Document wD6aJBmq4BV2DjLyGQqXBJx2V

CAUSTIC I / CHLOR - ALKALI 2 1994 REACTIVE CHEMICALS REVIEW CAUSTIC AREA - both plants Dow Confidential Information DO A 0461 20 CONFTDFNTTAL 09/29/94 NaOH EVAPORATOR AREA 09/94 SaltSkrrylo Brine Treating ^ DOW CONFIDENTIAL DO A 046121 CONFTDFNTTAl. NaOH CENTRIFUGES & PRIMARY COOLING AREAS From _ EV-304 V D-351 AJ MU A/B K7 Carrtw , 't D-SS2 Ia 09/94 'A ri _h La S-301 T kA~. To 3or E-SOS A/B/C SULLCF lii LA^ To Civtttc DOW CONFIDENTIAL DO A 0461 CONFTDFNTT NaOH FINISHING AND STORAGE AREA nr L&l, MU C.W./PW | E-i07 */i/C |f SHftce Wlttr V<nt _L_L* *^^]f1-370 A/8/C HP----- L&h 1 09/94 T* D-3SO Mil IA/% WS Steam ^4l 2\ 0-MZ DOW CONFIDENTIAL HO A 046.123 CONFTDFNTJAL CAUSTIC 1 EVAPORATOR AREA 23W STEAM TO CHLORINE JM BUTLER 09/27/94 CAUSTIC 1 CENTRIFUGES/PRIMARY COOLING CAUSTIC 1 CHILLING/FILTERING/STORAGE 09/27/94 CAUSTIC 1/CAll REACTIVE CHEMICALS REVIEW j OCTOBER, 1994 RAW MATERIALS/PROCESS AIDS - RAW MATERIALS Cell Effluent (8-11% NaOH, 15-17% NaCI, 72% Water) - PROCESS AIDS Steam (150# and 235#) Carrier Brine (Caustic I Only) Process Water River Water Instrument Air Plant Air - SUPPLIES DO A 046177 CONFTDFNTTAi. HCL (Used for PH Control at Caustic 1-Does Not Contact Process) Lithium Bromide (ARU-not in Contact With Process) .............. ....... - - JMBUTLER 09/28/94 1 --u<-- CAUSTIC l/CAll REACTIVE CHEMICALS REVIEW OCTOBER, 1994 RAW MATERIALS/PROCESS AIDS: SOURCE AND STORAGE - SOURCE Cell Effluent - CL2 and CA2 (Pipelines) Steam - Power 1 (Pipelines) Carrier Brine - CL2 (Caustic 1 Only-Pipeline) Process Water - Utilities (Pipeline) River Water - Plant Pumps (Caustic 1 Only-Pipeline) HCL - Solvents (Pipeline) Lith. Bromide - ARU (Contained Within Unit) CTW - Plant Pumps (CAII Only) - BLOCK STORAGE Cell Effluent - T-1 (Plant Feed), T-2 (User Feed), T-1A, T-2A, T-3, T-109 Tanks @ Caustic; D-301, D-316A @ CAIII D0 A 04f)1?8 HCL, Steam, Carrier Brine, Process Water, River Water confidfnttal - No Storage: Supplied via Pipeline on Demand Lith. Bromide - Stored Within ARU JMBUTLER 09/28/94 CAUSTIC l/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 RAW MATERIAL: SPECIFICATIONS Cell Effluent Caustic (NaOH) % Iron (Fe) PPM Sodium Sulfate (Na2S04) PPM Sodium Sulfite (Na2S03) PPM Sodium Chlorate (NaCI03) % 5-15 1.0 2500 1-20 0.03 DO A 046129 rONFTDFNTIAL JMBUTLER 09/28/94 CAUSTIC l/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 PRODUCTS/BY-PRODUCTS - PRODUCT 50% Caustic (50% NaOH, 0.5% NaCI, 49.5% Water) - BY-PRODUCTS Condensate (Boiler and Non-boiler Grade) Salt Slurry Sulfate Purge DO A 046130 CONFIDENTIAL JM BUTLER 09/28/94 i CAUSTIC l/CAll REACTIVE CHEMICALS REVIEW OCTOBER, 1994 PRODUCTS/BY-PRODUCTS: IN-PLANT DISTRIBUTION - PRODUCT Caustic - Pipelines to Storage Tanks in Plant and at Tank Farm Cell Effluent - Pipelines to Users (Backflow Protection Critical) - BY-PRODUCTS Condensate Salt Slurry Sulfate Purge - Boiler Grade Routed from Collection Tank to Power I or Used Internally - Non-Boiler Grade consumed in Process or Rout d to Canal - Routed from Two Salt Columns (D-205&D-207) to CL2 or Used Internally (CAII) - Brine from CL2 Mixed with Salt to Assist in Transfer - Routed to User Feed Tank (T-2) @ Caustic DO A 0461 CONFIDENT T r. <l CAUSTIC l/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 PRODUCT SPECIFICATIONS 50% CAUSTIC Caustic (NaOH) Salt (NaCI) Iron (Fe) Sodium Carbonate (Na2C03) Sodium Sulfate (Na2S04) Sodium Chlorate (NaC103) Nickel/Copper (Ni/Cu) Arsenic (As) Mercury (Hg) Lead(Pb) Heavy Metals as Pb Silicon (Si) Manganese (Mn) % % PPM % % % PPM PPM PPM PPM PPM PPM PPM 49.0-51.0 1.0 5.0 0.2 0.025 0.15 1.0 1.5 0.5 5.0 15.0 100 1.0 00 A 046132 CONFTDFNTT Al JMBUTLER 09/28/94 CAUSTIC l/CAII REACTIVE CHEMICALS REVIEW OCTOBER, 1994 BY-PRODUCT SPECIFICATIONS Caustic (NaOH) Salt Settle Volume (SV) Salt Slurry % % Conductivity Hydrazine Boiler Grade Condensate MMHOS PPM 1.25 Max 5-50 10 Max 0 DO A 046133 oonftdfntial JMBUTLER 09/28/94 CAUSTIC l/CAll REACTIVE CHEMICALS REVIEW OCTOBER, 1994 REACTIVITY: 50% NaOH - WATER - Dilution With Water is Exothermic - Rapid Temperature Increase Can Result - Heat of Dilution: Naoh*H20+H20-*- Na0H*2H20+175 BTU/LB - ACIDS - Reaction is Violent and/or Explosive - ORGANIC COMPOUNDS - Potential Violent Reaction - METALS - Rapid Reaction With Aluminum, Tin, and Zinc. - Can React with Amphoteric Metals in Water Solutions to Generate H2 Gas - Reaction With Bronze and Brass Flammability HO A 04M34 CONFTDENTTAl. - Not Flammable JMBUTLER 09/28/94 CAUSTIC 1 REACTIVE CHEMICALS REVIEW OCTOBER, 1994 REACTIVE CHEMICAL CONCERNS CONCERN Cell Effluent DistributionBackflow From User Plants PREVENTIVE MEASURES User Plants Surveyed in May, 1994 to Ensure Backflow Protection is In-place. Water/NaOH Heat of Dilution Water is Added Throughout Process. Continuous Flow and Closed System Control Temperature Increase Near Normal and Eliminate Impact Of Boiling Action, Respectively. Utility SystemsCaustic Contamination , Double Block and Bleed Used at All Cross Tie Points. Corrosion of Nickel Clad Vessels by Hypochlorites in the Cell Effluent Feed Cell Effluent Analyzed for Hypochlorites, Neutralized With Sodium Bisulfite. DO A 046135 OONFTDFNTTAL JMBUTLER 09/28/94 CAUSTIC I CRITICAL INSTRUMENT PROGRAM Tag - Instrument LSH1328 - T-2 HI LEVEL LSH1329 - T-1 HI LEVEL LSH1378-T-1A HI LEVEL LSH1537 - T-204 HI LEVEL LSH2104 - T-104 HI LEVEL LSH2105 - T-105 HI LEVEL LSH2106 - T-106 HI LEVEL LSH2108 - T-108 HI LEVEL LSH2109 - T-109 HI LEVEL LSH2110 - T-110 HI LEVEL LSH2111 - T-111 HI LEVEL LSH2629 - T-218 HI LEVEL LSH2630 - T-228 HI LEVEL LSH2654 - T-219 HI LEVEL LSH2655 - T-229 HI LEVEL LS5000A - T-21 HI LEVEL LS5007A - T-22 HI LEVEL LS5012A - T-28 HI LEVEL LS5024A - T-44 HI LEVEL LS5047A - T-47 HI LEVEL LS5061A - T-46 HI LEVEL LS5070A - T-49 HI LEVEL LS5075A - T-48 HI LEVEL LS7100A - T-20 HI LEVEL LS7168 - T-245 HI LEVEL LS7168A - T-245 HI HI LEVEL LS7200A - T-236 HI LEVEL LS82010 - T/C STATION #1 HI LVL SWITCH LS82011 - T/C STATION #2 HI LVL SWITCH LT1625 - E-204 LEVEL LT1626 - E-204 LEVEL PHI2418 - T-11 pH PT1621 - E-204 PRESSURE PT1621A - E-204 PRESSURE TRC3185 - ARU-204 LOW TEMP TRC3179 - ARU-205 LOW TEMP TT1628 - E-204 INLET TEMPERATURE TT7142 - HE-6 OUTLET TEMPERATURE TT1628A - P-204E DISCHARGE TEMP TT50006 - T-28 TEMPERATURE VI6551 - AC-301 SOUTH VIBRATIONS VI6552 - AC-301 MIDDLE VIBRATIONS VI6553 - AC-301 NORTH VIBRATIONS 6 MONTH 6 MONTH 6 MONTH 3 MONTH 6 MONTH 6 MONTH 6 MONTH 6 MONTH 6 MONTH 6 MONTH 6 MONTH 3 MONTH 3 MONTH 3 MONTH 3 MONTH 6 MONTH 3 MONTH 3 MONTH 3 MONTH 3 MONTH 6 MONTH 6 MONTH 6 MONTH 6 MONTH 6 MONTH 6 MONTH 6 MONTH 1 WEEK 1 WEEK 6 MONTH 6 MONTH 1 WEEK 6 MONTH 6 MONTH 6 MONTH 12 MONTH 12 MONTH 6 MONTH 6 MONTH 6 MONTH 12 MONTH 12 MONTH 12 MONTH Frequency DO 6 046136 C.ONFIOFNTT Al CRITICAL.DOC Dow Confidential 09/29/94