Document GKzbjk67ObpwBajmrYDgXo954

I ; Anniston ' -a-A;.*;.-: --- --'V- - : v; - V C. K. Eastman '? , 4. J. Koenig s 'v J. C. Landwehr i A. E.` Leisy | G. W. Miller f W. B. Papageorge W. F. Taffee . H. L. Williams General Offices H. C. Carder D. E. Cayard D. Banna (5) H. 0. Hehner P. B. Hodges D, B. Hosmer (2) W. A. Kuhn C. F. Luecke X. M. Patrick H. L. Payton N. L. Sample J. E. Smith R. J. Stratmeyer H. S. Trail COMPANY CdNftOtNtlAL Anniston Plant TECHNICAL SERVICES DEPARTMENT ..MONTHLY REPORT Summary October, 1968 Cost Improvement Results For First Ten Months Estimated Actual Target % of Target Month $ 18,640 $ 40,500 46 YTD $364,910 $415,935 88 { Organic Division South Second St. Solid Aroclor yield increase project 3015 and Santowax R column project 3OI6 sent to St. Louis for approval. Prior verbal approval was given on long term delivery items. These projects are needed to meet 1969 Solid Aroclor pro duction forecast. . Preliminary scope definition started with CEB on the Solid Aroclor expansion. Market testing to start on new blended Solid Aroclor 4465 Savings $12 M/yr. with zero NFC. i Other Locations D. W. Jackson - WGK Work on upgrading No. 1 Biphenyl Tubular Unit started in field. Shutdown expected in November to tie-in piping and equipment. Purification of biphenyl hydrogen for HB-40 via mixed bed adsorption continues to show good potential in pilot run. Now determining optimum conditions for maximum recovery efficiency. Preliminary Project Scope Report on chlorine bulk handling including flow diagrams and plot plans received from CED on 10/4. Scope was reviewed and returned with plant comments on 10/18. .. DSW 377270 an - 30(5 v CONFIDENTIAL INFORMATION :; "This document contains confidential Information which Is the proparty of Monsanto Company. Only those portions of tha document relevant to a duly authorixad individual's naad to know may ba axcarptad for :hlm. Tha report must not' ba sent outside the Company without writtan approval and tha authorixad racipiant is accountable for its safa keeping, excerpting or otharwisa disclosing of Its contents and lor its propar disposal. Tha docu- mant remain* tha proparty of Monsanto Company and shall ba returned within two months to Its author, except upon-special authorixation to hold for a longer period." STLCOPCB4099123 Company Confidential 2. Organic Division (Continued) Evaluation for production of Staley Grade Acid complete. An AFE was forwarded in October for $6,000 capital to pretreat before carbon towers so that organic loading to towers is in 200 ppm range they are designed for. Agricultural Division Parathion fume collection system successfully started up and is now operating at design conditions. Project has been accepted by production.. Rental centrifuge for pilot sulfur recovery unit has been returned to Bird Machine Company. Progress report summarizing conditions for sulfur recovery as determined in pilot plant studies was issued. PR&D has scheduled report on recommended process for purification of recovered sulfur in December. Design and Drafting Major effort was expended in October to expedite design and drafting for Santowax Still project. Utilities Cost Improvement Savings of $10 to $20,000 per year appear possible in power factor improvement and central compressed air system. CEP Liaison New warehouse occupied in mid-October. Flaking and bagging equipment targeted for mid-November. Personnel Alan G. McCarty was transferred from the Agricultural Division and promoted to Engineering Supervisor responsible for Parathion, PNP, **C1 and Chlorine to succeed Don Malm. Alan has extensive experience in Parathion and PgScj trough startups, production supervision, and production planning. J. C. Landwehr Unical Services Department jw DSW 377271 STLCOPCB4099124 o PNP wo ooo CO o wroo ooo ooo NIRAN COT\ roo o r4o> o o o o o' oo ooo AROCLOR ilPHENYL Vroo oP-- OoN O oO o oo ooo TT HB-40 .. t HCL i I :hlorine r>co o o o hO oo ,o ooo -H 5bo m in tn r~~ ,/i~SJ "1 /> to in > r ,1/*o=% j< rn ?=~ m > O m (/) DSW 377272 Sikj vsr.nawut>w* * s o-r*v< 1 STLCOPCB4099125 STLCOPCB4099126 NO. 3 4 0 -3 D !E TZO E N G RAPH PAPER G X D PER IN C H .EUGENE D lE U W tix M ADE IN U, B i A, , ^ * ' ,* - * _ .I.U * l* J* - \ . > ` : -a, ", -,,. K. ... i 4 . Jt * ' . : Ml! Company Confidential 3- AROCLOR E. E. Bowles, C. R. Mcllwain, (V. R. Haupt) Cost Improvement Month YTD Target $4900 $47,400 Actual $4085 $52,465 Evaluate QuaterphenylPolyphenyl Effects on Solid Aroclor Yields 1969 Savings - $65,200 NFC - $14,000 TSD Objective B-8 (a) Instrumentation for Solid Aroclor yield increase, ordered on verbal approval, to be shipped 11/1/68. Project 3015 mailed to St. Louis IO/3I/68 for approval. Application for Alabama Department of Public Health special license to be made in early November. Expand Solid Aroclor TSD Objective Department,________________________________________________ __________________________ 1969 CED preliminary scope reviewed by Anniston personnel and counter proposal sub mitted. Savings favor using one large line of equipment rather than two half size disimilar units. Therminol SystemEvaluationTSD Job 863 Results from the first computer simulation of the existing Therminol system were useful in efforts to eliminate unnecessary flow to individual users. Three tem perature control loops were not functioning properly. An effort is being made to repair these control loops. Further study is planned to determine the best route for system improvement. Solid Aroclor 4465 Savings $12,000 TSD Objective by Blending NFC zero 1969 Laboratory samples made by G. L. Arnett sent to St. Louis for market testing. Blending of solid and liquid Aroclors to make 4465 has passed all property specs and tests. Savings comes from a 4.6% capacity gain in Solid Aroclor manufacture. DSW 377274 STLCOPCB4099127 BIPHENYL-SANTOWAX W. G. Niemeyer, (V. R. Haupt) Cost Improvement Month YTD Target Actual $3,335 $6,630 $36,820 $100,130 Company Confidential 4. Debottleneck Bighenyl Capacity TSD Objective Stills to 87,6 M lbs/vr. Increase_______________________________ _______ B-7 (a) CED is working on drawings for changes in the distillation area. No. 1 Furnace Upgrade Capacity TSD Objective Liaison (CEA-1892)IncreaseB-7 (c) Concrete foundation and dike wall for new benzene storage tank is nearly completed. Preheaters have been set. Structural steel set at preheaters. Coke traps have been set and installation of external alloy piping is in progress. Biphenyl-Santowax MIP; TSD Objective _________________________ B-l (a) Rough drafts of all sections are complete. Completion of review and revisions will be delayed until December '68 due to full attention as CEA 1892 manufacturing representative, HB-40 hydrogen cleanup, and Santowax R still improvements. Santowax R Quality Distillation Column;___________________________ ;B-7 (d) TSD Objective This project will be installed in two phases: Phase I. Install column and new Montar 9 pump with manual controls. Phase II. Add instrumentation to control the new column. TSD is preparing a design package for Maintenance on Phase I. Package to be issued by 11/6/68. Electrical and instrumentation drawings for Phase II are nearly complete. Phase II will be installed when CED ties in their new Santowax C surge tank and pump. EDC of Phase II is February, 1969. This project 3OI6 was sent to St. Louis for approval. Verbal approval had been given to order long term items. DSW 377275 STLCOPCB4099128 HB-40 C. E. Woodward (V. R. Haupt) J. L. Brown (G. W. Miller) Company Confidential 5. Alternate Hydrogen Evaluation TSD Objective Supply;1969______________________________________________________________________________________________ Progress report issued detailing various routes to supply hydrogen to HB-40 when the Chlorine department is shutdown. Received bid from Chemical Design Company on their package unit for cleanup of hydrogen using silica gel and mole cular sieves. Details are being discussed with Chemical Design Company. CED will take over the project installation with the expected EDC of 1 May 1969. The Chlorine department will be kept running until this time. CHLORINE D. W. Dudley (D. C. Malm) Cost Improvement Month . YTD Target $2,600 $38,600 Actual $ 475 $57,380 Reduce Mercury Usage to Savings $1700 0.75 lbs, Hg/ton Clp________B-6 (b) TSD Objective Installation of acid wash tank for recovering mercury from ''butter" underway. Expected date of completion is end of November. Brine Dechlorination Savings $6,875 ' TSD Objective ____________ No change in status. Awaiting maintenance revisions to complete demonstration. Central Chlorine Project Scope TSD Job 860 Unloading^________________________________Development'______________________________________________ Official notification of delay (until May 1969) in chlorine plant shutdown received from Director of Manufacturing on 10/22. Preliminary scope issued by CED on 10/4 was reviewed and returned on 10/18. Project now to include Niran Chlorine handling facilities as well as hydrogen clean-up. DSW 377276 STLCOPCB4099129 HCl J. M. Jones (D. C. Malm) Cost Improvement Month Target $1830 Actual $ 400 YTD $6080 $2500 Company Confidential 6. Production of Staley Increased Sales Grade Acid& Savings $6.000B-10 (c) TSD Objective Final evaluation complete. AFG to install coalescer to enable Staley Grade acid production will be submitted by 11-7. Progress report published by 11-15. Muriatic Acid Storage_______ Savings $6750 ______________ TSD Job 497 Construction of tank foundation in progress. Bids have been received from rubber liners for construction of tank. Project awaiting letting of contract. PNP 0. J. Norris, J. M. Jones (D. C. Malm) Cost Imp r ovement Month YTD Target $2500 $114,000 Actual 0 $ 55,100 Comment Unable to demonstrate mole ratio reduction because of letdown problems. Demonstration of 20 M #/yr. Savings $99,000 TSD Objective B-9 (a) Demonstration complete. Production rate since July has been at a 20 M #/yr. rate or better. Debojttlenecking efforts will be continued to meet revised Niran requirements of 1.97 M #/mo. Preliminary estimate for pre-heating and pressurizing charge tank complete. Project premise will be issued 11/6 with AFE by 11/13. Expected rate gain is 0.8 M lbs/yr. DSW 377277 STLCOPCB4099130 PNP (Continued) Company Confidential 7. Increase Reactor Capacity TSD Objective Temperature;Increase;_________________________________________________________ B-9 (b) Reaction time back down to 68 minutes as optimization work on reactor cycle time continues. A KTA analysis on reactor depressurization problem is continuing in an effort to define the variable which causes letdown to take more than 30 minutes. Study of Molar EVOP TSD Objective Ratio NAOH/PNCB________ ,_________________________________________________________B-9 (c) Studies temporarily halted due to major work effort on increasing production rate. These studies are expected to be resumed by mid-November. Revise MIP ;- TSD Objective ____________________ :B-i_(g); Rough draft typing completed and being circulated for comments. Plant review target date is now 11/15. Final draft typing scheduled to be completed by 11/25 and review with TPM in early December. NIRAN K. J. Hale, D. W. Dudley (D. C. Malm) Cost Improvement Month YTD Target $19,365 $156,765 Actual $ 6,700 $108,850 Demonstrate Parathion Recovery Savings $70,000 and 10-15% Reduced COD Loading TSD Objective B-5 _(a)___ Demonstration has been delayed due to failure of original filters to effectively remove solids in feed to coalescer. Excess pressure drop has resulted. Life studies of alternate paper filters indicate they are uneconomical in this appli cation. The total project is being re-evaluated to determine the best course of action to achieve the claimed savings. A progress report summing work to date and recommended actions will be published in early December. Solvent Addition Savings $59,000 TSD Objective ;________________________________________________________ _______________ ;B-5 (a) Yield savings of $6700 were obtained in October. Savings are down compared with the four month period of May thru August reflecting a cut-back in Chlorine charges in early September. DSW 377278 STLCOPCB4099131 Company Confidential 8. NIRAN (Continued Sulfur Recovery $400,000/yr. Savings, 31% from Residue _______________ Reduction in SO^ in Air B-5 (d) TSD Objective Rental Centrifuge from pilot recovery tests has been decontaminated, cleaned and returned to Bird Machine Company. A progress report detailing pilot test results is in typing. Preliminary work necessary for project transmittal to CED is under way. PR&D work on final sulfur clean-up was continued. Results still indicate high probability of meeting desired specifications. Tentative process is expected out by mid-December. Submerged Pump for Savings $1,500 TSD Objective RI Control of B-5 (c) Chlorination_____________ '____________________ -______________________________________________ New light source arrived on schedule. Start-up delayed when monel circulating line was "pirated" to repair #1 chlorinator sample line. New target date to begin based on delivery of monel pipe is 11/15. Thio Acid Reactor Temperature Controlled Alcohol Addition No change. Safety TSD Objective A-10 Fume Collection System in Parathion Department Reduce Corrosive Atmosphere TSD Objective F-10 Fume collection system now running at design condition. Old incinerator stack fan failed and will be replaced on project. This will allow the extra capacity required for future addition to the system. A wrap up report is scheduled for mid-November. ENGINEERING DESIGN AND SERVICES Mechanical/Electrical/Instrument Design and Drafting J. C. Price. J. A. Veazey. R. L, Brewer. J. K. Rennie. (W. F, Taffee) Highlights Major effort in October was on Santowax distillation project with goal of meeting 12/15 deadline for installation of Phase I. November emphasis will be on Solid Aroclor instrumentation to allow improved cycles in chlorination and stills. AFE approved covering diversion of acidic spring water to process sewer. Design complete, drafting schedule for late November. DSW 377279 STLCOPCB4099132 ENGINEERING DESIGN AND SERVICES (Continued) Company Confidential 9. Design Responsibility Safety in Disaster Control Plan__________ '_________ TSD Objective '_________________________ A-7________ Awaiting information from radio supplier on recommended frequency allocations be fore writing specifications . UTILITIES COST IMPROVEMENT J. C. Price, L. 0. Chambers (W. F. Taffee) Progress report on program plans was forwarded for typing and issue. Project premise to change cooling water on Trane compressor at Niran to Tower Water - was approved and the AFE has been forwarded for typing and approval. Project premises for use of well water at Niran Jets (net savings $6000/yr. - NFC $15000) and Improved Treatment at Biphenyl Cooling Tower (net savings $6700/yr. - NFC $2500) were forwarded for approval. Progress reports covering evaluation of a plant central compressed air system (estimated gross savings$8000-$16*000/ yr.) and plant power factor improvement (estimated gross savings $2000-$6000/yr.) will be issued in late November or early December. PLANT IMPROVEMENT G. C. Goodwin (W. F. Taffee) 1968 road program AFE's have been completed. Design package for Parkwin Street from 5th to 6th Street was forwarded to Maintenance. Work on preparation of 1969 plant improvement program is proceeding on schedule. ASSIST OPERATIONS ON START-UP V. T. Langdon (W. F. Taffee) CEA 1450 - Aroclor Expansion Flaking and bagging equipment being installed with mid-November target for completion. Temporary drumming facilities to be installed early in November. CEA 1452 ~ Warehouse Warehouse occupied in mid-October. Only minor corrections have been required. POLLUTION CONTROL E. G. Wright (W. F. Taffee) Reporting Spills and Pollution Abatement TSD Objective other Non-Routine Operating F-4 Conditions in the Plant________________________________________________________ 14 air emission reports were filed by plant personnel. 6 were attributed to the unusually high amount of smoke from the P02SJ,5_ reactor and the other 8 were SOg complaints. DSW 377280 STLCOPCB4099133 POLLUTION CONTROL (Continued) Company Confidential 10. Provide Catch BaBin Pollution Abatement for Niran Spills____________________________ TSD Job 759 Project No. 2944 to provide a catch basin at the PgSij track was transmitted to Maintenance on 10/23/68,. Special Activities 1. Received and investigated one air pollution complaint noted odor of P^S,. in area where complainant lives. 2. On 4 trips to Coosa River everything was O.K. 3. Obsolete equipment at the Waste Treatment Plant has been dismantled. This has greatly enhanced the appearance of the area. 4. Contacted Drs. Gunning and Suttkus concerning another biological study of Choccolocco Creek. Study will be conducted in early 1969. Waste Treatment All wastes were effectively treated in October. The Niran turn-around began an October 27, and some necessary repairs are being made at Waste Treatment. The limestone neutralization pit is being relined. The valves with which the hold tanks can be segregated are also being replaced. Being able to segregate the tanks will make it possible to install vertical agitation in the north hold tank which will increase surge capacity. Average values for Monsanto to city treatment plant effluent in October are as follows: Average Daily Specifications PNP 1.0 <^5 ppm COD 66 200 ppm Parathion .09 ppm BOD 6.0 .20 ppm DSW 377281 STLCOPCB4099134 PROCESS AND QUALITY ANALYSIS W. B. Dunlap Company Confidential 11. PS. Parathion Correlation , Sfcuay ______ ;$50,000 Savings Potential TSD Job 827 A study of P0S5 batch sheets, control charts and cost sheets revealed that long term correlation of viscosity and % P is uncertain. Viscosity serves well as a relative day-to-day control of the reactor. Product composition shows considerable variability which must be stabilized before optimization studies are started. Identification of Parathion Potential TSD Job 828 Variables$17,000 Savings_____________________________________ ____________________ The assay of crude chlorinated thio acid was reviewed to determine total vari ability, and to define the components of variability. Total random error was excessive. A study was outlined to measure the effects of the various components to make possible better control. 0S\N 377282 STLCOPCB4099135 PLANT LABORATORIES Company Confidential 12. PROCESS RESEARCH AND DEVELOPMENT Solid Aroclor G. L. Arnett, (G. W. Miller) 1. All data requested by the marketing department as a prerequisite for producing Aroclor 4465 by the new process has been developed. No test differences were observed in the material produced by blending when compared with regular production material. 2. Several possible alternate catalysts for the production of Aroclor 5460 are under investigation. The purpose of the investigation is to reduce the color of the finished product. Initial tests show aluminum produces Aroclor 5460 with color slightly better than that produced with iron. Success in this project will solve the major solid Aroclor marketing . problem with minor additional manufacturing cost. ' Biphenyl Hydrogen Clean-Up - HB-40 J. L. Brown, (G. W. Miller) 1. The heatless solid bed adsorption pilot unit continues to satisfactorily purify Biphenyl hydrogen giving a product stream containing less than 50 ppm CO and no detectable amount of organics. Hydrogen recoveries / / .are averaging in excess of 70%. All PR&D test work will be completed 11 8 68 2. Biphenyl hydrogen purified with CD test unit produces HB-40 in a reaction time 8-10 minutes shorter than required when using DeNora hydrogen. These lab autoclave studies also consistently show that superior HB-40 color is associated with the use of purified hydrogen. 3. To finalize design considerations, a series of tests were performed to evaluate the threshold effect level of CO on the hydrogenationi At or below 50 ppm CO, no effect on cycle time can be observed; however, at 100 ppm CO definite catalyst deactivation caused by CO is observed. Sulfur Recovery W. H. Howard, I. Ransaw, (G. W. Miller) 1. Process step optimization studies are progressing on schedule to be completed 12/20/68. Major delays were caused by design and fabrication of equipment suitable for the laboratory investigations. 2. The initial sulfur wash has been improved by using a slightly alkaline wash. Optimum conditions are defined pending analytical results. 3. The process under development will consist of four steps: (1) Wash; (2) Hydrolysis possibly under pressure at 130-140C; (3) Steam sparge; (4) Filtration and drying. DSW 377283 STLCOPCB4099136 Company Confidential 13. analytical and quality control Aroclor 1. Plant personnel along with R. H. Munch, Organic Research Department, met with Messrs. R. H. Dewart and R. L. Bougreau in St. Louis October 17 to discuss analytical procedures for testing electrical Aroclors. The new analytical procedures developed by Dr. Munch were discussed along with our presently used techniques. As a result of this meeting a blind round robin test of Aroclor quality was begun to investigate method and ' laboratory precision. The results of this test will be published in , November. , 2. Only minor quality problems have been associated with the Aroclor tank farm .start-up. An initial build-up of white particles in the Aroclor was identified as a silicone glue leaching from the cartridge filters. This problem has been resolved and the material was purified by a simple cloth filtration. Initial quality from the system is excellent. Solid Aroclor 1. Inclusion of large pieces of extremely dark Aroclor 5460 due to the poor condition of the flaker continues to be a problem. A customer reaction report has been received from Precision Cast Parts Corporation complaining about the problem. A formal quality complaint is expected. Parathion Analytical work load was low during October due to the fall change over to ethyl parathion production. , Complaint Report Quality No. Material Customer Reason Justified 7-A-68 Aroclor 126210% Toluene Amsco High Sp. Gr. Yes YTD quality complaints/100 Shipments 0.10 : Target 0.20 Service YTD service complaints/100 Shipments 0.18 : Target 0.20 Cost and Operational Indices September 1968 YTD Average Target (1) Analytical Samples (2) Analytical Manhours (3) Manhour/Sample (4) $1 Manhour (5) % Total Plant Cost (6) Overtime % 4433 1856 0.42 7.80 0.88 5.70 4736 2022 0.40 8.66 1.07 4.60 0.40 8.50 1.50 5.00 DSW 377284 STLCOPCB4099137 Company Confidential 14. COMMUNITY RELATIONS. PERSONNEL. RECRUITING. AND DEVELOPMENT Personnel 1. D. C. Malm promoted to'Superintendent of Engineering Services and Plant Wide Engineering at the J. F. Queeny Plant. 2. J. T. Bell accepted an offer as Senior Process Chemist starting December 1. 3. C. E. Woodward transferred to Chocolate Bayou to work in TSD in the Pthalic Anhydride area. 4. Process Engineer Ken Buturla transferred to Kenilworth, New Jersey Plant of Plastic Products and Resins Division. Development 1. College level, non-credit, "Process Dynamics and Control" being taught from Auburn University campus by Dr. Z. L. Taylor via Victor Electrowriter and Telelecture system. Course with enrollment of nineteen technical personnel started October 1 and will meet twice a week until mid December. 2. The first department meeting in preparation for the 1969 objective setting and review of 1968 objectives was oh October 11. Visitors 1. R. C. Herman, CED Project Manager, Warehouse (CEA 1452) visited the plant October 17. ,' 2. Dr. J. R. Fair spoke to a group of fifteen technical personnel on the Subject of "Continuing Education Trends", on October 16. ' 3. Dan Woods and Bill Corlew from W.G.K. visited for PNP review Tuesday, October 29. 4. D. J. Schulz and J. Mazzocchio, CED, visited October 30 to November 1 to discuss details oh Biphenyl distillation on CEA 1892. 5. W. E. Chandler from General Offices visited concerning utilities improvement projects and plant improvement topics. DSW 377285 STLCOPCB4099138 PROCESS IMPROVEMENT ' DISTRIBUTION OF TIME BY TECHNICAL SERVICE Jan. Feb. Mar. Apr. May June July Aug. Sept, Oct. Nov. Dec. NEW PRODUCTS PLANT IMPROVEMENT ' jIST OPERATIONS SPECIAL ENGINEERING SERVICES TECHNICAL MANPOWER MISCELLANEOUS ACTIVITIES AND . ABSENCES /' f V, ^ DSW 377286 STLCOPCB4099139 IN MAINTENANCE FOR CONSTRUCTION IN MAINTENANCE COMPLETED NOT CLOSED TSD PROJECT SUMMARY > Mil PROJECTS SUBMITTED FOR APPROVAL APPROVED PROJECTS ' IN TSD 600 rzrzi 500 JL__ 1 400 k 500 200 frr/i 100 --I ~T 11 1 ___ L ^1 1 1 1: 1 1 1___ _ ---- 1 1 DSW 377287 0 Dec. Jan. Feb. Mar. Apr. May June July Aug. Sept.Oct. Nov. Dec. Jan. STLCOPCB4099140 Manpower/samp1e 1"-^--I ~j~ T-r i i ' i:i_____ l i ii i % Total Plant Operating Cost 2.0 1.5 1.0 0.5 - jti r r I 1 f rl 1 i >rc.L.r::,;rt-- ir^T 1 -1 i \- . Overtime 7> 1 -f~ -- _ _J L_J STLCOPCB4099141