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P A R R 5 0 0 I N T E R - O F F I C E C O R R E S P O N D E N C E Chester, Virginia philip ~ono~dential To: Ms. D.C. Saunders Date: July T; r~lBABC From: S.Z. Shakeri Subject: Summary of WEL-2 Clean-up Meeting- June 30,1992 Meetinc7 Objective A fact finding meeting with Hycor and Eng. Eq. Co. representatives to assess liability for the design criteria and the resuliting,failure of the HRS-3672 unit to perform as required. Attendance W.H. J.T. Bailey Bandy (absent) D.C. S.Z. Saunders Shakeri (rec) K.G. Braun D. Mathers (Eng.Eq. Co.) D.A. Clark T. Szostak (~regional sales D.R. L.J. Donaher Fox (vac) (facilitator) manager for Hycor) Items of Discussion Specific questions had been prepared for discussion. A list of questions were handed out to D. Mathers and T. Szostak. Questions and answers are as follows: Q1• What design specifications are needed to design a liquor clean-up rotoshear unit? Ans. It is very essential to know the goal for filtration process. Issues of concerns for designing a unit for any application are: Viscosity Total solids P.H. level Fiber Length Screen Opening Flow Rate

continued Q2. How is the mentioned data unit? phili cA0,~,ffdential used to desi~i"I@tt~ Vq eC Ans. To size a rotoshear unit , it is essential to perform~plant tests to verify the accuracy of the estimated maximum flow rate. The verified maximum~flow rate is the major factor for sizing the unit. This data is used to scale up or down for sizing the proposed unit. Q3. How is information such as liquor temperature, %solids and~fiber length accounted for in the design? Ans. Temperature of 40 degrees F or below will effect the separation performance. Higher temperature will pass more volume. These factors are used to determine screen size. Q4. What specific data did you request for the design of our unit? and how was the data communicated to Hycor/Eng.Eq.Co.? and by whom? Ans. The only specific design data requested was maximum process stream flowrate through the HRS- 2448 (small trial unit). This dat&was taken from B. Bailey and R. Smith's report. A copy of the report was not sent to Hycor/Eng. Eq. Co. The mentioned data was orally communicated to them, and'used~as a basis for sizing the new unit. (This report dated back in 1986, contained test results on the liquid separation performance of HRS-2448 unit. The liquor streams used for testing were SEL and WSW.) Tests were not witnessed~by Hycor/Eng. Eq. Co. Per T. Szostak, it is common practice for vendor to be present at time of unit evaluationi. Q5. How was the data used to design our unit? and, when were the design techniques explained to P500 personnel?

continued Ans. Sizing Data p Conf;ae estimated clean hydraulic original ac~f~p~f ~• n~al H20 flow rate test testing at P50'~V ABL+ HRS-2448 110 no data 50-70 GPM (SEL data 15 GPff (WEL data in 1986) in 1992) HRS-3672 350 353 158 calcul. 45-52 GPM (WELdata in 1992) Derate Factor * * 0.45 0.14 Actual data confirms sizing procedure is accurate. Inappropriate process flow rate data was used for sizing. Hycor and Eng. Eq. Co. were under impression that P500 engineering:knew the design criteria for sizing the rotoshear unit. There have been several engineers involved~with this project and the criticality of the test data may not have been known to every engineer. Q6. Was Hycor/Eng. Eq. Co. aware of the liquor stream that would be filtered'by the HRS-3'672? Ans. No. Eng. Eq. Co. was unaware of the liquor stream for which the HRS-3'672 will be used for filtration. NOTE* Several written documentations from Hycor/Eng,.Eq. Co. identifies design for an SEL liquor stream.

continued Q7. A //~~A0~'~~f~ae~ What effect would' the rotoshear h~Idbtl~O/~~ ~~C11 modification have on the flowrate through &MC unit? What type of testing has Hycor performed in the past to verify the improvement by modifying the headbox design? Ans. Head box design has an~impact on flow and its distribution through the rotoshear. Based on observations, the length was downsized to increase turbulence in the headbox, in order to minimize settling. However lengthening the headbox may increase flow capacity by as much as 10 %. Q8. How do you compensate for screen pluggage frequency in designing the unit? Ans. For almost any application, to prevent screen pluggage, it is necessary to frequently use screen shower. In few applications steam has been used to replace fresh water as cleaning agent. Filtered WEL-2 can be considered in this application, however the best cleaning will be achieved by using hot fresh water. Q9. Is the percentage of open area on the rotating 0.005" screen for our HRS-3672 unit different than the 0.005"'screen on the same model which was tested in 1986? Ans. No. The percentage of open area oniboth screens are identical. The same screen supplier has fabricated both screens. Hycor was unsure if exact same screen was used at both trials.

continued ph/l/p On~a"htla Q10. Are there any similar applications where ~ rotoshear is used to compare WEL-2 performance~ AeC Can we visit? Ans. No. Currently there is no process similar to our process where rotoshear is used. Additional Ouestions Q- How much of the total price of $64,000 for the HRS-3672 unit represents the cost of the 0.005" Screen? Ans. D. Mathers did not know at the time. He will contact Hycor for detailed pricing of the unit. Q. What impact would the increase in rotation'of the cylinder have on flow rate through the rotoshear? Ans. Speed change may increase maximum throughput by approximately 5-6 % . Hycor's Recommendations * Modify existing headbox * To separate wet zone from dry zone, replace existing screen flights with continuous flights (approx. 10 % increase in throughput) * Replace 0.005"screen with 0.010"screen (for HRS-2448 or HRS-3672) and evaluate liquor separation andhydraulic capacity of the unit. A 0.010" screen (for HRS-2448 or HRS-3672) will be available to P500 at no cost for a period of 30 days.

continued Park 500 Action Plan (responsibilities) * ~~~ onfi~rential SZS,JTB Identify all options for an alterna prioritize order of investigation of eachftd*Va4SC (Resources will be allocated as needed) SZS,JTB * Perform economic analyses of alternative to justify appropriate action (due week of 7/6/91) DAC * Provide current cost per lbs for scrap material U.Mathers * Lead time on delivery of 0.010" screen for HRS- 2448 and HRS-3672 units D.Mathers * Cost of 0.0051' screen for HRS-3672 unit cc: Park 500 attendees W.G. Estes D.L. Jenkins a:szs.wel2a3