Document rpLb4yoobZ7pERJLoBdB46jdJ

KANEGAFUCHI CHEMICAL INDUSTRY COMPANY, LIMITED Telephone: (06)208Cablet: CHEMIKANE OSAKA Tela: KANECHEM J63 58 2 2-4, 3-CHOME, NAKANOSHIMA KITAKU, OSAKA ,, tarot' JAPAN March 5, 1982 Mr- J. A. Debernardi Plant Manager VCM Plant Conoco Chemicals Conoco Inc. P. 0. Box 605 Westlake, LA., 70669 U. S. A. Dear Sirs, Catalyst and Diluent for Oxychlorination Process Please find enclosed "corrected operation manual" which is already informed by our telex No. 722 of March 3, 1982. Yours faithfully, h'hsJ' H. Mori Market Development Sect. Chemicals and Plastics Dept. Kanegafuchi, Osaka Japan CCR 000018119 Confidential Information Operation Manual Of New Kanegafuchi Catalyst Systems For R-301 to R-303 March 4, 1982 Kanegafuchi Chemical Industry Co., Ltd. CCR 000018119 The following is an operation manual for catalysts and a diluent newly developed by Kanegafuchi Chemical Industry' Co., Ltd- (Kanegafuchi) for R-301 - R-303 of the Stauffer Oxychlorination Process : 1. Caution in hadling the catalysts and the diluent The catalysts (K0C-1Q1, K0C-2Q1, and K0C-R3) and the diluent (KOD-55) should be kept from moisture at all times in a similar way to those for other catalysts for the Stauffer Oxychlorination process. 2. Catalyst and diluent loadings The new catalyst system of Kanegafuchi employs the cata- 4 lysts of three kinds ; KOC-101, KOC-201 and K0C-R3 with following mixing rates with the diluent KOD-55. The catalysts and the diluent are loaded to reactor zones ___ at determined mixing ratios.___ ______ Recommendable loading patterns are shown below : Reactors Catalysts Diluent i Loading Patterns by zones (vol.%) 1st 2nd 3rd 4 th 5 th R-301 KOC-101 KOD-55 65 65 65 100 100 R-302 KOC-201 KOD-55 68 68 77* 100 100 R-303 K0C-R3 KOD-55 90 90 100 100 100 Remark : revised figure -1- CCR 000018120 The above loading patterns may be changed in case of different sizes of reactor diameter from the Stauffer's original standard design. The top and the bottom 9-inch section of each tube should be filled with an inert solid such as fused alumina, fused silica, ceramics and KOD-55 in a similar way to conventional catalyst systems. Care must be taken to ascertain that the tubes are uniformally filled with the correct volume of proper catalyst particles and solid diluent. 3. Physical properties (characteristics) and packing of the catalysts --^catalysts Items ---- Shape CaCl content 2 (wt.%) K0C-101 Spherical 12.0"+ i. o' KOC-201 Spherical 16.Q +1.0 K0C-R3 Cylindrical 16.5 + 1.0 Drying loss (wt.%) 3 max. 3 max. 3 max. Packed density (Kg./l.) 0.76 - 0.80 0.78 - 0.82 0.75 - 0.79 Compression strength (Kg.) 2 min. 2 min. 1 min. Size range 3.5-5 meshes 95 % min. 3.5-5 meshes 95 % min. 4.8 irmcfi x 4.8 itm Packing 175-Kg. net 175-Kg. net 160-Kg. net new steel drums new steel drums new steel drums CCR 00001S121 4. Physical properties and packing of the diluent KOD-55 Shape Columner, length of 4 - 6 mm., diameter of about 5 mm. Carbon 99 % min. Apparent specific gravity 1.5 - 1.7 Kg./l. Packed density 1.0 - 1.1 Kg./l. Packing New steel drums of 200 Kg. net 5. Mixing the catalysts with the diluent Mixing the Kanegafuchi's new catalysts with KOD-55 is comparatively easier than mixing conventional catalysts with conventional diluents because of smaller difference in density between the new catalysts and the new diluent. Manual mixing is recommended for a uniform mixture and a uniform loading to each reactor tube by measuring into a polyethylene bag, for example, of certain amounts of the catalyst and the diluent per tube. Reactor loading It must be ascertained that the correct amount of a uniform mixture of the catalysts and the diluent is loaded into each reactor tube. OCR 0000181ZZ 3 7. Protection of workers A dust-proof mask, gloves, and other types of protectors must be worn by .a worker being engaged in mixings and loadings of the catalysts and the diluent. 8 Start-ups The know-hows of Stauffer Chemical Company are basically. applicable to start-ups. No special precautions are necessary for the new Kanegafuchi catalyst systems because the systems have relatively stable activities even at the initial stage of reaction. The following are recommended, however, as the start-up conditions for safety : 1) Recomended*start-up conditions HCl feed rate Volume ratio of : Half the design load vs HCl : 0.50 - 0.52 Reactors Recomended steam drum pressures Kg./cm G R-301 16 R-302 17 R-303 19 Air feed rate volume ratio of Air vs HCl N2 feed rate volume ratio of N2 vs HCl 0.37 - 0.40 0.13 - 0.15 .0.33 - 0.36 0.13 - 0.15 0.27 - 0.30 0.13 - 0.15 The recomended pressure of PRC-309 2.5 Kg./cm^G -4 - C.CR 000018123 2) Air feeding and confirmation of the reaction initiation Air feeding to R-302 must be started after confirming the reaction of R-301 is sufficient by observation of the steam generation and the temperature rise in the reactor. Air feeding to R-303 must also be started after a similar confirmation of the reaction in R-302. It is recommended that the high-pressured steam injec-^ tion to each reactor steam drum should continue until the initiation of reaction is confirmed. J }) Hot-spot temperatures Care should be taken that the hot-spot temperature will not exceed 300 C by adjusting the steam drum pressures at the start-up of each reactor. Shutdowns Shutdown procedures for the new catalyst systems should follow Stauffer's operation manual. - 5 - / end CCR 000018124