result. 3. Distillation Vacuum trouble on the stills is usually caused by flashing of product, plugged vacuum lines, or improper functioning of the vacuum jets. Flashing can usually be stopped by operating the still at a slower rate or increasing the flow of cooling water to the vapor condenser. Vacuum troubles can be traced systemati cally from the jets and usually isolated. 4. Earth Treatment Exclusion of atmospheric moisture is naturally important where high electrical resistivity is required. For this reason, the Attapulgus earth is dried for four hours at temperatures of 210-250C. All liquid Aroclors are earth or bauxite treated at the Anniston Plant to decrease the risk of contaminating electrical grade with non electrical grade Aroclors. There are too many common lines down stream of the stills to chance non-treatment of non-electrical grade Aroclors. DSW 543224 WATER PCB-SD0000051237 Comments on the Process Aroclors A. 5. Porocel Column Treatment The bauxite in the porocel column must be well dried prior to starting up after recharging column with fresh bauxite for same reasons Attapulgus earth must be dry. The bed is nitrogen blown until moisture is about 0.1%. Optimum operating temperature of bed is about 65C-70C for 12A2. Higher temperatures decrease adsorption efficiency of the bauxite. Bauxite bed is packed by vibration prior to starting up fresh column to minimize channeling and insure good resistivity from the start. Bed is changed out when plugging is evidenced by increased pressure drop (normal pressure drop about AO psi) , and dropping off of flow rate of Aroclor through column. Occasionally, resistivity problems are encountered which can be traced to moisture entering storage system through steam leaks into product from breaks in steam jacketed piping of system. 6. Quality Incomplete aeration in the blow tanks, or the addition of in sufficient lime to the still pot, will cause high acidities. High inorganic chlorides either indicate contamination or the presence of attapulgus earth in the product caused by a poor filtration. Batches with colors in excess of 30 APHA usually indicate excessive gas heat on the heating coils or air leaks in the vacuum system. A distillation carried too far will also show a dark distillate from the distillation of colored material from the residues. Another reason for color can be the material formed when chlori nating at low temperatures or with insufficient catalyst. Batches with specific gravities, softening points and viscosities out of specifications can indicate over or under chlorinations, or in complete draining of the process equipment when switching from one type of Aroclor to another. Iron has a deleterious effect on the electrical properties of the distilled Aroclors; therefore, tankage, process piping and pumps from the still receiver through the re mainder of the process are either aluminum, tin and zinc sprayed, or are constructed of monel, stainless steel, or bronze. 7. Special Grades a. Export Aroclor 12A2 DSW 543225 The export specs on 12A2 call for a resistivity of 5,000 min. and a Biphenyl content of 0.057. max. Domestic specs call for 500 min. resistivity and no spec on Biphenyl content. The Biphenyl content of 12A2 made on the continuous chlorinators averages below the 0.05% max. spec and, therefore, causes no production problems. To meet the 5,000 min. resistivity spec the 1242 can be earth treated two to five times using normal procedures until the resistivity exceeds 7,000 (dept, spec) and then drummed out from the filtrate receiver. More recently, specs on export 1242 are met by normal treatment through the WATER PCB-SD0000051238 Comments on the Process Aroclors 5. b. Export Aroclor 1254 ie The export specs on 1254 call for a resistivity of 5,000 min. and a Biphenyl content of 0.025% max. Domestic specs call for 500 min. resistivity and no spec on Biphenyl content. Presently, all 1254 is earth treated. By Fall of 1969, the 1254 will be treated in a porocel column. *The resistivity numbers above are a shorthand version. For instance, 5,000 above is actually 5,000 x 109 ohra-cm. measured at 100C. 8. Safety . Biphenyl is flammable, and burning should never be done in areas where Biphenyl or Biphenyl vapors are present. Light Aroclors are also flammable. The viscous Aroclor oils and the resins do not support combustion when heated alone, even at their boiling points - temperatures above 350C. 9. Dermatology and Toxicology Aroclors do not produce primary irritancy or sensitization of the skin. At ordinary temperatures Aroclors have not presented in dustrial toxicological problems. If Aroclors are used at elevated temperatures such as 200C or 300C in open systems, methods must be designed to exhaust any vapors arising from these open systems. B. SOLID AROCLORS 1. Chlorination Special flexible piping joints have been made to the weigh tank since this tank is placed on scales. Actuation of the scale system will require movement of this tank approximately 1/4 inch. These flexible piping joints should be carefully inspected to be sure there are no leaks, since the material contained in them is extremely hot. Steam is provided on the transfer lines and the coil to the weigh tank. From the bottom piping on the weigh tank, all the transfer lines and coils in the Solid Aroclor process vessels have Therrainol heat until the end of the process at the flaker hold tank. The No. 9, Solid Aroclor, chlorinator does not have a basket of iron turnings. Due to this, it is absolutely necessary that, five pounds of Ferric Chloride be added to each chlorinator charge in the weigh tank. DSW 543226 WATER_PCB-SD0000051239 Comments on the Process Aroclors 6. Plugging of the off-gas condenser in the Solids Clean-Up System can occur. To unplug the off-gas condenser the temperature of the Therminol system is elevated as required. During this time, the off-gas condenser can be by-passed. The Solids knock-out tank is provided with a drain system t:o empty the tank completely when products are to be changed on the No. 9 chlorinator. This will eliminate contamination in the weigh tank. 2. Air Blowing of Crude Aroclor Undistilled Aroclors 2565 and 5060 are lime treated in the blow tank to give a neutral acid number. Flaked 5060 on the acid side will cause the bags to fail. Upper limit of acid number is 0.05 mg KOH/g. 3. Distillation Vacuum problems on the Aroclor still are usually due to flashing of product over, plugged vacuum lines, leaks in the still system, leaks at pump packing, water adjustment on inter-condenser on jets, changes in steam pressure to the jets, or problems in the jet nozzles. Flashing can be stopped by adjusting the coolant flow on the condenser or operation of the still at a slower rate. Vacuum trouble must be traced systematically from the jet, to the receiver, and then to the still. It is important to be sure the coil in the Therminol cooling system surge tank is covered when the system is in operation. This assures the circulating pump has a positive suction and prevents surging in the heater coil. This will allow more uniform control of the tem perature in the Therminol cooling system. Care must be taken not to fill the surge tank too full during normal operation. This can cause the tank to run over when the circulating pump is stopped. A normal level will be about 6" to 12" in the sight glass. The flow measurement recording instrument for the still heater system is an extremely important portion of the controls for the No. 4 still system. A segmental orifice is used for obtaining differential pressure readings to indicate flow. This orifice system is in a specially designed Therminol jacketed pipe section. A specially designed d/p cell records the pressure readings and indicates flow. The orifice is designed to allow sucking the coil completely empty when a distillation is complete. The hole in the orifice plate is flush with the bottom of the pipe line. This flow recorder indicates low flow rates at the end of a distillation which aids the operator in completing a normal operation. DSVV 543227 WATER PCB-SD0000051240 Comments on the Process Aroclors 7. Lime addition to the Solid Aroclor still is very important. Cutting the amount of lime below 200 lbs. per batch results in occasional off-color batches. The longer still bottoms are circulated in the heater the higher the formation of HC1 and the greater the tendency to plug the heater coil. Every effort should be made to have Crude Aroclor available to charge the still at all times. 4. Solid Aroclor 1268 The bottleneck in 1268 production is the chlorinator. Increasing chlorine feed rates only increases Biphenyl and low chlorinated Aroclor carry-over to the off-gas collection system, and increases the tendency to over-chlorination and its ensuing problems with freeze-up of lines and equipment (hold points greater than 175C). The still has been found to run better when there is feed always available. Circulating of still bottoms while waiting on crude increases the breakdown of the Montar into more viscous material and hydrogen chloride. Draining the still between batches in creases. the tendency to plug the heater coil. To move the bottleneck from the chlorinator to the still requires charging the chlorinator with 1142 and chlorinating at a rate high enough to insure finishing the batch before the still batch is completed. Other higher chlorinated crudes can be charged to the chlorinator but they will not be as readily available as 1142 from the continuous chlorinators. DSW 543228 WATER PCB-SD0000051241 RJTDTfTM^rTJV DSW 543229 WATER PCB-SD0000051242 STANDARD MANUFACTURING PROCESS FOR ' . AROCLOR APPENDIX A - EQUIPMENT LIST Area 500 - Chlorinator Area 600 - Still Area 700 - Tank Farm Area 800 - Solid Aroclor Storage & Flaking DSW 543230 WATER PCB-SD0000051243 APPENDIX A - EQUIPMENT LIST AREA 500 1.. CHLORINATOR Item Equipment 505 No. 9 Chlorinator Equip, No. 22-0774 506 No. 9 Chlorinator Circulating Pump 19-0494 507 Aroclor Cooler No. 9 Chlorinator 508 No. 4 Chlorinator Cooler 32-0260 509 No. 3 Chlorinator Circulating Pump 19-0495 510 No. 3 Chlorinator Cooler 511 No. 2 Chlorinator Circulating Pump 32-0261 19-0496 Description Vertical 4" -6" dia. x 20' straight side carbon steel vessel with dished heads. Capacity 2,390 gallons. Self-priming, centrifugal pump (Pacific 2-1/2" SS type SVC, 10" impeller, 15 HP, 1750 RPM, 440 volt motor). Pump has a Crane No. 9 outside mech anical seal, Code QP-868. Capacity 250 GPM at 73' TDH. l'-8" dia. x 18'-6" long, carbon steel shell heat exchanger with 304-3/4" O.D. 304 stainless steel, 14 BWG x 16" long tubes. Four passes on Therminol side (tube side). Capacity 1,400,000 BTU/hour. An air-cooled 1" BUG 16.8' long steel tube with aluminum finned cooler for removing heat from crude Aroclor. 3' wide x 8' long x 6' high, equipped with an Annin pneumatic operator to adjust louvers (58 tubes). Fan has a 2 HP, 1800 RPM, 440 volt motor. Capacity 1,100,000 BTU/hour. Self-priming, centrifugal pump (Pacific 1-1/2 L Type SVC, 1-7/8" impeller, 15 HP, 1800 RPM, 440 volt motor). Pump has a Crane No. 9 outside mechanical seal, code QP-868. Capacity 220 GPM at 81' TDH. Same as Item 508 Same as Item 509 DSW 543231 WATER PCB-SD0000051244 APPENDIX A - EQUIPMENT LIST AREA 500 2/ Item Equipment Equip. No. 512 No. 2 Chlorinator 32-0262 Cooler 513 No. 1 Chlorinator 19-0497 Circulating Pump 514 No. 1 Chlorinator 32-0263 Cooler 515 No. 3 Blow Tank 22-0596 516 No. 3 Blow Tank Pump 517 No. 4 Blow Tank 518 No. 4 Blow Tank Pump 520 Biphenyl Feed Tank 22-0595 22-0788 520-A Biphenyl Feed Tank B & C Agitator & Drive 521 Biphenyl Feed Pump 19-0498 522 No. 5 Chlorinator 32-0264 Cooler 523 No. 6 Chlorinator 32-0265 Cooler Description Same as Item 508. Same as Item 509. Same as Item 508. 7'-6" dia. x 7`-6" high Dwg. D-234-4 Peerless Pump - Model 1-1/2 DS0.8, Serial No. 121336. Same as Item 515. Peerless Pump - Model 1-1/2 DS0.8. 5'-6" dia. x 5'-8" long, carbon steel tank with dished heads. Tank contains a 2" Sch. 80 coil approximately 90' long. Capacity 1,000 gallons. 6-blade, turbine type, carbon steel agitator with a 4 ELHZ Faulk motor reducer driven by a 10 HP, 1800 RPM, 440 volt motor. The agitator has a 2-3/4" dia. x 8'-8" long shaft. Capacity provides medium agitation. Self-priming, centrifugal pump (Goulds Model 3196 AVS-260, 6-5/8" open impeller 5 HP, 1800 RPM, 440 volt motor). The pump has a Crane No. 9 outside mechani cal seal. Code QP-868. Capacity 60 GPM at 42' TDH. Same as Item 508. Same as Item 508. DSW 543232 WATER_PCB-SD0000051245 APPENDIX A - EQUIPMENT LIST AREA 500 3. Item Equipment Equip. No. 524 No. 7 Chlorinator 32-0266 Cooler 525 No. 8 Chlorinator 32-0267 Cooler 526 Crude Aroclor Catch Tank 22-0789 527 Crude Aroclor Catch Tank Pump 19-0526 528 Continuous Air Blow 22-0682 Tank 529 Continuous Blow 19-0499 Tank Transfer Pump 530 Air Blower North 531 Solids Off-Gas Eductor 11-0338 532 Liquids Off-Gas Eductor 533 Therminol Surge Tank #9 Chlor. 22-0775 534 No. 9 Surge Tank Pump 535 Weigh Tank 19-0500 536 Weigh Tank Pump 19-0501 Description Same as Item 508. Same as Item 508. 5'-6" x 5*-8" steel vertical tank with flanged and dished top head. Capacity 1,000 gals. 100 GPM Q 75' head - vertical heavy duty centrifugal Taber pump - CV-3 #393. 500 gallon steel tank. Purchased from Dixie Steel & Supply Co. See MCC Dwg. D-548-3-0. Self-priming, vertical centrifugal pump (Taber vertical submerged, CL2-382, 7-1/2" open impeller, 3 HP, 1800 RPM, 440 volt motor). Capacity 15 GPM at 45' TDH. Model 7 H - Spec. SM-488-530. Purchased from Sutorbilt Corp. S&K Fig. 4010 Scrubber and S&K 4040 Separator Box Haveg & P.E. Const. 6" Suet. 6" Discharge. S&K Fig. 4010 Scrubber - 8" Suet. 8" Discharge. 4,-0" O.D. x S'-S". Steel const. Purchased from Opelika Welding,Machine & Supply, Inc. Spec. SM-488-534. P.0. No. OED-7734. Purchased from Goulds Pumps, Inc. 6'-6" x 7'-9" C. steel equipped with heating coil. 5 turns 2" Sch. 80 C.S. pipe. Capacity 2,000 gallons. Goulds Model 3196 AVS No. A 60 constructed of Ductile Iron. Capacity 125 GPM. DSW 543233 WATER PCB-SD0000051246 APPENDIX A - EQUIPMENT LIST AREA 500 4.. Item Equipment Equip. No. Description 537 No. 9 Chlorinator Mist Eliminator Monsanto Brink type demister in a 30" O.D. x 4* x 6' long carbon steel tank. Bottom nozzle 10" dia., 10" flange, with a 6" gas outlet. Designed for 30 psig at 450F. Contains a Brink element No. 2448. Capacity 325 cfm at 8 psig and 250C. Inlet mist loading 2,000 mg/cu.ft. Outlet mist loading 20 mg/cu.ft. Efficiency 997.. 538 No. 9 Chlorinator 32-0259 Cooler Carbon steel heat exchanger 8' long with 3/4" O.D. x 15 BWG tubes containing 184 tubes. Four pass heat exchanger on tube side. Special design Marquette expansion joint constructed of 304 SS on shell side of this heat exchanger. Capacity 1,400,000 BTU/hour. 539 No. 2 Blow Tank Pump 19-0502 Self-priming, centrifugal pump (Goulds Model 3196 AVS-A60, 7" open impeller, with a 5 HP, 1800 RPM, 440 volt motor, and a Crane No. 9 outside mechanical seal, Code QP-868). Capacity 125 GPM at 29' TDH. 540 Biphenyl Feed Pump Self-priming, centrifugal pump (Goulds Model 3196 AVS-A60, 6-1/16" open type impeller, 3 HP, 1800 RPM, 440 volt motor, and a Crane No. 9 outside mechanical seal. Code No. QP-868). Capacity 75 GPM at 39' TDH. 541 No. 2 Blow Tank 22-0777 7'-6" O.D. x 7'-6" straight side vertical tank, flat top with a dished bottom. Tank contains a 2" Sch. 80 pipe coil approximately 75' long. Capacity 2,500 gallons. 542 No. 1 Blow Tank 22-0266-02 Same as Item 515. 543 No. 1 Blow Tank Pump 19-0355 Vertical, centrifugal, submerged Taber pump. 2-1/2" inlet - 1-1/2" outlet. Cast iron construction. Capacity 50 GPM. DSW 543234 WATER PCB-SD0000051247 APPENDIX A - EQUIPMENT LIST AREA 500 5. Item Equipment Equip.No. 544 Weigh Tank Scale 24-0194 545 Crude Aroclor Catch Tank Transfer Pump 546 Brink Demister 41-0037 No. 7 Chlorinator 547 Brink Demister 41-0038 No. 6 Chlorinator 548 Brink Demister 41-0039 No. 5 Chlorinator 549 HC1 Off-Gas Condenser (Liquid System) 550 Chlorine Vaporizer 32-0185 551 No. 1 Chlorinator 22-0675 552 No. 2 Chlorinator 22-0673 Description Fairbanks-Morse, Inc. overhead suspension scale. Model CA, coaxial cabinet dial, having a 22" dia. chart graduated 0-24,000 pounds with a main tare bar graduated 20,000 pounds and 5,000 pounds. The dial has one adjustable Reed switch to operate at scale set point. Scale to be hung below 11' platform level built to contain the weigh tank. Capacity 0-24,000 pounds x 20 pounds increments for scale measure ment. Overall capacity 0-50,000 pounds. Self-priming, vertical centrifugal pump (Taber CV-3, #393, with a 2" suction and 1-1/2" discharge, 10" dia. x 3-1/2" I impeller, 5 HP, 1800 RP11, 440 volt motor). Capacity 80 GPM at 100' TDH. l'-8" dia. x 4'-2" straight side carbon 6teel shell with a Brink type mesh demister pad. Same as Item 546. Same as Item 546. 20* I.D, x 8' long, standard Monsanto fixed tube sheet heat exchanger with 304 3/4" O.D. x 14 BWG tubes. Exchanger has four passes. Overall area 460 sq.ft. Capacity 132,000 BTU/hour heat removal. Armstrong Chlorine Vaporizer, vertical type, complete with super heater section Monel construction - purchased from R. M. Armstrong Co. 90 tcr.s/day capacity. 3'-0" dia. x 16'-0". See Drawing E-6209. See Item 551. DSW 543235 WATER PCB-SD0000051248 APPENDIX A - EQUIPMENT LIST AREA 500 6. Item 553 Equipment Equip.No. No. 3 Chlorinator 22-0673 Description See Item 551. 554 No. 4 Chlorinator 22-0674 See Item 551. 555 No. 8 Chlorinator See Item 551. 556 No. 7 Chlorinator See Item 551. 557 No. 6 Chlorinator 22-0677 See Item 551. 558 No. 5 Chlorinator 22-0676 See Item 551. 559 No. 4 Chlorinator 19-0414 Same as Item 509. 560 Brink Demister 41-0040 Same as Item 546. No. 1 Chlorinator 561 Brink Demister 41-0041 Same as Item 546. No.2 Chlorinator 562 Brink Demister 41-0042 Same as Item 546. No. 3 Chlorinator 563 Brink Demister 41-0043 Same as Item 546. . No. 4 Chlorinator 564 Brink Demister 41-0044 Same as Item 546. No. 8 Chlorinator 565 Instrument Air 37-0098 Joy Manufacturing Company No. WFP0S-9, Compressor Sire 8" x 5" skid-mounted air compressor unit with after-cooler and air receiver. Operated by a 25 HP, 1800 RPM, 440 volt motor. Capacity 105 cfm at 100 psig. DSW 543236 WATER PCB-SD0000051249 APPENDIX A - EQUIPMENT LIST AREA 500 7. Item 566 567 569 570 571 572 573 574 576 Equipment Control Room Sink and Hood Equip,No. Control Room Air Conditioner 44-0098 No. 6 Chlorinator Circulating Pump 19-0414 No. 7 Chlorinator Circulating Pump 19-0414 No. 5 Chlorinator Circulating Pump 19-0394 No. 8 Chlorinator Circulating Pump 19-0405 HC1 Off-Gas Catch 22-0811 Tank (Liquid Chlorinator System) Trappings Transfer Pump (Liquid) Brink Mist Eliminator HC1 Catch Tank Description Fume Hood designed by Browne-Morse Co. #73 Green unit with a gray colorlith top. Fan is an American Blower 1-1/4 HP removing 782 cfm at 1/2 S.P., 1/3 HP, 110 volt, 1725 RPM motor. Capacity fume removal 782 cfm. Carrier Model 48 DA008-601. Roof mounted cooling and heating unit; 98.000 BTU/hour nominal cooling; 240.000 BTU/hour heating nominal direct fired natural gas heater. Same as Item 509. Same as Item 509. Same as Item 509. Same as Item 509. 8'-6" dia. x ll'-3" straight side, carbon steel tank, with dished heads and a 3" Sch. 80 carbon steel pipe coil approximately 120' long. Capacity 5,000 gallons. Self-priming, horizontal centrifugal pump (Goulds Model 3196 AVS-A60, con structed of Ductile iron with a 7" dia. open type impeller, 5 HP, 1800 RPM, 440 volt motor, with a Crane No. 9 outside mechanical seal, Code QP-868). Capacity 125 GPM at 75' TDH. Monsanto Brink type unit, 2'-6" dia. x 11' straight side, containing a Brink element designed for 5 psig at 105F. temperature. Capacity 635 cfm at 85% HC1 gas. Designed to collect 997. of entrained droplets and return to the catch tank. DSW 543237 WATER PCB-SD0000051250 APPENDIX A - EQUIPMENT LIST AREA 500 8,, Item 577 578 579 580 581 582 584 Equipment Equip.No. Therrainol Surge Tank for Solid HC1 Clean-Up Condenser Therminol Pump for Solids Knock-Out Condenser Therminol Cooler for Solids Knock-Out Condenser System HC1 Off-Gas Condenser (Solids System) HC1 Off-Gas Catch Tank for Solid System Water Pump for Liquid Aroclor Knock-Out Condenser Weigh Tank 22-0776 Description 3'-6" dia. x 4'-3" straight side, carbon steel tank, containing a 2" Sch. 80 carbon steel coil approxi mately 10' long. Capacity 300 gals. Self-priming, horizontal centrifugal pump (Goulds Model 3196 AVS-A60, constructed of Ductile iron, with an 8" open type impeller, driven by a 7-1/2 HP, 1800 RPM, 440 volt motor, pump equipped with a Crane No. 9 outside mechanical seal, Code QP-868). Capacity 150 GPM at 50' TDH. Disler Model No. 2 VH air-cooled aluminum finned tube cooler, 3' x 3'-6" x 5'-9" high. Contains a fan driven by a 1 HP, 1800 RPM, 440 volt motor. Capacity 550,000 BTU/hour. 2' dia. x 10'-6" long, carbon steel heat exchanger, with 80 1-1/2" O.D. X 14 BWG x 8' long tubes (six tube passes). Condenser contains 250 sq.ft, surface area. Designed for 150 psig and 160C. 4' dia. x 3'-9" straight side, carbon steel tank with dished heads. Tank is a jacketed carbon steel tank designed for 125 psig at 160C. Jacket designed for 110 psig at 160C. Capacity 300 gallons. Self-priming, horizontal centrifugal pump (Goulds Model 3196 AVS-A60, 2 x 3 - 10, with an 8" open type impeller constructed of Ductile iron with a Crane No. 9 outside mechanical seal, Code QP-868, driven by a 7-1/2 HP, 1800 RPM, 440 volt motor). Capacity 200 GPM at 75' TDH. 6'-6" O.D. x 7'-9". Purchased from Art Welding Co. DSW 543238 WATER PCB-SD0000051251 Item 585 586 587 588 589 592 APPENDIX A - EQUIPMENT LIST AREA 500 9 Equipment Chlorinator Charge Tank Air Blower (South) Air Blower (Middle) . Biphenyl Feed Tank Agitator Fume Jet No. 2 Blow Tank Instrument Air Compressor Equip.No 22-0787 11-0323 11-0324 Description 1,000 gallon steel tank purchased from Missouri Boiler & Tank Co. P.0. NO. D47909. Installed Nov. 1959. Rotary positive with extended base and V-drive, intake filter muffler, exhause muffler, V-belt guard, 1" pressure relief valve. Purchased from Sutorbilt Corp. Same as Item 586, 18-0106 35-0122 37-0073 Falk 4 ELHZ, Ratio 13.9 to 1. Spec. SM-488-520C. Dwg. D-488-M116. Spec. SM-488-531. S&K Figure 4014, Scrubber-Separator consisting of: 1-6" Fig. 4010 Haveg 61 Fume Scrubber. 1-6" Fig. 4040 Polyester Fiberglass Separator. JOY WFP0S-9, Size 6% x 4%, Capacity 50; SCFM at 100 psig output. Water cooled, single stage double acting, carbon ring, non-lubricated, with V-belt drive. 594 Instrument Air 14-0029 Electric regenerative desiccant Dryer dryer, manufactured by Trinity Equipment Corporation. DSW 543239 WATER PCB-SD0000051252 APPENDIX A - EQUIPMENT LIST AREA 600 10.. Item 601 Equipment No. 3 Blend Tank Pump Equip.No. 19-0293 602 603 604 605 606 607 608 609 610 611 No. 3 Blend Tank No. 2 Blend Tank Pump No. 2 Blend Tank No. 1 Blend Tank Pump No. 1 Blend . Tank No. 1 Vacuum Receiver No. 1 Vacuum Receiver Pump No. 2 Vacuum Receiver No. 2 Vacuum Receiver Pump No. 3 Vacuum Receiver 22-0087 19-0269 22-0270 19-0267 22-017801 19-0272 22-0026 19-0271 612 Receiver Pump 19-0244 (No. 3 Still) 613 No. 2 Filtrate 22-0086 Receiver Description 1-1/2 DSO 8 - all bronze, SAE 63 Frame 213 - Serial No. 121340 Peerless. 7*-0" O.D. x approx. 7'-0" on shell. Dwg. 9-C-8247. 1-1/2 DSO 8 - all bronze, SAE 63 Frame 213 - Serial No. 121340-Peerless. Same as Item 602. Same as Item 603. Same as Item 602. Same as Item 609. Fig. 3202 No. 90 VPR, all bronze. Purchased from Blackmer Pump Co. 5'-6" I.D. x 5'-6" Monel. Dwg. C-795. Same as Item 608 6,-6" dia. x 7'-9" straight side, vertical tank, lined with Monel plating. Tank equipped with a Monel coil con structed of 1-1/2" Sch. 40 Monel pipe with approx. 48 linear feet of coil. Capacity 2,000 gallons. Model GZ-CH NEMA 213. Fig. 3202, 90 VPR bronze, Blackmer Pump. . 7'-0" O.D. x 7'-0". Dwg. 9C-8247. Purchased from Chattanooga Boiler and Tank Co. DSW 543240 WATER PCB-SD0000051253 APPENDIX A - EQUIPMENT LIST AREA 600 11. Item Equipment 614 No. 1 Filtrate Receiver 615 No. 4 Still 616 No. 4 Still Circulating Pump 617 Freight Elevator 618 No. 4 Still Heater 619 No. 4 Still Condenser Equip. No. 22-0269 22-0779 19-0505 10-0200 32-0271 32-0282 Description Same as Item 613. 7'-6" dia..x 7'-0" straight side, vertical carbon steel tank with dished heads. Tank equipped with a heating coil constructed of 2" Sch. 80 carbon steel pipe with approx. 77 sq. ft. of surface area. Capacity 2,500 gallons. Self-priming, centrifugal, vertical pump, (Taber vertical submerged No. 345 CC-5, 12-1/2" dia. open type impeller, 25 HP, 1800 RPM, 440 volt motor, v;ith a jacketed stuffing box for water cooling). Pump has a special Zallea expansion joint with rods and discharge pipeline. Capacity 150 GPM at 120' TDH. 1,000$ all steel freight elevator with 3' x 4" platform. Purchased from Midvale Material Handling Equipment Co. Capacity 1,000$. Direct fired natural gas heater with insulation and refractory lining con structed by Alcorn Combustion Company. 7'-11" dia. x 11'-8" high shell con taining a 3" dia. Sch. 80 coil, 259 sq.ft, surface area in a 6' dia. circle. Heater also contains a John Zink VBM No. 10 gas burner. Capacity 355,000 BTU/hour heat absorption (heat input 550,000 BTU/hour). 20" dia. x 9'-10" long vertical condenser, carbon steel shell, 316 SS tubes - 3/4", 14 gauge tubes (304 tubes) purchased from Southern Heat Exchanger. DSW 543241 WATER PCB-SD0000051254 APPENDIX A - EQUIPMENT LIST AREA 600 12.. Item Equipment Equip.No. 620 No. A Still 22-0780 Vacuum Receiver 621 No. A Still Vacuum Receiver Transfer Pump 19-0506 622 Therminol Surge 22-0781 Tank 623 Therminol Cir. 19-0507 Pump for No. A Still Coolant 62A Therminol Cooler No. A Still System 625 No. A Still Catch 22-0782 Tank Description 6'-6" dia. x 7'-9" straight side, carbon steel vertical tank with dished heads. Contains a 2" Sch. 80 carbon steel coil with approximately 52 sq.ft, of surface area. Designed for full vacuum operation at A00 C. Capacity 2.000 gallons. Self-priming, centrifugal pump (Goulds Model 3196 AVS-A60, 7-7/8" dia. open type impeller, 10 HP, 1800 RPM, AA0 volt motor, jacketed stuffing box for Therminol heat. Crane No. 9 outside mechanical seal. Code QP-868, casing of pump jacketed for Therminol heat). Capacity 125 GPM at 50' TDH. 3'-6" dia. x A'-3" straight side, carbon steel vessel with dished heads, contains a 2" Sch. 80 carbon steel coil with 7 sq.ft, surface area. Capacity 325 gallons. Self-priming, centrifugal pump (Goulds Model 3196 AVS-A60, 8-1/16" dia. open type impeller, 7-1/2 HP, 1800 RPM, AA0 volt motor, with a Crane No. 9 outside mechanical seal. Code QP-868, constructed of Ductile iron). Capacity 100 GPM at 65' TDH. Air-cooled heat exchanger. Model No. 58E5AA8, 1" O.D. BWG 16 tubes. A1 long, with aluminum fins, 60 sq.ft, surface area. . Total fin surface area 1,171 sq. ft. Overall dimensions 2' x A* x A'-6" high. Manufactured by Disler Engine ering Company. Fan for cooler 1 HP, 1800 RPM, AA0 volt motor, capacity 5.500.000 BTU/hour. 3' O.D. x 3,-9" straight side, carbon steel tank with dished heads and a 1-1/2" Sch. 80 coil 6' long. Capacity 200 gallons. DSW 543242 WATER PCB-SD0000051255 APPENDIX A - EQUIPMENT LIST AREA 600 13. Item Equipment 626 No. 4 Still Vacuum Jet Equip.No. 35-0123 627 Therminol Surge 22-0783 Tank (No. 4 Still Cooling System) 628 Therminol Heater 19-0508 Circulating Pump 629 Therminol Heater 32-0274 631 Flaker Tank & Agitator 22-0700 632 Barometric Sump Tank Description Three-stage Worthington No. 2-1/2 JPD jet ejector. First stage special design; second stage No. 5; and third stage No. 6-A. Jet also includes a 10" I.D. porcelain barometric inter condenser. 5'-0.D. x 12* straight side, horizontal, carbon steel tank with dished heads. Tank contains a 3" Sch. 80 coil 20* long. Capacity 1,900 gallons. Self-priming, centrifugal pump (Taber vertical submerged No. 346-CC6, with a 12-1/2" open type impeller; 50 HP, 1800 RPM, 440 volt motor, jacketed stuffing box for water cooling). Capacity 350 GPM at 165' TDH. A helical tube heater with cross-flow connection of the four circulation type for heating Therminol FPv-2 by direct firing with natural gas, complete with insulation and refractory lining and coil, 8'-6" dia. x 15'-6" high shell with walls lined with 5" castable refractory Lummite-Haydite vermiculite 124 mix, suitable for 2,000F service. 4" Sch. 80 coil 350' long with a total surface area of 950 sq.ft. Furnace fabricated by Alcorn Combustion Co. Furnace provided with a North American 6" No. 214-88 dual fuel burner. Capacity rated at 8,150,000 BTU/hour for the burner. Total heat absorbed 6,000,000 BTU/hour. 6-blade turbine type impeller, 26" dia., constructed of carbon steel with a 3-1/2" dia. x 8 ft. long shaft. Motor reducer is a Falk 4 ELHZ speed reducer with a 13.9:1 ratio. Slow speed shaft, 125 RPM, driven by a 10 HP, 1800 RPM, 440 volt motor. Capacity, provide medium agitation, in 250 gal. steel jacketed tk. 3' dia. x 3' long vertical tank, fabricated by Fiberglass. Capacity 150 gallons. DSW 543243 WATER PCB-SD0000051256 APPENDIX A - EQUIPMENT LIST AREA 600 14. Time Equipment 634 Lime Hopper No. 4 Still Equip.No 635 Montar Conveyor 33-0055 636 Still Bottoms Blower 11-0339 638 Drum Conveyor 639 Scale (Toledo) 24-0182 640 Polishing Filter 641 Entrainment 41-0045 Separator #4 Still 642 Earth Oven 14-0033 643 Pyranol Filter 15-0029 644 Filtrate Receiver 19-0268 Pump 645 Floor Cleaning 49-0537 Machine 646 Micro Pulverizer 17-0027 Description 2' x 21 x 1' high hopper, fabricated of carbon steel. To fit a 6" nozzle. Capacity 50 lbs. of lime. 2'-0" x 20*-0" steel roller type conveyor. Drawing D-488-M132. Centrifugal fan per spec. SM-488-636. Blower for fume removal. V-belt drive and motor assembly for above fan. 5 HP motor, 440 volt, 60/CY, 3/Phase, for chemical duty. 2'-6" x 10'-0" used at Liquid Aroclor drum-out station. Model 2881 - Serial No. 4159, used for weighing Liquid Aroclor drums. Sparkler Filter - l'-9" x 3'-6" 0AH. Purchased from Wright Auston. P.O.No. 0ED-7952. 16 KW-2 door oven with controls. Standard electric oven. Purchased from Despatch Oven Company. Model 18-S-23 horizontal plate type 304, st. w/scavenger plate feature on pipe legs. Purchased from Sparkler Manufacturing Co. Pump 1-1/2 DSO 8 all bronze - SAE 63 Frame .213. Model No. 204325 - Serial No. EP 17646. 5 HP, 220 volt, 3 phase motor. Purchased from G.H. Tennant. 2 DH Micro Pulverizer with discharge chute mounted on steel base. Main motor 10 HP, 3450 RPM, fan cooled. Feed motor 1/3 HP, 1725 RPM, Serial No. 12184. Purchased from Pulverizing Machinery. DSW 543244 WATER PCB-SD0000051257 APPENDIX A - EQUIPMENT LIST AREA 600 .15. Item Equipment . Equip.No. 650 No. 1 Still Pot 20-0018-01 651 Circulating Pump 19-0230-01 No. 1 Still 652 No. 1 Still Heater 653 No. 1 Still Condenser 42-0018 32-0116 654 No. 1 Still Ejector 35-0105 655 No. 2 Still Pot 20-0002-01 656 Circulating Pump 19-0240-01 No. 2 Still 657 No. 2 Still Heater 42-0050 658 Ho. 2 Still Condenser 32-0141 659 No. 2 Still Ejector 35-0106 660 No. 3 Still Pot 20-0052 661 Circulating Pump 19-0248 No. 3 Still 662 No. 3 Still Heater 42-0052 663 No. 3 Still Condenser Description 6'-0" dia. x 5*-6" high closed steel as per drawing C-809. No..345 semi-stl. CC-5, centrifugal vertical motor pump. 3" inlet, 2-1/2" outlet. Purchased from Taber Pump Co. 3'-9" I.D. x 4'-10-l/2" steel sheet made per Dwg. E-886. 12" dia., 7'-6" long, 19-1-1/2" 1 PS Sch. 40 Monel tubes. Purchased from Dowington Iron Works. #9 N9BON001 Type G Carbate Ejector. 6'-0" dia. x 5'-6" high closed steel as per drawing C-809. Same as Item 651. No Description on File. Same as Item 653. Same as Item 654. Same as Item 655. Same as Item 651. No description on file. Same as Item 653. DSW 543245 WATER PCB-SD0000051258 APPENDIX A - EQUIPMENT LIST AREA 600 16 Item 664 Equipment No. 3 Still Ejector 669 Lime Slurry Tank 670 No. 1 Roof Tank 674 Circulating Pump (Spare) 690 Aroclor Flaker 691 Porocel Column 692 Porocel Column Filter 693 Column Pump 694 Therininol Tank for Column heat 695 Therminol Pump Equip. No. 35-0125 22-0790 22-0078-01 19-0238-01 Description 2-1/2 JPA 3rd Stage. Purchased from Worthington Corp. P.0. NO. 82036. Installed January 1966. Slurry Tank for No. 3 Still. 10" IRS steel Hyd. & flange assembly, steel internal parts. 8' dia. x 30' long. Capacity 11,000 gallons. Same as Item 651. 14-0031 20-0078 15-0109 19-0551 Model VKG 5-56, size 24" x 48". Stainless steel drum with feed pans. Purchased from Goslin. 28" O.R. x 13'-6" straight side, carbon steel - jacketed column constructed by Chattanooga Boiler and Tank Co. Sparkler Filter, model VR-17-6, 60 psi design pressure, 316 S.S. Viking general purpose rotary pump, 675 series, model #G-675G, 1200 RPM, motor. Style 80 FRS platecoil vessel, special model JF 1050 - Industrial Piping Supply Corp. Duriron centrifugal pump Durco MX11, type 1-1/2 x 1-6, speed 1750 RPM, impeller size 5-1/2" carbon steel, mechanical seal, viood's coupling and guard, John Crane Type 9- Coke QP808, motor 2 HP, 1750 PvPH, 3 phase, 60 cycle, 220/440 volts. DSW 543246 WATER_PCB-SD0000051259 APPENDIX A - EQUIPMENT LIST AREA 700 17. Item Equipment Equip.No 700 1254 Day Tank 22-0663 701 Transfer pump 19-0398 702 1242 Day tank 22-0662 703 Transfer pump 19-0397 704 1242 Storage 22-0899 705 1242 Storage 22-0900 707 1242 or 1254 Storage 22-0901 708 1254 Storage 22-0902 709 1248 Storage 22-0903 710 1221 or 1232 Storage 22-0904 711 1260 Storage 22-0905 712 1262 Storage 22-0906 713 1242 Transfer Pump 22-0899 713-001 1242 Pump Motor 22-0899 714 1254 Transfer Pump 22-0900 714-001 1254 Pump Motor 22-0900 715 Transfer Pumps, 1248, 22-0901 1221, 1232, 1262 715-001 Motor for Item 715 22-0901 717 1260 Transfer Pump 22-0902 717-001 1260 pump motor 22-0902 719 1242 Product Filters 15-0121 720 1254 Product Filters 15-0122 721 Filters for Item 715 15-0123 *A1. tank fabricated from type 5052 - H Description (Existing) 11,500 Gal. Al. (Existing) 150 HPM @ 120' (Existing) 11,500 Gal. Al. (Existing) 150 GPM @ 120' 27,000 gal. Al. (13'D. x 28') 27,000 gal. Al. (13'D. x 28') 27,000 gal. Al. (13'D. x 28') 27.000 gal. Al. (13'D. x 28') 18.000 gal. Al. (12'D.x 22') 18,000 gal. Al. (12'D. x 22') 18,000 gal. Al. (12'D. x 22') 18,000 gal. Al. (12'D. x 22') 3 x 2-10/10 160 GPM @ 94' 15 HP 1750 RPM Encap. Same as 713 Same as 713-001 Same as 713 Same as 713-001 Same as 713 Same as 713-001 2-Cuno Model PT 184 - Cuno-pore filters of 316 S.S. w/asbestos-cellulose filter media Same as 719 Same as 719 Aluminum DSW 543247 WATER PCB-SD0000051260 APPENDIX A - EQUIPMENT LIST AREA 700 18. Item 723 725 Equipment 1262 Product Filters Mix Tank Equip.No. 15-0124 22-0907 Description Same as 719 11,000 gal. Al. (ll'D. x 18' with 15 slope bottom) 725-002 Mix tank agitator 18-0118 208-RSES-15-Propeller type w/shut off for seal repair 725-003 Agitator motor 18-0118 Same as 713-001 726 "CM" Storage 22-0908 18,000 gal. Al. (12'D. x 22') 727 Blend tank (Relocated) 2,000 gal. 316 SS 728 Item 725 Transfer Pump 22-0907 Same as 713 728-001 Item 728 pump motor 22-0907 Same as 713-001 730 Item 727 Transfer pump 15-0125 Same as 713 730-001 Item 727 pump motor 15-0125 Same as 713-001 731 Filters for Item 725 15-0125 Same as 719 732 Filters for Item 727 15-0126 Same as 719 733 TCB Storage 22-0909 12,000 gal. Al. (ll'D. x 18') 734 TTCB Storage 22-0910 12,000 gal. Al. (ll'D. x 18') 735 TCB or TTCB Transfer Pump 22-0910 3 x 2-10/8 120 GPM @ 43.5' 735-001 TCB or TTCB Transfer pump motor 22-0910 7-1/2 HP 1750 RPM Encap. 737 TCB or TTCB Unloading pump 22-0910 3 x 2-10/9-1/2 120 (? 80' 737-001 TCB or TTCB Unloading pump motor 22-0910 10 HP 1750 RPM Encap. 739(605) #2 Filter Receiver pump (Existing) 740(603) t`1 Filter Rec. pump (Existing) 741(601) Pump Blend Tanks (Existing) 74 2 Motor Control Center DSW 543248 WATER PCB-SD0000051261 APPENDIX A - EQUIPMENT LIST AREA 700 Item Equipment 743 Clay Slurry Pot 743-001 Clay Slurry Pot Agit. 743-0Q2 Clay Slurry Pot Agit. motor 744 Scavenger Pump (PP0) 744-001 Scavenger Pump motor 745 CM Transfer Pumps 746 CM Product Filters 74 7 Toluene or Xylene Drum Pump 747-001 Toluene or Xylene Pump Motor 750 Condensate Pig 751 Nitrogen Filter Equip.No. 22-0914 22-0914 22-0914 22-0914 22-0914 22-0914 22-0914 22-0914 22-0914 22-0914 22-0914 Description Clay addition to 725 N 33-50 1/2 HP TEFC 3 GPM <a 30' 1/2 HP 1800 RPM Same as 713 Same as 719 186 PM (a 30' 1/2 HP 1200 RPM 3' D. x 6' steel PK 31.20 Cuno 19. DSW 543249 WATER PCB-SD0000051262 APPENDIX A - EQUIPMENT LIST AREA 800 20. Item Equipment Equip.No. Description 801 Drum filler Toledo twin lance high speed drum filler with "Print Weigh" system. Capacity 4-55 gal. drums in 5% minutes. 803.001 Conveyor on scale platform 40-006 5 ft. of chain driven live roller con veyor. Conveyor interlocked with scale so that it cannot be operated until drum filling cycle is complete. 803.002 Motor for 803.001 1/2 H.P. 803.003 Full pallet conveyor Heavy duty gravity roller conveyor 21 ft. long with a capacity of 5 full drum pallets. 804.000 Instrument air comp. 37-0105 100 SCFM Joy air compressor. 80 psig operating pressure. (Transferred from Dept. 236 at Krummrich Plant) 804.001 Motor for 804.000 37-0105 25 HP 1750 RPM 804.002 Aftercooler 37-0105 Jacketed cooler, with water in jacket. 804.003 Entrainment Separator 37-0105 Joy Mfg. Co. - no details available. 804.004 Instrument air receiver 37-0105 36"dia. by 8 ft. high manual drain. 804.007 Inlet air filter 37-0105 No data available. 806.000 Instrument air dryer 37-0105 Trinity heatless model 100 HA4-A7, Serial No. 8484, 100 SCFM flow and 1 14 SCFM regeneration flow. 806.002 Dryer Desiccant filter -37-0105 Pall Trinity Micro Corp. cartridge filter assembly 3-1/4" dia. tube. Replacement cartridge Part No. MCS 1001 E B. 807.000 Sewerage Pumps . 37-0105 Aurora 4" KSB 807.001 Motor for 807.000 37-0105 1-1/2 HP, 1750 RPM, TEFC 220/440 volts, 3 phase, 60 cycle severe duty 807.002 Same as 807.001 Ditto 808.000 Empty Drm. Pallet Conveyor 42-0053 Approx. 25 ft. conveyor with capacity of 6 pallets of empty drms. Conveyor to be heavy duty gravity roller with gradient for safe self movement. DSW 543250 WATER PCB-SD0000051263 APPENDIX A - EQUIPMENT LIST AREA 800 21. Item Equipment 808.001 Right Angle Transfer Conveyor Equip.No. 42-0053 810.000 Aroclor 5460 Stg. Tank 22-0911 810.001 Panel Coils 22-0911 811.000 Aroclor Flaker FeedTank 22-0912 811.001 Aroclor flaker feed tank coil 22-0912 812.000 Aroclor Flaker 14-0046 812.001 Aroclor Flaker Motor 14-0046 812.002 Aroclor Flake Breaker 812.003 Aroclor Flake Breaker Motor 14-0046 14-0046 Description Empty drum pallet conveyor at end of conveyor 808.000. Control mech anism for operating 90 turn located beside the Toledo Scale. 8'-6" D. x 11'-3" straight side vertical carbon steel tank with a working volume of 4,500 gals. Tank to be heated by therminol using panel coils. 168 ft.^ of heating area for 43 GPM of therminol FR-2. Heat transfer30.000 BTU/Hr. Maintain 250C. 8'-6" D. x 11'-3" straight side horizontal carbon steel tank with a working volume of 5,300 gallons. Tank to be heated by therminol using panel coils. 79 ft.^ of heating area for 35 GPM of Therminol FR-2. Heat transfer 200.000 BTU/Hr. Maintain temp, of 250C. 4' D. x 10' length chromium plated drum. Internal operating pressure 60 psig. H2O flow at design rate of 125 GPM. Drum immersion range 0 to 2". Pan depth 4" and therminol heated. Overflow of pan returns to flaker feed tank. Knife pressure controlled by regulated air pressure 20 psig. Design rate 6,900 lbs/hr. of Aroclor 5460. 10 HP, 1750 RPM, 60 cycles, 3 phse, 220/440 volt, TEFC Class I, Group D explosion proof motor. Reeves motor drive to provide drum speed of 5 to 15 RPM (Normal 8 RPM) Internal - series B. Steel. 1 HP, 1750 RPM, TEFC motor. DSW 543251 WATER PCB-SD0000051264 Item 813 814 815 815.001 815.002 -816 816.001 -817 318 APPENDIX A - EQUIPMENT LIST AREA 800 22. Equipment Equip.No. Description Aroclor Flake Bin 21-0104 Surge Capacity between Aroclor flaker and bagger of 87 cu.ft., 304 SS 1/8" thick bottom slope bin (20 ft.^ min. working volume). Aroclor Bag Filler 40-0005 St. Regis two tube series 9840 force flow packer with 14" Teflon coated chambers. Feed rate 2.3 bags of Aroclor 5460 and 1.7 bags of Biphenyl or 4.0 bags per minute. Biphenyl Flaker Feed Tank 22-0913 Biphenyl Flaker Feed Tank 22-0913 Coil 7'-6" O.D. x 11'-3" straight side horizontal carbon steel tank with a working volume of 3730 gallons. Tank to be heated by steam and/or cooled by water to control tank temperature at 80C. 9.8 ft.^ of heating or cooling area to keep Biphenyl at flaking temp, and provide heat to remelt scrap flakes. Biphenyl Flaker Feed Tank 22-0913 coil 58.5 ft.^ of heating area to maintain tank contents at 150C. when Santowax is being flaked. Can be used for cooling Biphenyl. Biphenyl Flaker 14-0047 4' D. x 6' length chromium planted drum. Capacity of 5,000 lbs. per hour of Biphenyl at 18 RPM. Normal drum speed will be 16 RPM. Flaking temp, of 85C. Drum immersion range 0 to 2". Steam heated flaker pan. Knife pressure controlled by regulated air pressure at 10 psig. Biphenyl Flaker Motor 14-0047 5 HP, 1750 RPM, 3 phase, 220/440 volt, 60 cycle, Class I, Group D motor. Variable speed drive of 6.7 to 20 RPM (normal 16 RPM). Biphenyl Flake Hopper 21-0105 Surge capacity between Biphenyl flaker and bagger of 87 cu.ft. 304 SS bin with vibrator, hinged top inspection door and safety glass inspection window. Biphenyl Bag Filler Same as 814 DSW 543252 WATER PCB-SD0000051265 Item 819 819.001 820 820.001 821 822 823 823.001 824 824.001 825 826 826.001 830 830.001 APPENDIX A - EQUIPMENT LIST AREA 800 23. Equipment Equip.No. Description Bag Flattener 40-0007 24" wide x 13' long x 14" to 7' high conveying surface of spring belts and grooved rollers for putting pressure on bag. Includes 90 powered dis charge .turn using tapered grooved rollers and spring belts. Bag Flattener Motor 40-0007 Two - 1 HP motors. Bag Conveyor 40-0007 36" wide x 10' long x 26" high with conveying surface of Ashworth flat wire mesh belting, complete with pulleys, pipe idlers and take-ups. Bag Conveyor Motor 40-0007 1 HP Motor. Glue Applicator 40-0007 Steel glue container with grizzly bar cover. Two wheels mounted on axle and rotating in glue, applying glue as bag passes over wheel. Bag Check Weigh Scale 40-0007 0-250# Scale relocater from Bldg. 27 Aroclor flake scale. Fluidizing Blower 40-0005 Roots-Connersville type AF 53 to supply minimum of 100 CFM at 10 psig to fluidize St. Regis force flow packer. Fluidizing Blower Motor 40-0005 7-1/2 HP, 1800 RPM, TEFC motor. Frame size 213 T, 3 phase, 60 cycle, 230/460 volt. V-belt drive 3B55 center distance 16.9, P.D. drive Sh. 6.0, P.D. driven Sh. 8.6. Fluidizing Blower 40-0005 Same'as 823. Fluidizing Blower Motor 40-0005 Same as 823.001 Fiber Drum Fill Scale 0-1000 Lb. Scale Aroclor 1268 Mill Design is incomplete. Mill Motor Design is incomplete. Mill Fume Hood Design incomplete. Drum Fume Hood Design incomplete. DSW 543253 WATER PCB-SD0000051266 APPENDIX A - EQUIPMENT LIST AREA 800 24. Item Equipment Equip.No. Description 831 Aroclor Flaker Feed Pump 22-0912 3x2 - 11, 1150 RPM open impeller Goulds AVS carbon steel pump to feed flaker 812 with overflow about 15 GPM, mix contents of tank 811 - 120 to 150 GPM or melt flakes in basket of tank 811. Cover plate and stuffing box are jacketed. 831.001 Aroclor Flaker Feed Pump Motor 22-0912 5 HP, 1150 RPM, TEFC motor. 832 Biphenyl Flaker Feed 22-0913 3x2 - 10, 1150 RPM 140 GPM at Pump 40' TDH ductile iron impeller and Crane mechanical seals. 832.001 Biphenyl Flaker Feed Pump Motor 22-0913 5 HP, 1150 RPM 834 Aroclor Flake Conveyor 33-0063 12" x 10' vibrating trough con structed of 304 S.S. max. slope of 5 from East to West. Design capacity - 10,000 lbs/hr. normal capacity - 7,000 lbs/hr. 834.001 Aroclor Flake Conveyor Motor 33-0063 1/2 HP, TEFC 837 Aroclor Lot Transfer 22-0911 3 x 2 - 11/10, 1750 RPM open impeller Pump AVS Goulds pump rated at 120 GPM at 104 ft. Seal-John Crane with TC seal faces and heated by therminol. Ductile iron casing, 316 SS shaft, and cast iron impeller. 837.001 Aroclor Transfer Pump Motor 22-0911 15 HP, 1750 RPM encapsulated motor. 838 Aroclor Dust Collector (Mill) Design incomplete. 838.001 Motor for 838 Design incomplete. 839 Blower (Mill) Design incomplete. 839.001 Blower Motor (Mill) Design incomplete. 840 Flaker Vent Scrubber 41-0046 Rotoclone Steel Scrubber - 4500 CFM. 843 Flaker Vent Blower 41-0046 10" blower with capacity of 4500 CFM. 843.001 Flaker Vent Blower Motor 41-0046 15 HP, 1750 RPM Motor. DSW 543254 WATER PCB-SD0000051267 APPENDIX A - EQUIPMENT LIST AREA 800 25. Item Equipment Equip.No, Description 844 844.001 Fiber Drum Conveyor (Empty) Fiber Drum Conveyor (Full) 42-0054 No data available. No data available. 845 Bag Gravity Conveyor 40-0007 Skate wheel discharge conveyor 24" wide x 25' long to be installed at an angle of decline to carry bag to check weigh scale. 846 Aroclor Flake Diverting Gate TE-Co, Inc. For details see Dwg. No. 9194. 847 Biphenyl Flake. Diverting Gate Same as 846. 848 Aroclor Pallet Conveyor 33-0064 Gravity conveyor for accumulating loaded pallets, 4' wide x 20' long. Conveying surface of pipe idlers, 2-1/2" D. , mounted on 6" channel iron frame. 849 Biphenyl Pallet Conveyor 49-0947 Same as 848 except 29' long. 850 Therminol Heater 32-0304 Capacity 450.000 Btu/lir. future 300.000 Btu/hr, present 100 KW present 150 KW future to delvier 287C. Therminol FR-1. Electric service is 460 volts & NEMA 12 spec. 850.001 Therminol Pump 32-0304 60 GPM at 60 psig centrifugal pump with cast steel casing. 850.002 Therminol Pump Motor 32-0304 460 volts, 3 phase, 60 cycle, TEFC 15 HP x 3500 RPM. 850.003 Therminol Expansion Tank 32-0304 125 Gallon capacity. 851 Unit heater, steam Trane 42 PL propeller type pro jection unit heaters. 852 Unit heater, steam Same as 851. 853 . Unit Heater, steam Same as 851. DSW 543255 WATER PCB-SD0000051268 APPENDIX A - EQUIPMENT LIST AREA 800 26. Item 854 Equipment Penthouse Roof Fan ' Equip.No. 41-0046 Description Penn Ventilator Co., Inc. Unit No. LC-32 with 2 speed - 2 winding variable torgue motor (440/296 RPM delivers 8480/5700 CFM) , 1 KP, 1750 RPM motor, 460 volt, 3 phse, 60 cycles. 855 Scrubber Water Tank 41-0046 500 Gal. 4' O.D. 4'-6" tangent length steel tank to hold re circulation water to scrub organics from exhaust of flaker vents. Tank per Monsanto Std. D 3.1, Std. 12. 856 Scrubber Water Recirculation Pump 41-0046 12 GPM at 72' lx 2-8 1750 RPM AVS A-50 pump. Casing of ductile iron and 8-1/4" impeller cast iron. 856.001 857 ScrubberPump Motor Aroclor Pallet Dispenser 49-0946 3 HP, 1750 RPM. FliC Corp. American Hydraulic Lift 24" x 48" platform - Model #1070. Empty chain conveyor 80 FPM, driven by 1/2 H.P. 43 RPM. Gear motor 440 V, 60 cycle, 3 phase. 857.001 Aroclor Pallet Dispenser Motor 49-0946 1/2 H.P. , Pump power unit, 220/440 volt, 60 cycle, 3 phase. 858 858.001 Biphenyl Pallet Dispenser Biphenyl Pallet Dispenser Motor 49-0947 49-0947 Same as 857. Same as 857.001. DSW 543256 WATER PCB-SD0000051269 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX B - MATERIAL SPECIFICATIONS FINISHED GOODS .a Aroclor 1221 b. Aroclor 1232* c. Aroclor 1242 d. Aroclor 1248 e. Aroclor 1254 f. Aroclor 1260 g- Aroclor 1262 h. Aroclor 1268 i. Aroclor 2565 (undistilled) j. Aroclor 4465** .k. Aroclor 5442 1 Aroclor 5460 m. Aroclor 5060 (undistilled) *Aroclor 1232 is a mixture of approximately 53.47c Aroclor 1221 and 46.6% Aroclor 1242 (by volume). **Aroclor 4465 is a blend of approximately a 1 to 1 ratio of Aroclor 1262 and A.roclor 5460. The softening point range of the blend determines the exact ratio. II - RAW MATERIALS a. Biphenyl b. Santowax C c. Santowax R d. Chlorine e. Hydrated Lime f. Attapulgus Earth g. Ferric Chloride h. Activated Bauxite DSW 543257 WATER_PCB-SD0000051270 mun juii iu ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION H. Williams 2/19/69 SALES W. Ault 3/10/69 CENERAL DESCRIPTION . .. ' r. ' plant AROCLOR 1221 PRODUCT CODE 1 Ann. 608 use Anniston DATE EFFECTIVE 826.10 SALES CODE Sales 3-1-69 APPROVALS RESEARCH 1040-225.-04/11-009 H. E. Gibbs 3/12/69 QUALITY CONTROL (Chief ChemleO R. Blowers 3/26/69 G. W. Miller 2/15/69 CHEMICAL FORMULA . MIXTURE MOL WT* SUPERSEDES specs, of 4/25/61 CHARACTERISTIC sample FOR ANALYSIS 2x1/2 gal. Amber Bottles LIMITS IStUCO BY G. Miller METHOD (R) Condition (R) Color, AFHA (R) Specific Gravity (25/15.5C) (R) Acidity, (Mg KOH/g) (R) Viscosity @ 100F Clear 100 Max. 1.182-1.192 0.014 Max. 38-41 SUS 4.0-5.5 Cp G-l 046 052 050 . 049 K 392 (R) Routine Analysis, All others Analyzed by request Only DSW 543258 WATER PCB-SD0000051271 IVIUII juiiiu ORC A H 1C CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION J. Mollov 3/21/69 SALES W. Ault 3/10/69 6CMCRAL DESCRIPTION H. Williams PLANT AROCLOR 1232 PRODUCT COOE USE Anniston & WGK oate effective . 826.11 6c 81115 sales cooe Sales 3*1-69 APPROVALS RESEARCH 1040-230-04/11/003/009 -. 1 nmi> WGK 246 2/19/69 M. E. Gibbs 3/12/69 OU*L1T CONTROL fCh/ef R Blowers 3/26/69 G. W. Miller CHCMICAL FORMULA 2/15/69 MIXTURE MOL WT. SUPERSEDES SPECS. OF 11-17-66 CHARACTERISTIC sample for analysis 2 x 1/2 gal. Amber Bottles LIMITS ISSUED BV G. Miller METHOD ' (R) Condition (R) Color, APHA (R) Specific Gravity, (25/15.5C) (R) Acidity, (Mg KOH/g) (R) Viscosity @ 100F Clear 50 Max. 1.270-1.280 0.014 Max. 44-51 SUS 6.5-10.0 Cp Anniston G-l 046 052 050 049 WGK 10084 10084 10114 10087 10086 ~~ `T,'r SP2 Koufine 1 --" ,7- ------------ -- ll others Analyzed by request Only ~ -- ,, - -- ' - --f ........................... " -- DSW 543259 .............z * ~ - - ~ ---------- * WATER PCB-SD0000051272 Monsanto ORGANIC CHEMICALS DIVISION TENTATIVE SPECIFICATION AUTHORIZED BY G. W. Miller GENERAL DESCRIPTION product Export Grade Aroclor 1242. Electrical Grade PLANT PRODUCT CODS Annis ton DATE EFFECTIVE 826.12 sales code 6-12-67 1040-240-16-009 SOURCE OF SPECIFIC ATION P. G. Benignus Memo dated 5-11-67 USE Sales CHEMICAL FORMULA Idept. 1 27-L HOI TO. ISSUE* EFFECTIVE UNTIL 6-1-68 CHARACTERISTIC UNRESTRICTED INFORMATION sample FOR ANALYSIS 3x5 pt. Amber bottles LIMITS ISSUED BY J. A. Liddle 5/29/6 method (R) Color, APHA (R) Condition (R) Specific Gravity @ 25*715.5C (R) Acidity (mg KOH/gm) (R) Moisture, H2O, ppm (R) Refractive Index @ 25C (R) Inorganic (free) Chlorides, ppm (R) Pour Point, C (R) Dielectric Constant 1 KC @ 100"C (R) Resistivity ohm-cm 500 VDC @ 100C, 0.1" Gap (R) Hydrolysis Stability Test (as chlorides) ppm (R) Monsanto Stability Test (as chlorides) ppm (R) Biphenyl, % (R) Distillation Range (ASTM D-20, Corrected) . 10% Distilled by wt. 90% Distilled by wt. Sulfates Dielectric Strength @ 25C Flash Point (F) Fire Point Viscosity @ 100F (SUS) 40 Max. Clear 1.381 - 1.392 0.010 Max. 35 Max. 1.6240 - 1.6260 0.05 Majc. -14 or lower 4.70 - 4.90 5,000 x 10^ Min. 0.5 Max. 0.4 Max. 0.05 Max. 325C Min. 360C Max. - None 35 KV Min. 338 - 392 None to Boil 82 - 92 046 G-l 052 050 047 048 045 053 113 121 010 . 133 100 054 . 12169 043 114 114 049 (WGK) RESTRICTED INFORMATION Typical Values Power Factor @ 100C 60 cycles 1000 cycles Report Report 0.30 - 0.50 0.08 - 0.10 113 /s/G. V?. Miller - 5-31-67____________________ G. W. Miller - Chief Chemist /s/H. L Williams - 6-1-67 H. L. Williams - Production /s/Wm. E. Ault - 6-8-67______________________ W. E. Ault - Sales . /s/L. R. Stark - 6-12-67 L. R. Stark - Research (K) R mifi'nr Analysis, All others Analyzed by request only. DSW 543260 WATER PCB-SD0000051273 Monsanto ORGANIC CHEMICALS DIVISION ANNISTON" LAND .KRUMMRICH. FINISHED PRODUCT SPECIFICATION PRODUCTION P. E, Heisler SALES W. E. Ault GENERAL DESCRIPTION PRODUCT lOEPT. Aroclor 1242, Electrical Grade | 246 PLANT WGK, Ann. PRODUCT CODE 81101 - 82612 use Sale s DATE EFFECTIVE i-------- 6/17/66 APFROV SLS ALC CODE 1040-240-04/11/16-03/09 . RESEARCH R, W. Bucknell . QUALITY CONTROL (ChM ChmimO O. E. Dolin ' ~ W. J. Gresham CHEMICAL FORMULA Alsoi: known as Pyranol 1499 27 I MOL WT. SUPERSEDES SPECS. OP 4-13-62 CHARACTERISTIC 3 x 5 pt. Amber Bottles LIMIT* UNRESTRICTED INFORMATION (R) Color (APHA) (R) Condition (R) Sp. Gr. @ 25/15.5C. <R) Acidity (mg. KOH/g.) (R) Moisture (H20) (R) Refractive Index @25 C. (R) Inorganic (Free) Chlorides 'R) Pour Point A) Dielectric Constant (1000 cycles @ 100C. ) (R) Re sistivity (500 VDC @ 100C. 0. 1" Gap) As OHM-CM x 109 (R) Hydrolysis Stability Test (As Chlorides) (R) Monsanto Stability Test (As Chlorides) (R) Distillation Range (ASTM D-20, Corrected) 10% Distilled by wt. 90% Distilled by wt. Sulfate s Dielectric Strength @ 25 c. Flash Point (F) Fire Point Corrosion Test (6 hrs. @ 210C. with bright aluminum foil) _ Change in v/t. of AL % A. C , Color (APHA) A.C. Condition A.C. Acidity (mg. KOH/g.) A.C. Inorganic (Free) Chlorides Vise.. @400^. (SUS) 40, max. Clear 1.381 - 1.392 0. 010, max. 35 ppm . , max. 1.6240 - 1.6260 0. 05 ppm., max. -14C. or Lower 4. 70 - 4.90 500, min. 0.5 ppm, max. 0. 4 ppm . , max. . - ,, 325 C. , min. 360C. , max. None 35 KV, min. 338 - 392 None 0. 0 60, max. Clear 0. 010, ma x. 0. 05 ppm. , max. 82 - 92 (Over) ItlWKD BY WGK 10084 10084 10114 10087 10620 10125 12741 10115 11608 11607 12672 11503 10117 12169 11605 10123 10123 10126 10084 10084 10087 12741 10086 J. P. Prader METHOO Anniston 14-44-54 G-l 14-49-54 14-42-54 14-53-54 14-34-54 014 14-47-54 14-36-54 14-35-57 010 14-61-57 14-31-54 043 14-28-54 14-28-54 14-55-57 14-44-54 G-l 14-42-54 014 14- 4-52 ` (R) Ro ne Anr.lysis, All others Analysed by request Only DSW 543261 WATER PCB-SD0000051274 GENERAL INFORMATION Specific Heat (g? 25 C. Coefficient of Expansion (25 - 65'C) Fixed Chlorine Power Factor @ 100 eC. - - 60 cycles 1000 cycles 0. 30 0.00068 cc/C. 42.5 - 53.5% ( Typical Values) 50.30 SPECIAL CUSTOMER REQUIREMENTS General Electric Thermal Chemical Chlorides 0.65 ppm., max. We stinghouse Hydrolizable Chlorine (Westinghouse Stability Test) 1.0 ppm., max. 12722 T-2219 DSW 543262 s WATER PCB-SD0000051275 Monsanto ORGANIC CHEMICALS DIVISION PRODUCT AROCLOR 1242 NON-ELECTRICAL GRADE PLANT PRODUCT CODE use oei>T"Ann. 608 WGK 246 FINISHED PRODUCT SPECIFICATION PRODUCTION Anniston & WGK 82612-81101 DAT EFFECTIVE SALES CODE Sales 3-1-69 APPROVALS RESEARCH 1040-240-04/11/009-003 J. Molloy 3/21/69 H. Williams 2/19/69 SALES M. E. Gibbs 3/12/69_________________________ QUAL.IT V CONTROL (Chief ChemltO W. Ault 3/10/69________________________________ ccrcril description R. Blowers 3/26/69 G. Miller 2/15/69 CHEMICAL FORMULA MIXTURE MOL nT. SUPERSEDES SPECS. OF 9/25/67 CHARACTERISTIC sample for analysis * 2 x 1/2 gal. Amber Bottles LIMITS ISSUED BY G. Hiller . METHOD (R) Condition (R) Color, APHA (R) Specific Gravity (25/15.5C) (R) Acidity, (mg KOH/g) (R) Moisture, ppm (R) Viscosity @ 100F Flash Point, F Fire Point, F Clear 100 Max. 1.381-1.392 0.010 Max. 50 Max. 82-92 SUS 22-26 Cp 338 Min. None to Boiling Anniston G-l 046 052 050 047 049 WGK 10084 10084 10114 10087 10620 10086 114 114 10123 10123 (R) Routine Analysis, All others Analyzed by request Only DSW 543263 WATER PCB-SD0000051276 Monsanto OROANIC CHEMICALS DIVISION WGK and Anniston! Plants -\ FINISHED PRODUCT SPECIFICATION PRODUCTION P. E. Heisler SALE* W. E. Ault ccncral description " PRODUCT _ 1498) Aroclor 1248 Electrical Grade{Pyranol | PRODUCT doDC 246 WG1 27 Ann. [Sat E CFFtCTIVE 5/10/67 APPROVALS RESEARCH 811.02 (SAUCI COOE. Sales 1040-260-04/11/16-03/09 .' ' N. F. Mueller G. W. Millerouality control (CMfIcmx) W. J. Gresham ' chemical formula Mixture MOL WT. SUPERSEDES SPECS. OP 1/10/64 & 2/16/64 sample por analysis 3x5 pt. Amber Bottles CHARACTERISTIC ^ UNRESTRICTED INFORMATION LIMIT* IHUCD BY L. E, Hornback WGK M1ETHOD Anniston (R) Color, APHA 50, max. (R) Condition (R) Sp. Gr. @65. 15. 56C Clear 1.405 - 1.415 (R) Acidity {mg. KOH/gm. ) 0. 010, max, (R) Moisture (R) Refractive Index @25C. . 35 ppm. , max. 1.6285 - 1. 6305 (R> Inorganics (Free) Chlorides (R> Pour Point (R) Dielectric Constant 0. 05 ppm. , max, 0"C. , max. 4. 5 - 4.7 (1000 cycles @100C. ) (R) Resistivity 500, min. (500 VDC @100C. 0. 1" GAP) as OHM-CM x 109 (R) Hydrolysis Stability Test (as Chlorides) 1.0 ppm, , max. (R) Monsanto Stability Test 0. 5 ppm. , max. (as Chlorides) (R) Distillation Range (ASTM D-20, Corrected) 10% Distilled by Wt. 3450C. , min, 90% Distilled by Wt. S85C., max. 10,084 10,084 10,114 10,087 10,620 10,125 T-2092 10,115 11,608 11,607 > T-2087 11,503 ' 10, 117 Sulfates . None Dielectric Strength @25C. 35 KV, min, Fire Point . None to boiling point Viscosity @54.4 0 C. (SUS) 73-80 Corrosion Test (6 hrs. @210C. with bright aluminum foil) Change in wt, of A1 (%) 0.0 A. C. Color, APHA 60, max. A. C. Condition Clear * A. C. Acidity (mg. KOH/g, ) 0, 010, max, A. C. Inorganic (Free) Chlorides 0. 05 ppm. , max. . 12,169 11,605 10,123 10,086 10, 126 10,084 10,084 10,087 10,118 14-44-54 G-l 14-49-54 14-42-54 14-53-54 14-34-54 014 14-27-54 14-36-54 14-35-57 010 14-61-57 14-31-54 __ 14-28-54 14-28-54 14-4-52 14-55-57 14-44-54 G-l 14-42-54 010 GENERAL INFORMATION Specific Heat@25C. Fixed Chlorine 0. 27 47. 5 - 48. 5% DSW 543264 WATER PCB-SD0000051277 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION J. Mollov SALES 3/21/69 W. Ault 3/10/69 general description H. Williams PRODUCT AROCLOR 1248 NON-ELECTRICAL GRADE PLANT PRODUCT CODE USE Anniston & WGK 82641-81102 DATE EFFECTIVE SALES CODE Sales OEPT'Ann. 608 WGK 246 3-1-69 APPROV ALS HRESEARC 1040-26CT-04/11 /009-003 2/19/69 M. E. Gibbs 3/12/69 [quality CONTROL (Chief Chemiat) R. Blowers 3/26/69 G. Miller 2/15/69 Chemical formula MIXTURE MOL TIT. SUPERSEDES SPECS. OF 9/25/65 CHARACTERISTIC ample FOR ANALYSIS 2x1/2 gal. Amber Bottles LIMITS ISSUED 0 V G. Miller METHOD * (R) Condition (R) Color, APHA (R) Specific Gravity, (65/15.5eC) (R) Acidity, (mg KOH/g) (R) Moisture, ppm (R) Viscosity, (? 130F Flash Point, F Fire Point, F Clear 100 Max. 1.405-1.415 0.010 Max. 50 Max. 73-80 SUS 19.5-22.5 Cp 370 Min. None to Boiling Anniston G-l 046 052 050 047 049 WGK 10084 10084 10114 10087 10620 10086 114 .10123 114 10123 (R) Routine Analysis, All others Analyzed by request Only DSW 543265 WATER PCB-SD0000051278 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCT Export Grade Aroclor 1254 - Electrical Grade plant PRODUCT CODE Anniston DATE EFFECTIVE 326.13 SALE* COOE 3/23/67 L040-280-16-009 USE Sales OEPT. 27-L PRODUCTION R. G. Moody/s/R. G. Moody 3/23/67 SALES . W. E. Ault/s/W. E. Ault 3/17/67 GENERAL DESCRIPTION ' RESEARCH L. R. Stark/s/L. R. Stark 3/21/67 QUALITY CONTROL (Chief Chemimt) S. W. Miller/s/G. W. Miller 2/23/67 CHEMICAL FODMULA Mixture MOL WT. SUPERSEDES specs, of Tentative 4/27/66 CHARACTERISTIC UNRESTRICTED INFORMATION sample for analysis 3 x 5 pt. Amber bottles limits ISSUED 6Y J. A. Liddle 2/21/67 METHOD (R) Color, AFHA (R) Condition (R) Specific Gravity @ 65/15.5 C (R) Acidity (mg KOH/gm.) (R) Moisture (H2O), ppm (R) Refractive Index (3 25C (R) Inorganic (free) Chlorides, ppm (R) Pour Point, C (R) Dielectric Constant 1000 Cycles Q 100C (R) Resistivity ohm-cm 500 VDC (3 100eC, 0.1" Gap (R) Hydrolysis Stability Test as chlorides, ppm (R) Monsanto Stability Test . as chlorides, ppm (R) Distillation Range, ASTM D- 20, . corrected 10% Distilled by wt. 50% Distilled by wt. 907. Distilled by wt. (R) Biphenyl, % Sulfates Dielectric Strength (3 25C Flash Point Fire Point Viscosity <3 210F (SUS) Corrosion Test 6 hours @ 210C with bright aluminum foil Change in wt, of A1 (%) A.C. Color, APHA A.C. Condition A.C. Acidity (mg. KOH/g.) A.C. Inorganic (free) chlorides, ppm 50 Max. Clear 1.495 - 1.505 0.010 Max. 35 Max. 1.6370 - 1.6390 0.05 Max. 7-12 4.15 - 4.35 10,000 x 10s Min. 1.0 Max. 0.5 Max. 366 - 378C 371 - 383C .379 . 394C 0.025 Max. None 35 KV, Min. None to Boil None to Boil 44 - 48 0.0 60 Max. Clear 0.010 Max 0.05 Max. 046 G-l 052 050 047 048 045 053 113 121 010 133 054 100 043 114 114 049 046 G-l 050 045 RESTRICTED INFORMATION Power Factor (3 100C & 60 Cycles Report (R) Routine Analysis, All others Analyzed by request Only DSW 543266 113 . WATER PCB-SD0000051279 Monsanto ' ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCT ION J. W. Molloy SALES W * E. Ault CENCRAL DESCRIPTION PRODUCT Aroclor 1254 Electrical Grade plant PRODUCT CODE WGK and Ann. DATE EFFECTIVE 81103 82613 SALES CODE USE Sales loEPT* 1 246 - 27 11/4/68 APPHOVALS RESEARCH 1040-280-04/11/16-03/09 R. W. Bucknell quality control. (Chief Chemlmt) G. W. Miller W. J. Gresham CHEMICAL FORMULA Also called Pyranol 1476 MOL TTT. supersedes specs. OF 6/28/65 CHARACTER IS TIC sample for analysis 3 x 5 pt. Amber Bottles LIMITS UNRESTRICTED INFORMATION (R) Color, APHA (R) Condition (R) Sp. Gr. (? 65/15.5C <R> Acidity (mg. KOH/gm.) (R) Moisture (HO) (R) Refractive Index @ 256C (R) Inorganic (Free) Chlorides (R) Pour Point (R) Dielectric Constant (1000 cycles @ 100C) (R) Resistivity (500 VDC @ 1006C 0.1" GAP) as 0HM-CM x 109 (R) Hydrolysis Stability Test (as Chlorides) (R) Monsanto Stability Test (as Chlorides) (R) Distillation Range (ASTM D-20, Corrected) 10% Distilled by Wt. 50% Distilled by Wt. 90% Distilled by Wt. Sulfates Dielectric Strength @ 25C Flash Point Fire Point Vise. @ 210F (SUS) Corrosion Test (6 hrs, @ 210C with bright aluminum foil) Change in wt. of A1 (%) A. C. Color, APHA A. C. Condition A. C. Acidity (mg. KOH/g.) A. C. Inorganic (Free) 50, Max. Clear 1.495 - 1.505 0.010, Max. 35 ppm. Max. 1.6370 - 1.6390 0.05 ppm.. Max. 7 - 12C 4.15 - 4.35 500, Min. 1.0 ppm., Max. 0.5 ppm., Max. 366 - 378C 371 - 3836C 379 - 394C None 35KV, Min. None None 44-48 0.0 60, Max. Clear 0.010, Max. 0.05 ppm.. Max. ISSUED BY E. McEntire/G. Stites METHOD WGK 10084 10084 10114 10087 10620 10125 12741 10115 11608 11607 12672 11503 10117 Ann. l4r44-54 G-l 14-49-54 14-42-54 14-53-54 14-34-54 014 14-27-54 14-36-54 14-35-57 010 14-61-57 14-31-54 12169 11605 10123 10123 10086 10126 043 14-28-54 14-28-54 14-4-52 14-55-57 ' 10084 10084 10087 10118 14-44-54 G-l 14-42-54 010 DSW 543267 (R) Routine Analys is, All others Analyzed by request Only WATER PCB-SD0000051280 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION J. Hollov 3/21/69 SALES W. Ault 3/10/69 CCNCRAL DESCRIPTION H. Williams PRODUCT AROCLOR 1254 NON-ELECTRICAL GRADE PLANT PRODUCT CODE USE oePT*Ann. 608 VGK 247 Anniston & WG!< 82613-81103 DATE EFFECTIVE SALES CODE Sal es ______ 3-1-69 APPROVALS RESEARCH 1040-280-04/11/009-003 2/19/69 M. E. Gibbs 3/12/69 QUALITY CONTROL (Chlei Chemist) R, Blowers 3/26/69 G, Miller 2/15/69 CHEMICAL FORMULA MIXTURE MOL WT. SUPERSEDES SPECS. OF SAMPLE FOR ANALYSIS 9/25/67______________________ 2x1/2 gal. Amber Bottles C HAR ACT ERISTIC LIMITS ISSUED BY G. Miller METHOD (R) Condition (R) Color, APHA (R) Specific Gravity (65/15.5C) (R) Acidity (mg KOH/g.) (R) Moisture, ppm (R) Viscosity @ 210F Flash Point Clear 100 Max. 1.495-1.505 , 0.010 Max. 50 Max. 44-48 SUS 7.5-10 Cp None Anniston G-l 046 . 052 050 047 049 WGK 10084 10084 10114 10087 10620 10086 114 10123 (R ) Routine Analys is AH others Analyzed by request Only DSW 543268 WATER PCB-SD0000051281 . . -Monsanto organic chemicals division ANNISTON AND KRUMMRICH FINISHED PRODUCT SPECIFICATION PRODUCTION P. E. Heisle r S ALES W. E. Ault CCnEra; OCSCRIPTlOH PROOUCT Aroclor 1260 PL*"T Anniston Krummrich DATE EFFECTIVE 5/25/66 Ann.Iospt. 1 Electrical Grade 1 WGK - 24i TOV^nn. USE 81105 - WGK SALES CODE Sa le s ' 1040-290-04/11/16 -03-09 APPROVA L 9 RESEARCH W, D. Robinson QUALITY CONTROL (Chltl ChtmlcO W. J. Gresham O. E. Dolin CHEMICAL FORMULA MOL WT. SUPCR)ED3 SPECS. OF 2/7/62 CHARACTERISTIC UNRESTRICTED SAM*LC FOP ANALYSIS 3x5 pt. Amber Bottles LIMITS INFORMATION (R) Color (APHA) 150, max. (R) Condition Clear (R) Specific Gravity @ 90, 15,5*C. 1.555 - 1.566 (R) Acidity (mg KOH/g.) 0. 014, max. (R) Moisture (H20) (ppm) (R) Viscosity @ 210'F, (SUS) 35, max. 72 - 78 (R) Refractive Index @ 25 *C. (R) Inorganic (Free) Chlorides (R) Pour Point (C) 1.6455 - 1.6470 0. 05 ppm, max. 25 - 34 (R) Distillation Range (ASTM D-20, Corrected) 10% Distilled by wt, 385 - 398 "C . 50% Distilled by wt, 390 - 404 *C . 90% Distilled by wt. 400 - 420C. (R) Corrosion Test (6 hrs . @ 210"C. with bright aluminum foil) (R) Change in weight of A1 (@) 0.0 (R) A . C , Color (APHA) 150, max. (R) A.C. Condition ' Clear (R) A.C. Acidity (mg. KOH/g.) 0. 014, max. (R) A.C, Inorganic (Free) Chlorides ' 0. 05 ppm, max. [ISSUED D r J. P, Prader METHOD WGK. 10084 10084 10114 10087 10620 10086 10125 10118 10115 10117 Anniston 14-44-54 14-49-54 14-42-54 14-53-54 14- 4-52 14-34-54 14-48-57 14-47-54 14-31-54 10126 10084 ' 10084 10087 10118 14-55-57 14-44-54 14-42-54 14-48-57 (Over) Routine of > y(R ) Analysis, All hers A naty zed request Only DSW 543269 WATER PCB-SD0000051282 UNRESTRICTED INFORMATION (Cont'd.) Characteristic Limits Flash Point None Fire Point None Fixed Chlorine (%) 59.5 - 60.5 (R) Dielectric Strength @ 50*C. 30 K. V., min. (R) Resistivity 500, min. (500 VDC @ I00eC. 0. 1" gap as ohm-cm x 10') (R) Dielectric Constant 3.6 - 3.8 1000 cycles, 100eC. Method WGK Anniston 10123 10123 10088 14-28-54 14-28-54 14-13-54 11605 11607 14-35-57 11607 . 14-36-45 RESTRICTED INFORMATION (R) Monsanto Stability Test (A s Chloride s in ppm . ) GENERAL INFORMATION (R) Evaporation Loss after 6 hr s. @ 100C. (%) (R) Stability test - after 30 days at 100'C. in glass sealed in air. 0. 7, max. 11503 0,2, max. 10116 No liberation of chlorine or chlorides 14-61-57 12-32-54 DSW 543270 "v WATER_PCB-SD0000051283 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION J. Mollov 3/21/69 H. Williams W. Ault 3/10/69 CCNCRAL DCSCRIPTION PRODUCT . AROCLOR 1260 MON-ELECTRICAL GRADE plant . PRODUCT CODE USE oePT* Ann. 20( WGK 246 Anniston & WGK 82614-81105 DATE EFFECTIVE SALES CODE Sales 3-1-69 APPROV ALS RESEARCH 1040-290-04/11/009-003 2/19/69 M. E. Gibbs 3/12/69 QUALITY CONTROL. (Chlmt ChemitO R. Blowers 3/26/69 G. Miller 2/15/69 CHEMICAL. FORMULA MIXTURE MOL TIT SUPERSEDES SPECS. OF 9/25/67 CHARACTERISTIC SAMPLE FOR ANALYSIS 2x1/2 gal. Amber Bottles LIMITS ISSUED BY G. Miller METHOD * (R) Condition (R) Color, APHA (R) Specific Gravity (90/15.5C) (R) Acidity, (mg KOH/g.) '(R) Moisture, ppm (R) Viscosity @ 210F Flash Point Clear 150 Max. 1.555-1.566 0.014 Max. 50 Max. 72-78 SUS 20-24 Cp ' None Anniston G-l 046 . 052 050 047 049 WGK 10084 10084 10114 10087 10620 10086 114 - 10123 f r~ L (R) Routine Analysis, All others Analyzed by request Only ' DSW 543271 WATER PCB-SD0000051284 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION c PRODUCTION J. Mollov 3/21/69 H, Williams SALE* W. Ault 3/10/69 GENERAL description PRODUCT AROCLOR 1262 NON-ELECTRICAL GRADE PLANT PRODUCT COOE USE AnnIston & WGK 82615 & 81107 DATE EFFECTIVE SALES COOE Sales oc,*T'Ann. 206 WGK 246. 3-1-69 APPROVALS RESEARCH 1040-/300/04/11/-009/003 2/X9/69 M. E. Gibbs 3/12/69 quality CONTROL (Chlml ChemltO R. B1overs 3/26/69 G. Miller 2/15/69 CHEMICAL FORMULA MIXTURE MOL WT. SUPERSEDES SPECS. OF sample for analysis __________ 3/2/66________________ 2x1/2 gal. Amber Bottles CHARACTERISTIC LIMITS ISSUED BY G. Hiller . METHOD (R) Condition (R) Color, APHA (R) Specific Gravity (90/15.5C) . (R) Acidity (mg KOH/g) (R) Viscosity @ 210F Clear 150 Max. 1.572-1.583 0.014 Max. 86-100 SUS 26-33 Cp Anniston G-l 046 052 050 049 WGK 10084 10084 10114 10087 10086 ( (R) Routine A nolys is, All others Anoly led by request Only DSW 543272 WATER PCB-SD0000051285 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moodv /s/ 12-30-65 SALES W. E. Ault /s/ 3-2-66 GENERAL DESCRIPTION Mixture PRODUCT . Aroclor 1268 PLANT PRODUCT CODE USE Annis ton__________ 826.16 OATS EFFECTIVE PALES CODE Sales 3-11-66 APPROVALS RESEARCH 1040-340-04-11-16 -009 L. R. Stark /s/ 3-8-66 quality control (Chlmt ChaiJ0 . 0. E. Dolin /a/ 12-29-65 CHEMICAL FORMULA JoCPT. 127-S MOL TIT. SUPERSEDES SPECS* OF ..4-25-61 CHARACTERISTIC SAMPLE FOR ANALYSIS ISSUED DY . I x 16 oz. Can or W.M. Bottle J. A. Liddle li-30-65 LIMITS METHOD UNRESTRICTED INFORMATION (R) Appearance and color Color, Gardner White to off-white powder 6 Max. (R) Hold Point, C 150 - 170 (R) Acid No., mg K0H 0.05 Max. RESTRICTED INFORMATION Screen Test, 7. retained on No. 16 mesh 0.1 Max. No. 20 mesh 10 Max. Specific Gravity @ 25/25C., Pycnometer 1.804 - 1.811 Loss @ 163 C., T. 0.15 - 0.24 G-l 119 116 120 1 ' OS'M WATER PCB-SD0000051286 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moodv /s/ 12-29-65 SALES W. E. Ault /s/ 3-2-66 6ENERAL DESCRIPTION Mixture ^ROOUCT . JoEPT. Aroclor 2565 plant PRODUCT CODE 127-S USE Anniston DATE EFFECTIVE 826.18 SALE!CODE Sales 3-11-66 1040-390-04-009 APPROVAUS RESEARCH ' L. R. Stark fsf 3-8-66 QUALITY CONTROL (Chief ChomlmO D. E. Dolin /s/ 12-29-65 .* CHEMICAL FORMULA MOL WT. SUPERSEDES SPECS. OF 4-25-61 CHARACTERISTIC UNRESTRICTED INFORMATION (R) Appearance and Color (R) Softening Point, cC (R) Acid No., mg KOH/g SAMPLE FOR ANALYSIS ISSUED BY . 1 x 16 oz. Can or W.M. Bottle J. A. Liddle 11-30-65 LIMITS METHOD Black, brittle resin 66 - 72 1.4 Max. G-l 115 116 OSVJ 54327A WATER PCB-SD0000051287 Monsanto Oft C A NIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION . R. G. Moodv Is/ 2-29-66 SALES W. E. Ault Is/ 3-2-66 GENERAL DESCRIPTION Mixture PRODUCT Aroclor 4465 plant PRODUCT CODE USE Anniston DATE EFFECTIVE 826.19 SALES CODE Sales 3-11-66 APPROVALS . RESEARCH 1040-430-04-11-16 -009 ' L. R. Stark /s/ 3-8-66 QUALITY CONTROL. (Chlmt ChcmltO 0. E. Dolin Is/ 12-29-65 CHEMICAL FORMULA JoEPT. 127-S - MOL WT. SUPERSEDES SPECS, OF 4-25-61 CHARACTERISTIC UNRESTRICTED INFORMATION (R) Appearance and Color (R) Color, NPA, Molten (R) Softening Point, C Acid No., mg KOH/g sample for ANALYSIS ISSUED SY L x 16 oz. Can or W.M. Bottle J. A. Liddle 11-30-65 Clear, light yellow resin 2 Max. 60 - 66 0.05 Max. G-l G-4 115 116 I f r> * -t / rr _ ,,i _ r . . _ _r t n ,, k. 0S\N 543275 WATER PCB-SD0000051288 Monsanto \'i oi FINISHED PRODUCT ^ SPECIFICATION PRODUCTION O. Moodv /s/ 12"30t65 SALES ' UJ W. E. Ault /s/ 3-2-66 ' CtNERAL DEtCRIPTION Mixture S mSlJ ItT. supersedes specs* of -4^25-61 CHARACTERISTIC UNRESTRICTED INFORMATION (R) Appearance and Color (R) Softening Point, C (R) Acid No. mg KOH/g PRODUCT Aroclor 5060 PLANT Anniston DATE EFFECTIVE PRODUCT CODE 826.20 SALES CODE USE Sales 3-11-66 APPROVA LS RESEARC H 1040-450-04-009 L. K. Stark fsl 3r8r66 quality CONTROL (Chtt! ChemltO 0. E. Dolin /s/ 12-29-65 CHEMICAL FORMULA loEPT. 1 27-S SAMPLE FOR ANALYSIS ItIUCD BY 1 x 16 oz. Can or W.M. Bottlel J. A. Liddle 11-30-65 LIMITS METHOD Black, brittle resin 105 - 115 0.5 Max. G-l 115 116 t Cl of >'j:ii bj in u <x C0-.1 o [.J DSW 543276 WATER PCB-SD0000051289 Monsanto organic chemicals division FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moodv /s/ 12-29-65 SALES W. E. Ault /s/ 3-2-66 GENERAL DESCRIPTION . PRODUCT Aroclor 5442 PLANT PRODUCT CODE use Anniston DATE EFFECTIVE 826.21 BALES COOE Sales 3-15-66 approvals RESEARCH 1040-470-04-009 L. R. Stark /s/ 3-11-66 QUALITY CONTROL (Chlet ChemltO 0. E. Dolin /s/ 12-29-65 CHEMICAL FORMULA loEPT. 1 27-S Mixture MOL WT. SUPERSEDES SPECS* OF 4-25-61 CHARACTERISTIC UNRESTRICTED INFORMATION (R) Appearance and Color (R) Color, NPA, Molten (R) Softening Point, C Acid No., mg. KOH/g sample FOR ANALYSIS ISSUED BY 1 x 16 oz. Can or W.M. Bottle J. A. Liddle 11-30-65 LIMITS ' METHOD Clear, yellow sticky resin 2 Max. 46 - 52 0.05 Max. G-l G-4 115 116 oS\N 543271 WATER PCB-SD0000051290 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION H. L. Williams 5/20/69 SALES W. E. Ault 6/10/69 CENCRAL DESCRIPTION PRODUCT AROCLOR 5460 (HIGH SOLUBLE GRADE) PLANT PRODUCT CODE USE [OCPT. I 826.17 Anniston DATE EFFECTIVE 826.22 SALE* CODE Sales 5-20-69 APPROV AtS RESEARCH 1040-480-04-009- , ' M. E. Gibbs 6/13/69 QUALITY CONTROL (Chief ChttnUl) G. W. Hiller 5/20/69 CHEMICAL FORMULA MIXTURE MOL WT. SUPERSEDES SPECS, OF 3-11-66 CHARACTERISTIC ample FOR ANALYSIS IWUEO BY lx 16 oz. Can or W. M. Bottl s LIMITS G. W. Miller METHOD UNRESTRICTED INFORMATION (R) Appearance and Color Clear, yellow to amber brittle resin or flaker (R) Color, NPA, Mol ten 2 Max. (R) Softening Point, C 98 - 105.5 (R) Solubility (25g in 25g . Acetone @ 25C) . ' 3 hour, .Min. Acid No., mg KOH/g 0.05 Max. Chlorine, T, 58.5 - 60.6 RESTRICTED INFORMATION . Hydrolysis Stability, ppm Cl 300 Max. G-l G-4 115 117 116 093 092 C' (R) Routine Analysis, All others Analysed by reguest Only os* WATER PCB-SD0000051291 Monsanto organic chemicals division PRODUCT Biphenyl Technical PLANT PRODUCT CODE . USE lOCPT. 1 20 FINISHED PRODUCT Anniston DATE EFFECTIVE 826.01 SALES CODE Sales a PRODUCTION SPECIFICATION 5-7-68 approvals RESEARCH 1315-000-03-09 H. L. Williams /s/H. L. Williams 5/2/68 SALES L. R. Stark /s/John F. Herber (QUALITY CONTROL cruel ChemlmO - W. E. Ault /s/W. E. Ault 5/7/68 G. W. Miller /s/G. W. Miller 4/29/68 GENERAL DESCRIPTION ' CHEMICAL FORMULA . White, crystalline solid MOLKT. SUPERSEDES SPECS. OP -5-5-61__________ CHARACTERISTIC AMPLE POP ANALYSIS 1 x 16 oz. can (R) Appearance (R) Crystallizing Point, cC (R) Color, Gardner White to pale yellow crystals 68.7 Min. 6 Max. General Tests (determined only on request) Biphenyl, 7* Distillation Range (Must include 1st Drop - Dry point, 2.5C 255C) r C12H10 (ISSUED ft V J. L. Brown Typical ' 99.9 METHOD 018 019 165 '" r. ' (R) Routine Analysis, All others Analyzed by request Only 0S\N 543279 WATER PCB-SD0000051292 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moody /s/ 2-1-66 SALES W. E. Ault /s/ 2-22-66 CCNCR&L DESCRIPTION PRODUCT Santowax C PLANT Anniston date effective 3-9-66 APPROVals RESEARCH PRODUCT CODE 829.10 ALES CODE 7795-050-99-009 loCPT* 1 32 USE Internal - L. R. Stark /s/ 2-3-66 - M. McEwen fsf 2-22-66 QUALITY CONTROL (Chill ChmllO 0. E. Dolin /s/ 2-1-66 CHEMICAL FORMULA Mixture MOL WT orsupersedes specs, 5-23-57 CHAR ACT ERISTIC RESTRICTED INFORMATION Appearance Boiling Point, C Ortho Terphenyl, 7. ^Meta Terphenyl, X Para Terphenyl, 7. Quaterphenyl, % Biphenyl, % Flash Point, C Chlorine, ppm Sulfur, ppm AMPLE FOR ANALYfll 2-1 Pint cans LIMIT* ISSUED BY J. A* Liddle 1-12-66 , METHOD Brown, waxy solid 350 Min. **10 **50 **26 **14 **0.1 **375 2.0 (Typical) 2.0 " G-l 064 064 064 072 064 114 Distribution of isomers and quaterphenyls vary with operating condition. Only limited data is available; therefore, the limits given are typical values of these characteristics. This product is mainly used as a raw material for other finished products produced at ^ 'nniston. This specification is for internal use only. ' DS\N 543280 WATER PCB-SD0000051293 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moody /a/ lr31-66 SALKS W. E. Ault /a/ 2-22-66 GENERAL DESCRIPTION MODUCT Santovax R PLANT MODUCT COOK Annlaton DATE EFFECTIVE 826.02 SALKS COOK 3-2-66___________ 7795-000-11-009 APPROVAL* RESEARCH use Sales IDCPT. 132 1 L. R. Stark /a/ 2-3-66 - M. MeEwen /a/ 2-22-66 QUALITY CONTROL (Chlel CfimJ.t) 0. E. Dolin /a/ 1-25-66 CHEMICAL FORMULA Mixed Terphenyla MOL RT. SUPERSEDES SPECS. OF 2-12-62 characteristic sample for analysis ! z 1 pint cans ' LIMITS ISSUKD IV J. A. Liddle 1-11-66 MKTHOO UNRESTRICTED INFORMATION (R) Appearance Yellow white noncrystalline flaked solid G-l (R) Color (liquid), NPA 4.0 Max. 128 (R) Upper Hold Point, *C 136 - 145 129 (R) Lower Hold, *C 48 - 63 129 RESTRICTED INFORMATION Distillation Range, *C, 80Z (Uncorrected) 350 - 400 Ortho terphenyl, X Meta terphenyl, X Fare terphenyl, X Quaterphenyls, X 10.0 - Typical Value 54.0 - " " 27.0 - " " 9.0 - " " (R) Routine Analysis, All others Analyzed by request Only DSW 543281 WATER PCB-SD0000051294 Monsanto ORU C m EMlC 4LW IV194014 MATERIAL CODE 826.38 PLANT . MATERIAL Chlorine Gas USING DEPTS, RAW MATERIAL SPECIFICATION PRODUCTION Anniston DATE EFFECTIVE 04, 05. 27 SUPPLIER 8-31-66 APPROVALS See below RESEARCH . R. G. Moody /s/R. G. Moody - 8/11/66 ' L. R. Stark /s/L. R. Stark - 8/29/66 PROCUREMENT .. . .... ~' .- QUALITY CONTROL fChia/ChamfvO H. L. Phillios /s/H. L. Phillips - 8/15/66 GENERAL DESCRIPTION . ; 0. E. Dolin /s/0. E. Dolin - 8/10/66___________ . CHEMICAL FORMULA Greenish yellow gas ' \ ^: . . . CI2 Mol. wt. 70.91 SUPERSEDES specs of Sept. 11, 1957 CHARACTERISTIC SAMPLE FOR ANALYSIS |GLC sampling container ' LIMITS ISSUED B V I J. A. Liddle - 5/16/66 Typical Values method UNRESTRICTED INFORMATION Material Supplied by Diamond Alkali Company Assay, (Vol. X) Residual Gaseis (Vol. 7.) Moisture, ppm Non-volatile Matter, ppm 99.4 Min 0.5 Max. 40 Max. 40 Max. 113 113 Material Supplied by Depts. 56, 51_ (Anniston) Assay (Vol. X) R2 (Vol. X) C02 (Vol. X) CO (Vol. X) N2 (Vol. X) 02 (Vol. X) - 85.5 - 93.5 113 1.5 - 2.5 113 (3 Max.) 0.5 - 1.0 113 Nil 113 3.0 - 8.0 113 1.2 - 3.0 113 (R) Routine Analyela, All other* AnmSyxed by requemt only. DSW 543282 WATER PCB-SD0000051295 Monsanto ORGANIC CHEMICALS DIVISION MATERIAL CODE 38800 PLANT MATERIAL Lime Hydrate USING DEPTS. CO OJ r*a CM RAW MATERIAL SPECIFICATION Anniston DATE EFFECTIVE 7-20-66 SUPPLIER Alabaster Lime Co. - PRODUCTION APPROVALS RESEARCH R. G. Moody /s/R. G. Moody 6/9/66 PROCUREMENT N. F. Mueller /s/N. F. Mueller 7/13/66 fQUALITY CONTROL Chief ChomlmO H. L. Phillips /s/H. L. Phillips 6/10/66 0. E. Dolin /s/O. E. Dolin 6/8/66 GENERAL DESCRIPTION CHEMICAL FORMULA White fine powder '* Ca(0H)2 SUPERSEDES SPECS OF Sept, 11, 1957 CHAR ACT ERISTIC UNRESTRICTED INFORMATION SAMPLE FOR ANALYSIS jZ - 1 lb. cans SXKEtX Typical Analysis Mol. wt. * 74.10 ISSUED BY J. A. Liddle 5/18/66 CaO (X) MgO (7.) sio2 (X) A1203 (7.) Fe203 (X) Ignition Loss (X) Ca(OH)2 (X Calculated) 73.00 1.20 0.36 0.60 0.30 24.04 97.50C1) Screen Analysis Through 200 mesh (7.) Through 325 mesh (X) 99.8 94 .'5 120 Basis of Specifications: Suppliers typical analysis of product (5/23/66) (1) Ca (OH)2 X = 1007. - [~mgO(X) + Si02 (X) + A1203 (X) + Fe^ (X>J (R) Povtire> Analyela, Alt ofhera Analyzed by requomt only. DSW 543283 WATER PCB-SD0000051296 Monsanto MATERIAL CODE 19400 PLANT MATERIAL Attapulgus Earth - RVM Grade USINC DEPT5. RAW MATERIAL SPECIFICATION Anniston DATE EFFECTIVE 7-20-66 27-L SUPPLIER Minerals & Chemicals Philipp Corp.. PRODUCTION APPROVALS RESEARCH R. G. Moody /s/R. G. Moody 6/9/66 PROCUREMENT . N. F. Mueller /s/N. F. Mueller 7/13/66 OUALIT V CONTROL (Chlot Clwnlat) H. L. Phillips /s/H. L-; Phillips 6/10/66______ 0. E. Dolin /s/0. E. Dolin 6/8/66 GENERAL DESCRIPTION CHEMICAL FORMULA Impure Hydrous Magnesium Aluminus Silicate SUPERSEDES SPECS OF Sent. 9. 1957 CHARACTERISTIC SAMPLE FOR ANALYSIS 1 lb. can LIMIT* UNRESTRICTED INFORMATION Screen Analysis Through 200 Mesh (X) 95 Min Loss on Ignition (X @ 950C) 15 Max Typical Analysis from Supplier (May 23, 1966) Si02 (X) 67.5 ai2o3 (X) Fe203 (X) 12.8 4.5 MgO (X) 11.1 CaO (X) 1.6 KjO (X) . 0.8 Na20 (X) 0.1 Ti02 (X) 0.6 Other (X) 1.0 ISSUED BY J. A. Liddle - 5/25/66 METHOD (R) Routine Anetyele, Ati other* An&lyred by retjueet only. DSW 543284 WATER PCB-SD0000051297 Efonsosnro Ciner/iiCAL C^iUirrr Wf ORGAWC CKStrCAJ.0 DIVIHON W. G. KRUMMRICH PLANT |pnODUCT CODE 33500 UCTHOD IDoMVIVY RAW MATERIAL 8PSG1FI6ATSOM . tUPPUElt MATERIAL FERRIC CHLORIDE ANHYDRIDE CHCi-JCAL rortiULA ISSUeDFeb. 26, 1957 bo 1laa u1 ntindnjor', **o kpi^'iuikjiii:r*> Krymrnr;:!) C,}; A 0? FeCl, SUPESSSEDCS SPECS. OK New SAUPUE FOR AN ALYL!! ____________1x8 oz. W, M. Bottle !43U UT. 162.21 UNCLASSIFIED INFORMATION . General Tests (made only on request) . ' Property . Specification J, F, Q. Method No. Appearance . Blade pov/der or granules . . . ' l6-A Assay : 97.0%, Min. . . 22-570 Sulfates ...... 0,05%, Max. 120-570 Ferrous Salts Trace, Max. S-570-1 Solubility: 10:10 of water ' ' 10:10 of Formula 30 . alcoliol ., Complete to . .. slightly turbid, Max. . . Complete to slightly turbid, . Max. . .. "' . . ' ' 112-B ' . .. .. . '. . . ' ' * DSW 543285 v.~~ WATER PCB-SD0000051298  STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX C - PHYSICAL CONSTANTS OF FINISHED GOODS, INTERMEDIATES. AND MAJOR RAW MATERIALS FINISHED GOODS RAW MATERIALS Aroclor 1221 - Not Available Biphenyl Aroclor 1232 - Not Available Santowax - Not Available Aroclor 1242 Santowax R - Not: Available Aroclor 1248 . Chlorine Aroclor 1254 Hydrated Lime Aroclor 1260 Attapulgus Earth-Not Avail. Aroclor 1262 Ferric Chloride Aroclor 1268 - Not Available Aroclor 2565 - Not Available Aroclor 4465 - Not Available Aroclor 5442 - Not Available Aroclor 5460 - Not Available DSW 543286 WATER PCB-SD0000051299 *10 Its k'- IH1 5 Csf P ad -T - 3 i3 ' j`*p o. - H 35 d* uic 5^2'>. S <-*J x* C-E> m (A II) V7 r* iCnD r* rr~* m. in -- esl r* m m 00 m if> in U1 m in u *o .n rt At i-n 'o' oo o' ID 2 Ur| oo 2Z rt mtr c m r>l s I m 3 m rx tn I TT in 0 1 m u <* in !* j** 3-^ a K CD. 5 in " <E 0 C %r c--* O m OM c u g & **D oo OD *r < d m V . in .; inr nin r lO *m O s O fl I o in H # m O <J, ; ol pCo ; ri 5 *^ * 2 - <<<*??* i < *< tfo i<*n<4. K*-. *n li O> Au** ZV r iI w* 2I* 2 JjrJ 7? ; `V<' * > io < j bo00w*i5n*- -'!-*!a! ^^O O)^ o 9fc. i1. #iSoo< " 2 I-1 of tt* S - z, * *?0 T<* 11H-Q. P &OOfM*` x . \ r. a - a uJ ---c'*I*t*l-<D*<D<"ilQd. ik/i: P H Y S IC A L C O N S T A N T S D A T A -C R U O E A RO C L O H. S 6 z6 z h00 CM CO O' m \ 5to o CD i (/) i=. iIrJ i ;* '<. : ,*i 5 < in l\ 2 11 V < Z! K0!1 ifl Z Z 2 < in IM \ * i/i < , rul i< in i-0 WATER PCB-SD0000051300 WO o 4^ 6 0 GO 2O t zz cn J=L H r v liW COWL 7AWrs i)ATA- k.->/A/t AP^CLOAS kc o -v/ ul O iA O a< S I )i S "i lA 3 5- w li u uo oi c+4 ; rsj *O ' o_j :l. < tr a O<n a ^ > u* * y- a> 3 ' zi 5 >t-; * * * 0 j a -f "***; h . i'^;t 5*?| |.S<0aiVJ i vnAwiCL j>^wii/-)o7 < o ._ d S W1 o a o o WATER PCB-SD0000051301 < __ ?l I 1w JA 2r-` 'J ' ? CSC * On S I ! ie L S i ;jl' " 9H. ii~ u"l 5_; --` U> * * n. s - -! =. -- - ^ 5 m O r. - rt S s*s 5j; I1-" c.u r^r* cZ J ^r 8i ii 0i m ri.*>r lj, Oj .i *i ? S* 0 o or 1 28: l III-'. I JJzl-S-f PC P > Si. I 3j 5ii-^jr~---a -* s ^ 111 rv. i|t55sf s5 $ < -s. toS^5iS3 = Z* t 0.0 \~ : -1 s; " r - * s ; Mcoo> CO to 5 to o l WATER PCB-SD0000051302 WATER PCB-SD0000051303  STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX D - UTILITIES The following is a list of utilities supplied to the Aroclor Department: Steam . Steam is supplied to the department through_a 6" main at 120 PSIG. Standard practice on steam is 0.213 M BTU/cwt. Liquid Aroclors, 0.432 M BTU/cwt. Solid Aroclors. Recovered Water Recovered water is supplied through a 6" main from a cooling tower. Standard practice is 909 gals/cwt. Liquid A.roclors, 1,437 gals/cwt. Solid Aroclors. Electricity Electrical power is supplied at 440 volts for power and 110 volts for lighting. Standard practice is 3.64 KWH/cwt. Liquid Aroclors, 8.38 KWH/cwt. Solid Aroclors. Natural Gas Natural gas is supplied through a 3" main at 40 psig^ Standard practice is 0.182 M BTU/cwt. Liquid Aroclors, 0.857 M BTU/cwt. Solid Aroclors. DSW 543291 WATER PCB-SD0000051304 STANDARD MANUFACTURING PROCESS FOR AROCLORS c APPENDIX E - PERSONNEL The Aroclor operations require one Chief Operator, Classification A-2, and four Operators, Classification A-4, per shift. The chief operator is in charge of all Aroclor operations during his shift. A relief chief operator relieves a regular chief operator one shift per week, and an operator four shifts per week. He also works for the regular chief operator during vacations, sickness, and other absences. Each operator is assigned a specific job and is respon sible for the operations of his job. There are nine (9) laborers, Classification A-8, employed in the Aroclor-Biphenyl group of departments. The laborers are normally assigned to day shift operations. Approximately 70% of all laborers' time is spent in Aroclor operations. The laborers' duties consists of filling drums, bags, crushing, screening, and milling of various products. They also clean tank cars. The Aroclor Department is supervised by a Production Supervisor and a Production Foreman. Attached is a Job Classification Schedule and Schedule of Hourly Wage Rates which also shows length of time required between auto c matic rate increases. The flaking, bagging, drumming and car loading operations are a serai-independent part of the Aroclor operations. The department is supervised by the Aroclor Production Supervisor and a Pro duction Foreman. Two chief operators. Classification A-2, operate the department and act as relief for each other. DSW 543292 WATER PCB-SD0000051305 JOB CLASSIFICATION SCHEDULE AND SCHEDULE OF HOURLY WAGE RATES AUTOMATIC RATE INCREASE GIVEN AT END OF: DSW 543293 JJ 4-1 JD r4 Q r; *0 CO CJ JJ CD o X > JJ CO CO CD sQ 00 CO o CM 3 o CO oo y Hs CO MT i-4 CO CO o r4 3 CO CM & 3 CO o \D & CO 00 *3- CO O ^5 3 CO CM V co CO <r CM 3 CO CHM po u CD 00 C o TD o e *H <U 43 JJ JJ U M CD CO QJ CD c=i JD CL JJ O M CO cl 00 vO r4 no C CD eo rl <r JJ < tA oX *>rt JJ JJ OC E jj CD orl 44 t-J c o M CO 0) GJ CD CO CL 44 CL 44 CL 0i TC--D1 <W Qa 00 Mr * co 00 CO CO CO 00 CO co 1 1 1 1 1 1 1 1 I 1 1 1 00 c 1-1 jj oc E jj u CD D Q C o t4 JJ o P o p CL < CO u oo CL p >> x> -o 0/ r--1 r4 rl Pl 1 1 1 1 u o uQ>JJ CD CL O VM JGfO-t a CM %'L snia a^B-g Xbq ln CM CO o <r CO CO CM 11 11 1 1 11 11 1 1 11 11 I 1 m CM 1 CO 1 o CM 1 CO 1 m r*4 1 CO 1 o1--1 I t CO 1--J w CO o 1 1 CO 1 1 1 1 1 1 1 1 1 l CO <r 1 c\m 1 CM CM . 60 CH CCTM\ XJ CM i--4 r. CM CO u DO OO cl p co * VO CM fo wO CM *o f--o4 r-t *rl <fsr CM vO 4 CM CM 1 1 1 V1 i c U o CD U H CD h) u o U o 6c0 i-l JJ JJ JJ Qt OCD CD Mu CD U a CL CL oo o <r r^. co CO e o i-l JJ CD O vJ 44 H r-A CD P cr H CD H U 0) CL CO 60 a *rJ > CD *C c* 0/ ,c CO o JJ CD U 60 C H O 60 O P o 44 44 O Po La CD JJ CD X3 Q> Po r-o4 CL B o o JD rO CD ys-N i-4 'w' WATER PCB-SD0000051306 STANDARD MANUFACTURING PROCESS ` FOR AROCLORS APPENDIX F - PACKAGING AND SHIPPING Solid Aroclors are packaged for shipment in 41 gallon Fibre drums, 40 gallon galvanized drums, 5 gallon gal vanized cans, and in paper bags. Liquid Aroclors are packaged in 55 gallon steel drums, and 5 gallon steel cans. These drums and cans are lined with two coats of B&V Series 46, #21971 clean Epoxy Phenolic lacquer. Liquid Aroclors are loaded into tank cars and trucks. Tank cars used for electrical grade material are either aluminum or zinc and tin lined. All trucks are stainless steel. Occasionally, non-electrical Aroclor is loaded into an iron car. All tank cars and trucks are entered, cleaned and inspected prior to loading. DSV\I 543294 WATER PCB-SD0000051307 APPENDIX I AROCLOR FINISHED GOODS CONTAINER WEIGHTS Material Weight Lbs. 1221 50 or 520 1232 50 or 550 1242 55 or 600 1248 55 or 600 1254 60 or 600 1260 60 or 600 1262 60 or 600 Inerteen 54201-A6 600 Therminol FR-0 60, 600, or 635 Therminol FR-Lo Temp. ' 55 or 600 Santicizer 794 600 Aroclor 1242-1248 55 or 600 Pyranol A13B3B 65, 360, or 675 Inerteen PPO 65, 360, or 674 Inerteen 54201-KA 674 Inerteen 70-30 674 Inerteen 54201-CM 600 Aroclor 1254 - 4465 650 Aroclor 1260-5% Toluene 60 or 600 Aroclor 1260-107. Toluene 60 or 600 Aroclor 1254-107. Toluene 600 Aroclor 1262-107. Toluene 60 or 600 Aroclor 1262-107. Xylene 60 or 600 Container 5 Gal. - 55 Gal. Steel Drum n11 II 11 nII 11 11 It It II ii 11 IT II ii It 11 II it It iiII II 55 Gal. Steel drum 5 Gal. - 55 Gal. steel drum M nII II 55 Gal. Steel Drum 5 Gal. - 55 Gal. steel drum 5 Gal. - 30 Gal. -55 Gal. steel drum tl II It 11 It II II 11 55 Gal. steel drum It II II It II It It It ft II 11 tl 5 Gal. - 55 Gal. steel drum It It it ti It II 55 Gal. steel drum 5 Gal. - 55 Gal. steel drum n it 11 11 it it DSW 543295 WATER PCB-SD0000051308 Material Aroclor 5442 Aroclor 4465 Aroclor 2565 KCS 295 Aroclor 5060 Aroclor 5460 Aroclor 1268 APPENDIX I AROCLOR FINISHED GOODS CONTAINER WEIGHTS PG. 2 Weight Lbs. 50 or 450 50,500, or 535 50 or 500 635 50 or 100 50 or 100 200 Container 5 Gal. - 40 Gal. Galv. drum 5 Gal. - 40 Gal. Ga lv. drum 55 Gal. Steel drum 5 Gal. - 40 Gal. Galv. drum 55 Gal. steel drum Paper Bags. Paper Bags 41 Gal. Fiber drums DSW 543296 WATER PCB-SD0000051309 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX G MATERIAL BALANCE Standard and Theoretical usages of rav; materials and hydrogen chloride produced for each Aroclor is shown in Figure 3. Figures 1 and 2 show the relationship between average number of chlorine atoms and per cent chlorine for Biphenyl and Santowax base Aroclors. Figure A gives molecular weights of the various Biphenyl base Aroclors. DS\N 543297 WATER PCB-SD0000051310 C n /-o j? i,v A 'n o // c u< T u S i X I r z i K i % ! WATER PCB-SD0000051311 c i z WATER PCB-SD0000051312 INCH . . tnt; FrtF.DCNICK I'OST CO.. CHICAGO. n \ . v"*" l a' A"T 1ft ' DSW 543300 L w vD O no ON CO m NO 00 H CM CO *o r-4 *4 t) co* H VO co CO NO m CO H CO CM \ % \\N t hs, H m ON o m o CO o to --i CM CM r> CO CO in <r tr CO CO JuZ c ! at P cO VO co<r CO r-4 CO O CO r*. r^. CM 60 O oO H CM O CO* O 00 o m H CM m M CO vO r^. r-4 h<- O UO ON r--i ON <r 6 coa CM CO <T m NO VO r^. ON vO On m VD >> w at *4oJ to ve4 mH vO <r cCoO o r-4 CO COMn ON mo r-4 v0D0 a1-->4 t--1 rs. cr--ot CO r-4 cCoM VD CO r-l CoO rvCMDO CM rmc--o4 CO fs. o - o CO m H r-f Oo iCnM <COr v%D3- r<Vu--ooO*4 Po JZ o poCJ oo CM o o <3* VD O O 00 o o VD ON oo CoO r-4 O o* o CM r-l oo C--Ml oo oo HvcOo oCO r-4 oo oo o CO M00T r--4 oo o CM r-4 oO o CM p o P CO o wOcCoO f--o1 ooP < w2 uoMp* TPQ3 TCC>O t4oJ TJ H pos P <au .0co u o t4oJ CXO 5o 4J cCO po01 to H 11 11 11 1r t1 1| 11 11 1t 1 11 1 1t OmN ON 11 l CM I ON 11 1 1 1 eCO 4 POGJJ* 05 *u0 XCO to 4oS-> 11 tccoo poV H 11 11 1 1 tON r-4 ooo s^- l-N. o o CM H CO co MT -ONT <r ON r-4 rr--vf r-4 IT)On r-l r--l r-4 o vD o MT o CM o r-l CO ac O>N CM -4 CO 1--1 N CM o o o o o ON ON CO MT Ct^O- h- CM mm CO oON NO CO O MT CM CO |1 C p o O CO oCL f-4 n o O corl PQ o VO n *--4 vO CO CO in r->. ON VD H On CO vD ON m CO rm <T <r Ocon co CO r^. CM CM CM 11 11 i i P o r--4 O r-4 CM CM CO <r o CM CO m uo CM o o o CM CO < <r m vD VD vO vD 'vO MT vO vD p CM CM CM CM CM CM CM CM in < i--4 r--4 r-l r-4 r--4 rH *--( r-4 CM <r o <r mm m WATER PCB-SD0000051313 ( c c WATER PCB-SD0000051314  STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX H - ATMOSPHERIC & STREAM DISCHARGE & WASTE DISPOSAL The following is an estimate of the atmospheric and stream discharge from the Aroclor operations at the maximum rate of 4,400,000 lbs/month Liquids and 950,000 lbs/month Solids. Chlorine HC1 (Gas) Montars ' Type Atmospheric Atmospheric Plant Dump Amount Negligible Negligible Approximately 10% of Total Aroclor Production 0S>N 543302 WATER PCB-SD0000051315 STANDARD MANUFACTURING PROCESS FOR c AROCLOR APPENDIX I - PROCESS CONTROL PROCEDURES Control samples are taken from the chlorinator circulating line at intervals throughout the chlorination. The samples are checked, by the operator, for specific gravity, soften ing point or hold point dependent upon the Aroclor being produced. Temperature readings are taken every hour and recorded on data sheet. A representative sample is taken of all distilled Aroclors and sent to the Analytical Laboratory for control tests prior to drumming, bagging, or loading into tank cars or trucks. The following control tests are performed by the Laboratory: Test (Liquid Aroclors) Anniston Analytical Method No. Specific Gravity 052 Moisture 047 Resistivity 122 r v Test (Solid Aroclors) Anniston Analytical Method No. Softening Point 115 Hold Point 119 Color 128 Solubility 117 A complete analysis is run by the laboratory on all final lot samples. DSW 543303 WATER PCB-SD0000051316 STANDARD MANUFACTURING PROCESS ` FOR AROCLOR ' APPENDIX J SAFETY & TOXICITY DATA AND ACCIDENT REPORTS Safety of operations in the Aroclor Plant depends on the individual operator. Materials being handled and operations must be observed closely to guard against the following: Cause and Action to Prevent 1. Chlorine Gas Chlorine gas is a very toxic corrosive gas. Leaks or high pressure can occur to liberate it. Action to Prevent a. Report Chlorine gas exposure immediately for treatment with Antidote. Milk may be used in mild cases to relieve throat irritation. Oxygen from the resuscitator in the Dispensary is available. b. Keep gas mask in good condition. Keep a good canister in the mask. Use these type masks only in chlorine concentrations to 2-3% chlorine in air. c. Use a Scott Air Pak in concentrations of chlorine gas above 37. in air. Three units are available in the AroclorBiphenyl Department. d. If caught in chlorine gas without a mask, hold your breath and go cross wind until you are out of range of the gas. Place a handkerchief over your nose in small quantities of chlorine. e. Report all chlorine leaks for repair immediately. Make temporary repairs with tape if possible. f. In case of a major chlorine leak, the source of chlorine gas must be stopped. Notify the Chlorine Plant immediately if the pressure on the chlorine manifold exceeds 30 psig. Cut off liquid chlorine from the car. 54^* OS'M WATER PCB-SD0000051317 APPENDIX J 2. Thermal Burns . 2. Cause and Action to Prevent Contact with hot uninsulated product lines ar the chlorinators and still areas. Contact with uninsulated steam lines and open steam. Contact with hot Aroclors from broken lines or leaks. Contact with open flames at stills or from heating lines in the department. Action to Prevent a. Know that contact with equipment and product will cause a thermal burn due to the high temperatures. Make changes in operations with this hazard in mind. b. Know the first aid treatment for bums. Cold Water Treatment attached. c. Wear gloves and long sleeve shirts with the sleeves rolled down when operating. Gloves and clothing can make the difference between first and second degree bums. d. Report uninsulated lines for repair of insulation. e. Use only steam lines with hose and hose clamps in good condition. f. The following operations are hazardous and should be done with care: (1) Catching samples at the Aroclor chlorinator circulating pumps. (2) Sampling the Solid Aroclor still receiver. (3) Drawing bottoms on the Aroclor stills. b WATER PCB-SD0000051318 APPENDIX J 3. Explosion A. Falls 3. Cause and Action to Prevent An explosion could occur in the chlorinators by slugging liquid chlorine to the distributor. Slugs of liquid chlorine could react fast enough to cause excessive pressure in the vessel. A rupture of the chlorinator could occur. Action to Prevent a. Observe operation of the chlorine vaporizer and do nt>t let liquid chlorine get into the rotameters. Pipe lines will be frosted. b. In case chlorine feed lines are frosted, close liquid chlorine feed valve to the vaporizer. Check steam addition to the vaporizer. Do not start up until source of trouble has been located. c. Observe temperature of the chlorinator periodically and be sure it is not too hot (180C. maximum). Slipping on cement floors, stairs, Aroclor on floor, ice conditions; tripping over objects (hose, pipe, valve handles, etc.); or losing footing on ladders, etc., can cause falls. Action to Prevent a. The majority of minor, serious, and near-miss injuries in the Aroclor Dept, are the result of falls. Prevention is always within the ability of the operator by use of expert operating practices. DSW 543306 WATER PCB-SD0000051319 APPENDIX J C 4. Cause and Action to Prevent 4. Falls (Contd.) b. The following items should be done: (1) Return hose to rack after using. (2) Keep operating areas clean of all foreign objects. (3) Return ladders to racks when not in use. (4) Keep gloves on and hands out of pockets, especially going up stairs. (5) Place guards around any area that presents a hazard that should be guarded. c. Poor lighting due to burned out bulbs should be corrected at once. Poor lighting due to inadequate facilities r should be reported. K. d. Spills must be cleaned up immediately following their occurrence. Report any spill that cannot be cleaned up within the shift to the Chief Operator. Spills are to be reported in the log book. 5. Fires Fires can occur by: Biphenyl, Santowax R, or Santowax C Ignition. Chlorine problems in the vaporizer allow ' ing reaction with steam to release hydrogen. Furnace burner backfire. Wood, rags, or paper on hot lines. Sparks from welding apparatus of open flames. r DSW 543307 WATER PCB-SD0000051320 APPENDIX J 5 5. Fires (Contd.) Cause and Action to Prevent Action to Prevent a. Area must be clear of trash or flammable materials. Use trash skips and cans. b. Smoke only in areas so designated. c. Use spark producing equipment only with a fire permit and proper in spection. d. Use care in lighting gas torch or the still furnaces. e. Fire fighting equipment includes: (1) Two wheeled dry powder units. (2) Hose house with 200 ft. of hose. (3) Two dry powder hand extinguishers, One CO2 hand extinguisher. (4) Two 3/4" water hoses. (5) Hose connection north of Santowax. (6) Scott Air Paks. (7) Fire truck in fire house. ' f. Observe visitors in the plant and be sure they observe safety rules. DSW 543308 WATER PCB-SD0000051321 APPENDIX J 6. Cause and Action to Prevent 6. The following is a list of chemicals handled in the Aroclor Plant operations and the precautions to be taken during their handling: a. Chlorine Gas This is a corrosive gas which is toxic. Leaks or back pressure can occur and liberate chlorine gas in the area. Operators should have their cartridge type respirators handy at all times while in the area. Use of gas masks is explained in Section 1. Chlorine Gas. If you are caught without a gas mask, and large amounts of chlorine gas are liberated, hold your breath and go cross wind until you are out or range of the gas. Once out of the area, obtain an emergency gas mask and return to the area and correct the trouble. A victim of chlorine gas fumes must be removed as quickly as possible from the gaseous area. Place patient on his back with head and back elevated. Milk may be used in mild cases as a relief from throat irritation. If the patient has stopped breathing, start artificial respiration immediately. b. Biphenyl Biphenyl is a flammable material which will bum. Burning should not be done in the presence of Biphenyl or Biphenyl vapors. The melting point is 68.7C., and the auto ignition temperature is 258C. Inhalation of Biphenyl fumes is not recommended, since it can cause a drugged effect on the person. c. Santowax R ' Santowax R is a flammable material which will bum. It is relatively non-toxic to human beings. However, the vapors of Santowax R are irritating to the mucous membranes and bronichial tract. Pro longed breathing of the vapors should be avoided. The melting point is 140C. DSW 543309 WATER PCB-SD0000051322 G r_ APPENDIX J 6. (Continued) d. Santowax C e. Ferric Chloride f. Attapulgus Earth f. Hydrated Lime h. Crude Aroclors i. Hydrogen Chlorine Gas j. Still Bottoms or Residue .Cause and Action to Prevent 7. Same as Santowax R, since it is the crude material prior to distillation. Ferric Chloride is a black-brown solid. It causes only slightly irritating effects on the skin or mucous membranes. When heated it will decompose and release toxic fumes of Chlorine. It will react with water to produce toxic and corrosive HC1 fumes. This material is a dried earth. No danger in handling. Wash off with water to clean. No particular hazard in handling this material. The dust is irritating to the eyes and skin, and should be washed off with water. Crude Aroclors are hot, since all are handled in steam traced or jacketed lines. They can easily cause thermal bums in contact with the skin. Prior to air blowing, the material has HC1 fumes entrained in it which are irritating to the skin or mucous membranes. This is a corrosive gas which is toxic. It is irritating to the mucous membranes, to the eyes, and to the respiratory tract. It will react with water to form Hydro chloric Acid. Fumes from still bottoms are toxic. They are extremely irritating to the mucous membranes, to the eyes, and respiratory tract. i. DSW 543310 WATER PCB-SD0000051323 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX K - BACKGROUND INFORMATION History of the Process in Monsanto In the years 1927 - 1928, the Swann Chemical Company developed a process for making diphenyl, but as the expected demand for it did not continue, other outlets were sought for the diphenyl. Aroclors were produced in the laboratory in 1928, and as they showed good electrical properties, fire resistance, and general inertness, the General Electric Company became interested, and developed the use of Aroclors in transformers and capacitors. Biphenyl production began on February 28, 1928; Aroclor production (3,000 lbs/day) started on December 16, 1928. In 1935 Monsanto acquired the Swann Company, so gaining access to their Aroclor patents. As the demand for Aroclors increased, additional production equipment was installed, located at the Monsanto Illinois factory (then Plant "B" and now called the Kruramrich Plant). This equipment came on stream in September 1936. The Krummrich plant site was chosen partly because of the availa bility of chlorine there, but when chlorine consumption overtook the production, and chlorine had to be purchased, proximity to the diphenyl production at Anniston had more weight, and additional capacity, largely designed on the plant "B" model, was installed at Anniston in 1941. By 1946 both plants had doubled their capacity, to give a total production capacity approaching 2 million pounds a month. About 1954, chlorine cells were installed at Anniston. The Newport plant was designed, mainly on Krummrich plant inform ation, but to a less extent on Anniston information, under Newport Project No. 12 of the London Central Engineering Department. Chlorination started at Newport in June 1951, Mr. Jack Clegom from Anniston spending some time at Newport to assist in starting the diphenyl and Aroclor plants there. - The first production of Pyranol by MCC was in 1936, when Pyranol 1488 was made for the General Electric Company, the blending being done at first in rail tanks. Pyranol 1495 was made in July 1938. Batch chlorinated Aroclors were made until November 1957 when continuous chlorinated Aroclors were first made in plant equipment. DSW 543311 WATER PCB-SD0000051324 Appendix K - Background Information Aroclors 2. Several test runs were made and sold to customers for evaluation. On February 14, 1961, continuous chlorinated Aroclor 1242 was made on a full time basis. Today Aroclor is made by both batch and continuous chlorination of Biphenyl and/or Santowax. In May 1965 an Aroclor expansion was completed to bring the capacity to 58 M pounds per year which includes 10 M pounds per year of Solid Aroclors. In the Fall of 1968, a new tank farm, car loading facilities, and automated drumming, bagging, and flaking facilities were added to the Aroclor department. . Aroclor Uses Monsanto Aroclors are used "as is" or in special formulations for the liquid coolant-insulation fluids in transformers and capaci tors . In capacitors, they provide for power factor correction in electric utility transmission lines. In fixed paper capacitors, Aroclors are the dielectric substance. These capacitors are used in home appliances such as air conditioners, furnaces, washers, and driers, in electric motors, and for ballast in fluorescent fixtures. General Electric, Westinghouse, and other producers of electric capacitors use Monsanto Aroclors in special formulations for the dielectric substance. Other important applications of both Liquid and Solid Aroclors in the electrical field are in wire and cable coatings and as impregnants for cotton and asbestos braided insulation. In addition, they are excellent dielectric sealants and are used to close the pores of carbon resistors and to seal electrical bushings and terminals. Aroclors are outstanding for use as the heat transfer liquids in indirect heating systems. Aroclor systems can transfer closely controllable, uniform heat to chemical process vessels, food cookers, potato chip and firto fryers, drying ovens, to heat corrugating rolls, crimping presses, and calenders in material processing, to heat treating metals such as Titanium and Vanadium, and to efficiently indirect heat distillation equipment. DSW 543312 WATER PCB-SD0000051325 APPENDIX K - Background Information Aroclors 3. It is interesting to note that as recently as 1941 only two methods of delivering process heat were known. Today non-pressurized, high temperature, fire resistant heat transfer systems based on Monsanto's Aroclor Liquids overcome practically all the deficiencies and draw backs of Direct-Firing and Pressurized Vapor Heating. Presently, there are numerous other uses for Liquid and Solid Aroclors and Aroclors in formulations. Only some of these uses are listed below: As the actuating medium in bellows controls, thermostats, industrial temperature control regulators, and other kinds of automation equipment. Liquid sealant for furnace roofs. Vacuum diffusion pump oil-pumps used to pull high vacuum for metalizing plastics, dehydrating foods, and medicinals. Dust entrapment-used to coat fibrous glass air filter pads, metal mesh, and other materials used for filtering air and gas streams. As a vapor suppressant to increase the kill life of insecticides. In waxes-waxes containing Aroclor are widely used in making dental castings, in the precision casting of aircraft parts, and for casting costume jewelry. In specialized lubricants, adhesives, ink formulation, caulking compounds, plastics, rubbers, paints, varnishes, and lacquer formulations. New uses for the various Aroclors are continually being developed. Continuous quality control, coupled with the unusual chemical and physical characteristics of the Aroclors, has resulted in wide spread customer acceptance and a limitless expansion of uses for them. 0^ WATER PCB-SD0000051326 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX K - BACKGROUND INFORMATION The following is an up-to-date (Aug. 1, 1968) bibliography of Research reports on Aroclors: Ashworth, G. W., Keller R. E. Development of Analytical Methods - 1960 Part 9 - Evaluation of General Electric's Improved Thermal Stability Test for Pyranols. Organic Research St. Louis No. 3033, January 1964 (On Aroclor 1242). Ashworth G. W. et al Analytical Chemistry and Spectroscopy Investigations1962 Part 2 - Special Studies. Organic Research St. Louis No. 3067 1/64 (On identification of Aroclors) Argo W. B., Knapp W. G., Gibbs M. E., Smull W. L. Heat Transfer Studies in a Fifty Gallon Glass-lined Jacketed Reactor. Organic Research St. Louis No. 2536 6/21/61 (On Aroclor 1248) Barkley L. B., Lippman A. E., Nufer H. L. 0-Phenyl-0-14-Nitrophenyl methylphosphonothioate. Ag. Research No. P2 6/15/61 (On Aroclor 1254 as a solvent) Bindbeutel A. J., Fowler L., Koerner W. E., Luebke H. W., Manno A. L., Trump W. N., Vogler C. E. Therminol Fluid Vapor Pressure . and Thermal Stability Instrument. Organic Research St. Louis No. 2961 7/6/63 (Aroclors and Aroclor 1232) Brooks. R. F., Koerner W. E., Spector M. B. IBM 704 Computer Program for Therminol Fluid Heat Transfer Coefficients. Organic Research St. Louis No. 2904 9/6/62 (On Aroclor 1242, 1248, 1254) Bucknell R. W., Campbell D. M. W. Building Manufacture of Santicizer 640. Organic Research St. Louis No. 2440'2/8/60 (On Aroclor 1260) Close H. J., Knapp U. G. Aroclor HDK-1 Pilot Plant Preparation. Organic Research St. Louis No. 3007 11/30/61 (On Aroclor HDK-1 and Aroclor 1132) . Cunningham E. P., Densmore D. W., Rinehart W. M. Evaluation of Chemical Modifiers for Asphalts. Organic Research No. 2529 1/4/60 (On Aroclor 1232) DSW 543314 WATER PCB-SD0000051327 APPENDIX K -2- Darby J. R., Touchette N. W., Wangler L. R. Application Work on Present Plasticizers - 1959. Organic Research St. Louis No. 2488 3/21/60 (Aroclors mentioned) Ellenburg G. M. Assistance to Sales and Development Departments on Aroclors, Biphenyl and Related Products. - 1954. Organic Research St. Louis No. 2420 1/8/60 (On Aroclor 1242, 1248, 1254, 1260, and 5460) Ellenburg. A. M. 1960 Minor Plant Investigations - Suitability of Biphenyl from Union Carbide as Raw Material for Aroclor Production. Organic Research St. Louis No. 3133 9/29/64 (On Aroclor 1148 and 1248) Ellenburg A. M. New Dielectrics - 1959 and 1960. Organic Research St. Louis No. 2737 2/22/61 (On Aroclors) Ellenburg A. M., Busch W. A. High Dielectric Constant Aroclor. Organic Research St. Louis No. 2676 12/27/60 (On Aroclor 1242) Ellenburg A. M., Merten H. L. Exploratory Fluorination Studies of Biphenyl Derivatives. Organic Research St. Louis No. 2455 4/19/60 (On Aroclor 1260) Ellenburg A. M., McHugh K- L. Manufacture of Aroclor HDK-1. Organic Research St. Louis No. P1090 12/28/60 (On Aroclor HDK-1) Erickson F. B., Sakornbut S. S. Paper Transparentizers - A Literature Survey. Organic Research St. Louis No. 2486 4/4/60 (On Aroclor 1260) Fallwell W. F., Raether L. 0. Final Report on Fire Retardents for Polyesters, Epoxies, Acrylics and Phenolics. Organic Research No. 2855 4/3/62 (On Aroclor 1260) Freeman R. C., Marco G.. J., Speziale A. J. The Preparation of Radio active CP 40294 (0-Phenyl-Cl4*-P-Nitrophenyl Methylphosphonothioate) Ag. Research No. 18 8/1/62 (On Aroclor 1242) Gaertner V. R., Schisla R. M. Chlorinated Diphenyl Ether Dielectrics. Central Research No. 1472 8/7/61 (On Aroclor 1242) WATER PCB-SD0000051328 APPENDIX K -3- Gebura S. E. Glycidyl Ethers and Polyethers of Bisphenol-A, Tetrachlorobisphenol-A and Hydrolyzed Aroclor 1262. Plastics Research Springfield No. 1413, 2/2/57 (On Aroclor 1262) " Graham P. R., Darby J. R., Wangler L. R. Study of Plasticizers in Plastisols Part II. Organic Research St. Louis No. 2648 11/14/60 (On Aroclor 1254) Hatton R. E., Cunningham E. P., Luebke H. W., Stark L. R. Functional Fluids Application Research. Organic Research St. Louis No. 2472 2/16/60 (On Aroclors) Hatton R. E., McEvan M., Sands T. P. Status Report on Synthetic Functional Fluids - 1950-66. Organic Development, Greve Coeur No. 1298 12/29/61 (On Aroclors) Knowles VI S., Smith T. C. Final Report on Preparation of Perfluorinated Compounds for Use as Functional Fluids Part I. Organic Research St. Louis No. 3176 3/25/65 (On Aroclor 1242 and 1268) Lancey R. C. Industrial Heat Transfer Fluids - A Market Study. (Organic Development Creve Coeur No. 1266 3/10/61 (On Aroclor 1248) Lancey R. C. Utilization of By-product Aroclots from the HDK-1 Process. Organic Development Creve Coeur No. 1263 12/7/60 (On Aroclor 1242, 1248, 1254, 1260, HDK-1, 1221.) McHugh K. L., Ellenburg A. M. Improved Aroclor 1242 Process Studies /Aroclor HDK-1/ Organic Research St. Louis No. 2755 3/6/61 (On Aroclor 1132, 1248, 1254, 1260, HDK-1) McHugh K. L., Sullivan J. D. MCS 177. Organic Research No. P1179 5/16/62 (On Aroclor 1134, 1234) McHugh K. L., Sullivan J. D. Tentative Process for MCS-177. Organic Research St. Louis No. P1234 3/12/63 (On Aroclor 1232) Mestdagh J. J. Flame Retardent Phenolic Phenolic Varnishes. Plastic Research Springfield Ho. 1581 10/14/60 (On Aroclor 5460) x Parks R. M. Polymerite File Market Study - Special Report. Organic Development Creve Coeur No. 1277 7/26/61 (On Aroclors) DSW 543316 WATER PCB-SD0000051329 APPENDIX K -4- Terpstra M. A. Hydrolyzed Aroclor 1268 /Alkaline - Methanol Hydrolysis/ . Organic Research St. Louis No. 2585 9/7/60 (On Aroclor 126S) Ellenburg A. M. Assistance to the Aroclor Production. Phosphorous Research SF 2084 Job No. 171-299 12/31/46 Ellenburg A. M., Felthara J. E., Richards H.B.,Jr. Aroclor 1142, Production, Increase in Chlorination Rate. Phosphorous Research SF 2790 Job No. 171-1028, 7/3/52 ' Ellenburg A. M. Aroclor 1154, Removal of Hydrogen Chloride from Waste Gases. Phosphorous Research An. SF 1978 Job No. 207 9/21/45 .I Ellenburg A. M., Simone R. A. Aroclor 1142 and 1154 prepn. from biphenyl by contin. chlorination. Organic Research SL Fin. 1530 Job No. 3040 6/4/56 . Metzner W. P., Becker T- H. Use of Standard Reactors for Making Aroclor 1160. Organic Research SL Fin. X-1491-IV Job No. 117-1491, IV 4/21/42 Ellenburg A. M., Cleveland T. H. Evaporation Loss of Aroclors. Phosphorous Research An. SF 2234 Job No. 451 7/14/48 Ellenburg A. M., Richards H.` B., Sears J. K. Aroclor 1221 and 1242, chlorination with DeNpra CL-air mixt. Phosphorous Research SF 2673 Job No. 171-790 12/10/51 Durgin C. B., Trementozzi Q. A. Specific Heats of Aroclors 1221 and 1232 Phosphorous Research SF 2083 1/17/47 Ellenburg A. M., Forbus F. C. Aroclor 1232, Brominated, Prepn. Phosphorous Research SF 2512 Job No. 171-628 9/13/50 Ellenburg A. M.,Good R. J., Wade W. W. The Effects of Prolonged Heat on the Electrical Properties of Aroclors. Job No. 171-616 12/7/50 Nellums R. O., Gruetzemacher E. C. Aroclors 1232 and 1248, as components of hydraulic fluids. Organic Research SL Fin. 1753 Job No. 3388 2/14/57 OS>N 643^7 WATER PCB-SD0000051330 APPENDIX K -5- Ellenburg A. M., Good R. J.; Richards H. B., Jr. Aroclor 1236, Dielectric Properties Phorphorous Research SF 2612 Job No. 171-615 5/21/51 ' Ellenburg A. M., Forbus F. C., Richards H. B., Jr. Aroclors 1236, 1238, and 1240 for General Electric Company. Phosphorous Research SF 2539 Job No. 171-609 12/11/50 Ellenburg A. M., Klaus I. S. Aroclor 1242, as heat transfer medium. Properties. Organic Research SL Fin 2252 Job No. 3371 3/11/59 Ellenburg A. M., Wade W. W. Aroclor 1242, Brominated, Prepn. Phosphorous Research SF 2419 Job No. 171-535 12/9/49 Ellenburg A. M., Richards H. B., Jr. Containers for Aroclor 1242. Phosphorous Research SF. 2523 Job No. 171-623 11/23/50 Ellenburg A. M., Richards H. B., Jr. Containters for Aroclor 1242. Phosphorous Research SF 2772 Job No. 171-719 Ellenburg A. M., Richards H. B., Jr. Aroclor 1242, 1254, and 1260,. distillation at 20-30mm. Hg. Phosphorous Research SF 2694 Job No. 171-1028 J2/15/52 Ellenburg A. M. Aroclor 1242, Electric Properties, Under Vacuum storage at 75 and 100C. Organic Research SL Fin. 1849 Job No. 2910 8/2/57 Metzner W. P., Behr L. C., Tyler L. D. Aroclor 1242, Formulation, for use .. as potential hydraulic fluid. Organic Research SL Fin. X-1332 Job No. 117-1332 10/21/42 Ruehrwein R. A., Pritchett T. R. Heat Content of Dowtherm A and the Aroclors. CR Sp. 687 - Job No. 4-8065, 4/18/52. Ellenburg A. M., Morgan J. F., Wade W. W. The Preparation of Aroclor 1244, 1242, 1248, 1254, and P1467 for the General Electric Company. Phosphorous Research SF 2362 Job No. 171-498 6/2/49 Keller R. E., Ashworth G. W. Aroclor 1242, High Chloride content, analy sis, Comparison of G. E., Westinghouse, and Monsanto Methods. Organic Research SL Fin. 2188 Job No. 3427 6/24/58 DSVJ 543318 WATER PCB-SD0000051331 APPENDIX K -6- Ellenburg A. M., Good R. J., Wade W. W. Aroclor 1242 and 1254, Effect of u.v. light on Electric Properties. Phosphorous Research SF 2500 Job No. 171-623 6/23/50 Ellenburg A. M. Aroclor 1242, 1248, and 1254, Density and Resistivity Studies. Organic Research SL Fin. 2420 Job No. 2681 1/8/60 Gaertner V. R., Weingarten H. I. Dielectric Liquids: Formation, Composition and Improvement of Aroclor 1242 and 1232. RE. Res. Da. Int 1318 Job No. 9442 1/29/60 Ellenburg A. M., Wade W. W. Aroclor-lithium stearate mixtures. Phosphorous Research SF 2496 Job No. 171-614 5/29/50 Ellenburg A. M., Wade W. W. Aroclor 1242, Mixture with Santodex, as hydraulic fluid. Phosphorous Research SF.2497 Job No. 171-530 12/5/49 Ellenburg A. M., Garrett L. C., Wade W. W. Aroclor 1242 and 1248 hydraulic fluid flammability tests for the Ford Motor Company. Phosphorous Research SF 2447 Job No. 171-614 2/4/50 Keller R. E., Koerner W. E., Brackbill C. H., Cecil 0. B., Livasy J., Williams W. D. Aroclor 1242, Mixts. with polymers, electrical properties of. Organic Research SL Fin. 2314 Job No. 3168 7/6/59 ! Ward D. W. Physical properties of the aroclors 1242, 1248, 1254, and 1260. CR Research Sp 597 Job Np. 4-6065 11/29/49 Ellenburg A.. Mi, Ashworth G. W., Merten H. L. Study of the Use of Ferric Chloride as Catalyst for the Production of Aroclor 1242. Organic Research SL Fin. 1842 Job No. 3368 7/12/57 Ellenburg A. M., Good R. J., Morgan J. F., Richards H. B., Jr. Utilization of Airco process for Aroclor production. Phosphorous Research SF 2642 Job No. 171-781 9/28/51 Ellenburg A. M., Wade W. W. Preliminary evaluation of anion exchange resins in the removal of inorganic chlorides from Aroclors. Phosphorous Research SF 2349 Job No. 171-535 4/21/49 ` Cleveland T. H., Gemcnihhardt P. G., Powers E. L., Sanguinetti P. A. Aroclor 1242, reaction medium for manufacturing of tolylenc diisocyanate. Phosphorous Research Int. 2943 Job. No. 171-1098 10/21/53 ^ WATER PCB-SD0000051332 APPENDIX K -7 Cleveland T. H., Machviart G. M. Aroclor 1242, reaction medium for phenyl isocyanate production. Phosphorous Research SF 2816 Job No. 171-1013 11/25/52 Saunders J. H., Gemeinhardt P. G., Llss R. L., Powers E. L'.r Aroclor 1242, reaction medium for tolylene diisocyanate. Phosphorous Research SF 2699 Job No. 171-720 2/20/52 Saunders J. H., Cleveland T. H. Aroclor 1242, reaction medium for tolylene diisocyanate. Phosphorous Research Fin. 2700 Job No. 171-743 2/22/52 Ellenburg A. M., Simone R. A. Resistivity Improvement.of 'Aroclor 1242. Organic Research SL Fin. 2096 Job No. 3203 6/6/58 Weddell D. S:. Aroclor 1242, rubber swelling by. Phosphorous Research Fin. 2082 Job No. 171-308 12/19/46 Cleveland T. H., Davis B. R., Flores Hector, Herndon A. B., Saunders J. H. Aroclor 1242, solvent in prepn. of m-tolylene diisocyanate.. Phosphorous Research Fin. 2547 Job No. 171-603 12/22/50 Ellenburg A. M., Merten H. Aroclor 1242 - Study of Unstable Product. Organic Research SL Fin. 1640 Job No. 3269 10/22/56 Ellenburg A. M., Good R. J., Richards H. B., Jr. Low Temperature dielectrics. Phosphorous Research Int. 2912 Job No. 171-1054 12/2/53 Ellenburg A. M-, Ashworth G. W., Merten H. L. 1. Aroclors (1242, 1254, 1260), chloride stability of, dependence on process variables. 2. Aroclor 1242, up-grading off-grade product. Organic Research SL Fin. 2072 Job No. 3428 5/4/58 Chadwick D. H., Duncan J. M-, Kaufman S., Koegle J. S., Llewellyn G. H., Reetz T. Aroclor 1242-tolylenediisocyanate, liquid-vapor equil. data. Organic Research An Fin. 880 Job No. 171-1101, 117-2669, VII 2/26/54 . Ellenburg A. M. Aroclor 1248 as a Heat Transfer Medium in a Lamont Forced Circulation Heater. Organic Research SL Fin. 1306.Job No. 2957 3/15/55 DSW 543320 WATER PCB-SD0000051333 APPENDIX K -8- Ellenburg A. M., Richards H. B., Jr. Aroclor in gases. Phosphorous Research SF 2325 Job No. 171-1089 : 10/16/53 Wallace P. P., Spring W. E. Insecticides plus Aroclors. Organic Research CC Fin. 965 Job No. 117-2542 4/14/54 Howard R. E., Hulette V. H., Vandeven P. Design and testing of a portable Aroclor heating unit. Organic Research SL Fin. 238 Job No. 117-2060, II. 8/1/48 ' Ellenburg A. M , Knight R. R. Treating contaminated Aroclor 1248. Phosphorous Research SF 2342 Job No. 171-451 3/25/49 Ellenburg A. M., Forbus F. C. Aroclor 1248 and Santodex - hydraulic fluid. Phosphorous Research SF 2529 Job No. 171-614 9/7/50 Ellenburg A. M., Morgan J. F. Pour point depressants for Aroclor 1248. Phosphorous Research SF 2396 Job No. 171-530 8/9/49 Hatton R. E., Sullivan J. D. Functional Fluids - Application Research (1956-1957). Organic Research SL Fin. 2176 Job No. 3132 10/14/58 Fordyce R. G. Arochlor 1254, as plasticizer for Cerex 226. CR Int. 397 Job No. 4004 10/15/45 Ellenburg A. M., Good R. J. Aroclor 1254, comparison \jith Fenclor. Phosphorous Research SF 2887 Job No. 171-1075 6/11/53 Ellenburg A. M., Good R. J. Aroclor 1254, comparison with Fenclor 54. Phosphorous Research SF 2527 Job No. 171-623 9/6/50 Ellenburg A. M. Galvanized plate drums versus galvanized hot dipped drums for Aroclor 1254. Phosphorous Research SF 2055 Job No. 171-297 7/18/46 Ellenburg A. M., Good R. J., Knight R. R., Wade W. W. Aroclor 1254 drum storage tests to check power factor change. Phosphorous Research SF 2421 Job No. 171-524 11/30/49 Ellenburg A. M., Richards H. B., Jr. Effect of exposure to mild steel on electrical properties of Aroclor 1254. Phosphorous Research SF 2771 Job No. 171-718 5/28/52 DSW 543321 WATER PCB-SD0000051334 Appendix K -9- Ellenburg A. M-, Knight R. R. Complaint of high power factor of Aroclor 1254. Phosphorous Research SF 2355 Job No. 171-524 5/13/49 Ellenburg A. M., Wade W. W. Corrosion inhibitor tests with Aroclor 1254. Phosphorous Research SF 2336 Job No. 171-530 3/17/49 Ellenburg A. M., Richards H._ B., Jr. Aroclor 1254, distillation at 20mm. Hg. Phosphorous Research SF 2689 Job NO. 171 1028 1/30/52 Nellums R. 0 ., Argo W. B. Aroclor 1254, heat transfer studies (Votator). Organic Research SL Fin. 1906 Job No. 2828 10/23/57 Ash J. R., D sniloff K. B., Dahn W. M. Preparation and Testing of an Emulsion of Chlorinated Rubber and Aroclor 1254. West Research SF 912 Project No. 13012-49-1002 3/28/49 Ellenburg A. M., Richards H. B., Jr. Phosphorous Research SF 2949 Job No. 171-1075 10/28/53 Ellenburg A. M., Sanguinetti P. A. Aroclor 1254, raixt. with Aroclor 4465, as waterproofing agent for electrical cables. Phosphorous Research Fin. 2027 Job No. 171-206 3/8/46 Ellenburg A. M., Richards H. B., Jr. Mixing Aroclor 1254 with secondary butyl acetate. Phosphorous Research SF 2788 Job No. 171 1029 6/25/52 Ellenburg A. M., Sanguinetti P. A. Aroclor 1254, mixt. with dibenzothiophene sulfone, dielectric constant. Phosphorous Research SF 2020 Job No. 171-243 2/8/46 Ellenburg A. M. Aroclor 1254, mixt. with trichlorobenzene, co efficient of expansion. Phosphorous Research SF 2964 Job No. 171-1075 1/18/54 Ruehrwein R. A., White W. A. Studies on light stability of electrical resistivity of Aroclor 1254. CR Sp. 543 Job No. 4-8065 1/11/49 Ellenburg A. M., Good R. J., Wade W. W. Power factor vs. resistivity of Aroclor 1254. Phosphorous Research SF 2458 Job No. 171-623 3/15/50 ' WATER PCB-SD0000051335 APPENDIX K -10- Mctzner W. P. Aroclor 1254, recovery from sample contaminated v7ith mineral oil dielectric. Organic Research SL Fin. X-1334-II Job No. 117-1334, II 4/23/42 Ellenburg A. M., Good R. J., Richards H. B., Jr. Line Material Company, Milwaukee, Wisconsin, complaint on Aroclor 1254 (Elemex). Phosphorous Research SF 2511 Job No. 171-614 9/12/50 Hubbard H. L., Mitoray J. P. Aroclor 1260, color of, investign. Organic Research SL Fin. 1570 Job No. 2319 7/1S/56 Ellenburg A. M., Merten H. L. Aroclor 1260, fluorination of. Organic Research SL Fin 2455 Job No. 3199 4/19/60 Ellenburg A. M., Knight R. R. Aroclor 1260, mixts. with tri-(2-ethelhexyl)- and trioctyl silicon fluorides, dielec, props. Phosphorous Research SF2376 Job Ho. 171-532 7/12/49 Ellenburg A. M., Richards H. B., Jr. Aroclor investigation on difference between Anniston and Krumrarich Aroclor 1260. Phosphorous Research SF 2881 Job No. 171-1088 5/6/53 Hubbard H. L., Brooks R. F. Aroclor 1260, viscosity and Refr. Index studies, comparison between Anniston and WGK. Organic Research SL Fin. 2118 Job No. 2602 7/16/58 Darby J. R., Cannon J. A. Aroclor 1262, as plasticizer for Saran, Evaln. Organic Research SL Fin. 2379 Job No. 3591, IV 10/26/59 Drumm M. F., Gebura S. E. Aroclor 1262, hydrolyzed, glycidyl ethers of. PI Res Spf Fin. 1413 Job No. 1845 2/2/57 Heliums. R. 0., Terpstra M. A.. Goss J. C., Lynch D. K. Pilot Plant Preparation of Hydrolyzed Aroclor No. 1262. Organic Research SL Fin. 1335 Job No. 3036 11/14/55 Ellenburg A. M.r Wade W. W. Aroclor 1268, hydrolysis to hexachlorodihydroxybiphenyl. Phosphorous Research SF 2317 qS\N 543323 WATER PCB-SD0000051336 APPENDIX K -11- Sharp D. B., Dazzl J., Gabbert J. D., LeBlanc J. R. Hydrolysis of Aroclor 1268 in Methanolic Sodium Hydroxide. RE Research Da Fin. 1061 Job Ho. 9411 7/11/57 Terpstra M. A. Hydrolyzed Aroclor 1268 (Alkaline-Methanol Hydrolysis). Organic Research SL Fin. 2585 Job No. 3502 9/7/60 Knapp W. G., Cooper R. L., Vandevcn P. Pilot Plant Preparation of Hydrolyzed Aroclor 1268. Organic Research SL Fin. 2334 Job No. 3899 8/17/59 Nellums R. 0., Terpstra M. A., Goss J. C., Lynch D. K. Pilot Plant Preparation of Hydrolyzed Aroclor No. 1268. Organic Research SL Fin. 1528 Job No. 3093 5/29/56 Adams J. F., Knapp W. G., Matthews R. L., Vandeven P. Pilot Plant Preparation of Hydrolyzed Aroclor 1268. Organic Research SL Fin. 2124 Job No. 3665 7/17/58 Gable C. L. Aroclor 1268, thiolysls product, as peptizing agent for rubber. Organic Research Ni SF 7649 Job No. 1550 7/8/57 Jenkins R. L., Metzner W. P. Aroclor 1269, solubility tests in various organic solvents. Organic Research SL Fin. X-1249-I & II Job Nos. 117-1249, I 1/30/40. (Pt. 3/20/40 (Pt. II) 1) Metzner W. P., Dobratz E. H. Aroclor 1270 from B-221-o. Organic Research SL Fin. 104 Job No. 117-1533 2/20/46 Lefforga J. W., Smith R. E. Impregnation of wood with Aroclor "4465" and "330". Phosphorous Research SF 2101 Job Ho. 171-398 3/17/47 Bogaard T. D., Saunders J. H., Slocombe R. J. Aroclor 5442, as plasticizer in residue from distn. of TDT. Phosphorous Research SF 2403 Job Ho. 171-523 9/21/49 Ellenburg A. M., Rueckert T. C. Muriatic Acid Tower Repairs. 5442. Phosphorous Research An SF 2140 Job No. 376 10/17/47 Gittings L. D-, Moose J. E. Aroclor 5460, adhesives from. Phosphorous Research Fin. 2054 Job No. 171-203, 171-298 7/11/46 oS>N WATER PCB-SD0000051337 APPENDIX K -12- Crenshav R. L., Ellenburg A. M., Morgan J. F., Wade W. W. Investigation of precipitate formation in organic solutions containing Aroclor 5460. Phosphorous Research SF 2492 Job No. 171-623 5/22/50 . Ellenburg A M., Richards H. B., Jr. Aroclor 5460 from Dow Tarophan D-25. Phosphorous Research SF 2883 Job No. 171-1077 5/12/53 Ellenburg A M., Wade W. W. Aroclor 5460, mixt. with Li stearate. Phosphorous Research SF 2496 Job No. 171-614 5/29/50 Ellenburg A M., Richards H. B., Jr. Aroclor 5460, soly, in mineral oil. Phosphorous Research SF 2949 Job No. 171-1075 10/28/53 Ellenburg A M. Solubility of Aroclor 5460. Phosphorous Research SF 2088 Job No. 171-397 2/6/47 Ellenburg A M., Morgan J. F., Wade W. W. The Solubility of Aroclor 5460 in Various Solvents. Phosphorous Research An SF 2272 Job Ho. 451 12/9/48 Ellenburg A M., Richards H. B., Jr. Preparation of a concentrated solution of Aroclor 5460 in xylene. Phosphorous Research SF 2960 Job No. 171-1075 10/28/53 Ellenburg A M. Investigation of decomposition in Aroclor still. Phosphorous Research SF 2046 Job No. 171-299 5/16/46 Metzner W. j Durland J. R. Aroclors, (1254 and 1260), odor improvement, study of. Organic Research SL Fin. X-1402-III Job No. 117-1402, III 12/5/40 Darby J. R., Allen W. G., Cannon J. A., Cowell E. E., Touchettc N. W., Wangler L. R. Aroclors 1262 and 1232, migration studies (1956). Organic Research SL Fin. 1730 Job No. 3129, III 1/22/57 Terpstra M. A., Lynch D. K. Hydrolyzed Aroclors 1262 and 1268 Sample Preparation. Organic Research SL Fin. 1706 Job No. 3038 1/8/57 DSW 543325 WATER PCB-SD0000051338 APPENDIX K -13- Bennctt G. E., Sharp D. B., Dazzi Joachim. Exploratory Aroclor Chemistry. Part I. Ethers by Alcohylysis. Hydrolyzed Aroclor Derivatives. RE Research Da Int. 1181 Job Nos. 4-9261, 4-9310, 9378; 8/1/58 Chadwick D. H., Ellenburg A. M., Marshall W. W. Alkylation of Aroclors for Evaluation as Extender Plasticizers. Organic Research SL Fin. 1184 Job No. 2682 (SL) 171-1042 (An) 1/17/55 Darby J. R., Cowell E. E. Application Work on Present Plasticizers 1953-54 - Flammability Studies with the SPI Tester Organic Research SL Fin. 1649 Job No. 2616, IV 11/20/56 Nielsen M. L. Aroclors, as glowproofcrs. CR Fin 572 Job No. 5-8064 7/19/49 Hatton R, E., Cunningham E. P., Luebke H. W., Stark L. R. Aroclors, as industrial fluid base stocks, evaln. Organic Research SL Fin. 2472 Job No. 3505, II 2/16/60 lletzner W. P., Durland J, R., Powers E., Lyles J.' M. General Electric Stability Test for Aroclors and trichloro benzene. Organic Research SL Fin. X-1436 Job Ho. 117-1436 4/17/42 .` Kyridcs L. P., Cravcr J. K. Compatibilities of Aroclors with Resins. Organic Research SL Fin. X-1362 Job No. 117-1362 6/4/40 Ellenburg A. M., Sears J. K. Exploratory Research Cyanogenation of Aroclors. Organic Research SL Fin. 1677 Job No. 2678 11/18/55 Ruehrwein R. A., Kenyon A. S., White W. A. Degradation of Aroclors. RE CR Da Int. 833 Job No. 4-4042 7/29/54 Ellenburg A. M., Richards H. B., Jr.. Aroclor in Gases. Phosphorous Research Int. 2892 Job No. 171-1089 6/17/53 OS'N WATER PCB-SD0000051339 APPENDIX K -14- Ellenburg, A. M. , R. A. Simone - Aroclors, dielectric properties. Organic Research SL Fin. 2305 - New Dielectrics - 1957 and 1958. Job No. 3316, 6/16/59. Sharp, D. B., Joachim Dazzl - Exploratory Aroclor Chemistry Part III. Glycidylation of Hydrolyzed Aroclors. Research'RE Da Int 1183, Job No. 9411, 10/9/58. Hubbard, E . H., F. R. Short - Determination of the oxlrane (o-epoxide) group by hydrochlorination in dioxane. RE CR Da Fin. 943. Job No. 9378, 1/30/56. Darby, J. R. , R. M. Parks - Preliminary Evaluation of Plasticizers - 1954. Part I: The Intensive Evaluation of Secondary Plasticizers Including the Aroclors. Org Res SL Fin. 1281. Job No. 2821, I, 5/16/55. Darby, J. R., W. G. Allen, J. A. Cannon, A. Y. Coran, P. R. Graham, L. R. Wangler. Org Res SL Fin. 1666. Job No. 2892, II, 10/28/56. Craver, J. K., J. Dazzi, J. A. Herbig, J. R. LeBlanc, J. Schwendemann. Synthesis and Application Studies on Hydrolyzed Aroclors and Derivatives. RE Res Da Fin. 1115. Job Nos. 9411, 9411-03-3, 9416-03-3, 12/30/57. Sharp, D. B., Joachim Dazzi, J. E. Katon. Exploratory Alcoholysis and Hydrolysis of Chlorinated Aromatics. RE Res Da, SF 1175. Job No. 9378, 9/9/55. Sharp, D. B., Joachim Dazzi, Exploratory Aroclor Chemistry, Part II. Diphenols by Hydrolysis. RE Res Da, Int. 1182. Job Nos. 9310, 9378, 9411, 5/13/58. DeGarmo, 0 , W. S. Dempsey, G. F. Ludvik, W. E. Spring. Insecticide Special Problems - Comparative Laboratory Evaluation of Niran, Niran and Benzil, and Niran and Aroclor 5460 Formulations (July 14 to October 12, 1955). Org Res SL Fin. 1382. Job No. 2760, 12/55. Metzner, W .P., J. R. Durland. Moisture in TCB and Pyranol Mixes. Org Res SL Fin. X-1508. Job No. 117-1508, 3/21/41. Sharp, D. B., Joachim Dazzi. Exploratory Aroclor Chemistry Part V. Nitrogen Derivatives by Ammonolysis. RE Res Da Int. 1177, Job No. 9411, 8/4/58. OS* 643311 WATER PCB-SD0000051340 APPENDIX K -15- El lenburg, A. M., P. A. Sanguinetti. Aroclors, operation of hydrogen Chloride absorpiton tower. Phos Res An Fin. 1979. Job No. 230, 6/14/45. Jenkins, R . L., W. P. Metzner. Aroclors, prepn. by chlorination of mixtures of diphenyl and high boilers. Org Res SL Fin X-1168-IV. Job No. 117-1168, IV, 10/7/40. Ellenburg, A. M., H. L. Merten. Continuous Chlorination of Aroclors Pilot Plant Demonstration. Org. Res. SL Fin. 2036. Job No. 3192, 5/7/58. Ellenburg. A. M., J. K. Sears. Aroclors, pyrolysis with HCN, lit. survey. Org Res SL Lit. 1246. Job No. 2680, 4/26/55. Darby, J. R., E. E. Cowell, P. R. Graham, R. M. Parks, P. W. Spink, L. R. Wangler. Org Res SL Fin 1523. Job No. 2595, 2563, 5/24/56. Aroclors, stabilizn. OS>N WATER PCB-SD0000051341 DSW 543329 WATER PCB-SD0000051342  STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX L - TIME CYCLES The continuous chlorinator operation, used for production of Crude Liquid Aroclors, consists of four cascade flow chlorinators in series. The maximum daily production from the continuous system is about 110,000 pounds. There are four batch operated liquid chlorinators and one batch operated solid chlorinator. See following table for time cycles and batch weights. The bottleneck in the production of Liquid Aroclors is the still system. The bottleneck in the production of Solid Aroclors is the chlorinator. DSW 543330 WATER PCB-SD0000051343 DSW 543331 c c p * o vO O m o CM o o m- H o CM CM Aa rH O n r*H cr CM IQ M 43 cn rH o mo CO CM o n* o u <r CO 00 o *n o A m ON vO ON rH i--4 * m vO o <r * m vO m CM * cn CO vO pHa r--4 rH o M w 3 CM 6 vO H HH < (Q 5o < vO H CO i-H o o m g r4 H M H PS Q CO sT oo rH H PS < CM <r r4 H oO m CM CO ON Aa m CO oo m vO mm a CM O o m a ON o o o A CO o o o A CO o o o * CO o o o a m o o o A cn O CM vO A O' CO - o in r*. * cn in n* cn a o o o o NO A OH o cn o a OH o o o A n* o vO m A m ocn cn A o o o o A m CM O o o A r*> CM 6 CM A CM CM O o m A o vO r-4 A r* o m cn A vO o vO vO A m o CO o A m B> M X vO H CO Vi 43 rH CO M 43 O CM CO Vi 43 00 rH CO Vi 42 r-A rH CO Vi 43 cn rH CO Vi 43 o rH CO U 42 - OH o iH o CM o H* H cn oo om vO rs* AA rH cn a Vi .C vO x: -o co CO at -h o J a) X2 V Vi O 43 O ad vi Vi 4J CO VJ a vi t4 a> 3U i-3 mo PQ q <n u g o e 3CO CO H X X *-i -o 1om B cr od C >N o OB T* X a) 0> -r4 m tH > 'O xQ H 0) c > X u 14 o X -U X Pi o H M 00 0) o o o -rl 3 o w O Vi X oy O Vl x: u u M 9 o Vi 00 T3 V h U r4 <0 o. a p a. u cr o C. t-l p O. B VI od x: j3 aH C0 to D. J3 a> Vi a. ai c O. t-l O < y u pa CO CO < ij ad 04 < y < H U ffl CO u o rH O O Vi < o H rH O CO K WATER PCB-SD0000051344 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX H QUALITY CONSIDERATIONS . Aroclors for electrical equipment uses must be highly pure with only slight traces of contaminants. Two to three drops of sweat contain enough salt to reject a drum of Aroclor on chlorides. They must be chemically stable and non-corrosive to a side variety of structural materials. Obviously, continuous quality control must be maintained during manufacture, packaging, and shipping to assure that the customer is always satisfied with the performance of our Aroclors. Normal power factor correcting capacitors used in air conditioners contain about ten cents worth of Aroclor. If the capacitor should explode and cause a fire, damage as high as $20,000 could result. These capacitors are designed for 12 to 20 year's life. Quality ingredients, such as Anniston Aroclor, must be used to guarantee this life as there is no non-destructive procedure for pre-determining this life. This vividly illustrates the "mush rooming" damage and the major reason for such intense desire for quality products by our customers. Each sales lot of Aroclor is analyzed prior to shipment. Pre liminary samples are analyzed prior to loading in cars, trucks, and/or drums. The specs to be met are given in greater detail in Appendix B. Each Aroclor tank car is thoroughly cleaned before filling to prevent contamination by material left in the car by the customer. Examples of the quality control charts kept by the Laboratory are included in this appendix. The charts are for Aroclors 1242 and 5460 (our heaviest demand products). All electric grade Aroclors have control charts that are monitored by the Laboratory, Quality Control Board, and Production. These charts are used to spot trends which would eventually lead to poor quality Aroclor. Besides showing maximum and/or minimum specs on each property, the averages and two sigma values are shown which make it relatively easy to spot both good and bad trends. Production is responsible for knowing the cause and corrective measures to be taken for any trends toward poorer quality Aroclors. Export lots of Aroclors 1242 and 1254 must meet additional specs of higher resistivities and lower biphenyl content. Aroclor Property Spec. 1242 I . Biphenyl :' . Resistivity 0.05 % max. 5,000 giga ohm cm min. 1254 Biphenyl Resistivity 0.025% max. 5,000 giga ohm cm min. DSW 543332 WATER PCB-SD0000051345 WATER PCB-SD0000051346 WATER PCB-SD0000051347 WATER PCB-SD0000051348 WATER PCB-SD0000051349 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX N - MISCELLANEOUS DSW 543337 WATER PCB-SD0000051350