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Monsanto i iFROM ( NAME ft L at on ) l. Neary (4-8156) - General Offices DATE April 20, 1970 SUBJECT Aroclor Fractionation - 1242-B REFERENCE TO J. 0. Bright Bergen^ Howard/R. M Mueller Munch Papageorge Richard Savage Kountz CONFIDENTIAL Introduction An estimate was developed for capital and manufacturing costs for Aroclor fractionation to reduce higher chlorinated mater ials from Aroclor 1242. This study is based on a production rate of 30M pounds/vear obtained by converting Krummrich facilities from the straight flash takeover distillation to a fractionation. The Krummrich plant was selected based on its ability to use the hiboiler stream. It is assumed that a sidestream of hiboilers will be taken from the bottom of the column and utilized in 1254 or 1260 manufacture. The bottoms will be sent to the existing residue recovery system for yield recovery. Summary 1. The estimated capita.] rv->R--fnr installation of Aroclor 1242-B~Tractionation facilities is $500M based on a preliminary equipment costTstimate ot $111M 'SncTar Lang factor of 4.5. The equipment list and flow diagram is attached as Appendix A. 2. The fractionation will increase the manufacturing cost by 0.5C/pound as shown in the table below. $ 30M Utilities $ 30M Repairs (6% of Capital) $ 50M Depreciation (10% of Capital) $ 15M Factory Indirect Expense (3% of $ 20M Labor, TSD and Miscellaneous $145m/30M pound/year = 0.5<:/pound Capital) 3. A price increase of l</pound is recommended to provide about 10% A.T. return on new capital. DSW 200400 STLCOPCB4058464 ) J. 0. Bright 2 April 20, 1970 Future Work The following recommendations are made for future Research work on this product: 1. Develop a means to analyze column performance and control its operation. 2. Define required overheads and bottoms compositions. 3. Demonstrate feasibility of continuous distillation with hiboiler side draw without lime in the feed. Check effect on quality. 4. if a continuous system is feasible, determine column require ments by: a. demonstration in laboratory unit C>R b. develop true boiling point curve If the continuous distillation with lime in feed feasible, a batch distillation will be adopted. case, CED will work with Research to help define requirements for demonstration and optimization. is not In either column 5. Evaluate fractionation of Aroclor 1130 to remove 4,4'dichlorobiphenyl and hiboilers. Details 1. Process Description It is visualized, based on a single Research batch frac tionation, that a 30 plate distillation column could be installed in parallel with the existing flash takeover still. Crude 1142 will be pumped from the existing inter mediate storage to the new column. The overheads fraction (82% of feed) is pumped to the existing surge tank to feed the present alumina treatment system. It is also visualized that a hiboiler sidestream (14% of feed) would be removed from tray two or three and held in a new surge storage tank for use in making the higher chlorinated 1254 and 1260 materials. Column bottoms will be transferred to the exist ing residue still for recovery of additional hiboilers which will also go to the new hiboiler storage. A slurry tank and pump will be used to continuously add lime to the column sump. The existing overhead receiver, catch pot and jet system will be used with the new column. DsW 200401 STLCOPCB4058465 o) J. 0. Bright 3 April 20, 1970 The new column size was estimated from the 5/1 reflux ratio used in the batch lab distillations by J. L. Bernhardt (Reference 1). The number of trays was increased to 30 from the 25 used in the lab unit. 2. Cost Estimate The total capital cost was estimated at $500M from an estimated equipment cost of $111M and a Lang factor of 4.5. An equipment summary with estimated costs is included in the Appendix. Manufacturing costs are based on 1970 standard cost sheet for Krummrich. Additional cost for repairs was taken as 6%, and depreciation was taken as 10% of the added capital. The increase in factory indirect expense was calculated as 3% of the new capital. Increased utility cost was cal culated from the increased requirements of fractionation. An additional $20M was added for inefficiencies in recycling hiboilers and for modest increases in TSD and PRD work. The increased conversion cost was calculated from the additional cost per year and a product rate of 30K pounds, per year. Attachments e7c-<:`^ R. L. Neary DSW 200402 STLCOPCB4058466 APPENDIX A 1. Flow Diagram 2. Equipment List DSW 200403 STLCOPCB4058467 I | 'O H -A aw REMARKS E S T IM A T E D P R IC E ! S) *m03Q:UaJ ___________ _ 1 80 ;V * <s 8 o or **> ' l 0 s> 0 <\ * ? \4 0 s k% fc * $$ _______________ ** O P E R A T IN G WEIGHT (POUNDS) 3 Vi 4 ji 4 M A TE R IA L OF CO NSTRUCTIO N $$ NJ '"i 1 i\a. JI \ l>" or $ i: 4 i ! 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