Document n9yXboB8NK0oLDZn0GMBRezQ8

to: SUBj iict : INTEROFFICE COMMUNICATION Westlake, Louisiana August 20, i960 Mr. VV. S. Stovall - Ponca City LAKE CHARLES VCM PLANT LOSS SUMMARY A review of the iosses from the VCM Riant has been made and a summary of the results is tabulated herein as basis for future discussions. Raw materia! consumption ratio: ere shown in Table i attached. Examples of actual consumption ratios are given oy inducing june 1963, four-month period cf April through July 1963, and the July 8-:0 performance run in the tabu lation. Plan* personnel advise that the s tanderd consumption figures were based on the guarantee quantities and not on any breakdown of less sources which could be used for comparison. The only design less pattern we can find is from the Stauffer flow sheers, and we have tabulated these quantities in Table ' l attached. Note that the flow sheet tabulation totais 0.092 lbs. loss per lb. VCM, where feed to product overall from these same sheets totcl C.104 !bs./lb. which is probably just a ten percent closure error in the design loss balance. We had extracted information on less sources from ail available cast correspondence and analyses to formulate the loss reduction program presented to you in my August 6, 1968 letter. Table 1 ! I attached, summarizes these losses snowing quantities previously reported, present loss, and quantity of loss predicted after cor rective action is implemented. Loss tabulations and attempts to assign quantities to each source rc-cate have cf necessity been based on very infrequent data points ar.c were expanded to esrimare what the totais might be for one month of steady operation. V/e have round that this can be very misleading especially since the plant Is operating at reduced capacity and suffers frequent shutdowns. For example, in the four-month period of April through July of 1968, the plant produced only 61 percent of design production and by making as detailed as possible accounting of losses during this period we still show a large "unexplained" quantity which is probably attributable to upset conditions CCR 000006843 .Mr. W Stcvai i Page 2 during rhe startup/shutaov/n periods. ;his ic s amr w;M not be shown by the rabuicrlo such cs !r. Table iii, 'out can only be derives cy ...... more cercllec procedures sucn as shown for the four-rr.cnI'.'. :=riod in Tcole IV > iC^r.vw. Many cf rhe ucntitles : Vr.e.e !w son new, or in the near rurure, oe mere cccurcreiy c ic rourlni: remaining iosses ccn ee cef; to be .ssuec on c murine dcs... mo :r. c rorrr. rhat the on;y way me 1 / r'or a loss ccocunr'ng `milor to rhert used for Table !V with assumptions cnc estimates repmcea with com i cucn 711 'es cs available. This ccccu would serve not only to point out loss::: from c i ic or intermittent sources bur also to sped lent incident trouble soars. RSM-MC Attachments > cc- SVS, HDB, DCC, DKP, PriG With Atfccnments . mews CCft 000006844 E'liylone CMorlne Hi 'orclTool TABLE 1 RAW MATERIAL CONSUMPTION POUNDS PER POUND PRODUCT VCM Plow Sheets Standard Gua ten free Porfot mrince Test July 8-10 Actual June 1968 .448 .568 .478 .642 .499 .662 .499 .662 .530 .687 .545 .713 Acfrual April llirouc. .556 .742 CCR 0 0 0 0 0 6 8 4 5 TOTAL 1.016 Losses 0 Uv-.se s (U.M IPs ./mo, of m _ : Ily -666 his.) Lor In rxcss of rpccfod (MM Ibs./mo) 1.120 0.104 5.2 - I.I6I 0.145 1.161 0.145 7.25 * 7.25* `^'expeefr- *0 ed loss'* 1.217 0.201 10.05 2.80 1.258 0.242 12.10 4.85 1,293 0.282 14.10 6.85 CCR 0 0 0 0 0 6 8 ^ 6 Stream 1. T--101 vent 2. Steam Stripper Effluent 3. L. E . Column Vent *Ar H. E. Column Vent 5. EDC Tar Still Vent 6. EDC Tar Still Boltoms 7. L. E. Column Overhead 8. VCM Tar Still Vent 9. VCM Tar Still Bottoms 10. Oxy Vent II. MCI in $-309 TOTAL Loss, Lbs ./Lb. VCM TAB LI LOSS SOURCEJTABULATION FLOW SHEET DATA Loss Nature EDC EDC EDC MCI EDC; 1,1,2; Tar Light Ends Tar; EDC EDC, ETC , C02, CO HCI Loss Lbs ./Hour 7.5 0 312.5 5.0 II.0 1787.7 2759.1 0 861.3 572.5 600.0 6916.6 0.092 Loss M Lbs./Mo 5 0 208 3 7 1,191 1,838 0 574 381 400 4,607 \ TA3LE ! : ! LOSS SOURCE TABULATION NOTE: All figures In MM lbs. per month (666 hours) SOURCE Nature Previously Reported Loss Present Loss After present Correcrive Ac Complete 1. Oxy vent Ethylene 0.8 to 1.0 0.2 (i) - 2. Entrainment in Oxy vent EDC 0.5 Nil (2) ' - 3. Chlorine analysis Cl 0.3 Nil - 4. Steam Stripper EDC 0.3 0.15 Nil (3) 5. Atmospheric Losses EDC Nil Nil - 6. Refrigeration Level EDC Part of ^ I Nil - 7. L. E. Weathering EDC 0.5 0.5 Nil (4) S. .EDC solubility due HCl EDC Nil Nil - 9. Ethylene Metering (5) Ethylene 1.5 0.6 Nil 10. L. E. Column Vent EDC Negligible Neg. - 11. H. E. Column Vent EDC (6) Neg. Neg. - 12. T-IOI Vent EDC (7) Neg. Neg. - 13. VCM car venting 14. Excess Cl to R-IGl VCM Cl. 0 td 0.25 Temporary Neg. Neg. - - 15. Excess HCl antifreeze HCi 0.03 to 0.06 Neg. Neg. (8) 16. By-producr losses - oxy Ethylene &C12 0.2 Neg. - 17. Tar Still Vent A. EDC B. VCM 18. Wash System & Upsets EDC 0.04 VCM, EDC, HCl 0.5 All No Estimate 0.04 0.5 .. 2.0 (Est.) Neg. (9) Neg. (9) !. 0 (Est.) (10) CCR 000006347 TABLE II! (Continued) NOTES: (I) 0.2 mm lbs./month is probably an economic limit. Further reduction would entail installation of a scrubber to remove chlorine from vent gas. (2) Indications during August operation are that demister has again failed and losses are back to 0.3 to 0.4 but recheck will be necessary when plant is near capacity. (3) New stripper installation estimated - First Quarter 1969. (4) It is our understanding that production accounting method for light ends will be changed January I, 1969. (5) Figures from study show approximately 5.4% difference prior to June and about 2.3% June and July. See letter from Michels to Butter August 13, 1968. (6) No sample point -- assumed negligible. (7) Negligible at low rates -- test planned to check loss at high rates. (8) Meter installation planned. (9) Losses not verified -- additional tests to be conducted when orifice installed and plant is at capacity. (10) New aqueous phase hold tank is being installed by the plant; should cut wash losses by approximately 1.0 mm lbs./month. 0oooo&al>a C.C* TABLE IV Actual Losses - April through July 1968 Total Ethylene and Chlorine Feed to Unit = 148,467,140 lbs. Total EDC, VCM, HC1, Tar and L. E. Out = 125,093,993 lbs. (Adjusted for inventory) Total Losses = 23,373, 147 lbs. Loss Sources A. Hydrogen (as water from reaction) = 2,200,000 lbs. Sub total loss = 23,373,147 - 2,200,000 '21,173,000 lbs. B. Light Ends Weathering Correction Design Flow - Total L. E. Overhead = 2759 Ibs./hr. Design Flow - EDC in L. E. Overhead= 406 Ibs./hr. Assume 50% recovery of EDC Total Pumpout & Weathering Loss = 2556 Ibs./hr. Total L. E. Loss 2556 Ib./hr. x 730 hr./mo. x 0.61 PF x 4.0 mo. = 4,550,000 lbs. Subtract actual pumpout of 470,000, loss = 4, 080,000 lbs. Sub total Loss - - 21/73,000 - 4, 080,000 XT, 0937000 ibs. NOTE: L. E. weathering loss is probably a lower figure. Actual could be determined by inventory accounting and analysis. C. T-500 Pit Truck Pumpout Mud Maver invoices for period total - 4540 bbi. which equals 1.9MMJbs. Assume 90% organic. Loss = !, 7GG, 0C0 lbs. Sub total Loss = 17,093,000 - 1,700,000 C* 0006a^9 15,393,000 Ibs. Table IV (Continued) D. S-309 Acid Losses Daily Average % HCl in S-309 aqueous effluent - 6.785% Total H2O * 19,784,000 lbs. Total HCI = (0.06785) (19,734,000) (07932T3] Sub total Loss = 1,440,000 lbs. = 15,393,000 - 1,440,000 13,953,000'lbs. E. Sewer Loss - Soluble EDC July Estimate = 800/000 lbs. From : T-102 & T-I03 Water Wash C-500 Other 190.000 230.000 46,000 340.000 Total Losses; 4 x 340 m I x 230 m x 0.61 4 x 236 m x 0.61 1.360.000 140.000 576.000 2.076.000 lbs. Subtotal loss = 13,953,000 - 2,076,000 11, 877, OOOTbs. F. Vents (Estimated) VCM Tar Still EDC Tar Still L. E. &T-I0I Vent 610,000 x 4 = 2,440,000 lbs. Sub total Loss 500,000 Ibs./mo. 50.000 Ibs./mo. 60.000 Ibs./mo. 61 0,000 Ibs./mo. 11,880, 000 (Rounded) - 2,440,000 9/440,000 lbs. CCR 000006350 Table IV (Continued) G. Mass Flow Meter - Ethylene June and before June and July Average 4-month period Average 5.4% 2.33% 3.85% high 63,.597,000 x 0.0385 = 2,440,000 lbs. Subtotal loss 9,440,000 - 2,440,000 7,000,000 lbs. H. Chlorine Analysis Assume 0.32% high Loss = 270,000 lbs. Subtotal Loss 7,000,000 270,000 6,730,000 lbs. I. Oxy Vent Losses From material balances made in June: (a) Average mole/hr. of CO and CO2 Lbs. carbon per month at 61% PF Four-month loss " 28.40 = 152.000 lbs,/mo. = 608.000 lbs. (b) Average lb. per hour EDC, ET Cl & HCI = 128 or 57,000 lb./mo. When demister failed = 581 or 258, 000 lb./mo. Four-month period with 2-1/2 months of bad demister Total Loss = 730,000 lbs. (c) With old R-4 catalyst and high ethylene vent content = [021 lb./hr. Average With new R-4 and operation = 255 lb./hr. One month of low ethylene and three with high ethylene Total Loss = 1,473, 000 lbs, Total Oxy Vent -- _______ 2,811,000 lbs. CCR 000006851 Table IV(Continued) Subtotal Losses 6,730,000 -2,811, 000 J. Unexplained Loss 37919700(5" lbs. 3,919,000 lbs ./four months or approximately 1,000,000 per month. This quantity we assume leaves the sewer as a separate EDC layer and as soluble EDC when more water than usual flows to T-500 via 7-252, T--103, T--102, or other due to operation, rainfall, upset, equipment drainage and drying, and other misceilaneouse sources . Also, vent losses occur between sampling and especially during upset which cannot be measured.Such vent losses would include tank car and filter venting, oxy imbalance, inerts bleeding and pressure correction by venting. CCR 00000685 VALUE OF PLANT LOSSES - 1970 Value of Feedstock - CI2 = 2.07 cents/lb. x 392,400 M lbs./yr = $8,122,680/yr. Design basis - annualized) C2H4 = 3.25 cents/lb, x 303,594 M lbs./yr r $9,866,805/yr. Average Value of Feedstock s $17,969,485 ___ 695,994,000 z 2.58 cents/lb. Value of 1.00% Losses of Feedstock = $179,695/yr. Value of Indentifiable Plant Yield Losses - per yr. 1) Oxy Losses - total a) Unconverted HCl & C2H4 b) H ions removed in oxy c) Overburning d) 1,1,2 trichloroethane e) ETC1 f) Chloroform $1,120,000 .440,000 250,000' 130,000 130,000 110,000 60,000 54.0,0 a o 2) Cracking Furnace Losses - total a) 1,1,22 tetrachloroethane b) 1,5 dichloropentane c) Hexachloroethane d) Chloroprene e) Carbon tetrachloride ' $ 77,000 23,000 20,000 14,000 2,000 18,000 3) Direct Chlorinator Losses- total a) 1,12 trichloroethane . b) VCM, Cis and trans dichlors 4) T-2 effluent pit waste EDC losses $ 77,000 57,000 20,000 200,000 5) Tar still EDC losses 120,000 6) Heavies and coke formation 110,000 7) Light ends column overhead EDC losses 43,000 8) T-101 vent EDC losses 38,000 9) Wash System Losses 27,000 (Thru steam stripper being out of service) 10) Unknown Losses 160,000 000006 853 1970 - PLANT LOSSES SUMMARY Product VCM, EDC, and HCl (to Ancon) Light Ends Hauled Away Tars Hauled Away H ions Removed in Oxy as ^0 Water Effluent Losses C-500 Vent Gas Losses Unknown Losses ,, Total Losses and Production as a % of CI2 and C2H4 Feedstock 89.0%-4-1 1.1% j 2.7% j 1.4%*"* 2.7% 2.5% 0.5% ^^ 100 % 1i CCR 000006S54- CCR 000006355 / VALUE OF PLANT LOSSES - 1970 Value of Feedstock - CI2 = 2.07 cents/lb. x 392,400 M lbs./yr r $8,122,680/yr. Design basis - annualized) C2H4 = 3.25 cents/lb. x 303,594 M lbs./yr ; $9,866,805/yr. Average Value of Feedstock = $17,969,485 695,994,000 = 2.58 cents/lb. '' Value of 1.00% Losses of Feedstock = $179,695/yr. Value of Indentifiable Plant Yield Losses - per yr. 1) Oxy Losses total a) Unconverted HCl & C2H4 b) H ions removed in oxy c) Overburning d) 1,1,2 trichloroethane e) ETC1 f) Chloroform $1:,120,000 440.000 250.000 130.000 130.000 110.000 60,000 2) Cracking Furnace Losses total a) 1,1,22 tetrachloroethane b) 1,5 dichloropentane c) Hexachloroe thane d) Chloroprene e) Carbon tetrachloride $ 77,000 23.000 20.000 14.000 2,000 18.000 3) Direct Chlorinator Losses- total a) 1,12 trichloroethane b) VCM, Cis and trans dichlors $ 77,000 57.000 20.000 4) T-2 effluent pit waste EDC losses 200,000 5) Tar still EDC losses 120,000 6) Heavies and coke formation 110,000 7) Light ends column overhead EDC losses 43,000 8) T-101 vent EDC losses 38,000 9) Wash System Losses 27,000 (Thru steam stripper being out of service) 10) Unknown Losses 160,000 CCR C00006856 1970 - PLANT LOSSES SUMMARY Produce VCM, EDC, and HC1 (to Ancon) Light Ends Hauled Away Tars Hauled Away H ions Removed in Oxy as ^0 Water Effluent Losses C-500 Vent Gas Losses Unknown Losses Total Losses and Production as a % of CI2 and C2H4 Feedstock 89.0% 1.1% 2.7% 1.4% 2.7% 2.5% 0.5% 100 % CC* oo06857