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t COMPANY CONFIDENTIAL to=-SV^>.& rsH^V < (!* ... ^' v f- - *i i j * * : . -v ^ XUST*-rs-r''*.'ufew _ *y"~~ -*r Z^-c^ZZZZZll Monsanto_^ -j- t _r*-^ -- - ,*#. - -* *J -V -t. w>. ,-u ' " Anniston Plant ' ( TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Anniston ; ^ A. H. Hill G. L. Jessee .. L. C. Lahman J. C. Landwehr G. W. Miller H. Schulte W. F. Taffee H. L. Williams Month Summary December 1969 Cost Improvement Results Est. Act. $57,515 Target $65,085 % of Target 88.4% General Offices YTD $591,846 $638,915 92.6% H. S. Bergen H. C. Carder / . Darrna (5) _. 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 Combined Production and TSD efforts to improve yields in the PNP Department have resulted in the best PNCB usage for any 1969 month. Agricultural Division Parathion recovery pilot test facilities were installed and checked out. Field tests are scheduled to begin January 7. OTHER LOCATIONS A. H. Forsten -- Alvin, Texas Plant Improvement Solid Incinerator Project (AFE 3094 - $20.0M) was approved. Corrosion proof channel in plant drainage to Snow's Creek (AFE 3088 - $8.7M) to protect City Water Main was completed and put in service. D. W. Jackson .. WGK v. i'. m. Patrick -. So. 2nd St. DSW 377498 AN-306 REV. 11/1/1968 "'T.. COMPANY CONFIDENTIAL INFORMATION V "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." STLCOPCB4099230 Company Confidential 2. Utilities Actual savings in 1969 for Utilities Cost Improvement will reach $10.8M ($20.2M/yearly rate). Design & Drafting The old 175 KVA Niran Emergency Generator was rebuilt and returned to Plant. Installation is scheduled to be completed in January. # Pollution Control > KemTech Labs Inc. conducted a three day Air Pollution Survey in.areas in and around the Anniston Plant. Quality Control The Plant Quality Score was 80.2, up 2,2 from November, with a YTD score of 86.6 against a 1969 target of 95.0. A Process Capability Audit was completed, revealing restrictive speci fications in 19 out of 44 finished product control tests. C. Landwehr OS\N 377499 STLCOPCB4099231 ORGANIC DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Sol.Aro.Level TAR Ind.& -Still SpG EST AFE 3015 ACT Solid Aro. TAR Lower 5060 Soft. Point EST. ACT 2250 2250 250 2250 250. 2250 2250 2250 2250 -- -- " "' - " 2600 2600 2600 2600 2600 2600 2600 .2600 2600 1500 5490 4390' 215C 467 C 800C 4230 773O 3475 1500 5490 4890 2150 467 C 800C 4;oU 773b 3475 - -- Sol.Aro.-Still Coolant temp. AFE 3015 TAR EST ACT 160 - 170 -. 160 170 . * 160 " 170 160 " 170 160 ** " S ol.Aro. -Chlortor TAR Batch End EST \ AFE 3015 ACT 390 390 390 390 390 390 390 390 390 -*- -- --" --" Sol.Aro. Yield TAR SW/R Composition EST. AFE 3016 ACT 2750 2750 2750 2750 2750 2750 2750 2750 - "-- *" " Solid Aro. Montar 5 Flake AFE 2949 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 5.00. 500 1690 1920 1630 1490 710 1180 990 220 1690 1920 1680 1490 710 1180 990 220 -- 10 710 350 10 710 Sol.Aro.-Verti- TAR cal Still Cond. EST- AFE 2324 ACT 70 80 70 80 70 70 90 90 9 0 90 - ' 70 90 90 90 90 - " Sol .Aro.Cl2 T/C Dock AFE 2342 TAR EST. ACT 940 940 950 0 -- 0 Sol.Aro.-New Cl2 TAR Unload - No Delay Irst- CED 1831 ACT 950 940 950 940 950 940 950 900 2330 2050 2320 1650 2360 164C 2180 900 2 330 P050 2320 1650 2360 1640 Solid Aro.-Flake TAR & Drum EST. CED 1430 ACT 3000 3000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 OOO 0 0 1000 2000 2000 2000 000 3000 3000 300( 3000 0 0 1000 2000 200C 3000 300c 3000 3000 3000 3000 Liq.Aro. TAR 3000 3000 48-53 M #/yr. AFE 2545 ESI. ACT 0 550C 0 550C -- -- -- Liq.Aro."No.2 TAR Still Entrain Sep. est: 3000 3000 -- AFE 3093 ACT Liq.Aro. -Montar TAR Disposal EST.' AFE 2952 ACT * 1080 1080 1080 1080 1080 1080 1080 1080 1080 1080 0 00 0 0 0 - - - 0 00 0 0 - - -- " Warehouse Reduce Manpower CEA 1452 TAR EST: ACT 2000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 2000 2000 200C 3000 3000 3OOO 3000 300C 300C 3000 3000 3000 2000 200C 2000 3000 3000 3000 3000 3OOO 3000 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 ~ 0 0 1500 3000 900 - - 0 --: Biphenyl Relocate TAR No. 1 Preheat EST CEA 1892 ACT HB-40 TAR 2nd Autoclave AFE 3102 EST ACT 500 500 500 500 500 500 500 500 500 500 500 500 1500 150C 0 1560 1870 0 6 10 187 0 0 0 00 0 150c - 0 1780 1780 __ 1780 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 2236 2580 0 3490 24 2 q 0 600 600 9000 10,40C 6000 8600 42UU /4jU 6950 5uu 1000 4b00 750 1400 4800 6000 DSW 377500 STLCOPCB4099232 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 Improve Pit. Power Factor TAR EST ACT TAR EST ACT 450 0 0 900 0 0 450 0 0 900 500 500 450 0 900 900 83O 450 584 585 900 VUif 990 450 645 645 900 900 980 450 50 50 900 950 940 450 450 | 725 700 725 900 900 955 . 950 955 Central Air TAR 1000 1000 1000 1000 System EST ACT :_ Optimize Rx Time PNP TAR EST ACT 2500 2500 2500 2500 2500 2500 2500 2500 2500 25 00 2500 0 3420 0 0 0 2940 12ur 0 0 0 4130 0 3420 0 0 0 2940 2370 0 00 Reduce Mole Ratio NaOH/PNCB PNP TAR EST ACT 4000 4000 4000 4000 4000 4000 4000 4000 4000 0 00 0U0 00 0 0 00 0 0 0 00 New Wash Water Pump PNP AFE 2998 Automatic pH Control PNP TAR EST ACT TAR EST ACT 50 50 50 50 50 50 50 50 25 50 50 50 50 50 50 50 50 50 50 25 50 50 50 50 50 50 50 50 50 500 500 500 00 0 00 HC1 Filter Pump TAR 330 330 340 EST 330 33O 340 ACT 330 330 340 New Blow Tank HC1 TAR EST ACT 200 200 200 200 200 200 200 200 200 200 500 200 200 200 200 200 200 200 150,000 Gal.-HCl Storage Tank AFE 2468 Produce Staley Grade Acid AFE 5076 ClaPlt. Shutdown CEA 1851 TAR EST ACT TAR EST ACT TAR EST ACT . 1760 1760 1780 1760 1760 1780 1760 1760 1780 U 0 2640 3290 2990 3500 3500 3500 0 2830 34 30 3125 3200 3700 780 790 790 780 780 790 --- " - 8880 8880 8880 8880 8880 8880 8880 8880 6655 +2385 L9900 V1990C 19900 L990C 19900 223C 6655 +2855 19900 1990C 19900 L9900 Hg Recover from Residue TAR EST ACT 250 250 250 250 3910 0 3910 0 00 00 Hg Wash Tank AFE 2802 Biphenyl Productivity Total Organic By Month M $ Total Organic YTD M $ TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT 250 250 250 250 00 00 00 00 15600 5600 5600 5600 5600 5600 5600 TSoo 5600 5600 5600 5600 0 9u0u 15,OCX. 1800 5900 13500 0 0 0 0 0 3578S l2700, 0 0 3078C 27001 0 00 00 0 23-3 26.3 29.3 37.5 42.3 51.1 51.6! 51.6! 51.6 .5253.5 50.6 27.1 30.2 11.5 36.3 39.^5 107.4 53^+4(49.41+ 40820ti<=,56C ^0380 16.5 23.3 27.8 11.4 25.75 45.9 110.22 258J6i51.930 40410^7340 L 23.3' 50.1179.4 116.9 159.& 2107; 1?5U .315- 365.1 |417.8 !47 1.3521.9 4679] 78.8 79.6 115.9 144.4 258.5 36&fr I412.2C458.35^09^41. 16.5! 40.3163.1 79.5 105.2 151.1 261.3a - - - -- 3 71-3 8 411'79|4 59132 -- *----------- -- * S-P--P7955 adj*ustment included for Ma^y 6: . Tiinp^ ** $27,780 adjustment included for months January thru June. DSW 377501 STLCOPCB4099233 AG DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Cooling Tower Repiping AFE 2598 Optimize N2 & Cl2 Levels TAR EST -ACT TAR EST ACT 420 420 410 410 420 420 410 420 420 0 00 00 0 O0O 0 00 00 0 . 0- O 6600 6700 67 00 6600 6700 67 00 0 00 0 00 00 00 0 0 Increase Waste Acid Sales TAR EST -act 400 300 300 400 300 300 400 300 3Q0 . . 00 0 0 00 00 0 00 0 0 00 00 Chlorinator R.I. AFE 2244 TAR EST ACT : 250 250 250 250: 250 250 - 00 00 0 0 00 00 O EVOP Condensation Rx. TAR EST ACT 750 750 500 0 0 12,615 0 0 12,615 500 750 750 0 0 2165 00 Cl2 Unloading CEA 1851 TAR EST ACT 5000 5000 5000 2000 2000 2000 0 0 1580 730 4150 3800 0 0 1580 730 4150 Recycle Wash Water AFE 2960 Parathion Recovery AFE 2655 Reduce Acetone Losses Formulations AFE 2897 TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT 290 290 290 290 290 -29.0 00 0 00 0 0 0 0 00 5800 5800 5800 00 0 00 4300:4300 4300 0; 0 1050 Oj 0 1600 1600 11600 1600 1600 1600 ! 3000 6600 10,0a 4570 2000 3950 1000 ^300 10/00 928E 4570 1205 2675 950 Change Cooling H^O Item 737 AFE 5067 Well H^O to Jets TAR EST ACT TAR EST ACT 125 125 125 125 125 125 125 125 125 120 130 155 272 333 310 218 240 220 120 180 171 272 333 310 220 300 500 500 500 O OO 00 Ag. Division by Month TAR EST 750 750 500 9145 9145 12/15 3,12C 6,730 91^5 10,155 1A 75 4842 14685 4033 14685 Iplt 14575 8872 1 LLR 5 14485 4920 7235 ACT 0 0 12/15 + ,433 10/30 9459 484: >6488 L3435 8825 5535 Ag. Division TAR YTD EST ACT Ag. Division TAR untargeted-R.M. EST Charges optimizati< ,rACT 750 1500 P000 12,615 111 45 15,735 P0P90 23,315 P9WS 441 on 37/70 41,916 53785 43,949 73470 3 8 045 10253: 63114 59/12 74584 117015 32434 0 0 12,615 17,035 27/15 57.07441,936 48,4% SQ839 59,664 75199 0 1700 3690 287C 1700 3690 287C 530 530 Organic Div. TAR Untargeted - HC1 EST Catch Tank& Coalec eCT 0 00 0 5000 6250 596C 4690 1330C 700C 6500 2000 0 9J5C 6817 4920 L5355 6500 7080 Ag Div.-Untargeted TAR jy'J ^12 Change out EST ACT 4180 4055 zoe;vn 4180 4055 555 Organic Division TAR uncargetea -optimise EST Reactor Variabies-I]NP ACT DSW 377502 2740 STLCOPCB4099234 Company Confidential 3. AROCLOR C. R. MeI1wain, E. E. Bowles, (V. R. Haupt) Evaluate QuaterphenylPolyphenyl Effects on Solid Aroclor Yields 1969 Savings - $63,200 NFC - $14,000 TSD Objective B-8(a)_________ The #9 chlorinator - #4 still system will be used primarily for Aroclor 1268 in 1970. Data on specific gravity of 1168 and 1268 will be obtained on the next production run to calibrate the nuclear specific gravity quality instrumentation to these materials. This type of instrumentation has been incorporated in the Solid Aroclor expansion project CEA 2080 and will be calibrated during the start-up. Porocel Columns CEP 2132'Technical AssistanceTSD Job No. 930 This CED project will be closed during the month of January 1970. Several small items will be completed by plant forces. Production is still experiencing problems with the power factor instrument. Tests thus far have not found the source. Further testing is continuing. BIPHENYL-SANTOWAX W. G. Niemeyer, D. A. Self, (V. R. Haupt) Biphenyl-Santowax MIPPlanningTSD Objective B-7(a) The Manufacturing Improvement Plan for Biphenyl-Santowax is 50% complete. MIP will be completed in January 1970. Eliminate Safety Hazards at No. 1 Benzene Feed TankSafety TSD Job No. 976 AFE No. 3373 was issued on December 3, 1969, to eliminate the safety hazards at No. 1 Benzene Feed Tank. Customer Assistance to Constellation Finishes, Dalton, GeorgiaSales SupportTSD Job No. 904 Provided cost information on conversion from flaked biphenyl to molten bulk biphenyl storage. TSD supplied this service to meet competition from Geneva Chemicals. DSW 377503 STLCOPCB4099235 Company Confidential 4. BIPHENYL-SANTOWAX - continued Santowax R - Solid Aroclor . Yield Test RunYield SavingsTSD Job No, 984 A test run was planned to determine how high and low quaterphenyl content of Santowax R affects Solid Aroclor yield. At least 10 Solid Aroclor still batches will be run on both high and low quaterphenyl Santowax R raw material. The Solid Aroclor still yield will be measured directly by stick ing the still receiver. This type of test run will require cooperation of both Aroclor and Santowax production personnel. TSD will monitor the test and collect test data. . HCl L. 0. Chambers, K. G. Hale, (A. G. McCarty) Production of Staley Grade New Earnings - $288M Acid - AFE 3076;;Potential Savings $71,000 TSD Objective B-10(c) Carbon treatment studies were delayed until an adequate analytical procedure can be developed. Attempts at using a Jacksonville University instrument (Beckman DBG) failed. The instrument had poor resolution and would not separate the contaminants absorbed at different wave lengths. Initial results of a Perkin Elmer - Model 124 Scanning UV instrument demon strated in the plant looks good. The PR&D group will continue evaluation for purchase of the instrument (estimated cost $3-4M). . HCl MIP TSD Objective ________________________Planning_____________________________ B-l (b) All review comments returned. Final plan will be issued in January 1970. Muriatic Acid Reduced High ChlorineQualityTSD Job No. 950 Rotameter has been delivered to permit maintenance to complete installation to air blow #7 storage tank to reduce free chlorine. This is an interim measure until process data can be collected to identify cause of intermittent high chlorine. PNP L, O. Chambers, K. G. Hale, (A. G. McCarty) PNP Dust Flammability Safety (S&PP Audit) TSD Job No. 814 Final report has been written and is now being circulated in plant for comments prior to typing. 3TT5a os'M STLCOPCB4099236 Company Confidential 5. PNP - continued PNP=Sulfuric Acid Unloading Pump Safety (S&PP Audit) TSD Job No. 979 Project premise for pump unloading was not approved by Production because of potential problems with pump as compared to present trouble - free air unloading. Alternate means of minimizing safety hazards (flange guards) will be initiated by Production. TSD report is out for comments, and will be issued by mid-January. PNP - Debottleneck Capacity______________________ ;TSD Job No. 482 The actual present capacity is being evaluated iii the different process steps. Alternates for expanding to 2.0M and 2.4M #PNP/month are being developed. Summary of alternates, expected capital required, and present capacities is targeted by mid-January. NIRAN D. W. Dudley, T. W. Lawrence, (A. G. McCarty) Demonstrate Parathion . Recovery__________________________________ TSD Objective B-5(a) Parathion recovery test facilities completely installed. Initial tests will begin in early January and are expected to last approximately two months. Acetone Savings $25,200 TSD Objective Recovery20% Reduced CODB-5 (i)_______________________________________ __ Acetone recovery project is operating near design conditions. No pump out. problems have occurred through 677 batches. Acetone yield for December was 6.18 lb./cwt compared to a 7,25 lb./cwt standard. After a piping modi fication in early December, acetone usage fell to 5.88 lb./cwt, close to the target of 5.18 lb./cwt. Optimization of ejector performance and repair ing vacuum leaks allow 100 mm Hg abs. will further improve acetone usage toward the targeted 5.18 lb./cwt. Improve Chlorinator Cooling System______ Potential savings $50,000 per 0.5 hour reduction in chlorination time TSD Objective B-5(g) A Tentative Process Amendment has been approved in th e plant and is await ing Division approval. A project premise, based on the use of Freon 21 in place of Freon 11, and an experimental expense AFE have been approved. Mechan ical design is in progress for temporary cylinder racks and piping. A spare vacuum pump, for use during the test, is available in the plant. Field tests are targeted to begin in late February and to last through May. DSW 377505 STLCOPCB4099237 Company Confidential 6. NIRAN - continued Chlorinator Off-Gas System Modification ______________ SafetyTSD Job No. 980 Investigation is continuing on means to completely el iminate violent de compositions and subsequent damage to equipment in the chlorinator off gas systems. Evaluation of an entrainment separator to preclude unstable material from catch-pots and piping showed this concept to be of question able value. Efforts are now being directed toward preventing the mixing of steam and water from the jets and direct contact after-condensers with the unstable material accumulated in the catch pots. Alternates have been developed and will be discussed with Manufacturing in January. Replace Nitrogen with Potential Savings HCl for Chlorination Sparge $20,000TSD Job No. 603 A Tentative Process Amendment has been prepared and is circulating for approval in the plant. Plans are to test the concept in the early part of the upcoming methyl run. PROCESS AND QUALITY ANALYSIS J. L. Murphree, (W. B. Dunlap) Process Surveillance The first Process Capability Report was completed, revealing restrictive specifications in 19 out of 44 quality specifications. A process correlation study was begun in Aroclors to determine critical operating variables. PNP - Identification of Potential Savings Critical Variables'$60,000TSD Job No. 839 TSD Objective C-3 Experimental operation of the PNP reactor was carried out through December at one optimization setting indicated by process analysis study of summer 1969. PNCB usage, calculated from batch weights, dropped from 117.6 to 115.3. A cost improvement target of $46,000 has been set for this job in 1970. Niran Still Control______ Potential Savings $79,000TSD Job No. 964 Installation of control instruments is underway. Target dates have been advanced for installation (1/15/70) and completion of the still control study (8/1/70). A review of the study was held with Production personnel. ENGINEERING DESIGN AND SERVICES Mechanical/Electrical/Instrument Design & Drafting J. C. Price, G. W. Richey, R. V. Carlisle, J. K. Rennie, (W. F.. Taffee) J. A. Veazey B. D. Morgan R. L. Brewer The rebuilding of the existing 175 KW Niran Generator was completed and the unit was returned on 12/22/69. Installation is about 50% complete with DSW 377506 STLCOPCB4099238 ENGINEERING DESIGN AND SERVICES - continued Company Confidential 7. Start-up scheduled for spring turnaround. Three projects covering the purchase and installation of additional Emergency Radios (AFE's 3389, 3390, 3391 - $0.8M each) were forwarded and approvedso as to extend emergency radio coverage to P2S5' Biphenyl and Shipping. Two projects were scoped and estimated. Replace Sight Glasses (AFE 3362 $2.5M), OMP Dismantling (AFE 3359 - $27M). Significant department effort was expended in compilation and review of material necessary for inclusion in the Anniston "L" Manual. Specific areas reviewed included: Electrical, Material Handling, Piping and Protective Linings. All long delivery items are on order and installations are tentatively scheduled for spring turnaround (Niran) on the following projects: Modify Agitator Interlocks (AFE 3118 - $9.7M), Automatic Alcohol Feed to Thio Acid Reactors (AFE 3161 - $3.9M). Drafting In progress: Eliminate Safety Hazards #1 Benzene Tank (AFE 3373 - $9.0M), Update Plant Single-Line Diagram. Review drawings were completed for the following projects: Formulation Revision - Niran (AFE 2754 - $22.8M). Construction drawings were completed for the following projects: Niran Soda Ash Deluge System (AFE 3149 - $1.4M), Aroclor - Eliminate Head-Knocker (AFE 3364 - $1.1M), Niran Agitator Interlocks (AFE 3118 - $9.7M), Niran Automatic Still Control Test (AFE 3347 - $2.2M). UTILITIES ENGINEERING J. C. Price, (W. F. Taffee) Completed first draft of progress report on Utilities Cost Improvement Results for 1969 and Plans for 1970. This report was discussed with W. E. Chandler and is being revised and will be published in January. Utilities Cost Improvement Actual Savings for 1969 will reach $10,8M ($20.2M/year). Furnished CED with operating data for Aroclor PNP cooling tower -for use in design of HB-40 Expansion. 0S\N 1501 STLCOPCB4099239 .Company Confidential 6 PLANT IMPROVEMENT G. C. Goodwin, (W. F. Taffee) A project to Install Solids Incinerator at Plaint Dump (AFE 3094 - $20M) was approved during December. Transmittal of design package is scheduled for mid-February with equipment delivery expected in February. Construction of Corrosion-Proof Channel to Protect City Water Main (AFE 3088 - $8.7M) was completed and put into service during December. Design packages for Renovating Niran Control Room (AFE 3369 - $19.5M) and Automatic Fail-Safe Valves on Storage Tanks - Niran (AFE 3326 - $9.0M) were deferred by the Agricultural Division due to limited capital money. The final design package for Grating Over Niran Process Trench (AFE 3367 $3.1M) was transmitted during the month. POLLUTION CONTROL E. G. Wright, (W. F. Taffee) Air and H20 Pollution Community and Governmental ComplaintsRelationsTSD Objective B-2 No H20 pollution complaints were received during December. Four (4) air pollution complaints were received during the month. Eimco Filter Unit TSD Objective F-4 at Waste TreatmentProduction AssistanceTSD Job No. 808 The Eimco representative visited the plant during December to aid in resolving the problem of cloth "blinding." As a result of his recommendation, the feed slurry was "thickened" and the unit's performance improved a significant amount. Addition of the Betz polyelectrolyte also increased the unit's effi ciency. During January, further tests are scheduled in order to optimize the process. It is tentatively scheduled to release the unit to Production by February 1. Air Sampling SlurryPollution AbatementTSD Objective C-2 On December 15, 16, 17 a representative from Kem-Tech Laboratories conducted an air survey around the plant perimeter using their mobile laboratory. We should be in receipt of their report during early January. HC1 Neutralization Pit.Pollution AbatementTSD Objective F-4 Since repairs of the Niran HgPO^ pit have still not been completed, it remains impossible to determine if the HCl pit has "broken through" due to the excess H.3PO4 present. As soon as- repairs to the Niran pit are completed a test will ^be run to determine the present effectiveness of the HCl pit. DSW 377508 STLCOPCB4099240 POLLUTION CONTROL - continued Company Confidential 9. Waste Treatment All wastes were effectively treated during December. Average daily values for Monsanto's effluent are as follows: Specifications 5 ppm 200 ppm 1.0 ppm 200 ppm DSW 377509 STLCOPCB4099241 ( Vs* PLANT LABORATORIES G. W. Miller Company Confidential 10. PROCESS RESEARCH AND DEVELOPMENT J. T. Bell Of the 110 mandays available to PR&D in December, 67 mandays were expended on projects included in the 1969 PR&D Program. Vacation, supervision, . miscellaneous, and special projects (Aroclor 5460 Acetone Insolubles, preparation of special Aroclor samples) account for the remaining time. Blend Scavenger Refinement (Aroclor) Improved Aroclor Electrical Properties J. L. Brown Upon receipt of a special order of Type 4A Molecular Sieve, a work plan will be issued outlining a final study for evaluation of this material as an absorbant for refining electrical properties of Aroclor 1242-Phenyl Glycidyl Ether blends. HB-40 Process Studies Determine Process Variables W. H. Howard The study to develop a continuous HB-40 process has been terminated. The inability to overcome equipment difficulties prevented reaching the original project objectives. A report has been prepared for issuance. Biphenyl Tubular Pilot Studies Obtain Desired Biphenyl/Terphenyl Ratio J. L. Brown The PR&D Polyphenyl Laboratory is now 98% complete. Installation of the control panels and process line will start 1/2/70 with a tentative installation EDO of 4/1/70. Low Color Aroclor 5460 Develop Alternate Process G. L. Arnett Laboratory work and corrosion studies have been completed. Support will be given for a plant demonstration. Parathion Condensation Reaction Studies Increased Yields I. Ransaw The evaluation of different catalysts in the condensation reaction has been delayed by difficulties in obtaining the necessary chemicals. The study of solvent effects has been initiated and as a result the overall program is essentially on schedule as indicated by the work plan. OS'N 151 STLCOPCB4099242 PLANT LABORATORIES (Cont'd) / PROCESS RESEARCH AND DEVELOPMENT (Cont'd) Company Confidential 11. Aroclor 5460 Acetone Insolubles __________ Quality ;G. L. Arnett The investigation to determine the process controls necessary to prevent the formation of over-chlorinated terphenyls is approximately 907. complete. Additionally, Aroclors 5420, 5425, and 5430 have been prepared in the laboratory for Organic Research. Muriatic Acid ________ ___________ Quality I. Ransaw_____________________________ The development of a quantitative method for the analysis of trace organics in Muriatic Acid is concentrated on two techniques: scanning UV and gas chromatography, A UV instrument is to be made available by the vendor by January 19 with a critical evaluation scheduled for completion by that date. The completion of the evaluation of the chromatographic method is tentatively set for March 13, based on an assumption of the return of that instrument from the factory in operating condition by February 15. ANALYTICAL AND QUALITY CONTROL S. 0. Kemp Complaint Report Quality Number Material Customer Reason 17-A-69 18-A-69 19-A-69 Aroclor 5460 Aroclor 5460 Aroclor 5460 Canada Colors to Swift & Co. Plasti-Kote Thomas Chemicals Dark Yellow Development of a gel in their formulatibn. Whitish Yellow Powder YTD Quality Complaints/100 Shipments 0.275 Target 0.20 OSIN 377511 STLCOPCB4099243 Company Confidential 12. COMMUNITY RELATIONS, PERSONNEL, RECRUITING, AND DEVELOPMENT Community Relations 1. J. C. Landwehr, A. G. Hill and J. C. Price attended the annual meeting of the Coosa-Alabama River Improvement Association, December 17. 2. E. G. Wright attended AIA Air and Water Resources committee meeting in Birmingham, December 11. 3. W. F. Taffee attended AIA Education committee meeting in Birmingham. 4. W.-'F. Taffee attended hearing on establishment of Birmingham Air Quality Control Region, December 17. Personnel 1. David Dixon, Chemical Engineering Co-Op from Georgia Tech, will start his first quarter of work on January 5 and will report to W. B. Dunlap. 2. George Jeffrey, Chemical Engineering Co-Op from Georgia Tech, will start his first quarter of work on January 5 and will report to J. C. Price. 3. Elton Allen, Drafting Co-Op from Alabama A&M, will start his first quarter of work on January 26 and will report to R. L. Brewer. Development 1. R. L. Brewer and G. C. Goodwin completed a short course on "Reinforced Concrete Design" taught by J. C. Price. Others completing the course from outside the department were J. 0. House and M. D.- Blair. 2. G. L. Arnett, G. C. Goodwin, W. H. Howard, B. D. Morgan, and G. W. Richey attended Safety Seminar at Holiday Inn, December 9-10 sponsored by Liberty Mutual. 3. J. T. Bell and J. L. Brown visited St. Louis December 11-12 to discuss plans for the Polyphenyl pilot test program. 4. TSD and Lab personnel attended TSD Safety Seminar on Design Safety, Decem ber 16, 1969 held at Alabama Power Company auditorium. 5. Lamar Murphree completed another Olivetti Underwood computer training course in December. TSD graduates were D. A. Self and J. A. Veazey. Visitors 1. R. S. Yates visited concerning HB-40 Process, December 9-11. DSW 377512 2. D. B. Hosmer visited December 11-12 to review Organic Division product MIPs and TSD-Lab programs for 1970. 3. W. E. Chandler visited the plant December 4-5 to discuss the 1970 Plant Improvement and Utilities budgets and the 1970 Utilities Cost Improvement Program. 4. V. W. Lepard, Kem-Tech Laboratories - Baton Rouge, La., visited E. G. Wright December 16. STLCOPCB4099244 DISTRIBUTION OF. TIMS BY TECHNICAL SERVICE Jan." Feb.'Mar. Apr. May June-July Aug. Sept, Oct. Nov. Dec. STLCOPCB4099245 ^iaaj^aaae-m Company Confidentia1 TSD PROJECT SUMMARY DSW 377514 STLCOPCB4099246 ANALYTICAL SAMPLES LABORATORY administration ANALYTICAL MANPOWER Manpower/sample $/Manhours 11.00 10.00 9.00 8.00 7.00 7o Total Plant Operating Cost Overtime % 2.0 1.5 1.0 0.5 j-------- -------- ]-------- 1 *----! L ^ L - i ... -........ 1 1 praaa. l_ i -- ` - (-- ' 1 1 1 a* 1 --n-- rr^ 1 !/ 1 N\l t- -- * fc .. .--i. ... : DSW 377515 1967 11 1 1 i 1968 J 1 VH f/\ i V\ . r*- 1 1 I\\ 1 1 1 1_ . ^1 l 11 u* 111 M A fi J JA 1_____ L,. s ~"o----sszzr-* u STLCOPCB4099247