Document GmYEmXbZ71pdwkJQ3x3zNVXom

uLiivirANY CONFIDENTIAL * Monsanto FL tEaX/H,'IBIT Anniston Plant - -/* # 7 TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Anni slon Summary C. K. Eastman A. G. Hill L. C. Lahman J, C. Landwehr G. W. Miller W, B, Papageorge W. F. Taffee H. L. Willlame Month September, 1969 Coat Improvement Results Eat. Act.Target7. of Target $63,120 $66,285 95.27. II j General Offices YTD $430,976 $438,570 98.37. H. S. Bergen H. c. Carder D. Danna (5) P. B. Hodges D. B, Hosmer (2) w. A. Kuhn J. A. Morgan w. R. Roblrds J. E. Smith J. A. Stephens R. J. Stratmeyer H. s. Trail OTHER LOCATIONS A. H. Foretan Alvin, Texas D. W. Jackson WCK T. M. Patrick So, 2nd St. Organic Division The Solid Aroclor 5460 yield increase instrumentation has been installed. Calibration and start-up will begin when 5460 is produced in early October. The Sandvik belt test on Montar 5 was successfully completed. Installation costs will be estimated in October. Muriatic Acid - MTP was reviewed in plant on 9/10. Neceaaary revisions to be completed during October. Agricultural Division - The Acetone Recovery project was verbally approved 9/29 for $32,125 capital and $28,600 expense. Expected savings are $40,000/yr. C.E.D. has suspended scoping and estimating activities on original Sulfur Recovery Project and will evaluate alternates to obtain the major yield savings at a lower capital cost. Nlran - Tentative Process Amendments are being prepared for plant trials of Freon-21 replacing Freon-ll as chlorinator coolant and HC1 replacing nitrogen as chlorination sparge ga. _ CO .Y CONFIDENTIAL TRAN 025165 v COMPANY CONFIDENTIAL INFORMATION ``Thu document contain* confidential infotmstion which is the piopeity of Monsanto Company. Only those pottlons of the document lelevant to a duly authoiized individual's need to know may be eneipted foi him. The lepoit mutt not be sent outside the Company without wiitten appioval and the lecipient is accountable lot its safe keeping, eseipting otheiwise disclosing of its contents and foi its piopei disposal." WATER PCB-SD0000005834 Company Confidential 2. Utilities Evaluation of Central Air Compressor system started, with December report target. Design & Drafting Data being gathered for electrical protective device study which will lead to reconanendations to improve reliability of overload protective devices in Important feeders. Construction drawings forwarded for Biphenyl Pilot Unit building and Parathlon emergency generators. Pollution Control HCl neutralization pit contlnues to successfully treat all waste acid. Construction 957. complete on test unit for removal of solids in Waste Treatment Plant effluent. Start-up targeted for early October, Quality Control The Plant Quality Score was 86.1, down 7.6 from August with a YTD score of 88,1 against a 1969 target of 95.0 minimum, Unfavorable trends continue in Aroclor 5460 solubility, Aroclor 1242 low dis tillation and TC Chlorides. Raw material benzol remain at low distillation level, with intermittent high toluene. . C, Landwehr :kd COiv/ii- /~\\ ) y CONFIDENTIAL TRAN 025166 WATER PCB-SD0000005835 ) ORGANIC DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV PRC Sol. Aro. Leve 1 TAR Ind.f, -Still SpC EST _AJLJLQI5_________ ACT Solid Aro. TAR Lower 5060 Soft. Point EST. ACT 2250 2250 .221 -- -- ** - 2250 225 0 225 0 2250 - -2600 S690 2600 2600 2600 2600 2600 2600 ?6oo 1500 5490 4090 215C 467 C 800C 4230 7TJCT 3475 1500 54 90 4 8 90 2L5C 467 C 800C 4eJpU 7730 - -- Sol.Aro.-Still TAR Coolant temp. EST. AFE 5015_________ ACT _i6o -120 *60 1,79 *60 170 160 170 L60 -" Sol .Aro, -Chlortar JM. Batch End EST; 3?0 399 .39a. 390 390 390 3?o 390 39 0 AE&JiflIS__________ ACT Sol.Aro. Yield TAR SW/R Composition EST ,,AFS ,3016_________ ACT Solid Aro, TAR Montar 5 Flake EST -^FE 2949__________ ACT 2750 2750 2750 2750 2750 2750 2750 2750 "" mo, IMP 1P?0 *0?0 1090 1080 1080 1080 -"" Sol.Aro, Blend 4465 TAR _25QQ 2590 2500 250Q 2500 2500 2500 piqp 25 0Q 2500 2500 2500 EST 1690 1920 1600 1490 710 1180 990 220 ACT 1690 1920 1630 14 9 C 710 1180 990 220 Sol.Aro.-Vcrti- TAR cal Still Cond. EST AFE 2324 ACT 70 70 90 90 70 90 0 70 9 0 90 " - " 70 90 90 90 90 - " Sol.Aro.Clg T/C Dock AFE 2542 TAR EST ACT 940 940 950 0-0 Sol.Aro.-New Cl2 TAR Unload - No Delay EST' -CEP.1851__________ ACT Sol id Aro.-Flake TAR & Drum EST. CED 1450 ACT Liq.Aro. TAR 48-53 M #/yr. EST AFE 2545 ACT 950 . 94Q 950 940 950 940 950 900 2330 2050 2320 1650 900 2 330 aosiL 2320 3000 5000 5000 5000 5000 5000 5000 5000 5090 5000 5000 0 0 100U 2000 2000 2000 300c 3000 3000 0 0 1000 2000 200C 3000 30CC 3000 5000 5QQ0- - - - - - - - - - - 0 550C 0 550C " -- -" - Liq.Aro.-No,2 TAR 3000 3000 Still Entrain Sep. est: AFE 5095 ACT Liq.Aro.-Montar TAR Disposal EST AFE 295? ACT T 08 0 108p 3,080 io?9 *090 1080 1080 1080 1080 1080 0 00 00 0 - 0 00 00 - Warehouse TAR Reduce Manpower EST' CEA 1452 ACT 2000 3000 3000 3000 5Q0Q 300Q 3000 3000 3000 3000 3000 3000 2000 2C0u t00C 3000 3000 3000 300c 300C 30UC 2000 200C 20a 3000 300C 3000 300c 300C Liq,Aro,New TAR Burners #3 Still EST ACT *?0p 1500 1500 1,500 1500 1500 1500 *500 1500 1500 0 0 1500 3000 900 0 - 0 0 1500 3000 900 - Biphenyl Relocate TAR No. 1 Preheat EST CEA 1892 ACT 500 500 500 500 500 500 5 00 500 500 500 500 500 1500 0 1560 1870 0 0 15DC 0 150C 0 6 10 1370 0 0 150C - HB -40 2nd Autoclave AFE 3102 TAR EST ACT 3000 2230 3490 3000 3000 2580 0 24 2C 0 3000 3000 3000 3000 3000 3000 3000 3000 600 iwu 6000 Wo 4?<TCT 5TJU 600 1.0,40c 8600 6950 COMTPmArv1 <vv/rJ TRAN 025167 CONFIDEN \ iAl WATER PCB-SD0000005836 ORGANIC DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MAY JUN JUL AUG . SEP OCT NOV DEC BiO Improve Tower Treat, AFE 5155 Improve Pit, Power Factor TAR EST -ACT TAR EST ACT 450 459 450 450 4S0 450 450 450 00 0 584 645 00 0 585 900 900 900 900 900 990 900 900 0 500 900 yOo 9U0 0 500 83O 990 Central Air System TAR EST 1000 1000 1000 1000 - ACT Optimize Rx Time PNP TAR EST ACT 21Q0. 2m 2100 2500 2500 2500 2500 2500 2500 2500 2500 0 3420 0 0 0 294 0 L2bcr 9 0 3420 0 0 0 2940 2370 Reduce Mole Ratio NaOH/PNCB PNP TAR EST ACT m 4000 4000 4000 4000 4000 4000 4000 0 00 0u0 0 00 0 0 New Mash Mater Pump - PNP AFE 2998 Automatic pH Control TAR EST ACT TAR EST so 50 50 50 50 50 50 50 25 50 50 50 50 5 0 su 50 25 __5jQ_ ~10_ 50 50 50 50 500 500 500 PNP ACT HC1 Filter Pump TAR 330 330 540 EST 330 550 >40 ACT 3 3 >40 Now Blow Tnnk HC1. TAR 200 290 209 200 200 200 EST 200 200 200 2U0 500 200 ACT 200 200 200 200 200 200 150,000 Cal.-HCl Storage Tank AFE 2468 ..... TAR EST ACT 1769 1760 1790 1760 1760 1780 1760 1760 1780 " u " 0 264 0 3290 2990 0 2830 3430 Produce Staley Grade Acid AFE 5076 TAR EST ACT O 00 r-* 780 790 780 780 790 - Cla Plt, Shutdown TAR EST CEA 1851 ACT 8880 8880 8880 8880 8880 8880 8880 0880 42885 L9900 *199(1 22% 6655 .2855 19900 H{j Recover from Residue TAR _250 250 250 250 EST 3910 0 00 ACT 3910 0 0 0 Hg Wash Tank AFE 2802 Biphenyl Productivity TAR. EST ACT -TAR _ EST ACT 250 250 250 250 o 0 0 0 0u 00 5600 5600 5600 5600 T600 Tgoo TSoo 5600 TSoo 5600 5600 S600 0 9u6u .5,0CX 0 0 0 3(3753; 2700 0 1800 5900 13.500 0 0 0 307 8 C 2700 Total Organic By Month M $ Total Organic YTD M $ ' TAR EST ACT TAR EST ACT 23-.; 20" 29.3 57.5 42-3 51.1 51.6 51.6 51.6 27.1 30.2 11.5 56.5 39.165 107.4 4 9.41C 16.5 23.8 27.3 11.4 25.75 45.9 110.SE 258.16 > 2?. 3 50. 1 46.9 79.4 78.8 116-9 79.6 159.2 115.9 2Wl 144.4 261.9 2505] Hhf 365.1, 315U3 3es.ee 417.8 1 16.5 40.3 68.1 79.5 105.2 15U a5l.2Qf 31945 55.5 47 1.3' 521.9 COMPANY CONFIDENTIAL **$27,780 adjustment included for months January thru June. TRAN 025168 WATER PCB-SD0000005837 ) AG DIVISION 1969 tsd cost improvement ANNUAL JAN Cooling Tower TAR Repiping EST AFE 2598 Optimize N2 6 ACT. TAR Cla Levels EST ACT Increase Waste tar__ Acid Sales EST ACT Chlorinator R.I, TAR EST AFE 2244 ACT EVOP Condensation Rx, TAR EST ACT 750 0 0 Cl2 Unloading TAR EST CEA 1831 ACT Recycle Wash TAR Water EST' AFE 2960 ACT Parathion Recovery1 TAR EST AFE 2655 ACT Reduce Acetone TAR Losses EST ACT Formulations TAR EST AFE 2897 , ACT Change Cooling TAR HsO Item 7}7 EST AFE 3067 ACT Well HqO to Jets TAR .. EST ACT Ag. Division TAR 750 by Month EST ACT 0 Ag. Division YTD TAR EST ACT 750 0 Ag. Division TAR untargeted-R.M. EST Charges optimlzatii nACT TAR Untnrgetod - MCI EST Catch Tank& Coalej eACT Ag Div,-Untargeted TAR EST ^3 Cl2 Change out ACT fpo OO 1 0 ,r00o0 0 01 K> OO1 FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC 40 420 410 410 420 420 410 420 420 0 00 00 0 0 00 00 66oo 6700 67 00 6600 67"00 67 00 0 00 00 0 0 00 00 400 00 00 300 400 500 0 00 000 0 400 $50 250 250 ?50 50 250 00 0 00 750 500 500 750 750 0 12,615 0 12,615 5000 5000 5000 2000 0 0 1580 00 890 ?90 290 P90 90 290 00 0 00 580015800 5800 4 500 4 500 45OO 1600 1600 a600 1600 1600 1600 J 000 6600 10,GOj 4570 2000 5950 43OO 10/t00 928 ^ 4 570 1205 125 135 125 125 125 125 125 125 125 12U 180 155 272 333 310 120 100 171 27 2 333 500 500 500 750 50C 914 5 9145 91 *5 14675 1A6B5 ,14575 1443 5 14485 126$ 6,7SO 10,155 4842 4053 L^lL 0 12,615 i,420 10,530 9459 484; 5 64 88 1500 ?QQC 13.145 2029.C 441 rc ,53785 7547 a 83045 KP5 < 1170,11 12,65 W %815 5? ,7* 41,9* 45,949 6^114 0 12,615 17,0^5 27,615 57.07441,916 48,404 0 17 OC 369 C 170C 0 000 5000 6250 596c 4690 1330c 0 9}5C 6817 4920 4180 3250 CC;'/P*NIV CONFIDEN. u->- WATER PCB-SD0000005838 AROCLOR ' Company confidential 5. E. E. Bowles, C. R. Mcllwaln, J. W. Mattern, (V. R. Haupt) Evaluate Quaterphenyl- Polyphenyl Effect# on 1969 Savings $63,200 TSD Objective Solid Aroclor Yield#___________________ ________________ $14.000B - 8(a) Radioactive source for level alarm installed. Representative from Ohmart Corp. conducted radiation survey and instrument checkout. Start up delayed because of department downtime and producing Solid Aroclors other than 5460. Expect to start mid October. Montar Use and Disposal Savings $13,000 Project 2952MFC. $10,000B - 8(g) TSD Objective Request to change route of piping to avoid going through the Chlorine plant has delayed installation of project. Necessary equipment delivery date is estimated at 4*6 weeks. Sandvik Belt Cooler for Montar 5 Solldlflcatlon Solid Aroclor Expan- TSD Objective slon Evaluation_________________ B - 8(1) The Pilot Unit Testing has been successfully completed with good results, Price and size estimations have not been finalized. However, preliminary "ball park" figures show that a belt to handle 8000#/hr, requires a cooling width of 4 ft. x 55 ft. long. The purchase price of this size unit is in the 3$ M dollar range. Porocel Columns Assist CEP 2132ProductionTSD Job No. 950 North Porocel columns to treat chlorobenzenes were started up on September 19, 1969. Results of first trial were Inconclusive. Further quality improvement tests are planned. The start-up of the South columns has been delayed by the Aroclor fire. Start-up is now planned for the week of October 6, 1969. BIPHENYL-SANTOWAX W. G. Niemeyer, D. A. Self, J. M. Jones, (V. R. Haupt) Debottleneck Biphenyl- Santowax Distillation Area Capacity to 87.6 M lbs./yr. BiphenylIncrease TSD Objective 8 - 7(a) Installation of by-pass loops with blow-out connections for the two Santowax C flow meters was scheduled for 9/10/69. However, only about one fourth of the planned work was completed. The problem was that the operators were not able to unplug the recycle line and it was not safe to cut and weld on the line. Maintenance is now scheduled to unplug the line, A capacity/performance tast run will be conducted on the Santowax distillation celumn after the meters are re-installed and calibrated. COMPr- * ' CONFIDENT, AL TRAN 025170 WATER PCB-SD0000005839 BIPHENYL-SANTOWAX - (continued) Company confidantlal 4. Low Biphenyl Santowax for FDA 5460 Salta Support TSD Objective B - 7(b) A tower water loop study is in progress to try to increase the cooling water flow to the Biphenyl/Santowax distillation area. Increased cool ing water flow to the distillation area is required to produce low biphenyl Santowax. Prediction and Control of Dust Explosion Potential in Biphenyl Flaker Packaging Svt*nSafetyTSD Job No. 9^1 At our last plant meeting on this problem, we decided to convert the biphenyl packer from fluidizing with air to fluidising with nitrogen. However, the estimated operating expense for nitrogen is much higher than originally thought. The estimated operating cost for nitrogen will be $15,000 to $14,000 per year compared to $1500 that was originally esti mated, Wa plan to proceed with this conversion, in spite of the high cost, to eliminate a hazardous situation. Inart gas generation equipment will be evaluated to compare operating costs and most economical method used long term. Designed Experiment Run on Process No. 1 Biphenyl FurnaceStudyB - 7(e) TSD Objective All the samples have bean analyzed. Preparation of a progress report is in progress. Test results will be used to update math model of this process. Install Knockout Tank on Santowax Jet Vent Safety __________ TSD Job No. 862 Complete design package was transmitted to Maintenance for construction on September 9, 1969. Natural Gas Safety Shut-off Interlock SwitchSafetyTSD Job No. 94B__________________ Complete design package was transmitted to Maintenance for construction on September 25, 1969. COfl/fp/An, ONFIDen , iAL TRAN 025171 WATER PCB-SD0000005840 I Company confidant la1 5. HC1 G. L. Moore, L. 0. Chembere, K. G. Hale, (A. G. McCarty) Production of Staley Grade New Earninga $288 M Acid - AFE-^076______ _____________ Potential Savings $71.000 TSD Objective B - lOfcl Savings of $13,300 resulted from the Coalescer and Catch Tank project during September, Spare elements of a modified deslgn are being completed by the vendor. Plant pilot carbon treatment studies are scheduled to be run in November. The objectives are; 1) Accumulate design data neceseary to expand the carbon treatment area, and 2) determine the carbon treatment and condi tions necessary to produce "Staley" acid. An experimental project for pilot test facilities is being Issued ($700 experimental expense). TSD Objective Issue HC1J1IEPlanning8_-. Ubl _ Plant review was held en 9/10/69. Revisions are being made to several sections as a result of plant review. Revised cep las will be submitted for final rev lew by IO/3I. Reduce High Free Cl2 in Muriatic Acid Quality TSD Job No. 9S0 An expense project is being Issued to Install necessary piping to air blow a second storage tank and provide a temporary air supply until the cause and/or cure to the high Cl2 problem can be found. PNP L. 0. Chambers, K.. G. Hale, (A. G. McCarty) Debottleneck to Capacity Savings -Li-H,, TSD Objective Process changes targeted at rsduclng PNCB usage resulted in let-down problems during September. No savings resulted in September, Additional changes will be made and monitored by P. & Q.A. to attempt PNCB usage optlmlxation. NIRAN K. G. Hals, D. W. Dudley, T. W. Lawrence, (A. G. McCarty) Demonstrate Parethion Recovery Savinge $17,400 10-15% Reduced COD TSD Objective B - 5(a) No change in status. Construction in progress on test fscilitles. TRAN 025172 WATER PCB-SD0000005841 NIRAN * icontinued) Company confidential 6. Acetone Savings $12,900 Recovery20% Raduced CODB - 5(1) TSD Objective Recovery teete on #3 condeneation reactor indicate a 30% reduction in acetone loss. Gross savings (ethyl and methyl) from increasing acetone recovery is $40,000 per year plus a 20% reduction in COD load. Project 3340 was verbally approved 9/29 for $32,125 capital and $28,600 expense. Manpower evaluations are presently underway to determine what parts of the project will be installed during the '69 fall turn-around. Central Chlorlne Unloading for Niran Savings $21,000 TSD Objective _____________________________________________g--................ Evaluation of rebuilding 12 year old compressor vs. purchasing new com pressor favors the new compressor. Compressor will not be purchased or Installed until late winter to prove worth of air pad on "cold chlorine cars" during winter. Sul fur Recovery from Residue $271,000/yr. Net Savings TSD Objective 53% Reduction in SO?B - 5(d) C.E D. has suspended work on the Sulfur Recovery scope and will evaluate alternates to obtain yield savings at a lower capital cost. The new objective would be to remove sulfur and recycle organics, but not clean-up sulfur for ra-uae. Improve Chlorinator Cooling System Profit New Sales and Productivity Savings $48,000/mo. per 0.5 Hour TSD Objective Reduction In Chlorination Time B - 5(g) A Tentative Process Amendmsnt is being prepared to cover plant trial of Freon-21. If approval is given, expect to begin trial approximately one month prior to the end of the 1969-1970 Ethyl run and extend approximately one month into the 1970 Methyl run. Improve Intermediate Distillation CapacityCapacity TSD Job No, 972 Possibilities are remote for obtaining significant increases in inter mediate distillation capacity with existing equipment. It is felt that thin-film or wiped-film equipment may be ouitable for processing this type of material rapidly. Contacts will be made with thin-film vendors to explore the possibility of application to this problem. TRAN 025173 WATER PCB-SD0000005842 ) NIRAN - (continued) Company confidential 7. Replace Nitrogen with HC1 for Chlorination Sparge Savings $60.000 TSP Job No, 6Q''> Anniston PR&D has shown that Hl sparge produces no adverse effects during chlorination compared to nitrogen sparge. Since HC1 is produced during chlorinetion, it could possible be recovered for use as sparge gas replacing nitrogen. A tentative Procees Amendment will be prepared covering a plant trial of sparging with cylinder HC1. PROCESSES! CLUALITLANALYS.IS J. L. Murphree, Allen Hale, (W. B. Dunlap) Process Surveillance An 18 month downward trend In distillation level of raw material benzol was revealed, culminating In 6 tank cars out of specifications. Toluene in benaol was found to be out of spec. These factors may be related to a documented Increase in Aroclor 1242 TC Chlorides over the last 5 months. PNP"Identification of Potential Savings Critical Variables$60.000TSD Job No. 8^9 TSD Objective C - J A final report on yield study was written. Reactor settings will be ad justed and controlled experimentally to verify the statistical prediction of the study. Potential Savings Nlran Still Control______________ $79.000TSD Job No. 964 An AFE was approved to obtain and install control equipment. Design and drafting is scheduled for the 4th quarter. Installation EDC is 3/1/70. ENGINEERING DESIGN AND SERVICES Mechanlcal/Elsctrleal/Instrument Design and Drafting J. C. Price, J. A. Veasey, J. 0. House, G. W. Richey, B. D. Morgan, R. V. Carlisle, R. L. Brewer, J. K. Rennie, <W, F. Taffee) Design was completed on Project 3161 - $3.8 M, Automatic Temperature Control of Thio Acid Reactors #1 & 2. Review drawings were transmitted with con struction drawings to follow in October. Design is in progress on Project 3II8 - $9.7'M, Modify Agitator Interlocks on all critical vessels in the Nlran department. Transmittal is expected in October. TRAN 025174 WATER PCB-SD0000005843 ' ENGINEERING.DESIGN AND SERVICES - (continued) Company confidential 8. The following project safety reviews wera held or attended: Fire Pump Capacity Check Equipment (AFB 3227 - $4.1 M), Install Pressure Control Valves in Fire Protection System (AFE 3211 - 95.7 M), Biphenyl Pilot Unit (AFE 3297 - $13 M). A program is underway to gather data necessary for preparatioa of a short circuit coordination study of the electrical portion of the Nlran department. The results of this study will lead to the compilation of a program for testing switches, circuit breakers, protective relays and, in general, all major electrical equipment that could cause prolonged downtime due to its failure. Training and supervisory time remained at a high level this month because of time necessary due to three recent manpower additions to the department, One E & I Technician la on loan to the Maintenance department to instruct maintenance employes in an alectrical instrument course. Premises wera prepared and forwarded for the following projects: Niran Intarmediate Tank-Car Cleaning, Building 27 Dismantling, Eliminate "Head Knocker" at Aroclor. Drafting Review drawings were completed for the following projects: Install 4" Heat Exchanger in Biphenyl (AFE 3282 - $1.4 M), Final Wash TankPNP (AFE 3342 - $2.0 M), Automatic Temperature Control of Thio Acid Reactors (AFE 3I6I - $3.8 M), Dual Chlorine Relief Valves - Nlran (AFE 33IO - $3.5 M), Acetone Recovery (Electrical) (AFE 33^0 " $50.7 M). Construction drawings were completed for the following projects: Replacement of Water Loop-HCl (AFE 3240 - $8.4 M), Biphenyl Pilot Unit (AFE 3297 - $13 M), Debottleneck Solid Aroclor (AFE 2897 - $20 M), Replace Niran Generators (AFE 3305 - $41.9 M), Install Nash Compressor at Eimco Filter-Waste Treatment (AFE 2820 - $4.6 M), Acetone Recovery - (Piping) (AFE 3540 - $50.7 M). UTILITIES ENGINEERING J. C. Price, J. 0. House, M. L. Marcum, (W. F. Taffee) Transmitted review drawings for Teat Heat Exchanger (AFE 3282 - 91.4M) on Biphenyl Coeling Water. The design package will be transmitted In October. Started preparation of Utilities Improvement Items for inclusion in the Aroclor MIP. Started evaluations of projects to replace existing air com pressors with a Central Plant Air Compressor (aaclmated gross savings $12.0 M 16.0 M per year) and to Improve Plant Power Factor (estimated gross savings 95.0 M - $9.0 M). The premise for the power factor project is expected to be forwarded in October and for the compressor project in late November or early December. Continued work on Steam Plant MIP with completion scheduled for December 15. COMPANY CONFIDENTIAL " ^AN 025175 t WATER PCB-SD0000005844 ) PLANT IMPROVEMENT Company confidant la1 9. G. C. Goodwin, (W. F. Taffaa) A premia waa prepared and forwarded for Renovating Nlran Control Room and Lunchroom. Deaign package waa forwardad for: Up-grading Fire Pro tection Syetem (AFE 3293 - $7.1 M). Meaara. K. B. Davis and J. Harrison of the Alabama State Highway Depart ment viaited the plant on September 26, to diacuaa the relocation of Highway 202 acroaa Monaanto property. They presented two schemes for the connection of old Highway 202 to the new 202 on the southeest side of the plant. POLLUTION CONTROL E. G. Wright, (W. F. Taffaa) Air & HgO Pollution Community and Complaints Governmental RelationsB - 2 TSD Objective No air or water pollution complaints were received at the Anniston Plant during September. P.C.B. in Choccolocco Creek Pollution Abatement TSD Objective F - _________ The first sat of samples taken from Choccolocco Creek ahow lavela of P.C.B, from 2 to 8 PPB. Theae levela will be checked at periodic inter vals beginning in October with another set of samples from the creek. HC. Neutralization Pit Production Aaaistance TSD Objective ____L-LJt______ The pit continued to neutralize all of the acid sewered thia month. No un-neutralited HC1 has left the plant since August 8. The pit is showing no signs of reaching a break-through point at the present time. Plans are to continue to extensively monitor the pit until it has reached the break-through point. Choccolocco Creek TSD Objective Wildlife StudiesPollution AbatementF - 4 __________ Requested Drs. Gunning and Suttkus to da another study of Choccolacca during the fall season. This study will prabably be conducted during lata Oetaber. Samples of the fish and other wildlife from the creek will be collected, frozen, apd sent to Organic Research for P.C.B. analysis. Thia will provide some base data far evaluating the magnitude of the P.C.B, problem in Choccolocco. CQMPf My TRAN 025176 WATER PCB-SD0000005845 Company confidential 10. POLLUTION CONTROL - (continued) Elmco Filter at TSD Objective F - 4 Waste TreatmentProduction AssistanceTSO Job No. 808 Construction la 95X complete, Start-up la scheduled for the first or second week In October. Watte Treatment All wastes were effectively treated during September. High solids continue to be a problem. Successful operation of the Elmco filter should ellminste the problem. Average daily values for Monsanto1s effluent are as follows: PNP COD Parathlon BOD Average dailv 1.0 PPM 12J .17 PPM k PPM SDeclficatlons 5 PPM <-200 PPM -=-1.0 PPM (max.) -=200 PPM COMPANY CCNFiDENTVAL TRAN 025177 WATER PCB-SD0000005846 ) PLANT LABORATORIES G. W. Miller Company confidential 11. PROCESS RESEARCH AND DEVELOPMENT J. T. Bell Of the 105 PR&D mandaya available in September, 63 were expended on projects outlined in the 1969 PR&D Progrem. The use of the remaining mandaya vara divided among vacation, supervision, illness, and miscellaneous. Blend Scavenger Improved Aroclor Refinement (Aroclor)Electrical PropertiesJ. L. Brown Evaluation of Type 4A Molecular Sieve as an absorbent for column refinement of Aroclor-Scavenger mixes was begun on 9/24 with completion targeted for 10/15/69. HB-40 Process Studies Variables Determine Process W, H. Howard Equipment failure has temporarily suspended attempts to prepare HB-40 via a continuous process. This aspect of the study is to be continued on 10/3. The effect of quaterphenyl level on reaction times and catalyst requirements has been determined by a batch process. Santovax C has been hydrogenated to HB-40 with an extended reaction period. Biphenyl Tubular Pilot Studies Obtain Desired Biphenyl/Terphenvl Ratio J. L, Brown Plans for the Biphenyl Pilot Laboratory were completed on 9/9 and trans mitted to maintenance. The plans were Issued for bids on 9/10. A delay of 15 days caused by failure of contractors to bid promptly has been encountered with construction now targeted to begin on 10/15. Low Color Aroclor 5460 Develop Alternate Process G, L, Arnett The distillation of Aroclor 5060 and 5460 over a combination of lime and NaOH is effective in reducing color. DTA studies indicate thermal atability of the combination of Aroclor 5060, NaOH, and 1ime up to 400*C. Samples have been forwarded to St. Louis for corrosion studies. A PR&D report is baing prapared. Parathion Isomer Reduction __________________ Increased YieldsG. L, Arnett This project has been delayed by illness but will resume by 10/6. COMPANY CONFIDENTIAL 00MP A * ?*/ TRAN 025178 WATER PCB-SD0000005847 PLANT LABORATORIES -(Cont'd) Company confidential 12. PROCESS RESEARCH AND DEVELOPMENT -(Cont'd) Farathlon Condensation Reaction StudiesIncreased Yields_____________________ I. Ransaw The project work plan has been Interrupted to derive a method for determining the actual 1 conversion In the condensation reaction. The reliability of the method Is to be determined by 10/3 with the study, as written in the work plan, to resume on 10/6. Acetone Recovery (ParathIon) Reduce COD LoadG, L, Arnett Sample analyses have been made to support a plant demonstration of increased acetone removal in the condensation step. This study has been terminated. ANALYTICAL AND QUALITY CONTROL S. 0. Kemp Complaint Report Quality Number Material Cus tomer 12-A-69 13-A-69 14-A-69 Aroclor 5460 HB-40 Aroclor 1268 Swift Addyston Plant Central Solvents YTD Quality Complalnts/100 Shipments 0.24 Reason Organic Hatter Color High Melt Point Target 0,20 COMPANY CONFIDENTIAL COMPANY TRAN 025179 WATER PCB-SD0000005848 Company confidential CCMflJNITY RELATIONS. PERSONNEL. RECRUITINC. AND DEVI Community Relations 1. J . C. Landwehr, W. P. Taffee and E. G, Wright attended a talk by Dr. Roy Ledbetter, Alabama State Extension Entomologist, on the positive benefits of DDT at the September meeting of the Decatur, Ala. Kiwanis Club, September 11. Personnel 1. Brode D, Morgan, BSEE from the University of Arkansas, reported to work on September 2 as Electrical-Instrument Engineer I. 2. Ralph Noel, D.O. student, Cobb High School, started to work in ED&S September 18, 1969. 3. G. L. Moore, Co-Op from Ga. Tech, has returned to school to complete studies to obtain degree in Chemical Engineering. 4. All members of TSD attended a seminar on Parathion Poisoning Symptoms conducted by Ishmeal Ransaw, September 16, 1969. 5. All members of TSD attended Job Holders meeting conducted by W. B. Papageorge, September 24, 1969. Recruiting 1. Summer employes reported to school September 15: P. D. Kinnear te the University of Chlcage, H. L. Marcum to the University of Tennessee, J. L. Gaines to Auburn University, and A. I. Hale to the University of Mississippi. Development 1. J. C. Lendwehr participated in Innovation Exchange Program at Brldgevlev Plant (Chicago), September 25-26. - 2. V. R. Haupt visited the Newport England Plant to assist with Biphenyl ,, problems, September 4-20. 3. G. L. Arnett held a seminar at the Luling Plant, Lu1ing, La., to train decontamination team, September 25. Visitors 1. Bob McCutchan visited the laboratory September 17 concerning Aroclor. 2. W. A. Kuhn visited September 3-4 and was special guest at the seminar end berbecue for new employes. 3. George Hunt from S&PP section of CED visited the plant on September 30 concerning the electrical failure in the Aroclor department on September 27. COMPANY CONFIDENTIAL TRAN 025180 WATER PCB-SD0000005849 ) PROCESS IMPROVEMENT distribution of time by technical service Jan. Feb. Mar. Apr. May June July Aug. Sept, Oct. Nov. Due. NEW PRODUCTS PUNT IMPROVEMENT ASSIST OPERATION'S SPECIAL ENGINEERING SERVICES TECHNICAL MANPOWER MISCELLANEOUS ACTIVITIES AND ABSENCES ---- m. j-- i .......:l.1 Jan. Feb. March Apr. May COMPANY CONFIDENTIAL June July Aug. Sept. Oct. Nov. Doc. TRAN 025181 WATER PCB-SD0000005850 IN MAINTENANCE FOR CONSTRUCTION IN MAINTENANCE COMPLETED NOT CLOSED PROJKC1S SUBMITTED FOR APPROVAL 3 ao uo, V) <g 600 tgo 500 H F5 400 ^00 200 100 00 APPROVED PROJECTS IN TSD W Wtilp * / VVlU4UUlib4Mt TSD PROJECT SUMMARY WATER PCB-SD0000005851 ) ANALYTICAL SAMPLES laboratory administration ANALYTICAL MANPOWER Manpower/sample $/Manhours 1 Total Plant Operating Cost ' 1.5 1.0 0.5 Overtime 7. COMPANY WATER PCB-SD0000005852