Document 8VyoxMR4VRD74jbBEgrBZyBja

ORGANIC CHEMICALS SS |PIVISION K , '. 1 TECHNOLOGY SS DEPARTMENT ..-. M| I| LONG RANGE PLAN 1971 PROJECTION S Match 1971 D. SPECIALTY PRODUCTS 1. Functional Fluids Resistance of higher chlorinated biphenyls to biodegradation and their biological activity similar to low-levels of pesticides have dictated substantial'changes in Aroclor technology and marketing. We have installed a high-temperature incinerator to destroy chlorinated biphenyls. We need new capacitor fluids. The first of these will have minimal amounts of the refractory penta- and hexachloro isomers which we eliminate by fractional distillation of Aroclor 1242. A plant is due to start up in July. Anticipated follow-on products with greater biodegradability include dichlorobiphenyls and dichlorophenyl ethers. Non-halogen capacitor fluids based on phenyl sulfones, phenyl ketones and phenyl or biphenyl ethers are also being evaluated in capacitors. Such non halogen fluids may be required by 1973-75 since government regulatory agencies are beginning to seek bans and control of poly chlorinated biphenyl. Direct control and ultimate incineration of Aroclor is our policy in transformer use. Reclaim and incineration processes are re* quired. Products will be required in 1972-75 to replace the dollar volume we expect to lose because of inroads of hydrocarbon, potting and dry-type transformers. We have tested the first candi date hydrocarbon fluid, a by-product benzene alkylate stream, in electrical cable, in switch gear and in transformers. General Electric has indicated the need for fire retardants in potting insulation for transformers. We have submitted halogenated terphenyls and quaterphenyls which could conceivably offset a decline in Aroclor transformer fluids in the 1972-1980 period. We reformulated all Pydraul fluids in 1970-71 to reduce the release of chlorinated biphenyl to the environment. Present Pydraul fluids will need to be reformulated to phosphate esters in 1971-72 and to still more environmentally acceptable fluids in 1972-75. We are developing high-viscosity nonylphenyl and cumylphenyl phosphates to meet this need. They have low toxicity and reduce our reliance on crcsylic acids. In the future still more biodegradable, less toxic fluids will be required. Esters and aliphatic polyethers are candidate base stocks. Recovery and reclaim of hydraulic fluids will be economically feasible and necessary in the 1970's. -30- O^U90 HONS We need to replace Aroclor 1242 in NCR carbonless reproducing paper to meet present environmental pressures. Isopropylbiphenyl and HB-40 are the first candidate replacements. We are examin ing products made by alkylation and hydrogenation of aromatic 1-, 2- and 3-ring compounda, condensed and non-condcnsed struc tures. Shifting requirements are anticipated throughout the 1970's as improvements in dyes and resin systems are made by NCR and the paper manufacturers. Fractionation of chlorinated biphenyls will yield useful intermediates e. g. * monochlorobiphenyl for use as a dye carrier by Geigy, as an intermediate for Dow and for our own hydrolysis to o-phenylphenol. Fully chlorinated biphenyl is desired as an intermediate by DuPont. We expect to build sales of chlorinated biphenyl and derivatives as intermediates to replace sales of chlorinated bi phenyl as an "end-use" product, hopefully forestalling shut down of the Aroclor complex. Halogenated terphenyls and quaterphenyls may be adaptable as fire retardants in fibers and plastics. We are supplying Aroclor 5468 and synthesizing highly brominated terphenyls and halogenated quaterphenyls toward this market need. The market is expected to develop from 1972-75 but will require new functional, nonextractable materials by 1975-80. The capacity of the tube furnaces for biphenyl and terphenyl needs to be increased in 1972 to avoid investment in a third furnace. We have demonstrated 20% increased conversion by catalyst in jection in a small reactor. Plant expansion in the biphenyl/terphenyl/ quaterphenyl purification train is required in 1971, We hope to use quaterphenyls in the 70's - in fact, may be forced into it. Hydrogenated quaterphenyls, undergoing electrical evalu ation in plasticizer blends, may help relieve the terphenyl shortage. Savings for 1971 are expected by higher conversions in the di butyl phenyl phosphate process, self-manufacture of tributyl phosphate, solvent stripping of VI improver at Monsanto (freight savings and reduced base-stock losses). Skydrol formulation changes in 1972-75 should improve shear stability, drag reduction, skin adsorption, fire resistance and wear properties. We shall formulate hydraulic fluids designed for the Concorde. -31- MONS 041191 Airport runway deicers represent a new opportunity for Monsanto to supply the aviation industry and government agencies. Non ionic corrosion-inhibited amides prevent ice from forming down to 0F. and aid in snow and ice removal to keep airports open. We have formulated an efficient, low DOD deicer. Self-manufacture or a favorable purchase arrangement for formamide and/or acetamide will be required to meet future profit requirements. Markets for chemical deicers are expected to build throughout the 1970's since control of ice by heating is inefficient and costly. 2. Ccllu -Chcm Two new competitive products are being introduced to the paper sizing market - Hercules' Newphor 100 and National Starch's R-68, based on rosin acid and alkylsuccinic anhydride respec tively. We need to develop rosin acid and alkylsuccinic anhydride dispersion technology to match these products. We have a lead to match R-68 in that our own polybutenylsuccinic anhydride (petroleum additive intermediate) exhibited sizing. Tall oil for rosin-acid manufacture may no longer be available from our present supplier after the contract expires in 1972. Since! tall oil and rosin quality will vary with each supplier, the tall oil to rosin and Mersize processes must be adapted. Generally the efficiency of surface size applied at the size press is better than size applied at the "wet end". The consquence is a shrinking market for paper size as size-press applications in crease. Participation in those market applications where size is required in the middle of the cellulose sheet, such as foodboard stock, will be required to maintain sales volume. We need a "harder", less water-soluble, and more reactive size to com pete in this market. Candidates are lacking at present. We need to match Aquapel in performance. Monsanto has led the industry in the application of sizing and hold out resins at the size press. The technical challenge is to improve product performance without increasing manufacturing costs. PP&R has demonstrated minimal handling and solvent losses in a "belt process" for SMA, This process will be required in 1972 and later to hold a competitive cost-performance position. -32- MONS 041192 Polyamines made by treating ethylene dichloride and/or epichlorohydrin with hexamethylcnediamine (nylon intermediate) are useful in imparting wet strength and in providing polycationic precipita tion action in paper. They are also useful flocculating agents for water treatment. Key to further development is FDA approval. Major growth in paper chemicals requires entering the converting field where excellent opportunities exist in large-scale, growing markets for polymer latices in printable coatings, packaging, disposable non-wovens, saturating resins and many specialties. We have chosen to base our entry into these markets on a Monsanto developed family of ethylene/vinyl chloride polymers. Our first products are proprietary terpolymer latices designed to meet specialty applications in the paper, printing-ink, non-woven, textile and carpet industries where they offer unique advantages. Our first plant (19M lbs.) is due on stream in August, 1971, and will require start-up, application research and technical service support to reach sales targets. We are also planning to develop a lower cost, continuous process for the next expansion. This will permit us to compete in the very large, low price market segments in the paper and other industries. The business target for 1980 is $30M Product from the first plant will fit limited applications owing to economics of the plant and limited polymer properties avail able from it. The continuous process should allow us to make the low-modulus, rubbery polymers which are needed in the saturating and non-woven areas at lower costs. The low cost product should allow us to enter profitably the pigment-binder market. Our balance of properties makes E/VC1 an ideal polymer for this ap plication. Both crosslinkable and self-crosslinking .polymers are needed. New fire retardance emphasis suggests opportunities for E/VC1 polymers. A good balance of oxygen permeability and water vapor permeability offer opportunities for E/VC1 films in the packaging area. Paint applications are attractive because of pigment-binding and low-water-sensitivity character. Environmental pressures will restrict sales of pentachlorophenol to applications such as wood treating. However, we see no re placement product before 1975. An immediate problem is to re duce color and sludge formation in wood-treating oils. An -33- MONS 041193 ameliorating approach is with stabilizers and chelating agents whereas long-term we hope to provide the solution by improved processing. Government regulations expected before May 1, 1971, will limit allowable chlorinated dioxin content in Penta. Reason: to reduce teratogenic effects and chick edema. Separation of the dioxin by-products is proposed since we do not have process ability to limit its formation in the first place. Chemical altera tion of the dioxin structure is also being considered. Santobrite sales are expected to decline precipitously in 1971 owing to environmental pressures. We plan to introduce o_phenylphcnol and lower chlorinated phenols as replacement products -34- MONS 041194 TABLE VHI ORGANIC CHEMICALS DIVISION 1971 TECHNICAL PROGRAM Specialty Products Business Group Pre-SQI Net Research, $M______ Actual Budget Projection 1970 1971 1972 1973 Diversification Ethylene Vinyl Chloride Can we launch our pigment binder project and build on ethylene/vinyl chloride technology by developing product and process variations and defining performance for application as saturating resins, non-woven binders, barrier coatings, carpet backing, elastomers? 480 534 400 400 Deicers Can we provide unique deicer compositions (for airport and highway use), with emphasis on proprietary corrosion inhibition, environmental compatibility and with a * Monsanto raw material position? 20 40 50 . 50 HONS 0 9 U 9 5 Expansion Wet Strength/Retention Aid Can we develop a profitable position with our new paper making additive based on Textile Division "amine residue" (and HMD) in the areas of wet strength and retention aids? (Cont'd.) % 9 Specialty Products Business Group (Cont'd.) Pre-SOI Net Research, $M Actual Budget Projection 1970 1971 1972 1973 Expansion (Cont'd.) Wet Strength/Retention Aid (Cont'd.) Will this help us penetrate the food board business by allowing us to work more efficiently with rosin acid > C jg fatty acids? Can we exploit our wet strength/ retention aid products in other areas, e.g., waste water treatment? 140 . 60 wO' Next Dielectrics Can we build on our present market position by develop ing fluids with better environmental acceptance and near equivalent cost/performance to those based on chlorinated biphenyl? ^ 280 300 Phosphate Ester Hydraulic Fluids Can we develop all-phosphate ester, fire resistance hydraulic and turbine lube fluids as profitable extensions X of our phosphate ester technology, and as alternatives O T to fluids containing chlorinated biphenyls or chlorinated (/i terphenyls? (We need to be aware of competitive phos phate esters and alternates to phosphate esters.) * 135 80 80 50 ar Specialty Products Business Group (Cont'cL ) Expansion (ContM.) Pre-SOl Net Research, $M_____ Actual Budget Projection 1970 1971 1972 1973 Diphenyl Ether Can we acquire an economical technical position in diphenyl ether to broaden our heat transfer fluid line? Can we use diphenyl ethers as a base or a raw material for dielectric and industrial fluid formulations ? Regenerative 40 54 60 30 MONS 0 4 1 1 9 7 Rosin Size/Surface Size Can we create process and property modifications to keep our Mersize and Scripsets technically competitive? 130 Pentachlorophenol/Santobrite Can we make Penta and Santobrite acceptable environ mentally and also achieve a favorable quality/cost position with the new process? Can we find substitutes for Santobrite? Aircraft Hydraulics 0 Can we decrease the cost and improve the performance characteristics of our Skydrol fluids to maintain a technical competitive advantage particularly in the areas of low density, streaming potential, increased fire resistance, shaft seal performance, erosion resistance, thermal stability (low cost base stocks) and low cost formulations? 106 123 0 60 250 300 100 100 60 60 > Specialty Products Business Group (Cont'd.) Pre-SOI Net Research, $M Actual Budget Projection 1970197119721973 R^enerati^^C^tldJ Industrial Fluids Can we reformulate our industrial hydraulic and lubricant fluids to eliminate PCB's? Can we develop fluid recovery procedures for non-water based fluids? Can we formulate more biodegradable and acceptable hydraulic and lubricant fluids ? 75 140 150 ' 140 Encapsulants ~ Dye Solvents w 09 Can we provide alternate products to replace PCB*s as encapsulant fluids and provide efficient manufacturing processes for these fluids? 60 56 60 60 Biphenyl Derivatives Can we develop new biphenyl/terphenyl/quaterphenyl inter mediates and derivatives to replace polychlorinated biphenyls and build on our biphenyl family tree; di and poly aromatics as fire retardants; substituted biphenyls as dye carriers? 20 81 100 100 Fluids Environmental Defense Can we defend against law suits and prevent contamination of the environment with Aroclor products and with new replacement products and formulations? 220 145 180 200 HONS 0 4 1 1 9 8 t J L -l r J 1--I g. ,,| K-*- J ft ft- -a im Specialty Products Business Group (Cont'd.) Regenerative (Cont'd.) Pre-SOI Net Research, $M Actual Budget Projection 1970 1971 1972 1973 Heat Transfer Fluids Can we provide expert heat transfer system design and technical support for our Therminol fluids? Dielectrics 30 20 30 40 Can we develop variants of our present biphenyl based products to maintain our profitable participation in the dielectric market in view of the PCB environmental problem? 100 90 100 50 HONS 0 4 1 1 9 9 > I TABLE IX SPECIALTY PRODUCTS MANPOWER REQUIREMENTS TECHNICAL PROGRAM MAN-YEARS PER YEAR Business Grouo: Soecialtv Products 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 Diver sification Deicing Materials Solid Insulations, Dielectrics Synthetic Hydrocarbons - New Industrial Fluids E/VC1 - Batch Process Derived Latexes E/VC1 - Continuous Process Derived Latexes and Solid Polymers Polycation Water Clarification Total Diversification 1 1 1 1 i i22222 -- 1 122333 33 - - 1 2223 34 44 15 11 8 8 8 8 8 8 8 9 10 - - 10 11 11 6 4 4 4 4 4 - - 222222222 16 12 23 25 26 21 22 22 23 24 25 Expansion Advanced Skydraul and Lubes --- Next Generation Dielectric Fluids Next Generation Industrial Hydraulic and Lube Fluids Heat Transfer Design and New Fluids Processes - Encapsulants, Dye Carriers New Bi/Tri/Quaterphenyl Derivatives Wet Strength/Retention Aid Total Expansion 1 1 22 3 3444 44 2 2 2 2 2 24 4444 422 244445 5 5 i i 1 1 i 2 2 .2 2 2 2 222333667 77 4 1 2 33 3444 44 14 9 11 13 16 17 24 24 26 26 26 zc z CO o o c i( I J ( 4 1 i E--4 t__l Iu4j r-1 * -m t. -3 m - (.ri m- i , > JlT I xirr*j]srrr a t. program Business Group: Specialty Products (Cont'd.) MAN-YEARS PER YEAR 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 Regenerative Skydraul/Coolanol Improvement ___ Dielectric Product Improvement Industrial Hydraulics and Lubes 2 2 2 2222 2222 3 32 333 3 3222 3 32222 3 3 333 Heat Transfer Design and Improved Products i 1 1 i 1 1 22222 Plasticizer Terphenyi Derivatives and Replacements Rosin Size Improvement New Wet End Sizing Systems _ 1 222 3 33 3 3 3 2222222222 1 4 4 4 4 4 4 4 4 4 Scripsets Modification and Replacements 5"^ 1 2 2 3 3 3 3 3 4 4 Pentachlorophenol Quality Process, Replacements - - 1 1 1 1 " - - - - Total Regenerative 18 12 17 19 20 20 22 22 21 22 22 Supporting Customer Technical Service Manufacturing Support Wood Treating Chemical Co. Support Management and Clerical Total Supporting 5 5 5 566 7 78 89 4 4444 5 6 6 7 77 4 422 33 3 3 3 3 3 3 17 11 11 12 13 14 16 16 18 18 19 MONS 0 4 1 2 0 1 TOTAL SPECIALTY PRODUCTS 65 44 60 69 75 72 84 84 88 90 92