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CH-1003 REV. *40
ISTMUSNCOMOt
E. I. d u Po n t d e Ne mo u r s & Co mp a n y
INCORPORATED
Wil min g t o n , De l a w a r e 19898
CHEMICALS AND PIGMENTS DEPARTMENT JACKSON LABORATORY
CC: rR- S. Weis D. Gray, C&P, Newark S. A. Dombchik, C&P, Newport K. H. Dietz W. J. Lawrenae
February 17, 1981
J. I. Hughes C&P, B-17302
1980 COST IMPROVEMENT ACCOMPLISHMENTS Attached is subject report detailing 1980 cost reductions for Colored Pigments R&D groups at Newark and Newport. Variances greater than 20% from forecast have been explained.
P. A. Wriede
PAW:jla Attachments
NEWPORT RS.D COST IMPROVEMENT ACCOMPLISHMENT REPORT - QA - 1980 39 e Vi /*m .t a 4- M o t .t a r * l r
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DU P050145737
N 26464.01
1980 COST REDUCTION ACCOMPLISHMENTS PROGRAMS WITH VARIANCES GREATER THAN 20%
o Sodium Methylate (^1^1 vs. $50M Fc.; $139 vs. $50 1980-84). Only claimed additional savings for 1981 rather than 1979 carryover on forecast; will claim in 1981; additional savings potential refined.
o Low Cost Gamma QA $0 vs. $54M; $0 vs. $225 (1980-84). Program not active at Newport; Premilling for RT-796 at Jackson Lab.; original trials did not achieve quality.
o Non-Cr QAQ $0 vs. $50M Fc.; $70 vs. $169M in 1980-84). Introduction of technology delayed due to environmental problems; process successfully demonstrated 1/81; savings will accrue in 1981; no basis for savings beyond 1982.
o Dowtherm ($291M vs. $180M goal; $391 vs. $180M in 1980-84). Improved utilization using "isolated" Dowtherm concept which eliminates solvent recovery processing for 35% of stream.
o Yield ($305M vs. $30M goal; $379 vs. $30M in 1980-84). Improved yields (/,*^10%I by eliminating pyrolysis Dowtherm from SSE reaction (Isolated Dowtherm)..
o QA - Low Cost Beta ($0 vs. $25M goal; $0 vs. $143M in 1980-81). Program not active at Newport; dropped at Jackson Lab.
o Membrane Press $0 vs. $110M in 1981). Program terminated following basic data; need for press evaporated. May re-examine at later date.
o Water Conservation ($0 vs. $23M in 1981). Program terminated in favor of energy.
o Alcohol Recovery ($0 vs. $100M in 1983). Program terminated as unattractive following laboratory work.
o Microprocessor ($0 vs. $70M in 1983). Program terminated as economically unattractive.
o XRT-959 ($0 vs. $560M in 1981-83). Product commercialized in 1980 with 3 yr. PTE of $1MM; this does not constitute cost reduction by current rules.
o XRT-256 ($0 vs. $750M in 1981) Process demonstrated; customer response lacking; may have future potential as resale product; product does not con stitute cost reduction by current rules.
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DUP050145738
N 26464.02
QA (cont'd.) o Reduce Substandard ($128 vs. $48M in 1981-84).
Additional opportunities identified. o QA Spray Drier ($0 vs. $100M in 1981).
Work to increase capacity does not qualify as cost reduction; energy savings will be reported under different line item. o Low Cost Transparent Red ($0 vs. $785M in 1981). Program not active at Jackson Lab.; RT-273 commercialized; does not qualify as cost reduction. o Low Cost DQA Oxidation ($0 vs. $399M in 1982-84). Program terminated at Jackson Lab.
DUP050145739
NEWPORT R&D COST IMPROVEMENT ACCOMPLISHMENT REPORT - CPC - 1980
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DU P050145740
N 26464.03
CPC
1980 COST REDUCTION ACCOMPLISHMENTS PROGRAM WITH VARIANCES GREATER THAN 20%
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Crude Consolidation ($575M vs. $310M Fc.). 7 months vs. 6 months operation; improved manpower ^ efficiencies achieved.
Presscake Facilities ($0 vs. $70M Fc.). Installation of the membrane press was delayed (delivery); startup occurred 1/81 with $118M savings forecasted for 1981; including second press (see below).
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Low Cost Alpha Process ($0 vs. $48M Fc.; $0 vs. $17M in 1981). Program not active at Newport; will review breaching vs. solvent milling BT-284 for merits.
Low Cost Beta CPC C$0 vs. $158M Fc.; $300 vs. $625M in 1980-84).
Satisfactory technology not developed per Jackson Lab.
_ fofWcai'fc; BT-487~~partially demonsJbrate.dj^ BT-4T) t> "be de-___v
^_ monstrated IQ/81; total savings limited by limited tecnnolog^
and lower forecast.
v~'------------------------------------------------- ^
Kerosene Reduction ($0 vs. $50M goal; $220 vs. $130M in 1980-84). No manpower; improvements to decanter will be implemented IQ/81 with resulting increased savings.
Manufacture Green Y ($0 vs. $190M goal; $0 vs. $809M in 1980-84). Satisfactory quality to allow elimination of shading component never plant demonstrated; program terminated due to
impending business decision.
Membrane Press ($0 vs. $10QM goal; $0 vs. $50M in 1981). Installation delayed (delivery); installed 1/81 with $118M savings forecasted for 1981; 2nd. press to be installed IIQ/81. Total savings forecasted use of 2 presses ($370M); reduced due to decreased sales volume.
Flash Distillation ($0 vs. $60M in 1981). Program associated with Green; terminated per business plans.
Automate Blue/Green ($0 vs. $40M in 1982) Program terminated in 1980.
Water Conservation ($0 vs. $23M in 1981). Program terminated in favor of energy.
Molten Phthalic Anhydride ($0 vs. $80M in 1981) Program terminated in 1980; poor economics.
DUP050145741
N 26464.04
CPC (Cont'd.) o Reduce Substandard ($99 vs. $60M in 1981-84).
Identified increased savings in 1981. HSO^Cl Green CPC ($0 vs. $800M in 1983).
Program terminated by Jackson Lab. due to Green Business Decision. Improved GE Quality ($0 vs. $260M in 1982). Program terminated due to Green Business Decision.
DU P050145742
( A ll v a lu e s In th o u sa n d s o f d o lla rs )
NEWARK
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N 26464.05
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INORGANICS
VARIANCE EXPLANATION - COST REDUCTION ACCOMPLISHMENT REPORT (ALL VALUES IN $M)
PROGRAM Flocculation
Liquid Alum
FIRM 25
GOAL 0
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28 28
0
Silica for Titanium Continuous YE-698-D
33 33 0 0 82 0
NOx Scrubber
12 0 6
Sodium Molybdate Yield
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0 10 07 07
EXPLANATION
Not feasible to use chemical flocculation instead of steam flocculation for Cont. Unit codes - quality suffers.
Project to use liquid alum Instead of dry form not install Higher priority maintenance ltc and design manpower limitations early in the year.
Use silica in place of tltaniuo for lightfastness for Cont. uni yellows - plant trials run inferior product produced.
Plant trials run technology nee fine tuning to obtain quality product. Revised production schedule,because of economic situation,delayed further trial
Recover nitric acid for use in making lead nitrate - system not in full operation until mid year.
Technical assistance provided t improve material conversion.
Reduction in use of this raw material in inorganic yellows.
Savings realized from program t routinely inspect steam traps.
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DUP050145744
N 26464.06
PHTHALOCYANINE R+D COST IMPROVEMENT ACCOMPLISHMENT REPORT
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DU P050145745
N 26464.07
PHTHALOCYANINE VARIANCE EXPLANATIONS - COST REDUCTION ACCOMPLISHMENT REPORT
PROGRAM Pigment Recovery
Reduce Mixing
Ingredient Savings from Inerting
FIRM 0
GOAL 54
ACTUAL 10
o 40 26
EXPLANATION
Excess membrane press capacity not used for CPC codes as originally forecasted. Membrane press problems.
Did not reduce slow moving inventory as expected. Forecast pounds down-CPC quality.
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C0a inerting during finishing reduced pigment loss caused by smoldering from hot embers.
DU P050145746
N 26464.08
QUINACRIDONE
R+D COST IMPROVEMENT ACCOMPLISHMENT REPORTPLANT NEWARK
DATE
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( A ll va lu e s In thousands o f d o lla rs )
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DU P050145747
N 26464.09
QUINACRIDONE
VARIANCE EXPLANATION - COST REDUCTION ACCOMPLISHMENT REPORT
PROGRAM
FIRM
GOAL
ACTUAL
EXPLANATION
Extend QA
Ingredient savings from inerting
5 0 0 Product quality suffers - drop program.
0 0 9 COa Inerting during finishing reduced pigment loss caused by smoldering pigment from hot embers.
DU P050145748
N 26464.1
OTHER ORGANICS R+D COST IMPROVEMENT ACCOMPLISHMENT REPORT
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DU P050145749
N 26464.11
OTHER ORGANICS VARIANCE EXPLANATION - COST REDUCTION ACCOMPLISHMENT REPORT
PROGRAM High Solids Press Drum Cleaner Reduce Mixing
Diazo Press
Ingredient Savings from Inerting
Blend Formulations E-Steam Trap Inspection
FIRM 69
GOAL 35
ACTUAL 4
40 0
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50
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EXPLANATION
Lower than expected production forecast^membrane press problems.
Manpower limitations to characterize cleaning unit. Installation delays.
Better progress made on liquidating slow moving inventory in Dalamar and Vatchung line.
Tested alternate devices for diazo clarification. Manpower limitations to resume testing because of other higher priority tech, assistance programs.
00
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0 0 35
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C0a inerting during finishing reduced pigment loss caused by smoldering pigment from hot embers.
Strong product standardized with in shipping limits to avoid giving away product.
Savings realized by routine inspection of steam traps.
DUP050145750
N 26464.12
COST REDUCTION FORECAST/ACCOMPLISHMENT
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NEWPORT PLANT COST REDUCTION FORECAST/ACCOMPLISHMENT
THIRD QUARTER 1981
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