Document 91X1OD15KBebgbx5vQxMgJX7e
Job No.
Report No.
Date:
Title:
Aroclor Manufacturing Improvement Plan
Objective: To develops guide to Improvements in cost, capacity, nnd quality In the Anniston Aroclor plant.
Personnel: J. MaePheraon (L. C. Fuhrmeister)
Reported by: J. MaePherson
Summary: *
The major emphasl ,vil2 be on quality attainment in the liquid
Aroclor product Ijh.% and capacity increase in the solid Aroclors.
A summary of targets <and commitments Is as follows:
v
Liquid Aroclors
'
Year
1968 1969 1970 1971
Taraet Capacity
53 53 65 65
Predicted Sales
Quality
Potential Savlnfts/F.arnlnfts
42.7 44.7 46.3 49.5
Intermediate Product Strategy
229,770 30,000
1,330, 000 30,000
Solid Aroclors
Year Taraet Capacity
Predicted Sales
Quality
Potential Savintcs/Earnlnzs
1968
1969 1970 1971
10.5 12 14 14
10.5 11.7 13.2
14.3
No Change No Change No Change No Change
150,100 233,800 238,200 121,700
A commitment of 1920 technical man-hours will be required to support the target programs.
This Issuance of the MIP marks a departure from the previous PIP format a j. enough the contex is essentially the same. The plan Issued on 2/9/66 has been partially absorbed by a CED project with the result that only one major savings item (Aroclor still modification) was available for implementation; the item has not been installed as yet.
HONS 03617?
TOWOLDMONOQ44571
Section
1
2
3
4
5
6
7
.8
9 10
n
12
I.
. 11. III.
IV.
V.
VI. VII.
VIII. IX. X.
Title
Introduction
,
Summary of Major Targets for Future Efforts
Cencral Process Description
Market Analysis
Process Analysis
Capacity AnaLysis
Cost Analysis
Competitive Technology
Patent Status
Stream and Air Pollution
Job List
Appendix
Process Sketchs *
Comparison of Competitive Materials
Market Analysis
Production Schedules
Non-produc t ive Time
Project Networks
MIP Contributors
(1) Production
(2) PR&D
(3) Quality Operations Control
(4) Maintenance
TSD Jobs and Projects
References
Cost Analysis Data
'
MONS 036178
TOWOLDMONOQ44572
Section 1 Page 1
Introduction The Process Improvement Plan (PIP) is being replaced by a Manufacturing
Improvement Plan (HIP). In general the contex is the same however the MIP is to present a broader base by including source information write-ups con tributed by personnel other than the area T.S.D. engineer. The procedures used to publish the MIP will be the same as for a PIP, the plan will be in the form of a progress report. Updating will be done when expedient to do so; certain sections may be updated quarterly while others only on necessity.
As with the PIPan MIP is to serve as a continuing guide to Improvements in cost, capacity, and quality.
The previous PIP was issued on 2/9/66. This plan was not Implemented because of product strategy changes. Divisional goals set in May 1966 required a much improved quality, this was not a major objective of the previous PIP The major savings item in the 2/9/66 PIP was a labor savings project in the: finished goods area; this project has been absorbed in a CEO project (Arocldr expansion CEA 1430). The second major item was a modification to the liquid Aroclor still to permit the use of indirect heating of the still and realizing fuel sevings, less productdecompo>ltlon and reduced maintenance, this project has not been Installed as yet, tentative EDO is 3/1/66.
MONS 036179
TOWOLDMONOQ44573
Section 2 Page 1 Recommendations to Attain Targets 1. Install adequate fixed bed refining capacity to handle all electrical grade 1242/1254. 2. Install still modifications to allow still capacity to match chlorination ability (65 M lba./yr.). 3. Maintain a T.S.D. effort of at least 1 engineer to attain estimated 8avlnga/earnlngs. 4. Ensure that all personnel involved with Aroclor arc aware of the capacity deficit situation in the solid product area.
MONS 036180
TOWOLDMONOQ44574
Pag* 2
Itai I960 1969
Vflmm ii tb/yr S3 S3
1970
65
1971
65
TARGETS
Llould Araslogft
Eatlwatad rotaot U1 Savlnaa/garnlnaa
qwUty Intermediate Product atratogy
labor eavlnaa _______ 10,000
O.S.T. aavlnaa 6,770 20,000
aarnlnaa 221,000
--
total 229,770
30,000
Produce atrategy goal
Produce strategy goal
10,000 10,000
20,000 20, 000
1, 300,000 1 ,330,000
--
30,000
1966 1969 1970 1971
10.5 12 14 IS
No Change No Change No Cliaitge No Change
MM MWlWl. Eat letted .Potentla 1 Stvlnaa/Earnlngg
labor aavlnaai
O.S.T, savins*
aarnlnaa
30,000
_____
120,000
____
33,800
30, 000
60,000
130,000
36,200
30,000
60,000
130,000
61,700
60,000
60,000
total 130, 100 733,600 238,200 121, 700
HONS 036181
TOWOLDMONOQ44575
Section 3 Page 1
Synopsis of the Process
A. Chlorinator Arco
There are lour batch operated liquid chlot inutors, one batch
operated solid chlorinator, and one continuous chlorinator system. The
continuous system consists of four chlorinators cascaded with overflow in
scries.
.
The liquid chlorinators are charged with biphenyl and ferric chloride catalyst; charges for the solids chlorinator depend upon the Aroclor to be produced. Chlorine gas added through a sparger reacts with the charge to release HCl and heat; the HC1 gas goes to the Muriatic Acid department. The specific gravity of the crude is used as the monitoring and control variable.
Crude Arociots from both batch and continuous chlorinator systems
are transferred to a tank to be air blown before distillation. Figures 1,
2, and 3 In Appendix 1 are sketches of the batch, continuous, and solid
chlorinators.
`
B. Still Area
There are four stills in the Aroclor department; stills No. 2 and 3 arc used for liquid Aroclor} only, No. 4 is for solids only, and No. 1 can distill any grade of liquid or solid with the exception of 1268
and S460.
(1) Liquid Aroclora
Crude Aroclor is charged from a blowing tank or a feed tank to a still. Hydrated line is added and a vacuum of 40 MM. Hg applied; the still charge is then direct fired by circulation through a coil in a gas furnace,, the distillate goes forward to a receiver. The distillation is semi-continuous since ten receivers are distilled prior to drawing residue from the still. The receiver charge Is in turn transferred to a blending tank where It Is treated with Attapulgus clay and filtered. Finished product is transferred to storage tanxs prior to loading Into drums or tank cars. Figure is a sketch of a typical liquid still.
(2) Solid Aroclora
Distillation of 9olld aroclors Is similar to liquids with the exception that the vacuum Is approximately 10 MM. Hg. absoluta and that generally two still charges are distilled before withdrawing residue.
Solid Aroclors 5460 and 1268 are flaked; all other refined solids are drummed from the receiver.
Figure 5 is a sketch of the solid still system.
HONS 036182
TOWOLDMONOQ44576
C. Chemical Equations
(1) Liquid Aroclors
Based on the forecasted demands through 1971, the average Liquid Aroclor could be called 1245.6.
C12H10 154.20
+ 3,66 C12 70.9
C12Hio(CS 66+ 3,66 HCL
283.8
36.5
(2) Solid Aroclors
` Based on the forecasted demands through 1971, the average Solid Aroclor would contain 60.47, chlorine and 2.92% Biphenyl.
.971 Santowax R + .029 Biphenyl + 10 CI2
230.3
154.2
70.9
Solid Aroclor + 10 HCL
586.0
3*5
HONS 036183
TOWOLDMONOQ44577
Section 4 Page 1
3
Appendices II and III present (1) a comparison of competitive materials with Aroclors 1242 and 1254 and (2) an analysis If the world market for Aroclors. If Monsanto Is to compete^ the following goals must be met:
1242/1254 Goals
In Plant Storage
As Packaged
As Delivered
1254 Resistivity 15f000>
PF (l!tc)
.3% .1
10,000 <0.47.
> 5,000 < O'. 5% (1 0.17.)
12M Resistivity 10, 000>
5,000
1>F (lkc)
0.67. t 0.1) <0.9X
> 3,000 < 1.0X (* 0.1)
Monsanto's share of the market in 1966 and the objectlve&for 1971 are presented below:
Capacitor Aroclor
1966
1971
Domestic Non-Domestic
78.4% 71.5%
71.5% 67.2%
Transformer Askarcl
1966
1971
Domestic Non-Domestic
61% 59.5%
67.4% 65.8%
It must be emphasised that.the quality goals presented above were introduced at the Corporate Aroclor meeting held In St. Louis on May 9 and 10; these goals represent marketing necessity as of 1967. The Product Strategy quality goal; remain at a higher quality level since they represent n long range goal.
HONS 036184
TOWOLDMONOQ44578
Monsanto OMOANIC CMtMtCALl OIVIIION
FINISHED PRODUCT SPECIFICATION
rnooucTtoN R. G. Moody/s/R. G. Moody 3/23/67 Aid W. E. Ault/s/W. E. Ault 3/17/67
CNCMAL oocnintioh
i*Mooucr
Export Grade
Aroclor 1254 - Electrical Grade
Anniston
i26,13
3/23/67 APflOVtLI
L040-280-16-009
Section 5 Page i
I27-1. S.I..
L. R. Stark//L. R. St.rk 3/21/67
QUALITY CONTROL (ihUIChumM)
"
5. W. Miller/s/G. H. Miller 2/23/67
chmical fonmi
3 " "'
Mixture
MOL WT.
AM0LI PON ANRLVBII
I.nttlve 4/27/66________________ 3 x 5 ot Amber bottles
CHAN ACT CNI* TIC
LIMIT*
UNRESTRICTED INFORMATION
V
J. A. tlddle 2/21/67 MtTMee
(R) Color, AFHA (R) Condition (R) Specific Gravity <? 65/15.5 *C (R) Acidity (mg KOH/gm.) (R) Moisture (H2O), ppm (R) R.fr.ctlve Index 0 25*C (R) Inorganic (free) Chlorides, ppm (R) Pour Point, *C (R) Dielectric Constant
1000 Cycles <9 100*C (R) Resistivity ohm-cm
500 VDC 9 100*C, 0.1" Gap (R) UydrolyiU Stability T..c
as chloridesi ppm (R) Monsanto Stability Test . as chlorides, ppm (R) Distillation Range, A81M D 20, . corrected
10% Distilled by wt. 50% Distilled by wt. 90% Distilled by wt.
(R) Biphenyl, % Sulfates Dielectric Strength <9 25*C
FLh Point Fire Point Vl.eo.lty 0 210*T (BUS) Corrosion T.st t hour. 0 210*C
with bright aluminum foil Change in wt. of A1 (%)
A.C. Color, APRA A.C. Condition A.C. Acidity (mg. ROfl/g.) A.C. Inorganic (free)
chlorides, ppm
30 Max. Clear 1.495 - 1.505 0.010 Max. 35 Max. 1.6370 - 1.6390 0.05 Hax. 7 - 12 4.15 - 4.35
10,000 x 10y Min.
1.0 Max.
0.5 Max.
366 - 378*C 371 - 383*C 379 - 394*0 0.025 Max. Non. 35 KV, Min. Non. to Boll Nona to Boil 44 - 48
0.0 60 Max. Clear 0.010 Max. 0.05 Max.
RESTRICTED INFORMATION Power Factor <? 100*0 & 60 Cycles
Report
(R) Routing Analysis, All othtrt Analyttd by rtfutsf Only
046 G-1 052
050 .
047 : 04B 045 053 113
121
010
133
054
100
043 114 114 049
`
046 G-l 050 045
MONS 036X83
113
TOWOLDMONOQ44579
Monsanto
ONOANIC CHEMICALS OIVUIOM
TENTATIVE SPECIFICATION AUT9*ONtEEO V
kU OKSCAIPTIOM
Ex jort Grade
Aroclor
1242.
El
ctrical Grade raoDuer coca
Section 5 Page 2
1JOB*T* 27-L
Anniston ffifTlMHflvS
626.12
Sales
6-12-67
1040-240-16-009
OUNCE or artciricAYiOM
P. 6. Benixnus Memo dated 5-11-67
CHlMCAh P9MMVI*
IIIUC* CHMACTKNIBTIC
EFFECTIVE UNTIL 6-1-68
UNRESTRICTED INFORMATION
AMPLE TON AMALVt'O
"
3x5 pt. Amber bottles
HiuITi J. A. Llddl. 3/29/6
(R) Color, APHA. (R) Condition
40 Max. Clear
(R) Specific Gravity 0 25*/15.5*.C (R) Acidity (mg KOH/gm) (R) Moisture, R2O, ppm (It) Refractive Index (3 25*C
1.381 - 1.392 0.010 Max.
35 Max. 1.6240 - 1.6260
(R) Inorganic (free) Chlorides, ppm
(R) Pour Point, *C (R) Dielectric Constant
0.05 Max. -14 or lower 4.70 - 4.90
1 KC 0 100*C
c (R) Resistivity ohm-cm
5,000 x 109 Min.
500 VDC <3 100*C, 0.1" Cap
(R) Hydrolysis Stability Taat
0.5 Max.
(as chlorides) ppm
(R) Monsanto Stability Teet
0.4 Max.
(as chlorides) ppm
(R) Biphenyl, %
0.05 Max.
(R) Distillation Range (ASTM D-20,
Corrected)
10% Distilled by wt.
325#C Min.
901 DlJtlUed by wt. Sulfates Dielectric Strength (? 25*C Flesh Point (*7) Fire Point Vlecoalty 0 10O*F (SUS)
360*0 Max. None 35 KV Min. 338 - 392 None to Boil 82 92
046 C-l 052 050 047 048 048 053 113
121
010
133
100 054
12169 (WCK) 043 114 114 049
RESTRICTED INF.ORMATICg
Typical Values
Power Factor (3 100*C 60 cycles
1000 cycles
Raport Report
0.30 - 0.50 0.08 - 0.10
il3
//C. W. Miller - 5-31-67 C. w. Miller - Chief Chemist
//H. L Williams - 6-1-67 H. L. Williams - Production
/Aim. E. Ault - 6-8-67 W. E. Ault - Seles
.
/i/L. R. Stark - 6-12-67 L. R. Stark - Research
IK) A**)yi)t. All tdnf dn.lyi.d tf I <r-
HONS 036X86
TOWOLDMONOQ44580
1
Section 5 Page 3
5. Process Analysis
Liquid Aroclors
A comparison of the Product Strategy quality goals and YTD Anniston performance Is as follows;
Color (AFHA)
Water (ppm)
Resistivity <3 100C (xlO9 ohm-cm)
Aroclors
1242
1254
14 18
24 26
1,450
?, 7 50
Project Strategy Coals (1242 & 1254)
10 Max.
20 Max.
10,000 Min.
Power Factor @ 10OC (7. at 60 cps)
2.70
.85
0.2 Max.
Thermal Chemical Chloride Stability (ppm)
.26
.42
0.1 Ma.
Intermediate product specifIcatlonsare presented on the specification sheets Included in this section.
To attain the targeted quality goals it will be necessary to (1)
improve the treatment capability of Aroclor refining, (2) reduce the atmospheric contamination during processing and storage, and (3) eliminate ionic contamination from the handling equipment.
It is possible to produce target quality 1254/1242 guides by multiple (3 or 4) batch absorbent treatments using Porocel (activated bauxite LVM grade). An apparent tachologicai breakthrough for the treatment operation is the
utilization of a fixed bed abaorbtlon unit chargedwlth Procel; figure ___ shows a resistivity versus time for an experimented unit installed on the Ho. 2 liquid still system in May 1967. The technique definately will product goal quality 1242. Laboratory tests are being conducted on Aroclor 1254, it is anticipated that 1254 will upgrade easily. The installed unit is considered a pilot unit for a larged capacity bed to be designed in December 1967.
Degradation of product occurs during transfer to the storage tanks,
on occasion while in storage, and in loading operations. The quality decrease
is attributed to atmospheric contamination since the blending tanks and storage
tanka (with the exception of the two major tanks for 1254 6'.242 storage) are free
breathers and to ionic contamination from exposed surfaces in the galvanized
piping and tank linings.
In-plant projects have been approved to install
nitrogen blanketing facilities on the storage tanks and refining systems. A
comprehensive project, CEA 1430 - Aroclor Expansion, has been prepared by CED
to provide improved storage and handling of product.Aroclors. In the liquid area this
will include 11 new bulk storage tanks, 3 blend tanks, pumps, filters, separate
product pipe lines, tank car and tank truck loading facilities.
.
MGNS 036187
TOWOLDMONOQ44581
Section 5 Page 4
Seeking all possible innovations to assist in the quality drive it has been proposed that Anniston PR&D initiate a program to define process conditioruneeded to determine when air blowing of the crude liquid is complete; TSD will prepare a project to remove contaminants from the blowing air supply.
The basic weakness of the Liquid Aroclor area is the fact that all the still
systems are botch operations and half of the available chlorinators are batch
units. Conversion to continuous would offer increased capacity, improved labor
efficiency, and optimum quality control. Projects oriented to continuous
operation Include (1) nn Anniston PR & D program to evaluate pulling sidestreams
for various grades of Aroclors from a continuous chlorination system, (2) a
proposed Oil) evaluation of crude blowing and distilling in the same unit, and
(3) a CED evaluation of converting Mo. 3 liquid still system to continuous
operation.
.
A basic need in the liquid Aroclor area is the establishment of the relation* ship between product isomer distribution and sales specifications; this in turn will
lead to control of proceas variables affecting isomer ratios and the establishment of optimum operating conditions. A TSD project to do such a study Is active.
The handling of the residue (Hontars) from the stills offers a hezafd to the operators and promotes labor inefficiency. Current practice Is to drain the still residue into drums and transport the drums to the company dump. A survey of the Montar problems has been completed, evaluation and reconmendatlons will be completed by 12/15/68. '
Solid Aroclors
Solid quality Is specified by softening point and color of the finished product. Quality problems were not evident until Santowax-R from the new still
(on stream Dec. 1966) was used for routine production of Aroclor 5460. Immediate production problems Included excessive HC1 evalution during distillation, Increased still residues, high product color, end Longer chlorinntor cycles. Laboratory investigations indicated that a higher quaterphcnyl content in the Santowax-R wee responsible; PR & D work is continuing In an effort to provide relationships between polyphenyl content, crude chlorlator levels, and yields. A TSD study based on the lab data, will be Implemented to determine the most economical operating conditions.
A primary need is an In-line analytical Instrument to measure chlorine content of thi chlorinetor charge either continuously or on demand with short US time. TSD will conduct a survey of available Instrumentation and recomnend a section based on the duties (buy, deveiope, or wait).
Residue handling is a hazard as in the liquid still area, a major difference Is that the majority of residue (Montar 5) Is solid. Recommendations
for handling the solids Montars will be generated during the analysis of the Montar survey.
MQNS 036183
TOWOLDMONOQ44582
Section 6 Page 1 Cnpncity Analysis Detailed analysis of the liquid and solid product lines follows however It Is important that the capacity goals of the Anniston plant be presented before any discussion. Table _____ is a projection of the commitments and desirable capacity goals for the Aroclor plant.
I
HONS 036189
TOWOLDMONOQ44583
Section & i'ogo 2
TABLE ____
Anniston Copaclty Goals
M lbs./yr.
1968
1969
1970
1971
Liciuid commitment . surge (30%)
42.74 44.67 46.26 49.51 12.80 13.40 13.88 14.85
Total
55.54 58.07 60.14 64.36
1972
51.72 15.50
67.22
Solid commitment surge (30%)
Total
10.47 3.14
13.61
11.66 3.50
15.16
13.15 3.94
17.09
14.33 4.30
18.63
15.02 4.51
19.53
HUNS 036190
TOWOLDMONOQ44584
Section 6 Page 3
Mould Aroclors
A brief summary of the liquid Aroclors production is ns follows:
1966
1967 YTD (Aug.)
Actual production
40, 735, 885
Scheduled production 41, 663,295
Capacity rate (Ibs/hr)
(1) design
5,974
(2) demonstrated
6,059
29, 639, 219 29, 821, 118
5,974 6, 779
87.51
The capacity raLes necessary to make scheduled production were 5430 lbs/hr for 1966 and 5955 lbs/hr for YTD, these rates are based on the actual O.S.T. However if the scheduled production had been equivalent to 48 FI lbs/yr the rates would had to.have been 6255 lbs/hr and 6430 lbs/hr based on the same O.S.T., rates of this magnitude have been demonstrated but It is stilllmperatlve that the O.S.T. of the liquid area be improved. It Is obvious that O.S.T. itself does not set the production rate, it is the combination of capacity rate and productive time. The objective is to eliminate es many causas of the non-productive time as possible and to permit the plant to 9et its productive capacity by varying the capacity rate. Appendix V presents s tabulation of the non-productive time for 1966 and 1967 YTD (May). Table ____ is a comparison of downtime for 1966, 1967 TYD, 1967 projection, and the standard values.
TABLE _____ Liquid Aroclors Downtime Comparison
Repair Process Other
Standard Hours
259 173 m 605
1966
220 355 369 944
1967 YTD (Aug.)
196 122 317 635
1967 Prolection
294 183 475 952
Table _____ presents a summary of downtime causes and corrective actions; the estimated time savings arc 58.0 process hours and 104.3 other' hours. An additional 29.3 other hours should not re-occur. A projection, based on successful completion of the indicated actions, for future downtime is:
Repair Process Other Total Hours
294 125 342 761
MGNS 036191
TOWOLDMONOQ44585
Section 6 Page 4 O.S.T. for this downtime sum would be 91.27,, requiring a capacity rate of 6100 lbs/hr. which has been demonstrated. Capacity beyond 48 M lbs/yr can be gainud by Installing level Instruments on the still receivers, blend tanks, and filtrate receivers and by replacing the existing still receiver pump with identical but new pumps.__ The capacity rate estimated for this modification is 6650 lbs/hr or 53 M lbs/yr.; a project has been approved for this modification. The 53 M lbs/yr. must be considered on iriterim production plateau since the chlorination capacity is estimated at 65 M lbs/yr. Steps to exceed the 53 M lb. level include items such as improved preheat for the sitll feed, improved-still condensers, and higher capacity vacuum jets; an estimated in vestment of $85,000 will allow the still system to match the chlorination capacity. It appears that Anniston can meet the capactiy goals through 1971.
HONS 036192
TOWOLDMONOQ44586
TABU
Oovnt 1m Cause 1. Walling on room In bland tanka
Corractlve Action
Time Savinas - hr*
i Expert grade 1242 to be refined In fixed bed refining unit.
14.5 Process
b. Inttall accond fixed bed refining unit to handle all 1242; flrat unit to handle all 1254.
0.5 Procese
) Resnonslbl litv
Unit Installed, production I to accept ae mnnuf. unit ,t , und of U/10/41 demonstiu* j tIon ooriod. (12/10/67) i T.S.U. to design bated on j data from first unit. EC . for Installed unlt-6/1/08.
2. Walling on crude
'barge trim alee of chlorine valvaa on batch chlorlnators.
35 Process
' Maintenance
3. C12 plant down
Inatall drowning system to that iroclor doea not Have accept 2lj air mlxtura during maintenance >pcratlone In chlorine plant.
27.5 Othor
i T.S.O. to doslgn drowning syMem - EDO?
it. Export erode Aroclor
'
5. Inventory Adjuatment
a. Sam at 1. a. >. Same ae l. b.
Inatall adequate flnUhed product storage.
20 Other 12 Other
44.fi Other
: l. 0. l. b.
C.E.O. design package; [ estlmAtod Installation date
10/15/68.
6. a. Uw CU pressure b. Empty Clj core
Inatall M jpot/loedtng atatlon to handle additional cart.
17.3 Other
Project approved, TS.P./
j consultant doalgn package 1 toady by 12/15/67.
i n
HONS 036193
TOWOLDMON0044587
Secttort 6 Page 6
Solid Aroclors
A summary of the Solid Aroclors production ie as follows:
1966
1967 YTD (Aua)
Actual production Scheduled production Capacity rate (lbs/hr)
(1) design (2) demonstrated O.S.T.
8,287,766 9, 435, 599
1247 1789 73.23
6, 280,503 6, 275,675
1289 1485 79.17
Design capnclty for the plant is 10 M lb/yr.; design rates for
1967 hnvebeen adjusted to reflect the change in O.S.T. standard, 90% versus
93% (1966). When discussing capacity it important to remember that the plant
ability is measured by both O.S.T. and capacity rate. For Instance, in 1966 a 1789 Ib/hr rate was recorded with an 81.46% O.S.T. und a 1312 lb/hr rate was
experienced with 88.69% O.S.T.; YTD O.S.T. was 79.17% with a 1349 lbs/hr,Th first objective in the solid Aroclor area is to reduce as many downtime cauaia
as possible In order to improve the O.S.T. and_malntain capacity rates at *
levels required to meet design production (10 M lbs/yr).
-
Appendix V presents a tabulation of the non-productive time for 1966 and 1967 Y.T.D. Table _____ la avcomparlaon of downtime for 1966, 1967 Y.T.D., 1967 projection, and the standard values.
TABLE _____
Solid Aroclors Downtime Comparison
Standard Hours
1966
1967 VTD (Auk.)
1967 Prolectlon
Repair Process Other
431 172 172 775
732
1039 486
2257
630
209 168 1007
945 314 252 1511
Corrective actions for some if the downtime causes are presented in
Table
. Predicated on the successful completion of the proposed projects,
future downtime la estimated at:
Repair Process Other
868 313 104
1285
_ This no,o-productive time represents 14.8% downtime or 85.2% O.S.T.;
at 10 M lbs/yr. this would be capacity rate of 1360 lbs/hr., this rate has
been demonstrated. To produce more than 10 M lbs/yr there must be:
.
1. bottleneck elimination 2. improved yield 3. Improved O.S.T.
MGNS 036194
TOWOLDMONOQ44588
Section 6 Pnge 7
The most immediate bottleneck is the solids flnker; this unit enn process 10.2 M lbs/yr. A new fLaker capable if handling 16 M lbs/yr is to be installed, estimated incentive for this new unit is presented in Appendix VIII. Timing of this installation will depend upon whether the unit is to be port of a CCD design package or an in-plant project.
The estimated capacity of the solids system is:
1349 lbs X 8640 hr X .90 O.S.T. X 90 goal yield
= 13 M lb/yr
hr . yr
73 actual YTD yield
To gain this 13 M lb., yield must be improved from the YTD 737, to 90% And the O.S.T. advanced to 90%; the improved O.S.T. must be gained while maintaining at least a 1349 Ibs/hr capacity rate.
A Increase in yield can be gained by an improvement in the quality of the erode (5060) produced in the No.9 chlorinator. From January 1 - January 4, 1967 the solids still had difficulty In finishing a distillation and experienced high evaluation of HCl at the end of a batch. The problems were traced to high quoterphenyl content (17.20%) In ssntowax R for the new still system. A Lab oratory investigation of this phenomena roported that not only did reduced j quaterphenyl content Improve yield but also reduced the chlorination time. ased on these preliminary lab results, the first estimate of the capacity gain at; a 5% quaterphenyl content would be:
1590
X 8640 hr X ,90 O.S.T. X 90 yield
- 15.26 M lb/yr.
hr yr '
73 yield YTD
This calculation Assumes an 2 hour decrease in chlorination time and an Improvement In yield to 90%. A plant study on the effects of varying quaterphenyl content la scheduled to be completed by December 1967; data from the study will permit a firmer estimate.
The program to-date has the ability to improve the O.S.T. to 82.5%; continued planning and updating of the project networks will be required to push the O.S.T. to 90%. Efforts will be continued to define targets for O.S.T. Im provement .
' Another opportlnuity to gain in capacity to gain in capacity rate is in chlorine quality; YTD chlorine delivered to the Aroclor chlorinators is 82.4%, chlorine quality at the header from the Ci2 plant is 90%. The chlorine used in the solid system has a higher quality since the Clo vaporiser output Is predominately used by solids, estimated quality is 90%. However if the delivered CI2 quality can be raised to 90% the solid feed chlorine quality would become
approximately 94.5%; this could raise Che capacity rate from 1349 Ibs/hr to 1415 lbs/hr. If the SW-R yield studies are fruitful that projected 1590 lbs/hr could be raised to 1672 Ibs/hr., 16.02 M lbs/yr at 907. O.S.T. and 90% yield.
Based on the analysis it would appear that Anniston can meet the solid
goals through 1970. If the solids market continules to expand it may be necessary
to install a second solids chlorinator.
,
A suonary of capacity calculations Is presented after Table
HONS 036195
TOWOLDMONOQ44589
Downtime Cause
1 11. Still clrculotln a plugged
12. (a) Switch Cl2 cor (b) Low pressure, C 2 cars (c) empty C12 car
3. Clj plant down
4. (a) Chlorlnator pump (b) C1^ dlatrubutora
TABU Corractlva Aetlon lnatall flowmeter capable of withstanding high tamparaturaa
lnatall RR spur to handle two additional Cl] tank cars; loading stations will be required.
Install drowning system eo that Aroclor does not have to eeeept Cl^/alr mixture during maintenance operations in Cl^ plant.
improve availability of spare parte
46.511.3 Process ; TSD select and Install Repair 1 Instrument - SDC ?
148 Other
1 Project approved; TSD . working on desLgn,
Installation will be construced EDC 2/1/68
90 Other 30 Ropelr
j TSD to design system EDC '
i i
i | Halntenencu
MONS 036196
TOWOLDMONOQ44590
Section 6 Page 9
Solid Aroclor Production Potential October 16. 1967
17, 500 lbs batch
* @ 16.hr/batch
13 hr/batch
* includes downtime 1 a real cycle
1. No damage in yield or cycle time: improved O.S.T. only
17,500 lhs x 8640 hr x batch x .7917 O.S.T. = 9.21 M Iba/yr
. batch
yr
13 hr
9.21 M lbs/yr x .8500 9.88 M Ibs/yr .7917
9.21 M lbs/yr x .9000 - 10.48 M lbs/yr .7917
i :
2. Yield raised from 73% to 90%
lbs/vr
O.3.T.
11.38 12.18 12.92
.7917 .8500 .9000
3. Yield raised from 73% to 90% and cycle time dropped from 13 his to 11 hrs.
lbs/yr
O.S.T.
13.42 14.40 . 15.26
.7917 .8500 .9000
4. Yield - 901
cyole time - 11 hr
improved Cl? quality; YTD supplied by Cl. plant 82.5 % YTD eat. at solid chlorine i 90%*
combination of Clj plant, chlorine + vaporizer supply
Target quality * 94.5 for solid system
lbs/vr
O.S.T.
14.10 15.10 16.02
.7917 .8500 .9000
HONS 036197
TOWOLDMONOQ44591
Page 10
HONS 036198
TOWOLDMONOQ44592
Section 7 Page 1
Cost Analysis
l. Cost Variances
Table I presents a summary of the YTD variances (July 1967) for Liquid and Solid Aroclots. Comments on the individual variance item* and copies of the YTD tfost report are presented in Appendix X.
The total product cost variance for 1967 is projected to be $340,000; of this amount 74% ($252,000) will be in direct conversion costa. These costs are due for the most part to unforsoen increases in TSD, Research, and Experimental costs and in some items unrealistic cost standards. A savings item in tills cost category is the production department containers; this cost in Incurred by the present procedures for handling the waste Montars from the Aroclor plant. A study is being conducted to determine possible alternate handling techniques, potential savings arc estimated to be $9,300/yr.
A target In the material costs is chlorine. Total CI2 variances for the Aroclor plant amount to approximately $70,000/year. Program# required to reclaim these costa include (l) an Improved monitoring system for the cell efficiency In the chlorine plant, (2) a study to determine how to improve
chlorine quality, and (3) a study of chlorinator efficicnces In the Aroclor department. Anticipated dates for the recovery of the $70,000 are not available at this time.
Of particular interest are labor savings to he gained by the
installation of Improved drumming, flaking, and storage facilities (CEA 1430) in
the Aroclor department. Labor requirements to meet projected production rates
are compared below in two categories, with existing facilities and with
improved plant:
(CEA 1430)
Year
Existlns Plant
Improved Facilities
1968
1969 1970 1971
11 12 12 13
8 8 8 8
Labor savings by CEA 1430 may range from $30,000 to $50,000/yr.
An unusual cost item is the handling of Montar 5 which is tt\e residue from the Solids still. The material Is solid in three basic forms (1) coarse crush 375 Ibs/drum (2) fine crush 375 ibs/drum, and (3) fine crush 350 lbs/drum. A comparison of selling price and cost are as follows:
Coarse crush 375 lbs/drum Fine crush 375 Lbs/drum Fine crush 350 Ibs/drum
iOb Selling Price
$.053 $.053
$.053
Cost
$.0569 $.0835 $.0606
HONS 036199
TOWOLDMONOQ44593
Section 7 Page 2
A study will be made on the production of labor costs in the
handling of this product. However this will continue to bo a marginal item
since drum/material costs are as follows:
$/lb
Drum/Material Costs
Selling Price
Coarse crush 375 lb/drum Fine crush 375 lb/drum Fine crush 350 Ib/drum
$ .0412 $ .0412 $ .0412
$ .053 $ .053 $ .053
The required reduction In labor costs is as follows:
Labor Cost
to match
Present Labor
Manuf. Cost
Labor Cost Reduction
Coarse crush 375 lb/drum Fine crush 375 lb/drum Fine crush 350 lb/drum
$ .0157 $ .0423 $ .0183
' $ .012 $ .012 $ .012
$ .0037 $ .0303 i .0063
TABLE I
YTD (July 1967) Cost Variances for Aroclors
Direct Conv. Indirect Product
Material Cost
Cost
Conv.
Cost
Liquid Total Solid Total
$ 18,234 $ 19, 567-
$ 119, 794 $ 227 $ 7,648- $ 5,857-
$ 138, 175 $ 42,615-
Potential Raw Material Savings
Improve Santowax R/Blphenyi yields in the Solid Aroclors product line. If all yields can be raised to 90% the following material savings potentials exlat:
1968
1969
1970
1971
1972
Solid Aroclors $30, 100 $33,800 $ 38,200 $ 41,700 $ 43, 700
Production Cost Standard yields are as follows:
Santowax R
Biphenyl
1269 4465 5442 5460
78 92 78
78 78
YTD (July) yields ore 73% vs. 78%.
MOMS 036200
TOWOLDMONOQ44594
Anniston, Alabama September 22, 1967 AHOCLOK CO:C?STITIOH
Georgo R. Buchanan General Offices
Section 0 PaSe l |
A Monufacturing-IaprovacMmt Flan is beIns prepared for the Aroclor
product line at Anniston. Ona section of thlo report is entitled competitive technology.Comparison of competitive materials lias bean
performed at Anniston, however, a description of tho competing componioo is not available. Can you provide data on Bayer, Prodelec, nnd V Items euch ao hono office, aocots, product linos,
etc, would be raoat dosirablo,
.
Thank you
JMikd
John MacPhorson
HONS 036201
TOWOLDMONOQ44595
Annloton, Alabama
November 8, 1967
'
Section 9 Pug<> 1
R. C. Layer Patent Attorney Conaral Offlcea
A Manufacturing Improvement Plan is being prepared for the Aroclor
product line at Annloton. One section of' this report lo entitled
patent otatua. Can you furnish a brief description of the patent
situation for tho Aroclors?
.
Thank you.
V
JMPikd
MONS 036i02
TOWOLDMONOQ44596
Section 10 Page l
Stream ond Air Pollution
A survey of the Aroclor plant pollution will be completed by
2/15/68.
-
HONS 036203
TOWOLDMONOQ44597
TITLE OftAWN BY
CMCCKRO
APPAOVIO
DATE
,, CALI
AUTM. MO. JOS NO.
TS-A 804-S
MOMS 036204
TOWOLDMONOQ44598
TOWOLDMONOQ44599
TOWOLDMON0044600
TOWOLDMONOQ44601
TOWOLDMONOQ44602
TOWOLDMONOQ44603
DY .S.H1'. A........... DAT
chkd
oati:5/'A Av..
SUUJECT.................
..SOUp^MCL..-
^Kl. 'L.U!*'
SHLLI NO JOtl NO..
or .
Section 12 Appendix t Page 6
HCt. A 5 0 R e e R
HONS 036210
TOWOLDMONOQ44604
.... DAU- T/'iSUUJUCT.................................... . .
CHKD. riYj.'.i'? ..DATE. K 1.%/M'. .. L/.GiJ.ib.. "ft* ...CfVv.
O.
sncr.r ho
. ok
JOU NO.. .
.
Section ]2
HONS 036211
TOWOLDMONOQ44605
See l i on 12
cuva:;y conf:*:- ; - RESEARCH AND DEVELOP,'.',ENT REPORT
ANNISTON PLANT
- ,\ppe i.: II 6 No; u I No.
Job No
Dofo._
l. J7Q-50) .5-5-67 .
OTHER LOCATIONS
GENERAL OFFICE
ANNISTON PLANT
J. R. Savage - WCK P. E. llcislcr - WGK D. C. Armstrong - WGK A. F. Regan - MCL C. R. Coleman - MCL H. L. Hubbard - So. 2nd
H. C. Carder
v,,
W. B. Papngeorge
P. G. Benignus
> v L, C. Fuhrmclster
R. A. Stccnrod
- \J. MacPhorson
G. R. Buchanan
J. G. Bryant
H. 0. Hehner
V, R. Haupt
R. A. Munch
W. B. Dunlap
C. M. Williams
J. Crcsce
Tiller
Quality Report on Japanese Kanechlor 300 and Bayer Clophcn A-50
Personnel: Problem:
S. 0. Kemp and G. W. Miller
Quality Surveillance of Competitive Insulating Fluids in Competition with Monsanto Aroclor
Justification: Protection of Domestic Sales and Increase Potential for Foreign Sales
Summary:
Bayer Clophen A-50 is quite superior to Anniston and WGK Aroclor 1254 in electrical properties. This material as received exhibited a resistivity ' of 150,000 x 10' and thermal chemical chloride stability of 0.27 ppm.
Japanese Kanechlor 300 is also superior to Anniston and WGK Aroclor 1242. Even though this material had a 9,600 x 10^ resistivity and 0.08 ppm TC it Is still considerably better than any routine domestic production in Monsanto operations.
1 /dp
Gt W/Miller
HONS 036212
TOWOLDMONOQ44606
Research and Development Report No. I
Job No. 370-503
-2 -
Section 12 Appendix II Page 2
Background
The last report concerning competitive Aroclor type material was issued during October 1966. In that report (435-5-66) a comparison of Clophen A-30, Pyralene 1499, and Aroclors from the three Monsanto production facilities was presented. Also presented was a comparison of Pyralene 1476 and Anniston Aroclor 1254.
The additional data presented in conjunction with values cited from the above report should serve as a useful data source for summarization of Monsanto's marketing position at the end of 1966.
Discussion Bayer Clophen A-50
This material was received in a 16 gauge, welded seam galvanized steel drum. Even though the drum was equipped with rolling hoops It was dented in several locations
during transit. It is apparently characteristic of Bayer to use drums equipped with side wall bungs.
As in previous sampling of competitive drums this material was sampled by Insertion of a clean glass tube and displaced into clean bottles with dry nitrogen. One sample of the material was obtained at room temperature; however, due to the high
viscosity the drum was necessarily transferred to the Aroclor Department hot house to aid In sampling. Analysis of the sample drawn prior to warming the drum gave a resistivity of 190,000 x 10^. This value could not be achieved alter warming. Several replicate teats on the samples collected from the warm drum showed a maximum of 150,000 x 10^. All stability tests were performed In duplicate or triplicate.
The dielectric fluid compares favorably with Monsanto Aroclor 1254 specifications In all areas except that gravity and Index are too low and the dielectric constant is above our spec limit.
Isomer distribution and a full analysis report are included In the attached tables.
Japanese Kanechlor 300
This material was received in a 35 gallon welded seam galvanized steal drum. This material was sampled Indoors without any heat being applied.
The material ves submitted to at least two analyses on all electrical and stability
properties.
.
There ere no test properties on this material which are not within the specification limits of Aroclor 1242.
Isomer analysis and a full analysis report arc Included in the attached tables.
MQNS 036213
TOWOLDMONOQ44607
Research and Development Report No. I
Job No. 370-503
-3
Section 12 Appendix It Page 3
Future
Two five pint samples of these materials arc being forwarded to WCK for analysis It would be appropriate to report WGK results on the af orc-mentioned materials in this report; however, in the interest of having this data available at the May 9 quality conference the report contains only Anniston results. If serious dis crepancies develop in the data comparison with WGK, a follow-up report will be issvied.
/dp Att. 4
HONS 036214
TOWOLDMONOQ44608
Research ontl Development Report No. 1 Job No. 370-503
-4 -
Sect ton 12 Appendix H Page 4
Table I
Comparison of Competitive Materials With Monsanto Aroclor 1242
Property
Bayer Ciophon
A-30
Prodelec Pyralene
1499
Anniston AH-248
Color, APllA
<5
<5
15
Acid No.
0.001
0.002
0.001
Ref. Ind. <? 25 *C 1.6237
1.6245
1.6248
Sp. Or. <? 25*C
1.370
1.387
1.386
Vlec. <? 100'F, SOS 79.8
85.7
90.2
Moisture, ppm
63
35
30
Free Chlorides, ppm 0.01
0.01
0.01
HST, ppm Cl
0.11
0.16
0.14
l. a. Stab., ppm Cl 0.06
0.06 ` 0.11
TC Stab., ppm Cl 0.07
0.12
0.28
West. Stab., ppm Cl 0.40
Re.let. x 109,
Oim/CM, 100'c P.F. 9 100*0
60 cycles l KC
15,200
0.22 0.06
0.48 1,270
4.6 0.33
0.51 1,980
2.0 0.17
D.K, 0 100'C. .
4.90
4.87
4.83
Distillation 10% 327 90X 348
330 352
328 352
Type drum
Steel, gelv. Steel, welded
dipped,
earns. Type of
16 ge.
lining to be
determined
One coat phenolic lining
Appearance of drum Good, no dents
Head bent, rim seam split, lining flaking
Good as produced
MCL Z-16 15 0.001 1.6249 1.388 86.9 52 0.01 0.32 0.12 0.48 1.56 1.900
WGK B 450 15 ... ... ... ...
28 0.01 0.50 0.16 0.48 0.93 1.030
3.4 0.25
4.8 0.20
4.80
4.90
327 ... 348 ...
Two coats Bottle phenollc lining
Good, no major dents
Bottle
Kanechlor 300
10 0.001 1.6248 1.390
24 o, oo9
0.11 0.06 0.08 0.36 9.600
0.55 0.13 4.82 331 352 Steal welded seams, ga Ivanized Good
MONS 036215
TOWOLDMONOQ44609
Research and Development Report Mo. I Job No. 370-503
5
Section l.i Appendix II Page 5
Tabic II
Comparison of Competitive Material With Aroclor 1254
Test Date
10-15-66
10-5-66
4-30-67
Property Color, APHA
Prodelec Pyralene
1476
10
Aroclor 1254 AH-68
20
Beyer Clophen
A-50
7
Acid No.
0.002
0.002
0.001
Ref. Ind. @ 25'C Sp. Cr. @ 25*C
1.6380 1.503
1.6382 1.504
1.6365 1.490
Vise. 0 210T, SUS
66.2
45.9
Moisture, ppm
30 20 30
Free Chlorides, ppm Hydrolysis Stab., ppm Cl
0.02 0.14
0.02 0.14
0.009 0.07
Thermal Chem. Stab., ppm Cl
0.32
0.30
0.28
Woetlnghouse Stab., ppm Cl Resist, x 109, OHM/CM, 100*C
1.00 3,180
1.13 5,880
0.62 150,000
Power Factor @ 100*C, 60 cycles 1 KC
1.5 0.14
0.60 0.10
0.288 0.09
Dielectric Constant, <3 100*C, 60 cycles
Distillation - 10% 501 90%
4.23
368 376 387
4.25
370 376 388
4.37
365 373 387
Monsanto Stability, ppm Cl
0.18
0.14
0.10
Type drum
Steel, welded seams, 16 ga. Type of lining to be determined
One cost phenolic lining
Steel welded seems. Ga Ivanized rolling hoops
..^peersnee of drum
Good, no dents
Good ss produced Good
HONS 036216
TOWOLDMONOQ44610
Research and Development Report No. 1 Job No. 370-503
-6-
Seciio;'. L Appunii:: II
6
Table III GLC Analyses of Competitive Aroclor 1242
Peek 1 2
Japan Kanechlor Anniston 300 WGK
0.03
0.01
O.U
0.79
0.01
0.13
England 0.05 0.18
Baver Prodelec Identification
Trace 0.009
Biphenyl
0.003 0.01
2 Chloro
3-4-5 6-7 8-9-10 11
0.25 ' 4,39
11.79 1.15
Trace 3.02 8.57 1.15
0.04 0.07 3.30 3.69 9.98 10.19 0.74 1.26
0.03 Trace 4.91 3.44 12.36 8.91 1.19 1.06
3 Chloro-4 Chlovo
2.2'! 2.6
2,5; 2,4; 2,3'; 2,4'; 2,3 3,5
12-13-14-15 16-17-18-19-20
21.64 27.56
24.03 32.27
26.50 25.04 32.72 32.78
26.33 28.23 31.32 34.26
3,4; 3.4'; 2.5.2' 4; 4; 2,3,2' 2,5,4'; 3,4,2'; 2,3,4
21-22-23-24
7.50
7.08
7.05 6.59
5.79 6.79
25-26-27
10.04
10.22
9.69 8.84
8.58 9.51
3,4,4'
28-29-30-31
8.07
7.24
6.26 6.23
5.29 6.66
32-33-34
3.50
3.31
2.51 2.64
2.32 2.60
35-36-37-38-39-40 1.57
1.19
0.69 0.87
0.85 0.77
41-42
0.69
0.62
0.23 0.36
0.46 0.40
43-44-45-46 '
0,41
0.39
0.11 0.25
0.31 0.22
47-48-49
0.09
0.21
0.02 0.08
0.16 0.09
50-51
0.04
0.04
0.02 0.11
0.03 0.02
52
0.01
0.04
Trace 0.03
0.01 0.005
53-54-55-56
0.07
0.13
0.02 0.22
0.03 0.09
57
NDA
0.08
NDA 0.02
NDA NDA
"-59-60
0.06
0.10
Trace 0.26
0.01 0.01
61-62-63
Trace
0.08
NDA 0.17
NDA Trace
64
NDA
Trace
NDA 0.10
NDA NDA
MONS 036217
TOWOLDMONOQ44611
Research and Development Report No. I Job No. 370-503
7
Section 12
Appendix II Page 7
Peak 1 2 3-4-5 6-7 . 8-9-10
n
12-13-14-15 16-17-18-19-20
1-22-23-24 25-26-27 28-29-30-31 32-33-34 35-36-37-38-39-40 41-42 43-44-45-46 . 47-48-49 50-51-52 53-54-55-56 57 58-59-60 61-62-63 ,4
Table IV
GLC Analyses of Competitive Aroclor 1254
Anniston 1254
WGK 1254
Bayer Clophen
A-50
0.015
0.02
Trace
0.01 Trace
0.36 0.16
Trace 0.01
0.07
0.04
0.23
0.46
0.19
0.75
0.05
0.01
0.03
1.09 1.59
0.48 0.81
0.76
l.n
8.34
*
7.80
8.03
4.01
3.59
4.61
13.29
13.09
14.27
16.11
16.24
16.66
17.77
18.23
19.35
13.14
14.12
12.85
11.05
11.65
10.23
8.32
8.77
7.10
1.98
2.02
1.68
1.56
1.56
1.37
0.64
0.66
0.39
0.50
0.62
0.50
NDA
Trace
Trace
NDA NDA 0.02
Prodelec Pyrnlene
1476 Trace Trace 0.12 Trace 0.30 0.04 0.90 1.35 8.08 3.32 12.35 15.80 18.10 14.26 11.93 8.70 2.10 1.36 0.80 0.46 Trace 8D4
MONS 036218
TOWOLDMONOQ44612
Section 12
Appendix III Page 1
TABLE I
THE WORLD MARKET FOR CAPACITOR AROCT.OR
Total Potential and Monsanto Share 1966 and 19Y1 (Estimated)
DOMESTIC markets
Metric Tons ( 0 < U.f. 1
USA UK France Germany Japan
Total
1266
Total
Monsanto Share
11,000 930 515
1,100 ,-Liqo
15,845
11,000 930 0 0 0
11,930
1971
Total
13,000 1,400 1,000 1,400 3,300
OOO-OOtf O O O
re,-?
Monsanto Objective
20,100
14,400
NON-DOMESTIC MARKETS
EFTA EEC E. Europe Asia-Pacific Rest of
Americas Rest of World
Total
740 1,370
305 330
1,035 --212
4,150
Grand Total
19,395
285 200
90 235
975 100
1,885
13,815
925 1,850
725 665
1,940 6C0
6,705
26,805
500 0
300 500
1,900 `>00
3,600
18,COO
MONS 036219
TOWOLDMONOQ44613
See Lion 12 Appendix IH Page 2
TABLE IX
NON-DOMESTIC MARKETS FOR CAPACITOR ADOPT.OR BY AREA - BY COUNTRY
Austria Denmark Finland Norway Sweden Switzerland
Total
Italy Belgium Holland
Total
Czechoslovakia East Germany Hungary Poland Romania Yugoslavia
Total
Metric Tons
EFTA
70 25 95 30 290 230
7/10
EEC '1366
800 350 220
1,370
EASTERN EUROPE
13k6
20 100
15 70 15 85
305
1321
80 ^5 100 50 350 300
925
1971
1,050 500 300
1,850
1971
A5 200
50 200 100
122
725
HONS 036220
TOWOLDMONOQ44614
Section 12 Appendix III Potc 3
TABLE XI (continued)
N0N-D0M3STIC MARKETS FOB CAPACITOR AKOCLOR BY AREA - BY COUNTRY
Australia India Hong Kons
Total
Argentina Brazil Mexico Canada
Total
Metric Tons
ASIA-PACIFIC
1266 170 150
10
330
REST OF THE AMERICAS
126" , 100
250 135 550
1,035
1221 350 300
15
663
1971 380 450 360 730
1,940
Israel South Africa Spain
Total
rest of the world
1266
30 0
30
370
1221
50 50 500
600
MOWS 036221
TOWOLDMONOQ44615
See Lion 12 A|)|>CijJix III I'age 4
TABLE III
ESTIMATED WORLD PRODUCTION CAPACITY*
;
USA Prance UK Germany Italy Spain Japan
TOTAL AR0CL0RS
Million Pounds
Monsanto Prodelec MCL
80 10 10
Bayer Caffaro FI lx
10 2 1
Kanegafuchl
_7 120
Tons 36,200
4,600 4,600 4,600 1,000
500 3,500 55,000
*Also produced In East Germany and Russia
MONS 036222
TOWOLDMONOQ44616
TABLE IV
KNOWN WORLD MARKET BY PRODUCER - i oAf,
(Metric Tonal
MAJOR DOMESTIC MARKETS
B.F.T.A. E.E.C. H, EUROPE ASIA-PACIFIC RK5T OF AMERICAS REST OP WORLD
TOTAL
M.C.L.
930 220 200 90 210
0 -29 1,7*10
BAYEH
1,100 155 805 115 50 50 0
2,275
PRODELEC
515 365 300 100 50
0 -32 1,360
CAPFARO FLIX
00 00 65 0 00 00 00 _0 250 65 250
kaneoa. FUCH1
1,700 0 0 0 0 0
____ p 1,700
M.C. TOTAL
11,000 o0 0 1, j t 0 3C>
20 310 965 1,07.3
0 12,005 19, y}j
HONS 036223
TOWOLDMONOQ44617
(
R,IMPOSITION Bsnsonc Chlorine
PROD, DUALITY
IP.kZ
ANALYTICAL
date PROD. STARTED Years
PRODUCT RANGE
SALES ORGANIZATION Strength Method Visit Frequency
Customer Relations
TECHNICAL SERVICE
OTIKR ASSETS
.
SUPPLY SITUATION
TABLE V
ELECTRICAL AROCLOR TABLE OP COMPETITIVE STRENGTHS
KCL/MC
Buy/Make Make
Good/Fair Pair/Fair
Adequate
1951/1930 1* 35
Very large
BAYER
Buy Make
Good Good ' Adequate 1930
35 Very large
PRODELEC
Buy (Progil) Make (Progil)
Good Good Adequate
1930-1939 27
Limited (Progil)
Good Dircct/Agcnts
Much respect Good
Good Dlroct/Agents Europe more than MCL Much respect
Good
Oood Dlreet/Agents Europe more than MCL Much respect
Good .7'
RFTA (Large Comp,)
Drums OX Dull? ?
EEC (Large Comp.)
Drums OX Bulk Oood
EEC (Progil)
Drums OK Dulk Oood
CAFFARO
Buy Make
Good Pair Adequate Post 19A5
Limited
Italy only . Direct Italy OK Bit amateur Not as good
Big Three Local
Drums OK
MONS 036124
TOWOLDMONOQ44618
Tftb.V l
(
RESEARCH EFFORT
NEW PRODUCTS
AROCLOR
.
IMPORTANCE (IJC)
FRICK LEADERS/ gutters
philosophy
MCL/MC
Needs MC/MCL liaison
Yes
BAYER
. Rot obviously energetic
No
PRODFXEC Very active
Very active (1500)
Small but valuable
Small but valuable
large
caffaro Non-exlsten No
Kodlum
Stability
Stability
Leaders
Cutters
Common schedule Common schedule Common schedule To capacity
9**4
HONS 036223
TOWOLDMONOQ44619
Section L2
Append i>: I.i.i
1'atc a
TADLK I THE WORLD MARKET FOR TRANSFORMER ASKAHEL
TOTAL POTENTIAL AND MONSANTO SHARE 1966 AND 1971 (ESTIMATED)
loop pounds - (finished- blends)
DOMESTIC MARKETS
USA UK Franco Oermany Japan
TOTAL
.
1266
TOTAL MONSANTO SHARE
17000 650
6100 3600 1600
17000 650 0 0 0
28950
' 17650
TOTAL
25000 3000 7000 4000 2500
41500
1971
MONSANTO SHARE
25000 3000 0 0 0
28000
NON-DOKESTIC MARKETS
EFTA EEC Eastern Europe As la-Pacific Rest of Americas Rest of World
TOTAL
520 2000
175 620 3380 --ZIP
7445
GRAND TOTAL
2km
30 0
25 270 3380 _3
v 4005
21655
730 2500
250 750 3860? 1040
9130
50630
200 0
100 500 38607 700
5360
12360,
MONS 036226
TOWOLDMONOQ44620
tabie :a
SCC Hichi l.-! / | ? J > (.' 11<ili.H III I'aBO !
non-domestic; markets for transformer askarkl
BY AREA - BY COUNTRY
1000 POUNDS (FINISHED BIHNDS)
Austria
Denmark
Finland
Sweden
Switzerland
Norway
Portugal
' TOTAL
EFTA 1966
100 None None None
300 20
' 100 520 .
>. .
1971 150
None None None
400 30
150 730
Italy Belgium Holland
TOTAL
EEC 1966
750 1200
50 2000
.1222 1000 1400
100 2500
_ MONS 036227
TOWOLDMONOQ44621
Czechoslovakia East Germany Hungary Poland Romania Yugoslavia
TOTAL
EASTERN EUROPE
12L
None
7 None
;
25 None
150
175
Section 12 Appendix ILL
10
12Ii None
7 None
50 None
200 250
Australia India Hong Kong
. '
TOTAL
ASIA-PACIFIC
1266
`280
.
340 "
'.
None
620
1211 350 400 None 750
MaMb-xiMCKraMK**:aki.j.
HONS 036228
TOWOLDMONOQ44622
AppciiJi:: [II lMfaC 11
Arcentlna
Brazil
.
Mexico
Canada Chill
Puerto Rico Panama
TOTAL
REST OP THE AKTRTCAS
1266 70
200 170 2900 20 10 ' ___10 3380
19-71 120 A 00
. 300 3000 20 10 ___10 3860
REST OP THE WORLD
Israel South Africa
.1266 ' 70
150
Spain Pakistan
500 . --22
TOTAL , 750
1211 . ' 100 " , 200
700 ' ___40
1040
HONS 036229
TOWOLDMONOQ44623
Page 12
TAME j-K- 32
KNOWN WORLD MARKET BY PRODUCER - 1966
1000 POUNDS (FINISHED BLENDS)
MARKET
MONSANTO UK BAYER PRODELAC CAFFARO FLIX
Major Dome otic Markets 650
3600
6100
0
0
KANKOA- MONSANTO
PUCHI
USA
1600
17000
TOTAL 28950
nm
30 270 220 0 0
0
0 520
EEC
0 350 900 750 0
0
0 2000
Eastern Europe Aola-Paciflo
25
0 jl50
00
0
0 175
260 200 150 0 0 0 10 620
nest of Amorloos
0
0
0
00
0 3380
3380
Root of tho World
300
0 50 0 400 0 0
750
TOTAL 1265
4420
7570
750 400
1600 20390
36395
HONS 036230
TOWOLDMONOQ44624
Monsanto
TO
H. J. Day, St. Louis General Offices
September 7, 1967 LIQUID AROCLORS Requirements Through 1972
Mr. H. W, Tlppee
H. C. Carder G. R. Buchanan J. Cresce ............. lLdu"Furr; .ci liter P. E."Holder D. B, Hoomor
N. L, Sample R. P, Stevens Jack Kolloy
Hill Williams Bob Yates
- GBUOH JCPJiS
- /in..lr.';c. ICru:... rl
- duos;'. - i:sa;-:p
- RST2V - Wrut,i;.\rlt
- Annlatoi - RYATE
The attached shows the U. S. requirements for Liquid Arocloro through 1972. This is based on sales estimates received by this group on August 17, 1967.
Note that the forecast is down somewhat from thot calculated on July 13, 196T! Current Anniston capacity is 08,000 i'i lbs./year and WOK oapaolty is 28,800 w lbs/yr,, total, 76,800 M lbs./year. It might be interest ing to note that 7 months 1967 total liquid aroclor production has been at an annual rate of 73,700 H lbs./year and inventories at this writing are at a maximum, -
Jms Attachment
H. J. Day
HONS 036231
TOWOLDMONOQ44625
Section 1?. AppciuUx IV V{jc 2
\
XiXQUT.D AROCLOHS 5-YEAR FORECAST (IN THOUSANDS OF LBS.)
TOTAL REQUIRED FROM U.S. PLANTS
Krummrich 1242
1248
1254 1260 1262
1960
16,107 5,049 4,031 6,638 125
32,750
1969
1970 .
19,037 4,596 5,039 6,953 135
35,760
21,404 4,571 5,462 7,345
___
39,007
1971
23,772 4,447 '957 8,l4o 155
42,471
1972
25,572 4,861 6,257 e,405 165
45,340
Anniston . 1242 1248 1254 1260 1262 1221 1232
DIV. TOTAL
' 28,636 1,782 8,647 2,291 630 110 593
42,739
75,489
29,745 1,908 9,426 2,360 649 120
2
44,671
80,431
30,691 1,993 9,555 2,725 64l 130 526
46,261
85,268
33,491 2,308 9,445 2,078 656 140
____ m.
49,511
91,982
35,247 2,708 9,265
m
51,718 97,05a
H. J. Day 9/7/67
HONS 036232
TOWOLDMONOQ44626
II, J, .Bay,.. St,._Bpu:Ls General Offices
Section 1.2 Aj'j'cucl ir. IV Page 3
September 8, ly67 SOUP AltOCPOKS HEQUlKiiiiJCNTS TUHOUGil 1972
Hr. H. W. Tippee
It. is. unecr H. G, Caj'Uoi* J. Crcoco Pou I',uhj,woister P. B. Hoainer Don Marrincr
N. L. Sample
n. P. Stevens W. F. U&ychoff
Hill Williamu
Bob Yatea
__ KUDO 1ICAJU)
J OAKS Anniston _ DHOSI! - DMAKJ-i _ NSAHP
- KSTJiV - VAMYC
- Anniston - RYATli
The attached shows the Anniston requirements Cor Solid Aroclors through 1972. This is based on sales estimates received by this croup on August 17, 1967.
/Jms Attachment
H. J. Pay
MONS 036233
TOWOLDMONOQ44627
See Lion l?. Appendix IV P.ige /,
SOLID AKOCLORS ' FIVE-YEAR FORECAST (IN THOUSANDS OF DBS.)
TOTAS REQUIRED FROM ANNISTON
1268
im-'-
5060 5442 5460 - 5
Rated Capacity
Deficit
1968
290 25
865 410 186 . 8699
10469
1QOOO
469
1362
300 25
925 420 210 9780
11660
ICjpOO
1660
1970
310 25
985 440 240 11150
13150
1Q000
3150
mi
320 25
1045 450 270
12220
14330
lQlOOO
4330
mi
330 25
1105 466 300
12800
15020
lqooo
5020
H. J. nay 9/8/07
HONS 036234
TOWOLDMONOQ44628
5cc t i -an 12 Append L . V l'ngc l
Linn
Process non produc tive_ T 3 me
Plugged lines Waiting on room in ble nd tisilk Switch products Lack of still capacity Drawing out receiver Waiting on crude Vacuum troubles Repack pomp Misce11 nneouR
1966
DM KV
43.4
2.0
33.7
4.5
3.1
49.6
2.4
202.0 22.0
23.6 1.6
20.0
1.3 1.6
--
340.A1 71 .4
1967 Y.iTL.Oi PN uV 15.8
2.1.0?
47'. 92
4.1 i.o
11.3 -
102.1 1.0
1. 1966 DN Time report is for February - December, years' total is 3S5 including January.
2. Requires change to Cl^ control valve trim.
3. Due to export grade
4. For projection, use 10 hrs. for WOR in blond tanks and 20 hours WCC.
Liquid /.rodor
Other Non-productive Time
Faulty Cl- car Low Cl. pressure CI2 plant down No CI2 car Switch CI2 cars Empty CI2 car Poor CI2 quality Steam press lino. Product change Rcbri.ck furnace Export grade Aroclor Lack of still capacity Inventory adjustment Product demand low Refining pilot plant Miscellaneous Water linos
1966
DN KV
15.9
2.3 12.5
17.5
7.8
6.4
7.2
25.2
16.1
9.7
15.9
11.4
44.6
23.2
50.0
91.1
12.0 12.6 ---- TfO1 "65? 5
1967 DN
7.1 27.5
10.2 9.0
32.0 44.8 15.0 44.4 14.3 204.T"
'il RV 3.2
-- ~r
MQNS 036235
TOWOLDMONOQ44629
Section 1'
Append]. V rage 2
1. 1966 DM lino is Iol Feb. - December, year's total i.r. 169 including January.
?.. For projection of 1967 VXD u?e only 16 hr:;, for export DM, 0 hr*.. DN for pilot plant, 3 hrs. for loo Clj pressure, 5 hrs. Cor empty cars end 0 hrs. for voter lines.
Liquid Ai'oclor
Repair Non-producti.vc Vine
1966 DN RV
1967 YTD (Lav) DN RV
Still receiver pumps
Still circulating pumps
Blend tank pump
Catalyst check
Chlorinntor coil replacement
Still circulotingcoil
Cl vaporizer
Piping failures
Miscellaneous
i
37.6 28.2
12.0 90.6 19.8
6.0
1.2 .
___ 18.5
4.6 ' 11.8
11.5 50.7
7.7 7.7 ___
37.3
____
....
.. --
212.01 18.5
131.3
1. 1966 DN line is for File - December, year's total is 223 including January.
MGNS 036236
TOWOLDMONOQ44630
SceL.inn ) Append.'.:: V Pi'B 3
Solid
hv;;;
. iiH1L"P ~<>d
71 :>'C*
1.906
WN itv
Clj feed liw:; plugged Chlovinntion cooler plugged Still cireulotting lino
plugged Uniting or fInker Vacuum trouble Waiting on crude Miscellaneous Waiting on room, blow tank
Chock softening point Plugged liner Operating errors Drumming 4465 Vaporizer
28.9 3.0
VO. 3 159.6 194.6
37.0 186
37.1 2.0
92.0 57.0 21.0 21.6
*910.1
61.4 21.0
--
"8277?
l967t_XV0..(i;--v) i);<T ' Y`*
7.5 2.0
LI.3 6.0 8.0
1.0 10.0
8.8
_
457b
_
~8
Solid Aroclovs
Other Non-productive Tima
1266 DN RV
1967 VXD DN
w
Santo\\':<-U Cost Switch Cl2 car Low pressure Cl. car Motor in SM-il 1
CI2 plant down Empty Cl. cars CI2 quality Cooling water problems Steam problems Therminol TJ.c-in Miscellaneous Product change over Equipment mod if lent ion Still Therminol System
83.5 38.7
-
88.0
66.2 32.4
13.0
32.0
38.5 39.2 88.6
--
487.7 "27 4"
72.1 75.8*
6.51 17.6 39.7 26.11
2.5 11.5 11.0 30.9
-
--
29177
27.6 7.5
"8. B
31.7 -- "7576
1. Use 30 hru. switching. 2 hrs. 1 iv pressure. 10 hrs. empty cars for
projection tine saving based on projection.
MQNS 036237
TOWOLDMONOQ44631
Solid AmeJor
P>ci>;:jLr . Ijon-iu o'hx l: i
J9J36 UN* IIV
Flaker-grinder |',vi.n :ilng Theruinol leak Demister No. 9 chlo.rinntor Weigh Lank agitator
ChLorinator pump Still pump Still entrainment separator Chlorine.tor CI2 distributors Therminol system Clp vaporiser Cl flow control valve Vacuum jot burst furnace coil
Miscellaneous Off-gas condenser Vacuum problems F laker Steam leaks Instruments
152.7 To
31.0 75.6 157.7
21.6
54.3 48.0
64.0 23.1 11.3 89.4
35.0 _
_ __
729.5 40.0
Section 17 Append/... V I'ngc 4
1967 Yif) (;5ivJ
Si riv*
51.7 55.8 23.8 11.5 18.0
13.0 82.8
33.0 35.5
7.0 1.3.1
9.0 46.5 66.0
_ _ 51.6 _
T
T 15.0 _ __ _
"
466.7
66.6
MONS 036238
TOWOLDMONOQ44632
nlb.Af
a/* /sy
WcuK?. (Kamt (TAfioTy
*.* 7a sto.
o/.* /,,
Append!:-. VI
Pete l
MOWS 036^39
TOWOLDMONOQ44633
HONS 036240
TOWOLDMONOQ44634
MONS 036241
TOWOLDMONOQ44635
St cL .1 I. VII
Pr<;c }. VI'/.. till* Contributors
1. Production - n separate sect ion vill.jjqt be v.'.-ritten by lit? Production Supervisor since the basic outline of the Jill' developed in conversations between Production end TSP.
2. PRfrJ) - to be written by 2/15/68. 3. Quality Operations Control - to be written by 2/15/68. A. Maintenance. - to be written.
HONS 036242
TOWOLDMONOQ44636
Authority j No. :
2(1? 6
:
27)9 22V.' M2J 2374 m?. ?37V 2345 .7366
TABUS _____
Description Anorovod Prolccta
Pin (.nil to MnnlCoUl Inutruswnts
Department
626,08
Aroclor Still Revision Aroclor Alnm System
826.03
826.08
Klxcd Bod Tower fur Rcfinlnn Aroclor 926.08
[/vol Indicator on th Still Receiver 826.17
Vortical Condenser on ff4 Still
826.17
UAllruad Rwur Cor Chlorine Tank Cots 826.17
1 Capital
U.OOQ
Se.vlno* 6.T 1 Sueeens factor
--
931
1.1.600
3.900
857.
1.450
2.870
437. 1
2.515
2.020
Ou.-litv
1. 300
031 7 57.
16.600 3U 700
6. RO'J 21.200
057. 33`i
Drumout ll.no Tor '.roc lor 4463 Uirboitloncck Liquid Aroclor Still Svstem I'hitucoi.l. llcnt Supply tor "1 Hoot Tank
826.17 026.08 826.08
3.400
17.130 221.000 !. 5.70 --
90?. 03''1 1007
7-b'
MGNS 036243
TOWOLDMON0044637
HONS 036244
TOWOLDMON0044638
MONS 0362<5
TOWOLDMONOQ44639
n ir
MONS 036Z46
TOWOLDMONOQ44640
References 1'. TSD Job No. 370-500,. Report No. 2, 4-20-67. 2. TSD Job No. 370-500, Report No. 1, 2-13-67.
Section 12 Appendix IX Page 1
MONS 036247
TOWOLDMONOQ44641
Section 12 Appendix X Page l
Coat Analyst!
A. Liquid Aroclors Cost Variances
1. Net material cost: major contributor (767, of total variance) la the chlorine coat; delivery of plant chlorine to Aroclor Is baaed on cell efficiency, standard Is based on pegged numbers. A program ia planned for the Improvement of cell efficiency monitoring.
2. Indirect conversion:
.
(a) ateam - this is an assigned valve, true value will recorded when steam meters are Installed.
. (b) gas - negative variance 19 a result of pushing the stills
(lower efficiency) to gain higher production rates
(c) labor - variance is the result of high overtime
(d) packing containers - high negative variance is the result Increased export demand and the use of an Improved drum ,
($0.50/drum)
*
(e) laboratory - high production rates have required increased
laboratory effort.
-
(f) production deportment containers - increased production rates
have exceeded predicted usage
(g) Pilot plant exp. * high positive variance resulted from delay
in project for waste heat recovery
(h) Technical Services - Increase in personnel assigned
(1) experimental - bauxite refining unit was installed under
experimental expense funds
(j) research expense - increased activity (k) plant process research - Increased personnel assigned plus higher
activity level (l) mechanical expense - low budget
B. Solid Aroclors Cost Variances
' l. Net material cost: major contributor (70Z of total variance) is the chlorine cost; again this la a pegged value rather than
, a true measurement. The program planned for the Improvement of . .chlorine cell monitoring will Improve chlorine assignment to
solid Aroclors.
2. Indirect conversion:
*
(a) steam - this is an assigned value, cost should improve as steam casters we installed
(b) gas ~ YTD reflects three months below capacity production
HONS 036248
TOWOLDMONOQ44642
Section 12 Appendix X Page 2 (c) packing containers - low estimate of required amount (d) laboratory - YH> reflects increased sampling in previous months with production difficulties (o) technical services - Increased personnel assigned to department () mechanical expense - low budget
HONS 036249
TOWOLDMONOQ44643
f ' Section 12 Appendix X - Page 3
COST REPORT YEAR TO DATE - ORGANIC DIVISION
ANNISTON, ALA*
'LIQUID AROCLORS
DEPT. 02606 PRODUCTION CODE B260B
ACTUAL PRODUCTION - YEAR TO CATE 25,815,494
SCHEDULED PRODUCTION - YEAR TO DATE 25,822,500
JULY 1967
* MATERIAL
TEAR TO OATE QUANTITIES
OR EXPENSE
ACTUAL QUANTITY SCHEO. CUANT1TY OVER-UNDER SCH.
STEAM
MBTU
80,065
60,412
19,673-
ELECTRICITY CKWH
6,861
10,325
1,444
. HATER PLANT MGAL
268,373
257,682
10,691-
GAS MBTU
54,472
47,337
7,135-
LABCR
HRS
16,903
15,287
1,616-
PACKING LABOR
4,956
4,956
LA8CRATCRY HRS
2,499
1,931
518-
CLAY ATTAPULGUS
25,100
33,560
8,460
FERRIC CHLORIDE
2,053
7,745
5,690
LIME KYCRATED
141,567
129,078
12,689-
NITROGEN
154,000
154,000-
PORCCEL
14,185
14,185-
BIPEENYL
14,786,618
14,914.095
127,477
CKLCRINE
23,882,425
25,117,633
764,792-
H C L 100
12,193,770-
12,193,770-
. MCN1ARS
876,248-
' 613,831-.
37,563-
530 533 542 545 570 601 610 19400 33510 38800
43100 48269 12601
62638 82851
82868
0 0 0 0 0 0 0 0 0 0
0 0 0
Q 0
0
MATERIAL OR EXPENSE CLAY ATTAPULGUS FERRIC CHLORIOE LIME HYDRATEO c NITROGEN V PORCCEL BIPEENYL
CHLCRINE HCL ICOt M0N1ARS NET MATERIAL COST
. : YEAR TO DATE AMOUNTS
ACTUAL COST SCHEDULED COST OVER-UNDER SCH.
' 985
1,397-
' 412 : 19400
329 1,242
913 33510
1,586 330.. .
1,442 ' ; ''**
144330-
38000 43100
$73'
573-
48289
709,327
713,543
6,216
62601
641,210
621,871
19,339-
82631
196,148-
198,148-
62851
13,328-
16,328-
1,000-
82668
'1,140,864
1,127,019
'13,845-
;
0 0 0 0 0 0 0 0 0
It
i
RAH MATL. HAND. TOTAL MATERIAL COST ,
4,389 ;1,14?,233
1,127,019
4,38918,234-
530 d ..A.
MQNS 036250
TOWOLDMONOQ44644
Section 12 Apptndlx X Page 4
C'
COST REPGRT YEAR TO DATE - ORGANIC DIVISION
r\
ANNISTON, ALA.
'LlQU10 AROCLORS
DEPT. 8260E PRODUCTION CODE 82608
I ACTUAL PRODUCTION - YEAR TO CATE 25,815,686
; SCHEDULED PRODUCTION - YEAR TO CATE 25,822,500
JULY 1967
` STEAM ELECTRICITY
WATER PLANT GAS LABCR SALARIES . PAYROLL OVERHEAD , SUPPLIES L PACKING LABOR PKG CONTAINERS PACKING O/H LABCRATORY CLOTHING .LAUNORY PROC OEPT CONTNR PILOT PLANT EXP TECHNICAL SERVIS EXPERIMENTAL RESEARCH EXP PIT PROCESS RES . MECP EXPENSE TOT OIRECT CCNVERSION jTOT CIRECT MFC. COST
i DEPRECIATION 1 FACT. 1N0 EXP. TOTAL INDIRECT CONV.
PERFORMANCE VOL. TOTAL PRODUCT COST ' PRICE C MAT. MIX
UNSCHEDL1EO CAP. INV. VALLE 8 TOT VAR.
39,29* 5,716 5,770
16,295 63,681
9,862 13,318 11,699 : 15,716 96,601
3,563 16,007
1.379 .11,718
26,029 27,766 30,708 .12,261 23,850 58,587 . 692,579 1,637,832
56,079 60,268 94,328
1,736,160
30,768 6,646 5,67$
14,595 58,363
9,599 13,783
9,525 15,796 69,705
1,763 16,959
871 . 1,931 . 59,703
11. ,7.6.7.
1,033 5,900 4 C344 372,785 1,699,806
58,766 37,337 96,101
80 1,585,885
93,639967-
1,501,379
8,5*5- ^ 930 96- i
1,700- < 5,338- <
263465 2,176-
78 26,696- ' 1,800- '
3,068-^ 608-
9,787-' 33,674 15,87930,70811,228-17,45019,263114,794138,028-
2,685 2,912-
227-
80 138,17593,639-
967232,781-
530 533 562 545 570 575 578 590 601 602 603 610 616 618 620 621 635 651 657 694
698 700
994
996 997
/V"
'""~G- - - - - - - - - - - - - -
------------------- G
HONS 036251
TOWOLDMONOQ44645
Section 12 - Appendix X - Page 5
COST REPORT TEAR TO DATE - OHGANIC DIVISION
ANNISTON, ALA.
REF SOI ARCCLORS
DEPT. 82617 PRODUCT ION CODE 82617
ACTUAL PRODUCTION - YEAR TO CATE 5 ,647,469
SCHEDULED PRODUCTION - YEAR 10 OATE 5 ,550,324
JULY 1967
MATERIAL
YEAR TO OATE CUANTITIES
OR EXPENSE
ACTUAL QUANTITY SCHEC. QUAN1ITY OVER-UNDER SCH.
STEAM
MBTU
32.544
24 * 384 ' 8,560*
ELECTRICITY CKWH
4,460
5,071
611
WATER PLANT MGAL
83,693
81,165
2,728-
GAS MBTU
43,263
35,807
7,456-
LABCR
HRS '
8,222
8,365
143
PACKING LABOR
5,138
5,138
LABCRATORY HRS 1 FERRIC CHLORIDE
' ` 650 528
337 1,654
313766
LIME HYORATEO
37,047
28,237
5,610-
BIPHENYL
181,803
176,827
4,576-
SANTOWAX R
2,568,658
2,821,254
147*364-
CHCR1NE
:5,276,064
8,653,577
582,487-
H C L ICO* .
3,857,071-
3,857,071-
MONTARS
120,707-
120,707
SOLID AROCLOR RE
1,462,655-
1,462,655-
MATERIAL OR EXPENSE
FERRIC CHLORIOE LINE HYORATEO
BIPHENYL SAN10WAX R
( CHLCRINE H C L 1C0S MONTARS SOLID AROCLOR RE
NET MATERIAL COST
' - - YEAR:TO DATE AMOUNTS
ACTUAL COST SCHEDULED COST OVER-UNDER SCH*'
' 150
273
123 -
422 314 108-
6,784
8,537
247-
.132,252
125,775
6,517-
228,27i
213,565
14.703-
62,877-
62,677-
3,211-
3,211
35,(36-
35,836-
268,156
245,555
18,241-
530 533 542 545 570 601 610 33510 .38800 82601 82602 82638 82851 82868 82865
33510 36600 82601 12602 82638 82851 82868 82865
,
RAM HATl. HANO. TOTAL MATERIAL COST
1.326 265,522
245,555
1,326-
530
HONS 03625.;
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Section 12
Appendix X Page 6
COST REPORT YEAR TO DATE - ORGANIC OTVISICN
ANNISTON, ALA.
REF SOI ARCCLORS
06PT* 82617 PRODUCTION CODE 82617
ACTUAL PRODUCTION - YEAR TO CATE .5,667,669
SCHEOULEO PRODUCTION - YEAR 10 OATE 5,990,326
JULY 1867
,11...-
'
j
ir
ii
;' ; 1 !
STEAM ELECTRICITY
MATER PLANT GAS
LABCR SALARIES PAYROLL OVERHEAO SUPPLIES PACXING LABOR
PNG CONTAINERS PACXING 0/H LABCRATCRY
CLOTHING LAUNDRY
PROC DEPT CONTNR TECPNICAL SERVIS EXPERIMENTAL
i PLT PROC RES MECP EXPENSE
`tot DIRECT CONVERSION TOT OIRECT MPG. COST
1 DEPRECIATION FACT. IND. EXP. TOTAL INCIRECT CONV*
PERFORMANCE VOL. TOTAL PRCOUCT COST
PRICE 8 MAT. MIX > UNSCHEDULED CAP.
INV. VALLE TOT VAR.
16,269 3,092
1,965 12,931 30,991
6,716 7,596 ............... 907 19,277 19,634
572 6,718
682 5,802 6,656
937
' . . . ....
26,878 '159,566
629,C88
62,130 23,882 66,012
495,100
12,623 3,501 1*921
11,281 31*885
4,845 8,617 3,500 16,303 11,863
298 2,625
593 12,181
6,130
100 600 23,250 151*916 4C1.E73
40,455 19*720 60,175
9,563452,685
34,15530,654 666*984
3,846409 24-
1,650- . 934 1 131 -
1,021 ' 2,593 1,026 7,776-
2742,093-
876,379
526937100 600 3*6287*64627,215-
1*6754,1625,837-
9,36342,615-! 34,15530,654 46,116-
530 533 542 545 570 575 578 590 601 602 603 610 614 618 621 635 651 657 694
698 700
^94
996 997
' -f"
.
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