Document 5Lx3m3R2R2prM5rJJaJKaZ1qR

064X9 GRACE TO: R. J. Bettacchi FROM: A. N. Crawford cc: J. E. Danel/C?D Enoree W. J. MeCaig/CPD Libby J. C. Tang DATE: September 26.," 1963 SUBJECT: September, 1983 Monthly Report MONTHLY HIGHLIGHTS The Wilder plane continues to produce Monokote from SBO treated 1-3 concentrate with no manufacturing probleae. The average furnace yield Improvement for the flrat twelve carloade is 3.2*. e Auguee YTD aales to Gypsum customers are $1,215,144 which Is 18.52 over budget and 28.91 over prior year. The strong recovery we saw in the first half Is expected to slow down, but should still finish the year well over budget. Air samples taken during the Firemate teat at Mlnnkota Power Company Indicates there were negligible amounts of tremolite fiber In the air. The combination of surface creating the L-4 concentrate and Dearborn's enclosed handling equipment are responsible for the low fiber levels. The highest TWA measured was 0.03 f/ce in an area where there was a large vermiculite spill. I. YEBMTCULITE CONCENTRATE (VCX) A. Dearborn Chemical's Firemate Process 1. Mitmkota Power Co. completed a three week evaluation of Firemate using high fouling coal containing 92 sodlrna. They are now planning a three week test of Perlite using DUSCO's Injection equipment and burning normal grade coal containing only 4.52 sodium. DUSCO will then have another chance to run Firemate under the same operating conditions and sodlta content to ceaipare directly to Perlite. DUSCO eat lutes that Minnkote will run several more full scale teats before making a decision of which materials to use. 2. The fiber levels measured during the Mlnnkoca Test were extremely low (highest recorded was 0.03 f/ee HA). Even though we ran one control T/L without SBO treatment, we could not show any correlation between treated and untreacsd since most areas measured were xero or extremely low and beyond the accuracy of the test methods. VJR0007990 0641935 3. DCSCO is discussing another possible trial with the Allegheny Power System in Willow Island, West Virginia. This is a 17S MW unit with a tube fouling problem, which would consume 500,000 lbs./yr. (250 TTY) of vemitulite. DCSCO has requested Enoree concentrate due to landed cost difference with Virginia Versicuiite Co. We have agreed to supply test quantities from Enoree. B. Tremolite Binder Project 1. Wilder continues to run SB0 treated L-3 with no apparent problems. The mine assay yields are avcreging 3.22 over untreated, and Wilder is reaching the higher assay yields. Table I shows the data on the first 12 cars. The yield improvement ranges from (1.82) to +7.22. The "flake yield" is the assay yield divided by the concentrate grade, which is Che calculated yield on a 1002 vermicullte basis. The wide fluctuation in yield is suspected to be due to sampling techniques at the mine. Once the oil treatment becomes a standard procedure, it will be easier to establish sampling procedures to get more accurate data. 2. We have targeted Dallas as our next plant to continue scale-up evaluation of SBO L-3. The first C/L should arrive the week of October 10, 1983. Monokote will be made and compared to control material in the field. Uc will also produce Terra Lice #3 and send to Travelers Rest for growth tests. 3. A split C/L of SBO treeced L-4 was made with a control split from the same conveyor and sent to New Orleans. This will be used to cheek roof deck performance via C-45A tests. ZCA will be produced the week of October 10, 1983 from this test material. C. Semi-Bulk Packaging We are continuing to experiment with the return of cote sacks to Enoree. The bags returned from USC's Sweetwater, Texas plant are on their 3rd trip end have little attrition. USG's Canadian plant has returned bags and nearly half are not suitable for reshlpmenc. We will collect all cost information relative to return of tote sacks and use this to determine if we should accept this as standard policy. D. Account Status 1. O. S. Gypsum Co. - DSC purchasing is working to justify a plant evaluation of our SBO treated L-3 based on the freight savings to western plants ($115,000) and the lower FOB price ($137,000).. WR0007991 0<SI 95<s -3- USC management is reluctant to purchase front Libby due to the traBolite issue. We hope the new surface treatment and the potential 5272,000 savings will convince t'SG tc run a full scale test. II. KZV PRODUCT DEVELOPMSTT A. Vermiculite Emulsions The patent investigation of the ICZ patent turned up a prior patent expiring on June 13, 1984 which enables Grace to sell vermiculite emulsions using the ICI process without infringement after this date. Several companies have been approached by ICI offering to sell the technology to produce a vermiculite emulsion. We have received Inquiries from some of these companies such as: Owens Coming, J. P. Stevens and Armstrong World Industries. Also three paper companies are interested in this technology for paper eoaclngs. We are working with these potential customers to develop a vermiculite emulsion for their specific textile and paper applications. B. Vermiculite Foam ICI holds a strong patent position on ehe production of vermiculite foam. The foams we have made in the lab using their patented method have severe shrinkage problems. Unless these shrinkage problems can be resolved, this foam will be of limited coamercial value. K&C is working on several ideas to solve the foam shrinkage problem. A totally inorganic vermiculite foam would have great market potential as a fire retardant insulation. C. Athletic Surfaces Ue have a video recording of local tennis professionals playing on the experimental ZIC Tennis Court. It was raining most of the day and quite cool, therefore, the cooler playing characteristics were not apparent. Consents from the pro's indicate it is a good medium speed surface, with excellent boimce. Before continuing with this idea, we will wait until Spring of 1984 to determine the product's resistance to winter freeze/thaw conditions. A preliminary market survey will also be complete by the first quarter of 1984. / VJR0007992 0641957 -4- III. INDUSTRIAL VTRMICULITT (Z0S0LITS) A. Texture Coatings Verlite Corp., Tampa, Florida is now supplying U. S. Cy?Su= with African expanded vermieulite for acoustical plaster and texture compounds. This business was formerly supplied by Stronglite Products Co. Zonolite has been tesced and rejected due to darker color. USC reports that they are now switching several formulae to polystyrene beads due to lower cost of PS beads vs. veraiculice and Perlite. B. Plastics Filler Occidental Petroleum Corp. has found both Zonolite #4 as well as ground vermieulite to be an effective filler for Phenolic resins. The vermieulite also Improves the heat resistance of the Phenolic. Tests are still underway. Potential sales volume is not known. ANC:mg WR0007993 064i?38 H $ 5 s: 8 8 8 R 2 z g 5 8 w tf) * 5 55sssassss?? * '"R^SdcfiRS a i* C I S S 5 8 8 8 8 IS s a i . 5? h d M s tT n Q tfl in Ifl II *S Urf ? *i s jnsj*ujsspi *x 8 S88s8889l83i8 8 5S382B8S8S3!! 8 01 f00lfltfnA0 000 | 0 tfl 8S8fB82ggR8S i 8 m 3? 8 8 88 8 8 8 8 8 8 ! 2 * SI s? :iSS3J55533j !! 9 i 3 S88SS8888& ` & il3 is 8= 80k# *2^*3082A2iA2(A808208#f !SI ': i S? 2 *8888228888(! ^ s 1C 8588833888 1 -i WR0007994