Document B5r0V3KO2QZv2QaLQYBwyYNMm

AP0004I188 cmd Cemieai- CSCAMIIA PLANT IN6. INTEROFFICE MEMORANDUM To: From: Re: Mr. A. K. McMillan R. E. Jones Dot#: Copies: Monthly Report - August, 1974 11 September 1974 The ammonia plant performance continued below standard and was a major contributor to unfavorable plant variances. A major plant outage of 10 days was required to replace broken packing in the carbonate system regenerator. Plant production losses are shown in the following: Carbonate System Outage Low Temperature Shift Converter Catalyst Activity Refrigeration Outage Z, 900 tons 310 tons 90 tons Total 3, 300 tons Production- for the month was 4, 954 tons as compared to a standard of 7, 553 tons. The ammonia plant was forced down on July 31, following an emergency outage caused by an electrical failure on July 28, The outage caused a pressure surge in the reform system which "lifted" the packed sections of the carbonate super regenerator. This lifting caused considerable breakage of the porcelain packing resulting in gas flow restrictions in the column. Replacement packing was found and was installed and the plant restarted on August 11. The replacement packing is not the recommended material and will have to be replaced during the next scheduled turnaround. In addition to the above plant problems the Low temperature shift catalyst is showing rapid activity decline. Sulfur levels in the natural gas have increased significantly during the summer and breakthroughs are occurring through the OSR vessels. Replacement of the existing OSR vessels will be required at the higher sulfur loads in the feed gas. Outages are continuing to occur in the west refrigeration machine because of water leaks in the freon condenser. A replacement condenser is on order. Ammonia plant outages continue to contribute to unfavorable production variances in the downstream facilities. AP00041189 Mr. A. K. McMillan -2- 11 September 1974 Nitric Acid production continues to exceed standard values with an August production of 16, 020 tons as compared with a standard of 15, 146 tons. An outage for a routine gauze change was taken in the No. 1 plant during the month. The No. 2 plant gauze will be changedin September. The No. 1 nitric acid plant will be shut down in mid-September for a scheduled fitting of the spare Elliott rotor and for absorber inspection. A fiveday outage will be required. The ammonium nitrate area at sales limiting production rates. 83% AN inventories were increased to maximum levels during the month at the expense of prilling. Production figures for the month are shown in the following: Month Tons % of Budget Year to Date Tons % of Budget 83% AN AN Prills Bay-Sol Urea U-32 Solutions 17,673 3,758 1,785 1, 195 2, 908 214 75 357 132 124 201, 071 151, 803 16, 837 18,201 45,833 130 122 183 99 96 PrilLing rates will be increased during September to maintain 83% AN inventories. Urea outages totalling 472 tons resulted from the ammonia plant outage taken at the beginning of the period. U-32 solution was also below standard due to the urea outage. Methanol production was 2, 391 M gallons or 113% of standard in spite of the loss of CC>2 during the ammonia plant shutdown. Production loss of 264 M gallons was incurred due to this outage. Gas efficiencies were also adversely affected because of this. The methanol expansion continues well on schedule. At month end all the new compressor foundations have been poured and overhaul work on the two main gas engines is proceeding ahead of schedule. Project completion iB still scheduled for March 1, 1975 with equipment coming on stream in various stages. Compressor work will be completed by February 1. PVC production for August was 6, 075 M pounds or 94. 6% of budget primarily because of continued recipe problems with 2,200 resin causing gross reactor fouling and with "glassyn particle problems with 1230P. Recipe changes were made and some improvement has been noted. AP00041190 Mr. A. K. McMillan -3 11 September 1974 The new stainless steel reactor was installed in the No. 8 position during the month. The No, 8 reactor was replaced instead of the scheduled No. 9 reactor because of a jacket failure. The energy group has been working closely in the PVC plant to resolve obvious energy discrepancies. A general plant overhaul of steam traps and leak repairs have reduced steam usage by approximately 24% from a July value of 2.98 lb./lb. The following summarizes the Escambia Plant program in reducing VCl exposure. Personnel Monitoring a. Century readings have averaged 5-10 ppm throughout the month. These readings continue to be taken by a maintenance mechanic on routine leak patrols. This program has been successful in reducing the number as well as severity of VCl leakage from equipment. b. Personnel monitoring showed further decreases in personnel exposure. August exposures to 50 ppm and greater decreased to 1.4% from 4. 5% in July. 95. 9% of all readings were below 10 ppm as compared to 81. 1% in July. All August sampling has been long term (7-7- 1/2 hrs. ), c. The Bendix multi-point chromatographs show the same downward trend with only 1. 1% above 50 ppm as compared with a July value of 2.4%. d. The Bacharach explosion monitoring system continues to require excessive maintenance to be really operable. Spare parts delivery is very slow and results in some portion of the system to be out of service virtually all the time. e. Ambient air samples were taken on three occasions in the PVC operating area. VCl levels of <1 ppm were recorded each time. Particulate measurements in the area around the product collector discharge were also made and show very small quantities of particulate concentrations. Personnel Protection a. Ventilation by removing one course of the building siding has been very effective in reducing VCl excursions. Removal of additional siding will be evaluated. b. Relocation of the VCl charge pumps was completed during August. Leakage from these pumps and VCl filter will be outside the building. c. Revisions of the safety and emergency procedures have been completed and will be issued in September. AP00041191 Mr. A. K. McMillan .4. 11 September 1974 Product Collectors Delivery of the new Ducon product collectors is scheduled for November 4 shipment. Steel and duct work will be completed by November 13 and the installation completed at that time. VC1 Residual in Resin. Measured VCL residuals in all resin grades have been within the VCM specification with the exception of 1230P resin. Only 54% of the samples analyzed were below the 500 ppm level for this resin. PVC Expansion Expansion cases were reviewed with all involved with a considerable amount of information updating accomplished. Cases for the economic alternates have been fully developed for the project presentation. Solvent Cleaning Solvent recovery laboratory work continued in August with excellent results. An easily filterable precipitate can be made with steam precipitation of PVC from the solvent at 90C. This process coupled with water extraction of the filter cake indicate a DMF recovery of 98 to 99.5% is indicated. Details are presented in Mr. Tolar's report. Amines product rates continue below budget primarily caused by extended outages for repairs to corroded equipment (IBN) and because of ammonia column deficiencies caused by tray corrosion in the No. 1 plant. Methylamines production was limited to only 82% of budget because of the unstable ammonia column operation. Loss of trays is indicated below the feed tray. Replacement will be required at next pLant outage. The No. 1 plant was started up on MIPA on July 27 and has operated satisfactorily since even with the apparent deficiencies in the ammonia column. Loadings in MIPA are not as critical as with methylamines. DNPA production was continued in the No. 2 plant until July 18 and was well above budget with good alkyl efficiencies. Outage associated with product turnaround and corrosion during the IBN startup resulted in 102 hours of plant outage. In general, the IBN production run is much improved over the past run with above budget rates being achieved. Plant mechanical difficulties however have prevented any extended operating periods. AP00041192 Mr, A. K. McMillan - 5- 11 September 1974 Raw material yield losses in both plants have been determined to be directly attributable to low pressure vent scrubber losses. Venting is required from product columns because of the inability of the ammonia columns for stripping all ammonia from the mixed amines stream. Revisions to the ammonia stripping system are being designed with implementation of the revised process scheduled by January 1. The No. 1 plant expansion continues on schedule in spite of some slippage of critical instrumentation this month. Early October startup is still forecasted. The Escambia Plant effluent treatment system experienced an extreme change in biological makeup. AIL of the biological ponds went from aerobic to anaerobic over a period of one week as a result. The entire month of August was spent in returning the system to its former condition. Excursions from the NPDES permit in BOD,- and suspended solids were experienced. At month's end the system seems stabilized and previous good results are anticipated. Considerable project work was accomplished with the NO^ and prill tower abatement systems. Preliminary plant layouts of both the Masar units for NOx abatement and the venturi-shroud system have been made. Actual construction was begun prior to September 1 to achieve the third increment of progress for the nitric acid plant final compliance schedule. The energy group continues to determine energy losses throughout the entire plant with a particular emphasis in PVC. Results in reducing steam consumption in that facility have been encouraging. Anticipated reductions in other production units will exceed our in-plant goal of 20% savings. The ammonium nitrate solution tank insulation project was approved and work begun on the large 10, 000 ton tank at month end. Steam usage was measured for the 5000 ton tanks and was found to be approximately 5000 ibs. /hr. The project will reduce 91% of the total steam requirement in these tanks. The total plant variance continued unfavorable with ($171.1M) for August. Major variance contributors were as follows: Ammonia ($58.4M) Unfavorable variances occurred from the unscheduled outage of 10 days for carbonate system packing replacement. Methanol $26.9M Methanol generated positive variances due to increased volume effects of the Phase I expansion. This was AP00041193 Mr. A, K. McMillan -6- 11 September 1974 Methanol (cont'd) Amines ($94.9M) PVC ($51.3M) Agricultural ChemicaLs $35.2M Overhead & Utilities ($28. 6M) accomplished in spite of rate and efficiency losses incurred during the ammonia outage. Large amines variance occurred primarily due to low methyiamines production and raw material efficiencies in the No. 1 plant caused by ammonia column tray losses due to corrosion. Additional corrosion problems in the No. 2 plant caused extended startup problems. Unfavorable PVC variance was caused principally by recipe problems with 2200 and 1230 P resins ($19. 5M) and unfavorable maintenance costs for product collector replacement accrual and VCl exposure reduction items ($44. 5 M). Favorable nitric acid and 8 3% AN volumes - $78. 8M - offset by unfavorable prills due to sales demand ($56. 4M). RE J:fis Attachments (3) AP00041194 EXHIBIT I PRODUCTION SUMMARY Agricultural Chemicals (tons) Ammonia Nitric Acid 8 3% AN Bay-Sol Prills Urea U- 32 Industrial Chemicals Amines (M lba, ) Methanol (M gals. ) Plastics PVC (M lbs. ) August Actual Budget Year to Date Actual Budget September Plant Estim. Budget Inven. 4, 954 16, 020 17. 673 1, 785 3. 758 1, 195 2. 908 5, 600 80. 369 83,000 10, 800 190.059 166,225 8, 272 201, 071 154,082 500 16,837 9, 200 5, 000 151,803 124, 242 900 18,201 18, 440 2. 345 45,833 47,514 7, 500 7, 638 3, 956 13, 900 15,525 241 16, 414 14, 021 18,784 1, 412 800 140 8, 175 6, 000 413 1,720 1, 560 0 3, 870 4, 181 1, 199 4, 374 2, 397 5, 621 2, 150 52,967 56, 906 18, 909 19,ooo 4, 816 2, 600 5, 181 2, 080 6, 013 1, 317 6, 075 6, 381 68,057 68,364 6, 421 6, 421 767 AP00041195 EXHIBIT II PRODUCTION VARIANCE SUMMARY () Unfavorable Agricultural Chemicals Ammonia Nitric Acid 8 3% AN Prills Urea Bay-Sol Total Industrial Chemicals Amines Methanol Total Plastics PVC Overheads & Utilities August Actual Budget (58.4) 2. 6 44. 0 2. 0 34. 8 0. 6 (56.4) 1.2 6. 3 0. 6 6.5 0, 1 (23.2) 7. 1 Year to Date Actual Budget September Estim. Budget (288.5) 1.9 23. 6 (1.9) 319.0 1.4 ( 2.0) (1.4) 286. 3 0.4 5.5 (0.4) 246. 3 0.9 ( 2.0) (0.9) 5.3 0.4 1.2 (0.4) 26,9 0. 1 3. 8 (0. 1) 595. 3 5.1 30. 1 (5. 1) (94.9) 26,9 (68. 0) 4. 1 3.2 7. 3 (505.0) (489.9) (994.9) 2. 9 2. 1 5. 0 20. 0 65. 0 85. 0 (2,9) (2. 1) (5.0) (51.3) (28.6) 3. 6 0. 0 (151.3) (386.2) 2. 6 0. 0 (36.0) (30.0) (2.6) 0. 0 GRAND TOTAL (171.1) 18. 0 (937.1) 12.7 49. 1 (12.7) AP00041196 EXHIBIT. Ill VARIANCE SUMMARY OVERHEAD AND UTILITY () Unfavorable Plant Administration Engineering & Drafting Maintenance Instrument 4c Electrical Personnel & Training Safety 4c Medical Purchasing Warehouse Equipment Pool Process Development General Yard Electricity Steam Water Total Spending $ 14,410 August Budget $16, 323 Variance $ 1, 913 23, 710 12,362 (11, 348) 27,774 7,991 14,386 11, 808 (13, 388) 3, 817 8, 910 7, 088 ( 1,822) 9, 071 10,109 1, 038 8, 873 7, 281 ( 1,592) 5, 797 7, 881 2, 084 9,421 8, 140 ( 1,281) 17,184 22,877 10, 336 15,886 -- -- 12,982 11,483 $169,000 $133, 083 ( 6,848) ( 6,991) 230 ( 5,808) ( 1,499) $(41,495) Year to Date Variance $ 22,872 5, 832 (27.506) 36,874 (18, 723) ( 6, 225) ( 8,808) 7, 421 ( 1, U2) (56, 006) (93, 730) (10,130) (112,025) ( 7,124) $(268, 390) AP00041197 Plastics *m AP0004I198 PVC Monthly Report August, 1974 Page 6 e) Leak Patrol - The leak patrol program which had begun in previous months was continued throughout August. The value of the.pro-gram is now well established in that fewer leaks, aill of h minor nature are being found; This points out the effectiveness of leak repairs in prior months. f) Equipment Modification - The two VC1 charge pumps were removed from the first floor of the reactor building and relocated outside the building. The VC1 filter was also relocated outside the building, now any seal or gasket leaks will not be venting VC1 into the operating area. After unloading a VC1 tank car, the flexible lines used to connect the car must be vented before disconnecting. This vents Less than 1/2 lb. of VC1, but to remove it from the operating area a vent stack was installed. g) Procedure Changes - A revised **Safety and Emergency Procedures" book was prepared . It will be issued as soon as the copies are made. SEPTEMBER Production and efficiency in September are forecast at budget. Variance is forecast at $36M unfavorable due to the following: Volume Bagging Volume Utilities Maintenance - Major Maintenance Labor Laboratory Materials & Supplies Total ($3. OM) 5. OM 3. OM (12. OM) (17. 9M) (4. OM) (5. OM) (2. OM) ($35. 9M) WCW:aw W. C. Wilde AP00041199 EXHIBIT I STATISTICS Prime Production, M lbs. % of Budget -August Actual Budget 6, 075 6, 422 94. 6% Year to Date Actual Budget 68, 058 68, 825 98. 9% Off-Grade Homopolymer Tails Sweeps & PTS 134 115 29 278 0 539 96 1, 555 0 430 96 2, 524 0 0 0 Total Production % of Budget Off-Grade, % of Total Bulk Production, % Prime VCM Efficiency Reactor Availability 6, 353 97. 5% 4.4% 77. 3% 92. 0% 70. 3% 6,518 70, 582 101. 4% 1-5% -- 94. 0% -- 3. 6% 75. 8% 93. 5% 72. 8% 69, 857 1.5% -- 94. 0% -- Type 2250 2200 2250 2200 2250 2200 2250 2200 North Line Hours 61. 5 776 248. 5 930 98 468. 5 133. 5 396. 5 3112.5 PRODUCTION. SEQUENCE!, August 1974 South Line Batches Type Hours 5 1230 517. 5 77 1225 602 16 1230 973. 5 93 1225 280 7 2200 255 50 1230 1697.5 10 4325.5 29 287 Bate he 79 56 106 28 23 180 472 PRODUCTION SUMMARY - PRIME M lbs lbs/hr. lb/annual gallon Type August YTD August Budget % Budget Actual Budget 1225 682 9,224 645 7 09 91. 0% 1, 310 1. 439 1230 2, 998 32,651 784 787 99. 6% 1. 592 1, 598 2160 82 2, 011 -- 642 -- -- 1, 380 2200 2, 064 20,521 609 668 91. 2% 1, 309 1. 436 2250 249 3,650 381 544 7 0. 0% 819 1, 170 AP00041200