Document 3Qao3jQqK6mB877KrjedongR0

V '* MONSANTO COMPANY Location: Texas City., Texas Date : July 15, 1966 To ; Ray Rosenberg cc: C. H. Duhon W. H. Lane/ J. A. Glass W. R. Nisbet J. L. Price J. L. Roughton T. E. Shirley w. H. Slager L. J. Schlechte Subject VCM Plant Quarterly Manufacturing Report 2nd Quarter 1966 SUMMARY Production rates for the second quarter in percent of rated capacity were: VCM Department 23 EDC Oxidative Chlorination EDC 99.8# 111.356 73*3# Rates were limited by: l) C2H2 distribution; 2) failure of plant water supply; 3) fouling of reboilers and a number of mechanical failures. Quality control was generally good. Plugging of 22D14 (VCM final purification column) in June and the resin bed test during May caused most of the off-spec material. A new quality control record was set in April. Hie quarterly unit manufacturing cost was 5-84 jf/lb. VCM. This was above standard (5.321 ji/lb. VCM) because of: l) high vari ances in Department 23 due to the high price of chlorine; 2) high catalyst usage in Department 26; and 3) low volume in June. CBY 1112518 RSV0032631 VCM Plant Quarterly Manufacturing Report - 2nd Quarter 1966 Page 2 OPERATING DETAILS A. Summary Table Production VCM - MM Lbs. Cra eking Reaction Total April May June 2nd Qtr. Totals Std. Year to Date 9.52 10.53 2.45 2.30 11.97 12.83 7.87 1.78 9.65 27.92 6.53 34.45 27.6 6,.9 34.5 55.78 16.05 71.83 EDC - MM Lbs. Department 23 Department 26 14.79 14.76 1.71 2.06 12.30 1.24 41.85 6.01 Total 16.50 16.82 13.54 47.86 Acid, M Gals. Scheduled - Acid 201 180 281 180 219 180 701 540 37.5 7.5 83.73 9-64 45.0 93.37 1163 980 On-Stream Time Cracking Reaction Department 23 Department 26 Department 21 100 96.6 100 88.1 85.3 100 98.4 93.9 96.6 91.0 97.1 83.4 79.6 67.2 63.1 99.03 92.80 91.10 83.90 79.80 99.5 95-6 91.7 83.6 76.7 Yields Deartment_22_ EDC to VCM CaH2 to VCM Department 23 C2Hjj to EDC Cl* to EDC Department 26 C2H4 to EDC HC1 to EDC 93.54 96.69 95.33 98. 54 91.87 94.56 100.22 98.73 98.57 101.41 93.56 100.26 57.78 73.45 72.18 76.13 70.18 81.92 Standard 95.5 97 95 95 88.4 91.0 CBY 1112519 RSV0032632 VCM Plant Quarterly Manufacturing Report - 2nd Quarter 1966 page 3 OPERATING DETAILS (continued) B. Operations and Maintenance April 1966 The spare rotor was Installed in the York refrigeration drive turbine, 22DT1-1 along with steam carbon rings which failed. The 22E21 (the EDC purification column reboiler) and 22E30 (the EDC drying column reboiler) were changed out one time each. The hydration reactor, 22R3 was recharged. Piping was installed to allow bypassing this reactor without shut ting down the CaHa reaction unit. Catalyst usage in Department 26 was high. The recycle compressor was down 17 days to prevent damage to it from corrosion. The HC1 compressor 21C2-1 was overhauled. May 1966 The HC1 stripper reboiler (22E14) and the cracking feed vaporizer (22E1) were changed out one time. The VCM compressor (22C2) was overhauled to replace leaking seals. The VCM reactor (22R1-3) catalyst recharge was started. A leak was repaired on the high pressure chlorine line feed ing the crackers. External corrosion from failure of the insulation weather coating caused the leak. The resin bed test for HC1 removal in product VCM caused low dilatometer and high acetylene. Removal of HC1 could not be measured because product VCM did not go off spec on HC1 during the test period. Seven leaking tubes in 21D2 were plugged. Two nozzles in the cooler piping for the EDC reactor 23V! were replaced because of corrosion. C8Y 1112520 RSV0032633 VCM Plant Quarterly Manufacturing Report - 2nd Quarter 1966 page 4 OPERATING DETAILS (continued) B. Operations and Maintenance Corrosion in the 26KI caustic scrubber outlet piping resulted in a leak in the surge tank, 26T9. Raw ma terial metering and product EDC metering problems in dicated low yields and low product production. A new column was installed in the feed gas chromatograph. Outside purchases of tank car chlorine due to start-up troubles at the Alcoa Cl2 plant had a serious effect on VCM cost. June 1966 The VCM purification column (22D14) was boiled out two times due to plugging. The EDC purification column re boiler (22E21) was switched twice. VCM reactor (22R1-3) catalyst change was completed. Both VCM dryers 22A1-1 and 2 were recharged. A new HC1 absorber (21D3) was installed and a new-lid was put on 21T2 (acid storage tank) in Department 21. Repairs were made to the severely corroded shell of the EDC reactor cooler, 23E2-4. The top three rows of tubes, which were severely corroded, were plugged. The liquid chlorine barge valves on 23T1-1 and 3, Cl2 storage tanks, were replaced along with the liquid chlorine tank car valve on 23T1-3. To reduce pressure drop and achieve higher thruput, the 26RI tubes were hand fluidized and each ferrule orifice cleaned. 26T9 (overhead surge pot for the 26KI caustic scrubber) was repaired and replaced. The Penwall suppres sion system was installed and on-stream testing started. C. Personnel and Safety April 1966 Safety meetings were held with all operators covering protective masks and the "Escape Suit". There was one (1) minor injury to a maintenance craftsman during the month. CBY 1112521 RSV0032634 VCM Plant Quarterly Manufacturing Report - 2nd Quarter 1966 Page 5 OPERATING DETAILS (continued) C. Personnel and Safety May 1966 Safety meetings were held with all operators covering ''Thermal Bums", There were five (5) injuries; one doctor case and four minor injuries. The doctor case injury was an abdomen strain to a maintenance craftsman. The minor injuries occurred to an operator, an instrument repairman, and two maintenance craftsmen. June 1966 CBY 1112522 Safety meetings were held with all operators covering "Flammable Liquids". There were five (5) injuries during the month; one major, one serious, and three minor. The lost time injury in volved a pipefitter who swung down from a scaffold and landed on some pipe resulting in bone fractures of both ankles. The serious injury was to an electrician who cut three fingers on a new pump base while installing new concuit. The three minor injuries were to an operator, an instrument repairman, and one maintenance craftsman. Mr. H. W. Catcher reported back uo work as an assistant operating supervisor. He had been in Haifa, Israel, on a plant start-up. Mr. G. A. Danner, operating supervisor in VCM, was pro moted to general operating supervisor for the methanol plant. Mr. K. F. Webb, assistant operating supervisor in VCM, was promoted to operating supervisor for the VCM plant. Injuries Serious Minor Operator Other Operator Other April 0 0 0 1 May 0 1 13 June 0 2 12 2nd Qtr. Total 0 3 2 b Total-To-Date 1 5 2 12 RSV0032635 VCM Plant Quarterly Manufacturing Report - 2nd Quarter 1966 OPERATING DETAILS (continued) Page 6 D. Costs Total Mfg. Cost - $ Total Mfg. Unit Cost April May June 2nd Qtr. Total Total-to-Date Actua1 Standard Actual Standard The main contributors to the above standard costs were: 1) high variances in Department 23 due to the high price of Cla, 2) high catalyst usage in Department 26, and 3) low volume in June. Chlorine price was high in April and May due to operating difficulties at the Alcoa plant. Ab normally high catalyst usage continued in Department 26. Improper feed ratios caused by incorrect analyzer analysis resulted in catalyst poisoning. Until the catalyst is turned over or changed out, high usage will continue. Low volume in June was caused by two boilouts of 22D14 (final VCM purification column) and a plant wide water supply failure. E. Quality April 1966 Quality control continued to be excellent. A new quality control record of 10056 of gross production on-spec was made. Product VCM was high in methyl acetylene and allene while the Hydration Reactor was being recharged. Total gross production from 22D14: 13,981 M lbs. Total slopped: 0 Recycle due to low 22T32 level: 1,300 M lbs.; 0.94$ gross Total on-spec production: (all met Springfield spec) 12,681 M lbs.; 99.06$ gross CBY 1112523 RSV0032636 VCM Plant Quarterly Manufacturing Report - 2nd Quarter 1966 Page 7 OPERATING DETAILS (continued) E. Quality May 1966 Quality control was good during the month. 283,000 lbs. of VCM made during the resin bed test were low on dilatometer and high on C2H2. ^3,000 lbs. of VCM were slopped due to a rotometer failure on the styrene oxide addition system and on upset of the 22D14 purification column. Total gross production from 22D14: 13,4-96 M lbs. Total slopped: 329 M lbs.; 0.245# gross To off-spec storage: 222 M lbs.; 55# slopped Reason: Slop material resulting from resin bed test. Product VCM out of resin bed had low dilatometer and high C2H2, To 22T32 feed tank: 107 M lbs.; 45# slopped. Reason: 6l - Resin bed test 26 - Styrene oxide pump failure 17 -Upset in 22D14 Recycle due to low 22T32 level: 404 M lbs.; 0.3# gross Total on-spec production: (all met Springfield specs) 12,763 M lbs.; 99.455# gross June 1966 Quality control was good after the second boil-out of 22D14. Product VCM was off-spec in EtCl for three days prior to the first boil-out of 22D14. The first VCM rundown made after the boil-out was off-spec in EDC. A second boil-out was re quired a week later probably due to not getting a good clean out the first time. CBY 1UZ52* RSV0032637 VCM Plant Quarterly Manufacturing Report - 2nd Quarter 1966 Page 8 E. Quality A CTW pressure surge from CI2 caused an upset in the 22D13-22D14 VCM purification columns. 4-7,000 lbs. of off-spec VCM was slopped during this period. The 22D14 bottoms draw-off line plugged, and product VCM went off-spec in EC1. 132,000 lbs. of VCM was slopped during period. The 22T9-1, off-spec VCM storage sphere, RV developed a leak at the flange in late May. 22T9-1 had to be pumped to 22T9-2 so 22T9-1 could be depressured for repairs. 90,000 lbs. of VCM was used to flush 22T9-2 , spec VCM storage sphere, so it could be returned to spec VCM storage. Total gross production from 22D14: 12,968 M lbs. Total slopped: 2,040 M lbs.; 15.8# gross To off-spec storage: 1,568 M lbs.; 76.8# slopped. Reason: 760 - Off spec in EtCl before 22D14 boilout. 55^ - VCM made during 22D14 boilout. 254 - Off spec in EDC after 22D14 boilout. 90 - Used to flush 22T9-2 for spec VCM storage. To 22T32 feed tank: 472 M lbs.; 23.2# slopped. Reason: 293 - 22D14 boilout 132 - Off spec in HC1 due to 22D14 bottoms drawoff plugging. 47 - Upset in 22D13-22D14 caused by CTW surge from CT2. Recycle due to low 22T32 level: 190 M lbs.; 1.47# gross Total on spec production: 10,738 M lbs., 82.73# gross. {2 T/C's, 4-50 M lbs. shipped to Carbide - HC1 1.2 ppm) jb CBy 1112525 RSV0032638