Document r66NLe1eQVaQzXvGaXBwOwreV

, l/C p&dr" (conoco) Interoffice Communication To J. A. Debernardi RECEIVED MAR 51976 From D. V. Porchey and R. C. Lindberg Date March 2, 1976 ' Subject Project Status--Catalytic Oxidation of VCM Containing ^Streams A meeting was held January 20, 1976 between plant and R&D personnel to discuss the catalytic oxidation project. At this meeting, R|&D agreed to provide information to assist in your decision regarding the; applicability of catalytic oxidation for VCM removal from your vent streams. Following is a summary of the project status, speculative estimates ofi the relative economic value of reactor schemes operating outside the flammability limits, and an estimate of project charges if continuation of this work is judged appropriate. Project development has led us to a point where most of our technical objectives have been achieved. 1. Free chlorine production was reduced to less than l of total chloride. 2. Oxidation temperatures were low enough to use available alloys (Inconel 600 or Incoloy 800) for the reactor material of construction. 3. VCM was reduced to less than 10 ppmv (usually 1 ppmv or less). i 4. Commercially available catalysts were demonstrated to be effective. 5. Catalyst life of over 240 hours was demonstrated. Nevertheless, the major barrier to continuation of our work qn the present prototype concept in your plant is the fact that operation in]side the estimated flammability limits is required. This is unacceptable. We have defined some potential reactor schemes that might allow loxidation of the vent streams either on the lean or rich sides of the flammability envelope. But, these options cannot be developed in time to fit into yoiur decision sechedule for EPA compliance. Based on that fact and the economics discussed below, we are winding down our VCM plant related work and wi 1 fl concentrate on PVC plant applications for the catalytic oxidation technology1,. The table on the following page summarizes cost comparisons ojf the original PED Budget Design, and potential reactor options for operatioh outside the flammability envelope. Options include air, hot gas recycle,: and steam dilution to allow lean gas oxidation, and a staged reactor to| allow rich gas oxidation. Only in the Budget Design case does 600 psig steam recovery generate sufficient savings to make the extra investment attractive. The energy savings are still present. However, the reactor costs are significantly increased, relative to incineration, because the reactor design must insure VVC 000011725 J. A. Debernardi Page 3 March 2, 1976 operation outside the flammability envelope. If the incineration concept would later be judged technically unacceptable or the relative economics would change, we are in a position to pick up work on this project at the prototype stage with any of the reactior options dis cussed. To proceed through prototype development, the time required would be 9 - 11 months at a cost of about $155,000. I Research Group Leader Engineering Research Section Chemicals Research Division Research and Development Department Robert C. Lindberg Senior Research Chemical Engineer Engineering Research Section Chemicals Research Division Research and Development Department cjb CC: FK:WRBe:DHS:AJM:RGG JHM:DAK:RELe:RDG:DOP VVC 000011726 VVC 000011727 TABLE I COMPARISON OF REACTOR CONCEPTS PED BUDGET DESIGN Incineration Catalytic Oxidation Incineration Air Dilution CURRENT "TYPICAL" VENT Nitrogen Dilution (Hot Gas Recycle) FEED RATES (SCFH) Air, Na, Steam Vents TOTAL INVESTMENT ($MM) Increased Investment Over Incineration ($MM) 282,000 44,000 326,000 3.5(1) 2 -- 282,000 44,000 326,000 3.8^ 0.3 854,000 82,000 936,000 1.21 ^ -- 1 ,366,000 82,000 1,448,000 3.61 ^ 2.40 HEAT RECOVERY Steam (Ib/hr) ($/yr)(3) -- 9,750 -- -- 284,000 -- 16,300 475,000 (1) Investments are for total system (2) Reduced Investments are for incinerator or reactor only and are based on enlarged vent streams (3) Steam (600 psig) valued at $3.57/M lb. 1,192,300 82,000 1,274,300 3.44^ 2.23 17,630 514,000 Steam Dilution Staged Reactor 1,023,400 82,000 1 ,105,400 3.07 ^ 1.86 721,600 82,000 803,600 4.09^ 2.88 9,620 280,000 20,860 608,000