Document 2JYvGaL0Ezbgenq70BO4VEqqa

INTEROFFICE MEMORANDUM To: From: Subject: H. F. Roderick T. L. Carey July Production Report Date: August 11, 1966 Copies: J. C. Gibert L. W. Gopp H. L. Harwell Dr. W. M. Smith Dr. T. H. Vaughn J. F. Walrath The production units under Mr. McMillan's direction continue to be the bright spots in our production area.. The major ammonia turnaround was accomplished essentially on schedule which reflects good and careful planning* The PVC plant produced a $22, 653 positive variance which gave them a year to date total of $ 113, 000. The nitrate area was essentially a zero variance and the NP-AF plant had a $10,000 negative variance. The negative variance was entirely due to sustained test run trying to make a 20*20-0 product. The product was finally made to specification but the rates were so low as to virtually preclude this being an economic product in this plant. The first half of the month was spent in making 16-20*0 and on this product the results were very good. This is our highest production rate product. Methanol had a negative variance of $5, TOO which was due to low volume. This because of lack of COg during the ammonia plant shutdown. The total variance for all of the above units was negative $64,455 compared to the estimate of $74, 800. It is expected that these plants will produce a total of $50, 000 positive in August* , Amines > t- The amines plants had considerable difficulty during July with a turnaround in each plant. In both plants it was necessary to make major repairs to the ammonia columns, primarily due to corrosion. A new column was ordered for the #2 plant which will be constructed of 316 stainless steeL. This coupled with the unbudgeted depreciation, lower than budgeted yields and an inventory adjustment resulted in an unfavorable variance of $138, 000. AI90 included was $16,400 freight cost to return unused iaobutanol. 4 1 '4 VK AP00045566 H. F. Roderick -2- August 11, 1966 It is estimated that the amines operations will produce a negative variance of approximately $50,000 per month for the remainder of the year. A concerted effort will be made to reduce this to a minimum. The budget for these plants for 1966 was obviously unrealistic. An RFE is being prepared in the amount of $ 1, 300, 000 to debottleneck both of the amines plants to increase capacity sufficient to meet 1967's projected sales. The expenditure will show an excellent payout. Methacrylate This problem plant continues to show improvement. The results are still a long way from being good. However, in both MAA and MMA new production records were made. We are confident that August will produce another significant improvement. We returned to the production of crystal HIBA in July and after considerable difficulty with pumps and flows had the mechanical aspects reasonably well straightened out. The continuous centrifuge was performing well at month's end. At this writing a number of 23,000 to 25, 000 lbs. HIBA production days had been attained. (Plant design is 33, 000 #/day) Concerted efforts are being made to locate and recover losses up to this point in the HIBA purification section. The LiPD section shows yields much improved over last month. With good control of the variables, yields of 80% have been attained and we feel this can be further improved. Serious attention will soon have to be given to purge recovery from this system. Any recovery of this material will directly improve the overall yield. The MMA section ran very well in the first part of the month. Later rather severe polymer problems occurred which resulted in considerable product loss. It is felt we know the cause of this problem and can correct it. This coupled with the conversion of the methanol stripper column to an external condenser should result in yields approaching 90% of theoretical. AP00045567 H. F. Roderick -3- August 11, 1966 DNT I call your attention to the photographs in the report showing the plant erection. It is estimated the plant will be started up about the first of October. Supervisor training has begun and operators will be assigned to the operation shortly. Chemico has been advised we will want a Biazzi representative present to assist in startup operations. TLC/djs 7 T. L. Catey AP00045568 (T e ch n ica l S u m m a ry ESCAMBIA CHEMICAL CORPORATION INTBROFFICB MEMORANDUM Tot Promt Ret Mr. T. L. Carey Dattt J. J. Dorsey, Jr. Coplcft Summary of Technical Department Monthly Reports - July 1966 August 8, 1966 NEW PRODUCTS DNT The plant construction schedule is slightly behind, but will apparently be completed in the second half of September. It is anticipated that the plant will be ready to start about October 1, 1966, depending primarily on weather since all equipment is ready for installation. Indications are that Wyandotte will not require material for delivery before December 1, 1966. Tentative arrangements have been made for the assistance of a Biazzi representative for start-up. The training program for supervisors and operators will commence on August 15, 1966. ADE A detailed report of the commercial plant design basis as compared to the original proposal, and pilot plant results, is in preparation, but has been temporarily shelved due to the need to design a new alkylamines plant. When all the data from the laboratory and pilot plant programs were evaluated, it became apparent that the equipment and conditions to produce ADE was well understood when the project was first begun, and therefore only minor changes or modifications were envisioned for the commercial plant. The only major change made based on the development work was the use of pressure distillation to break the EDA-water azeotrope instead of using caustic. The addition of this column eliminates the need for 73% caustic and its attendant equipment. Another simplification is the elimina tion of one of the absorbers for recovering ammonia and eliminating vinyl chloride. It was found that the small amount of vinyl chloride is easily vented without losing much ammonia. The accountable yield loss in the pilot plant program was found to be 0.4 - 1.7%, representing an accountability of 98. 3-99. 6% total amines AP00045569 Mr, T. L, Carey -2- August 8, 1966 produced. In the original economics of the project, a 3% loss to VC1 and a 5% handling loss was used to give an overall yield of 92%. The 92% yield thereby allowed 6.0 - 7.3% loss due to unexplained causes. Material for another Struthers-Wells salt removal test is available if such a test is necessary or desirable. This is a surprisingly simple, straightforward chemical operation which is ready for detailed plant engineering to firm up the investment, and need for additional data. LABORATORY Laboratory operating costs were above budget this month because of the continued work load on MMA, amines, and other areas. The development of the necessary control and operating information for all plant operations suffers from a lack of technician and chemist manpower. This is a serious problem, and will only improve by hiring permanent technicians and additional chemists. Laboratory work on DNT, amines, and other areas is reviewed in the laboratory summary. Individual areas of work are reported as completed in separate memoranda. ENGINEERING The following projects were completed in the amines area this month: amines feed preheater in the No. 2 plant, installation of two DMA check tanks, a gas fired heater and a new converter for the No. 1 amines plant. In DNT, both Chemico and Escambia engineering work is complete except for minor items. Structural steel delivery was a little later than expected, but late receipt of engineering details caused this. The con struction schedule now indicates a completion by the week of September 18, or shortly thereafter. This is dependent upon how well the prefabricated piping fits. Approximately 80% of the piping and structural items of the new 600# boiler have been received. Piping design is about 70% complete and founda tions have been installed for the main boiler feed pump, high pressure booster pumps, and the new pipe rack. Ammo-Fhos production facilities are 95% complete. Agitators for phos acid tanks and Wilfley pumps are due in August and will be installed when production permits. AP00045570 Mr. T. L. Carey -3- August 8, 1966 A new type 316 stainless steel ammonia column was ordered for the No. 2 amines plant to replace the corroded one repaired in July. Delivery and erection is expected in 12-14 weeks on a straight time basis. SPECIAL PROJECTS 1. New Methylamines Plant Design work was begun on a new 40 million lbs/yr. methylamines plant. Scale-ups on the original methylamines plant and the present No. 2 plant give almost identical equipment requirements for the proposed No. 3 plant. Stainless steel equipment is planned in the reaction system and ammonia column to minimize corrosion and insure long life. A topping still for higher quality monomethylamine and additional trays in most of the distillation columns are provided to produce products with tighter specifications in the future. The topping still would remove the last traces of ammonia, which is difficult in our present operations. Estimated cost for the No. 3 plant is $3. 2 million. 2. Miscellaneous A summary report from M. B. Rogers to J. J. Dorsey, Jr. is attached, giving highlights of the following special projects: (a) Saran Type Resin (b) New PVC Plant (c) Ammonia-Methanol Plant Information (d) Urea Details of these projects are to be found in reports already issued or to be issued shortly. mdc AP00045571 Protect No. Title JULY. 19 66 SUMMARY OF PROJECT WORK STATUS Appropriation M$ Committed Revied Completion M* MS Date Remark* 6501 6509 6553 6S6S Water Softener* to Pro vide Water for Boiler Air Condition 6 Encloee Wet Bay Control Room Ammonia Recovery Pressure Control System DNT Plant 18.0 6.0 3. 3 870,0 6585 Equipment to Product 1BN b DEA - Amine* 223.9 8. B 4.5 1.5 1096. 0 198.5 IB. 0 6.0 3. 3 1250.0 to 1300.0 224. 0 11/1/66 8/31/66 Expediting equipment delivery. Deilgn and field work on schedule. 9551 complete. 9/1/66 Waiting for material deliveries. 9/18/66 ------ > 98% of materials on hand and most of equipment is eat. Con struction schedule ia complete by September 23. Production complete; storage by 11/1/66. Foundation will be completed In August and tank erection will atart in September, 6604 6605 6613 New 600 pii 100. 0001/Hr. Boiler 320.0 Upgrading Water Treatment 105.0 Product Coating Syetem -NP 15. 5 6616 6640 6617 Provide Office*. Locker Room and Storage Maintenance Shop-Area B Additional Bulk Car Loading Facilities - PVC 14. 3 26.0 10. 4 6621 6622 6626 6628 6631 6636 6632 6633 6635 Refrigeration Unit for Cool ing Solution* Tank* PVC Spare Block for Recovery Compressor* PVC 12.0 14. 3 Packaging Equipment to U*e Valve Bag* for PVC 18.0 New Feed Preheat Exchanger, 12. 0 No. 2 Plant Additional Electric Heat and New Converter for #1 Plant 8.0 15.0 H.P. Water Pump. H.P. Scrubber - No. 1 Plant 4. 0 New Methylamine* Check Tank* Plant Steam Recorder 12.4 1.8 6641 1580-80002 6642 Crystalliaer Revision* Purchase of Lab Equipment 18. 3 23.4 193. 5 99.0 4.5 non* none 6.4 8. 0 12.0 18. 8 10. 8 55.2 1. 5 14. 3 1.2 19.7 6.2 320.0 105. 0 15.5 14. 3 26.0 10.4 12.0 14. 3 18. 6 10.8 55.2 4.0 14. 3 1.8 19.7 23.4 11/1/66 11/1/66 9/1/66 Expediting auxiliary equipment. Some delay possible. Equipment being expedited. Equipment on order. To be completed prior to resumption of NP production, Indefinite Quote* received and evaluated Indefinite but approval etill pending. 9/1/66 Awaiting final material dellvary and available manpower for installation. 9/1/66 Material scheduled for delivery in early August, Indefinite Evaluating equipmant conditions for Installation.of spare. 6/15/66 Completed. 8/1/66 Job Is complete. 7/29/66 Job complete - Report on cost to be prepared in August, Indefinite Installation dependent on Production's decision as to proper uae. 7/28/66 Complete. Overrun due to additional fire protection. Indefinite Material received. Waiting for shutdown to Install. Additional revisions being Indefinite considered. Indefinite AP00045572 Summary of Project Work Status June, 1966 Protect No. Titl* 6647 Ammo-Phot Production 6649 Ammonia Reform Gas Guard Vessel 1580-18829 Independent Raw Water Supply - PVC 1560-18839 1580-18862 New Blowdown Tank for Compressor Building Revie* Condensate System from PVC Dryers 1770-6003 PVC Reactor Reglassing 1770-6021 Liquid Phase Dehydration System Pag* 2 Appropriation Committed Revised Completion MS MS MS Date Remarks 220. 0 192. 5 200. 0 10/11/66 Job complete except for three agitators and two pumps which are on order* 31.3 9.7 24.5 .4 31. 3 9/1/66 9. 7 9/1/66 Piping tie-in made during shutdown. Vessel installed. Piping installation in progress. Design work and material procurement complete. No work started due to higher priorities. 2.7 2. 6 2.7 Indefinite Piping revisions being sched uled as manpower is available. 3.0 1.9 3. 0 Indefinite Engineering complete. Equip ment ordered. Installation and fabrication will be made as manpower becomes available. 38. 0 23. 1 38.0 Indefinite Vessel released to Glascote for modification and reglasaing. 40. 0 55. 6 55. 6 9/15/66 Removal of old system remains to be completed. 8/5/66 /fls AP00045573 ESCAMBIA CHEMICAL CORPORATION Interoffice Memorandum To: Mr. T. L. Carey Date: August 2, 1966 From: E. M. Spurlock Re* Monthly Report - Personnel Department - July, 1966 PERSONNEL Activity for the Month Division No* of No. of Employees July July Employees 1966 6/30/66 Additions Separations 7/31/66 Budget Admin* & General Research Agrl* Chemicals Industrial Chemicals Production 57 60 173 16 429 2 2 4 1 .2 3 56 56 2 60 59 14 163 194 * 0 17 18 i4 J2b 4o6 Totals 735 18 33 720 733 * Thia includes 160 as listed on the budget sheet plus 34 temporary employees who were not shown In number on the budget sheet. There vere 31? walk-in applicants, 177 applications were issued and 7 were received by mall* Ninety-four applicants were interviewed and 55 were tested* TRAINING School was held for the operation of trackmobiles and 2 trackmobile operators vere licensed* SAFETY She Corporation has worked 5k days or approximately 226,000 man-hours without a disabling injury* The various division records are as follows: Division Man-hours Pays New York Office Research Division Atlanta Division Pensacola Plant Corporation 350,000 830,000 100,000 138,000 226,000 1,822 3,302 82 54 54 The Research Division completed nine years without a disabling injury. P ersonnel AP00045574 Monthly Report -2- August 2, 1966 SAFETY (Coat'd.) Medical Section The Medical Section treated 28 injuries for Escambia and 48 for Carroll, performed 17 pre-employment and 5 annual physicals and gave a total of 24 Immunization Injections. EMPLOYEE RELATIONS Two 5-year service awards and six 10-year service awards were presented. INSURANCE We paid a total of 77 claima under our Group Hospitalization program which amounted to a total of $ 14,301.73 during the month of July. Ve settled the following claims during the month of July: Four claims amounting to $ 680.30 under our Automobile Physical Damage Insurance. Ifcree claima amounting to $ 2,375 under our Public Liability and Property Damage i"e1,v* EMSjkc AP00045575 PRODUCTION MONTHLY REPORT August, 1966 AP00045576 S um m ary [ ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM Tei H. F. Roderick Datts September 13, 1966 Fromi Ret T. L., Carey August Production Report Copica: J. G. Gibert L.. W. Gopp H. L. Harwell Dr. W. M. Smith Dr. T. H. Vaughn J. F. Walrath Methacrylates August production was at new record rates in both MAA and MMA. Production was; HIBA MAA MMA 452,000 275,000 320,000 August was devoted to "zeroing" in on the HIBA problem. HIBA production and costs is the real key to methacrylates by our process. The major problem area is the degradation and consequent loss of HIBA in the HIBA concentration section of the plant. The oxidation and hydrolysis sections produce HIBA at approximately design rates and then in the distillation columns the HIBA is "destroyed" to the extent of 30 to 35%. It is only recently that we have gotten to this point in our process. If we can solve this problem the increase in production will flow through the final two sections to product. A very detailed and specific program has been instituted on this ' problem and we expect to produce the desired results. At this writing it appears that the changes made early in September have resulted in an increase in HIBA production of approximately 5, 000 pounds per day to a rate of 25* 000. Design is 33, 000 - to 10 MM lbs/year rate of MMA. Two other changes are scheduled for mid-September that should produce further improvement. By the end of September the plant should be producing at very significantly higher rates. There are still a number of problem areas that will require refining of operating controls and conditions, but once the HIBA situation is under control we are confident these can be solved. Amines This too is an area where specific improvements are beginning to show up. The new operating staff seems to be working out very well and we are hopeful of obtaining approval for the debottlenecking RFE that will increase production rates and improve production costs. J I 1 J ! 1 1 ;r AP00045S77 H. F, Roderick -2 - September 13, 1966 Other Plants All other units are in good shape and operating well. Preliminary budgets for 1967 are being prepared and, as is usual, this requires a great deal of time and effort. TLC/djs AP00045578