Document z46RVLmMwaEQzeJ9qLqrxpjB

I B4 INTER- office memo TENNECO CHEMICALS, INC. To W.C. Champion From F.W. Kanzler Subject MONTHLY PROGRESS REPORT February, 1975 AT Burlington At Burlington Date February 26, 1975 copy to ^ Dickerson P. Gawason H.R. Horton D.J. Krzywicki R.A. Lojewski P.R. Scarito A.C. Siegel W.E. Stewart E/ Young ^File I. ROUTINE ANALYSES A. In-Process Styrene in RVCM-VAcM 2-EHP - Assay, A(0) Residual Sodium Lauryl Sulfate in RVCM B. Finished Product Residual VCM - Resin - Slurry Bound Acetate Residual TCE c. Environmental and Personal Monitoring Samples VCM in Air - Perimeter Residual VCM Effluent Water Personal Monitoring VCM in Recovery Exhaust 1 .15 1 195 66 2 120 12 580 3 Total 995 II. SPECIAL TESTING A. Resin Plant 1. Raw Materials a. DHW-80 DHW-80 shipments from Henkel were exclusively manufac tured from Darling oleic acid throughout the report period. Oleic acid manufactured by Gross and by Darling were eval uated via gas chromatography for impurity levels. It was found that the Darling material contained a considerably lower level of impurities when compared with Gross oleic acid. The table below lists a summary of the integrated levels: COLORITE 010361 Elution Time, sec Gross, % Darling, % 0-43 868 875 - 981 1061 1325 1512 0.20 29.5 24.1 46.2 0.008 ND 0.017 29.2 ND 70.8 ND 0.006 A sample of Givaudan 9-A - the inhibitor used by Gross is on hand and a bottle polymerization run will be set up to study the effect of this inhibitor on bottle kinetics. This will be accomplished by comparing the reaction rates of an unspiked Darling DHW with a Givaudan 9-A-spiked Darling DHW. A sample of uninhibited Gross DHW-80 is on hand in Burl ington and will be run with the next scheduled bottles to be run on a regular preshipment sample. In-Process 1. Set-up in Reactor #10 A batch of 315 formulation resin run in this homopolymer reac tor set up on 2/6/75. Spot-check for gelatin in the reactor liquor showed positive. Quantification via gravimetric deter mination showed a level of 0.11%. As a result of a meeting held on 2/7/75, the Burlington Analyti cal Group was assigned the task to evaluate incremental addition of VAcM-VCM-TCE versus "pre-mix" addition of the above monomers in a bottle polymerization, the aim of which was to characterize some of the variables existing when copolymer batches are run in the Homopolymer Plant. Both bottle runs showed indications of set-up, e.g., bb's, large agglomerates and coarse resin particles in the bottles prepared with incremental addition. Bottles charged via "pre-mix" showed normal resin particles with no indi cation of any aggomeration. It should be noted that the bottles run at Polymer Research in Piscataway showed results contrary to our findings. A detailed report will issue. 2. Residual VCM Residual VCM analyses were performed on slurry samples as well as dried resin on a routine basis and in support of Process En gineering projects other than the current stripping program. COLORITE 010362 Page 3 C, Environmental Testing 1. Material Balance Air and water samples were analyzed in reevaluation of this Process Engineering program. 2, Fixed Monitoring System All seven instruments started last month ran satisfactorily throughout the report period. In addition, L/A-l and C-l in struments were put on stream during the month of February, A recorder malfunction in the B/V-l unit has prevented this start-up to date, A program is underway to retrieve data from the recorder charts which will enable us to establish daily average area exposure values, percent excursion levels and with the aid of a computer program, TWA's by job classification. D. Miscellaneous 1. Revised Test Methods Revised test methods for OVA sampling and charcoal tube sampl ing were reissued. A method covering routine work on the Bendix gas chromatographs was written and also issued. 2. Running Account of Analyses August September October 878 1014 1419 November 1194 December 1317 January 1076 FWK/jst F.W. Kanzler COLORITE 010363 TABLE IV BURLINGTON RESIN HALTS.' OPERATING PERSONNEL TIME-WEIGHTED VCM EXPOSURES Employee Classification Suspension Area 1. Area Foreman 2. Homopolymer Reactor Operator/Charger 3. Homopolymer Reactor Operator/Dumper 4. Copolymer Reactor Operator/Charger 5. Copolymer Reactor Operator/Dumper 6. Dryer Operator 7. Bagger/Cleaner 8. Labor Pool/Bagger Plastisol Area 9. Area Foreman 10. Shift Foreman 11. "A" Plant Tower Operator/Charger 12. "A" Pi ant Tower Operator/Dumper 13. "B" Plant Tower Operator/Charger 14. "B" Plant Tower Operator/Dumper 15. Laborer/Cleaner (Jet) )6. Laborer/Cleaner (Manual) 17. Bagger 18. Atomizer Dryer Operator 19. Additive Dryer Operator Laboratory 20. Quality Control laboratory Supervisor 21. Analytical Chemist 22. Colorist 23. Quality Control Technician/Day 24. Quality Control Technician/Shift Warehouse and Miscellaneous ^TsT. Warehouse' Supervisor 26. Warehouse Clerk 27. Warehouse Receiving Clerk 28. Warehouseman - Outside 29. Warehouseman - Inside 30. Effluent Operator 31. Boiler Operator 32. Lead Operator/Etoiler-Effluent 33. Utility Man - Outside 34. Utility Man - Inside 35. Yard and Service Man - Outside 36. Yard and Service Man - Inside *0ver SO ppm TWA February, 1975 7.9 10.9 21.5 6.2 7.2 3.9 3.9 1.3 7.0 3.3 12.4 12.5 6.7 9.0 6.6 4.0 * 3.5 2.6 3.2 8.1 9.5 11.5 14.5 15.7 .2 .3 1.4 .1 .2 .8 .1 1.2 .5 2.9 .1 1.1 COLORITE 010364 TA3LE II BURLINGTON RESIN PLANTS VCM MONITORING SENARY Monitoring Point* 1 11 Copolymsr _Plant Ground Floor 1. Copolymer nrng-uut, (Juts ide 2. Copolymar Slurry Pumphouse 3. Blacktop, Outside Near BMW Tank 4. South-East Stairwell *5. Recovery'Area, Outside .6 Draining Recovery Receivers .7 Draining Master Mix Tanks .8 Draining Recovery Pumps 9. Recovery Compressor Area 10. Center Aisle 11. Reactors, Clean-Out Valve Open 12. Solution Make-Up Tank Area 13. Dry Chemical Weighing Area 14. Weigh Scale Area .Copolymer Plant, Second Floor 15. Lavatory 16. Panel Eoaxd/Desk Area 17. Center Aisle 18. Weigh Scale Area 19. Reactors, Opening 6Tt Access Hole 20. Reactors, Opening Man-way 21. Reactors, Manual Cleaning 22. Chemical Hoist, Outside 23. Blend Tanks, Catwalk 24. Blend Tanks, Sampling for 02 25. Walkway to Homopolymer Homopolyrrer Plant. Second Floor 26. Panel Board/Desk Area 27. Center Aisle 28. Opening Reactor Lenape Cover 29. Reactor Washout 30. Manual Reactor Cleaning 31. Sampling Blend Tanks for 02 32. B/T Catwalk Homopolyme Plant, Ground Floor 33. Slurry Pumphouse 34. Recovery Area, Outside 35. Recovery Compressor Area 36. Weigh Scale Area 37. Center Aisle 38. Reactors, Clean-Out Valve Open 39. North-West Stairwell > OVA Reading, ppm aximum 95 44 57 70 32 Air Air Air 120 17 12 22 22 22 38 26 26 26 13 Air Air 26 120 Air 44 41 42 38 Air Air Air 38 48 42 42 32 32 32 26 Averaj 11.3 6.4 5.5 8.9 7.9 Air Air Air 18.8 6.4 7.5 5.0 5.0 5.0 7.9 . 7.8 6.9 5.9 5.9 Air Air 2.6 15.4 Air 9.1 13.9 6.4 7.7 Air Air Air 3.4 6.0 8.5 14.3 6.7 6.1 10.4 2.2 COLORITE 010365 Burlington monitoring summary Page 2 (Onit`orin<! Point Dispcrsion Plant "A", Ground Floor ~Z(S7 UA:1 Plant Drug-Out, Outside 41. North-East Stairwell 42. In-Line Mixer Area 43. Moyno Pump Area 44. Dryer Panel Pjoard Area 45. Under Tower, Opening Hamer Blind 46. Under Tower, Water Cleaning 47- Under Tower, Manual Cleaning Dispersion Plrint ''A'1, Second Tloor 48. NorGi-Last Stairwell 49. Stxi.pper #1 Area 50. West Cake Bin Area 51. Latex Blend Tank Area 52. Homo System Area Dispersion Plant "A", Third Floor "53T Kmel Board/Desk Area 54* Catwalk, Filter #1 55. Back of Filter pi 56. Back of Filter #2 f>7. Catwalk, Filters p2 and 3 58. Back of Filter 3 59. Batch Mix Tank, Back 50. Batch Mix Tank, Weigh Scale 51* Catalyst Charge Pot 52. Cake Breakers 53. Elevator Dispersion Plant r'A1T, Penthouse *54". Center Aisle ' 65. Opening Tower Manway 6. Water Cleaning Tower 67,. Manual Cleaning Tower 58. North-East Stairwell Dispersion Plant "3", Penthouse 69. Center Aisle 70. Opening Tower Manway 71. Water Cleaning Tower 72. North-West Stairwell Dispersion Plant ''B", Third Floor 73. North-West Stairwell 74. Back of Filter 16 75. Back of Filter 5 76. Catwalk, Filters 5 and #4 77. Back of Filter 14 78. Catwalk, Filter #6 79. Cake Breaker Area 80, Batch Mix Tank, Back OVA Reading, ppm Maximum 26 13 32 32 38 26 26 26 9 38 41 70 32 42 Air 26 26 Air 26 120 120 120 170 7 19 120 8 44 120 ND 8 19 32 32 Air 32 Air 22 32 Average 5.4 1.4 13.5 20.3 17.8 13.8 13.8 13.8 1.2 14.4 17.4 22.6 18.6 14.9 Air 11.7 11.7 Air 11.7 23.3 23.3 23.3 38.5 1.1 3.2 4.5 2.1 9.5 13.8 ND 1.9 1.7 7.9 7.9 Air 7.9 Air 10.4 9.4 COLOR!TE 010366 - BLHLT.NCTON MONITORING SUMMARY Page 3 Monitoring Point Dispersion riant "B", Third Floor (cont'd) "8l. Botch Mix lank, Reign Scale 82. Catalyst Charge Pot83. Panel Board/Desk Area 84. Latex Blend Tank - Tween 20 Funnel 85. South^-Center Stairwell Dispersion Plant "D", Second Floor 86. Latex Blend lank f:t> 87. Stripper Area 88. Ket Cake Bin Area 89. Homo System Area 90. Lavatory Dispersion Plant "B", Ground Floor "91. North-West Stairwcll 92. "B" Plant Drag-Out, Outside 93. Dryer Panel Board Area 94. In-Line Mixer Area 95. Moyno Pump Area 96. Vacuum Pump Area "97. Under Tower, Opening Hamer Blind 98. Under Tower, Water Cleaning 99. Under Tower, Manual Cleaning Tank Farm 100. Unloading Station, Outside 101. Tank Cary Sampling 102. Tank Car, Connecting Lines 103. Storage Tank Level Check 104. Compressor House *fl 105. Compressor House #2 106. Refrigeration Building Classification Building 107. Atomizer Room 108. Plastisol Bagger 109. Syntrons 110. Merchan Feeder Area Suspension Dryer Building XII. Dryer Panel Board 112. Operator's Desk 113. Dryer Area 11^* Copolymer Bagging Station US* 10MM and 40MM Bagging Station X6. cleaning Copolymer Dryer 117* Cleaning 40MM Dryer cleaning 10MM Dryer 119. Centrifuge Deck 120. 40MM and 10MM Line Magnets OVA Reading, ppm Maximum 32 32 26 30 13 Average 9.4 9.4 7.6 15.3 5.2 Air Air 32 13.7 32 14.4 32 10.9 7 2.3 13 2.5 6 .9 15 5.9 29 7.9 32 10.2 32 11.6 --- -: 8 .6 Air Air Air Air Air Air 13 1.4 13 1.7 17 1.3 1 .5 6 4.0 4 2.4 3 2.0 7 3.4 13 6.4 6 1.6 3 1.2 13 4.8 3 1.3 3 2.0 COLORITE 010367 BURLINGTON' MONITORING SUMMARY - Page 4 Monitoring Points .121 10MM Sifter .122t t 40MM Sifter 123. I0MM and 40MM Line Palletizing 124. Copolymer Palletizing 125. Dispersion Palletizing 126. Lunch Room-Last End 127. Lunch Room-West End 128. 129. 130. Maintenance Shop-North End Maintenance Shop-South End Maintenance Shop-Welding Well Production and Maintenance Offices 131. Maintenance General foreman's Office 132. Maintenance Foreman's Office 133. Engineer's Office 134. Safety Supervisor's Office 135. Production Foreman's Office "^rehouse J6~. West Aisle 137. West-Center Aisle 138. Checker's Desk Area 139. Shipping Office 140. Receiving Office 141. East-Center Aisle 142. East Aisle 143. Bass Office Copolymer Bulk Station 144l Sifter Desk 145. Second Desk 146.' Tailing Hopper, Outside loading Area 147. Homopolymer Transfer House 148. Bulk; Truck 149. Hopper Car 150. Initiator Freezer 151. Initiator Weigh House Effluent Plant 152. Ground Floor-South 153. Ground Floor-North 54. Laboratory 155. Second Floor-North 156. Second Floor-South 157. Catwalk, Outside 158. Boiler House-North 159. Boiler House-South OVA Reading > ppm Maximum 6 3 3 1 4 1 ND 1 6 4 1 1 1 1 1 ND ND 1 1 1 1 1 3 Average 1.6 1.6 1.4 2.4 2.8 0.2 ND 0.2 1.4 .8 0.4 0.4 0.4 0.5 0.4 ND ND ' 0.2 0.4 0.2 0.2 0.2 0.8 3 0.6 ND ND ND ND 1 0.5 ND ND ND ND 3 0.8 ND ND 3 0,6 1 0.2 ND ND 1 0.2 3 0.8 3 2.0 ND ND ND ND COLORITE 0X0368 BURLINGTON MONITORING SUMMARY Page 5 Monitoring Point ARDO Duildin2 160. " O]m:aior' s Desk Area 161. Panel Board 162. latex Blend Tank Quality Control laboratory 163. Hood Area 164. Desk Area -16S. Constant Temperature Room 166. Analytical Laboratory ~167.- Vent Area "168. "Reception Area 169. Office Hall;,'ay 170. Outside Plant-Upwind 171. Outside Plant-Downwind t OVA Kgading > PPtn Maximum 17 17 17 32 27 29 18 17 4 4 ND ND Average 3.6 3.4 4.0 21.4 18.8 10.0 10.0 13.8 1.6 1.8 ND ND \ COLOR!TE 010369