Document MJYaROee4zw878OvkekJk7y6y

r Anniston j. T. Bell J. L. Corder A. G. Hill G. L. Jessee L. C. Lahman J. C. Landwehr H. E. Schulte W. F. Taffee General Offices H. C. Carder D. Danna (5) M. W. Farrar P. B. Hodges F. J. Holzapfel D. B. Hosmer R. E. Howard W. K. Johnson C. F. Luecke W. R. Richard W. R. Robirds C. W. Roos J. R. Savage J. E. Smith J. A. Stephens COMPANY CONFIDENTIAL Anniston Plant TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Summary SEPTEMBER 1970 Month COST IMPROVEMENT RESULTS Est. Act. ______ Target % of Target $67,676 $45,175 150% YTD $635,723 $542,780 117% Organic Division South Second St. P. 0. DeGarmo The new autoclave for HB-40 (CEA 1482) was installed in early September. Startup for the new vessel (using the existing therminol system) will be during the week of 10-5-70. Total TSD time expended on project this month was 369 hours. A test run was begun on the Polyphenyl Tubular Unit to deter mine capacity and operating bottlenecks when attaining a 50/50 biphenyl/Santowax C split. Redesign of the Aroclor chlorinator chlorine spargers was completed and Maintenance will fabricate two units to be in stalled and tested for chlorine efficiency (free chlorine in the HC1 gas). Other Locations A. H. Forsten Alvin, Texas D. W. Jackson W.G.K. One batch of low color Aroclor 5460 was successfully produced and met all specs. Samples were sent to Marketing for evalua tion. Cost will be less than one cent per pound. Progress report will be issued first week October. A sampling/analysis program was started on Aroclor 5460 to determine relationship between biphenyl in Santowax R and PCB in 5460. A project (AFE 3605) was forwarded for approval to decrease/ contain Aroclor leaks to decrease the loss of PCB to the plant effluent ($15,300 capital and $6,850 expense). an- 306 '_________________________________________________________ ... CONFIDENTIAL INFORMATION 1 "This document contains confidential information which is tha property of Monsanto Company. Only those portions of the document rl*v*nt to a duly authorized individual's nod to know may be excerpted for him. The report must .not be sent outside the Company without written approval and the authorized recipient is accountable for its safe keeping, excerpting or otherwise disclosing of its contents and for its proper disposal. The docu- ment remains the property of Monsanto Company and shall be returned within two months to its author, except upon special authorization to hold .- STLCOPCB4089867 * Organic Division - continued 2. Muriatic Acid - A design and safety review was held for Project 3512 Improved Organics Catch Tank in HC1 Off-gas Line. Drawings were revised and the project will be transmitted the week of October 5. Preliminary design proceeded on the HC1 Fume Collection and Scrubbing System to reduce water load to the sewer and the need for subsequent PCB removal. An AFE will be submitted in mid October. CED transferred $28,000 to the plant from CEA 1831 to modify Chlorine Unloading Facilities and provide nitrogen pad for unloading of cars. TSD began design of new facilities late in September. Agricultural Division Assistance was provided to determine causes for high raw material and acetone usage in the condensation step, and also to correct a color problem in stored refined intermediate. Some success was achieved in acetone usage and color correction. The raw material yield problem remained unsolved at month's end. Field testing of the "Hydrocarbon Dilution of Still Residue" process amend ment proceeded independently of "Chlorination In The Presence Of Acetone." A progress report is in preparation for issuing in October. Process correlation studies on the parathion intermediate chlorinators, followed by a confirming process control experiment, have demonstrated a 4% yield improvement from optimization of chlorine flow rate. Instrumenta tion to provide automatic control have been installed on one reactor to give long-term confirmation for a potential $50,000 annual savings. Quality Control The Plant Quality Score was 76.9, down 11.0 from August, with a YTD score of 85.0 against a target of 95.0, and the lowest score of 1970. All depart ments except Parathion dropped sharply in quality scores. Pollution Control The new neutralization pit was started up on September 23. The PCB content in the pit effluent is running below the 10 PPB division goal. A skimmer has been installed on the Aroclor sump and preliminary indications are that it is working satisfactorily. An additional set of fish samples from Choccolocco Creek and the Coosa River were collected in September. STLCOPCB4089868 D 3. PLANT LABORATORIES ANALYTICAL AND QUALITY CONTROL - S. O. Kemp Complaint Report Quality None. YTD Quality Complaints/100 Shipments 0.29 Target 0.20 DSW 551452 STLCOPCB4089869 COMMUNITY RELATIONS, PERSONNEL, RECRUITING AND DEVELOPMENT % 4. Community Relations 1. Dr. Fred Lippman, Ag Research, visited PR&D concerning Parathion Research. 2. Mallory visitors were here concerning the product - Aroclor, and worked with Chief Chemist, J. T. Bell on special analysis. 3. J. C. Landwehr attended A.I.Ch.E. meeting in Birmingham on September 23. 4. J. T. Bell and J. C. Landwehr went to Auburn, Alabama for Alabama Environmental Conference, September 30 and October 1. Personnel Development 1. D. J. Johnson completed his summer of employment and returned to the University of Alabama on September 4. 2. D. G. Dixon, Co-Op student from Georgia Tech, completed his second quarter of work and returned to school on September 25. 3. D. A. Secrest, Co-Op from Georgia Tech, reported for work on September 28. Billy will report to W. B. Dunlap. 4. M. M. Marcum completed his second summer of work and returned to the University of Tennessee on September 4. 5. Department Safety Meeting was held two days, September 30 and October 1. Meeting was conducted by Tom Lawrence, Safety Supervisor. Visitors 1. P. E. Cherry, CED, visited plant on September 11 to discuss limestone neutralization pits and to look at construction of new pit. 2. Drs. Gunning and Suttkus conducted a biological survey of Choccolocco Creek and the Coosa River on September 22, 23, and 24. DSW 551453 STLCOPCB4089870 D 1970 DISTRIBUTION OF TIME BY TECHNICAL SERVICE EXISTING PRODUCT TECHNOLOGY IMPROVEMENT NEW PRODUCT EVALUATIONS MAJOR FROJECT SUPPORT PROCESS CONTROL IMPROVEMENT CjQ <D Oj fn M <d S U >1 CUrtJ =C S CrH 3O ^ >7) O' D<+J > O 3 <U O O <D WOZQ PROJECT DESIGN PROCESS MAINTENANCE TECHNOLOGY AND TECHNICAL SUPPORT TECHNICAL MANPOWER PLANT IMPROVEMENT ' PROGRAM REAL ESTATE MANAGEMENT DSW 551454 STLCOPCB4089871 .' .- -ORGANIC DIVISION 1970 TSD COST IMPROVEMENT a % FUNCTIONAL FLUIDS TAR EST ACT Disposal of Liquid Montar TAR EST ACT #3 Aroclor Still . New Burners TAR EST ACT #2 Still Entrainment TAR EST Separator ACT 1242 Distillatio i Productivity TAR EST ACT TAR EST ACT TAR PLASTICIZERS EST ACT Flaking & Drum ming Facilities Headcount Solid Aroclor Instrumentation TAR EST ACT TAR EST ACT TAR Sandvik Belt EST ACT Add Tray Strip TAR ping Sections to EST Santowax ACT TAR Cl2 Bulk Handling Facilit i.es EST ACT Solid Aroclor Expansion . TAR EST ACT Chlorinator Back Pressure TAR EST ACT TAR EST ACT TAR EST ACT TAR . EST ACT TAR EST . ACT JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC 1500 600 600 1080 0 C 1080 1080 1080 1080 1080 1080 >0 0 0 U 0 0 cO 0 0 Q 1500 500 500 3000 0 0 1080 3000 1080 150C 1500 1500 1500 1500 1500 1500 1500 1500 C 100 1000 1520 2565 2U0U 1210 C 100 1000 1520 2565 2000 1080 1500 3000 3000 3000 2nnn 3500 3500 3000 2000 1000 3000 2000 1000 3000 2000 1000 1000 lDoC 1000 3750 0 3750 3750 3750 3750 3750 3750 --------CT -------O' -------cr O 0 0 000 2250 2250 2250 2250 0 00 00 4580 4580 4580 4580 4580 4580 4580 0 00 0 0.0 0 00 00 ?nnn 2000 2000 3550 1950 3440 3550 3050 3440 30000 5000C 30000 4950C 5000C 10000 36000 24000 20000 L7900 4300C 5190C 5590C 1050C 38500 23500 24700 27600 - 360 360 0 3750 2250 4580 360 3750 2250 4580} 1 360 ' - - - -- S' DSW 551455 STLCOPCB4089872 ORGANIC DIVISION 1970 TSD COST IMPROVEMENT FUNCTIONAL FLUIDS & PLASTICIZERS TAR EST ACT JAN FEB' MAR APR MAY .JUN JUL AUG SEP OCT NOV DEC (AFF ECTIN 3 BOT] l BUS] NESS GROUP S) Aroclor Ware house Reduced Headcount TAR --1QQCL 1000 EST 1000 1000 ACT 1000 1000 1000 10Q0 1000 Unproved Santowax Yield TAR EST ACT 4000 4000 4000 4000 4000 4000 4000 4000 4QQQ 5900 2800 5800 4000 97C 6630 6280 4450 2800 5800 4000 97C 6630 4Q0.Q . HB-40 Reduce Nickel Catalyst Usaqe Substitution of Santowax C for TAR EST ACT TAR EST 1160 700 1330 1335 700 700 700 525 1230 425 525 2080 565 700 0 C 700 0 0 700 540 20QQC . 2QQQ0 Santowax R ACT TAR EST ACT GENERAL CHEMICALS TAR EST ACT (BIP TENYL PNP, HCl 1 Biphenyl Cool ing Water Treatment PNP Modify Acidifies Dump Valve Svste m Install Entrain ment Separator Prodnction_______ Optimize Reactoi Variables-PNP Refuse Well Water TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT 600 670 670 3150 520 520 600 680 680 600 580 580 3150 3150 1277 2164 3016 2164 600 600 600 '600 67C 675 625 625 625 625 463T 12: 1604 12' ' 1605 600 440 440 600 290 29C 625 625 625 625 625 625 625 625 625 625 625 5500 5500 5500 550Q 0 0 0 00 0 1525 1780* 0 1525 1780 236E 500 625 625 5500 5500 i 50Q 500 \ Untargeted PNCB Heel Credits HCl HCT Catch Tank & Coalescer 150 M Gallon Storage Tank HCl . Ins trumentation TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR 5700 2500 2500 4300 4300 4300 2275 563 3078 1650 920 2275 563 3078 1650 920 5700 5700 5700 57Q0 7560 9000 1030C 6545 7560 9000 1030C 6545 4300 4300 4300 4300 4300 410 410 550 550 753 4300 4300 4300 4300 4300 4300 1875 4000 1230C 4000 1230C 4300 4300 4300 4300 1875 1875 1875 1875 1875 1875 3440 6500 3940 8160 129QC 3440 6500 3940 8160 1875 j -1.875.. EST ACT TAR ---------------------------- - -- EST ACT DSW 551456 - STLCOPCB4089873 ORGANIC DIVISION 1970 TSD COST IMPROVEMENT -' PLANT WIDE Improve Plant Power Factor Central Air Compressor Chlorine Plant Shutdown RTN Cooling Water to Tower Cooling Con veyor - P2S5 Total Organic Month - M $ Total Organic YTD - M $ JAN FEB MAR APR MAY__ . JUN JUL AUG SEP OCT NOV DEC TAR EST - . , * ACT TAR EST ACT TAR EST ACT 950 900 940 950 STJO 914 950 9TB 840 950 790 . 790 950 BW 810 950 845 845 ._ ..... t .. . TAR 1000 1000 1000 EST * ACT TAR 19900 EST 19900 ACT 19900 19900 19900 19900 19900 19900 19900 19900 19900 19900 9950 9950 9950 TAR EST 25 25 25 25 25 25 0 00 ACT TAR EST ACT TAR EST ACT TAR EST ACT 40.6 72.1 96.88 58.07 44.62 27.97 34.12 30.52 30.88 64.68 51.68 51.68 36.29 94.54 103.6 70T39 74'161" 43758* 30733 37.6b 67.68 36.33 99.86 109.1 70.89 77.98 42.22 35.03 47.35 TAR 40.6 112.7 209.6 267.6 312.3 340.2 374.3 404.9 435.7 500.4 552.1 603.8 EST 36.29 130.9 239.8 3T377 390.8 437.7 467.7 510.0 587.6 ACT 36.33 136.2 245.3 316.2 394.1 437.3 472.4 519.7 . OSV\f 551^57 STLCOPCB4089874 AG DIVISION 1970 TSD COST IMPROVEMENT JAN TAR FEB MAR APR MAY JUN JUL AUG SEP OCT NOV PARATHIONS EST ACT Replace #3 Chlorinator TAR EST ACT 4860 . 4860 3500 2340 2340 3500 0 0 3500 0 0 3500 0 Improve Cl,Still Yields TAR EST ACT 3000 3000 00 00 3000 0 0 3000 0 0 3000 0 3000 Increase Chlor- TAR inator Coolings EST ACT 8500 U 0 8500 0 8500 Acetone Recovery TAR 2800 2800 EST 1957 TO 69 ACT 1957 1069 2800 1225 1225 2800 1935 1935 2800 130 130 2800 715 715 2800 0 0 2800 0 0 2800 '0 2800 2800 Chlorine Unloading TAR 2250 EST 3634 ACT 3634 2250 4237 4237 2250 3350 3350 3200 1406 1406 3200 3431 3431 3200 2430 2430 3200 1750 1750 3200 2710 2710 Optimize Methyl TAR 3000 3000 3000 1500 PNP/PCT Ratio EST ACT 00 00 00 0 0 Optimize Ethyl PNP/PCT Ratio TAR EST ACT 500 0 0 750 2641 2641 750 0 0 500 Change Cooling TAR 200 200 200 H-0 - Item 737 EST 310 230 270 ACT 310 230 270 Untargeted: Plant Test - TAR EST ACT TAR 2430 2430 `' 5270 5270 EST ACT Total AG Month M $ TAR EST ACT 5.75 5.90 5.90 6.0 6.0 8.17 ' 4.85 8.17 4.85 6.0 10.63 10.62 15.5 11.2 11.2 15.5 3.15 3.15 15.5 1.75 1.75 22.5 Z !L 2.71 14.3 0 14.3 3.3 Total. AG YTD M $ TAR EST ACT 5.75 11.75 17.75 23.75 5.90 14.08 18.92 29.55 5.90 14.03 18.92 29.55 39.25 54.75 40.73 43.87 40.73 43.87 70.25 92.75 107.1 121.4 45.62 48.33 48'.3T 45.62 48.33 124.7 TAR EST ACT Total Plant Month M $ TAR 46.35 78.1 102.9 64.07 60.12 43.47 49.62 53.02 45.18 EST 42.19 102.8 108.5 81.02 '85.79 46.72 T77UB 40.36 67.68 ACT 42.23 108.0 113.9 81.52 89.15 45.36 36.78 50.06 78.98 54.98 Total Plant YTD M $ TAR 46.35 124.5 227.3 291.4 EST 42.19 145.0 258.8 345.3 ACT 42.23 150.3 264.2 345.8 351.5 395.0 444.6 431.5 481.6 513.3 434.9 481.2 518.0 497.6 542.8 621.8 558.3 635.7 568.0 676.7 DEC 50C .5 125.2 52.18 728.9 DSW 551458 STLCOPCB4089875