Document 2qgnXpOOdwdNgyxv7qddd0Q6p

:K 'TJSgFttf ;' ( COMPANY CONFIDENTIAL Monsanto ^-i3- i Anniston Plant TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Anniston Summary C. K. Eastman A. G. Hill L. C. Lahman J. C. Landwehr G. W. Miller W. B. Papageorge W. F. Taffee H. L. Williams November, 1969 Month Cost Improvement Results Est. Act. Target % of Target -----------T.---------- Z--=-------i---------------------- ----- I|p!?51f4f3QOT $67,985 75.7% General Offices YTD $532,936 $573,830 92.9% H. S. Bergen H. C. Carder D. Danna (5) 9. B. Hodges D. B. Hosmer (2) W. A. Kuhn C. F. Luecke J. A. Morgan W. R. Robirds J. E. Smith J. A. Stephens R. J. Stratmeyer Organic Division Solid Aroclor Montar 5 Sandvik belt estimated cost is $123M with savings of $36M and new earnings of up to $45M. Progress report to be issued in December '69. Preliminary test was run on Santowax R column to determine operating conditions for improving capacity/ yield while meeting the desired compositions for Solid Aroclor 5460 and HB-40. Test results are encouraging and further testing will be done in January '70. Agricultural Division OTHER LOCATIONS Acetone Recovery equipment was installed during the Parathion turnaround. Preliminary indications are that the equipment'is meeting performance specifica tions. A. H. Forsten Alvin, Texas A Parathion MIP review meeting was held in St. Louis with representatives of Agricultural Division and CED. D. W. Jackson WGK M. Patrick So. 2nd St^ 3775^6 qs>N V. n/1/1968 . COMPANY CONFIDENTIAL INFORMATION "This document contains confidential information which is the property of Monsanto Company. Only those portions of the document relevant to a duly authorized individual's need to know may be exerpted for him. The report must not be sent outside the Company without written approval and the recipient is accountable for its safe keeping, exerpting or otherwise disclosing of its contents and for its proper disposal." STLCOPCB4099248 Company Confidential 2. Design & Drafting Parathion Emergency Power Supply - installed and satis factorily started up. Rebuilding and reinstallation of one "old" unit remains. Fire alarm system in which alarm horn may be dialed direct from any telephone in the plant successfully put in opera tion 11-17-69. Pollution Control Test unit to remove solids from Waste Treatment Plant Effluent started up. Rapid cloth "blinding" has prevented extended operation. Eimco representative advising on cloth selection. Quality Control The Plant Quality Score was 78.0, a new low for 1969, down 5.1 from October, with a YTD score of 87.1. A comprehensive raw material quality control system was accepted in scope, and detail procedures for tank car shipments were adopted. :kd DSW 377517 STLCOPCB4099249 ORGANIC DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Bi0 Improve Tower Treat. AFE 5155 TAR EST ACT 450 450 450 450 450 450 450 450 00 00 0 584 585 645 645 50 725 50 Improve Pit. Power Factor TAR EST ACT 900 900 900 900 900 900 900 900 0 500 900 yOo 900 950 955 0 500 83O 990 980 940 Central Air TAR 1000 1000 1000 1000 System EST ACT . r --- Optimize Rx Time PNP TAR EST ACT 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 0 3420 0 0 0 2940 0 00 0 3420 0 0 0 2940 2370 0 0 Reduce Mole Ratio NaOH/PNCB PNP TAR EST ACT 4000 4000 4000 4000 4000 4000 4000 4000 4000 0 00 0 "u " 0 00 0 00 0 0 0 0 New Wash Water Pump ~ PNP AFE 2998 TAR EST ACT 50 50 50 50 50 50 50 50 25 50 50 50 50 50 5u 50 50 50 25 50 50 50 50 50 50 50 50 Automatic pH Control PNP TAR EST ACT 500 500 500 00 .0 HC1 Filter Pump TAR EST ACT 350 330 340 3^0 330 340 33O 330 340 New Blow Tank HC1 TAR 200 200 200 200 200 2P0 ---- ---EST 200 "200 200 200 500 200 ACT 200 200 200 200 200 200 150,000 Gal.-HCl Storage Tank . AFE 2468 TAR EST ACT 1760 1760 1780 1760 1760 1780 1760 1760 r1780 - u 0 2640 3290 2990 3500 (3500 0 2830 343O 3125 3200 ! Produce Staley Grade Acid AFE 5076 Cla Pit. Shutdown cea mi TAR EST ACT TAR EST ACT 780 780 790 780 780 790 _- ' ~ "" 8880 3880 8880 8880 8880 8880 8880 8880 6655 +2885 |l9 9 00 V1990C 19900 L990C 223C 6655 ^2855 19900 1990C 19900 Hg Recover from Residue TAR EST ACT 250 S&P 250 J?5JL 5910 0 T 0 3910 0 0 0 Hg Wash Tank AFE 2802 Biphenyl Productivity TAR__ _ 250 250 250 250 'est ACT 00 00 00 00 -------- TAR 5600 5600 5600 5600 "5600 5600 5600 5600 5600 5600 5600 5600 EST o 9U0U Ipoc 0 0 0 30/a0:;p700 0 0 0. ACT 1800 5900 135C0 0 0 0 30780)2700 0 0 Total Organic By Month M $ Total Organic YTD M $ . TAR EST ACT TAR EST ACT 25.;f2bTS 29.3 _42.3 51.1 51.6? 51.6! 51.pl 6? JlSJlmI ~5oT6 {27.1 30.2 11.5 36T3 39.1S5 107.4 p3*8,4l49.41Q40B20,4535( 16.51 23.8 27.8 11.4 25.75 45.9 110.SEj2 58J6-51,93 cf4041Oj 2).4 50.1 79 74 116.9.. 159.2 '2IO.3 261.9; 5I361365.I |17.8 1471.3 5.21.9. 146.9 78.8 79.6 1159 144.4 25 3.5 Bl5i^i363.^412-2Q45 835 16.5140.3 63.1 79.5 105.2 151.1 -2--6-1.2-VLJ_3-1-9--.4-5--3--7-1-3>8--4-1--1,---79J-------- ** .January thru June. led for months DSW 377518 STLCOPCB4099250 ORGANIC DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Sol.Aro. Level TAR Ind.fie -Still SpG EST AFE 5015 ACT Solid Aro. TAR Lower 5060 Soft. Point EST. ACT 2250 2250 2250 2250 2250 2250 2250 2250 2250 -- -- --- - ". 2600 2600 2600, 2600 2600 2600 2$00 600 2600 1500 5490 4890 2150 467 C 800C 4230 //30 3475 1500 5490 4890 2150 467 C 800C 4230 7730 3475 - -- Sol.Aro.-Still Coolant temp. AFE 5015 TAR EST. ACT 160 170 160 170 160 170 160 170 160 -- - -- -" - Sol .Aro. -Chlortcr TAR Batch End EST.' AFE 5015 ACT 590 390 390 590 590 390 390 390 590 -- -- --" *** Sol.Aro. Yield TAR SW/R Composition EST. AFE 5016 ACT 2750 2750 2750 2750 2750 2750 2750 2750 - " "* Solid Aro. Montar 5 Flake AFE P949 TAR EST ACT 1080 1080 1080 1080 1080 1080 1080 1080 -"- -- - --- Sol.Aro. Blend 4465 TAR EST.. ACT 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 .25.00. 2500 1690 1920 1680 1490 710 1180 990 220 1690 1920 1680 1490 710 1180 990 220 -- 10 710 10 Sol.Aro.-Verti- TAR cal Still Cond. EST' AFE 2524 ACT 70 80 70 80 70 70 90 90 9 0 90 70 90 90 so 90 - - " "- Sol.Aro.Clg T/C Dock AFE 2*142 TAR EST ACT 940 940 950 0 -- 0 * Sol.Aro.-New Cl2 TAR Unload - No Delay EST' CED 1851 ACT 950 940 950 940 950 940 950 900 2330 2050 2320 1650 23601 164C 900 2 330 2050 2320 1650 2360 Solid Aro.-Flake TAR & Drum EST. CED 1450 ACT 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 0 0 looo 2000 2000 2000 3000 3000 3000 3000 300C 0 0 1000 2000 200C 3000 3000 3000 3000 0] ! wMOoo Liq.Aro. TAR 5000 48-53 M #/yr. ' EST AFE 2545 ACT 0 550C 0 5500 -- -- -- Liq.Aro."No.2 TAR Still Entrain Sep. EST. 3000 5000 -- AFE *509*5 Liq.Aro.-Montar Disposal AFE 2952 Warehouse Reduce Manpower CEA 1452 ACT TAR esx; ACT TAR EST: ACT 1080 1080 1080 1080 1080 1080" 1080 1080 1080 1080 0 00 00 0 - - - 0 00 0 0 - --- 2000 3000 5000 5000 3000 5000 5000 5000 3000 3000 5000 5000 2000 2000 200C 3000 3000 3000 3000 3OOC 300(i 3000 3000 2000 200C 20CC 3000 3000 3000 3000 3OOO 3000 3000 Liq.Aro.New TAR Burners #3 Still EST ACT 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 0 0 1500 3000 900 0 - 0 0 1500 3000 900 - - 00 0 Biphenyl Relocate TAR No. 1 Preheat EST CEA 1892 ACT HB-40 TAR 2nd Autoclave AFE *5102 EST ACT 500 500 500 500 500 500 500 500 500 500 500 500 1500 0 1560 1870 . 0 0 1500 0 0 1780 1500 0 6 10 137 0 0 0 1500 - - 5000 5000 5000 3000 3000 5000 5000 5000 5000 3000 3000 5000 2230 2580 0 3490 2420 0 600 9000 6000 56 0 0 42oU" PU'J 1000 4800 600 10,40C 8600 /h5U 6950 750 1400 DSW 377519 STLCOPCB4099251 AG DIVISION 1969 TSD COST IMPROVEMENT ANNUAL Cooling Tower TAR Repiping EST AFE 2598 -ACT Optimize N2 & TAR Cl2 Levels EST ACT Increase Waste TAR Acid Sales EST ACT Chlorinator R.I. TAR EST AFE 2244 ACT : EVOP Condensation TAR Rx. EST ACT Cl2 Unloading TAR EST CEA 1851 ACT Recycle Wash TAR Water est: AFE 2960 ACT Parathion Recovery TAR EST AFE 2655 ACT. Reduce Acetone TAR Losses EST: ACT . Formulations '` TAR EST AFE 2897 - ACT Change Cooling TAR HgO Item 737 EST AFE 3067 ACT Well HsO to Jets TAR EST ACT Ag. Division TAR by Month EST ACT Ag. Division TAR YTD EST ACT Ag. Division TAR untargeted-R.M. EST Charges or>timizati< ItAct Oroanir Dnr TAR Untargeted - HC1 EST Catch Tank& Coale: eACT Ag Div."Untargeted TAR EST #3 Cl2 Change out ACT JAN 750 0 0 750 0 750 0 FEB MAR APR MAY JUN JUL AUG SEP 420 420 410 410 420 420 0 00 0 00 00 O0 0 0 6600 6700 6700 6600 6700 67 00 0 00 00 0 0 00 00 0 400 300 300 400 300 300 00 00 0O 0. O 00 00 250 250 250 O0 0 000 750 500 0 12,615 0 12,615 OCT NOV 410 ~4P0 00 Q 400 O 0 250 0 0 500 0 0 300 0 250 0 750 0 DEC 420 300 250 750 5000 5000 5000 2000 2000 2000 0 0 1580 730 4150 0 0 1580 730 290 290 290 290 290 .290 00 0 00 00 0 0 5800 5800 5800 00 0 430014300 4300 00 0 1600 1600 0.600 1600 1600 1600 i 3000 6600 10,00c 4570 2000 3950 1000 +300 10,400 923c 4570 1205 2675 950 125 125 125 125 125 125 125 125 125 120 130 155 272 333 310 218 240 120 180 171 272 333 310 220 500 500 500 00 0 750 50C 9145 9145 91,35 I4a J4653. 7 4/85 14575, 144S2 1205 3P2C 6,730 10,155 4842 4033 13,710 8873 4920 0 1205 4,42) 10,580 9459 484 P 6488 12,435 882j 1500 P00c 11145 PQP90 P94P5 441 rr 58785 7347 C 38CA5 1025 -d 117015 12,615,15,735 23,815 37,770l41^26 wpw 62,114 59,712/4584 0 12,635 17,035 27,615 57.07441,9:6 48,404 5Q839 3^66^ 0 5000 0 0 17 00 369 d 287C 1700 3690 2870 530 0O 0 62501 596C 4690 1350^ 7000 6500 9350 6817 4920 L5355 650C - 4180 4055 3250 il80 4055 i1 1 DSW 377520 STLCOPCB4099252 Company Confidential 3. AROCLOR C. R. Mcllwain, E. E. Bowles, J. M. Jones, J. W. Mattern (V. R. Haupt) Evaluate QuaterphenylPolyphenyl Effects on Solid Aroclor Yields 1969 Savings - $63,200 TSD Objective NFC _______ - $14,000 ________ B-8 (a) Lab data shows no relationship between specific gravity and softening point of Aroclor 5460 within the range of our specifications. Density gage now located on the still receiver circulating line will be relocated to the Montar circulating line. Distillation end point will be determined by specific gravity change of the Montar. Solid Aroclor 5460 Solubility ProblemsQuality;B-8 (e) TSD Objective Statistical tests to.correlate Aroclor 5460 solubility problems with various operating parameters yielded the following results: (1) There is a definite correlation (99.5% confidence) between 5460 softening point and solubility. Solubility problems occur more frequently with soft points above 102.0C. (2) No correlations are apparent between 5460 solubility and: 5060 soft point, percent quaterphenyls in SW/R, yield, ratio of para isomer to quaterphenyls content in SW/R, or the amount of trappings charged to weigh tank. Since this data is at best sketchy, reasonable doubt exists as to conclusions drawn. In order to collect more complete data for further analysis, the following was recommended to production: a) Continue taking a sample from each SW/R weigh tank charge for analysis to assure correct relations between lab analyses and operating data, b) Take a 5460 sample from the receiver just prior to pumpout and analyze for soft point in plant and solubility. Further studies will be carried out by PR&D in December 1969. Sandvik Belt Cooler for Evaluation for Solid TSD Objective Montar 5 SolidificationAroclor ExpansionB-8 (j) Based on test data Sandvik has quoted: For a 8000#/hr. unit (72 ft. long) $31,795; for a 14000 #/hr. unit (122 ft. long) $42,950. Total installed project cost is estimated at $120M +_. A progress report will be issued in December 1969 covering details of this work. Porocel Columns CEP 2132 Technical AssistanceTSD Job No. 930 Initial tests of the new columns were hampered by instrumentation problems. These problems appear to be solved. High power factor readings by the in-line instrument were found to be due to contamination by particulate matter and corrosion. The cell has been cleaned and will be placed back in service soon. DSW 377521 STLCOPCB4099253 Company Confidential 4. BIPHENYL-SANTOWAX W. G. Niemeyer, D. A. Self, (V. R. Haupt) Debottleneck BiphenylSantowax Distillation Area to 87.6M lbs./yr. Biphenyl____________ Capacity Increase TSD Objective B-7(a) A capacity/performance test run was conducted on the Santowax distillation column for November 11 through November 14, 1969. The detailed results will be reported in a TSD progress report to be issued during the week of December 8. Two different types of Santowax R were attempted: HB-40 grade with quaterphenyl content up to 15% and color to 2-1/2; and Solid Aroclor grade with quaterphenyls to 5% and color up to 3. A Santowax R production rate of 26 M lbs./yr. with 93.5% on stream time was demonstrated on HB-40 grade Santowax with somewhat higher rates possible. Solid Aroclor grade capacity will be lower. Additional testing will be scheduled in January 1970. Designed Experiment Run on TSD Objective No. 1 Biphenyl FurnaceProcess StudyB-7(e) _________ A computer regression analysis and graphical print-out of #1 Biphenyl fur nace designed experiment has been received from MISD. This information will be converted into a more direct reading form for in-plant use to improve process control. Eliminate Safety Hazards at No. 1 Benzene Feed TankSafetyTSD Job No. 976 This project will eliminate existing safety hazards at the same time the No.l benzene feed tank is replaced. . Project premise issued December 2, 1969. AFE to be issued by December 5, 1969. HB-40 J. W. Mattern, (V. R. Haupt) HB-40 Control Variable Study"Process StudyB-12 (d) TSD Objective The investigation to correlate operating variables with high color has been indefinitely delayed. In December, Production will start a planned test of reduced fresh catalyst usage by increasing the recycle quantity. There is a potential savings of $4800.00 in 1970. HC1 L. 0. Chambers, K. G. Hale, (A. G. McCarty) Production of Staley Grade New Earnings $288M TSD Objective Acid - AFE-3076Potential Savings $71,000B-10 (c) Pilot carbon treatment studies have been delayed by late delivery of equip ment. All equipment is now on hand, and arrangements have been made with Jacksonville University to use their analytical facilities to develop a DSW 377522 STLCOPCB4099254 HC1 Production of Staley Grade Acid - continued Company Confidential 5. more sensitive analysis. A revised schedule for the tests will be issued by December 14. HC1 MIP Planning TSD Objective B-l(b) Final draft is ready for TPM review. Targeting for issue in December. Muriatic Acid Reduced High Chlorine Quality;__________________________ TSD Job No. 950 Installation of the temporary air blowing system for reducing residual chlorine in #7 acid storage tank has begun. Completion is pending rotameter delivery. PNP L. O. Chambers, K. G. Hale, (A. G. MCCarty) - PNP Dust Flammability ______ Safety (S&PP Audit)____________ , TSD Job No. 814 Additional tests will be run to learn something of process conditions. A final report will be issued following collection of data and comments. PNP-Sulfuric Acid Safety Unloading Pump(S&PP Audit) TSD Job No. 979 A project premise for the replacement of.present air pad unloading of sul furic acid with a bottom pump unloading system, as recommended by S&PP, was issued November 25. NIRAN D. W. Dudley, T. W. Lawrence, (A. G. McCarty) Demonstrate Parathion Recovery' Savings - $17,400 TSD Objective 10-15% Reduced CODB-5 (a) Field construction continues. Test equipment (precoat filter and coalescer) placed on order for early December delivery. Tentative outlook for pilot testing is January 1970. Savings - $12,900 TSD Objective Acetone Recovery20% Reduced CODB-5 (i) Equipment was installed during Ethyl changeover and is being utilized to strip acetone at higher vacuum. .Improvements for charging pump-out water through the reactor bottom nozzle is reducing reactor pump-out problems. Performance evaluation will be made in December. Several small items remain to complete the project. DS\N 377523 STLCOPCB4099255 Company Confidential 6. NIRAN - continued Parathion MIP Planning TSD Objective B-l(c) An MIP review meeting was. held with representatives of Agricultural Division Manufacturing and Research, and CED. Chlorinator Off-Gas System Modification . Safety ___________ - TSD Job No. 980 The accident investigation of Haveg piping rupture at the No. 2 chlorinator off-gas catchpot pointed to water from.the vacuum system back flowing into the catchpot and reacting with the organic material trapped there as prob able cause. A study was started to provide modifications to prevent re currence . Profit on New Sales and Producti- Improve .Chlorinator vity Savings: $48,000/mo. per 1/2 TSD Objective Cooling System______ '_____ Hour Reduction in Chlorination Time B-5(g) Tentative Process Amendment is circulating for approval. PROCESS AND QUALITY ANALYSIS J. L. Murphree, (W. B. Dunlap) Process Surveillance - A process capability report is-being prepared which relates process levels to specifications. This will.identify unrealistic specifications - an important feature in the plant.process and quality control program. Raw Material Control A system of quality control for. raw materials in tank cars was developed and adopted by the Quality Control Board. A similar system for raw material in bags and drums is being prepared. PNP - Identification of Potential Savings Critical Variables _____ - $60,000 ______ TSD Objective C-3 TSD Job No. 839_______ Equipment failures plus the scheduled shut-down prevented experimental verification of reactor control settings for improved yield in November. This will be done in December. Circumstantial evidence indicates that reactor air flow before shut-down was greater th an indicated. Instrument calibration during shut-down has restored former control-valve settings. The air flow control valve is oversized for sensitive low-flow control, and a modification is being designed. Niran Still Control _________ Potential Savings $7900 TSD Job No. 964 Equipment has been received. Design is targeted for 12/15. The installstion target date of 3/1/70 is still realistic. DSW 377524 STLCOPCB4099256 Company Confidential 7. ENGINEERING DESIGN AND SERVICES- Mechanical/Electrical/Instrument Design & Drafting J. C. Price, J. A. Veazey G. W. Richey, B. D. Morgan R. V. Carlisle, R. L. Brewer J. K. Rennie, ^ (W. F. Taffee) The new Plant Fire Alarm system which connects all phones in the plant to the new fire signals, became operational on 11-17-69. The system has per formed well in all tests conducted to date. All areas of the plant are now using the new system. The H2S Monitor, intended for use in the Niran department as a safety device, was installed and placed in operation on 11/12/69. To date, the unit has performed flawlessly; however, further testing is in progress to determine if the unit will operate successfully for extended periods of time with little or no maintenance. Initial installation and startup of the new Niran Emergency Generator (AFE 3305 - $41.9M) was completed on 11-7-69. The unit has been tested each day and has operated successfully at all times. The older, 175 KW generator, was removed and is in the process of being rebuilt. J. C. Price is conducting a class entitled "Reinforced Concrete Design." In attendance are two draftsmen and two maintenance engineers. To date, five class sessions have been held - completion is scheduled for December. All data and information necessary to complete the short circuit coordination study for the Niran area was forwarded to CED for computation using the computer. The results will be returned and used to compile a program for testing and setting, circuit breakers, switchgear and motor control centers in the Niran department. All equipment necessary to conduct a test to determine the feasibility of Automatic Still Control in Niran (AFE 3347 - $2.2M) has been received. De sign work required for installation is underway and will be completed in December. A statistical study in 1968 indicated an estimated savings of $79M/year would result from improved process control. Two projects were prepared, revised and forwarded for approval. Tank Car Washing Facilities at Niran (AFE 3351 - $3.9M), OMP Dismantling (AFE 3359 - $27M). Drafting In progress: Replace Benzene Feed Tank (AFE 3371 - $ to be determined), Install Grating Over Niran Process Trench (AFE 3367 - $3.1M), Eliminate "Head Knocker" in Aroclor department (AFE 3364 - $1.1M). OSVM 37752s STLCOPCB4099257 Company Confidential 8. Drafting - continued Review drawings were completed for the following projects: Renovate Niran Control Room (AFE 3369 - $19.5M) , Modify Agitator Inter locks in Niran (AFE 3118 - $9.7M). Construction drawings were completed for the following projects: Niran Tank-Car Washing Facilities (AFE 3351 - $2.0M). UTILITIES ENGINEERING J. C. Price, J. 0. House, (W. F. Taffee) Started preparation of progress report on Utilities Cost Improvement Results For 1969 And Plans For 1970. Completion of this report is scheduled for December. PLANT IMPROVEMENT G. C. Goodwin, (W. F. Taffee) Plant maps, prepared by Atlantic Aerial Surveys, were received and neces sary corrections and additions were made before returning them for final printing. Final transmittal of all maps from Atlantic to Anniston is ex pected by mid-December. Two design packages were checked and forwarded for review.. Renovate Niran Control Room (AFE 3369 - $19.5M) and Install Grating Over Niran Process Trench (AFE 3367 - $3.1M). POLLUTION CONTROL E. G. Wright, (W. F. Taffee) Air and H20 Pollution Complaints Relations Community and Governmental TSD Objective _______________________________________ B-2; One air pollution complaint was received during November. There were no ^0 pollution complaints received. Eimco Filter Unit At Waste Treatment TSD Objective F-4 Production AssistanceTSD Job No. 808 Testing with sludge input was begun. The unit is performing satisfactorily mechanically. Filter cloth "blinding" by fines has prevented continued operation to date. Three cloth densities tested so far; two more on hand. Laboratory work by Betz representative indicates one of their polyelectrolytes will agglomerate the sludge and alleviate the blinding. Field test of polyelectrolyte scheduled for December. DSW 377526 STLCOPCB4099258 POLLUTION CONTROL - continued Company Confidential 9. Waste Treatment All wastes were effectively treated during November. Average daily values for Monsanto's effluent are as follows: PNP COD Parathion BOD Specifications 5 PPM 200 PPM 1.0 PPM 200 PPM HC1 Neutralization Pit Pollution AbatementTSD Objective F-4 Indications are that the neutralization pit may have reached the break through point sometime in mid-November. An accurate determination of the condition of the pit cannot be made at this time due to the fact that the Niran department is presently sewering waste H-jPO^ through this pit while their pit is being repaired. As soon as the Niran pit is returned to service, a test will be made on the HCl pit to determine its condition. STLCOPCB4099259 PLANT LABORATORIES G. W. Miller Company Confidential 10. PROCESS RESEARCH AND DEVELOPMENT J. T. Bell For the month of November, PR&D expended 50 mandays of the 85 mandays available on projects listed in the 1969 Program. The remaining time was utilized on non-scheduled work (Aroclor 5460 Acetone Insolubles), illness, vacation, supervision, and the KTA training course. Blend Scavenger Refinement (Aroclor) Improved Aroclor Electrical Properties______ __ _______ J. L. Brown The laboratory evaluation of Type 4A Molecular Sieve as an absorbant for electrical properties refinement of Aroclor 1242-Phenyl Glycidyl Ether mix was completed on 11-17-69. No further work in this area is planned. HB-40 Process Determine Process Studies'Variables_________________________________________ W. H. Howard A revised work plan is being prepared. Equipment malfunctions and slow delivery of necessary replacement parts have again delayed project progress. Biphenyl Tubular Pilot Studies ______ Obtain Desired Biphenyl/Terphenyl RatioJ. L. Brown Construction on the Polyphenyl Pilot Laboratory is now 75% complete. Slow delivery on certain building materials has necessitated extending the EDC . from 12/1 to 12/15. Low Color Aroclor 5460 ___________ Develop Alternate Process G. L. Arnett The primary laboratory work has been completed and a possible plant demon stration awaits the results of corrosion studies being conducted in St. Louis. Parathion Isomer ReductionIncreased Yields:G. L. Arnett Experimentation employing polar solvents in the chlorination process has been conducted. The project will again be delayed for approximately 20 days to investigate acetone solubility problems with Aroclor 5460. Parathion Condensation Reaction Studies _______ Increased Yields _______ I. Ransaw Completion of the evaluation of different catalysts in the condensation reaction is scheduled for 12/11. A revised work plan has been issued. DSW 377528 STLCOPCB4099260 PLANT LABORATORIES (Cont'd) Company Confidential 11. PROCESS RESEARCH AND DEVELOPMENT (Cont'd) Aroclor 5460 Acetone Insolubles Quality ______G, L. Arnett An investigation to determine the process controls necessary to prevent the formation of over-chlorinated terphenyls has been initiated. An estimated 20 days is required for completion. In addition, support has been given to eliminate other plant difficulties. ANALYTICAL AND QUALITY CONTROL S. 0. Kemp Complaint Report Quality Number Material Customer Reason 16-A-69 Montar 5 Philip Carey Corp. Large chunks of material causing difficulty in dissolving as contrasted to the smaller pieces. YTD Quality Complaints/100 Shipments 0.25 Target 0.20 DSW 377529 STLCOPCB4099261 Company Confidential 12. COMMUNITY RELATIONS, PERSONNEL, RECRUITING, AND DEVELOPMENT Personnel 1. J. W. Mattern will be a shift supervisor on the Solid Aroclor Start-up and will be temporarily transferred December 1 from TSD to Production reporting to R. A. Haydel. Development 1. J. T. Bell, D. W. Dudley, K. G. Hale, W. H. Howard, T. W. Lawrence, C. R. Mcllwain, W. G. Niemeyer, I. Ransaw - attended Kepner-Tregoe training course taught by C. H. Woods November 16-21. 2. G. L. Richey attended an Instrument Training Course presented by CED in St. Louis November 3-21. 3. R. L. Brewer attended the Annual Materials Engineering meeting held in St. Louis on November 18, 19 and 20. 4. Plant wide training in use of. the Olivetti-Underwood computer was started November 3 with a class selected from TSD and Accounting. TSD graduates November 14 included T. W. Lawrence, K. G. Hale, C. R. Mcllwain, J. C. Price and Brode Morgan with J. L. Murphree as instructor. 5. G. W. Miller visited Organic Research and attended Ag Division meeting in St. Louis November 17 and 18. 6. A. G. McCarty went to St. Louis November 17 and 18 to review Parathion MIP. Visitors 1. R. S. Yates visited V. R. Haupt to discuss Solid Aroclor expansion November 5, 6, and 7. 2. Angelo Testa, CED electrical engineer, visited the plant on 11-17-69 to discuss relocation of the 440v transformer formerly serving Chlorine. 3. R. G. Graham, Senior Sales Representative from New York-Monsanto Offices, and Dick Hanson, Westinghouse Project Engineer, visited November 20 and 21 to discuss liquid Aroclor handling. DS\|\| 377530 STLCOPCB4099262 ( PROCESS IMPROVEMENT DISTRIBUTION OF TIMS BY TECHNICAL SERVICE Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. NEW PRODUCTS PLANT IMPROVEMENT / ASSIST OPERATIONS SPECIAL ENGINEERING SERVICES TECHNICAL MANPOWER MISCELLANEOUS ACTIVITIES AND ABSENCES ( DSW 377531 STLCOPCB4099263 Comp any C on tid en t i a i' TSD PROJECT SUMMARY [ STLCOPCB4099264 ( ANALYTICAL SAMPLES LABORATORY ADMINISTRATION ANALYTICAL MANPOWER ( Manpower/sample $/Manhours 7,, Total Plant Operating Cost ( Overtime % STLCOPCB4099265