Document 6R3Z1947669OrmO9Gk0poBGpR

WILLIAM G. KRUMMRICH PLANT TABLE OF CONTENTS Plant Overview........................... Plant History .............................. Products .................................... Safety........................................... Industrial Hygiene .................... Environmental Control .............. Community Responsibility .... About Monsanto......................... 1 2 4 5 6 8 10 12 DSW 136393 STLCOPCB4036356 WGK PLANT OVERVIEW T __he William G. Krummrich Plant, a part of the Specialty Chemi cals Division of Monsanto Chemical Company, is located on approxi mately 311 acres in Sauget, Illinois. Krummrich produces 25 diversified intermediate chemical products used by other Monsanto locations and other industries. The plant ships approximately 55 million pounds of chemicals per month to almost every state in the U.S., as well as Western Europe, the Middle East, Africa, Latin America, Asia, Mexico and Canada. End uses for WGK products include applica tions in tires, detergents, dyes, cosmetics, herbicides, swimming pool disinfectants, and a variety of other products. WGK is committed to producing high quality chemical products, while maintaining a safe workplace for employees and a clean environ ment for the community. To do this, the Krummrich plant has instituted a Total Quality effort, maintains an energetic safety and industrial hygiene program, and has instituted a number of safeguards including a community alert system to warn the surrounding community in the event of a chemical emission. The plant is also active in commu nity affairs, supporting a number of charitable and civic activities as well as professional organizations. WGK is on the leading edge of tech nology, and has instituted PRoVOX control computer systems, a com puter-aided design and drafting department, an energy-efficient powerhouse, and a modem laboratory. To support the manufacturing func tion, the plant organization includes Maintenance, Technical Services, Environmental, Accounting, Pur chasing and MIS, and Personnel. Hourly workers at Monsanto are represented by Local 12 of the Inter national Chemical Workers Union (I.C.W.U.) and the Guards are rep resented by Local 19 of the American Federation of Peace Officers, Guards Enforcement and Security Personnel (A.F.P.O.) The average Krummrich employee is 38 years old and has 12 years of service with Monsanto. Minority representation is 25% of the work force, and 13% are women. For more information on the Krummrich plant, you may con tact the plant's Communications Department. STLCOPCB4036357 WGK PLANT HISTORY The William G. Krummrich Plant is the second oldest in the Monsanto family. It had its begin ning in 1907 when the Commercial Acid Company acquired land on the East side of the Mississippi River and constructed facilities to manu facture sulfuric, muriatic, and nitric acids. A major customer of Com mercial Acid was the Monsanto Chemical Works directly across the Mississippi in St. Louis. With an eye toward future expansion and to protect its supply of heavy acids, Monsanto purchased Commercial Acid in November, 1917, gaining 70 new employees, 20 acres of land and a product line which included the acids, as welLas zinc chloride, phenol, salt cake and nitric cake. The plant became known as Plant "B," and in 1925 added caustic soda and chlorine to its inventory of prod ucts. The following year, facilities were added for the production of chlorobenzols, paranitroaniline, and catalysts for contact sulfuric acid plants. The plant expanded rapidly during the 1930's, adding nitrated organic chemicals, chlorophenols, benzyl chloride, aroclors, hydrogenated products, phosphorus halides and phosphoric acid to its product line. This expansion was halted during World War II, when emphasis was placed on maximizing production of existing products to support the war effort. After the war, Plant "B" began producing a line of weed and brush killers and detergent ingredients. The 50's brought more new products and facilities. In February 1951, the employees petitioned the Monsanto Executive Committee to change the name of the plant in honor of a former Plant Manager, William G. Krummrich, who became a - Monsanto Vice President before his death that year. Expansion continued in the 1960's, with new units for the production of chlorobenzenes and other products, a nitration facility, a modernized phenol production plant, and expan sion of aroclor production units. In 1964, the Village of Monsanto was changed to the Village of Sauget in honor of Leo Sauget, the mayor of the village for four decades. A qual ity-control and process-research laboratory was added in 1966. In the seventies, WGK continued both its production of heavy acids and its diversification into new prod ucts. October 1, 1970 brought the final shutdown of the phenol depart ment, a product made at WGK since 1916. Santosite facilities also were renovated. In the eighties, the number of products produced by the plant was pared down to adjust to a changing economy. In October, 1986, the shutdown of four units was announced -- chloralkali. PNA, para-phenetidine and nitrated ben zenes. Also late in 1985, WGK announced a commitment to the Total Quality concept, to improve the quality of goods and services produced at WGK. In 1986. Krummrich replaced its hydro genations department which is part of rubber chemicals operations. William G. Krummricli 2 DSW STLCOPCB4036358 STLCOPCB4036359 PRODUCTS Product End Use Chlorosulfonic Acid ......................... 4-Nitrodiphenylamine (4-NDPA) . . . Orthonitroaniline (ONA).................. Orthonitrophenol (ONP) .................. Santoflexes......................................... Sulfuric Acid .................................... ACL.................................................... Monochlorobenzene (MCB)............. Muriatic Acid (HCL) ...................... Orthodichlorobenzene (ODCB) . . . . Orthonitrochlorobenzene (ONCB) . . Paradichlorobenzene (PDCB) ......... Paranitrochlorobenzene (PNCB) . . . Phosphorus Oxychloride (P0CL3) . . Phosphorus Pentasulfide (P2S5) . . . Phosphorus Trichloride (PCL3) . . . . Nylon, shampoos, tooth cappings Rubber chemical intermediates Dyes, photographic agents Furadan pesticide Tires, rubber products - . Refrigerants, paints, metals, fertilizers Scouring powders, swimming pool disinfectants, bleaches Lasso herbicide Starch, glucose, gelatin, paper, leather, steel Degreasers, dry cleaning, polishes, oil additives Resins, pesticides, paints, plastics, dyes . Deodorizers, mildew/moth control, pesticides Animal feed additives, pain relievers Medicines, dyes Oil additives, pesticides Medicines, defoliants osw 6391 4 STLCOPCB4036360 SAFETY s, afety is a major commit ment at the Knimmrich Plant. In addition to a basic safety orienta tion, each employee is given "hands-on" training in protective equipment and devices and contin ing encouragement to institute and maintain safe work practices. Thiaccomplished through the following safety programs: Safety Training A supervisory training course gives supervisory personnel tools and information for accident prevention and promotes a general awareness of the need for safety. Fire and res cue training is offered quarterly: fire extinguisher and Scott Air Pak train ing is given to all employees; plant emergency procedures are reviewed regularly; OSHA requirements are followed for forklift driver certifica tion and a continuing program trains Emergency Medical Tech nicians (EMT's). Zone Safety Committees Each of the plant zones and service groups has a safety committee com posed of both hourly and salaried participants responsible for estab lishing safety promotion programs, coordinating topics for monthly de partmental safety meetings and con ducting monthly hazard inspections. Hourly Safety Committee This committee works on special assignments such as the ladder tag ging program and participates in monthly safety committee meeting-, and quarterly plant manager's stall safety meetings. Thev also conduct walking tours with individual super intendents on a monthly basis and conduct safetv inspections. Job Safety Analysis Supervisory personnel have been given training in Job Safety Analysis (J8A) to aid in analyzing possible safety hazards and developing means to lessen these hazards. Similar training is offered to hourly personnel. Safety Inspections Each month, a tour composed of the plant manager, a general superin tendent, a member of maintenance supervision, a member of production supervision and an hourly person inspect plant departments seeking positive and negative safety prac tices and checking compliance with plant procedures. Safety Promotions Safety promotion programs offer incentives for employees to improve the safety of their own work, their department and the plant. Safety Log Books Log books are kept in each control room. If an employee encounters an unsafe condition, it is entered into the log book. This condition must then be addressed and the supervi sor enters the response in the log. DSW 136398 _. o | , STLCOPCB4036361 INDUSTRIAL HYGIENE T __he Krummrich Plant has had a health surveillance and pres ervation program in effect since the 1940's. In 1976, a separate Indus trial Hygiene group was formed, and the plant currently has an active department with a certified Industrial Hygienist and a graduate (M.S.) Industrial Hygienist. WGK was one of the first plants in Mon santo to have a certified industrial hygiene lab. Training is an important function of the industrial hygiene department. It starts with employee orientation and continues with respirator and hearing conservation training using personal as well as video and audio visual training methods. WGK also has instituted an exten sive hazard communications program to inform workers of the hazardous chemicals used or manu factured at the plant to conform with current OSHA regulations. Medical and biological monitoring programs and a sustained atmos pheric monitoring program are in effect for all regulated and many unregulated materials to which an employee could be exposed. A major respiratory program has been developed, and includes a respirator fit, maintenance and training facility. Current industrial hygiene activities at Krummrich include upgrading old monitoring methods with state-ofthe-art passive dosimetiy, eliminat ing conventional sampling pumps and improving the cost effectiveness of the sampling program and imple mentation of state and federal hazard communications standards. WGK has also completed implemen tation of the MEHI system, fully documenting occupational exposures and work histories for all employees. Soon retrospective work histories will be complete, providing a com puterized work history for all employees from 1946 to the present. DSW 136399 6 STLCOPCB4036362 Sk 136400 l STLCOPCB4036363 ENVIRONMENTAL CONTROL S ound environmental management is a cornerstone of ; Monsanto's corporate policy, and ! this is reflected in the Krummrich Plants emphasis on environmental ;( control. Water The William G. Krummrich Plant discharges wastewater to the Sauget Village treatment system, which began with the construction of sewers and a pump station in the late 1930's. The system was Hazardous Waste The Krummrich Plant's Hazardous Waste Management plan exceeds regulatory requirements and meets Monsanto's worldwide environmental guidelines. A major objective is to convert from landfill methods to I Air expanded and improved over the methods such as incineration, or ! The plant vents are regulated by the years to meet new needs and stand processes to render the wastes non- ! Illinois Environmental Protection ards. During the 1970's, under hazardous or immobile. i ! , Agency (IEPA) for particulates, sulfur dioxide, nitrogen oxides, benzene, carbon monoxide and specified organics in the air. Peri odic internal plantwide audits insure regulatory compliance, and new projects are reviewed and are Monsanto's leadership, the Sauget industries committed to construct a nine-million-dollar physical-chemi cal treatment plant. This plant was built as an important, initial treat ment step for the village's industrial and municipal wastes. Industrial operations at the Krum mrich site predate the turn of the century. While acceptable environ mental practices over this period met the legal requirements and accepted practices of their time, . they obviously did not meet current ' required to utilize the best technol- A major addition to the system was environmental requirements and" j ogy for emission reductions. Pre- the American Bottoms Regional standards. j permit preliminary discussions are Wastewater Treatment Facility. The | held with the IEPA for potential $100 million plus project provides i emission problems. The plant holds secondaiy treatment for Sauget : approximately 60 air permits cover wastewater as well as primary and ing 160 vents. secondaiy treatment for adjacent To assure that our past or current operations have not contaminated the soil, or groundwater such that it poses a threat to human health or the environment, we are involved in Since 1980, some 50 process communities. The regional system an overall study of our site and adja improvements to reduce emission has a 27-million-gallon-per-dav cent areas which our operations may potential have been installed at a capacity and serves an estimated have impacted. cost of $9 million. Projects to elimi 86,000 people. Local funding of the nate emissions through engineering project was financed by a $42 mil controls are continuing. In 1984, lion bond issue backed by industrial WGK provided the industrial commitments made by Monsanto, leadership for installation of a com munity warning system for emission episodes. Pfizer, Cerro Copper, and Ethyl Petroleum Additives. The project stands as a major landmark to com munity-industry cooperation to meet common needs. _ Krummrich has also initiated numerous projects to promote water conservation and reduce product losses to the sewers. The new south trunk sewer replaces the existing 40-vear-old svstem. DSW 136401 8 STLCOPCB4036364 Chemical Transportation Emergencies Krummrich personnel also help handle chemical transportation emergencies. The plant's ongoing training program qualifies individu als on regulations, field response techniques and chemistry. Krumm rich people respond on a mutual aid basis to any major incident in the geographical locale for Monsanto plants or other industries. Seminars are provided for the local Illinois State Police Hazardous Materials Office, Coast Guard, earners and local fire departments. Plant priori ties are the safety of all individuals including response personnel, pro tection of the environment and recovery of company assets. 0SW 136^0? 9 STLCOPCB4036365 COMMUNITY RESPONSIBILITY T he plant plays an important role in civic and charitable activi ties. WGK employees provide personal guidance and support to the following groups: Junior Achievement, Boy Scout Explorer Careers program, Red Cross Blood Bank, fire department safety and emergency training, and the East Side safety council. Through the employees' Charity Fund and the Monsanto Fund, WGK has been a contributor to: the United Way, Target 2000, East St. Louis Chamber of Commerce, St. Clair County Private Industry Council, the Urban League, Boy and Girl Scouts, Khoury League, Illinois Center for the Autistic, Children s Center for Behavioral Development, East St. Louis LISC, Big Brothers/Big Sisters, and the Call for Help. 10 STLCOPCB4036366 STLCOPCB4036367 ABOUT MONSANTO MI onsanto Company is one of the largest chemical compa nies in the United States. It is a multinational research, manufac turing and marketing company producing a wide variety of prod ucts, including chemical and agricultural products, pharma ceuticals, low-calorie sweeteners, industrial process controls, man made fibers, and electronic materials. With world headquarters in St. Louis, Monsanto employs more than 56,000 people worldwide, operates plants, laboratories, and related facilities throughout the U.S. and in 100 countries around the world. It's total assets are $8.8 bil lion and sales are approximately $7 billion. Monsanto was founded in 1901 by John Francis Queeny, then a pur chasing agent for Meyer Brothers Drug Company in St. Louis. Queeny believed that saccharin, then pro duced in Germany, could be manufactured profitably in the United States. With $1,500 of his own money and $3,500 borrowed, he started Monsanto Chemical Works, named for his wife, Olga Monsanto. The fledgling company earned its first profit, a little over $10,000 in 1905, and in 1907 Queeny quit his job at Meyer to devote all his energies to Monsanto. The chemical industry in the U.S. started to boom in the first 20 years of the turn of the century, due in large part to the need for a diversi fied chemical industry during World War I when shipments from Europe were cut off. Monsanto rode this boom and added many new chemi cals to its product line. Foreign operations began in the 1920's, and the company continued to diversify through World War II. It joined the fiber market with the formation of Chemstrand Corporation. Since then, a number of well-known products have been added to the Monsanto line, including Astroturf, and Lasso and Roundup herbicides. Monsanto rejoined the artificial sweetener market in 1985 with the acquisition of G. D. Searle & Com pany, the makers of NutraSweet. The Chairman and Chief Executive Officer of Monsanto Company is Richard J. Mahoney. Earle H. Harbison, Jr., is President and Chief Operating Officer. - John Francis Queeny 12 0** STLCOPCB4036368 Monsanto The William G. Krummrich Plant 500 Monsanto Avenue Sauget, Illinois 62206-1198 DSW 136406 STLCOPCB4036369