Document 0qde6ZvR4xBpLzG8Qpq8JeZqJ

TO FIELD POIMT OR D6PT. & BLOG. MO. C- YOUR LETTER ______ Regional & District Managers, National Account Managers & Plastics Salesmen FROM FIELD POINT OR DEPT. S. BLDG. NO. DATE THIS LETTER G. F. COHANCleveland D/5401____________ ________ __________ ;____ 5/30/75 SUBJECT LOW RVCM SUSPENSION RESINS (Geon 102EP F-5. 103EP. 103EP F-76) STATUS REPORT I. SUMMARY During April 89% of all EP resin production contained less than 20 ppm residual vinyl chloride (RVCM). The major portion of this con tained less than 10 ppm. As we reach lower levels with present equipment slight resin property differences are noted between plants and productivity losses become severe. Personal monitoring for ambient vinyl chloride (AVCM) in the field is showing that resin containing less than 20 ppm RVCM does not expose personnel above the action level under normal good work practices. For these reasons it seems prudent to maintain the goal for the plants at 20 ppm RVCM for a brief period, until the new stripping equipment is installed. The first unit is scheduled for July with the balance to be installed as soon as received at the various plants during the remainder of 1975. When this is accomplished, RVCM will be about 1.0 ppm. Bear in mind that 20 ppm is the goal today and not a maximum so that if some resin exceeds this value, it will be shipped. We will continue to supply resin with less than 10 ppm RVCM to those accounts who request it or to accounts where it is needed to maintain or increase business. The above applies to Geon resins 102EP F-5, 103EP and 103EP F-76. Geon 110X334 for bottle use will continue to be supplied at^l.O ppm RVCM. II. MANUFACTURING STATUS - June 1. 1975 1. Geon 102EP F-5 Long Beach and Avon Lake are running the new UPS-1 version for both outside sales and internal compound consumption. Avon Lake started this week with Lot 27537 (bags) and Lot 23065 (bulk). Henry is still making the original version. This resin is not made at the other plants. 2. a) Geon 103EP b) Geon 103EP F-76 All plants are making the new UPS-1 versions for both out side sales and internal consumption. Pedricktown is starting this week. BfG-4956-C 7/74 IITH0 USA BFG32950 Continued 246Z7001 2- 3. Compound All of our compound except that portion using 102EP F-5 at Henry is now based on the new versions of our EP resins. We have had some instances of inconsistencies in rigid compounds, parti cularly in the cellular vinyl area, and are working diligently to improve this situation. III. DIFFERENCES BETWEEN THE NEW AND OLD VERSIONS At this point in time it is difficult to establish a specification covering all plants but this will be done as soon as possible. Mean while, the attached physical property comparison will indicate the differences experienced to date in our quality control testing. 1. Geon 102EP F-5 Table I shows the comparison of the old and new (UPS-1) versions. The Henry values on the new version are experimental only since this plant is still on the old version. The resin at Avon Lake is slightly coarser with a narrower particle size distribution. (The smaller the number the narrower the distribution -- value for Geon 92 is about 18.) Very little difference has been noted at Long Beach. Recent trials at a wire and cable account showed that the Henschel mixing cycles and processing properties of the new UPS-1 version from Avon Lake performed the same as the old. Results at Long Beach are satisfactory though outside sales are small. 2. Geon 103EP As noted in Table II, 103EP is slightly more porous with a correspondingly shorter powder mix time. The resin is somewhat finer with a lower incidence of fisheyes. Production has just started at Pedricktown so we do not yet have a lot of experience here. On the whole, field performance has been good. Clarity seems better, electricals are good though slightly lower. In the long run it is expected that this version will be a significant improvement over the original. 3. Geon 103EP F-76 Since this resin had the greatest amount of RVCM, the modi fication of the particle structure to permit release of VCM has resulted in significant property differences as shown in Table III. These differences concern handling, mixing, and processing character istics and not end product properties for the molecular weight (I.V.) is the same as the old version. The new resin is slightly finer in particle size with a narrower particle size distribution. Porosity is higher, result ing in a lower bulk density. K) NT BFG32951 Continued*: -3- Because of these differences some changes have had to be made in mixing, formulating and processing, though this varies among customers. In general, the lower bulk density requires a lower charge size in the high intensity mixer. Overloading the mixer re sults in poor mixing and undispersed resin particles. The higher porosity of the resin may absorb lubricant decreasing the amount available to aid processing. Additional lubricant may be necessary to prevent frictional heat build-up during extrusion. The lower bulk density results in 5 to 107. decreased extrusion rates in multiple screw machines. IV. GENERAL COMMENTS 1. Advantages of the New Versions This is one phase of our efforts to eliminate health con cerns among our customers while continuing to supply high quality resins which meet their needs. The new resins have a lower level of fisheyes, are slightly finer in particle size though less dusty, and have a slightly narrower particle size distribution. 2. Disadvantages of the New Versions The differences in the new resins have resulted in a variety of problems in the field, largely in the nature of "growing pains" for they are not common to all customers nor do they result from deficiencies in the resin; rather, they require changes in formula tion or process to adapt to those properties of the new resins which differ from the old. Typical of these would be the possible need to reduce batch size and adjust lubricant level with 103EP F-76 in rigids. The major problem encountered is the build-up of a static elec tric charge on these resins. This tendency is inherent in the new system and is worse than that found with the old resin during the winter months. Addition of water during the mixing cycle has eliminated the charge and permitted normal processing. This is a temporary solu tion and every effort is being made to solve the problem. We do have some encouraging leads now being evaluated in the field. One of the consequences of reducing RVCM has been shipment of extremely dry resin with very low moisture content. This, of course, has contributed to build-up of a static charge. Another disadvantage inherent in the resin is the lower extrusion rate on multiple screw machines, caused by the lower bulk density. Solution of this problem is longer range in nature. Changes in 102EP F-5 and 103EP are smaller so customers see little or no difference. Of the 16 field trials with the new 103EP we've had only one adverse report. To date we have produced over 50 million pounds of 103EP F-76 and over 10 million pounds of each of the other resins in the revised form. 24627003 BFG32952 Continued TABLE I Geon 102EP F-5 PHYSICAL PROPERTY COMPARISON Inherent Viscosity (I.V.) Porosity, cc/gm Powder Mix Time (PMT), sec. Apparent Density, gm/cc Compact Density, gm/cc Particle Size (PS) 7. Ret. 60 mesh 7. Thru 140 mesh Average Particle Size (APS), mm Particle Size Distribution (PSD) RVCM Fisheyes 1. 6 min Benner 2. Mill 3. Mill, large/small ALGC-East Old New 1.14 1.14 .30 .30 280 325 --m Henry Old New 1.13 1.13 .30 .30 300 350 --- Old New 1.12 1.13 .31 .32 313 302 .46 .47 .55 .56 25 95 ' 140 150 23 19 64 .8 .2 10 7 145 145 21 18 .2 .2 1.3 16 135 31 45 .7 16 134 26 9 20 5 10 25 7/3 5/3 tO O A zV frz GFC/ez 5/30/75 BFG32953 TABLE II Geon 103EP PHYSICAL PROPERTY COMPARISON I.v. Porosity PMT App. Dens. Comp. Dens. PS % Ret. 60M PS Thru 140M APS PSD RVCM Fisheyes 1. Mill 2. Mill 3. Benner Long Beach Old New 0.99 .26 389 .50 .59 1.3 13 138 30 95 1.005 .27 340 .49 .59 1.1 16 137 29 11 14/9 7/5 CM Louisville Old New 1.025 1.025 .26 350 335 --<1 10 20 135 125 25 25 150 10 4 2-3 Pedricktown Old New 1.000 .25 300 .50 .60 .5 7 145 23 1 1.000 .27 300 .48 .58 1 10 140 20 1 30 20 SQQIZ 3& Z GFC/ez 5/30/75 BFG32954 TABLE III Geon I03EP F-76 PHYSICAL PROPERTY COMPARISON ALGC-East Old New Henry Old New Long Beach Old New Louisville Old New Pedricktown Old New CM Q \ CM 00 I.v. .925 .925 Porosity .16 .23 PMT - - App. Dens. .57 .54 Comp. Dens. .68 .63 PS 7. Ret. 60M 2 .5 PS 7. Thru 140M 8 16 APS 145 135 PSD 29 24 RVCM F.E. Benner 20 7 3 .92 .92 .15 .20 .91 .92 .15 .18 -- .65 .5 .2 10 14 140 135 22 19 50 7 .55 .65 1.3 15 137 33 150 .52 .62 .5 16 134 27 31 .92 .21 .92 .51 .51 .60 .60 O <1 15 20 130 120 25 25 150 10 m .92 .15 .20 .54 .52 . 66 .62 .5 1 7 10 145 140 23 20 100 40 GFC/ez 5/30/75 BFG32955 cn Q 8 -4- 3. Requests Customers should be advised that these resins differ slightly in particle structure to assist in release of VCM. Though the average account will see no difference in 102EP F-5 or 103EP there may be subtle differences in mixing or processing in his particular operation. He should watch performance carefully, particularly those involving the most recent plant introductions (102EP F-5 from Avon Lake and 103EP from Pedricktown). Please send us a note on any pertinent customer comments, good or bad, of minor or major importance to him. The overall picture is of vital importance in insuring optimum quality at low levels of RVCM. We would also like to know how our resins compare with compe titive resins of comparable RVCM levels. This is particularly true of the pipe industry in comparing our suspension resins with competi tive mass resins. A brief note will be appreciated. CONCLUSION The introduction of these improved versions of our standard resins gets us closer to achieving one phase of our objective to eliminate customer concern over RVCM. The installation of new stripping equipment will complete this. Further refinements may occur but will be minor as we continue to improve our manufacturing processes to minimize exposure to our own personnel. Your cooperation and patience as well as that of our customers is sincerely appreciated. GFC/ez (Attachments) CC: J. F. Malone G. F. Cohan W. S. Lodge H. L. Wuerth All Product Managers & Product Engineers D/5401 International Dept. Mailing List G. D. Schaff F. E. Krause) G. A. Small ) H. H. Marty ) ALTC 24627007 BFG32956