Document J32Kr3EOvbkk5Bz6YvYKyMMEX

CSTAUSHCn E. 1. d u Po n t d e Ne mo u r s 51 Co mp a n y . ItMBORPORATKD Wil min g t o n , De l a w a r e 19898 CHEMICALS AND PIGMENTS DEPARTMENT JACKSON LABORATORY CC: $. W. Severance, B-6237 J* S. Thackrah, B-6237 P, A. Hopkins, B-17249-4 R. S. Weis, B-17202 Ft B. Bredimus, C&P, Newport J. M. Loether, C&P, Newark April 7, 1982 J. P. Glas, B-17206 G. C. Tunis, B-6237 B. F. Kennedy, B-17249-2 COLORED PIGMENTS R&D; PROCESS 1MPROVEMENT/DOCUHENTATION ACCOMPLISHMENT REVIEW Attached are charts used at the review held on March 30. CH-1003 REV. fl-M E. I. d u Po n t d e Ne mo u r s Si Co mp a n y WILMINGTON, DELAWARE 19898 CHEMICALS AND PIGMENTS DEPARTMENT JACKSON UBORATORV CC: S. W. Severance, B-6237 J, 5. Thackrah, B-6237 P. A. Hopkins, B-17249~4 R. S. Weis, B-17202 F. B. Bredimus, C&P, Newport J. M. Loether, C&P, Newark April 7, 1982 J. P. Glas, B--17206 G, C* Tunis, B-6237 B. F. Kennedy, B-17249-2 COLORED PIGMENTS R&D; PROCESS IMPROVEMENT/DOCUMENTATION a c c o mp l is h me n t r e v ie w Attached are charts used at the review held on March 30, PAW:jla Attachment N 25851 DUP050145443 A- NEWARK pr o g r am r eview 0. GRAY 3/30/82 DUP050145444 N 25851.01 REVIEW ITEMS BACKGROUND INFORMATION d o c u me n t a t io n FACILITIES IMPROVEMENT DUP050145445 PRODUCTION TRAIN BATCH MAKING SYNTHESIS/TREATMENT ISOLATE/WASH DRY FINISHING GRIND SEMI FINISHED pac k OUT ---------* INVENTORY EVALUATE FORMULATE MIX**-- BLEND PACK OUT EVALUATE------- -- CONTINUOUS MAKING FINISHING f EVALUATE FINISHED PRODUCT (AFS) DUP050145446 PROCESS DOCUMENTATION PROBLEM MASTER TECHNICAL FILE INADEQUATE t BATCH CARDS ARE CURRENT - NEED UPGRADING * EXPAND OPERATING INSTRUCTIONS - REQUIRES SKILLED OPERATOR - DEFINE CRITICAL PROCESS STEPS PLANT ASSISTANCE AREA CHEMIST/ENGINEER APPROACH t DOCUMENT CURRENT TECHNOLOGY PRINCIPLE; REACTIONS; END USE BASIS - PROCESS NOTES; PLANT TRIALS; BATCH CARDS EQUIPMENT; MATERIAL OF CONSTRUCTION CHEMICAL HAZARDS BILL OF MATERIALS; SPECS; WASTES; YIELD PROCESS STEPS; OPERATING PARAMETERS/LIMITS DRAFT - TECHNICAL AND MANUFACTURING REVIEW # FINAL - OPERABLE/REPRODUCIBLE TO PROVIDE AFS EDIT BATCH CARD DUP05014544 DOCUMENTATION SCHEDULE/STATUS STATUS ' SCHEDULE ACTUAL IIQ82 DRAFTr^rlNAL 29 7 35 10 FINAL II III IV TOTAL 29 30 37 103 TECHNOLOGY IMPROVEMENT IDENTIFIED CYCLE TIME SOLUTION MAKE UP WASH TIME DRYING TIME CRUDE ACCEPTANCE TEST RAW MATERIAL SAVINGS QUALIFY NEW SOURCES * ELIMINATE CONTAMINATION SOURCES DUP050145448 AZO PIGMENTS PRODUCTS DAIAMAR YELLOW 1982 FIt M LBS 613 ' WATCHUNG/BON RED 1248 JEST = 87% OF TOTAL AZO'S PROCESS AMINE---*DIAZO COUPLER t DALAMAR COUPLER . DYE SALT BA, CA, SR ^ WATCHUNG MN BON RED CLARIFICATION CLARIFICATION AMINE CARBON OR w .-.ii.i..-,. iii.-i.. . DEVICE i ..I. ii'.i. DIAZO FILTER AID PROGRAM QUALIFY NEW SOURCE RAW MATERIALS ELIMINATE CARBON DULLING IMPURITY CYCLE TIME/LABOR YIELD LOSS DUP050145449 FACILITIES UPGRADING GRINDING EQUIPMENT PROCESS CONTROL EQUIPMENT MATERIAL HANDLING AND PACK OUT DUP050145450 FACILITIES UPGRADING CONTINUOUS UNIT F/C 16MM LBS 1982 - 8 WEEK CYCLE PROCESS STRIKE--# ISOLATE mm 3 MILLS; *> DRY--# Ig RINd I-- PACKQUT 2 - SALES GRADES: 1 - COMPONENT PROGRAM - REPLACE MILLS MAINTENANCE DUST SOURCE UTILITY - STATUS BAUER MILL - $11OM, 108% NROI CHARACTERIZATION TO DATE 5 OF 9 PRODUCTS TESTED EXCELLENT RESULTS COMPLETE TESTING BY 6/82 DUP050145451 SUMMARY DOCUMENTATION - ON SCHEDULE BENEFITS CYCLE TIME REDUCTION RAW MATERIAL SAVINGS ELIMINATE PIT FALLS TIME DELAYS CONTAMINATION FACILITIES UPGRADING CONTINUOUS UNIT * GRINDER FINISHING - PACKERS DUP050145452 NEWPORT PRODUCTIVITY IMPROVEMENT PROGRAM I Q - 82 REVIEW S. A. DOMBCHIK 3/30/82 DU P050145453 PROCESS IMPROVEMEMT/DOCUHENTATXOH ] Q COMMITMENT 5 aRT.li: ATED-^6 APPROVED - 5* D IAN ILINODIHYDROTEREPHTHAUTE (QA) N-76A3 (RT-899) N-7531 - QAAF SUCCINYL SUCCINIC ESTER (QA) QU1NACRIDONEQUINONE (II Q) - ANTICIPATED* EXCEPTION - 1 (TO APRIL) N-7102 (RT-790) I PROCESS APPROVED THROUGH SR, SUPR. PRODUCTION i LAST CAMPAIGN YELLOW t INTENSE TINT NEED TO ASSURE BLENDABILITYTO RT-790 ' WIDEN SPECIFICATIONS II Q COMMITMENT - A (+ H-7102) DIHYDRO-QA (QA) - DRAFTED/UNDER REVIEW N-8510 - DRAFTED; PUNT WORK COMPLETE; LAB QUINACRIDONFGUI NONE - APPROVED* N-7609-UB WORK COMPLETE; BEING WRITTEN (N-8833, N-8730, LC CRUDE EARLY) DUP050145454 GOAL: ALL COMPLETE BY YEAR END (117) 1 0 GOAL-77 (16/QUARTEB RATE) APPROVED-78 UNDER REVIEW-13 TOTAL - 32 APPROVED - 21 UNDER REVIEW - 8 N-CODE SPECIFICATIONS FOR NEWARK TWO LEVELS OF ACCEPTABILITY TEMPORARY' SPECIFICATIONS (IF UNCERTAINTY) TEST DEVELOPMENT NEW STANDARDS INSTRUMENTAL COLOR (N-7500, N-7102/A, N-S510) DU P050145455 FACILITIES - IQ COMMITMENTS WATER SOFTENER (SA) ELIMINATE 903 SCRUBBER BASIC DATA COMMITMENT 1/82 2/82 .. .. ..STATUS COMPLETE) TWO UNITS ORDEREI COMPLETE; < $10M VS.> $50M MCN - II Q DOWTHERM SAVINGS - MIXING - COALESCER 3/82 3/82 COMPLETE; MCN TBD >200% NROI ON $50M COMPLETE) MCN TBD ^llEZ NROI ON 0M DUP050145456 SUMMARY ' DELAWARE RECLAMATION PLANT (DRP) START UP FORECASTED FOR IV 0- 82 USING AIR DRIED SLUDGE FROM CURRENT LAGOON INVENTORIES. NEWPORT R&D WILL MONITOR SLUDGE TO ASSURE ACCEPTABLE CPC LEVELS (APRIL) ' BIRD TESTING INITIATED (250/500 PPD)j RESULTS IN JUNE I Q 82 CPC LOSS 5A0 PPD - 83% OF IV Q 81 - LOW PRODUCTION MAJOR LOSS POINT IDENTIFIED - CPC CRUDE MGF. AT EAST KEROSENE DECANTER - 50% OF TOTAL LOSS - FILTRATION OF LUWA DRYER CONDENSATE TO CONTAIN PIGMENT STARTED UP - RESULTS MIXED (RESOLVE IN APRIL). $ OTHER LOSS REDUCTION PROGRAMS PROGRESSING ON/AHEAD OF SCHEDULE DU P050145457 y \ L T ^ A T lOH O F LU W A COMTEK? ^ T O -fc 'DE'CAM T'?5X, CPC WASTE STREAM CONTROL ESTABLISH GATE LOSS SPECIFICATIONS (6/82) - BIRD TESTING INITIATED - B! WEEKLY DRP DIGESTER SAMPLING INITIATED - ESD COMPUTER MODEL FOR PEAK LOSS IMPACT (APRIL) REDUCE CPC LOSSES TO ACCEPTABLE LEVEL (200-300 PPD RATE) - LOSS POINTS AND MAGNITUDE (1/82) ' COMPLETE (EAST DECANTER, MEMBRANE PRESS, POINT SOURCE) - EAST DECANTER (2/82) - WEST DECANTER (2/82) ' VISUAL ON ROTARY FILTER . STREAMS - BGD ROTARY FILTERS (6/82) BACKUP FILTER ON ORDER (DUE NOW) - CAKED MILLS (3/82) SCHEME DEVELOPED - TOTE MODIFIED STARTUP APRIL (NEED 2A3 TANK) DUP050145459 r CPC HASTE SfREAM CONTROL (CONTD.) - SEPARATED BATCHES (DEFINE 3/82) BB PROCESS SUCCESSFULLY MODIFIED ' RECOVERY SCHEME DEVELOPED/MINI FLASH FABRICATED/START UP APRIL ' RECYCLE FEASIBILITY IN APRIL - PRESS ISOLATION (DEFINE 1/82) ' MONITOR PLATE & FRAME RECOVERY SYSTEM-MEMBRANE (APRIL) - SPILL CONTAINMENT (DEFINE 3/82) TANK OVERFLOW a LINE BREAKS PRESS BREAKOUTS - GRADE CHANGE FLUSHOUTS (6/82) - COMMUNICATION (NEW) ' PRODUCTION COMMITMENT/MANPOWER ' WEEKLY REVIEW SHIFT MEETINGS - IMPLEMENT ACROSS SITE ill I 0/82 DUP050145460 11 Q FORECAST PROCESS IMPROVEMENT/DOCUMENTAT ION - ON SCHEDULE SPECIFICATIONS - ON SCHEDULE FACILITIES - NOTHING FORECASTED CPC WASTE STREAM CONTROL - DEFINE ALLOWED GATE LOSS - KEY TO SUCCESS FOR REMOVAL (EAST DECANTER) - MANAGE USE OF SLUDGE BY DRP KEROSENE - ACTIVE (REPORT NEXT TIME)