Document Nez43K6NBmD9BNb5yq3No26Mw

I-IM (SOM) inter-office memo TENNECO CHEMICALS, IflC. '7 T 1 T APR 101969 To M. W. Williams At Piscataway From- P. F. Albanese AT Flemington Subject MONTHLY REPORT - MARCH, 1969 PROCESS DEVELOPMENT RAW MATERIALS MVC Date Copy to April 7, 1969 H. B. Oarr E. Farber J. C. Fisher J. B. Gottlieb E. J. Hourihan C. W. Johnston G. W. Leach L. Medeiros M. K. Rosen P. R. Scarito A. C. Shah A. C. Siegel R. A. Vallette A. V. Wagner W. D. Wesely A 42,000 gallon tank car of Allied MVC and 9 tank cars of PPG monomer were processed through the Burlington site as part of a monomer evaluation program. All of the data gathered is still under review and at this point, the PPG monomer is comparable to good Tenneco monomer. The major significant effect*noted was the quality of the Allied recovered monomer which gave a noticeable improvement in reaction kinetics over the Tenneco monomer. A report will be issued shortly with a detailed list of savings that could be expected with a better quality monomer. In-process monomer sampling, to more closely relate to process performance, is being delayed because of the heavy load*of monomer samples resulting from the Allied and PPG* evaluations. A memo was issued detailing the cost savings that could be ascribed to a decrease in propadiene level which was noted during the early part of February. The cost savings reported was based on the improvement in reaction times noted for 1730 and calculated to represent an addition to annual profits of approximately $75*000. P.E. has been monitoring the storage life of Lupersol-li and catalyst storage facilities in Burlington. After one month storage, the Lupersol-11 was in specification for activity and the storage temperature was held below 28F. It is planned to continue with this study. It was reported in the last report period of the number of unusual occurrences in FVC reaction behavior at the Burlington site; poor reactions and long dry blend times. Observations to date have noted some improvement and more consistent homo polymer quality; coarser particle size, low SHDBT and higher bulk densities which also coincides with the dispersion resin plant using their own recovered monomer. COLOR!TE 006178 M. W. Williams -2- April 7, 1969 DHW-80 No change in status. MC-15 Makeup Centrifuge studies were completed and an interim report (LOP 729) was issued. The data shows an overall reduction in gel level and a reduction in the number of large "fibers" but not appreciably affecting the total number of "fibers." Data is still being collected to determine if the improved filtration of water has also had an effect on the gel level. Solution cooling of MC-15 is still being considered for a trial run at Burlington. Engineering has been requested to estimate the cost of providing the Methocel make-up tank with "brine" water. PRODUCTIVITY IMPROVEMENTS Suspension 2-EHP - Two single-batch runs were made this period; the first into a cleaned reactor followed by a second into the same reac tor uncleaned. Both batches were sluggish and were dumped early with the prime suspect being the activity of the 2-EHP. Q.C.'s evaluation of the catalyst showed a 25% reduction in activity. Although the data may be meaningless, the most critical property, gels, was in spec, 2 and 8, respectively. Large-scale runs will be made using 7-batch lots as soon as a new shipment of 2-EHP is received. IPP - A program was started in the Flemington plant on evalu ating the use of IPP as a possible raw material savings in catalyst cost. It is planned to conduct the IPP-program in Flemington whereas the 2-EHP will be studied in Burlington. Information and data on the Flemington runs will be' reported during the next report period. Aposet 435 - No change in status. Apogee was notified of the Lucidol patent on Lupersol-11. We have not heard Apogee's comments on the patent, and at this point, if the patent is valid, there is not sufficient incentive to replace Lucidol with Apogee's material. EHP - Reflux - No change in status. It is not planned to conduct any development work in this area pending the return of Tenneco Plastics personnel from Tenneco Oil. COLORITE 006179 M. W. Williams -3- April 7, 1969 O c+ Increased Reactor Loading - Burlington and Flemington Production are continuing with their programs via LOP to increase reactor loading. The monomer charge for the 315 formulation was in creased, however, due to excessive vibration in the copolymer centrifuge, the charge was lowered again. At this point, we have no reason to believe higher monomer loading is the cause. 250-2 - No lumpy batches were encountered this period. Dispersion Resin Sodium Bisulfite - At 0.03 phm of sodium bisulfite in our 1790 formulation, induction times were eliminated and cycle times correspondingly reduced. A memo was issued reporting a savings of $63,000 per year based upon the current 1790 production rate. The evaluation is still in progress on an every-other-batch basis for the 1790 formulation. The program has not been started for the 1730 formulation or on the addition of sodium bisulfite to the emulsifier. Recovered Monomer - LOP 796 was approved to evaluate the effec of recovered monomer on dispersion reaction kinetics and produ properties; a maximum usage of 2,000 lbs. per batch is author ized. Samples of the recovered monomer will be submitted for G.C. analysis and bottle polymerizations. Two vs. Three Stage Homogenization with 1790 - LOP 725 was issued to evaluate two vs. three stage homogenization and the effect on resin properties, especially Brookfield viscosity. Although all data has not been evaluated, three stage appears to produce resin with one day Brookfield viscosities approxi mately 5 poise higher than that produced with two stage. Lots 939011 thru lot 939019 have been evaluated. None of the eight pallets produced via three stage had one day Brookfield viscositiesi lower than 95 poises, while five of seven pallets produced via two stage had one day Brookfield viscosities lower than 45 poises. As soon as time permits, a report on this LOP will be written. Antifoam DE-190 - No action this month. DRY BLEND RESIN PROCESS A status report is being prepared and will issue the first week of April. Results to date and recommendations for future work will be included. It is now apparent that large particles alone do not produce a dry blend resin. Agglomeration of fines caused by the presence of a surfactant is required to produce the required dry blend and dry flow properties. COLORITE 006180 M. W. Williams -4- April 7, 1969 The program was expanded to also include a 200 type resin pri marily to obtain a less expensive resin for Elm Coated Fabrics. There is insufficient data available at this time to base any conclusions. VP-631 The second batch charged during the present plant VP-631 program did not initiate and had to be recovered. Complete coverage of the batch was provided by R & D and the reason for not initiating is not known. A follow-up batch, the third in the series, was charged after taking certain precautions of eliminating only traces of recovered monomer entering the charge. This batch failed to initiate during the prescribed time period but did initiate after raising the temperature ten degrees. The result ing latex gave acceptable blending resin properties after being processed in the modified 10MM line, however, after 3 days, it had to be scrapped because of poor latex stability. A more detailed report will follow during the next report period. BLENDING RESINS Copolymer Blending Resin Nine batches of copolymer blending resin were run under NPI Extension 733-1- This run was our first attempt to dry and screen this product through the large copolymer line. Two batches of lot 799009 started processing using a 100 mesh screen, but screen rejects ran high at approximately The balance of this lot was dried into a bin and held until later when it was screened through production's standard 50 mesh screen. The seven batch lot (799005) was processed through 80 mesh to reduce tailings and provide Wheaton with a truckload of resin. We had 16% tailings and an average drying rate of 2,700 lbs. per hour. 'An Interim Report (NPI Extension 733-1 Copolymer Blending Resin dated March 25, 1969) was issued. Slurry sam ples from each batch have been forwarded to the Pilot Plant for drying and subsequent evaluation by Surface Coatings Group. Based on the low production rate and the screening problem on the 40MM line, it is recommended future development work be done on the 10MM line. Additional runs are planned pending Wheaton's evaluation of this latest resin and their subsequent orders. As time per mits, classifying and screening studies will be conducted on the resin produced during this latest run. COLORITE 006181 M. W. Williams -5- April 7, 1969 The addition of silicone to a copolymer formulation has shown a tendency towards a finer particle with less agglomeration taking place. This was also evaluated in the Pilot Plant using a copolymer blending resin formulation with the expectation this would improve the fineness and decrease the amount of agglomeration. Samples were submitted to Product Development for evaluation. Medium Particle Size, PD-03j?3? No change in status. Coarse Particle Size, PD-03334 It was also planned to evaluate processing on the 40MM lb. line with PD-03534. However, based on our recent experience, devel opment work for this resin should be done on the 1QMM lb. line. NPI Extension 677-3 is circulating for approval to run four batches. This will be done following the copolymer runs. Fine Particle Size No change in status. No additional work is planned in the Pilot Plant pending the return of A. C. Shah from Tenneco Oil or until the modified 380 resin program progresses to a satis factory end point. AMP" s The rough draft covering the formulations and process condi tions for the Flemington plant is completed. This draft will be reviewed with Production within the next report period. The 1716 AMP was modified so that unless a special request is made, lauryl alcohol will be used. For a specific non-FDA use. Production will be specifically requested to use tridecanol. Each of the variations are on separate AMP's with different formulation numbers. NEW PRODUCTS Dispersion No work was done in this area at the Plant or Pilot Plant level. 1738 - Polymerization work is pending Product Development's evaluation of a 1738-type resin by means of an intermediate reaction temperature and TAIC. COLORITE 006182 M. W. Williams -6- April 7, 196g 0565 - __Samples were submitted to Product Development represent ing 0565 that was polymerized at a lower temperature. This approach was taken to improve the rheological properties since previous work on 1738 had shown an increase in gel time with a decrease in polymerization temperature. -S--u--s--D---e--n--s,io, n Modified 380 - NPI 737 was issued to produce a faster fluxing resin than the previous attempt, NPI 695. A stringent clean out, a reduction in Methocel level and the elimination of a forced heat kick were incorporated as an attempt to lower the fusion time. Product Development found the resulting resin to be an improvement over the previous run as far as cross-contam ination was concerned, however, the fusion time was not sig nificantly improved to the point where it would be acceptable. The Pilot Plant is presently studying the effect of agitation and colloid level on particle size, bulk density and fusion time to determine if this will lead to further improvements in fusion time. An additional program was initiated to develop an absorptive of-olefin modified 380 by way of a surfactant/colloid system. Runs made to date have given comparative fusion times to Escambia 6l80Y and at times has surpassed the Escambia resin. Work is needed to optimize the formulation in terms of repro ducibility, reactor cleanliness and process controllability. Agglomeration at certain formulation conditions is a problem. Also, for some unknown reason, kinetics appear to be poorer with the surfactant system. Film Grade Resin- 17F - TAMILS evaluation of the 6,000 lb. sample of 17F (589008J showed it to be within tolerable limits for their "Rolla-Glass" operation. They requested a 10,000 lb. sample of another lot of 17F in order to make a final decision based on our ability to reproduce. A second attempt to make this resin resulted In over 150,000 lbs. of resin (lots 589013 and 589014) comparable in properties to lot 589OO8 based on Q.C. properties. Product Development is presently evaluating this lot along with in-process samples. Twenty-four thousand lbs. of lot 589008 was shipped to Edison Plastics after this resin was released by CSL and P.D, Polymix - No change in status. Tenneco 10R - No change in status. COLOR!TE 006183 M. W. Williams -7- April 7, 1969 Solution Grade Resin (VYHH type) - Wo additional work will be carried out until the PDA status of the Ganex V-816 is clari fied. A 10 lb. sample of batch 10-3120-C has been sent to C. W. Johnston for transmittal to GAF for extraction studies. Fast Flowing; 150 Kesin - A scaleup to a 200 gallon reactor was made to provide sufficient quantities of a fast flowing low relative PVC resin for customer evaluation. Although the relative viscosity was the same as a previously-accepted batch, the resin had twice the melt flow expected. Additional runs are needed at a revised level of TCE to provide the desired melt flow. l6RS - Reduction of Fines - No change in status. Graft Copolymers - A graft copolymer with 10$ Hypalon 20 was attempted in the Pilot Plant. It is planned to go to a 5$ graft since a considerable amount of undissolved and unreacted Hypalon 20 was present in the final product. PVC 300 - Wo change in status. Wo further work is planned until receipt of the expected orders for this resin. 180/llR - NPI 7^2 was issued to produce a resin with properties somewhere between 10R and 12R plus improved heat stability and a slightly coarser resin. This resin is expected to meet the requirements for FDA bottle formulations. All target proper ties were met with the exception of heat stability, 98$ vs. 100$. Resin is presently being evaluated by CSL and Product Development. PRODUCT REFINEMENTS Tenneco 989 - Two SPA extensions were issued, 795-1 and 795-2. The primary objectives were to better define the. particle size requirement at Capitol and to also lower the relative viscosity so as to lessen the dependence of extrusion time on particle size. The resin objectives were met and we are presently waiting for an evaluation at Capitol. Modified 12R (SPA 728) - We have not received any feedback on the special resin prepared for a compound shipment to Sloane. Modified 715-2 (SPA 7^9) - Marketing requested a finer particle size version of Tenneco 315-2 so as to sample to GAF. Approval at GAF would mean an additional 5MM lbs./year of business at GAF. The SPA was issued and approved, however, because of the tight scheduling in the copolymer plant, this resin has not been made. COLORITE 006184 M. W. Williams -8- April 7, 1969 FVC 200 (SPA 724) - SPA (724-1) was extended so as to produce a lower cost resin by reduced venting. The extension covered the period from 2/25/69 to 5/25/69 during which 25 lots were produced in the No. 5 Plant, exclusively. Since there have been no customer complaints on this resin, it is expected that the longer dry blend times will remain in effect. NEW DISPERSION RESIN PLANT Process Engineering has advised Production on the excessive surge resin capacity in their dispersion resin bagger hoppers. The capacity of the new hopper is 800 lbs. vs. 200 lbs. in the old bagger. As a result, the additive system can only be checked within 4-0/. The recent erratic resin rheology could be the result of our inability to check the additive levels. An attempt will be made to lower the high level alarm to the halfway mark. However, even at this level, we could only expect to be able to control the additive system within 20/. If control continues to be a problem, a more expensive modifi cation may be necessary, e.g., install a hopper scale. PFA:em P. F. Albanese COLORITE 006185  f~ *- > t-/'' -f f-s _'c-K.'dgf? Vv>7-^ ^ t - 0-' r-r-^ f '-- ' -^ ^ fc /\`--C<P- o->L <_ ^-'i- /< . - COLORITE 006X86 r <j jp y COLORITE 006187 COLOR!TE 006188 :<r sis' ' 7' ' / ./r^.f --:^l-- ,-f ^ *t- ,'?-/: -f-i -Z-l,- -; -: '"- r? Zt - V is'-. t,e? ''_^t,_-/~ sT'r ~r?'? iL--e f-t- +-c- -'t^ ' -S ' / . / ; . V I - `L-^J _4'if' ' . /. --- ---r"4 ' /_ 4Tfi : ^ 4:' - ' _---S<~, .^ ' ~~ ' V 4 Vc.t o " "y^ 3- .V. ^_^yyyr^__ ^ 'V ^4'co (S-^. 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"7 COLORITE 006199 --t * -t-- ' ' '1 ` -rr.^-- rv /* ' . COLORITE 006200 : ' v -i .- . 'VVi^v/A/ if . ,.V )I 'OCt-tT- -*-'.. dr / 2 O?-OO .f' y /J. )/ 000 ^7/"^rOrr._ ^0_,_ ,_^ 2 ^ , '1 <-;V? ^ Z-7.-; -*' *7. t / /'_-C^.1 ^'.. _, . 0n-Oz\-^i 2Cj . <- ^ ^ r.-# r 4l ' /W *:'^" 7' ^- ''/<'.<.? .?2 r;<ycr- _, rr c".* ''OJrr --tc,.-^j1 ''^ . v'.*/ > <. ,,~0O- . Z ^ - oo'^o .^4U1-J2tr/ 7^ y. yzy y*" ^ rrO-O yv -v3 A--< ,-t zr, Ift<* ^oy.>. < 02. OO or/ /2^,-c ^o~^03' /"'"<^ - / .0 01? Cox.o,< '"?7 yy- /^ t- Q^Ulr d,,r ^^^O^rruuCtajL . jO-v^-l ****0 -t?r<. JUo J c. -y u.^ ^Co (J O v /C J/l tv''..,r; ,<. r 7 cyd:-/L .{XOl, 0& {lOo-cOOl, ^22,000 Os- <. o-r. t:- -j ^ . - s. ^ /\OJ-c2-^C^rx^J y. .< O'? ( z,, / ^ -f Ot<^, 20, d> A-- O-f(`O0 71^/Ok - ,<7^^ ./ fO 0 y7 ^ COLORITE 006201 fr/X/Q ?K>Sc POLYMER (PVC) CONVERSION TEST WITH DIFFERENT VCM SAMPLES Reagents: To 75 cc, of 0.5^ Sodium Lauryl Sulfate add 0.25 grams of K2S208 in 10 cc. of H20 and 25 grams of VCM. Test Conditions: Polymerize for 5 hours at 40C (l04F) and determine the percent conversion. Monomer Source Conoco (CONX 9054 - Burlington) Ethyl (UTLX 83804 - Burlington) Pantasote (SACX 9015 - Burlington) B. F. Goodrich (GATX 21968 - Burlington) v Stauffer (GATX 98227 - Burlington) B. F. Goodrich (UTLX 82521 - Flemington) . B. F. Goodrich (Recovered - Flemington) xTenneco (NATX 38053 - Burlington) ^Tenneco (NATX 38037 - Burlington) Tenneco (Car 38042 - Flemington) Tenneco (Recovered - Flemington) / Conversion Date 80.0 84.8 55.6 62.0 8l.6 56.0 32.8 61.6 18.4 66,4 18.8 8/1/68 7/19/68 8/8/68 8/9/68 July, 1968 5/17/68 6/10/68 Sept., 1968 Sept., 1968 SUSPENSION POLYMERIZATION KINETICS Reagents: 150 grams of H20 + 0.40 grams MC-15 + 0.125 grams L202 + 80 grams VCM. Test Conditions: Polymerize for 10 hours at 132F (55.5C) and determine the percent conversion. Monomer Source 100/ B. F. Goodrich (UTLX 82521 - Flemington) 80/ B. F. Goodrich (UTLX 82521 + 20/ Recovered Goodrich VCM) 50/ B. F. Goodrich (UTLX 82521 + 50/ Recovered Goodrich VCM) 20/ B. F. Goodrich (UTLX 82521 + 80/ Recovered Goodrich VCM) 100/ Tenneco (Car 38042 - Flemington) 80/ Tenneco (Car 38042 + 20/ Recovered Tenneco VCM) 50/ Tenneco (Car 38042 + 50/ Recovered Tenneco VCM) 20/ Tenneco (Car 38042 + 80/ Recovered Tenneco VCM) 100/ Tenneco (Cars 38042, 38016, 38038, 38039) * 50/ Tenneco (Cars 38042, 38016, 38038, 38039) + 50/ Recovered Tenneco VCM / Conversion 84 84 80.5 76 87.5 , , 75' (?) 86 80 COLORITE 006202