Document B54kb4j4jaeV8XB8jrZradErm

ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM Tot Fvmbj Km Mr. T. L. Carey Defeat J. J. Dorsey, Jr. Copiot Summary of Technical Department Monthly Reports - September 1966 October 8, 1966 NEW PRODUCTS DNT The DNT plant was completed the last week of September. It was decided, however, to delay the startup of the plant until the Biazzi represen tatives arrived and they had an opportunity to inspect the plant. Many instru mentation and electrical problems were resolved through the intensive efforts of the Construction and Design, Instrument and Electrical groups. Similarly, shortages of equipment were solved by the Construction group with the cooperation of other sections of the plant to provide alternate pumps and other equipment where necessary to complete the plant on time. Full credit and appreciation is expressed to all of the operating, Construction, Design, and Maintenance personnel involved. It is expected that the plant will startup during the first week in October. ADE There was no opportunity to do any work on the ADE project this month because of unexpected problems in amines and the necessary assignment of personnel to the DNT plant startup. R. E. Jones and I am attempting to summarize the engineering phase of the work, while Messrs. Fowlkes and Tolar are attempting to summarize the laboratory phase. The information is here; it is simply impossible to find time with the other problems to do this work at this time. I am afraid it may be necessary to delay summarizing the ADE work until sometime during December. LABORATORY Laboratory work during this period has been concerned with the special projects and amines problems over and above routine control work. Training of the DNT personnel and laboratory technicians in DNT analyses has proceeded throughout most of the month. T e c h n ic a l Sum m a ..4_J AP00045593 Mr. T, L. Carey -2- October 8, 1966 The laboratory group has concentrated on evaluating new MIPA catalysts. At month end a new Harshaw catalyst was tested and installed in the plant which appears to give superior conversion fend selectivity to desired products. This catalyst also is stronger than previous catalysts and appears to be a considerable improvement. It is unfortunate that we did not have the manpower to 8 eek an improved MIPA catalyst during the past 18 months, because it now appears that better catalysts are available which should be evaluated and which could allow a substantial reduction in catalyst costs as well as improved yields and selectivity to desired products. Catalyst testing of MEA catalyst also was carried out on a crash basis because it is impossible to obtain delivery of new catalyst on other than an extended delivery basis. ENGINEERING The DNT plant was essentially completed except for tracing and insulation on the lines leading from the check tanks to storage and loading at month end. Final costs of this project will be approximately $1, 350, 000, depending on the amount of overhead which must be paid Chemical Construction on their work. The new 600# boiler and water treating facilities are proceeding on the revised schedule with completion expected to be about November 15 to Decem ber 1, depending on equipment delivery. Details of the various projects are covered in the Engineering report. Separate memoranda are being issued explaining project overruns which have occurred. Most of the overruns can be explained by the accelerated need for the improvement involved which has required overtime, increased labor costs, and changes in the scope of the project since estimated. SPECIAL PROJECTS Mr. Rogers issued several evaluation reports on the production of ammonia and methanol from new large plants located either at Pace, Florida or in Texas, or in Louisiana. The lower gas costs for a single facility in Texas or Louisiana are compensated for by economies in adding to the Pace facility when a single plant is built. However, if two facilities are built, substantial economies occur in a Texas or Louisiana location, GENERAL The plant Process Improvement group does not have sufficient manpower to accommodate all of the present and projected needs nor does it appear that AP00045594 Mr, T. L. Carey -3- October 8, 1966 the 1967 budget is adequate to sustain the manpower required. Essential work in amines, DNT, and some other plant areas can be handled. Other essential work will probably have to be handled on on a hit-or-miss basis as has been the case for the past two years. Mr. Ronald Beech joined the Process Development Department at month's end and is assisting with the DNT plant startup. mdc AP00045595 SUMMARY OF PROJECT WORK STATUS Protect No. Title Appropriation MS 6501 Water Softener* to Provide Water for Boiler 18. 0 Committed Revised Completion M* MS Date 10. I 18. 0 12/1/66 Remark* Equipment due early Novem ber. Field piping In progress. 6509 6535 6565 6585 Air Condition It Enclose Wet Bay Control Room Ammonia Recovery Preeaure Control Syetem DNT Plant ' Equipment to Produce IBN ft DEA - Amine* 6.0 3. 3 B70.O 223.9 6604 6605 6613 New 600 pel 100,000 I/Hr. Boiler 320.0 Upgrading Water Treatment 105.0 Produet Coating Syetem - NP IS. 5 6616 6617 6621 6622 6631 6636 6632 6633 6635 6640 6642 6647 Provide Office*, Locker Room and Storage Additional Bulk Car Loading Facilities - PVC 14. 3 10.4 Refrigeration Unit for Cooling Solution* Tank* - PVC Spare Block for Recovery Compreeaore - PVC Additional Electric Heat and New Converter for #1 Plant H.P. Water Pump, H.P. Scrubber No. 1 Plant 12.0 14. 3 8.0 15.0 4.0 New Methylaminca Check Tanka Plant Steam Recorder Maintenance Shop-Area B 12.4 l.a 26.0 Purchase of Lab Equipment Amtno-Phoi Production 23.4 200.0 6649 6652 Ammonia Reform Cae Guard Veaael Amine* Plant Expansion* 31.3 1360.0 4.0 6. 0 1.5 3. 3 1323.0 1385.0 218.0 224.0 238.8 320.0 101.3 7.5 105. 0 15.5 none 9.5 14. 3 10.4 10.7 14.2 55.2 1.5 12.0 14. 3 55.2 4.0 15.8 1.2 none 9.9 208. 0 15.8 1.8 26.0 23.4 210.0 27.7 111.3 31. 3 1360.0 10/31/66 Still 95% complete. 11/1/66 ------ > *--> 12/1/66 12/1/66 Indefinite Waiting for material deliveries Ic available instrument man power. Production Qmpiete: 9/16/66 Storage Complete: 9/30/66 Production complete; storage by 11/1/66. Tank foundation complete. CBfcl fabricating tank. Piping fabrication in progress. Field work on schedule. Equipment due second week of Octobe r. Field piping in progress. Equipment due early Nov. Elevator received. Job being deferred at requeet of Pro duction. Approval still pending. Indefinite 9/30/66 95% complete. Awaiting available manpower for Installation, Complete. 8/15/66 Complete. 7/29/66 Complete. Indefinite 7/28/66 Installation dependent on Production's decision aa to proper uae of pump. Complete. Indefinite 1/31/67 Indefinite Indefinite 8/31/66 Waiting for ahutdown to imtall Approval obtained. Construc tion will start immediately. On* agitator remaina to be Installed. Will be completed when Production releaaea tank for work. Complete. 4/1/67 NH3 column to be delivered by 12/1/66. Condenser* due in December. Engineering in progress. AP00045596 Summary of Project Work Statue September, 1966 Page 2 Project No, Title 1580.18829 Independent Raw Water Supply - PVC Appropriation MS 9.7 Committed Revieed Completion MS MS Date Remark! 3, 6 9.7 10/15/66 Work in progreei. 1580.18339 New Blowdown Tank for Compreeeor Building 1580.13862 Revise Gondenaate Syatem from PVC Dryere 1770-6003 PVC Reactor Reglaulng 2.7 3.0 38.0 3. 7 2.5 23. 1 3.7 3. 0 38.0 8/31/66 Complete. Indefinite Indefinite Awaiting delivery of pumpi to complete job. Spare reaetor being regiaaeed at Glaacote with acheduled hipping date of December 2. 10/5/66 / n* AP00045597 PHOTOGRAPHS OF COMPLETED DNT PLANT As of September 30, 1966 View of interior of structure showing nitrators in series. View of completed plant from the Southeast. AP00045598 1 ESCAMBIA CHEMICAL CORPORATION Interoffice Memorandum To: Mr. T. L. Carey Date: October 5, 19^6 From: E. M. Spurlock Re: Monthly Report - Personnel Department - September. 1966 PERSONNEL Activity for the Month Division No. of Employees 8/31/66 Admin. & General Research Agrl. Chemicals Industrial Chemicals Production Totals 6515 167 17 Jfl1 731 September Additions 23 15 20 31 September Separations 1 6 92 _7 25 No. of Employees 9/30/66 57 57 163 16 444 737 1966 Budget 56 59 167 * 18 406 706 * This includes 160 as listed on the budget sheet plus 7 temporary employees vho were not shown in number on the budget sheet. There were 210 walk-in applicants, 154 applications were issued and 6 were received by mall. Sixty-nine applicants were interviewed and 109 were tested. TRAINING School was held for the operation of trackmobilee and 2 trackmoblle operators were licensed. SAFETY The Corporation has worked 10 days or approximately 43,500 man-hours without a disabling Injury. The various division records are as follows: Division Man-hours Days New York Office Research Division Atlanta Division Pensacola Plant Corporation 358,500 850,000 171,000 26,500 43,500 1,883 3,363 143 10 10 The laboratories and the Warehouse completed eleven years without a disabling injury. The Maintenance Department completed three years without a disabling Injury. P ersonnel AP00045599 Monthly Resort SAFETY (Coat'd.) -2- Oetaber 5, 1966 Medical Section The Medical Section treated 28 Injuries for Escambia and 25 for Carroll, performed 16 pre-employment and 13 annual physicals and gave a total of 44 immunization Injections. EMPLOYEE RELATIONS Labor Day picnic vaa held on September 5, 1966 with approximately 800 in attendance. Six 10-year service awards were presented. INSURANCE ve paid a total of 66 claims under our Group Hospitalization program which amounted to a total of $ 10,4o8.8o during the month of August and 84 claims amounting to $ 17,748.84 during the month of September. Ve settled the following claims during the month of September; Two claims amounting to $ 88.62 under our Automobile Physical Damage Insurance. One claim amounting to $ 192,667*3^ for payment In full of Physical Damage portion of Methanol Explosion which occurred on October 24, 1965* Check ves received In the amount of $ 27,807*00 covering Workmen's Compensation Second Interim Retrospective Premium Adjustment. EMSjkc AP00045600 PRODUCTION MONTHLY REPORT October, 1966 AP00045601 lum inary ESCAMBIA CHEMICAL CORPORATION Interoffice Memorandum To: Mr. H. F. Roderick From: T. L. Carey Subject: Monthly Report for October, 1966 Date: November 10, 1966 The item of major interest this month was the substantial improvement in the production cost of methyl methacrylate. The variance from standard has been running in the range of negative $120, 000 to $130, 000. October was a negative $69. 000. There still is a long way to go but the month showed a very s ignific ant impr ovement. The N-P plant produced 16. 5-16. 5-0 grade all month and had the lowest actual cost per unit in the history of the plant. These costs were $2. 50 per ton under standard. The DNT plant started up early in the month and by month's end had made a 96 hour performance run which demonstrated the plant capability of producing specification material at design rates. Unfortunately, our customer Wyandotte, will start taking product at a low rate in January and has tentatively scheduled increasing quantities to full rate at mid-year. Some of the raw material usage rates are higher than guarantees. These will be studied and recommendations made for negotiations of acceptance with Biazzi. Amines results still leave a lot to be desired. Maintenance and yields are the biggest problems. A negative variance of $77, 000 had been predicted for October and an actual of $108,000 was made. In an effort to apply more technical assistance to the problems, the overall operating responsibility was transferred from Mr. Dorsey, Director of Engineering, to Mr. J. Kramer, Production Manager. This will apply specific production know-how to the area and allow the technical group under Mr. Dorsey to work on the yield problems directly. The amines expansion program is coming along well and appears to be on schedule. This project should be complete in March at which time these plants should be on budget. PVC appears to have overcome its recent problems and with a good product mix a very good production for November is predicted. AP00045602 Mr. H. F. Roderick 2- - November 10, 1966 All other plants are In good shape and operating well. November should be an excellent month from the production standpoint. AP00045603