Document pBK1noz3ZNdKpMZwkvx0mM7Q6

II HONSANTO COMPANT J \ ORGANIC CHEMICALS DIVISION #J ANNISTON, ALABAMA STANDARD MANUFACTURING PROCESS FOR AROCLOR Departments 826.08 826.17 Supersedes: Standard Manufacturing Process . For Aroclor Issued: 10/22/57 Prepared by: M. J. Williams Prod. Foreman Supervisor: V. R. Haupt Production Supt.: R. G. Moody Issued: September, 1966 COPT HO. IL 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 authorisation. Either retain in a secure file or retun to the Standards Department. DSW 303353 WATER PCB-SD0000050904 STANDARD MANUFACTURING PROCESS FOR AROCLOR DISTRIBUTION Technical Information Center - St. Louis Research 2 Copies Security File 1 Copy Technical Production Manager 1 Copy Plant Manager 1 Copy Production Superintendent 1 Copy Production Supervisor 1 Copy Maintenance Superintendent 1 Copy Technical Services Department Files \piant Standards Department 3 Copies - Extras SVV 303354 WATER PCB-SD0000050905 STANDARD MANUFACTURING PROCESS FOR AROCLOR TABLE OF CONTENTS SECTION I - SYNOPSIS OF PROCESS SECTION II FLOW SHEETS SECTION III PROCESS IN DETAIL A. Batch Liquid Chlorlnators B. Continuous Chlorlnators C. Biphenyl Mix Tank and Feed Tank D. Solid Batch Chlorlnators _ E. Blowing Tank Operation F. Liquid Stills G. Earth Treatment and Filtration . H. Solid Still I. Packaging SECTION IV COMMENTS ON THE PROCESS APPENDIX A. Equipment List B. Finished Goods, By-Product, A 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 OSNN**'55 WATER PCB-SD0000050906 STANDARD MANUFACTURING PROCESS FOR AROCLOR AMENDING RECORD SHEET The disposition of the Amendments to the Standard Manufacturing Process dated October 22, 1957 are as follows: Amendment No. Title or Description Date Disposition A B C-Rev.#l Reclaim Pyranol made with TTCB 12/21/60 with high hydrolyzable chlorides Circulate chlorlnator material 10/22/57 during entire chlorination period Use of LVM Attasorb 5/15/59 Accepted Accepted Rejected D Optimum Lime Concentration 12/31/58 Rejected E Use of Undrled Earth 1959 Rejected F Recycle Boildown to .Still 5/15/59 Rejected G Number of Runs before Boildown 6/16/59 Rejected H Earth Treat (0.2%) Aroclor 1242 9/22/61 Accepted at 70-80C. Dry earth at 100- in part 300C or use as received I Earth Treat (0.1-0.4X) Aroclor 11/15/61 Never Tried 1242 at 50-100C (Re-submit) J N2 Blanket Blend Tanks, Filtrate 8/29/63 Rejected Receivers and Storage Tanks due to large losses of N2 K-Rev.*l Remove Catalyst Basket from Chlorlnator to make Aroclor 5060 7/29/64 Accepted L Optimize Earth Treatment Time 8/18/64 Accepted M Eliminate Earth Drying 1/20/65 Rejected N Increase Mesh Size of Earth 2/5/65 Rejected 0 Start-Up of No. 9 Solid Aroclor 5/3/65 Accepted Chlorlnator DSW 303356 WATER PCB-SD0000050907 OF FttUCbii WATER PCB-SD0000050908 STANDARD MANUFACTURING PROCESS FOR AROCLOR SYNOPSIS OF PROCESS Aroclors are the reaction products formed by chlorination of Biphenyl and/or Terphenyls using Ferric Chloride Catalyst. The by-product BC1 gas produced is absorbed in water to produce Muriatic Acid. Crude Aroclors are produced in the chlorinators, air blown, distilled, earth treated, filtered, and loaded for shipment. Aroclor is a trade name used to disignate chlorination products of Biphenyl, Terphenyls, or mixtures of the two. The physical properties ary from light free-flowing liquids to crystalline and non-crystal line solids. Depending on the-degree of chlorination and the com position of the raw materials, Santowax R, and mixtures of Biphenyl and Santowax R, or Biphenyl and Santowax C, yield products of increas ing 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 1001 technical grade Biphenyl. The hundreds digit denotes whether or not the product is distilled. The -1-- indicates un distilled, 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 chlori nated Biphenyl containing 601 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 40X Santowax R and SOX technical Biphenyl. This is chlorinated to 65X. 2. Aroclors 5060 and 5460 Aroclor 5060 is the crude from which Aroclor 5460 is distilled. The starting raw material is 100X Santowax R which is chlorinated to 60X. DSW 303358 WATER PCB-SD0000050909 Aroclor Manufacturing Process Synopsis of Process 2. 3. Aroclor 5042 and 5442 Aroclor 5042 la the crude from which Aroclor 5442 is distilled. The starting raw material is 1001 Santowaz R which is chlorinated to 42Z. 4. Aroclor 2565 This is an undlstilled product. The starting raw material consists of 25Z Santowaz C and 75X technical Biphenyl. This is chlorinated to 65X. 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 nezt. 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 ezternal air cooled heat ezchangers. The specific gravity of the crude is checked after chlorine feed has been on for four hours, again when 80Z 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. DSW 303359 WATER PCB-SD0000050910 Aroclor Manufacturing Process Synopsis of Process 3. Still Area Liquid Aroclors Aerated Aroclors from a blowing tank or a feed tank are charged to a still, hydrated lime la added, a vacuum of 720 nxn Hg (40 mm Hg absolute) Is applied, the still furnace is fired, and the Aroclor is distilled into a receiver. The dlatlllation la semicontinuous, since ten (10) receivers are distilled prior to draving bottoms of residue from the still. Every two receivers (or approximately 2,000 gallons) are treated with 40 lba. of earth for two hours and then filtered. The finished product la transferred to storage tanks prior to loading into drums or tank cars. 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 la dependent upon the particular Aroclor being produced. Solid Aroclors are not earth treated or filtered. They are dnsmed directly from the receiver or are flaked (Aroclors 1268 and 5460). Chemical Equations Liquid Aroclors Based on the forecasted demands through 1969, the average Liquid Aroclor could be called 1244.7. + 3.4 Cl2 +3.4 HC1 Biphenyl 154.2 Chlorine 70.9 Yields per CWT Aroclor Chlorine Biphenyl Hydrogen Chloride Aroclor 1244.7 271.5 Hydrogen Chloride ` 36.5 Theory Standard 89.4 56.5 45.7 96.1 58.2 38.8 SW 303360 WATER PCB-SD0000050911 Aroclor Manufacturing Proceaa Synopaia of Proceaa 4. Solid Aroclora Baaed on the forecaated demanda through 1969, the average Solid Aroclor would contain 60.7X chlorine and 11.9Z Biphenyl. 0.881 Santowax R + 0.119 Biphenyl + 10.3 CI2 Solid + 10.3 HC1 Aroclor 230.3 154.2 70.9 586.0 36.5 TieIda per CWT Aroclor Chlorine Biphenyl Santowax R Hydrogen Chloride Theory 121.4 5.01 36.2 64.1 Standa: 146.3 -- 42.3 54.5 0S\N 303361 WATER PCB-SD0000050912 WATER PCB-SD0000050913 STANDARD MANUFACTURING PROCESS FOR AROCLOR FLOW SHEETS DSW 303363 WATER PCB-SD0000050914 H C L H E A D E R TO M U R IA T IC A C ID A B S O R B E R S WATER PCB-SD0000050915 HCL LINE TO MURIATIC ACID _ ABSORBERS BIPHENYL OR SANTCWAX AIR FROM BLOWERS charge) TANK--' CHARGE TANK tranfer pump CHLORINATOR : BLOWING TANK PUMP Tto ROOF TANK OR STILLS CHLORINATOR, CIRCULATING PUMP BATCH CHLORINATOR OPERATION -FLOW SHEET -- DSW 303365 ANNISTON PLANT -- MONSANTO CHEMICAL COMPANY - ANNISTON. ALA. TITLE . -BATCH. CHLORINATOR OPERATION - FLOW SHEET DRAWN IT EAE APPROVED DATE s-r-64 CALS NiorNE DEPT. AROCLOR TS-A - TO 1 WATER PCB-SD0000050916 SANTO CHEMICAL COMPANY j UQimq_|3_j- _Cf'jf _G/v_^ NIC CHCMICAua divi;oh 4ZCRINO DIPAZTMIHT outa uiHOum , -C-leAiv. Uf.____ ___________________ ! PLANT AfctlS >TO N_____ _________ l< -ocation Tj2 W Ala ______ _____ li l' DtllQN MANUAL srCTlON NO..:_____ |l ErTIMATC NO___________ ji PR [PARED BV awirr-------------- or___ intM NO__________ Z. A NO___ OATZ________ u IND isaAL <c u u -r 5 76 CcMiC-t E.fc f i Towta Va.tl* OvT TcvwSR WriK IN LiGtu'tDS C0!l<?c.+ ic-n Tf\NK. V. NO. 13 fl OATS REVISION APPROVED T DATE Y DSW 303366 WATER PCB-SD0000050917 STEAM VACUUM JET GAS- AROCLOR FEED FROM BLOWING TANK OR ROOF TANK !_ L.0 , \ RECEIVER PUMP FILTER AROCLOR STILL- FLOW SHEET TO AROCLOR STORAGE TAMK5 . TANK CARS. OR DRUMS. DSW 303367 ANNISTON PLANT - MONSANTO CHEMICAL COMPANY - ANNISTON. ALA. TITLE AROCLOR STILL- FLOW SHEET JOEUDTiiS.- i-TM. - DRAWN BY EA E APPROVED DATE S-lO-^4 CALC none: DEPT. ' AROCLOR TS-A-704 WATER PCB-SD0000050918 -I _ -------M A W W l ----------A9HMYVQ - WATER PCB-SD0000050919 WATER PCB-SD0000050920 H . i` ONSANTO CHEMICAL COMPANY j' Sty.e_jjCL Off 6 AS_____ RQANIC CHtNICALI DIVISION !. VP___________________ 40INCCKINO OtPAHTMINT ' RLANlAhMSXCN__________________ r LOUIS MISSOURI -QgATinN An fli j-STOfy A lA, li I DUION MANUAL SICTION MO_____ I7TD4 NO_________ || ISTIMATS NO---------------------------------------------- *. A NO ! RsrRASfD BY_________________________________ OATS_____ |i OH SITOS WATER PCB-SD0000050921 WATER PCB-SD0000050922 PROCESS IN DETAIL WATER_PCB-SD0000050923 STANDARD MANUFACTURING PROCESS FOR AROCLOR III. PROCESS IN DETAIL A. Batch Liquid Chlorlntor> Crude Liquid Arodors 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 chlorlnator is a by-product which is recovered in the Muriatic Acid Department. Crude Aroelor produced in batch chlorinators is transferred to the bloving operation when the chlorination is completed. Chlorine gas is fed to the chlorinators from the Chlorine Plant and/or from tank cars. A chlorlnator charge (3,000 lbs.) of specification grade Biphenyl is pumped to the chlorlnator charge tank from a Biphenyl storage tank. One and one-half (1-1/2) pounds of Ferric Chloride is slurried in Aroelor and dumped into the charge tank with each chlorlnator charge. The Biphenyl and Ferric Chloride is agitated for a minimum of 15 minutes and then transferred to the chlorlnator. Aroelor 1142 can be used to charge a batch chlorlnator for the production of 1148, 1154, 1160, or 1162. When 1142 is used for a chlorlnator charge no Ferric Chloride is added. After the chlorlnator has been charged the circulating pump is started and then the chlorine feed is put. on the chlorlnator. As the chlorination progresses the specific gravity is checked at intervals until the desired gravity has been attained. When a chlorlnator is finished it is transferred to a bloving tank. B. Continuous Chlorlnator Operation The continuous chlorlnator 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 chlorlnator where the material is chlorinated and overflows to the second chlorlnator. 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 DSW 303373 WATER PCB-SD0000050924 Aroclor Manufacturing Process Process In Detail 2. to another blow tank for additional blowing. Chlorine is fed to each chlorlnator continuously. This chlorination system can be reduced to three (3) chlorlnators 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 chlorlnators set for different levels of chlorination. C. Biphenyl Mix Tank and Feed Tank When Biphenyl is needed for the continuous chlorlnator operation a charge is pumped from a Biphenyl storage tank to the mix tank. Three and one-half (3-1/2) 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 25% 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 chlorlnator operation. D. Batch Solid Chlorlnator Crude Solid Aroclors are produced by batch chlorination when a weighed quantity of Biphenyl, Santowax, or a mixture of the two is chlorinated in a vertical reaction vessel with Ferric Chloride as a catalyst. Chlorine gas is added at the bottom of the vessel. By-product HC1 gas vented at the top of the chlorlnator is recovered in the Muriatic Acid Department. Crude Solid Aroclors produced in batch chlorination are transferred to the bloving tank operation when the chlorination is completed. (The only exception being 1168 which is not air blown but pumped directly from the chlorl nator to the still). Chlorine gas is fed to the chlorlnator from the Chlorine Plant and/or from tank cars. E. Blowing Tank Operation Crude Aroclors produced in the chlorlnators are air blown for a minimum of one hour, for removal of residual HC1, before the material is fed to the stills. Steam is maintained on the colls 333y4 WATER PCB-SD0000050925 Aroclor Manufacturing Process Process in Detail 3. of the Liquid bloving tanks during this operation. Therminol heat is maintained on the coil in the Solid blowing tank. Residual HCl 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 containing aerated Aroclor, is fed to the still tank. Hydrated lime is added to the crude Aroclor. Vacuum is applied to the still and the Aroclor is circulated through the furnace coll and heated to the vaporisation temperature. Vapors pass up an open coluam to the condenser. Distilled Aroclor is collected in a receiver and then trans ferred into a blending tank. Distilled Liquid Aroclors are treated with Attapulgus Earth in the blending tank, filtered, analysed, and packaged or held in storage. Still residue or bottoms are sold as Montars or discarded. G. Earth Treatment and Filtration All Liquid Aroclors are treated in the blending tank with Attapulgus Earth. This earth is dried in an oven for a minimum of four hours at a temperature of 210-250C. The material, vlth the earth added, is agitated and then pumped through the filter press and back to the blend tank. When no earth is visible in the material it is then directed to a filtrate receiver. The filtered Aroclor is then ready for drumming or transfer to a storage tank. H. Solid Still Aerated Crude Solid Aroclor from a blowing tank is pumped to the No. 4 still pot. Hydrated lime is added to the crude Aroclor. .. i Vacuum is applied to the still and the Aroclor is circulated through the furnace coll and heated to the vaporisation temperature. DSW 303375 WATER PCB-SD0000050926 Aroclor Manufacturing Process Process in Detail 4. Vapors pass up on open column to the condenser. Distilled Aroclor Is collected in a receiver. Quality of the distilled Solid Aroclors is analysed by the laboratory, and if in specification, it Is drawn directly from the receiver into suitable containers or transferred to the flaker operation. Still residue or bottoms are sold as Montars or discarded. I. Packaging Solid Aroclors are packaged in fibre drums, galvanised drums, galvanised cans and in paper bags. Liquid Aroclors are packaged in steel drums and cans. These drums and cans are lacquer lined. Liquid Aroclors are also loaded into tank cars and trucks. SW 303376 WATER PCB-SD0000050927 COMMENTS ON PROCESS WATER PCB-SD0000050928 STANDARD h^vfo-:I'.'RING PROCESS FOR AROCLORS COMMENTS ON THE PROCESS A. LIQUID AROCLORS 1. Chlorination a. Temperature Chlorination tercp...lii.ui -.u of I20C or lower yield a product which will not p.. j Iho stability tests on electrical grade Aroclors. A mini-ora of 130C has been set for the chlori- nators. An upper twu.,crutvr*i lliivit is not defined as critical to high quality Arc-clci rod-jction. A practical limitation is governed by t-1 of overhead product loss to the off-gas collecti-.i L--..V . T"--j liouial temperature range is between 140C and 170C. b. Catalyst The basket cont l-i,.g a led of iron turnings in the chlorinator provides tact surface for the Chlorine and Biphenyl, and the iron reacts wit;, the Chlorine forming Ferric Chloride which is the actual uaL-lyst. Consumption of the turnings makes it necessary to *:.^ecL the chlorine tor semi-annually and replenish the to .-.lugs if necessary. Ferric Chloride (anhydrous powder) iu the amount of 0.05Z 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 ea-.h chlorinator be inspected semi annually. Aroclor supplied to General Electric and Westinghouse must be produced in eltlvi. Inatr-rs containing the basket,, (Prior to any shipment f lie .: r l-.cl Grcde Aroclor being shipped to General Electric and VihL Ir.ghouse from a process where the baskets are removed* M-ckoting will review the process change with both customers.) The catalyst is added Lo the chlorinator charge tank or mix tank (continuous c' h .. h.uLcn;) and agitated for at least 15 minutes but usually cl leuaL an hour before charging or feeding the chlorinators. yjL ,*nd kGX Aroclor Departments do not pre mix the catalyst, r... .:c.r has indicated the tendency to producing unstable Aroclors can be attributed to improper catalyst concenli i ' lob may be brought about by insufficient mixing prior to chlorination. 0S\N 303378 WATER PCB-SD0000050929 Comments on the Process Aroclors 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 indicate formation of unstable Aroclor. If this situation occurs it should be corrected immediately. Take samples from the in dividual chlorinator off-gas and have them analysed 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 fronr chlorine in the off-gas line. c. Chlorine Although the effect of air in chlorine on Aroclor quality is unknown, the amount of air in chlorine does effect the chlori nation rate and therefore effects the production rate. Problems with the dhlorine vaporiser 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 vaporiser with the control system provided. Entrainment of Biphenyl or crude Aroclor into the HC1 lines can occur from excessive chlorine rates. This same situation can occur in case the Chlorine Plant is blowing too much air. This can be checked by observing the off-gas from the chlori nators in the sight glasses on top of the Brink Demister on each chlorinator. Normal operation of the chlorinator should be to minimize this carry-over. Abnormally high or lour chlorine header pressures can cause operating problems. High chlorine header pressure causes problems within the Chlorine Plant to DSW 303379 WATER PCB-SD0000050930 Consents on the Process Aroclors 3. the department operating personnel. Chlorine fumes are forced back into the Chlorine Department and at times sulfuric acid can be blown from the Nash compressor system. Since this presents a safety hasard to the department personnel fevery effort should be made to eliminate high pressure problems. 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. d. Chlorinetor Off-Gas Collection The demister on top of the liquids collection tank Is used as a final knock-out for Aroclor and Biphenyl entrained drop lets 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 thlB 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 con denser 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 down. 2. Air Blowing of Crude Aroclors Air blowing of crude Aroclors takes place with compressed air from air blowers. The air is not dried by any means other than that caused by compression and cooling in the air blowers. Judging by the corrosion exhibited around nozzles atop the blowing tanks a good argument can be made for thoroughly dried air. Wet air may also be the cause of poor electrical properties that occasionally occur during period of rain and high humidity. Wet air can also carry in chlorides, S(>2, and H2S from the atmosphere. An air dryer would tend to scrub out these undesirable gases. OS\N 303280 WATER PCB-SD0000050931 Comments on the Process Aroclors 4. 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 trouble can be traced systemati cally from the jets and usually isolated. 4. Earth Treatment Exclusion of atmospheric mqisture is naturally important where high electrical resistivity is required and of course the Attapulgus earth needs to be well dried. All liquid Aroclors are earth treated at the Anniston Plant to decrease the risk of contaminating electrical grade with non-electrical grade Aroclors. There are too many common lines downstream of the stills to chance non-treatment of non-electrical grade Aroclors. 5. 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 high color 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 remainder of the process are either aluminum, tin and sine sprayed or are constructed of monel, stainless steel or bronze. 6. Special GradeB a. Export Aroclor 1242 The export specs on 1242 call for a resistivity of 5,000 min. and a Biphenyl content of 0.05X max. Domestic specs call for 500 min. resistivity and no spec on Biphenyl content. The DSW 303381 WATER PCB-SD0000050932 Comments on the Process Aroclors 5, Biphenyl content of 1242 made on the continuous chlorinators averages below the 0.05Z max. spec and therefore causes no production problems. To meet the 5,000 min. resistivity spec the 1242 is earth treated two to five times using normal pro cedures until the resistivity exceeds 7,000 (dept, spec) and then drummed out from the filtrate receiver. b. Export Aroclor 1254 The export specs on 1254 call for a resistivity of 5,000 min. and a Biphenyl content of 0.025Z max. Domestic specs call for 500 min. resistivity and no spec on Biphenyl content. To meet the 5,000 min. resistivity spec the 1254 is earth treated two to five times using normal procedures until the resistivity exceed 7,000 (dept, spec) and then drummed out from the filtrate receiver. Two methods have been tried to assure low Biphenyl content. (1) Batches three through eight in the normal ten batch distillation run have a greater tendency to meet the Biphenyl spec than the remaining four. Each batch is analyzed for Biphenyl and then earth treated when in spec. This method is hit and miss and has about a 50Z reliability of success and causes still downtime. (2) Aroclor 1154 is chlorinated from low Biphenyl 1142 rather than Biphenyl. Chances of success are so great that all ten still batches have been earth treated and placed .in an empty storage tank and then additional earth treatment is scheduled to avoid generating still downtime. The second method is used whenever possible and has resulted in better inventory control of export 1254. . 7. 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. 8. 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 200 or 300C in open systems, methods must be designed to exhaust any vapors arising from these open systems. DSW 303382 WATER PCB-SD0000050933 Comments on the Process Ar odors 6. B. SOLID AROCLORS I. 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/A 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 coll to the weigh tank. From the bottom piping on the weigh tank, all the transfer lines and colls in the Solid Aroclor process vessels have Therminol heat until the end of the'process at the' flaker hold tank. The Mo. 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. 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 to 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 The same comments on corrosion for Liquid Aroclors hold true for the Solid Aroclor blow tanks. Undistllled 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 fall. 3. Distillation Vacuum problems on the Aroclor stils 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 con denser 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. DSW 303383 WATER PCB-SD0000050934 Comments on the Process Ar odors 7. 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 coll. This will allow more uniform control of the temperature 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 Mo. 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 coll 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 dis tillation which aids the operator in completing a normal operation. 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 BG1 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 freese-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 coll. DSW 303384 WATER PCB-SD0000050935 Comments on the Process Aroclors 8 To move the bottleneck from the chlorlnator to the still requires charging the chlorlnator 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 chlorlnator but they will not be as readily available as 1142 from the continuous ehlorinators. DSW 303385 WATER PCB-SD0000050936 DSW 303386 WATER PCB-SD0000050937 STANDARD MANUFACTURING PROCESS FOR AROCLOR APPENDIX A - EQUIPMENT LIST Area 200 -Bulk Storage Area 500 - Chlorinator Area 600 - Still DSW 303387 WATER PCB-SD0000050938 APPENDIX A - EQUIPMENT LIST ABEA - 200 BUUC STORAGE Item Equipment Equip. No. Description 201 No. I Aroclor 22-0077 10' x 26' metal sprayed with xinc Storage Tank and tin. Capacity 15,000 gallons. 202 No. 3 Aroclor 22-0089 Horisontal, cylindrical dla. 8'-0", Storage Tank length 30*-0". Metal sprayed with sine and tin. Capacity 11,000 gals. 203 No. 2 Aroclor 22-0076-01 10* x 26' metal sprayed with sine Storage Tank and tin. Capacity 15,000 gallons. 204 No. 4 Aroclor Storage Tank 10' x 26* metal sprayed with sine and tin. Capacity 15,000 gallons. 205 South Pyranol 22-0108 14'-0" I.D. x 10'-0" high. Mix Tank Dwg. D-6455. / 206 North Pyranol Mix Tank 6'-6" I.D. x 8*-2" Jacketed steel tank. 208 Ho. 1 Storage Tank Pump Taber vertical submerged pump. Type CL-4. Capacity 75 GPM. 209 No. 2 Storage Tank Pump Taber vertical submerged pump. Type CL-4. Capacity 75 GPM. 210 No. 5 Aroclor 22-0663 12,000 gal. vertical aluminum tank. Storage Tank See 22-0662, 19-0397, 19-0398, 94-0179, 94-0180, 49-0777, 28-0532. 211 No. 6 Aroclor 22-0662 12,000 gal. vertical aluminum tank. Storage Tank See 22-0662, 19-0397, 19-0398, 94-0179, 94-0180, 49-0777, 28-0532. > 212 No. 6 Storage 19-0397 20-A-30, 3 x 2 - 13/110 Mark 11 pump Tank Puatp v/crane seal #9 outside QP-191, Base steel plate #53 7FL Falk Spacer coupling. sw 303388 WATER PCB-SD0000050939 APPENDIX A - EQUIPMENT LIST AREA 200 2. Item 213 214 215 Equipment No. 5 Storage Tank Pump Equip. No. 19-0398 No. 3 Storage Tank Pump No. 4 Storage Tank Pump Description 20-A-30, 3 x 2 - 13/110 Mark 11 Pump w/crane seal #9 outside QP-191 Base steel plate #53 7FL Falk Spacer coupling. Taber vertical submerged pump. Type CL-4. . Capacity 75 GPM. Taber vertical submerged pump. Type CL-4. Capacity 75 GPM. DSVJ 303389 WATER PCB-SD0000050940 APPENDIX A - EQUIPMENT LIST AREA 500 3. CHLORINATOR Item Equipment Equip. No. 505 No. 9 Chlorinetor 22-0774 506 No. 9 Chlorinetor 19-0494 Circulating Pump 507 Aroclor Cooler No. 9 ChlorinAtor 508 No. 4 Chlorinator 32-0260 Cooler 509 No. 3 Chlorinator 19-0495 Circulating Pump 510 No. 3 Chlorinator Cooler 511 No. 2 Chlorinator Circulating Pump 32-0261 19-0496 Description Vertical 4'-6" dla. x 20' straight side carbon ateel vessel with dished heads (3" Sch. 80 coil 75' long). 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 mechani cal seal. Code QP-868. Capacity 250 GPM at 73' TDH. l'-8" dla. 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" BWG 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 mebhanical seal, code QP-868. Capacity 220 GPM at 81' TDH. Same as Item 508 Same as Item 509 SW 303390 WATER PCB-SD0000050941 APPENDIX A - EQUIPMENT LIST AREA 500 A. Item Equipment Equip. No. 512 No. 2 Chlorlnator 32-0262 Cooler 513 No. .1 Chlorlnator 19-0497 Circulating Pump 514 No. 1 Chlorlnator 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 Chlorlnator 32-0264 Cooler 523 No. 6 Chlorlnator 32-0265 Cooler Description Same as Item 508. Same as Item 509. Same as Item 508. 7'-6" dla. 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" dla. 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 EIBZ Faulk motor reducer driven by a 10 HP, 1800 RPK, 440 volt motor. The agitator has a 2-3/4" dla. x 8'-8H 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 303391 WATER PCB-SD0000050942 APPENDIX A - EQUIPMENT LIST AREA 500 5. Item Equipment Equip. No. 524 No. 7 Chlorinetor 32-0266 Cooler 525 No. 8 Chlorinetor 32-0267 Cooler 526 Crude Aroclor Cetch Tenk 22-0789 527 Crude Aroclor Cetch Tenk Pump 19-0526 528 Continuous Air Blow 22-0682 Tenk 529 Continuous Blow 19-0499 Tenk Transfer Pump 530 Air Blower North 531 Solids Off-Gas Eductor 11-0338 532 Liquids Off-Gas Eductor 533 Thermlnol Surge Tank #9 Chlor. 22-0775 534 No. 9 Surge Tenk Pump 535 Weigh Tank 19-0500 i 536 Weigh Tenk Pupp 19-0501 Description Seme 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 @ 75' head - vertical heavy duty centrifugal Taber pump - CV-3 #393. 500 gallon steel tank. Purchased from Dixie Steel & Supply Co. See HCC Dug. 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* TEH. Model 7 H - Spec. SM-488-530. Purchased from Sutorbllt Corp. S6 Fig. 4010 Scrubber and S 4040 Separator Box Haveg & P.E. Const. 6" Suet. 6" Discharge. S6K Fig. 4010 Scrubber - 8" Suet. 8" Discharge. 4'-0" O.D. x 5'-3". 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 coll. 5 turns 2" Sch. 80 C.S. pipe. Capacity 2,000 gallons. Goulds Model 3196 AVS No. A 60 con structed of Ductile Iron. Capacity 125 GPM. DSW 303392 WATER PCB-SD0000050943 APPENDIX A - EQUIPMENT LIST AREA 500 6. Item Equipment Equip. No. 537 No. 9 Chlorinator Mist Eliminator 538 No. 9 Chlorinator 32-0259 Cooler 539 No. 2 Blow Tank Pump 19-0502 540 Biphenyl Peed Pump 541 No. 2 Blow Tank 22-0777 542 No. 1 Blow Tank 22-0266-02 543 No. 1 Blow Tank 19-0355 Pump Description Monsanto Brink type demister in a 30" O.D. x 4* * 6' long carbon steel tank. Bottom nostle 10" dia., 10" flange, with a 6" gas outlet. Designed for 30 pslg at 450F. Contains a Brink element No. 2448. Capacity 325 cfm at 8 pslg and 250C. Inlet mist loading 2,000 mg/cu.ft. Outlet: mist loading 20 mg/cu.ft. Efficiency 99T. Carbon steel heat exchanger 8' long with 3/4" O.D, x 15 BWG tubes containing 184 tubes. Pour 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. 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. 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. 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. Same as Item 515. Vertical, centrifugal, submerged Taber pump. 2-1/2" inlet - 1-1/2" outlet. Cast iron construction. Capacity 50 GPM. DSW 303393 WATER_PCB-SD0000050944 APPENDIX A - EQUIPMENT LIST AREA 500 7. Item Equipment Equip.No. 544 Veigh Tank Scale 24-0194 545 Crude Aroclor Catch Tank Transfer Pump 546 Brink Demister 41-0037 No. 7 Chlorinetor 547 Brink Demister 41-0038 No. 6 Chlorlnator 548 Brink Demister 41-0039 No. 5 Chlorlnator 549 HC1 Off-Gas Condenser (Liquid Sys tern) 550 Chlorine Vaporiser 32-0185 551 No. 1 Chlorlnator 22-0675 552 No. 3 Chlorlnator 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 stain tare bar graduated 20,000 pounds and 5,000 pounds. The dial has one adjustable Reed svitch to operate at scale set point. Scale to be hung below 11' platform level built to contain the veigh 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 RPM, 440 volt motor). Capacity 80 GPM at 100' TDH. l'-8" dia. x 4'-2" straight side carbon steel 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 Vaporiser, vertical type, complete with super heater section Monel construction - purphased from R. M. Armstrong Co. 90 tons/day capacity. 3*-0" dia. x 16*-0". See Drawing E-6209. See Item 551. OSVJ 303304 WATER PCB-SD0000050945 APPENDIX A - EQUIPMENT LIST AREA 500 8 Equipment Equip.No. No. 3 Chlorlnator 22-0673 Description See Item 551. 554 No. 4 Chlorlnator 22-0674 See Item 551. 555 No. 8 Chlorlnator See Item 551. l" 556 No. 7 Chlorlnator See Item 551. * ' 557 No. 6 Chlorlnator 22-0677 See Item 551. l/ 558 No. 5 Chlorlnator 22-0676 See Item 551. ^ 559 No. 4 Chlorlnator 19-0414 Same as Item 509. C \ f t- , p 560 Brink Demister 41-0040 Same as Item 546. No. 1 Chlorlnator 561 Brink Demister 41-0041 Same as Item 546. No.2 Chlorlnator 562 Brink Demister 41-0042 Same as Item 546. No. 3 Chlorlnator 563 Brink Demister 41-0043 Same as Item 546. No. 4 Chlorlnator 564 Brink Demister 41-0044 Same as Item 546. No. 8 Chlorlnator 565 Instrument Air 37-0098 Joy Manufacturing Company No. WFPOS-9, Compressor Sise 8" x 5" skid-mounted air compressor unit with after-cooler and air receiver. Operated by a 25 HP, 1800 EPM, 440 volt motor. Capacity 105 cfm at 100 psig. ,0^S4 WATER PCB-SD0000050946 APPENDIX A - EQUIPMENT LIST AREA 500 9. 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 Chlorlnator 19-0414 Circulating Pump No. 7 Chlorlnator 19-0414 Circulating Pump No. 5 Chlorlnator 19-0394 Circulating Pump No. 8 Chlorlnator 19-0405 Circulating Pump HC1 Off-Gas Catch 22-0811 Tank (Liquid Chlorlnator System) Trappings Transfer Pump (Liquid) Brink Mist Eliminator HC1 Catch Tank Description Fume Hood designed by Brovne-Morse Co. #73 Green unit with a gray colorllth 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 11'-3" straight side, carbon steel tank, with dished heads and a 3" Sch. 80 carbon steel pipe coll 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 pslg at 105F. temperature. Capacity 635 cfm at 851 EC1 gas. Designed to collect 99X of entrained droplets and return to the catch tank. DSW 303396 WATER PCB-SD0000050947 APPENDIX A - EQUIPMENT LIST AREA 500 10. Item 577 578 579 580 581 582 584 Equipment Eqtilp.No. Thermlnol Surge Tank for Solid HC1 Clean-Up Condenser Tberminol Pump for Solids Knock-Out Condenser Therminol Cooler for Solids Knock-Out Condenser System HC1 Off-Gas Condenser (Solids System) HCl 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 coll approxi mately 10* long. Capacity 300 gals. Self-priming, horlsontal 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 EPM, 440 volt motor, pump equipped vith a Crane No. 9 outside mechanical seal. Code QP-868). Capacity 150 GPM at 50' TDR. Dialer 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, vith 80 1-1/2" O.D. x 14 ENG 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 vith 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, horieontal centrifugal pump (Goulds Model 3196 AVS-A60, 2x3- 10, with an 8" open type impeller constructed of Ductile iron vith 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. OS\N 303397 WATER PCB-SD0000050948 APPENDIX A - EQUIPMENT LIST AREA 500 11. Item 585 Equipment Chlorinator Charge Tank 586 Air Blower (South) 587 Air Blower (Middle) 588 Biphenyl Peed Tank Agitator 589 Fume Jet No. 2 Blow Tank 592 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. D' 47909. 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-Separafor consisting of: 1-6" Fig. 4010 Haveg 61 Fume Scrubber. 1-6" Fig. 4040 Polyester Fiberglass Separator. JOT WFPOS-9, Site 6% x 4%, Capacity 5U 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 303398 WATER PCB-SD0000050949 APPENDIX A - EQUIPMENT LIST AREA 600 12. Item 601 Equipment No. 3 Blend Tank Pump 602 Ho. 3 Blend Tank 603 No. 2 Blend Tank Pump 604 No. 2 Blend Tank 605 No. 1 Blend Tank Pump 606 No. 1 Blend Tank 607 No. 1 Vacuum Receiver 608 No. 1 Vacuum Receiver Pump 609 No. 2 Vacuum Receiver 610 No. 2 Vacuum Receiver Pump 611 No. 3 Vacuum Receiver Equip.No. 19-0293 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 DS0 8 - all bronze, SAE 63 Frame 213 - Serial No. 121340 Peerleaa. 7'-0" O.D. x approx. 7'-0" on shell. Dug. 9-C-8247. 1-1/2 DS0 8 - all bronze, SAE 63 Frame 213 - Serial No. 121340-Peerlees. 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. Dug. C-795. Same as Item 608 6'-6" dla. x 7'-9" straight side, vertical tank, lined vlth Monel plating. Tank equipped with a Monel coil con structed of 1-1/2" Sch. 40 Monel pipe vlth approx. 48 linear feet of coll. Capacity 2,000 gallons. Model GZ-CH NEMA 213. Fig. 3202, 90 VPR bronze, Blackmer Pump. 7*-0" O.D. x 7'-0". Dvg. 9C-8247. Purchased from Chattanooga Boiler and Tank Co. DSW 303399 WATER PCB-SD0000050950 APPENDIX A - EQUIPMENT LIST AREA 600 13. Item Equipment 614 No. 1 Filtrate Receiver 615 No, 4 Still Equip.No. 22-0269 22-0779 616 No. 4 Still 19-0505 Circulating Pump 617 Freight Elevator 10-0200 618 No. 4 Still Heater 32-0271 619 No. 4 Still Condenser 32-0272 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 coll 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" dla. open type Impeller, 25 HP, 1800 RPM, 440 volt motor, with 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" dla. x 11'-8" high shell con taining a 3" dla. Sch. 80 coll, 259 sq.ft, surface area In a 6' dla. 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). l'-2" dla. x 10' long, carbon steel heat exchanger with 112-3/4" x 14 BWG x 8' long tubes, designed for four passes on tube side. Designed for full vacuum. Condenser contains a special design Marquette expansion joint constructed of 304 stainless steel with Sch. 30 welding ends. Capacity 477,000 BTU/hour. DSW 303400 WATER PCB-SD0000050951 APPENDIX A - EQUIPMENT LIST AREA 600 14. Item Equipment Equip.No. 620 No. 4 Still 22-0780 Vacuum Receiver 621 No. 4 Still 19-0506 Vacuum Receiver Transfer Pump ' 622 Therminol Surge 22-0781 Tank 623 Therminol C^r. 19-0507 Pump for No. 4 Still Coolant 624 Therminol Cooler No. 4 Still System 625 No. 4 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 coll with approximately 52 sq.ft, of surface area. Designed for full vacuum operation at 400C. Capacity 2.000 gallons. Self-priming, centrifugal pump (Goulds Model 3196 AVS-A60, 7-7/8" dia. open type Impeller, 10 HP, 1800 RPM, 440 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 CPK at 50' TDH. 3*-6" dia. x 4*-3" straight aide, 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, 440 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. 56E5A48, 1" O.D. ENG 16 tubes, 4* long, with aluminum fins, 60 sq.ft, surface area. Total fin surface area 1,171 sq. ft. Overall dimensions 2' x 4' x 4'-6" high. Manufactured by Dialer Engine ering Company. Fan for cooler 1 HP, 1800 RPM, 440 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 coll 6' long. Capacity 200 gallons. DSVV 303401 WATER PCB-SD0000050952 APPENDIX A - EQUIPMENT LIST AREA 600 15. Item 626 Equipment Ho. 4 Still Vacuum Jet Equip.No. 35-0123 627 Thermlnol Surge 22-0783 Tank (No. 4 Still Cooling System) 628 Thermlnol Heater 19-0508 Circulating Pump 629 Thermlnol 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 aide, horizontal, carbon steel tank with dished heads. Tank contains a 3" Sch. 80 coll 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 RFM, 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 Thermlnol FR-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 Lummlte-Haydlte vermicullte 124 mix, suitable for 2,000P 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" dla. 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 RFM, 440 volt motor. Capacity, provide medium Sltation, in 250 gal. steel jacketed tk. 3' dia. x 3' long vertical tank, fabricated by Fiberglass. Capacity 150 gallons. osflM3402 WATER PCB-SD0000050953 APPENDIX A - EQUIPMENT LIST AREA 600 16. Time 634 Equipment 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 Pulveriser 17-0027 Description 2> x 2' x 1* high hopper, fabricated of carbon steel. To fit a 6" nozzle. Capacity 50 lbs. of lime. 2'-0M 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" 0AB. 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 C.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. DS\N 303403 WATER PCB-SD0000050954 APPENDIX A - EQUIPMENT LIST AREA 600 17. Item Equipment Equip.No. 650 No. 1 Still Pot 20-0018-01 651 Circulating Pump 19-0230-01 Ho. 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 No. 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 Ho. 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. fi'-O" dia. x S'-b" 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. DSVV 303404 WATER PCB-SD0000050955 APPENDIX A - EQUIPMENT LIST AREA 600 18 Item Eauipment 664 Ho. 3 Still Ejector Eouin.No. 35-0125 669 Lime Slurry Tank 22-0790 670 No. 1 Roof Tank 22-0078-01 674 Circulating Pump (Spare) 19-0238-01 690 Aroclor Flaker 14-0031 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. Model VMS 5-56, size 24" x 48". Stainless steel drum vith feed pans. Purchased from Cosiin. DSW 303405 WATER PCB-SD0000050956 STANDARD MANUFACTURING PROCESS FOR AROCLOR APPENDIX B - MATERIAL SPECIFICATIONS I - FINISHED COOPS a. Aroclor 1221 b. Aroclor 1232* c. Aroclor 1242 d. Aroclor 1248 e. Aroclor 1254 f. Aroclor 1260 g. Aroclor 1262 h. Aroclor 1268 1. Aroclor 2565 (undiatilled) j. Aroclor 4465 k. Aroclor 5442 l. Aroclor 5460 *Aroclor 1232 is a mixture of approximately 53.4% Aroclor 1221 and 46.6% Aroclor 1242 (by volume). II - RAW MATERIALS a. Biphenyl b. Santovax C c. Santovax R d. Chlorine e. Hydrated Lime f. Attapulgua Earth g. Ferric Chloride DSW 303406 WATER PCB-SD0000050957 IT f t 4 Monsanto Chemical Company ORGANIC CHEMICALS DIVISION ANNISTON FINISHED PRODUCT SPECIFICATION product (Trade name) AR0CL0R 1221 PRODUCT (Chemical name) CHEMICAL FORMULA Mixture RAODUCT CODE 826.10 (27-L) METHOD IDENTITY SALES CODE 1040-225-04/11/16-09 TYPE Distilled TYPE SUPERSEDES SPECS OF 7 /oo/*;*; SPECIAL JOB NO. m SAMPLE FOP ANALYSIS 2 x 1/2 gal. amber jugs UNCLASSIFIED SPECIFICATION Routine Tests Property Color, APHA Specific Gravity @ 25/15.5C . Acidity, mg KOH/g. Viscosity @ 100F., SUS Specification 100, Max. 1.182-1.192 0.014, Max. 38-41 General Information Chlorine, 7. 20.5-21.5 Issued 4/25/61 B y L1!xvv*~~p W. W. Klemme Anniston Plan Standards Dep MOL WT. USE Sales Method No. 14-44-54 14-49-54 14-42-54 14-4-52 14-13-54 DSW 303407 WATER PCB-SD0000050958 om m Monsanto Chemical Company ORGANIC CHEMICAL* DIVISION ADISTCH FINISHED PRODUCT SPECIFICATION PRODUCT (Trad* name) AROCLOR 1232 PRODUCT (Ot**meai name) CM KM CAL FORMULA PMBUCT CAM tti.ll (17-L) HKTMOD IDENTITY ae AUKS CODS 1040-230-04/11/16-09 TTPK Distilled TTPK Mixture actturcRtcoctsr op 4/25/61 MKCML JO NO. SAMPLE FOR AN ALT MS 2x1/2 gel. amber jugs UHCLASSPIED SPECIFICATIOHS Routine Tests Property Specification Color, APHA 100, Max. Acidity, mg KOB/g. 0.014, Max. Specific Gravity @ 23/15.5C 1.270-1.280 Viscosity @ 100*P., SOS 44-51 General Information Chlorine, X SI.5-32.5 RESTRICTED SPBCIPICATIOHS Routine Tests Veter, ppm 35 Max. ' Refractive Index 9 25*C 1.6180-1.6200 Condition Clear Liquid General Information Inorganic Chlorides, ppm Resistivity, ofam-ca 500V DC,0.1" gap, 100*C. 0.10 Max. 300 x 109 Min. Dielectric Constant 9 1 KC,100*C. 4.3-4.5 Distillation Range, *C. corrected: 10X, by wt. 293, Min. 50X, by wt. 310-320 90X, by wt. 360, Max. Issued: 10/21/63 ' y: 0. > )o-& o. e; toils Analston Plant Standards ley t MOL WT. " ' -- -- UtK 8al.es - . Method Ho. 14-44-54 14-42-54 14-49-54 14- 4-52 14-13-54 14-53-54 14-34-54 10-084 014 14-35-54 14-36-54 14-31-54 COO cOcoo o WATER PCB-SD0000050959 Azmis ton Finished Product Specification Product: Arodor 1232 (Distilled) RESTRICTED SPECIFICATIONS General Information - Continued Pour Point, *C. Belov -30 Corrosion Test Change in wt. alualnua, X 0.0 Acid No. after test, ag KOH/g. 0.015, Max. Inorganic Chlorides after test, ppa 0.10, Max. Condition after test Clear Color after test, APSA 100, Max. OED/ga 10/28/63 ?i|e 2 14-47-54 14-52-54 014 G-l 14-44-54 DSW 303409 WATER PCB-SD0000050960 Monsanto OKO A N 1C CHCMICtLI DIVISION ANNISTON" 1ANB = KRUMMRICH. FINISHED PRODUCT ' SPECIFICATION PRODUCTION P. E. Heisler SALU W. E, Ault CCHCRAL OCICRIPTIOn PNODuCT Aroclor plnt WGK, Ann. DATS CPrUctivk 6/17/66 1242, Electrical Grade DCT. 246 PPOOUCT COOK 81101 - 82612 Sale s *Lt* COOS 1040-240-04/11/ 16-03/09 APPROVAL! RESEARCH " R, W. Bucknell quality control (Chit cstmi.o W. J. Gresham (J. E. Doiin . CHEMICAL FORMULA 27 L " Alsou known as Pyranol 1499 MOL WT. UMKttDU IPICI. OP 4-13 -62 CHARACTERISTIC IAMPLI for AMALTAI! 3 x 5 pt. Amber Bottles LIMITS UNRESTRICTED INFORMATION (R) Color (APHA) 40, max. (R) Condition Clear (R) Sp. Gr. @ 25/15.5*C. 1.381 - 1.392 (R) Acidity (mg. KOH/g.) 0. 010, max. (R) Moisture (H2O) 35 ppm. , max. (R) Refractive Index @25 C. 1.6240 - 1.6260 (R) Inorganic (Free) Chlorides 0. 05 ppm . , max. 'R> Pour Point -14C. or Lower ,R) Dielectric Constant 4. 70 - 4.90 (1000 cycles @ 100C. ) (R) Resistivity 500, min. (500 VDC @ 100*C. 0. 1" Gap) As OHM-CM x 109 (R) Hydrolysis Stability Test (As Chlorides) 0.5 ppm, max. (R) Monsanto Stability Test (As Chlorides) 0.4 ppm., max. (R) Distillation Range (ASTM D-20, Corrected) 10% Distilled by wt. 325 "C, , min. 90% Distilled by wt. 360 C, , max. Sulfate s None Dielectric Strength @ 25 c. 35 KV, min. Flash Point (F) 338 - 392 Fire Point None Corrosion Test (6 hrs. @ 210C. with bright aluminum foil) Change in wt. of AL % 0. 0 A. C. Color (APHA) 60, max, 1A . C . Condition Clear A.C. Acidity (mg. KOH/g.) 0. 010, max. A.C. Inorganic (Free) 0. 05 ppm. , max. Chlorides [ Vise. @ 100'F. (SUS) 82 - 92 (Over) - (Rj Routine Analysis, All others Analysed by request Only ISSUE V J. P. Prade METMOO WGK Anniston 10084 10084 10114 10087 10620 10125 12741 10115 11608 14-44-54 G-l 14-49-54 14-42-54 14-53-54 14-34-54 014 14-47-54 14-36-54 11607 12672 14-35-57 - 010 11503 14-61-57 10117 14-31-54 12169 11605 10123 10123 10126 043 14-28-54 14-28-54 14-55-57 10084 10084 10087 12741 10086 14-44-54 G-l 14-42-54 014 14- 4-52 DSW 303410 WATER_PCB-SD0000050961 GENERAL) INFORMATION Specific Heat @ 25 *C. Coefficient of Expansion (25 - 65-C) Fixed Chlorine Power Factor @ 100'C. 60 cycles 1000 cycles 0. 30 0. 00068 cc/*C, 42.5 - 4B.5% ( Typical Values) 5 0. 30 SPECIAL CUSTOMER REQUIREMENTS General Electric Thermal Chemical Chlorides 0.65 ppm., max. Westinghouse Hydroliaable Chlorine (Westingkouse Stability Test) 1.0 ppm., max. 12722 T-2219 =3' DSW 303411 WATER PCB-SD0000050962 MONSANTO CHEMICAL COMPANY OMAMC CHCMCALS DIVMION M*OOUCT COOK 81102 uu I 27 Ann. W.G.K. and Anniston FINISHED PRODUCT SPECIFICATION PNOOUCT (IMi Ita^ Sales SALn COOK 1040-260-04/11/16-03/09 TVPi Aroclor 1248 Electrical Grade (Pyranol 1498) rNODUCT (Ctimmloal TYM C HCMCAL POUMUtA Issued l/l0/64 W. G. Rrummrian Plant ' By Hpj . IS -TkJs Corrected 2-16-64 ` Mixture MOL WT. 2-12-60 SAMPLE WO* ANALYSIS 3 x 5 pt, Amber Bottles UNRESTRICTED INFORMATION Routine Tests Specification Color, APHA Condition Sp. Gr. @65/15.5C Acidity (mg. KOH/gm.) Moisture Refractive Index @25C Inorganics (Free) Chlorides Pour Point Dielectric Constant (1000 cycles @100c) Resistivity (500 VDC @100C 0.1" GAP) as OHM-CM x 10* Hydrolysis Stability Test (as Chlorides) Monsanto Stability Test (as Chlorides) Distillation Range ' (ASTM D-20, Corrected) IO56 Distilled by Wt. 9056 Distilled by Wt. 50, max. Clear 1.405 - 1.415 0.010, max. 35 ppm., max. 1.6285 - 1.6305 0.05 ppm., max. 0C, max. 4.5 - 4.7 500, min. 1.0 ppm., max. 0.5 ppm., max. 345C, min. 385C, max, General TeBts (made only on request) Sulfates Dielectric Strength @25-C Fire Point Viscosity @54.4C (SUS) Corrosion Test (6 hrs. @210C with bright aluminum foil) Change in wt. of A1 (%) None 35 KV, min. None to boiling point 73 - 80 0.0 (over) Method No's. WGK Anniston 10,084 14-44-54 ' 10,084 G-l 10,114 14-49-54 10,087 14-42-54 10,620 14-53-54 10,125 14-34-54 T-2092 014 " 10,115 14-27-54 11,608 14-36-54 11,607 14-35-57 T-2087 010 11,503 14-61-57 10,117 14-31-54 12,169 - - 11,605 043 10.125 14-28-54 10,086 14-4-52 10.126 14-55-57 DSW 303412 r~) IN H <N*V. II/Ml WATER_PCB-SD0000050963 A. C. Color, APHA A. C. Condition A. C. Acidity (mg. KOH/g.) A. C. Inorganic (Free) Chlorides 60, max. Clear 0.010, max. 0.05 ppm., max. GENERAL INFORMATION Specific Heat @25C Fixed Chlorine 0.27 47.5 - 48.5 10,084 14-44-54 10,084 G-l 10,087 14-42-54 10,118 010 03 0s'*4 3 WATER PCB-SD0000050964 MONSANTO CHEMICAL COMPANY OMAMC CHMCAU DIVISION Kruimnrich and Anniston > FINISHED PRODUCT SPECIFICATION MOOUCT <TMS* Ham*) . Aroclor 1248 PRODUCT (CAmImI Jlmil . psoouct cooc Idkpt. okjos . 81102 - 82641 IVOR 246-Ann.27 Issued JUL 1 5 1964 UN . W. 0. KrummrlcTi Plant Sales SALKS COOK . By 'W 7 1040-260-04/11/16-03/09 TVPK Non-Electrical Grade TTPE CNKMCAL FORMULA ^- . .. . . . . Mixture . . ... ,, . _ HM. WT. . . wnniKi SPica op SASTLK PON ANALVSW 5-4-61______________________ ____5-JC-16 QZ. W. M. Bottles____________________ UNRESTRICTED INFORMATION Routine Tests Appearance Condition ,7 Color, APHA Sp. Or. 65/l5.5*C ' * ^ X <: . Acidity (mg. KOH/g.)' Moisture (HaO) (ppnu) Viscosity 150*F (SUS)lr; General Tests Specification Colorless to light yellow-green liquid Clear s"` ' ' 100 max. . ; 1.^05 - 1.415^:: . 0.010, max. > V *V , -> ./V **. **: *~y - ' 75 - 80. -^:^:; -> WOK Anniston Method Wo. 10084 0-1 0-1 046 052 050 047 049 - 14-28-54 WATER PCB-SD0000050965 . 4 Monsanto Od.AMIC CHEMICALS OIVt**4H - FINISHED PRODUCT SPECIFICATION PRODUCT ior P. E. Heisler Kkll . W. E. Ault . (nciul occaiftion PdOOwCT ' Aroclor FuVnV 1254 ^ Electrical Grad e MTSImMt 461---- -- , |MFf. 1 246 - 27 .WOK and Ann. STTT MI8U11C0H3K---8--2--6---1--3-------_-_--_--_--S---a--l-e---s--------------_--_--_--- JUN 281965 J4Q-28o-04/11/i6-03/qq__________ KCICANCN ................. R. W. Bucknell OUALITV COKTHOL (Chief C/MmltO W. J. Gresham. 0. E. CHEMICAL FORMULA Dolin Also called Pyranol 1476 MOL. WT. ' UFKRAKDKS tFSCA. OF 4-15-62 CHARACTERISTIC foa tMirin 5x5 Pt. Amber Bottles LIMITS UNRESTRICTED INFORMATION Color, APHA 50, max. Condition Clear Sp. Or.. @65/15.5C 1.495 - 1.505 Acidity (mg. KOH/gm.) 0.010, max. Moisture (H2O) 55 ppm, max. Refractive Index @25C I.6570 - 1.6590 11 Inorganic (Free) Chlorides 0.05 ppm., max. Pour Point 7 - 126C Dielectric Constant 4.15 - 455 (lOOO cycles 9100C) (R) Resistivity 500, min. (500 VDC @100C 0.1" GAP) as OHM-CM x 109 (R) Hydrol^Bsa^Stability Test 1.0 ppm., max. (as Cn^frlddff' (R) Monsanto Stability Test 0.5 ppm., max. (as Chlorides) (R) Distillation R^tnge (ASTM D-20, Corrected) 10# Distilled by Wt. 566 - 578C 50# Distilled by Wt. 571 - 585 C 90 Distilled by Wt. 579 - 594C Sulfates None Dielectric Strength @25C 55KV, min. Flash Point None Fire Point None Vise. @210F (SUS) 44-48 Corrosion Test (6 hrs 9210C 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 M. D. Dealy MTMD WGK T0584 10084 10114 10087 10620 10125 T-2092 10115 II608 11607 T-2087 11505 10117 Ann. PT^4-54 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 10084 10084 10087 10118 043 14-28-54 14-28-54 14-4-52 14-55-57 14.44-52. G-l 14-42-51 010 (R) Routine Analytig, All othert Analygei by request Only svv 303415 WATER PCB-SD0000050966 MONSANTO CHEMICAL COMPANY OM/UIC CHEMICALS DIVISION Krummrich and Anniston s FINISHED PRODUCT ' SPECIFICATION fHOOUCT (IM IS--n) Aroclor 1254 PRODUCTfCA----l IV--; PROOUCT COO* jo*FT. OR JOS -T , JUL 15 1964 81103 - 82613 IWQK-246-Ann.27 Issued US* w. G. Krummrich Flapt SaleB By `Ytf 15 75 ^ SALKS COO* 1040-280-04/11/16-03/09 TVS* Non-Electrical Grade TVS* CMMCtL FORMULA Mixture MOL WT. SUPKRSCDKS SPECS OP 5--6i__________ :___ ' S/UPLI POM ANALTSIS 3 x l6 oz. V. M. Bottles UNRESTRICTED INFORMATION Routine Tests ,, Color, APHA Sp. Gr. 65/15.5*C Acidity (mg. KOH/g.) Moisture (HgO) (ppm.) General TeBts Flash Point Viscosity 210*F (SUS) Specification 100, max. ' 1.495 - 1.505 0.010, max. 50, max. None 44-48 WGK Anniston Method no. 10084 10114 10087 10620 046 052 050 . 047 10123 10086 14-28-54 049 . IM * tftCV. U/M) *\ / DSW 303416 WATER PCB-SD0000050967 ** MONSANTO CHEMICAL COMPANY ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION product (Trade name) AR0CL0R 1260 PRODUCT (Omricd name) CHEMICAL FORMULA PRODUCT CODE - . 62614 - Anniston Rims - urrr Department 27_ Anniston SALES CODE 246 - VGC 1040-290-04/11/16/-03/09 TTPB Electricel Grade TTPE (Pyranol 1482) Issued 2/7/62 V. G. Krumsrich Plant By g. 0. Martin MIXTURE MOL. VT. WUHIDU IPICI OP SPECIM. JOB HO. 3/W/58 UNRESTRICTED INFORMATION USE (AMPLE FOR ANALYSIS 3 x 5 pt. Amber Bottles Sales Routine Tests: Property Color (APHA) Condition Specific Gravity @ 90/15.5*C Acidity (mg HOB./g.) Moisture (H2O) (ppm.) Viscosity & 210F (SUS) Refractive Index @ 25*C Inorganic (Free) Chlorides Pour Point (*C) Distillation Range (ASTM D-20, Corrected) 10X Distilled by wt. 50X Distilled by wt. 90X Distilled by wt. Corrosion Test (6 hrs. @ 210C with bright aluminum foil) Change in weight of AL (l) A.C. Color (APHA) A.C. Condition A.C. Acidity (ag.KOH/g.) A.C. Inorganic (Free) Chlorides Specification 150, Max. Clear 1.55^-1.566 0.014, Max. 35, Max. 72-78 1.6455-1.6470 No detectable amt. 25-34 385-398*C 390-404#C 400-420*C - 0.0 150, Max. Clear 0.014, Max. Ho detectable amt. Method No. HGK Anniston 10,084 10,084 10,114 10,087 10,620 10,086 10,125 10,118 10,115 10,117 14-44-54 -- 14-49-54 14-42-54 14-53-54 14- 4-52 14-34-54 14-48-57 14-47-54 14-32-54 10,126 14-55-57 10,084 10,084 10,087 10,118 14-44-54 14-42-54 14-48-57 General Tests (made only on request) Flash Point Fire Point ' Fixed Chlorine (Z) Dielectric Strength @ 50*C Resistivity (500 VDC 0 100*C 0.1" gap as . ohm-cm. m 10') Dielectric Constant 1000 cycles, 100*C Hone Hone 59.5-60.5 30 K.V., Min. 500, Min. 3.6-3.8 10,123 10,123 10,088 11,605 11,607 11,608 14-28-54 14-28-54 14-13-54 14-35-57 14-36-45 DSW 303417 WATER PCB-SD0000050968 BHRESTRICTIB UFORHATIO* (eeatinned) Property Restricted Information Monsanto Stability Teat (A.s Chlorides in ppst.) General Information Evaporation Loss after 6 hrs. (? 100*C (I) Stability test - after 30 days at 100*C in glass sealed in air Specification 0-7, Max. Method Ho. ICI dtmiston 11,503 14-61-57 0.2, Max. 10,116 Ho liberation of chlorine or chlorides ------ 14-32-54 -------------- Retyped: March 7, 1963 /g* DSW *>34r5 WATER PCB-SD0000050969 KOKSANTO CHEMICAL COMPANY 04OIK) AHI C CHEMICALS VIMOM Krummrich and Anniston FINISHED PRODUCT SPECIFICATION ROOUCT (Tifc Mmmm) Aroclor 1260 PRODUCT (Ctmmloml ftmm*) FROOUCT cooc DCFT, OR jom 81105 - 82614 WOK 246 Ann.27 UMt Sales MLD COOC 1040-290-04/11/16-03/09 T VFC ____ Non-Electrio Grade___________ TTFE Issued JU L 1 5 1964 W. 0. KjMJurjmrlch /^lant By * IHCMiCAL FORMULA Mixture toL rr. lUFIMUXt MMICI OF 5-4-61 - UU^LC FOR ANALTMC 3 X 16 OZ. W. M. Bottlfifl UNRESTRICTED INFORMATION Routine Tests Condition Color, APHA Sp. Gr. 90/15.5*0 Acidity (mg. KOH/g.) Moisture (H2O) (ppm.) ViscoBlty 210*F (SUS) General Tests Flash Point Fire Point Specification Clear 150, max. 1.555 - 1.566 0.014, max. 50, max. 72-78 None None WOK Annletoc .Method.Wo, 1 10084 10084. 10114 10087 10620 10086 G-l . 046 052- || 050 ^ 047 \l 049 10123 10123 14-28-5J 14-28-5* 0s^' ti WATER PCB-SD0000050970 Monsanto ORGANIC CHEMICAL* division PROOUCT -f'C ' AROCl/OR >L ANT DISTILLED 1262 use 1Ilocrr. Aa nn-*WGK-24f ANNISTON AND KRUMMRICH ANN. k WGK 811 07 -WGK_____ Sale s FINISHED PRODUCT >AfI If/*4tivE salI*eobt > SPECIFICATION MAR 02 1966 approval* 1040-300-04/11/16-03-09 production CM P. E. HeiBler w. D. Robinson SACKS Quality CONTROL (Chlgf ChnmltO q g Dolin W. E. Ault W. J. Gresham '' CCNCRAC DCICRlPT ION CHCMICAC foawuca mol ITT. tU^CRIEDU IPKCI. or 1/24/62 C MAR AC T KR IS TIC tAbf UK won ANALYSIS 2 x 16 oz. W.M. Bottles UMTS iisucd sr J. P. Prader MKT MOO UNRESTRICTED INFORMATION (R)^ Appearance Viscous liquid 10084 (R) Color APHA 150, max. 10084 (R) Specific Gravity @ 90/15.S"C. 1.572 - 1.583 10114 (R) Acid No. (mg. KOH/g.) 0. 014, max. 10087 (R) Viscosity @ 210F. 86 - 100 SUS 10086 GENERAL INFORMATION Pour Point (ASTM) 35 - 38C. Distilling Range 390 - 425C. Total Chlorine 61.5 - 62.5% Specific' Gravity Temperature Coefficient (85 - 130 *C .) 0. 001/ 'C. (Rl Routine Analy* i, All otktrs Analyttd by Only DS^ 303*20 WATER PCB-SD0000050971 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 COOK use Anniston DATE EFFECTIVE 826.16 SALES CODE Sales 3-11-66 approv als RESEARCH 1040-340-04-11-16 -009 L. R. Stark /s/ 3-8-66 (QUALITY CONTROL Ch/.f Chwni.U . 0. E. Dolin /s/ 12-29-65 CHEMICAL FORMULA DEPT* 27-S MOL WT. SUPERSEDES SPECS. OF 4-25-61 CHARACTERISTIC SAMPLE FOR ANALYSIS ISSUCO BY lx 16 oz. Can or W.M. Bottle J. A. Liddle 11-30-65 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 KOH 0.05 Max. RESTRICTED INFORMATION Screen Test, % retained on No. 16 mesh 0.1 Max. No. 20 mesh 10 Max. Specific Gravity @ 25/25C., Pycnometer 1.804 - 1.811 Loss @ 163C., 1 0.15 - 0.24 G-l 119 116 120 (R) Routine Analysis, All others Analyzed by request Only DSW 303421 WATER PCB-SD0000050972 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moody /s/ 12-29-65 S ALES W. E. Ault /s/ 3-2-66 GENERAL DESCRIPTION Mixture PRODUCT Aroclor 2565 PLANT PRODUCT CODE USE Anniston DATE EFFECTIVE 826.18 SALES code Sales 3-11-66 APPROVALS RESEARC H 1040-390-04-009 L. R. Stark /a/ 3-8-66 QUALITY CONTROL (Chlel ChcmtmO 0. E. Dolin /el 12-29-65 . CHEMICAL FORMULA OCPT. 27-S `. MOL WT. SUPERSEDES SPECS. OP 4-25-61 CHARACTERISTIC UNRESTRICTED INFORMATION (R) Appearance and Color (R) Softening Point, C (R) Acid No., mg KOH/g SAMPLE FOR ANALYSIS ItlUKD BY 1 x 16 oz. Can or W.M. Bottle J. A. Llddle 11-30-65 METHOD Black, brittle resin 66 - 72 1.4 Max. G-l 115 116 (R) Routine Analysis, All others Analyzed by request Only oSVJ 303422 WATER PCB-SD0000050973 Monsanto organic c hemic al$ division FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moodv /s/ 2-29-66 SALES W. E. Ault /s/ 3-2-66 GENERAL DESCRIPTION Mixture PROOUCT Aroclor 4465 PLANT Anniston OATE EfFICTIVI PROOUCT COOK 826.19 SALE CODE use Sales 3-11-66 APPROVALI RESEARCH 1040-430-04-11-16 -009 L. R. Stark /s/ 3-8-66 QUALITY CONTROL (Chtmt CtmmteO 0. E. Dolin /s/ 12-29-65 CHEMICAL FORMULA 1 1DCPT. 27-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 ISBUEO BV L x 16 oz. Can or W.M. Bottle J. A. Liddle 11-30-65 LIMIT* MCTMOO Clear, light yellow resin 2 Max. 60 - 66 0.05 Max. G-l G-4 115 116 (R) Routine Analysis, All others Analyzed by request Only DSW 303423 WATER PCB-SD0000050974 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moody /s/ 12-29-65 SALES V. E. Ault /s/ 3-2-66 CCNERAL DESCRIPTION PRODUCT Aroclor 5442 PLANT PRODUCT COOK use Anniston DATS EFFECTIVE 826.21 SALES CODE Sales 3-15-66 APPROV A L > RESEARC H 1040-470-04-009 L. R. Stark /s/ 3-11-66 QUALITY CONTROL (Chltl ChmmhO 0. E. Dolin /a/ 12-29-65 chemical formula DEPT. 27-S Mixture MOL TTT. SUPERSEDES SPECS, OF 4-25-61 CHARACTERISTIC UNRESTRICTED INFORMATION (R) Appearance and Color (R) Color. NPA, Molten (R) Softening Point, C Acid Ho., mg. KOH/g sample for analysis ISSUED 6 Y 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 DSW 303424 WATER PCB-SD0000050975 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moodv /si 12-30-65 SALES W. E. Ault fsl 3-2-66 GENERAL DESCRIPTION PROOUCT Aroclor 5460 PLANT (High Soluble Grade) PRODUCT CODE USE Anniston OATS EFFECTIVE 826.22 SALES CODE Sales 3 11 6- - $_________________ APPROVALS RESEARCH 1040-480-04-009 L. R. Stark fsf 3-8-66 QUALITY CONTROL ('Chief ChtmxlmO O. E. Dolin /s/ 12-29-65 CHEMICAL FORMULA DEPT. 27-S Mixture MOL WT. SUPERSEDES SPECS. OF 4-21-61 CHARACTERISTIC SAMPLE FOR ANALYSIS ISSUED ft V 1 x 16 oz. Can or W.M. Bottle J. A. Liddle 11-30-65 LIMITS METHOD UNRESTRICTED INFORMATION (R) Appearance and Color Clear, yellow to amber brittle resin or flakes G-l (R) Color, NPA, Molten 2 Max. G-4 (R) Softening Point, C 98 - 105 115 (R) Solubility (25 g in 25 g. Acetone @ 25C.) 3 hpur, Min. 117 Acid No., Mg KOH/gm. 0.05 Max. 116 Chlorine, L 58.5 - 60.6 093 RESTRICTED INFORMATION Hydrolysis Stability, ppm Cl 300 Max. 092 (R) Routine Analysis, All others Analyzed by request Only SVV 303425 WATER PCB-SD0000050976 mi M Monsanto Chemical Company ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION product (Tfodc ttotncj Biphenyl p roduct (Otencal mane) Biphenyl CHEMICAL FORMULA PRODUCT CODS . 826.01 METHOD IDENTITY IALII CODE 135-000-03-09 Type Technical type Technical Cl2a10 SUPERSEDES SPEC* OP 7/8/65 . SPECIAL JOB NO* SAMPLE FOR ANALYSIS 1 x 16 oe. can ^ LT Issued 5/5/61 Anniston Plant By V. V. K1 earner Revised to add r.yo values 11-18-65 MOL VT. 154.20 USE Snlss Characteristics Routine tests ' Appeerance . .' - Crystallising Point, *C Color, Gardner Limits White to pele yellow crystals 68.7 Min. 6 Max. Typical Values White crystals 68.8 1.5 General Test (determined only on request) Biphenyl, 1 Hapthalene, I 3 - Hethylbiphenyl, X 4 - Methylbiphenyl, X Unknown, X Distillation Range; *C . 1st drop - Dry Point Must include 255*C 99.9 0.001 0.05 0.02 <0.03 DSW 303426 . This specification for internal use only /. . . . |. ill f WATER PCB-SD0000050977 Monsanto ORGANIC chemicals division FINISHED PRODUCT SPECIFICATION : OD UC T1 ON . G. Moody /b/ 2-1-66 LE . E. Ault 1st 2-22-66 EnERAL description PRODUCT OCPT, Santowax C plant PRODUCT CODE 32 use Anniston DATE EFFECTIVE 829.10 ALEI CODE Internal 3-9-66 approvals RESEARCH 7795-050-99-009 L. R. Stark /s/ 2-3-66 - M. McEwen /s/ 2-22-66 QUALITY CONTROL (Chlal ChemltO 0. E. Dolin /s/ 2-1-66 CHEMICAL FORMULA ixture >L TTT PERIEDES SPECS. OF -23-57 haracteristic ESTRICTED INFORMATION ppearance oiling Point, C Ortho Terphenyl, 7. Meta Terphenyl, 7. Para Terphenyl, % Quaterphenyl, % Biphenyl, 7. lash Point, C hlorine, ppm ulfur, ppm AMPLE FOR ANALYSIS 2-1 Pint cans LIMITS ISSUED B Y 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 inniston. fois specification is for internal use only OS\N 303*^ WATER PCB-SD0000050978 Monsanto ORGANIC CHEMICALS DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION R. G. Moody /s/ 1-31-66 SALES VJ. E. Ault /s/ 2-22-66 GENERAL DESCRIPTION proouct Santovax R PLANT Anniston DATE EFFECTIVE PRODUCT CODE 826.02 SALES CODE USE Sales OCHY. 32 3-2-66 APPROVAL1 RESEARCH 7795-000-11-009 L. R. Stark /s/ 2-3-66 - M. McEwen /s/ 2-22-66 QUALITY CONTROL. (Chlal ChemitO 0. E. Dolin /s/ 1-25-66 CHEMICAL FORMULA Mixed Terphenyls MOL WT. SUPERSEDES SPECS. OF 2-12-62 CHARACTERISTIC SAMPLE FOR ANALYSIS t> x 1 pint cans ISSUED 6 Y Lj. A. Liddle 1-11-66 UNRESTRICTED INFORMATION (R) Appearance Yellow white noncrystalline flaked solid G-l (R.) Color (liquid), NPA (R) Upper Hold Point, C (R) Lower Hold, C 4.0 Max. 136 - 145 48 - 63 128 129 129 RESTRICTED INFORMATION Distillation Range, C, 80% (Uncorrected) Ortho terphenyl, % Meta terphenyl, 1 Para terphenyl, X Quaterphenyls, % 350 - 400 10.0 - Typical Value 54.0 - " " 27.0 - " " 9.0 - " " (R ) Routine Analys is, All others Analyzed by request Only 902 DSW 303428 WATER PCB-SD0000050979 Monsanto MATERIAL CODE 826.38 PLANT MATERIAL Chlorine Gas UStNO DEPTS. RAW MATERIAL SPECIFICATION PRODUCTION Anniston DATE EFFECTIVE 04. 05. 27 SUPPLIER 8-31-66 APPROVALS See below RCSCARCH R. G. Moody /s/R. G. Moody - 8/11/66 ' PROC UREMCNT L. R. Stark /s/L. R. Stark - 8/29/66 QUALITY CONTROL fChi./CfMotl.O H. L. Phillins /s/H. L. Phillips - 8/15/66 0. E. Dolin /s/0. E. Dolin - 8/10/66 CCNERAL DESCRIPTION CHEMICAL FORMULA Greenish yellow gas ci2 Mol. wt. 70.91 SUPERSEDES SPECS OP Sept. 11, 1957 C MAH ACT CKtSTlC SAMPLE POP ANALYSIS )GLC sampling container LIMIT* ISSUED Y I J. A. Liddle - 5/16/66 Typical Values mktmoo UNRESTRICTED INFORMATION Material Supplied by Diamond Alkali Company Assay, (Vol. Z) Residual Gases (Vol. Z) Moisture, ppm Non-volatile Matter, ppm 99.4 Min 0.5 Max. 40 Max. 40 Max. 113 113 Material Supplied by Depts. 56, 57 (Anniston) Asaay (Vol. Z) H2 (Vol. Z) C02 (Vol. Z) CO (Vol. Z) N2 (Vol. Z) 02 (Vol. Z) 85.5 - 93.5 1.5 - 2.5 (3 Max.) 0.5 - 1.0 Nil 3.0 - 8.0 1.2 - 3.0 113 113 113 113 113 113 n,0 0s WATER_PCB-SD0000050980 iw n i iv/ Monsanto MATERIAL CODE 38800 PLANT Lime Hydrate US'NS OEPTt, RAW MATERIAL SPECIFICATION Anniston DATE EFFECTIVE 7-20-66 27, 28 SUPPLIER Alabaster Lime Co. . PRODUCTION APPROVALS REIEAACH R. G. Moody /s/R. G. Moody 6/9/66 PROCUREMENT N. F. Mueller /s/N. F. Mueller 7/13/66 Quality control (Chlml Chnit) H. L. Phillips /s/H. L. Phillips 6/10/66 0. E. Dolin /s/0. E. Dolin 6/8/66 GENERAL DESCRIPTION CHEMICAL RORMULA White fine powder Ca (OH) 2 SUPtMCOKl SPCCS OP Sept. 11. 1957 CHMICTWHTIC UNRESTRICTED INFORMATION ample pop ANALYSIS l lb. cans Typical Analysis Mol. wt. 74.10 ISSUED Y J. A. Liddle - 5/18/66 CaO (Z) 73.00 MgO (Z) 1*20 sio2 (Z) ? A1203 (Z) -36 0.60 :i Fe203 (Z) Ignition Loss (Z) Ca(0fl)2 (X Calculated) 0.30 24.04 9 7.50^) ' Screen Analysis 7 Through 200 mesh (Z) 2s Through 325 mesh (Z) 99.8 94.5 120 Basis of Specifications: Suppliers typical analysis of product (5/23/66) (1) Ca(0H)2 Z - 100Z - [*g0(Z) + 8102 (Z) + A1203 (Z> + *e203 (if] DSW 303430 WATER PCB-SD0000050981 Monsanto material code 19400 PLANT MATERIAL Attanulgus Earth - RVM Grade USING DEPTS. RAW MATERIAL SPECIFICATION PRODUCTION Anniston DATE EFFECTIVE 27-L SUPPLIER 7-20-66 APPROVALS Minerals & Chemicals Philipp Corp. research R. G. Moody /s/R. G. Moody 6/9/66 PROCUREMENT N. P. Mueller /s/N. F. Mueller 7/13/66 QUALITY CONTROL CChiaf ChamlmO H. L. Phillips /s/H. L, Phillips 6/10/66______ 0. E. Dolin /s/0. E. Dolin 6/8/66 GENERAL DESCRIPTION CHEMICAL PORMVJLA Impure Hydrous Magnesium Aluminus Silicate SUPERSEDES SPECS OF Sent. 9. 1957 CHARACTERISTIC AMPLE FOR ANALYSIS 1 lb. can LIMITS UNRESTRICTED INFORMATION Screen Analysis Through 200 Mesh (X) 95 Min. Loss on Ignition (X @ 950C) 15 Max. Typical Analysis from Supplier (Hay 23, 1966) Si02 (X) 67.5 ai2o3 (X) 12.8 Fe203 (X) 4.5 MgO (X) CaO (X) 11.1 1.6 1^0 (X) 0.8 Na20 (X) 0.1 / --N CM O H 0.6 Other (X) 1.0 1 ISSUED GY L A* Liddle - 5/25/66 METHOD DSW 303431 WATER PCB-SD0000050982 RAW yKdgt^aiiiw MATVMAL rBKJUC <a>t^jpye AHHTEJpg CMRMCA4. K tb. 24, 19 It RFI rXiwMrfdi LaL~<CtT / WWftlllLIV----------T^isrw. y. m. _______Htw____________ / UKCLASSnrDKQ ZKrOKMATZOM % Gaatnl Tacts (ismdt aaly e*. rtfuit) ' Property tJgcdLfLcatica Appa&nuaea Mack powder or gnunlac Aaocy 97.0S, 3ft*. Solfctae j|,05S, Wax. Ferrow Salts Trace, Mir. Solubility: 10:19 ok water 10:10 of Fcrania 30 alcabci . Gamplat* to slifbtiy tcxbid, Max. Camplate to alifhtly taxbld. Max. -____ * ' J,y.Q. MatiodlGb Ur*' ' 2Z-ttp 1*0-IT* 5-870^1 luujtf f OSW 303432 WATER_PCB-SD0000050983 WATER PCB-SD0000050984 JI X H -IP*, r- ? ;; i .i n - 0 OKI 3"-Sk. ----- 4 I: t01 * oV r< < <14 <- -.'* V =T ^o I hS 'J 4 \J *'! is; > * . . m ;^ rU :< ^" ;' r r 3 w> -' -" o ^ - ' S? 5 -O " Z v> O' -J i - = t h-, 1 rr* o* O .o- p v> kr>"' wan %" '.>*PJ" I"ri 0 ul af --X> z > i i/ ' n d J;d S;<:! 5J?? r;;;:".;,3k,,;>*-;":;i 'j i 1 Ji<**'< ~-'--S'5i:; 1r ^ s.V^s ) V d " " ^ "* ; * t i^ * l loo <z *75x? 2 !1 1 * ft-- * 3 j ** "^uo - ^ ;i d UK SS3'1i', i s < 4 t( ?s hi *.*>*a -5 | j*.0 WATER PCB-SD0000050985 a >iU1 2ix u:ji i i l\ * ;i2~ jil r- y ! i ?- M W > lO " 3ru*u#i ? Jv, j' V r- (tJ* r 2AO= 1 I* 3 5= a ? 5 Sj - o- S'< s_l4i... ;_ -^ *" w >3r*1 ^ r:! 2 212 - 6- 2 ^ i r' i * Xi 11 lO CO ^J* CO o CO .*$ to Q v2" !i il J io /i ;< ' *o ?5 a 'si ;I lr := j? v 4= *2 "* s i!os'- I* c4 '^2 3i ill Hi t rS - o- y- i C f? * s, - "s! s- . I U^*5;S \U& I;:Um ' 1* U-Ii i ilii V53jil|fi iiiHll jK oU > ZZ iii ^* sJ !9 ??ii n-iO o 'C Ci WATER PCB-SD0000050986 WATER PCB-SD0000050987 STANDARD MANUFACTURING PROCESS FOR AROCLOR APPENDIX C - PHYSICAL CONSTANTS OF FINISHED GOODS. INTERMEDIATES. AND MAJOR RAW MATERIALS FINISHED GOODS Aroclor 1221 - Not Available Aroclor 1232 - Not Available Aroclor 1242 Aroclor 1248 Aroclor 1254 Aroclor 1260 Aroclor 1262 Aroclor 1268 - Not Available Aroclor 2565 - Not Available Aroclor 4465 - Not Available Aroclor 5442 - Not Available Aroclor 5460 - Not Available RAW MATERIALS Biphenyl Santovax - Not Available Santovax R-Not Available Chlorine Hydrated Lime Attapulgue Earth-Not Avail. Ferric Chloride DSW 303437 WATER_PCB-SD0000050988 STANDARD MANUFACTURING PROCESS FOR AROCLOR 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 137.5 lbs/cvt. Liquid Aroclors, 239.5 lbs/cwt. Solid Aroclors. Recovered Water Recovered water is supplied through a 6" main from a cooling tower. Standard practice is 625 gals/cwt. Liquid Aroclors, 1,197 gals/cwt. Solid Aroclors. Electricity Electrical power is supplied at 440 volts for power and 110 volts for lighting. Standard practice is 3.25 KWH/cwt. Liquid Aroclors, 7.19 KWH/cwt. Solid Aroclors. Natural Gas Natural gas is supplied through a 3" main at 40 psig. Standard practice is 0,1625 ICF/cvt. Liquid Aroclors, 0.5389 WCF/cwt. Solid Aroclors. SW 303438 WATER PCB-SD0000050989 STANDARD MANUFACTURING PROCESS FOR AROCLORS 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. Be is also in charge of the Biphenyl group of products. 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 responsible for the operation of his Job. There are ten (10) laborers. Classification A-8, employed in the Aroclor-Blphenyl group of departments. Each shift has a minimum of two laborers while some shifts have three laborers. Approxi mately 60% 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 alBo 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 automatic rate increases. DSW 303439 WATER PCB-SD0000050990 JOB CLASSIFICATION SCHEDULE AND SCHEDULE OF HOURLY WAGE RATES AUTOMATIC RATE INCREASE GIVEN AT END OF: n u Xo >xH4--1l *VJ# *> m aS Xq'L w >> u Q e(S0 GO CD O^ CM 5 oa 00 Jt -> s <r <r i-H ^ CO CO O J4 . B) CM ^5 r- 5 a O s> 3 CO CO -Si a 5 to o _5 <3- 5 CD CM ,2 cn 5 CO CM 5 CM r-H GO oWi n Pi o -< X CT> u-> t<co0 *cwj H4eo-Jt 0o3 THO-l U0) g >4H aC Xo aa.. uo <o IH CO (0 00 O. S3 QC CJ CM a* r*. CM CM crv r^. in m CM CM CM CM CM 1 ro 1 r^. rH 1 cn I CM r-t CO Os as 1 1 CM 1 1 1 1 Os 1 t CM On 00 1* 1 CM 1 1 1 1 00 1 rM I CM t r*- 1 *! CM 1 CM CM m 1 1* 1 CM CM GO a \o o% T3 vO <r |> P CM CM GO O. 3 H v> vO O 1 CM CM 'U i-M <00r oa CM V g US u a.j 4poJ P O. o 4poJ a HP PO Xpo) 3 0e0 -ocr-:l PC&J o P oa p CO o H 4J a pM MM H H 3 a- H a a* 00 0 *r4 > C c pfi 4J p GO 3 o GO P o MM MM O a U T5 O i-M CL b x> >* 2 DSW 303440 WATER PCB-SD0000050991 STANDARD MANUFACTURING PROCESS FOR AROCLOR . APPENDIX F PACKAGING AND SHIPPING Solid Aroclors are packaged for shipment in 41 gallon Fibre drums, 40 gallon galvanized drums, 5 gallon galvanised 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 one coat of A &tf 4.A lacquer. Liquid Aroclors are loaded into tank cars and trucks. Tank cars used for electrical grade material are either aluminum or sine 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. DSW 303441 WATER PCB-SD0000050992 Material 1221 1232 1242 1248 1254 1260 1262 1262 - 10X Toluene 1262 - 10X Xylene 1260 - 10X Toluene A13B3B 5442 4465 2565 Inerteen PPO Inerteen 54201-KA Santicirer 794 W2S 295 5060 5460 1268 APPENDIX I AROCLOR FINISHED GOODS CONTAINER WEIGHTS Weights Lbs. 50 or 520 50 or 550 55 or 600 55 of 600 60 or 600 60 or 600 60 or 600 60 or 600 60 or 600 60 or 600 65 or 675 50 or 450 50 or 500 500 65, 360 or 674 674 600 635 100 100 200 Container 5 Gal.-55 Gal. Steel Drum tt tt II II 11 If II It II ft II II IT ft II II . 11 fl If If II IT IT If 11 II 11 IT II 11 If II II H It 11 If If 11 If 5 Gal.-40 Gal. Galv. Drum 1 II 11 11 II II II 5 Gal.-30 Gal. -55 Gal . Drums II H ft 11 II ft It 11 If Paper Bag Paper Bag 41 Gal. Fibre Drums DSW 303442 WATER_PCB-SD0000050993 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX G - MATERIAL BALANCE Standard and Theoretical usages of raw materials and hydrogen chlorine 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 4 gives molecular weights of the various Biphenyl base Aroclors. SlV 33443 WATER PCB-SD0000050994 DSW 303444 WATER_PCB-SD0000050995 A"TH p n C DSW 303445 WATER_PCB-SD0000050996 FIGURE WO. 3 Theory and Standard Usage fo r A ro c lo ra Lba. p e r CWT A ro c lo r r\ CV ' r\ m **0 OV CO GO CM o o o CO CO CO os H f rH 3 CO 00 p- *3 3 *0 4J CO vO H P*. CM 3 Ov so SO vO CM CM 7-1 CO rH CO 3 3 m m m m in CO m m M O rH JC u n Ov o 00 3 rH 00 O CM CM CO 00 CO o a a) m ov rH CO e in VO Os GO CO rH vO vO K 3 rH l CM j CO o\ U1 rH o\ vO VO CO rH rH CM \coy ^3- m vO vO vO vO 3 vO SO vO CM cn CO CO CO vO m CO o m 00 *o i--4 co CM rH o CO CO V0 VO CM 3 m 4-1 CO m o CO vO Ov CO CO CM vO rH CM <3- 01 e ON o rH rH rH CM rH co vO rH rH CO rH m rH o rH CM rH 3rH H (4 O >- M o o o o o o o o O O O o .C o o o o o O o o o o o O o u at e CM sr CO VO o\ CO o o CM M3 vO CM CO o CO o CO *3 CO O CM o CM rH rH rH rH rH rH rH rH *0 O *j CO * * 5 4J *H eo 0) 1 1 1 1 o 1 1 | >3 1 1 1 1 11 1 Os 1 1 1 t rH CM 11 I1 11 1 1 1 ! 1 1 Os 1 1( o4 co K 6 4J (4 co * ft) cog t t t 1 3 CO m CO CM CM m Pn. * 1 1 1 11 Ov CM CO i 1 11 t rH vO *3 -3* 3 OV rH rH rH n- r-. , 1 l li l *3 Ov rH rH 1 1 li 1 rH m 3 3 vO CM CM o o os GO os vO *0 o o o o o os vO rH CO o4J 0 7-4 CO CM H m Ov CO Ov CO in i i i c 00 VO m <r *3 <3 CO CM CM 1 i i V C * P- H o Ov r*. CO rH vO CO co o v4 O vO H CO m r** p- ov vO rH SO 01 On Os CO f*s, rH ov CO n* CM r-* m m 3 *3 ro CO CM CM 1 1 1 1 M O O rH CM CO O CM 00 m m CM o o o CM 3 3 m vO vO so vO v> *3 vD vD u CM CM CM CM CM CM CM in 3 *3 O 3 < i--4 H i--4 H rH rH rH CM 3 m m m DSW 303446 WATER PCB-SD0000050997 WATER PCB-SD0000050998 ' STANDARD MANUFACTURING PROCESS FOR AROCLOR 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 4,027,000 lbs/month. Chlorine HCL (Gas) Montars Type Atmospheric Atmospheric Plant Dump Amount Negligible Negligible Approximately 10% of Total Aroclor Production DSW 303448 WATER_PCB-SD0000050999 STANDARD MANUFACTURING PROCESS FOR 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 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. WATER PCB-SD0000051000 STANDARD MANUFACTURING PROCESS FOR AROCLOR APPENDIX J - SAFETY & TOXICITT 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 3% 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. DSW 303450 WATER PCB-SD0000051001 APPENDIX J 2. Thermal Burns 2. Cause and Action to Prevent Contact with hot uninsulated product lines ar the chlorlnators 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 burns. 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 burns. 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. DSW 303451 WATER PCB-SD0000051002 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 vaporiser and do nbt 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 vaporiser. Check steam addition to the vaporiser. 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 303452 WATER PCB-SD0000051003 APPENDIX J 4. 4. Falls (Contd.) 5. Fires Cause and Action to Prevent 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 hacard that should be guarded.' c. Poor lighting due to burned out bulbs should be corrected at once. Poor lighting due to inadequate facilities should be reported. 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. Fires can occur by: Biphenyl, Santowax R, or Santowax C Ignition. Chlorine problems in the vaporiser 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. CSV*30'153 WATER PCB-SD0000051004 APPENDIX J 5. 5. Fires (Contd.) Cause and Action to Prevent Action to Prevent a. Area must be clear of trash or flammable materials. Dse 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. Dse 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. DS\N 303454 WATER PCB-SD0000051005 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. Dse 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 burn. 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 burn. 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. SW 303455 WATER PCB-SD0000051006 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 Resldue 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 hasard 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 burns in contact with the skin. Prior to air blowing, the material has HCl 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. DSW 303456 WATER PCB-SD0000051007 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX K - BACKGROUND INFORMATION History of the Process in Monsanto In the years 1927 - 1928, the Svann 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 Ibs/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 "E" and now called the _ Krummrich 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 303457 WATER PCB-SD0000051008 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. 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 frito 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 303458 WATER PCB-SD0000051009 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-vaxes 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. DSW 303459 WATER PCB-SD0000051010 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX K - BACKGROUND INFORMATION The following is an up-to-date (June 1, 1966) bibliography of Research reportB 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., Sraull 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. O-Phenyl-O-14-Nitrophenyl methylphasphonothioata^ Ag. Research No. P2 6/15/61 (On Aroclor 1254 as a solvent) Bindboutel A. J., Fowler L., Koerner W. E., Luebke H. W., Kanno 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. 2440r2/8/60 (On Aroclor 1260) Close H. J., Knapp W. 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 303460 WATER PCB-SD0000051011 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 Bt. 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. H., Merten E. 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 Arocior 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) DSW 303461 WATER PCB-SD0000051012 APPENDIX K -3- Gebura S. E. Glycidyl Ethers and Polyethers of Bisphehol-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, Grave Coeur No. 1298 12/29/61 (On Aroclors) Knowles W.` 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 ancl 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 No. 1581 10/14/60 (On Aroclor 5460) Parks R. M. Polyroerite File Market Study - Special Report. Organic Development Creve Coeur No. 1277 7/26/61 (On Aroclors) DSW 303462 WATER PCB-SD0000051013 APPENDIX K -4- Terpstra M. A. Hydrolyzed Aroclor 1268 /Alkaline - Methanol Hydrolysis/ Organic Research St. Louis No. 2585 9/7/60 (On Aroclor 1268) Ellenburg A. M. Assistance to the Aroclor Production. Phosphorous Research SF 2084 Job No. 171-299 12/31/46 Ellenburg A. M., Feltham 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., Simon* R. A. Aroclor 1142 and 1154 prepn. from biphenyl by contin. chlorination. Organic Research SL Fin. 1530 Job No. 3040 6/4/56 Ketzner 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 Ho. 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., Fortrus F. C. Aroclor 1232, Brcxninated, Prepn. Phosphorous Research SF 2512 Job No. 171-628 9/13/50 Ellenburg A. M.,Good R. J., Wad* W. W. The Effects of Prolonged Heat on the Electrical Properties of Aroclors. Job No. 171-616 12/7/50 Nelltnns R. 0., Gruetzemacher E. C. Aroclors 1232 and 1248, as components of hydraulic fluids. Organic Research SL Fin. 1753 Job No. 3388 2/14/57 WATER PCB-SD0000051014 APPENDIX K -5- Ellenburg A. M., Good R. J., Richards H. B., Jr. Aroclor 1236, Dielectric Properties Phorphorous Research SF 2612 Job No. 171-613 5/21/51 Ellanburg A. M., Forbus F. C., Richards H. B., Jr. and 1240 for General Electric Company. SF 2539 Job No. 171-609 12/11/50 Aroclors 1236, 1238, Phosphorous Research 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 20-30nm. 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 Dovtherm 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 DSW 303464 WATER PCB-SD0000051015 APPENDIX K -6- Ellenburg A. M., Good E. 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: and Improvement of Aroclor 1242 and 1232. Job No. 9442 1/29/60 Formation, Composition RE. Res. Da. Int 1318 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. EL, 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 No. 4-8065 11/29/49 Ellenburg A. M., 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., Gemeoinhardt P. G., Powers E. L., Sanguinetti P. A. Aroclor 1242, reaction medium for manufacturing of tolylene diisocyanate. Phosphorous Research Int. 2943 Job. Ho. 171-1098 10/21/53 dS\N 303465 WATER PCB-SD0000051016 APPENDIX K -7- Cleveland T. H., Machvart 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., Liss R. L., Powers E. L. 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 In5>raveroent. of Aroclor 1242. Organic Research SL Fin. 2096 Job No. 3203 6/6/58 Weddell D. Sl. 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 ra-tolylene diisocyanate. Phosphorous Research Fin. 2547 Job No. 171-603 12/22/50 Ellenburg A. K., 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. H., 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 303466 WATER PCB-SD0000051017 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 tf. E. Insecticides plus Aroclors. Organic Research CC Fin. 965 Job No. 117-2542 4/14/54 Howard R. K., 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 Pordyce 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 with 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 OSVN 203467 WATER PCB-SD0000051018 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. H., Wade W. W. Corrosion inhibitor tests with Aroclor 1254. Phosphorous Research SF 2336 Job No. 171-530 3/17/49 Ellenburg A. H., 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., Daniloff K. B., Dahn W. H. 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, mixt. 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 DSW 303468 WATER PCB-SD0000051019 APPENDIX K -10- Metzner W. P. Aroclor 1254, recovery from Bample contaminated with 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 7/19/56 Ellenburg A. M., Marten 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-ethel~ hexyl)- and trioctyl silicon fluorides, dielec, props. Phosphorous Research SF2376 Job No. 171-532 7/12/49 Ellenburg A. M., Richards H. B., Jr. Aroclor investigation on difference between Anniston and Krunmrich 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 Drunn M. F., Gebura S. E. Aroclor 1262, hydrolyzed, glycidyl ethers of. PI Res Spf Fin. 1413 Job No. 1845 2/2/57 Nelluas.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 DSW 303469 WATER PCB-SD0000051020 APPENDIX K -11- Sharp D. B., Dzzi J,,, Gabbert J. D., LeBlanc J. R. Hydrolysis of Aroclor 1268 in Mathanolic Sodium Hydroxide. RE Research Da Fin. 1061 Job No. 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., Vandeven P. Pilot Plant Preparation of Hydrolyzed Aroclor 1268. Organic Research SL Fin. 2334 Job No. 3899 8/17/59 Heliums 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, thiolysis 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 SLFin. X-1249-I & II Job Nds. 117-1249, I 1/3Q/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 Lefforge J. W., Smith R. E. Impregnation of wood with Aroclor "4465" and "330". Phosphorous Research SF 2101 Job No. 171-398 3/17/47 Bogaard T. D., Saunders J. H., Slocoobe R. J. Aroclor 5442, as plasticizer in residua from dlstn. of TDT. Phosphorous Research SF 2403 Job No. 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 SW 303470 WATER PCB-SD0000051021 APPENDIX K "12 Crenshaw R. L., Ellenburg A. M., Morgan J. F., Sad* W. W. Investigation of pr*cipitat* formation in organic solutions containing Aroclcr 5460. Phosphorous Research SF 2492 Job No. 171=623 5/22/50 . ' Ellenburg A. M., Richards H. B., Jr. Aroclor 5460 from Dow Tarophsn D-25. Phosphorous Research SF 2883 Job Ho. 171-1077 5/12/53 Ellenburg A. M., Wad* 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 Aroclcr 5460. Phosphorous Research SF 2088 Job No. 171=397 2/6/47 Ellenburg A. M., Morgan J. F., Wad* W. W. The Solubility of Aroclor 5460 in Various Solvents. Fhosphorous Research An SF 2272 Job No. 451 12/9/48 Ellenburg A. M., Richards H. B., Jr. Preparation of a concentrated solution of Aroclor 5460 in xylene. Fhasnhorous Research SF 2960 Job No. 171=1075 10/28/53 Ellenburg A. M. Investigation of decomposition in Aroclor still. Phosphorous Research SF 2046 Job He. 171=299 5/16/46 Metzner W. P., Durland J. R. Aroclors, (1254 and 1260), odor improvement, study of. Organic Research 5L Fin. X=1402=111. Job No. 117=1402, III 12/5/40 Darby J. R., Allen W. G., Cannon J. A., Cowell E. E., Touchette N. W., Wangler L. R. Aroclors 1262 and 1232, migration studies (1956). Organic Research SL Fin. 1730 Job No. 3129, III 1/22/57 T*rp8tra M. A., Lynch D. K. Hydrolyzed Aroclors 1262 and 1268 Sample Preparation. Organic Research SL Fin. 1706 Job No. 3038 1/8/57 DSW 303471 WATER PCB-SD0000051022 APPENDIX K =13" Bennett G. E., Sharp D. 5., Dazzl Joachim. Exploratory Aroclor Chemistry. Part I. Ethers by Alcohylysis. Hydrolyzed Aroclor Derivatives. BE Research Da Int. 1181 Job Nos. 4-9261, 4-9310, 9378 8/1/58 Chadwick D. H., Ellenburg A. M., Marshall tf. W. Alkylation of Aroclors for Evaluation as Extender Plasticizers. Organic Rasaarch SL Fin. 1184 Job No. 2682 (SL) 171-1042 (An) 1/17/55 Darby J. ., Cowall E. E. Application Work on Present Plastlcizars 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 glowproofers. GE. 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 Metzner 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 No. 117-1436 4/17/42 Kyrides L. P., Craver 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. 171-10B9 6/17/53 SW 303472 WATER PCB-SD0000051023 APPENDIX X -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 Dassi - Exploratory Aroclor Chemistry Part III. Glycidylation of Hydrolysed Aroclors. Research RE Da Int 1183, Job No. 9411, 10/9/58. Hubbard, E . M., F. R. Short - Determination of the oxirane (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 Plasticisers - 1954. Part I: The Intensive Evaluation of Secondary Plasticisers 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. Dassi, J. A. Herbig, J. R. LeBlanc, J. Schvendemann. Synthesis and Application Studies on Hydrolysed Aroclors and Derivatives. RE Res Da Fin. 1115. Job Nos. 9411, 9411-03-3, 9416-03-3, 12/30/57. Sharp, D. B., Joachim Dassi, 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 Dassi, 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 Bensil, and Niran and Aroclor 5460 Formulations (July 14 to October 12, 1955). Org Res SL Fin. 1382. Job No. 2760, 12/55. Metsner, 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 Dassi. Exploratory Aroclor Chemistry Part V. Nitrogen Derivatives by Ammonolysis. RE Res Da Int. 1177, Job No. 9411, 8/4/58. DSW 303473 WATER PCB-SD0000051024 APPENDIX X -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. Metrner. 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. X. Sears. Aroclors, pyrolysis with HCN, lit. survey. Org Res SL Lit. 1246. Job No. 2680, 4/26/55. Darby, J. R., B. 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, stabilirn. DSW 303474 WATER PCB-SD0000051025 STANDARD MANUFACTURING PROCESS FOR AROCLOR APPENDIX L - TIME CYCLES The continuous chlorinetor operation, used for production of Crude Liquid Aroclors, consists of four cascade flow chlorinators in series. The maximum dally production from the continuous system is 90,000 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 Aroclors is the still system. DSW 303475 WATER PCB-SD0000051026 AROCLOR TIME CYCLES AND BATCH WEIGHTS * o m o m on * CM oo0k o\ Oo CM 00 ON * m CO * oo m m in m0k m cm CM *o oo o m fk rk Ov O CM ir-kk * co fr--Hk ok CO <tHHnr ok CO CO H 0k H CO CM o rk i-k CO rk o CM pk o0k rk CO o * CM m r* CO * *3* . pH CM A <* CO o m 0k co m CO * - oo0k ON o oCO> ON ^o3* N Om m o CO COOk 4- . o o 0k H o o ON CN| CM o o o0* VO H o o ok m CM o oSk CM CM <rOk CM CM O mk Ok m CO0k k m o00k uo in CO B Vi co k B Vl o\ B n J3 vO rk B Vi H B Vi o CM BVl CO rk BVl r-* r-k VBi rC--O< VBl Ho MCO ON B Vl 41 o o 4) Vi B O 06 <0 *k o VI 4) VI VI VI VI o 41 Vi VI v< 4) CO oi Qo5 o < VI 3 rk JO -H Vi O r-l 41 60 Vi 00 u 0c)x H K CO * O V> co X(0 :o* to Q O CQ 0 ^ "O k 41 41 K O Vi CX CV < 00 Vi cr Ooo c4x2) u Ck cC iVi VI Bob *KH O vi 41 Vi 00*0 CX-k p CV 4> p -< S 0 3 Ko VClu a < ^cr 41 0* 46) *3 H O 03 O 0Vkr o VI o VBI eo M O ik o o Vi < i*-koH *too 303476 WATER PCB-SD0000051027 STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX M - QUALITY CONSIDERATIONS Aroclors for electrical equipment uBes 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 1242 Property Biphenyl Resistivity ,Sj.ec 0.05 X max. 5,000 giga ohm cm min. 1254 Biphenyl Resistivity 0.025Z max. 5,000 giga ohm cm min. DS\N 303477 WATER PCB-SD0000051028 .*.:' * ' ` .Y ,^^N^'j^-c^Hewfciltu.<foMp!ANr - control, chart - ns?*[nfcMjL mrxM . r* MdC^IT -SWr i- T"' rjjL^C. TiijiJ't L fv-^'5 OF &JL. ' Viv ^V*stf,w|V4iVvA'^: X W^CjfVN^ NKNNtN ..... MjmjiSvi' *' Sl-vX. 1X11 31 - - --r -.t>. ..;* * <V .*5 -f O h': ' +i-t-rYth-.i H3f.-hr,i (- ^JC H-Ocr*, ! if j. fctswT-- T - /, <t j.544:" ' i-: / *25 21ilzn.-rir:; / . 6 2 So : --}! /.,! ^ r' ~ ` /. i2<*6 /, 4>24-<- __ /. (f'z4i7 A/. H^r/C.V 2J4 H 3'iS J2.G tsi; 3 '24 f~ ------tTT 1" 1------------------s ',3 .'.j :":,T3 --- H Sr1 mu l: 'iO'i AlS os^ WATER PCB-SD0000051029 dfciwiftexCc^i^AN v conwit;olAH`ti ' y a>riv<' > ___HZoz.lqjl. .J 1 4 2 - ------A- i, m ezj-.z/ls-p-; a -rrr^P^U. .......... . *;' ~i-*i- --<; --i 'PK>iflSi*J<N ^ \*NNC'- 'v vf; H-h -j-H- --Ft- f.-_Pl:-f-H- -i ; -!- r .--; ; /- V, P ^ WATER PCB-SD0000051030 DSW 303480 WATER PCB-SD0000051031 i 2 `> N 1 .*>--- . "J * * fi. / H*.- DS^ 303*^ WATER PCB-SD0000051032 i STANDARD MANUFACTURING PROCESS FOR AROCLORS APPENDIX N - MISCELLANEOUS WATER PCB-SD0000051033