Document mmXgeGX2JgoBENRm5j48d7ovQ

N r E R OFFICE V E V O To W. F. Gabel at Piscataway From p. M. Reed at Piscataway Inital Testing for EPA Rule Date March 26, 1976 Copy tToO R. A. Lojewski G. I. Rozand R. C. Coldiron J. T. Sweeney P. Scarito The proposed EPA regulation will require modification of operat ing procedures and existing plant equipment in addition to in stallation of new equipment. Analytical Service and Process Engineering studied the plants in light of the proposed rule and learning curve techniques. From these studies a sampling plan was developed which should define our process problems with a minimum of analytical work. Analytical service will place six (6) employees on 60 hour/week of scheduled work for approximately 5 weeks to do the majority of the testing. Mr. F.W. Kanzler will directly supervise their effort. In addition, the operating de partment and process engineering will be requested to obtain the majority of the samples. In the attachments, the hand written list of water streams requiring analysis at Burlington are pre sented. Utilizing this information and the overall requirements found in Table (I), Mr. F.W. Kanzler has estimated man power re quirements, which will be found in Table (III). This plan will lead to a reduction of plant analytical service to the minimum. Mr. Kanzler is expected to spend 50 to 75 per cent of his time on the project for the 5 weeks and Mr. Lojewski will supplement him as needed. During the time of the project, no_tiine_will be available to do extra Vuyl m air samples and no extra slurry samples will be taking except as part of the program. The cur rent analysis required by~0SHA regulations and the-VCM in resin programs will remain at the present level at both plants. Analytical Service will employ our standard analytical techniques to the samples taken. These methods provide reliable data from which valid engineering calculations can be made. In addition, an internal Analytical Service project has been developed to evaluate the proposed EPA procedures. The first "Method 106 Determination of Vinyl Chloride from Stationary Sources" will be evaluated by Mr. R.J. Young, since the Pasadena Plant is the only site having sample points in stacks suitable for this method. All other sites will be required to install suitable sample points as specified by the EPA on all stacks discharging to the atmosphere when the rule goes into effect. Evaluation of "Method 107 - Determination of Vinyl Chloride content of inprocess wastewater samples, and vinyl chloride content of Poly vinyl Chloride Resin, Slurry, wet cake, and Latex.Samples" will be made by Messers. P.M. Reed and R.A. Lojewski with the aid COLOR!TE 017326 INITIAL TESTING FOR EPA RULE 2 of R&D's analytical service at Piscataway. After the evaluation of the data gathered, a limited sample scheme will be applied to streams at Flemington, Process /"i Engineering will establish conditions which should allow us to be at known VCM levels based on Burlington's data. If the analysis confirms these levels, engineering can procede to design appropriate equipment. If the data does not con firm the calculated values the process will be reexamined and additional testing will be required. It is anticipated that the program will be implemented during the week of April 5, 1976. The cost of this approach will be approximately $900.00 per week above our current labor cost. Assuming the project can be completed in five weeks, the total labor cost will be $4,500. If recipients of this pro gram can see deficiencies in the plan they are requested to so notify me. PMR:km P. M. Reed COLORITE 017327 TABLE I INITIAL TESTING FOR PROPOSED EPA RULE BURLINGTON PLANT I. Reactor Openings A. Refinement of Evacuation Techniques 1. Suspension Plants - Homopolymer and Copolymer 20 openings - Z& samples/opening Completion 4/1/76 2. Dispersion 20 openings - top and bottom samples Completion 4/15/76 II. stripper Vapor Samples - After Transfer Completion A. Homopolymer 5 Vapor samples regardless of resin type Completion 4/15/76 B. Copolymer 5 Vapor samples regardless of resin type Completion 4/15/76 III. Slurry Evaluation A. Homopolymer 1. Refine stripping technique T-175 4 Samples 2. Slurry Analysis Completion 6/1/76 20 Samples each type = 120 (60) Completion 6/1/76 B. Copolymer Type Number of Samples T-314 T-315 T-390 T-391 T-392 5 20 20 20 5 = 70 Total Completion 6/1/76 1 COLORITE 017328 2 III. C. Dispersion X 1. Be-afrM-ftgfeon Plant only 25 samples/week - 5 days for 3 weeks 2. AR-901 10 samples Completion 5/1/76 Completion 6/1/76 IV. Waste Water 4= A. Total 61 streams - 3 samples/stream $ B. (17) pump streams (Total) 25 Sump or discharge streams ( o i AC MV \ Completion 6/1/76 RetfO s Special Sampling Procedures to be developed 1 - Fume Scrubber 2. Barometric Condenser - Homopolymer not installed 3. Condensate from stripper - Copolymer 3 samples of the above each FLEMINGTON PLANT I. Reactor Openings A. Refinement of Evaluation Techniques Confirmation of proposed method. 10 openings - 3 samples/opening Completion 4/30/76 B. Stripping Vapor Samples - after transfer completion 5 vapor samples Completion 4/30/76 0 W^ -v 1 , COLORITE 017329 -- /j o-AstJL. ^Jj. ^At^oiXii u . ' >-n..uny/f ; .->.^3C , M~tzZi^ ------- ._______________________ . i>A*-y-n*XA. $JCsCaT\ _ . /V<? 7~> ,* X) e-tCJX - 0-^-LA-^-tr%V-*Q . _ hi ya X^aMa ---*.------------------------------:'...- .. &b*t.. hrf~2i*4 aTq o ..._______ S s^/." jTij -^`'7. X4-ciA-i^i^ '/>UX_hrWJO , 4T?xcJla*>4J/{. ^^vVtrV^vt^w{ ~-------- --------- -- ------'------------- - - *^7 ~k^s&\ >&4ULjrr<jtk^ ^MCyZ-fzJA (^Cr^cLc^cuA 2' t____ , ,s/j%*-U. _d_-_C_r_v_v_ - ' t ' *-----" ` * . / '-_J4&l2Lt,LC^XvJyt^j . -- .yJ , jr_ 5^1l *^- * - \r / ^.O, (P&-H mf &uleis<*y S,*r jG Lrl tf4<ww ----^ y2. *"^ yotZyt. ><0. pc$ esA lr ^ . '".^. yvc*v .e*l/LCw*1 -\ y^ *qT-^A. G0TM~J4AMrfri y2 ^/oT^C, cllSTfrvitA QLAjU'JZ dlkCU*A 3 S:/?r* *S - (ftiLcevu/tt^, $2x^-0 d^A-***. -^y^-- -: ls^~*ot***/L - Jf^O, /^cJh eb Aivt ' .( _ 1*J f /* 1 OVLa*~\ . 2 ^Aw\j ___ ` /^x. C^^i^t/iA tri oL a**~v ... . } * 'r"-- 2M *<)Xi^yL- cAo /^-t-C .^iJL^Ji, _ s <T ' / / xO/a- p /-# / "/ 3_ C*-f* K O^ ^4 .< . ^ j A',Q. pe&.cUo*"* ^ *X ~ $}^gy~MA Jb^-^A. / -^1 oT*^ C J *5 * XiXa aj . Q - y3 /* - . ' ?VViS-*vv. . t * COLORITE 017330 tzp, ^---------------------------- _ / ' . -- 5^^- .. (- f^C<iX}>^ ... ... ------------------------------------------------i--:------ ._ . ... V'' ./fJT.sQlfe^As *C>0. f ------------------- - --" * *------ \- -*-..* ** ` JZ/'e* sqTZja.. /C. /ic^y -clux^i---------------- ------------ -`---"Vr'-.-- 'f / f O~ /2 6-*~yaAjw3w ch<z~Z, ^A*vv------ l. / ^ 2, -pJF~ -- ------ -----:- ,/^.Q, *h#r~vt_._ _.- \-J? sqTZjX, dstytsu^yl ,^t MS.-~~ /Q-Ctn^J^t. /*^C .......... ~ ' **6~<?Cc*Ctrv***^. /C*.0. ft# <?U C. ^ _ _ __ _ `/'sT/o7ZpJL A'.fl. .potf >4 .... pO^T, 6&- ____ 1.__ ____ I joTsyUr - &&*~y2AA4&0l 2. ^ /ofeju,. C<r*yMJL&0 n _ c>U <t*vv ,-- ---- > 7 /3Jcr<Ar-'.~Do^Lrn $ba&u*ja .-............... ...............- - '....................... - - -- . - v/^ V . v5" /<#--J^J .*:o. .ff t / /cjO~^ - - - --- -- -- - 4- * *- ............- -- -r -- ... / ,` - -- - -: - ;7~; --................ *_ -'-- .......... - ; ^p MP? 7^;^VtA+'-'l- .- COLOR!TE 017331 Jt /2/vf o {7?rrfAj-y1 ^) ------------------------- ^y'J? KC (/2co* >wcv^-v .^2e-ciw^^ */ . ^o. .yn(r*o - /QsC&Am cImuaa / t-o^- JCi.0. j_p*+\ h-... &U ; ^1er^*A. - /flO. 7%^ lt_~. ,v COLORITE 017332 EPA Rule Ho. 61.65(b)(g)(i) 61.64 (a)(1) 61.64 (c) E^A ; \)G" E1JGIN3EF iMG \ 7- I j AREA A BEACT07. 1, Exactor '..'ash Uater ar.-'feeks Compliance Expected '* cess EngNovember! SCOPE STATUS Yes (Present Systa/j) A closed collection system for the reactor wrsh 'later blcwdovu will be required If closed reactor operatic:. is im;lemented. Closed reactor testing required: OC coating devices - July 1, 1976. Closed reactor testing - July 15. 2. Re.ictor Evacuation System 6 No A carbon adsorption system will be required leactor vapor sampling program on the evacuaticn pump discharge. teing repeated after discovery of leak, problem in #4, 3. Wet Slurry Screens Jj Yes Modifications to wet screens are required. Oversize overflow collection system design required August 1, 1976. 61.64(e)(1)(H) B. RESIN STRIPPING 1, Slurry Yanks 61.64 (b) 2. Carbon Adsorber 9 u. 65 (b) (g) (i) 3. Carbon Adsorber Blowdowns Yes Yes No Stripping compliance data to be collected. Round the clock sampling o slurry tanks required. Stripping data to be completed by J une 30. Determine capacity and scale up requirements for expansion. Regeneration requirements still undefined as a result of unexpected high toluene levels. A closed collection system is required. CAR to he written July 1, 1976. COLORITE 017333 EPA PROGRAM- ENGINEERING (cont'd) EPA RULE No. 61.65(b) (g)(i> Man-Weeks Compliance Expected AREA C. RECOVERY Process Eng. November 1 SCOPR 1. Recovery Area Blowdowns Ha No A closed collection system for the recovery area blowdown is required. 61.65(b)(g)(1) 2. Caustic Scrubber Blowdown h Yes Blowdown to the caustic wash column as makeup is proposed. 2 STATES Collection system designed. CAR to be written July 30. Effect of blowdown solids on caustic wash column being evaluated. Aug. 1 61.65(b)(g)(i) 3, Wash Column 6 61.65(b) (g)(1) 4. Caustic Wash Column Blowdown 1% 61.65(b) (6) (i) 5. Heavy Ends 2h No A closed collection system for the wash 1 Complete. column and filter blowdown is rf'uired. Reactor discharge valve ramping adjustments required. No A system for separation and recovery of A stripping column design is the VCM, toluene and caustic Is required. under evaluation. Aug. 1 No Disposal of the heavy ends by various Incineration disposal to be means must be Investigated. tested. August 1. 61.65(b) (6) (li) 61.65(b)(g)(1) 6. Vessel Clearing System 1 61.65(b) (g)(1) 61.65(b) (l)(i) 61.65(b)(5) D. LOADING 1. VCM Transfer Pump Seal Water 1 2. Loading Hoses/Sight Glass Blowdowns ih 3. Tank Car Purging 2 No A collection system la required for the Collection system design water used to displace VCM vapors (to underway. July 1. gaa bolder) In vessels being cleaned. No A cSHpPPputection system will be required Alternates being evaluated. July 15. No A closed vapor collection/treatment system is required. Alternates being evaluated. July 15, No A closed vapor collection/treatment system le required. Alternates being evaluated. July 15. COLORITE 017334 EPA PROGRAM - ENGINEERING (cont'd) 3 EPA RULE No. AREA E. MISCELLANEOUS Man-Weeks Compliance Expected Process Eng. November 1SCOPE STATUS 61.65(b)(g)(ii) Water Stream Stripping 7% 61.65(b)(6) Sample Bomb Purgings 1 No Tea Evaluation and design of surge tank and stripper for all contaminated water streams Is require.. Batch versus continuous and steam vs. nitrogen stripping will be evaluated. R&D testing underway. August 1. Purging of sample bombs containing high VCM Purging system design levels will be to the gas holder. underway July 15. COLOR!TE 017335 6/18/76 PASADENA PVC PLANT ENGINEERING CONSIDERATICTS OSHA VCM COMPLIANCE REACTOR AREA Use hydraulic cleaning devices In reactors to reduce frequency of opening between batches Use 0C nozzles In reactors to reduce frequency of opening reactors between batches SCOPE Operational testing required, Additional operational testing required Breathing Air Req'd April 1 TIMING Testing completion target July 15, 1976. Testing completion target July 1, 1976. 4. Install activated carbon adsorption unit to reduce VCM from slurry tank and vent condenser below 10 ppm 5. Carbon Adsorber Blowdowns 6. Wet screen and wet screen overflow collection drums Regeneration equipment modifications may be necessary to achieve less than 10 ppm VCM consistently. No A closed collection Bysten for the liquid blowdowns at the carbon adsorber area is being designed. Modifications to wet screens are required. Alternate collection drum contaminant/disposal methods required. Tests are being QMljMbt'tf to determine whether alternate equipment ttf/jg/ggg&d to replace the wet screens altogether. Yes Yea Regeneration modifications are 952 complete. Operational testing completion target August 1, 1976. CAR to be complete July 1, 1976. August 1 completion target. COLORITE 017336 8. Reactor Wash Water 9. Evacuation Pump Discharge A closed collection system for the reactor wash water blowdowns is being evaluated. Yes Extensions Ptno --th--eJ --Jevac-u-pai-t-ion pum* p dls :harge stacks are being Evaluation completion target July 15, 1976. Evaluation completion target COLORITE 0X7337 PASADENA PVC PLANT ENGINEERING CCtvSIDERATIONS OSHA VCM COMPLIANCE (cont'd) DRYER AREA 2. lecre.-te Dryer Stack Height KBCOVERY AREA 1. Recovery Area Blowdown 2. Caustic Scrubber Blowdown 3. Wash Column Backwash Frequency LOADING AREA 1 SCOPE Breathing Air Req'd April 1 TIMING Additional area sampling necessary to define stack extension requirements. Yes Evaluation complete. No exposure problem found. A closed collection system for the recovery area blowdown is required. Laboratory testing is required on a system that has been hstalled to blowdown the caustic/alumina scrubber water into the caustic wash column as makeup rather than to the sewer. Smaller mesh filter elements are being tested on the wash column water circulation system to reduce column backwash frequency i.e., VCM discharge rate into the REW pond. Yes Yes CAR to be complete July 1976. h Operational target August 1, 1976. Yes Complete. A closed Bystem for collectli|i$j|i| VCM transfer pump seal flush water will be reqdMWR A permanent vapor gathering/treatment system will be designed. Yes Engineering completion target July 15, 1976. lilt! Flemlngton -r /-t -u ISSUED BY; lob io. DESCRIPTION Tenneco Chemicals, Inc, MANDAYS A. Original B. Revised C. Total To-Date EROC___ IpRfi.T: PRIORITY TYPE EST. REQUESTED Z COMPLETE ORIGINAL ISSUE' DATE ESTIMATED COMPLETION DATE PROCESS DESIGN PROJECT INVESTIGATION. RELEASED TO PROJ. ENGj THE REQUIRED s B ; 1 April <Jfl H May Jun^ V ? ' PROJECT T.SVrMATF. OTPDAE COMPLETE/KEPT.ISSUED O ESTIMATED ' ! ACTUAL i( A 0 0 r July Augus t sept. Oct, Nov, De c . Centrifuge Overload k/A A-8 2 C <to <l(lS 4 a; O 552 A, L. Rees Noise Level Control 565 A.- F. Holmes VAC Tank Overfill Protect. 599 < bJA. A- 5 2 C._ IOO io/ts a(ig A ! 2 3 ID 6 e DC ) F C Af 1 Af Pi 2C vt 1C 3-7 b -- ---- --r . I 1 if> 1L _ Reactor Press 600 A, L. Rees U A- 1 IOO 2-lb 3-7b A Zt } > at 'C > jp i :a A P >c v/t :C > Reactor Ventilation 602 I, A, Rumberg Double Mechanical Seals A-'? FajJte M A A-iO tA z-nc. 4-lb A 1 c 30 2-7b 7_7> A D: ' A0 jI ! COLORITE 017383 I. A. Rumberg * Thiostop System 606 A. L. Rees Vessel Ooenines 1003 E. Schvartz/I. A. Rumberg Watet Drain/Vapor Recovery 1005 E. Schwartz Utilities Review 1007 A. F. Holmes Pilot Plan EPA Compliance 1012 J. P. Sands ted t NO :i ! i i epA 2- 2 2 z Kl A- A_q_ z CJ too 31b 4-lb A. u T D C E D' F DC dA-AZ 1 c o 3'7> q-i<b A ' X P 5Dou6v*C EPA1 rt i i- h 5/ '3 'i AHO A-33 1 c o 3-1b S-7G A ^ XPV OCWGW6^ EPA 80 54 c A IE i m M XI t: Af 3 4 'l O f 2. d 41 U A. A-40 1 c '( o 3-7fc q-ib A EPA 2 8i D IO O O A-tO 1 C o 3-7fo 7-lb A jo jna \k/M EPA- 33 22 L l ______ 1___ ___ .......| ii 1 COLORITE 017338 PASADENA ^felANT ENGINEER I mBRjN SID ERAT IONS OSHA VCM COMPLIANCE (cont'd) MISCELLANEOUS 1. Breathing Air System 2. Sample Bomb Purging I 6/18/76 SCOPE Breathing Air Req'd April 1 TIMING Extension of the breathing air headers to all plant areas la required. Specific locations have been defined and the distribution system is being designed. Purging of sample bombs containing high concentrations of will be routed to the gas holder. A purge gathering system is being designed. Complete.. Tes CAR to be complete July 15, 1976. C C Att- t/Cj/J//CM cCrfd /J. s/iA-Wc 2 <2/J^)/_Xs</a) (irki/t . c. /Co f*sc\ tC tlfLtfi'/tiX, Cye'Sl >j/0C tU.UL o -"lL<~<-u_ ioaettafayt* a-- LL-he/Uh C. -/oL?tf~ `^'U-C^S* itiJ-lAti. (f / j7^t2Z/y>`V* 61 ?*tz 6,&V) 3 J/tZ //cV y Ad s jy? a&f &'$COU.' O'ZcT' X^fO cl^c<^j^>/ctcct Otu.ir~ ^ /S oc'j-c (2 f <**' A COLORITE 017339 /11 v 1 ! ' \ R li ] e No. 6!.63(b)(a)(i) 6 REA A. REACTOR 1. Reactor Wash Water Me n-Weeks Cor., o] iar.ee Expect! I re. Eng . Novemb !: r 1 SCOPE (Present System) A closed collection system for the reactor wash water blowdown will be required if closed reactor operation is implemented. Closed reactor testing required: 1. OC coating devices 2. OC c-i if irg frequency 3. Closer reactor testing 6!.64 (a)(1) 2. Reactor Evacuation System 61.64 (c) 3. Wet Slurry Screens k No Yes A carbon adsorption system will be required on the evacuation pump discharge. Reactor vapor tampling program reaov to connente. Carbon adsorber design pending results of adsorber testing. Modifications to wet screens are required. Vent tie-ines to carbon adsorber complete. Lab testing required on water seal on overflow line. Water seal design required. Oversize overflow collection system design required. 61 .6 3(b)(g)(i) 61.64 { e) (1) ( ii) 4. Evac Pump Seal Water B. RESIN STRIPPING 1. Slurry Tanks 61.64 (b) 1 2. Carbon Adsorber h 4 9 No Yes Yes A closed collection system will be required. Lab testing complete, Stripping compliance data to be collected. Round the clock sampling of slurry tanks required. Stripping rates using nitrogen are being established. Laboratory sampling program defined. Determine capacity and scale up requirements for expansion. Additional instrumentation being installed. Regeneration Improve ments being implemented. Lab sampling program defined. >1.65(b)(g) (i) 3. Carbon Adsorber Blowdowns H No A closed collection system is required. Proposed collection system designed. CAR to be written. COLORITE 017340 :fa cohpli.wW PROGRAM (cont *d) f.PA RULE No. 61.65(b)(g)(i) Man-Weeks Compliance Expec ted AREA Process Eng. November 1 SCOPE C. RECOVERY 1. Recovery Area Blowdowns 1% No A closed collection system for the recovery area blowdown is required. 2 STATUS Collection system designed. CAR to be written. 61,55(b)(g)(i) 2. Caustic Scrubber Blowdown H Yes Blowdown to the caustic wash column as makeup is proposed. Laboratory determination of blowdown solids composition being made. 61.65(b)(g)(i) 3. Wash Column 6 No A closed collection system for the wash Testing of smaller mesh filter column and filter blowdown is required. elements to reduce column Reactor discharge valve ramping backwash frequency underway. adjustments required. 61.65(b)(g)(i) A. Caustic Wash Column Blowdown lh No A system for separation and recovery of A stripping column design is the VCM, toluene and caustic is required. under evaluation. 61.65(b)(6)(i) 5. Heavy Ends 2h No Disposal of the heavy ends will be Alternates being evaluated. accomplished by deep well injection by outside contractor. A loading filter will be required. A loading vapor clearing system will be required. 61.65(b)(6)(H) 1>1.65(b) (g)(1) 6. Vessel Clearing System | 61.65(b)(g)(i) D. LOADING 1. VCM Transfer Pump Seal Water 1 No A collection system is required for the Collection system design water used to displace VCM vapors (to underway. gas holder) in vessels being cleaned. No A closed collection system will be required. Alternates being evaluated. COLORITE 017341 61 .65(b) (1) Cl) 2. Loading Hoses/Sight Glass Blowdowns 1% No A closed vapor collection/treatraent system Is required. Alternates being evaluated. 61.6 5(b)(5) 3. Tank Car Purging 2 No A closed vapor collection/treatment system is required. Alternates being evaluated. EPA COMPLIANCE PROGRAM (cont'd) 3 EPA RULE No. 61.65(b)(g)(il) 61.65(b)(6) AREA E. MISCELLANEOUS Man--Weeks Compliance Expected Process Eng. November 1 _________________________ SCOPE STATUS 1. Water Stream Stripping ylj 2. Sample Bomb Purgings 1 [jo Yes Evaluation and design of surge tank and stripper for all contaminated water streams is required. Batch versus continuous and steam vs. nitrogen stripping will be evaluated. Alternates being evaluated. Purging of sample bombs containing high VCM Purging system design levels will be to the gas holder. underway. COLORITE7 017342 /12/76 COMPLIANCE PROGRAM AREA Al 2 3 L B1 2 n Cl y 3 4 5 6 D1 2 3 EL 2 PROJECT DESCRIPTION Reactu** " --h Reactor Evacuation Svstem i'et Slurry Screens Lvac Pumr> Seal Water | Slurry Carban ,\<J -orber Cirbon Alsorber HiavJowns bjc.iver Area Blowdowns C rustic Scrubber Blowdown i -h Cohr ,tt 11i -*r ir Cash Column Blowdown Heavy E"JS Us'tl Civ,Tint; System V'M lransi or Pump Seal Water bonding boAes/Sight Gloss Slowdowns I*'a A Gar Purging Cater SLi'i am Stripping Pi.'ple Bomb Pur^inps APRIL MAY JUNE ie 25 O 9 1 5 23 30 6 13 20 27 I _J_i 'lU 1 Contract A + * SLR !c imtract V B ' APG | ejh AI >G ft 1 r 1 Zo nt. SER B i Contract G , I LKB Clont C LKBl DM D D 1% II Cont. D Cent B/B -.1 LL -JL 111_ + SER # APG * LKB JULY 4 11 18 25 1 X1 ! "1" j r COLORITE 017343 4/13/76 wzlto airao'ioo LAB SAMPLING REQUIRED FOR EPA AUGUS'1' 1 DEADLINE 1. VCM vapor in reactors after final evacuation 20 samples per product type 20 x 4 = 80 samples total take samples at reactors with probe 2. VCM in resin - round the clock sampling, twice per shift on each of three slurry tanks. Approximately two months of this sampling is required. 3. VCM in slurry tank vapors - same frequency as VCM in resin 4. Carbon Adsorber - twice a shift sampling on outlet. 5. VCM in water seal on wet slurry screen overflow - approximately five samples required. 4/12/76 sfrz.TO airaoioo WATER STREAMS REQUIRING TREATMKbr POR ?A 1. Reactor Area ,1 Lb/Day Reactor Wash Water 780,000 Evacuation Pump Seal Water Drain(H301A6B) 5,000 Total 785,000 2. Loading Area VCM, ppm Mean VCM ppd 10-20 12 5-350 _1 13 VCM Transfer Pump Seal Water 3. Carbon Adsorber Blowdown 3,000 400-800 1.2 Carbon Adsorber Drains 4. Recovery Area 7,200 500-1,000 5.4 A. Blowdown (H3021 Recovery vacuum pump seal water drain 13.000 300-700 Gas Holder Overflow (D340) 6,0003 400-800 Gas Holder K.O. pot (C35G,1) 3 ,000-5,0001 500-4,000 Crude Tank Drain (C352) 0-50 2,300-4,000 Recovery Area VCM Pump Seal Water 20.000 400-800 Caustic Sciubber Blowdown (C346) 4,500 8,000 Total 48 ,500 - 50, 550 B, Column Back Wash Water Wash Column (C344,5) Water Wash Column Filter (L327, 8) 525.0002 90,000 200-750 300-1,700 Total 615,000 5.5 3.6 9 nil 12 52 83 250 90 340 Notes: 1. Basis - 8 reactors and 18 batches per day 2. Improved recovery flow control should reduce this amount. 3. Calculated quantity. g REACTOR AREA 1. Install hydraulic cleaning devices in reactors to reduce frequency of opening between batches 2. Install OC nozzles in reactors to reduce frequency of opening reactors between batches Install gas chromatograph computer system for VCM monitoring and develop program for determining worker exposure levels a- Install activated carbon adsorption unit to reduce VCM from slurry tank and vent condenser below 10 ppm 5. Carbon Adsorber Blowdowns 6. Wet screen and wet screen overflow collection drums PASADEfl^Wt PLANT ENGINEERING CONSIDERATIONS OSHA VCM COMPLIANCE SCOPE System installed. Operational testing required. System installed. Additional operational testing required. Computer programming to calculate worker exposure levels is complete. Breathing Air Req'd April 1 TIMING Testing completion target August 1, 1916. Testing completion target August 1, 1916, Chromatograph operational Jan. 15, 1976. Instrumentation for monitoring emission rates and regeneration equipment operation Is being installed. Regeneration equipment modifications may be-necessary to achieve less than 10 ppm VCM consistently. Extension of vent stack by 20 ft. to allow better dispersion from immediate work areas is being Installed. Ho Laboratory data is required and a closed collection system for the liquid blowdowns at the carbon adsorber area is being designed. Yes Modifications to wet screens are required. Alternate collection drum contaminant/disposal methods are being developed. Tests are being conducted to determine whether alternate equipment can be used to replace the wet screens altogether. Yes Stack extension operational April 1, 1976 Regeneration modifications completion target Apr. 15, 1976 Operational testing completion target Mav 30, 1976 / CAR to be complete Apr. ;30, 1976 Testing completion target April 30, 1976. COLOR!TE 017346 7. Oily Water Sump 8. Reactor Wash Water 9. Evacuation Pump Discharge The oily water sump grating is being enclosed and a vent stack to disperse VCM vapors from immediate work area ia being installed. No A closed collection system for the reactor wash water blowdowns is being evaluate. Yes Extensions to the evacuat':v,n pump discharge stacks are being evaluated to minimize e::;- n In reactor building area. Operational April 1, 1976 Evaluation completion target* July 30, 1976. Evaluation completion target July 30. 1976 COLORITE 017347 PASADENA PVC PLANT PNC,'IMEERING CONS1DERATIONS OSHA VCM COMPLIANCE (cont'd) DRYER AREA 1. Centrifuge Water Blowdown Tank Increase Dryer Stack Height RECOVERY AREA 1. Recovery Area Blowdown 2. Caustic Scrubber Blowdown 3. Wash Column Backwash Frequency LOADING AREA I SCOPE Breathing Air Req'd April 1 TIMING Modifications are being made to reduce emissions. These include installing cover on top manway, installing a liquid seal pot on the overflow line and extending the vent stack to achieve better dispersion. Additional area sampling necessary to define stack extension requirements. Yes CAR submitted March, 1976. Yes Evaluation completion target Sept. 1, 1976. A closed collection system for the recovery area blowdown is required. Laboratory testing is required on a system that has been installed to blowdown the caustic/alumina scrubber water into the caustic wash column as makeup rather than to the sewer. Smaller mesh filter elements are being tested on the wash column water circulation system to reduce column backwash frequency i.e., VCM discharge rate Into the REW pond. Yes Yes Collection system design complete Apr. 15, 1976. CAR to be complete May 1, 1976. Operational target Apr.30, 1976 Yes Evaluation completion target May 31, 1976 A closed system for collecting tint VCM transfer pump seal flush water will he required! K permanent vapor gathering/treatment system will be designed. Yes Engineering completion target June 1, 1976. COLOR!TE 017348 PASADENA PVC'TLANT engineering considerations (,'SiiA VCH COMPLIANCE (cont'd) LABORATORY AREA ISCELLANEOUS 1. Breathing Air System 2. Sample Bomb Purging A/13/76 SCOPE Breathing Air Req'd April 1 TIMING The air intake ducts for the laboratory are being relocated to prevent contamination by the hood exhaust duet. The hood fan/duct capacity is being evaluated. A VCM sample disposal system is being evaluated. -- Air duct revisions complete March 1976. ' Extension of the breathing air headers to all plant areas Is required. Specific locations have been defined and the distribution system is being designed. Purging of sample bombs containing high concentrations of VCM will be routed to the gas holder. A purge gathering system Is being designed. Installation underway. Yes CAR to be complete May 15, 1976