Document 3JgKqK3O00LrXwzzwxy5MwEZn

COMPANY CONFIDENTIAL Anniston . _ C. K. Eastman . 1 A. J. Koenig - * -It )J. C. Landwehr A. . Leisy G. W. Miller . W. B. Papageorge W. F. Taffee ' H. L. Williams General Offices H. S. Bergen : 'J. 0. Bright H. C. Carder ? D. E. Cayard D. Danna (3) L. C- Fuhrmeister H. 0. Hehner 1).; B. Hosmer R. E. Howard R. M. Kountz W. A. Kuhn C. F. Luecke H. L. Payton W. R. Richard N. L. Sample A. J. Stratmeyer H. S. Trail J. H. Zwemer South Second St. Anniston Plant TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT ..... Summary . . August, 1968 - Cost Improvement Results For First Eight Months Estimated Actual Target % of Target Month $21,150 $49,955 42.5 YTD $369,940 $310,570 99.6 Organic Division Solid Aroclor still level indicator-alarm project approved verbally for $8000 instrumentation. Total NFC $14.9 M- savings $63.2 M. Two Montar handling projects forwarded for approval in August. NFC $20 M with expected savings of $24.2 M. 0. DeGarmo M. E. Gibbs J. F. Quinn J. R. Savage - JFQ Other Locations D. B. Edwards - DR A. H. Forsten - CB J. W. Graves - Luling D. W. Jackson - WGK W. R. Kellogg - Nitro R.C. Swanson - Seattle J. F. White - Everett Santowax R column project approved verbally for $3500 instrumentation. Received formal notification of January 1, 1969 target to discontinue manufacture of Chlorine/Caustic at Anniston. May be delayed past January to provide adquate tank car unloading and distribution facilities now in design on CEA-I83I. Staley Grade HC1 via activated carbon treatment studied and reported by Pittsburgh Activated Carbon. Labora tory scale recommendations will be tested on plant scale with final recommendations targeted for October. PNP reactor optimized at 175C. and 66 minutes. This time represents approximately a 631 decrease in cycle time. Reactor agitator and pressurization of charge tank will be studied in September. DSW 377309 an - 306 , ' CONFIDENTIAL INFORMATION **ThU document contains confidential information which U tha property of Monsanto Company. Only those portions of the document relevant to a duly authorised individual's need to know may be excerpted for him. The report must not be sent outside the Company without written approval and the authorized recipient is accountable for Its safe keeping, excerpting or otherwise disclosing of its contents and for its proper disposal. The docu- mfoernta relomnagienrs ptheeriopdr.o"perty of Monsanto Company and shall be returned within two months to its author, except upon special authorization to hold STLCOPCB4099162 Agricultural Division Company Confidential 2. Plant tests on experimental Sulfur Recovery unit are underway - scheduled for mid-September completion. Centrifugal separation looks good to date. Fume Collection System 95% complete with start-up targeted for week of September 16. Engineering Design and Services Transmitted design packages for winterization of Niran safety showers, plus several minor ones. Completed pre-startup checkout of instrument and electrical installations on the sulfur recovery pilot plant and the Niran fume collection system. Forwarded project premises for water and sewer system projects. Utilities Cost Improvement Project premises have been issued to collect sewered water in PNP and Aroclor departments. NFC $8M with expected savings of $4.2M. Plant Improvement Design packages for Niran Storage Tank Dikes, and two minor jobs were transmitted to maintenance. AFE forwarded covering surfacing, curb and gutter on Fifth and Duncan Streets. Liaison Warehouse office complete; flushing of lines and tanks with Aroclor 1242 started by Production. Insulation incomplete because of insulator's strike. Roof of warehouse complete, siding installation started but going slowly; flakers set. Warehouse section occupancy date will be controlled by siding installation about October 1. ' Installation of 300 M gallon Benzene tank started on CEA-1892. Design of facilities to handle liquid chlorine from tank cars underway on CEA1831. Waste Heat Recovery Progress report covering final phase issued August 21. Unit is being placed in stand by condition for next three months. Pollution Control Two atmospheric pollution complaints were received and handled in August. Malathion waste studies complete. Malathion reduction was 99%(+) in the pilot unit. This indicates that malathion waste can be effectively treated in our waste treatment plant. Final report targeted for September. DSW 377310 Quality Control The RFT Index was 98.7 with 8 lots rejected out of 635; 8 out of 540 from the Organic Division. The Quality Score declined to the lowest level of the year, from 96.5 to 92.2, due largely to divergence in liquid Aroclors and Muriatic Acid. STLCOPCB4099163 STLCOPCB4099164 Company Confidential STLCOPCB4099165 ND. 34Q -B DIETZSEN GRAPH PAPER 8 X B PER INCH ----- EUGENE DIETZBEN CG M A D E IN U. S. A. AROCLOR Company Confidential E. E. Bowles, C. R. Mcllwain, D, A. Self, (V. R. Haupt) 3. Cost Improvement Month YTD Target $16,630 Actual 75* $32,580 $25,435 *Making solids on liquid system plus unusable liquid still revision TSD Objective B-8(a) Evaluate Quaterphenyl-Polyphenvl Effects on Solid Aroclor Yields. a Received verbal approval for $8000 on project 3015 to purchase radiation instruments. Instruments will measure specific gravity on the chlorinator and still receiver and also provide a low level alarm on the still. Total Total project cost will be $14,900 NFC and $900 expense. Savings claimed are $63,200/yr. TSD Job No. 398 Liquid Still Revision for Therminol Heating No. 2 still was converted to Therminol heat supply. Pressure drop problems developed in Therminol system and resulted in unacceptable production rate. The still will be converted back to original heat supply. The main Therminol system containing 22 branches is being analyzed to decide what must be done to improve existing system and take care of future needs. TSD Objective for 1969 - Montar Handling AFE 2952 has been issued for approval to provide for pumping of Montars to the Montar pit. NFC is $10M with $13M savings'. AFE 2949 has been issued fo~r approval to provide for flaking Montar 5. NFC is $10M with $11.2M savings. BIPHENYL-SANTOWAX W. G. Niemeyer, J. W. McGee, (V. R. Haupt) Cost Improvement - : Month YTD Target $3,550 $30,150 Actual $4,990 $80,675 TSD Objective B-7(a) Debottleneck Biphenyl Stills to 87.6 M Lb's./yr. Biphenyl Rate By 2/69. . ' This work has been included in CEA-1892. CED and the plant are planning a capacity test run during the week of September 9 to firm up scope in this area. TSD Objective B-7(c) Provide Assistance (Liaison) to CED As Necessary On Project To Upgrade No. 1 Furnace. CEA-1892. Field construction is underway. Foundation work is in progress on dike wall for new benzene storage tank and footings and slab for new preheaters. DSW 377313 STLCOPCB4099166 BIPHENYL-SANTOWAX - continued Company Confidential A. TSD Oblective B-l(a) Revise Biphenyl-Santowax Manufacturing Improvement . Plan By____________ ' Rough drafts of all sections are complete. Review and revisions are in progress. Quality TSD Oblective B-7(d) Demonstrate Quality Improvement on Santowax Still via Addition of Eight Tray Column. Received verbal approval on 8/22/68 to order long delivery equipment and in strumentation ($3500) for proper control of this column. Working with CED on their part of column auxiliaries. CHLORINE D. W. Dudley, G. L. Moore, (D. C. Malm) Month YTD Target $2,625 $33,375 Actual $715 $55,845 Comment The Anniston plant was notified on 8/14 of the decision to shut down the Chlorine Plant by 1/1/69, or as soon thereafter as possible. TSD effort is being concentrated on shutdown preparations. TSD Oblective B-6(a) Monitor Mercury Usage by Radioactive Inventory Thirty-one cells were spiked and samples forwarded to Organic Research for measurement. Determination and publication of results should follow in September. TSD Objective B-6(b) Develop Program to Reduce Mercury Usage to 0.75 lbs. He/Ton Chlorine. *" Mercury wash tank was delivered 8/21/68. Maintenance is scheduling installa tion for September. TSD Oblective B-6(c) Assist in Demonstration of Brine Dechlorination by 4/1/69 No change in status. Demonstration will follow maintenance revisions. Process TSD Job No. 328 Titanium Brine Heat Exchanger (Savings $2.500) Project for reducing steam temperature was transmitted to maintenance for installation 8/14/68. DSW 377314 STLCOPCB4099167 CHLORINE continued Company Confidential 5. TSD Job No. 860 Central Chlorine Unloading; Plant goals and objectives for liquid chlorine handling and distribution facili ties were defined and transmitted to CED. Final project scope is targeted for 10/15. TSD Job No. 861 HB-40 Hydrogen Study________;_____________ ________________ __ Objectives for this job are: a) Define and report catalyst penalty for using untreated Biphenyl _ hydrogen at HB-40. Catalyst penalty would be $28,00Q/yr. plus a 4 M lb./yr, HB-40! capacity losses. The penalty was defined by company standard batches of HB-40 versus batches of HB-40 produced from Biphenyl hydrogen in a laboratory autoclave, b) Define catalyst poison and propose means of reducing effects. The poison has been defined as carbon monoxide. Carbon monoxide is pre sent in small percentages ranging from 2-10%. A means of reducing the carbon monoxide concentration is presently being tested in the laboratory. TSD Job No. 854 Chlorine Backflow Prevention - Safety Project 2955 ($2,500 NFC) was estimated and approved for prevention of chlorine backflow from Aroclor to the chlorine plant. The project is scheduled for final design and drafting in early September. HC1 K. J. Buturla, G. L. Moore, (D. C. Malm) Cost Improvement Target Month $1,050 YTD $2,350 Failure to meet the month's target caused by hold-up on installing HC1 storage tank Actual $700 $1,900 TSD Objective B-10(a) Demonstrate Reduction of Unaccounted HC1 Losses to 10% of Total HC1 Available. Recycle line project in maintenance backlog. No action. TSD Job No. 497 Muriatic Acid Storage ________________________ With the shutdown of the chlorine plant, and the installation of a new central tank car unloading facility, chlorine tank cars will no longer be unloaded in the immediate area of the new HC1 storage tank. A decision has been made to change drawings and relocate the tank to the original site. Work will begin on the new drawings to construct the tank at the original location about Septem ber 1. All construction work will be halted until the design can be prepared. Package transmittal is targeted for October 1, 1968. DSW 377315 STLCOPCB4099168 HC1 - continued Company Confidential 6. TSD Job No. 801 Enable Routine Production of Staley Grade Acid The study to determine how to produce Staley Grade HC1 is continuing. Pitts burgh Activated Carbon Laboratories have completed tests on Anniston HC1 and have written a report which indicates our carbon towers should be capable of removing organics. New tests are planned for verification of results in our HC1 plant. A coalescing separator filter is also being given consideration in solving the problem. Efficiency and economic evaluations of the alternatives will be made. Final recommendations are targeted for early October. - PNP 0. J. Norris, K. J. Buturla, (D. C. Malm) Cost Improvement Month YTD Target $16,500 $95,000 Actual $6,000 $*5,250 TSD Objective B-9(a) Assist in Demonstration of 20 M lbs./vr. Rate Charge tank pressurization study indicated a 7 minute reduction in reactor cycle time is possible by pressurization and preheating raw materials. A project will be forwarded for approval by 9/10 to make the necessary modifica tion. If successful^ this change will increase capacity to 22 M lb./yr. Addi tional work in September will be aimed at a study of reactor agitation in an effort to improve heat transfer rate and reaction rate. TSD Objective B-9(b) Increase Reactor Temperature (9/1/Target) Field tests at 175C. successfully completed with a 4 minute reduction in re action time. New reactor rate is now 1.78 M pounds per month based on a 66 minute reaction time. August production (1.66 M) below expected because of unusual repair downtime. TSD Objective B-9(c) EVOP Study of Molar Ratios NaOH/PNCB Test program will be outlined with production by 9/10 so that field tests can be started by 9/15. NIRAN K. G. Hale, 0. J. Norris, D. W. Dudley, J. L. Gaines, (D. C. Malm Cost Improvement Month YTD Target Actual $22,175 $8,300 $115,275 $95,850 DSW 377316 TSD Objective B-5(a) Demonstrate Parathion Recovery ($70.000/yr. Yield. Savings + 10-15% Reduction in COD Loading) Metal edge filters were removed and cellulose filter test unit installed. Filter tests were begun but were interrupted by feed pump failure - test to re sume in early September. Augus;t test of cellulose filter lasted two hours with no build up of solids on filters as experienced with metal edge filters. STLCOPCB4099169 NIRAN - continued Company Confidential 7. TSD Objective B-5(c) Demonstrate Solvent Addition to Residue (Interim) Process * By 6/1/68 ($59.000/vr. Yield Savings) Yield savings of $8300 were obtained in August. Phase J> tests (increase Cl2 level) were stopped in late August by production. Yield losses of $6000$8000/month are expected if Cl2 level is dropped back to 104 average. TSD Objective B-5(d) Evaluate Sulfur Recovery from Residue by 7/1/68 ($400000/vr. Savings + 31% Reduction in SOo to Air Experimental recovery tests are approximately 60% complete. Results to date indicate 907. recovery of solids with 0 dryness of 80-957. solids in cake depending on centrifuge condition. EDC for tests 9/15. / .PR&D work on process continues. Completion of process is i\ow expected during 10 68 TSD Objective B-5(e) Demonstrate Reliability of Submerged Pump for R.I. Control of Chlorination Temporary replacement of light source installed. Tests will be resumed upon completion of repair work to circulation line. Safety TSD Objective A-10 Eliminate High HgS Pressure in Thio Acid Reactor by Demonstrating Temperature Controlled Alcohol Addition Trial run completed by production with excellent control results. Alcohol addition time averaged 5 minutes/batch longer than on manual control. A progress report will be issued in November, TSD Objective F-10 Assist in Demonstration of Fume Collection in Parathion Department Construction completed 8/29. Water system checkout completed 8/3O. Startup will be delayed until old incinerator stack fan bearing? have been replaced. Start up now scheduled for week of 9/23* TSD Job No. 815 Survey Water Savings Potential in Parathion Department Design of experimental project ($3>700/yr. savings) to re-use water from wash columns at pre-washers will be transmitted by 9/6. Progress report covering survey of water savings potential was issued in early August. K. G. Hale, (D. C. Malm) Cost Improvement Month Target 0 Actual 0 YTD 0 0 OSVM 3713''7 STLCOPCB4099170 PgS5 - continued Company Confidential 8. Safety TSD Objective A-15(a) Provide Design to Reduce Fumes in PoSg Working Areas bv 4/1/68 at Surge Tank Vent Project transmitted to P & S on 8/5/68, ENGINEERING DESIGN AND SERVICES Mechanical/Electrical/Instrument Design and Drafting J. C. Price, J. A. Veazey. R. L. Brewer. J. K. Rennie. (W. F. Taffee) Highlights Review drawings were Issued for Emergency Escapeway at Niran Foremen's Office, Emergency Escapeway and Reactor Dam at P^S^, alterations to wash piping at Niran, safety shelter @ PNP, and slurry valves at Niran, Revised drawings were issued for the Niran Fume Collection System and $9 chlorinator pump and piping. Final drawings were Issued and design packages forwarded for Hourly Parking Lot Lighting, Alarm on Fire Water System, Power Distribution Panel for TSD Annex and Niran Safety Showers. Forwarded premises for corrosion protection of 20" City Water Main and Sewer, to collect acidic spring water and HC1 loading dock drainage. Assisted in checkout and startup of the Niran sulfur recovery pilot plant and the Niran Fume Collection System. Design, construction and liaison services were provided for sixteen (16) other jobs during the month. Objectives There has been no change in status of objectives except as reported below: TSD Objective A-5 Winterize Safety Showers Design package for Niran showers (Project 2770) was transmitted to maintenance on 8/15. TSD Objective A-6 Procedure for Electrical Testing Forwarded report defining problem and scope. Plan to meet with maintenance to establish responsibilities and work plan in September. UTILITIES COST IMPROVEMENT J. C. Price, A. I. Hale, L. 0. Chambers, (W. F. Taffee) Evaluation of a preliminary survey conducted in July indicates potential savings of about $200,000/yr. in the cost of utilities for the Anniston plant. Pre liminary estimated capital cost to obtain these savings is $325,000. Progress reports on steam metering, water metering and program plans were forwarded for typing. Forwarded project premises for approval and AFE's for review on re-use of sewered city water at PNP and re-use of sewered tower water at Aroclor. Net savings at these projects will be $4200/yr. AFE's for water meters in Niran and Organic Division steam meters were forwarded for approval. AFE's for Organic Division water meters and a gas meter at Biphenyl were for warded for review. Started evaluation of treatment for Biphenyl cooling tower to reduce or eliminate scaling of tfie tempered water cooler. DSW 377318 STLCOPCB4099171 PLANT IMPROVEMENT Company Confidential G. C. Goodwin, (W. F. Taffee) 9. Design packages forwarded to maintenance covering Niran raw material storage tank dikes, upgrading chlorine lunchroom and revision of shipping office. Forwarded AFE's for resurfacing Fifth street east from Cla railway to new warehouse, Duncan street from fifth to sixth streets, and upgrading lights along Fifth street west side of plant. CEP LIAISON V. T. Langdon, (W. F. Taffee) CEA 1450 - Aroclor Expansion Training of operators on tank farm completed by L. L. Faulkner. Flushing of system and all other activities in the field will be carried out by Production. Insulator's strike has delayed insulation completion and our ability to handle anything higher than 1248. Flakers set in place, roof and siding of flaker "penthouse" remains to be completed. Approval received for pallet dispenser variance. CEA 1452 - Warehouse Installation of roof completed, siding installation progressing slowly. Pre sent prediction is that warehouse will be ready for occupancy by September 23 Construction of Sixth street to serve warehouse and tank truck docks nearing completion. Sprinkler installation underway at months end. WASTE HEAT RECOVERY C. E. Woodward, (W. F. Taffee) Progress report covering experimental observations obtained for Phase III published 8/21. Report contains test results for modified equipment. Special emphasis was made to compare performance of the test unit during periods of 1) normal fluctuation in $8 boiler firing rate and 2) during periods when the firing rate was held constant. Additional results for Brink and Selas Therminol recovery test units also included. .............. Actions to place the test unit in a stand-byshutdown delayed one week. Equip ment and piping drained of Therminol and water inventory. Expect to complete shutdown 9/5. POLLUTION CONTROL E. G. Wright, (W. F. Taffee) , TSD Objective F-^ Establish a Monitoring System for Air Effluents from the Plant Thirty-six atmospheric samples were collected and analyzed for S02 in August. Will begin sampling at a second point as soon as instrument shelter arrives. TSD Objective F-5 Publish a Newspaper Article to Further Community Understanding of Pollution Abatement Problems. ........... - An article will be published in the plant newsletter during September. A pro gram to invite local political figures and newspapermen in the plant is being worked out with the Plant Manager and the Personnel department. DSW 377319 STLCOPCB4099172 POLLUTION CONTROL - continued Company Confidential 10. TSD Objective F-7 Investigate Installing Permanent Monitoring Device on Choccolocco Creek. Potential sites still being investigated. ...................... TSD Job No. 808 Install Solids Removal Equipment at Waste Treatment. November 15 is target date set by maintenance for installation. TSD Job No. 864 Effluent Task Force. .............. , Issued a memo outlining a method for controlled caustic sewering. Also issued recommendations of repairs required to the HC1 neutralization pit. Special Activities . 1. Collected samples at Paul Hodges request for Research to begin their in vestigations of Aroclors in Snow Creek. Waste Treatment: All wastes were effectively treated in August. Average values for Monsanto effluent in August are as follows: Average Daily Specifications PNP COD Parathion BOD 1.0 PPM 100 PPM .11 PPM 1.0 PPM ^5 PPM ^200 PPM -l PPM -^200 PPM PROCESS AND QUALITY J. P. Chadwick, (W. B. Dunlap) ..... TSD Objective C-2 Apply Statistical Control to Solid Aroclor Process -- The plant experiment designed to verify predictions of the computer study reported in July continues to show a 5-77o improved yield. The test is continuing. . TSD Objective C-6 Correlation of PaS^ -Parathion Operations Still controls were found to outweigh all other variables studied. No prolonged yield changes were revealed which could be expected to relate to upstream units. Work on this phase of the study will be completed in September and a progress report written. Procress Improvement Plan for PNP ............ ...... A quality control and process surveillance section was contributed to the Manufacturing Improvement Plan for Paranitrophenol. DSW 377320 STLCOPCB4099173 Company Confidential 11. COMMUNITY RELATIONS,, PERSONNEL. RECRUITING. AND DEVELOPMENT Development 1. Cliff Woodward attended the ASME/AIChE Joint Heating Transfer Conference held in Philadelphia, Pa., August 12-14; he assisted in a Paper which he coauthored with D. E. Steinmeyer of CED. Recruiting 1. Lee 0. Chambers, Co-Op, was hired August 26. He attends Auburn University. Visitors 1. Mr. Carl R. Martinson, CED Specialist in "L" Standards for Painting, visited the plant August 30. A special consultation was held with Maintenance and TSD. 2. Mr. Elwood Robinson and Mr. G. Buchannan, Lion Oil El Dorado, visited August 13 to discuss electrical test procedures for insulating fluids. Public Relations . 1. Mr. J. C. Landwehr attended the Associated Industries of Alabama Water Pollution Task Force meeting held at Mobile, Alabama, August 14. DSW 377321 STLCOPCB4099174 Company Confidential DISTRIBUTION OF TIME BY TECHNICAL SERVICE PROCESS IMPROVEMENT NEW PRODUCTS RIANT IMPROVEMENT ASSIST OPERATIONS SPECIAL ENGINEERING SERVICES w o PESd Cm 0 .. T 1 -- ^--I __JI__ j1_._._ TECHNICAL MANPOWER MISCELLANEOUS ACTIVITIES AND ABSENCES Jan. Feb. March-Apr. May June July Aug. Sept. Oct. Nov. Dec. STLCOPCB4099175  TSD PROJECT SUMMARY 500 400 300' 200 100 00 600 500 400 300 200 100 0 600 500 400 300 200 __ 7 100 00 600 1111 __ V Y 500 400 300 200 nDcb\vMv ^07* 7 323 ---1100 ------I0 ic. Jan. Feb. Mar. Apr. May June 1 July Aug. Sept.Oct. Nov. Dec. Jan, STLCOPCB4099176