Document 4vw8x3yKO8YZppjKv6NBKYNwV

%7l ' * aft? *" ^^^*T} ?&H,, .i. ',. . t jSt*~^-/> * ,v coOTroEkriAE^^^fe . t,-'*,. *- - mm m, ~ t '<* _F*t- /., . .. . VjtrJdW.IK^ J.f.c!.t.w.*..'^...".L.^.S......wWK- "tS-~ W>** L m$mmmmzmm , V ,* -r- - s. -- JTC-S -- T -**' Anniston Plant g*" TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Anniston C. K. Eastman A. G. Hill i. C. Lahman J. C. Landwehr G. W. Miller W* B. Papageorge W. F. Taffee H. L. Williams Summary August, 1969 1* r -- *- - Cost Improvement Results Month $57,877 $66,285 87.5% General Offices YTD $361,080 $372,285 97.0% H. S. Bergen ' C. Carder Danna (5) P. B. Hodges D B. Hosmer (2) W. A. Kuhn W. R Roblrds N. L. Sample J. E. Smith J. A. Stephens R. J. Stratmeyer H. S. Trail OTHER LOCATIONS Organic Division Sandvik belt arrived late August for testing with Solid Aroclor Montars handling in September. A designed experiment was run on the Biphenyl tubular unit to better describe the process variables and their relation ship. Process Analysis /- ^ .. . Correlations (99.9%) confidence) have been found between PNCB usage and reactor pressure, temperature and caustic concentration when these variables are combined into a cal culated parameter,^. T, which is the difference between the reactor temperature and the boiling point of the reactor mass. From these correlations several combinations of variables will be defined and tested to restore standard PNCB usage for a potential $10,000 per month savings over present levels. Agricultural Division A. H. Forsten Alvin, Texas Parathion MIP was completed and reviewed with Director of Manufacturing, Crop Protection Group, on August 29. D. W. Jackson WGK C M. Patrick - So. 2nd St. Change out of No. 3 chlorinator was completed on August 16, and a 2 hour reduction in batch cycle time has been dem onstrated. Productivity gains of $3250 resulted in August. DSW 377569 AN-308 REV. 11/1/1968 company confidential information ``This document contains confidential information which is the property of Monsanto Company. Only those portions of the document relevant to 3 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." STLCOPCB4099301 Company confidential 2. Utilities Initial results of Biphenyl Cooling Tower Treatment are good and August savings are estimated to be $600. Design and Drafting A project to improve the emergency power supply for Parathion (AFE 5305 - $41.9M) was approved on 7-30-69, All long delivery items have arrived and installation should be completed by September. Pat McGinley of CED contributed to a large degree to the rapid development of this project. Pollution Control The HC1 neutralization pit was cleaned out in mid-August. Preliminary tests indicate that treatment of sewered acid has improved considerably. Quality The Plant Quality Score was 93.7, up 6.1 from July with a YTD score of 88.4 against a 1969 target of 95.0 minimum. P2S5 color Aroclor 5460 solubility, HB-40 specific gravity show unfavorable trends. . . C. Landwehr kd OS'N S'1510 STLCOPCB4099302 ORGANIC DIVISION 1969 TSD COSY IMPROVEMENT ANNUAL JAN FEB MAR APR RAY ' JUN JUL AUG SEP OCT NOV DEC 1 r ! IU1| ! ' Sol.Aro.Level TAR Ind.& -Still SpG EST ARE 4015 ACT Solid Aro. TAR Lower 5060 Soft. Point EST. ACT 2250 2250 2250 -- - 2250 2250 2250 2250 " --- " 2600 2600 2600, 2.600 2600 2600 2600 2600 2600 1500 5490 4890 215 0 467 C 8000 4230 7/'3<r 1500 5490 48 90 2150 467 C 800C 4^30 - -- Sol.Aro.-Still TAR Coolant temp. EST. AFE 4015 ACT Sol.Aro. -Chlortcr TAR Batch End EST; AFE 4015 ACT 160 - 490 -- 170 490 - 160 170 ' - - ** -" 490 390 160 490 ' 170 390 160 390 170 490 160 490 Sol.Aro. Yield TAR SW/R Composition EST. AFE 4016 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 2r 2500 2500 2500 1690 1920 1630 1490 710 1180 990 1690 1920 1680 1490 710 1180 990 Sol.Aro.-Verti- TAR cal Still Cond. EST' AFE 2424 ACT 70 80 70 80 70 70 90 90 9 0 90 " - 70 90 90 90 90 - Sol.Aro.Cl2 T/C Dock AFE 2442 TAR EST; ACT 940 0. 0 940 950 - Sol .Aro.-New Cl = TAR Unload - No Delay EST' C.ED 1841 ACT 950 940 950 900 2330 5050 2320 900 2 330 2050 940 950 940 -9.5.0.. Solid Aro.-Flake TAR & Drum ESI. CED 1440 ACT Liq.Aro. TAR 3000. 4000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 6 0 1000 2000 2000 2000 3OOC 3000 0 0 1000 2000 200C 3000 300C ' 4000 3000 - - - - - - - - - - - 48-53 M #/yr. AFE 2545 Liq.Aro."No.2 EST. ACT TAR 0 550C 0 550C - -- -- " 3000 3000 Still Entrain Sep. EST. AFE 4094 ACT Liq.Aro.-Montar TAR Disposal EST. AFE 2952 ACT Warehouse TAR Reduce Manpower EST; CEA 1452 ACT Liq.Aro.New TAR Burners $3 Still 'EST ACT 1080 1080 1080 1080 1080 1080 1030 1080 1080 1080 0 00 00 0 0 00 00 2000 4000 3000 4000 4000 4000 3000 4000 3000 3QQ0 3000 4000 2000 2000 2000 3000 3000 3000 300C 300C 2000 200C 2 00C 3000 3000 3000 3000 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 0 0 1500 3000 900 0 0 0 150C 3000 900 Biphenyl Relocate TAR No. 1 Preheat EST CEA 1892 ACT HB-40 TAR 2nd Autoclave AFE 4102 EST ACT 500 1500 15 OC 500 500 500 0 1560 1870 0 6 10 1370 500 0 0 500 0 0 500 500 l5uU 0 1500 500 500 500 500 3000 4000 3000 3000 4000 4000 3000 4000 3000 3000 4000 4000 2230 2580 0 34 9 0 2420 0 600 9000 6000 560 0 4200 600 10/40C 8600 /AoU | DSW 377571 STLCOPCB4099303 ORGANIC DIVISION 1969 TSD COST IMPROVEMENT Bi0 Improve Tower Treat. AFE 5155 Improve Pit. Power Factor ANNUAL TAR EST ACT TAR EST ACT JAN FEB MAR APR MAY 450 0 0 900 0 0 JUN__ JUL 450 u 0 450 0 900 900 500 900 500 83O AUG , SEP 450 450 534 900 900 yutr OCT 450 900 NOV 450 900 DEC 450 1 900 Central Air TAR 1000 1000 1000 1000 System EST ACT Optimize Rx Time PNP Reduce Mole Ratio NaOH/PNCB PNP TAR EST ACT TAR EST ACT 2500 2500 2500 2500 2500 2500 3500 2500 2500 12500 2500 0 3420 0 0 0 2940 1260 0 3420 0 0 , 0 2940 4000 4000 4000 4000 4000 4000 4000 14000 4000 0 00 0 01 0 00 0 New Wash Water Pump _ PNP AFE 2998 Automatic pH Control TAR EST ACT TAR EST 50 50 50 50 50 50 50 50 25 50 50 50 50 50 "50" 25 sn 50 50 50 50 500 500 500 PNP . ACT HC1 Filter Pump TAR EST ACT 5^0 33 550 550 540 55O 340 5 50 340 New Blow Tank HC1 TAR EST ACT 200 ,,2J)0 200 200 200 200 200 200 200 200 200 200 500 200 200 200" 200 150,000 Gal.-HCl Storage Tank AFE 2468 TAR EST ACT 1760 1760 1780 1760 1760 1780 1760 1760 1780 .- u - 0 2640 3290 0 2830 Produce Staley TAR Grade Acid EST AFE 5076 ACT Cla-Plt, Shutdown TAR *EST CEA 1851 Hg Recover from Residue ACT TAR EST ' ACT 250 250 5910 5910 0 0 250 6 0 250 0 0 _Z80 _L80. 790 - " 780 780 790 88 8 O' 8880 8880 8880 8880 8880 i8S80 8880 42335 19900 2230 du5c t-2355 Hg Wash Tank AFE 2802 Biphenyl Productivity Total Organic By Month M $ Total Organic YTD M $ TAR EST ACT TAR EST ACT I'AR EST ACT TAR EST ACT ' 250 ,250 250 250 o 0 0 r0 ' u 0 00 .560015600 *5600 5600 5600 5600 5600 7600 5600 5600 5600 5600 [ 3 9U0U (L5,CCi 1800 5900 13,500 0 0 0 0 0 36789; -~*27D J 0 30780 ' 25-3 "2O | 29.3 37.5 42.3 51.1 51.61 51.6* 51.6 5?. 7 73.-5 50.6' 27.1 30.2 11.5 >0. y 39.75 107.4 P3.&4 16.5' 23.8 27.3 11.4 25 .75*45.9 110.322 50.1 '7974 11679' 1597? 21S.5 25L9 At 417.8 b?X3 521.9 46.9 78.8 79.6)115.9 144.4 253.5 j 16.5 40.3 68.1 7 9.5 jl 05.2 151.1 251.3TL . _ $22,955 adjustment included for May & June ** $27,780 adjustment included for months January thru June. DSW 377572 STLCOPCB4099304 AG DIVISION 1969 TSD COST IMPROVEMENT ANNUAL Cooling Tower TAR Repiping EST AFE 2598 Optimise N2 & -ACT TAR Cl2 Levels EST ; ACT Increase Waste TAR Acid Sales ESI ACT ' Chlorinator R.I. TAR EST AFE 2244 ACT . EVOP Condensation TAR Rx. EST ACT Cls 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 HsO Item iy] EST AFE 5067 ACT Well H^O to Jets TAR EST ACT Ag. Division by Month TAR EST ACT Ag. Division TAR YTD EST ACT Ag. Division TAR untargeted-R.M. EST Charges optiraizati<1?nACT nrftflm' r \i TAR Untargeted - HC], EST Catch Tank& Coaie: eACT JAN 750 0 0 750 0 750 0 FEB MAR APR 420 0 0 MAY 420 0 0 JUN 410 0 0 JUL 410" 0 0 AUG 420 0 SEP 420 OCT 410 NOV 420 DEC 420 6600 6700 6700 6600 6700 6700 0 00 0 00 00 0 400 0 0 500 0 0 500 0 0 400 0 0 300 0 300 400 300 300 250 250 250 250 250 250 00 0 750 500 500 750 750 0 12,615 0 12,625 5000 5000 5000 2000 2000 2000 00 0 290 0 0 290 0 290 290 290 290.... 5800 5800 5800 430014300 4300 1600 1600 '1600 1600 1600 1600 5000 6600 10,0.0 457 0 2000 I5OO 10,400 923? 4570 125 120 120 125 180 180 125 155 171 125 272 272 125 333 125 125 500 125 500 125 500 750 50C 9145 9145 9135 14675 1 46r 3 146.85. 1.4575 14488 14488 J 32^5j5,12 C 6,730 10,155 4842 4033 0 1205 1,420 10,530 9459 484: > 1500 OO QC ims ?0?90 2945 44 i nr 58785 7347 C 3 8045 1025 i 117015 12,615 23,315 37,770 41,91c *5>4ST 0 12,615[17,055 27,615 57,074 41,916 1 0 17 00 0 5000 0 00 0 6250 5960 4690 9p5C 6817 DSW 377573 STLCOPCB4099305 AROCLOR Company confidential 5. E E. Bowles, C. R. Mcllwain, P. D. Kinnear (V. R. Haupt) Aroclor Safety AuditSafety TSD Objective A-1 Completed preliminary review of all Aroclor Safety Audit items, either project premises or maintenance repair orders have been issued initiating the completion of these items. Aroclor MIP TSD Objective B-1 Preliminary groundwork for the 1970 Aroclor MIP has been started. Pro duct outlook based on the new sales forecast is such that capacity will not be an important factor in this year's MIP. The major items of in terest will be operating efficiencies as related to decreasing the unit cost of Aroclors. Department commitment for date of issue of approved plan is November 15th. Evaluate QuaterphenylPolyphenyl Effects on Solid Aroclor Yields 1969 Savings $63,200 TSD Objective NFC $14,000 .... B-JSfc)- Operator training on radiation instruments was conducted during August. Waiting for radioactive source for level alarm to be installed before start-up in early September. Debottleneck Liquid Aroclor Stills Yield & Capacity TSD Objective Increase ___________ ;B - 8(i) High Aroclor inventory prevented the field test of Aroclor Tentative Amendment B during the month of August. Sandvik Belt Cooler for Solid Aroclor Expansion TSD Objective Montar 5 Solidification __________ EvaluationB - 8(1) The stainless steel cooling belt was delivered 3 weeks later than expected. Test runs will begin early in September. BIPHENYL-SANTOWAX W. G. Niemeyer, D. A. Self (V. R . Haupt) Debottleneck BiphenylSantowax Distillation Area to 87.6 M lbs/yr. Biphenvl________________ Capacity Increase TSD Objective B - 7 (a) Fabrication of spool pieces for installation of by-pass loops around Santowax C flow meters is complete. Installation of by-pass loops will be completed by 9/11/69. A capacity/performance test run will be con ducted on the Santowax distillation column after the meters are re installed and calibrated. DSW 377574 STLCOPCB4099306 Company confidential 4. BIPHENYL-SANTOWAX - (Cont'd.) Low Biphenyl Santowax for FDA 5460 _____________________ Sales Support;B - 7(b) TSD Objective During August, we produced Santowax C with approximately 0.15% biphenyl due to running at a low production rate. To make it routinely year round, increased cooling water capacity is required in the distillation area. Tank Truck Shipments of 'Molten Biphenyl Sales Support__________ TSD Job No. 824 TSD has assisted in the conversion of a large biphenyl customer, Chemical Processing of Georgia, from flaked biphenyl in bags to molten biphenyl. Two truck loads were shipped during the last week in August. Prediction and Control of Dust Explosion Potential in Biphenyl Flaker Packaging System Safety TSD Job No. 9^1 Safety review committee has accepted the recommendation to convert the biphenyl bagger from air fluidization to nitrogen fluidization to main tain an inert atmosphere in the hopper. In addition, help will be re quested from S&PP on hopper design changes. Designed Experiment Run on No. 1 Biphenyl Furnace Process Study TSD Objective B - 7(e) A designed experiment was conducted on the No. 1 biphenyl furnace from August 4 through August I3. Around-the-clock TSD coverage was provided to record temperature data and supervise sampling. Four blocks of data were collected with 12 trials in each block. The variables studies were: 1. converter outlet temperature, 2. converter pressure, 3. promoter concentration, and 4. per cent biphenyl recycled in benzene feed. The primary purpose of the test run was to determine what set of process conditions would produce the desired product split with minimum quaterphenyl production. Install Secondary High Level Alarm on Biphenyl Column Safety TSD Job No. 817 Complete design package was transmitted to Maintenance for construction on August 25, 1969. DSW 377575 STLCOPCB4099307 Company confidential 5. BIPHENYL-SANTOWAX - (Cont*d.) Install Knockout Tank on Santowax Jet Vent _____ __________ Safety _____ TSD Job No. 862 Design package will be transmitted to Maintenance by September 12, 1969. HB-40 J. W. Mattern (V. R. Haupt HB-40 Control Variable Study Process Study with TSD Objective $10 M Potential SavingsB - 12(d) Collection of base line data has been postponed due to frequent shutdown from high inventory and lack of an adequate, safe sampling port for in coming Santowax R. A plan for catalyst savings is currently being reviewed by Production. HC1 G. L. Moore, L. 0. Chambers, K. G. Hale (A. G. McCarty) Production of Staley Grade Acid - AFE ^076 New Earnings $288 M TSD Objective Potential Savings $71.000 B - 10(c) Coalescer and catch tank contributed $4700 savings during August. The coalescing element was changed during the month because of considerable deterioration. . Alternate designs are being evaluated with the vendor to increase element life. Issue HC1 MIP Planning TSD Objective _______ B - 1(b) Finished draft complete. Plant review scheduled for 9/10/69 with issuance targetted in September. Reduce High Free Cl2 in Muriatic Acid ______ Quality TSD Job No. 950 Air blowing of acid storage tank continues to alleviate high free Cl2 problem. Plant tests to determine source of free Cl2 will be scheduled later. PNP G. L. Moore, L. 0. Chambers, K. G. Hale (A. G. McCarty) Debottleneck to 1.8 M Capacity Savings $27.500 TSD Objective B - 9(a) Letdown time continued good during August. Savings of $1260 were gained during the month. Installation of a new filter pump was completed removing a bottleneck to capacity gains by further reactor cycle improvement. However, long cooling cycles have recently developed in the acidifier, and these will be investi gated in September. DSW 377576 STLCOPCB4099308 Company confidential 6. NIRAN K. G. Hale, D. W. Dudley, T. W. Lawrence, J. L. Gaines, (A. G. McCarty) Demonstrate Parathion Recovery Savings $17,400 10-15% Reduced COD TSD Objective B - 5(a) No change in status. Construction in progress on test facilities Acetone Recovery Savings $12,900 20% Reduced COD TSD Objective B - 5(i) Recovery tests on #3 condensation reactor were completed in August. Re sults have not been evaluated as yet. Initial design and drafting were complete 8/12. Review of design will be complete 9/11. Project will be submitted for approval 9/12. Project transmittal to Maintenance will be 9/19. Construction still slated for fall turn-around. Central Chlorine Unloading for Niran TSD Objective Savings $21.000 ______ _B - 6(a) Operation of new unloading facilities good except for rate. Rate has.not improved over present due to lack of sufficient air pad. Evaluation of new compressor versus rebuilt compressor underway. Evaluation will be complete by 9/15 with EDC dependent upon decision. Sulfur Recovery $271,000/Yr. Net Savings TSD Objective from Residue______407, Reduction in S0o _____________________ B - 5/d) C.E.D. is active on summarizing scope and initial estimating. Anniston TSD providing assistance as necessary. Optimize Cl2 & N2 Levels;Savings $40,000 TSD Objective B-5 Savings of $6600 were realized during August, when compared to June YTD usages. Methanol and P^j yields increased slightly over July. TSD continues to monitor yields and Cl2 & N2 level tests. No. 3 Chlorinator Long Profit New Sales: 25,000/Mo. TSD Job No. 927 Cycle Time;Productivity Savings: 5.000/Mo. TSD Objective B - 5 No. 3 chlorinator changed out 8/11 - 8/16. Operations since 8/16 indicate approximately 2.0 hours reduction in batch cycle time. Productivity savings of $3250 were obtained in August. OS'N 317577 STLCOPCB4099309 Company confidential 7. NIRAN - (Cont'd.) Profit New Sales and Productivity Improve Chlorinator Savings $48,000/Mo. per 0.5 Hour TSD Objective Cooling System _______Reduction in Chlorination Time.B - 5(g) Information on boiling refrigerant cooling indicates that heat transfer advantage will be obtained from Freon-21 over the currently used Freon-11. A recommendation for a plant trial of Freon-21 will be submitted after some additional work to optimize the present system. PROCESS AND QUALITY ANALYSIS J. L. Murphree, Allen Hale (W. B. Dunlap) Process Surveillance The first semi-annual recalculation of control chart standards has been completed. The results were as follows: 36 improvements, 11 relaxations, and 17 unchanged. This three to one improvement in product quality is consistent with past history of the Quality Control Program, PNP - Identification of Potential Savings TSD Objective C - 3 Critical Variables ;_____________________ $60.000_______ TSD Job No. 839 Correlations (99.97. confidence) have been found between PNCB usage and re actor pressure, temperature and caustic concentration when these variables are combined into a calculated parameter,^ T, which is the difference between the reactor temperature and the boiling point of the reactor mass. From these correlations several combinations of variables will be defined and tested to restore standard PNCB usage for a $10,000 per month savings over present levels. Potential Savings Automatic Still Control$79,000 TSD Job No. 964 A progress report was written outlining the Phase I approach adopted by the Task Force (Dunlap, Lawrence, Veazey). An AFE is being written. The Parathion MIP prepared by Process Engineering Group I shows a required date of 10/1/70 for a decision on distillation practice. A target of 3/1/70 is realistic for installation of Phase I instrumentation, leaving 6 months for study and modification to meet this deadline. ENGINEERING DESIGN AND SERVICES Mechanical/Electrical/Instrument Design and Drafting J. C. Price. J. A. Veazey. J. 0. House. G. W. Richey. R. V. Carlisle. R. L. Brewe J. K. Rennie. J. Childress (W. F. Taffee) The new emergency generator, for replacement in the Parathion department, has been received. Completion of design and installation is targeted for September. DSW 377578 STLCOPCB4099310 ENGINEERING DESIGN AND SERVICES - (Cont'd.) Company confidential 8. Acetone Recovery > $12.9/yr. savings and Automatic Still Control $79 M/yr. savings received major instrument-electrical attention during August. Premises were prepared and forwarded for the following projects: Dis mantle Santowax OMP Facilities, Dismantle Old Santowax Still, Install Barricades Around Aroclor Heaters. Review drawings were completed for the following projects: Reduce Acetone Stripping Pressure - Niran, Install Jet Vent, Tank Santowax (AFE 3052 - $2.5 M), Biphenyl Pilot Unit (AFE 3297 - $13 M), Debottleneck Solid Aroclor (AFE pending - $20 M). Construction drawings were completed for the following projects: Biphenyl Column Level Alarm (AFE 3^38 " $3*3 M). Drafting in progress on the following projects: Replace Niran Generators (AFE 33^5 - $41.9 M), Install Heat Exchanger in Biphenyl (AFE 3282 - $1.4 M). UTILITIES ENGINEERING J. C. Price, M. L. Marcum (W. F. Taffee) Initial results of Biphenyl Cooling Tower Treatment are good and August savings for this project are estimated to be $600. Transmittal of this project is scheduled for September. Completed final design of Steam Meters (AFE 2821 - $12.9 M) and Water Meters (AFE 2984 - $18.9 M) and forwarded for drafting. Completed review of steam plant operation and collection about 507. of data required for preparation of the Steam Plant MIP. .. " Plant Improvement G. C. Goodwin (W. F. Taffee) AFE 3226 - $9.0 M - Automatic Fail Safe Valves for Niran Raw Material Storage was forwarded for approval. AFE 3293 " $7.1 M - Upgrade Existing Fire Water System was approved. Design is scheduled for late September. Design packages were forwarded for: Aroclor Safety Shelter (AFE 3202 $1.5 M), Niran Safety Shelter (AFE 32O3 " $1.5 M), Biphenyl Safety Shelter (AFE 3204 - $1.5 M), HC1 Area Drainage (AFE 3221 - $1.9 M). POLLUTION CONTROL E. G. Wright (W. F. Taffee) Waste Audits Aroclor, HC1, Niran and PNP'Pollution Abatement F - 3 TSD Objective Report on waste audits in Aroclor and HC1 departments was completed and and issued during August. Audits in Niran and PNP departments have been completed and report will be prepared during September. DSW 377579 STLCOPCB4099311 Company confidential 9. POLLUTION CONTROL - (Cont'd.) HC1 Neutralization Pit____________ Production Assistance TSD Objective F -4 A test run is being conducted on the HC1 neutralization pit to determine its capacity and to determine how often it must be cleaned out. Pre liminary data indicates with clean and fresh rock and design retention time it will completely neutralize the present average daily loads from the Aroclor department. Waste Treatment All wastes were effectively treated during August. Solids sewering continues to create some problems. Average daily values for Monsanto effluents are as follows. . PNP COD Parathion BOP Specifications 5 ppm > 200 ppm >-1.0 ppm (Max.) >-200 ppm DSMl 3115M STLCOPCB4099312 PLANT LABORATORIES G. W. Hiller Company confidential 10. PROCESS RESEARCH AND DEVELOPMENT J. T. Bell Of the 105 PR&O mandays available in August, 67 were expended on projects listed in the 1969 PR&D Program. In addition, 8 mandays were used in the HB-40 Color Improvement project with the remaining mandays divided between vacations, illness, supervisory, and miscellaneous duties. Blend Scavenger Refinement (Aroclor) Improved Aroclor Electrical Properties J. L. Brown Active work suspended temporarily by equipment failure. The necessary changes to the refining column are set for 9/15/69,. at which time the project will be resumed. HB-40 Process Determine Process Studies;__________________________ Variables ;_______________________ W. H. Howard Contamination in the laboratory equipment has prevented hydrogenation by a continuous process. Substitution of equipment has reduced but not eliminated th6 problem. This study is approximately 25 mandays behind the schedule of the project work plan. Biphenyl Tubular Obtain Desired Pilot Studies Biphenyl/Terphenvl Ratio ____________________ J. L. Brown , Cost estimates for the proposed Biphenyl Pilot Building currently being prepared by potential contractors are due 9/2/69. Final plans will be, completed and issued for construction by 9/8/69. Muriatic Acid Organics Level Determination_______ I. Ransaw The laboratory study as defined in the project work plan has been completed. A PR&D report will be issued 9/3/69. Low Color Aroclor 5460: Develop Alternate Process;G. L. Arnett An alternate process to the sodiutn treatment of Santowax has been demonstrated. The distillation of Aroclors 5060 and 5460 over a combination of lime and NaOH is effective in reducing color. The optimum levels of the color reducing agents have been determined. . HB-40 Color Improvements;____________ Column Absorption________J. T. Bell The identification of HB-40 color bodies by infrared and gas chromatograph techniques have been unsuccessful. A study of various bed lengths has been delayed by a lack of high color starting material. DSW 377581 STLCOPCB4099313 PLANT LABORATORIES (Cont'd) Company confidential 11. PROCESS RESEARCH AND DEVELOPMENT (Cont'd) Parathion Isomer Reduction ' Increased Yields G. L. Arnett A project work plan has been issued with work to resume immediately. Parathion Condensation ' Reaction Studies ______ Increased Yields,____________________ I. Ransaw A project work plan was issued 8/15/69 to cover the initial phase of the study. Effort is being expended to determine the cause for the low assay parathion that is being produced in the laboratory. ANALYTICAL AND QUALITY CONTROL S. 0. Kemp Complaint Report Quality None YTD Quality Complaints/100 Shipments 0.23 Target 0.20 DSW 377582 STLCOPCB4099314 COMMUNITY RELATIONS. PERSONNEL. RECRUITING. AND DEVELOPMENT Personnel 1. G. W. Richey, BSEE from McNeese State, reported to vork on August 18 and assumed the position of Electrical-Instrument Engineer I. 2. J. 0. House reported for work on August 18 as Senior Design Engineer. Development 1. R. V. Carlisle, G. W. Miller, T. W. Lawrence, I. Ransaw, and J. L. Brown attended "Safety Management Seminar" conducted by Liberty Mutual Life Insurance Company at Holiday Inn, August 12-13. 2. J. C. Landwehr participated in Innovation Exchange Program August 7-8 at the Avon Plant. 3. V. R. Haupt visited Goslin Corporation August 8 at which time Aroclor 1268 flaking was demonstrated successfully. 4. All department supervisors attended the workshop sessions at which time Van der Water Associates, Inc. presented the feedback of the recent plant attitude survey. Visitors 1. Mr. C. A. Beuhler from the WGK Plant visited on August 11 and 12 to obtain information necessary to compile an "L" manual for the Anniston Plant. 2. Gene Stewart of CED visited on August 13 and 14 concerning new HC1 tank car loading track. 3. W. R. Robirds visited August 24 at which time the lastest revision of the Parathion MIP was reviewed. 4. R. S. Yates visited August 11 and 12 to discuss solid Aroclor expansion. DSW 377583 STLCOPCB4099315 ( PROCESS IMPROVEMENT DISTRIBUTION OF TIME BY TECHNICAL SERVICE Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. NSW PRODUCTS PLANT IMPROVEMENT ASS 1ST OPERATIONS SPECIAL ENGINEERING SERVICES TECHNICAL MANPOWER MISCELLANEOUS ACTIVITIES AND ABSENCES Jan. Feb. March Apr. May June July Aug. Sent. Oct_ DSW 377584 STLCOPCB4099316 ( IN MAINTENANCE FOR CONSTRUCTION IN MAINTENANCE COMPLETED NOT CLOSED i PROJECTS SUBMITTED FOR APPROVAL tPoi -3 OQ POn QCO < CCOD O H M55 APPROVED PROJECTS IN TSD ( TSD PROJECT S UMMARY DSW 377585 STLCOPCB4099317 ANALYTICAL SAMPLES LABORATORY ADMINISTRATION ANALYTICAL MANPOWER ( Manpower/sample $/Manhours 7. Total Plant Operating Cost Overtime "L STLCOPCB4099318