Document vBJvoZBokneYxX1LzJM8K25bb

f$?gpksLr~:^ 5~P/?f2-YJfto ( Y^ tJU. A-C & v 63^.00 SUMMARY This process described herein is designed to produce Opalon 610 QeA i&%Q type resinsusing A-6 catalyst in 3700-gallon glass-lined reactors. __^J1I11|lliU>|f| nf i[im1 iii11nilniiin 7itiiiinri i'it11i~tii j ~ hit I*" 11*.... Tfccsc rewt ftrt umi Vytan* kirfcU C&^pouwd,* iw &S WtAj. RSV0028626 RSV0028627 63^.01# SUMMARY OF POLYMERIZATION CONDITIONS* 610 630 A. Formulation and Measuring Technique 1 . VCM Meter 2 Water kettle charge Meter Water - B-2 charge Vol, & Meter Water - B-2 flush Meter 3. B-2 Wei gh 4. C-l Weigh 5. TCE Weigh 6. A-6 Wei gh 7. A-6 Solvent Weigh 8. Anti foam Volume 9-.. Ionol Volume 11 ,000 lbs. 1 ,850 gal. SO gal. 80 gal. ,5 lbs. 10 oz. 30 lbs. 185 lbs. 2 1 bs . 8 o2 . 7 lbs. Hallco CPH-35N 3 qts . max. 100 gms. 11,000 lbs. 1 ,850 gal. &Q gal . 80 gal. 5 lbs. 8 oz. 34 lbs. 65 lbs. 2 lbs. 8 oz. 7 lbs. Hallco CPH-35N 3 qts. max. B. Water Temperature During Purge C. Vacuum.'Purge,. Minutes @ Boil D; BATCH Temp. 0. Catalyst Addition E. Reaction Temperature 58 - 61 10 56 - 59 C. 58 C. 58 - 61 C, 10 55 - 58 C 57 C F. Maximum Heat Kick 1. Full Cold Water 2. Water Inj., 250 gal. 250 gal. addition @ second e taiO G * Final Vent 50 psig or 20 min. 50 psig or 20 min. ' after 75 after 75 psig H. Agitator Speed 107-110 rpm. 107-110 rpm. i ' The exact batch formulation and reaction temperature for each kettle are specified daily by the Operating Supervisor, on a daily instruction card. Jt ay.oz SUMMARY OF EMERGENCY PROCEDURE 650 fcfO ^sCrfiK a.rt.d-Q'G-Q' 1. Heat kick control at 1C above reaction temp. at 2C II at 63C batch temp. FCW 250 gal. water inj. twice if necessary for a total of 500 gal. Vent to gasholder and/or stack. at 66C " and appears it will not turn over in the next 2C Add 1 gal. of styrene and continue venting. 2. Note: Although the above procedure is based on batch temperatures, add 1 gal. of styrene at any point if the pressure reaches 140 psig and is sti11 rising.. 3. Note: After catalyst injection, there will on occasion be as much as a 4C overshoot. This is not a heat kick and requires no action. However, it should be watched carefully until it shows it will come back down. RSV0028628 i tt fi 3V-Id RAW MATERIALS 5^.11 Description.and Hazards of Raw Materials, The raw materials normally encountered in the polyr.3 rizatic area are listed below with a brief description of the h&zar A more complete definition is written in Section 1160, Safe 1. TCE + high heat : (open flame-) phosgene (highly toxic) 2, TCE + caustic explosive mixture (dichloroacetylene) 3* Caustic >, VCM Causes extremely bad chemical burns, exothermic (gives off heat), when dissolved in water. Extremely flammable and explosive TCE 3-1 & B-2 C-l Net flammable--store in cool dry place, Extremely flammable--store in cool dry place. No fire but dust explosion hazard. No fire or explosion hazard. RSV0028629 63<jf,IO R'AU MATERIALS (Cont'd.) Description and Hazards 'of Haw Materials (Cont'd.) HydrWtfae- -WfTti j&3@mafr?bex * spying' h^a-rd, 19 --^9^jjsA^ 1l;oi>art^S^s^g: |o. Halloo CPH35W 31. Tetrahydrofur (Solvent) No fire, slipping hazard. eyes, nose, etc. Must be routinely inhibited to prevent formation of peroxides. %2. A-6 Catalyst Unstable material, decomposes violently at temperatures above 5-SC, 13. DEM (A-6. Solvent) Slightly flammable.; irritating odor; ' can cause irritation to skin. |4. A-6 Solution Unstable material1,' decomposes violently at temperatures above.40C; slightly flammable; irritating odor; can causeirritation to skin. lljf.12 Raw material Charge Measurement A polymerisation log sheet, Form MS &&', is to be completely filled out with all readings recorded. A sample of the form ***0 d 1/ vd9 Water, Nettle Charge B-2 Charge S-2 Flush Summary (#1, #2,$3 Tanks) I85O gai. 50 gal. 80 gal RSV0028630 6-;?, 10 HAH MATERIALS (Cont'd.) 633M2 Raw Material Charge Measurement (Cont'd,) 63Sf.l21 Vinyl Chloride Monomer Charge Quantity Due to density changes with temperature* it i-s necessary to correct the -VCM volume charge for VCM temperature as shown'in the following table. ton m 1 VCM Temp,,C .0 1 2 l 5 6 -7 8 9 10 11 12 13 14 15 16 17 18' 19 20 21 22 23 24 25 26 - 27. 28 29 30 31 32 33 34 35 VCM Vol* Gal 1391 1393 1396 1399 1401 1464 1406 1409 1412 1415 1418 - 1420 1423 1425 1429 1432 1434 .1437 . 1440' 1443 1445 1448 1451 1454 ' - 1-457 1459 1462 1465 1468 1471 1474 1477 1480 1433 1486 1489 RSV0028631 ro >i c10 RAW MATERIALS . (Cont * d.) G/.' 12 Raw Material Charge Measurement (Ccnt'd.) 63$. 122 Vinyl Chloride Meter- Calibration Accurate VCM charging is essential. Hence, VCM meters are calibrated.cn a weekly ~^?ii Tirvif-1^-rnr 63^.123 Process -Water Charge Quantities . Process water is divided between (a) the initial kettle vTate charge and -(b) the water used for dissolving and flushing 3- (a) Kettle Charge for 88 Blag, and 92 Bldg, kettles Dipstick inches 81-86 Kefties gallons 87 Kettle gallons 70 71 72 73 74 75 76 77 78 79 80 Si 82 83 ` 0*4 85 2025 1995 1965 1935. 1905 1 1875 . 1844 1813 1782 1751. 1720 I089 1658 1627 - /a*\ o'">ipr- 1995 1965 1935 1905IS 75 1844 1813 1782 '1751 1720 I0S9 1658 1627 (b) VAater Charge - Is JO- I'iv-' or Premix Pa A v ora.1 of 130 ga. -L 2. Gol 3 of water ar to she reactor. - The f j_r*s u Du p*b.li C * + C 2 while an addit ional 80 gal to fluah the B-2 into the reactor. 92 Bldg ._ Kettles gallons ..'>1785 .1756. 1727 . .1698 : ; 1669 1640 1609 1578 ' 1547 . 1516 ^ 1485 :' 1454 1423 - RSV0028632 0. 63ff. 124 B-2 Charge The exact amount of B-2 is weighed into a container and the net weight is printed on the back of the batch log sheet. Since B-2 absorbs moisture from the atmosphere, it is important that the surplus supply of B-2 be kept in polyethylene lined drums and the drums be covered at all times when not in use. Use only the specified lot of material. 63tf. 125 C*1 Charge The exact amount of C-l is weighed into a container and the net weight is printed on the back of the batch log sheet. The C-l viscosity increases rapidly as the temperature drops and, therefore, it is necessary to keep all C-l 55-gallon drums in a warm storage area. Besureto^jos^^onl^ the specifiejLlojLpf C-l. 63^. 12& TCE Charge The TCE weight tank system is used to accurately charge the specified amount of TCE. The weight tank is filled, and the red pointer set at the weight to be delivered. The starting weight (tare weight) and discharge weight are printed on the back of the log sheet. RSV0028633 63ST.10 RAW MATERIALS (Cent1 d. ) 63<y. 12 Raw Material Charge Measurement (Cont'd.) 63^. 127 DEM Charge The exact amount of DEM is weighed directly into the A-6dissolving tank. Prior to the weighing, the scale poise should be moved until the empty tank is tared to zero scale reading.. 63#. 128 A-6 Charge The exact amount of A-6 is transferred directly from the 10# trays into the DEM in.the dissolving tank. During this operation it will be necessary to have the 10# trays in contact with dry ice. With an ice pick the cake of A-6 can be gently broken up into small pieces and these can be transferred with a plastic scoop. The scale reading will Indicate both the DEM and A-6 weight. Mi13 Raw Material Preparation 63^. 131 Dissolving and Filtering B-2 in 1st Floor Premix Tanks At least two hours before kettle is to be charged, start. the B-2 makeup. As B-2 solution can be held indefinitely, prepare the next batch as soon as the tank is empty. .a. Weigh the specified quantity of B-2' into a container and position near the tank. Record lot number on log sheet. b. Add approximately 20 gallons 2 to 3 Inches above bottom impeller of hot water--65 to 80C on tank thermometer. c. Start tank agitator. d. Slowly add the B-2 to the hot water over a 1-2 minute period. e. After the B-2 is thoroughly wetted, 1-2 minutes, add cold water until tank is half full. Temperature 1 should be below 30C. f OHM t 20 RSV0028634 63#, 10 RAW MATERIALS (Cont'd.) 639.13 Raw Material Preparation (Cont'd.) -- - 63#.131 Dissolving and filtering B-2 in 1st Floor Premlx Tanks(con f. g. Record time and solution temperature on log sheet. Allow B-2 to mix and dissolve for two hours before filtering. After two hours the agitator can be shut off to avoid spillage. 63*/. 133. Preparation of A-6 Solution. a. A-6 solution can be kept indefinitely under refrigeration in the kettle hold tanks. However, for simplicity of control in case of an emergency keep A-6 solution inventory in hold tanks down to 4 batches. RSV0028635 D 3<jf. i Q rAVI' MATBKaAIS (Cont'a.) 63*/. 13 Raw ' Material Preparation ( Cont1 d.) 63'j/.I33t Preparation ox'* A-S Solution (Cont'd.) D, Operator must wear gloves and goggles (or face shield) in the dissolving room c. At least once osr sshhiifftt/a1 adddd sounfffiicc:ient dry ice to all Oiransporu Bones containing" d. Place the dissolving tank on the scale and adjust poise to aero scale reading. e. Turn DEM spigot over tank and carefully add 7 'lbs. DEM. Evt. iicor.OL'ja (60-70?). O<V by using the 5 lb. weight. )EM. -'Add sufficient dry .peratura to lp-20C accuracy once per shift 'h, Remove--a tray of A-6 from "Transport Box and place in the refrigerated holder 1. Remove cover x'rom A-6 tray .and gently break A-6 into small pieces using an ice pick. 1 j. VJith a scoopj transfer* the A.-6- into the dissolving tank. Add the specified'amount.. k. Replace cover on A-6 tray and return to the Transport Box. A-6 solid should not be left outside of the* Transport Box for more than 5 minutes.. 1 ' l. .Carefully move-dissolving tank to the agitator station. m. Slowly lower agiuator into tank by steadying the agitator wiuh the left hand and slowly turning the 2-way valve handle. n. Start agitaeor. Small needle valve on motor base controls EPM; use slowest"speed. o. Dissolve A-o for 8.minutes. The solution temperature v:ill drop quickly as the A-6 dissolves. Follow the temperature closely, ,(a) At the start the tmeprature should be 15-20C . (o0-70R). RSV0028636 o3#.10 'RAW"MATERIALS (Cont'd.) 63$. 13 Raw Material Preparation (Cont'd.) 63$. 133 Preparation of A-6 Solution (Cont'd..) (b) After 3 minutes of agitation, the temperature should be less.than 5C (40p), (c) After 8 minutes of agitation, the temperature' should be less than -6c (20p). If solution temperature goes higher, stop agitation .-arid add sufficient dry ice to the-material to cool it. .: After dissolving period, shut off main-air valve to stop agitator. Slowly raise agitator steadying the system with the left hand while turning 2-way valve with the right hand. q,, Close cover of tank and immediately transport this material to the desired kettle hold tank--never: delay,.. r. At no time leave the dissolving room.area until all is completed. 635f.l3S Emergency Procedure in Dissolving Hoorn a. If you are in need of dry ice to restore inventory level--contact Foreman immediately. b. Never place an object on top of Transport Boxes; C02 gases-must be - allowed to vent* . ^'If DEM spills occur: Large spills should be soaked up with Vermicullte and swept up. Place in the disposal can. Wash down area with water. Small spills should be' washed 'down with water. d. If solid A-o spills occur: Spills should be swept up with Vermicullte and placed in a flat open tray. The sweeps must not be thrown into a drum or with other trash. Remove the sweeps to the area north of Bldg. Switioutside of the building spread'.<#n the gftowwK Notify the. foreman. RSV0028637 fr-if n n pah MATERIALS (Cont' d.) f-.-tit i? prw Material preparation (Cont'd.) VJ , V~** _ . . 1--T *' " o3#. ^SlS' Emergency procedure, in Dissolving.' Room' (Cont1 d. ) o.' X? A-o/DSM spills occur: l a| ** Large soill should be soaked up with Vermiculite. Do r.ot^allow pools to exist. Handle the same way as large . * soills of A-6; that is, remove sweeping to the gar.tsbd.e c<TW^j7 *-hnmmt*nin 370='" soills should be washed down with water* a. . Phe A-6 solution nust be transferred to the-refrigerated charging tank immediately after completion of the dis solving operation. . . b. preparation for the transfer: (a) Position dissolving tank in support ring, but do not open drain valves. , (b) Loosen cover on the transfer tank.. . h (c) Be sure 2" vent valve is open on the kettle hold bank. (d) Drain any liquid from the kettle hold tank into a pail containing some dry ice. If more than a few drops, drain, remove to disposal area after com pleting the transfer. (c) Check kettle hold tank charge valve and drain valve. (f) Check Solution" temperature gauge--should be below S^C. (s) Refrigeration must be operating and "brine temperature out" must be below 2c. RSV0028638 63#. IQ RAW MATERIALS (Cont'd.) 63$.13 Raw Material Preparation (Cont'd.) 63#.13# Transfer of A-6 Solution (Cont'd.) c. Transfer the solution by making up the quick-coupling and then opening'the (a) kettle hold tank transfer valve ' first* and (b) then opening the dissolving tank drain valve. d. When the A-6 solution is completely drained* first close the dissolving tank drain and then the kettle hold tank valve. A-6 solution is now ready for the charging operation. 63^.135* Emergency Procedure If any abnormal condition* such as listed below* arises drain the solution into a pail containing dry ice. Disp^^ of this material by spreading Vermiculite $n the .gjaauttd and pouring the solution cn top.In this manner* gradual decomposition will occur. Abnormal Conditions a. Equipment maintenance 'is required. b. Solution temperature rises either due to decomposition . or lack of refrigeration. (1) Normal A-6 Solution Temp. (2) V/arning Temperature (3) Drain A-6 Solution (4) Allow A-o Solution to decompose in holdp( tank*f". 1 Tl L** wi4t" Vhi O2"" vent valvet T r, -A 4- tr ^ "1 > ^ open 0 to 5C 10C 150C 30C or higher 63^.14 Charging Water* 3-2, C-l* J* 1 i4 fo I / ou/^ * RSY0028639 r\ 0 6^.10 RAW MATERIALS (Cant'd. } S^tj. 14 Charging Water* `3-2, C-lj (Contfd.) Use $1 * $2.) #3 B-2 Tank ?roc bss Water Charge B-2 Make-Up Water. B-2 Water Flash Total 1850 gal. 50 gal. ___80 gal. 1980 gal. 1. The Instrument settings to he used during the water charge are as follows: ., Kettle Batch Temp. Recorder and Controller (3TRC) .......... on Manual* set point reaction temp. Jacket Temp. Recorder and Controller (JTRC) .......... on Automatic* set point 62C. Charge Water Temperature Controller p.^-h r.,Ant at 5^8nC. / VCMi i^availeb-Be * eAtf.' r eh&pge. i " \y/ o cf/cjhe water cha^ge-~a .'.ttlfe /has been filled vilfc '// ^wnsoreem of the Durco/ ,___ ,, . |/f prpe isfiiot* /ahd ft, stop^hnarg^g sequence and-nav v;aLer^charge is started* charge B-2 solution. a. sur^ a--a sewer valves are closed* b. Line up valve from tank to pump through filter and into the kettle. ` : c. Start pump and drain tank completely. o RSV0028640 I o. 63$,10 'HAW MATERIALS (Cant'd.} 63^.14 Charging Water., B-2, C-l (Cont'd.) ^ When using 1st floor pre-mix tanks: a. When ready to filter B-2 pressurize system' between 3-2 tank "bottom valve and kettle valve with water to 30 psig to be sure of no leaks in the system. b,, Pump B-2 solution to kettle. c. Add 80 gallons (metered) of cold water to the tank to flush out the system. Pump out flush "water while .......a.-d...d..i.n...g. ...t..o___t_a_n__k_._ _ .. . . / .. . -vx. ...... .. s________ _ . Baring the process water addition and the B-2 addition charge the C-l to the reactor via the manhole. Before closing manhole cover, check the catalyst water- flush. Open the. rotameter valve wide to be sure line : clear.and-chan adjust JLr> Tit -> to 9~lo: gph:' j.f.line is u: clear, reuair V. p *T ore proceeding any further The flusn is to be xept on au aTl times ^except during kettle entry for.cleaning.) D/p 5 7*1' c lc 'looic-h LtVtfL /a i~'i J As soon as the B-2, and C-l and dog down manhole cover. have been addedJ\ close , ___ ______ As soon as the -manhole cover is secured, start vacuum purge operation. w **>$f.!5 Vacuum Purging a. Check to be sure all kettle valves are closed*^Mwq8i^ ; '"** 01 ri i 1 i^nngaMnBsiir, RSV0028641 \ Determine and record maximum vacuum controller* level. a. Do not proceed unless water is flowing to barometric .conaenserp and b. the system vacuum is below 3*5 inches 'absolute. Open vacuum valve on kettle.- After adding 3-2 water and process v;ater* the batch temperature should be in the p4-6lQc range and approaching a constant temperature. a.. If it is necessary to adjust batch temperature to the desired range* hold up vacuum on kettle until temperature is within range. Maintain a 5-minute vacuum boil. a. ' If the water is boiling at the completion of the,water charges* close water valve and purge for an additional p minutes-. b. If the water is not yet boiling at the completion of. the viater charges* close water valve.. Continue to' purge, until a b:il is reached* and hold vacuum for an adoi cionaj. p manures. The batch water is boiling when the vacuum controller is reading less than the theoretical boiling pressure listed below* and the actual pressure is not dropping faster than' C.2 inches per minute-. Batch Temp. 53.0'C 53*5 54.0 54.p 55.0 55.5 56.0 56.5 57.0 57.5 Theoretical Boiling Pressure 4.22 inches of Mercury 4.32 ' 4.43 4.52 4.61 4.73 4.86 4.98 5.10 5.20 RSV0028642 18 MAiPRiAlS (Cent' d 'acuum parking (Cont'd *5 XjS.T'Or*! ^ vOil *-/ * 0. P ^ pkOA . .> u to. 5 59.0 59.5 Sc. o ... ' / bO .5 63.. 0, 61.5 62.0 Theoretics.! Boiling Pressure 5.40 inches of Mercury 5.50 5.60 ' 5.75 ' 5.90 o.OO 6.15 6.30 '6.45 7. Motes__________________ _______ __ _______ ____..__ faffrL /|cCwr*fc WW \I^<V| w^errto*V` HIm ^ovY imCW* wftfc -Vta. v*wWU- upe* ^<i iffrtvfc -ft* utcr* <-!** oua 1. At the end of the vacuum purge, charge the specified amount .of TCE from the weigh, tank. Z, Print the discharge weight on the log sheet. RSV0028643 63#. 10. RAW MATERIALS (Cont'd. ) 63#. ry Charging-VCM 1. After completion of the vacuum purge and TCE charge, charge all the VCM to the kettle. twc 2. As the VCM is added, the batch temperature will drop. Try to keep batch temperature as close as possible to reaction temp. a. BTRC is maintained on manual control. b. JTRC is maintained on automatic control. 3. Make adjustments as necessary to jacket temperature set point to attain 56-59 C. batch temperature by the end of the VCM add; adjust BTRC set point to reaction temperature. 4. During the VCM charge, read the VCM thermometer and determine the proper gallonage figure from the chart. 5. When the VCM charge is completed, close the valve at the VCM meter first, then the valve at the kettle to allow the liquid in the vertical line at the kettle`to drain. This will lessen pres sure buildup problem caused by thermal expansion of VCM. 63#. iff Charging of A-6 Solution 1. After the VCM charge is completed and the reaction temperature is between 56-59C. , prepare the A-6 solution charging. 2. At the kettle panel, open the high pressure flush water valve to 9-10 gph rotameter setting. (Note that catalyst flush water must be flowing before starting the VCM charge. ) 3. Check to be sure the water flowing through.the catalyst charge line is cool to the touch. Do not charge if water is hot. \ RSV0028644 63^.10 RAW MATERIALS (Cont'd. ) 63#,fc Charging of A-6 Solution (Cont'd. ) 4. Check to be sure the A-6 solution temperature is below 10C. 5. Check the kettle hold tank drain valve--must he closed. 6. Close transfer valve to charge tank. 7. Drop the Reactor Jacket Water Setpoint to 50c, 8. Close 1/4" needle valve on control panel--finger tight. 9. On A-6 Instrument panel push "Close Button" which automatically closes the contromatic vent line valve. (Valves are equipped with a timer that re-opens valve at the end of an 8-minute period. If A-6 charge time is extended beyond 8 minutes, contromatic vent valve can be reset for another 8-minute period by pushing "close" button a second time. ) 10. Slowly open 1/4" nitrogen needle valve and pressurize tank to 325-350 psig. Then, close needle valve. 11. When jacket temperature has dropped below 55C., start A-6 solution addition. 12. Slowly open 1/2" plug charge valve below tank. As the solution-, flows from the tank to the reactor the pressure in the tank will drop. Adjust charge valve so that pressure drop from 325/350 to 150 psig. takes 1 minute. This,is necessary to permit complete drainage of the tank. 13. When the tank pressure reaches 150 psig., close the charge valve. Repressurize to:; 325 psig. and slowly charge to kettle again. 14. When the tank pressure reaches 150 psig. , close the charge valve and de-pressurize the charge tank by opening the 1/4" needle vent valve at the control panel. 15. When hold tank pressure drops below 5 psig., open the 2" vent valve by pushing the "open button. " 1 6. Place a pail of Vermiculite beneath the charge tank drain valve and open valve. Report to supervision if more than a few drops of liquid drain from the tank, t/SvlSt^S >**<&HtM, NOTE: Gloves and goggles must be worn during this operation. 17. After the 1-minute high water flush period, adjust the flow rate to 6 gph and maintain. Do not shut off unless kettle goes down for cleaning. $ RSV0028645 STANDARD PROCEDURE. Plant ........../.....Sprlngfiel Departmejn ............... .^s TITLE .... PROCESS Number.... .............. Sh L FOR...QBA1$N,,6.50 AHD_660 .... 63#20 REACTION TEMPERATURE CONTROL 63^.21 Heat-up Control ,1* Instrument Settings BTRC ................................................ .. on Manual Proportional Band..................................... 18-20 Reset .............................................................. 10 Derivative .,.................... .. 10 Set point .................... ..................... .. at reaction temp. JTRC ........................................................................ on Automatic; Proportional Band................................. 10 # Pneumatic........... . 50 2. Between G-10 minutes after the A-6 catalyst solution has teen added to the kettle, switch BTRC t automatic control. 3. Normally the settings above will automatically control the batch temperature. However, in the evidence of a batch temperature over-shoot or cycling proceed as follows: Batch Over-Shoot Action 55- 7c 58vc . 59C None, normalr yei*-shnot ; Switch BTRC td^WantKLl and drop Jacket set to zero. Put FCW on jacket; Inject 200 gallons of water "Veist %e""gafl'hlieW!l Tent to gasholder and/or stack Inject 1 gallon styrene After batch has turned over and started to return to 1 reaction temperature, level off system under normal eontrol. Switch to automatic eontrol when reaction temperature is under good control, + lwc. ^ry # w * * vT*<l fifths Abt*e # fc- * TOL'-.'uaat ^ Any batch that must be Aweatod in order to control reaction temperature will be down graded to Technical Code - 6. form 120 . ISSUED 3-26-65 STANDARDS DEPARTMENT ey RSV0028646 STANDARD PROCEDURE; PLASTICS DIVISION Plant .................. D partment ............ ............... .............................. TITLE ZS370pR0CEfKM A- 6 PR.............. 63^.20 REACTION TEMPERATURE CONTROL (Cont'd.) 633722 Heat Kick Control NufiS,M:..Sfi?..88;633:0 Sh ts Pag h *4- I fi t / f i <t 4' * cfi&tf hrjrfp. ^ tjr ** * - - * * *c$ ^Tr *m^cry**$> if **.c&**My Ac a ~Trn%v *fz cac <47" 4.?%. (6^`"74.4 73'/"?^-- * Vv / 7^r f. * z4t>l</c*c r fa^ s-77 l.ac *r /^ri4 A jjp *t,AJR / T* M/| /i H Z*~T" otrdk /*v Ac vr*rAl ._____ __ ________ / cAt, ^ *rryes*c ' J c*>n- TTr# mc ^ciyTT'Wd-< yfrT.73.: d/77toucKf "7A < s j-J / euL, *ye fcr*.ijtc W ^^ivc xiT" 7s h* J ^ 477V4 7* *<*/& >yr T^c l/J<~U pK *}>&*&. * fiJ * 6 $TV/ K.*****^- - 4^77#; c*77 Jy 77" Ajrc*777 o* ^ ?7irc v*-* // ^ <c ^ s*0*1 hr ai fr\vz,h A # <^. oycKS h Tifc 43 is AS ST" At J CC~ ^ v t Kc i & T**h , ffvw c v*?a% t T S A / if h c ^TTc 4 J c*- *i'*s ' tT H # V S' 4 o-Uf ^ 7 jr w/ ; h#dk* 4. <*<*>*$ , FORM 126 RSV0028647 ISSUED 3-26-65 STANDARDS DEPARTMENT ey <f 6-:*j4?0 FISAL V5N1 ' 1, start the final vent at 50 psig or 20 minuoes after- baton, pressure drops below 75 psig> whichever comes iar-s^. .2 Prior to starting the final vent* add 3 quarts of Hallco anti-foam to the anti-foam bomb, hnA &T**T.'rkc vr<-rr a ciew b tQS&C SDPjfcJS-Aj' 3. Pressurize the anti-foam bomb to 75-80 psig with nirtr*vo. gen vaive. Goose 4, One minute before starting the final vent, open anti-foam valve to kettle for continuous addition during the vent. 5. If foaming occurs, slow down the,rate of venting. 6. After the final vent is complete, drop jacket temperature water to 5"&0ic* 11> n w i a RSV0028648 24. Sjtf.HO E-SFtlENCY ac-x-ion / if for any specific r-eason there is danger of a set-up batchy / add one vallm of styrene monomer to the kettle. Specifically> styrene injection should be employed for the following conditions 1. Power Failure \ See Secti-on 637.0EmergencyProcedure; (add l/2 gallon of \ styrene monomer to eachbatch.) . 2. Water Failure . j Same as above. i ,> \ 3.' Mechanical Failure of Equipment Causing .loss of Agination ; ' : if for any reason (such as seal leak spark,generation, motor ! overload,, excessive vibration at both high and low speed ? agitation, reducer failure, belt breakage) it becomes necessary to* stop agitation immediately, add 1/2 gallon cf styrene to the batch. If repairs cannot be effected in- 30 minutes, vent off ^ remaining VCM with batch temperature reduced to 35-5C^0.' If repairs can be completed, start up agitation (by jogging agitator on-off) and' complete batch polymerisation. i ` ; 4. Meebanical Failure of Equipment Causing Partial or Complete T.ces"oir'"0:-clang Warner. Basically, the emergency is very similar to /Water Failure Emergency Procedure-Section 637.0". Add-1/2 gallon of styrene if necessary to maintain batch temperature- below 70 C and/or batch pressure below 135* psi; 5. Suspending Agent Omission or Failure If the B-2 charge is accidentally omitted (or only partially charged) or if the 3-2 suspending agent is destroyed by an impurity--such as caustic--batch set-up will occur. An early indication of this problem is a sudden drop in the jacket v;ater temperature after only 3 to 4 hours of polymerization. A hear kick'will follow immediately^__ RSV0028649 5. Suspending Agent Omission or Failure (Cont' d.) - V/ith these symptoms, add 1/2 gallon of styrene to the batch. ; O1 I fONW | ic RSV0028650 STANDARD PROCEDURE. Plant .............. .Springfield^..,, jT Department ........... TITLE....j[W 660 T^SIHS- VIA LtHE A-6 PROCESS 63#. 50 BATCH CLASSIFICATION .Sheets .SDP. .88-633.0 Page.... 2.6 63^.51 Reclassification of -Batches In Kettle Downgrade to Code 6 (Technical Grade) for the following reasons: (a) Batch is mischarged. 00 Agitator is off more than 15 minutes after A-6 charge , has been started. '(c) RVCM is used. (-d ) J^t ___ ST'/A^V* * ^ Addl'd oE / r >. tfxCf f d i (o&C. (e) Particle size Is obviously too coarse. (f) Excessive temperature cycling occurs, tiipe1 wO.1^gen^ralXy^vary" on batph.es us>ng~RVCM tlmsff" aa/me.all:rejiyfrom ...^art or catalyst to &'ft&'Sdns^r^rtifojas^ if ara^j&i , lmtrgiali.tiaa._such ks poor^emry'control, high heat 63^.52 Segregation of Batches 1. Complete wash-out of lines and slurry tanks is required between all product changes, i.e., going from-##L to, '0#fP!L and vice versa. E*d*\ Go-l 2. No clean-out is necessary between product changes of Technical Grade material. 3. Code 1 and Code 6 are kept completely segregated. If it . . --becomes necessary to dump a Code 6 batch into a tank that has not been washed out, then the entire contents are immediately downgraded to Technical Grade. rouM lie RSV0028651 ISSUED 3-26-65 a STANDARDS DEPARTMENT BY 5^.60 -DUMPING 0? BATCHES 1. Take required samples from each batch before dumping. .2 Dump slurry in tank with adequate space for batch-- avoid spillage' ^ * Vfnen kettle has been dumped, lower the jacket temperature point to sero so that kettle can be inspected (without steam vapors) during subsequent flushing and inspection opera ^ion, 4. Plush dump lines to and from the pumps for 2-3 minutes with water to prevent solids settling and plug-ups. ft theryhil" ' /t^\rpum ^and-1^^" wi-pa JlaiL^rS^^ JJ,er 1, h$. If normal dumping is not possible ^i.e., .plugged dump hole) use "Siphon TJnloading^Technique". (Section 639-70) frtr&vrm.m IM ^ i ~-- ... U- i'rh *<- Vi A ~Th p fcJTTL* P/byA hyf * *?** , 6*' b*-~c /i\ /cvs -<? d-ofet, F4<^/ ^ifA,rd sH^V A q /T$ ' ?*'",F".c*< ,, i (i ' **\ ! />/ sTVy d '1 (0 < Mir'-**/* .. 45 z7"3 .c-j/i . y-'n <- r 'r > ^ ^ c ^JU"'C? * *1 i0 L ' <m r i * ^ ^ tCc,, p -r < dMr'M^,'f/ush -P-Hvl qe^urer, u */r \ i' iJtT. ;/,,./ j,,c, -r-, "'!U 'P-1 ' <<1 , . =/- /;Tj - fV o tw 77V- ft/ u 5 A J^jLiSkh^^ GVl.l r o m u* o RSV0028652 STANDARD PROCEDURE. Plant ... Sheets / Page 28 'QR..0P4R0J' 650.,AND. ` PROCESS " " `.......... ^8....................................................................... 63^70 KETTLE FLUSHING 1. Considerable attention must be given to cleaning out all loose adhering polymer before proceeding with the water charging of the next batch. Residual polymer will result in high, out-of-spec flsheye level. 2. While the batch is being dumped, gently wash down kettle walls with low pressure water. J _ _*1 *J 1 *- TM ^ .* ...... "1 ^ J. . . ,, r .................. ..... 'I'Hq'ilffiom ...... fnri1iri'i|ll'li,i^i^Miwii'mii1iNi4i4|ii<i|<NiflwAaiiliiiiii.ii s ?. /or a JL'UtteJ -/if// Arttfc -f/oth *y<J*~*j <, tec T&fi gcibeme TKr^t*/ 4 j yj u , ISSUED 3-26-65 1 STANDARDS DEPARTMEN RSV0028653