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INC. ESCAMBIA PLANT
INTEROFFICE MEMORANDUM
R. E. Davis
From: , A. Primeau
Rs: PVC Monthly Report November, 1972
Dots: December 1, 1972 Copies:
SUMMARY
Prime resin production for November was 5, 174 M lbs versus a budget
of 5, 129 M lbs and a November 20 forecast of 5, 285 M lbs. Off-grade, tailings
and sweeps amounted to 55 M lbs which represents 1.1% of total production versus a budget of 4. 5%. Approximately 120 M lbs of resin production were lost on the north product line when the blower on the dryer failed due to metal fatigue in the impeller. The line was down 36 hours while a new impeller was installed and balanced.
A total of 573 charges were made, an average of 19 per day.
The variance generated by PVC for November was ($10, 664) unfavorable. The variance resulted from:
1. PVC Bulk 2. PVC Bagging -
($13,668) $ 3,004
The forecasted variance on November 20 was $3,400 favorable. The items affecting the variance were:
Raw Materials Process Costs Volume Machine Hours
Total
Forecast
$2,000 { 200)
3, 600 ( 2.000)
$3, 400
Actual
($ 3,807)
( 7,297)
( 564)
( 2, 000)
($13, 668)
211*1
ANALYSIS OF VARIANCE
Raw materials were unfavorable due to:
1) An nnfavflrahlfi ($1, 5M) variance in VC1 due to a manufacturing efficiency of 92% for November versus a budget of 94.5%* Part of this high
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Mr. R. E. Davis PVC
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December 1, 1972
usage was due to leaks in a vent line which now has been replaced with new piping.
2) A low production level for off-grade resin resulting in an unfavorable variance of ($4,8M) in by-product credit.
These unfavorable variances were partially offset by a $1.8M favorable variance
in process chemicals and $0. 6M favorable variance in royalties.
Process costa were ($7. 3M) unfavorable mainly due to {1) high main tenance costs in the chemical cleaning unit when the shell of the rototherm unit collapsed, and (2) the establishment of a $3. 4/month accrual account for the purchase of NMP solvent.
Volume variance was ($0.6) unfavorable. 5,201M lbs. of prime resin was produced versus a standard production of 5, 174 lbs. Machine hour variance was ($2, 000) unfavorable due to 30-day month, December projection is 5,400 M lbs. of resin which will generate $3. 0M favorable primarily from PVC bagging.
DISCUSSION
During November, the PVC plant produced seven resin types. Resin type 1230-P accounted for 44% of the total prime production. The south reactor line was utilized 22 days in November to produce 2, 282 M lbs. of 1230-P resin in 221 charges. The average yield per reactor hour for the 1230 was 665 lbs. versus a budget of 664 lbs. per hour.
On November 5, the impeller on the north drying line failed due to metal fatigue in one of the blades. As a result, the entire north product line was out of service for 36 hours while a new impeller was installed and balanced. Approximately 120M lbs. of resin production were lost due to the outage.
The EDTA test program to reduce fouling in reactors charged with 1200 series homopolymer resins was continued. Test results continue to show a reduction in the rate of reactor fouling with an extended number of charges between cleanings.
During the month information was received showing that EDTA was FDA-approved in numerous food applications, including direct application in salad dressings. Based on this information, small residual quantities of EDTA in resin used in water pipe applications should meet FDA standards. Therefore, it is recommended that an application for FDA approval be submitted.
CHEMICAL CLEANING
The chemical cleaning system was started up and operated on NMP during
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R. E. Davis (EAP)
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the month of November. After some initial problems with operating conditions, the Rototherm unit was able to produce a "dry11 particle equivalent to the particle produced in the pilot plant at Artisan.
In the middle of the month, a section of the inner shell of the Rototherm unit collapsed due to the reduction in the wall thickness resulting from erosion and corrosion while in DMF service. The collapsed section was cut out and replaced with a heavier patch of metal. The blades damaged when the wall collapsed inward were replaced and the unit was returned to service.
In an effort to improve the operations of the recovery unit, and reduce solvent losses, a new set of vacuum jets was ordered to replace the exist ing Bet which is badly worn. Delivery of the jets is scheduled for midDecember.
PVC EXPANSION
A major part of the month of November was spent working with the engineering department to prepare investment and operating cost studies for a PVC expansion at the Escambia Plant. Three cases were studied at a pro duction level of I70MM lbs per year and two cases at a 340MM lbs per year level. Initial results indicate that 17 0MM or 340MM lbs per year plant should be built north of the existing plant if sales volume can justify the expan sion,
PVC bagging
A total of 2, 258M lbs of PVC was bagged at a cost of $11, 188 in November.
Variance is as follows:
Volume Spending
Total
$ 900 2, 104
$3, 004
PVC LOADING & SHIPPING
A total of 5, 463M lbs of resin was shipped from Pace. Bulk shipments accounted for 3, 129M lbs. Starting resin inventory was 790M lbs and closing inventory 672M lbs.
EAP/as Attach.
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STATISTICS
Prime Product Homopolymer Subtotal
November
Actual
Budget
5, 174 5, 174
5, 129 5, 129
Year- to-Date
Actual
Budget
10, 567 10,567
10, 429 10,429
Off-Grade Homopolymer Tails Sweeps Subtotal
0-
49 6-
55 231
0 119
14 133
-
481
Total Production
5,229
5, 360
10, 700
10, 910
Off-Grade, % of Total Production
Bulk Prod, % Prime VCM Efficiency, % Reactor Availability Production #/Gal Yr
1. 1
56.4
92. 0 93.5 1, 320
4. 5
-
94. 5 92.5 1, 307
1.2 59.7 92. 0 94.2 1, 325
4. 5
-
94. 5 92.5 1, 307
OFF-GRADE ANALYSIS
None.
PRODUCT SEQUENCE - NOVEMBER
North Line
Type
Batches
2225
3
1220
2
2160
8
1225
19
2200
13
2250
6
2225 2200
19 47
2250
14
2160 2200
15 21
2250
25
2200
42
2160 2250
17 20
27 1
South Line
Type
Batche;
1230
90
1225
27
1230 1225
59 24
1230 1225
72 30
302
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STATISTICS (continued)
Page 2
PRODUCTION SUMMARY - M Lb*
Type 1200 1225 1230-P 2160 2185 2200 2225 2250
Total
November 15
893 2, 282
330 0
976 169 509 5, 174
DOWNTIME ANALYSIS
Cleaning Reactors Schedule Charges Behind on Recovery Hold to Drop Plugged Drop Valves Change Type Slow Drying Hydraulic Motor Maint Miscellaneous
November 515 129 124 167 11 14 56 53 40
1, 109
Year-to-Date 15
1,933 4, 803
397 2
2,095
539 85 3 10, 567
% 6. 5 1. 6 1. 6 2. 1 0. 1 0. 1 0. 7 0. 7 0. 5 13. 9
Yr-to-Date 1, 056 185 233 315 33 29 106 70 90 2, 067
% 6,6 1. 1 1.5 2.0 0. 2 0. 1 0. 6 0. 5 0. 5 13. 1
EAP/as 12/1/72
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Personnel
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