Document O37GBkdJxkyLwLnGZJRnz7NYM

ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM Tot From Rtt Mr. T. L. Carey J. J. Dorsey, Jr. Datat Cefiast Summary of Technical Department Monthly Reports - October 1966 November 10, 1966 DNT The DNT plant start is covered as a Production operation. APE The investment and cost information required by Mr. Schultis was supplied to him this month for the computer study on the ADE project. There was no opportunity to prepare the three reports which are planned. These reports are: (1) a summary of the laboratory work at Pensacola, (2) a summary of the pilot plant work at Pensacola, and (3) a review of the process, investment, and economic changes necessary based on the additional information developed. Since we do not have any one specifically assigned to this project, it appears that this work will have to wait until someone can be assigned to it. AMMONIA-METHANOL Mr. Rogers has continued to develop economics for the production of ammonia and methanol in new centrifugal compression plants either at Pace, or other locations. These continue to show that a location other than Pace is less economically attractive than the Pace location unless CO^ is provided free. Even there, the added cost of establishing a new site overbalances much of the economy from a lower natural gas price. It is absolutely necessary to obtain a quotation from Chemical Con struction to cover any site other than Pace. This quotation should also include the total project as envisioned by management which would include responsibility for off-site investment and total project management. PVC Various studies are in progress on PVC. Most of the work was done in the Production Department by Mr. Smith. The status, priority, and responsibility for the PVC work with Columbian Carbon and the Pechiney economics is not clear. ! T e ch n ica l S um m ary 1 AP00045604 Mr. T. L. Carey -2- November 10, 1966 LABORATORY Special work in the laboratory this month centered primarily with the DNT start, assistance with the startup of the ammonia plant with new sulfurremoval carbon and low temperature shift catalyst, and detailed work in the amines development area. The laboratory did an excellent job in the DNT project in supplying the necessary information and working closely with the Biazzi peopLe in verifying that the product produced was satisfactory. Messrs. Marlow, Wolfe, Barber, and Fowlkes all collaborated in this DNT work and in the development of a successful method for extracting TNT from some of the off-spec DNT produced. A catalyst was found which successfully converts DEA to MEA and TEA. It appears practical to utilize twc converters in parallel to provide additional quantities of TEA while producing MEA in the normal manner. ENGINEERING Major projects completed this month are reviewed below. The DNT plant is substantially over budgeted investment. This appears to be the result of a misunderstanding of the complexity of this project both by Chemico and Escambia. However, the plant will do an excellent job of producing product, and can readily be expanded. It appears that the total project economics will not be greatly affected by the overrun, assuming that sales proceed up to an ultimate Level of 40 MM lbs/yr. The IBN project investment was completed this month with the installation of the 200, 000 gallon storage tank. This job will be closed out. The new 600# boiler will be completed during November. The decision was made to proceed on an overtime basis to complete the boiler early because of the need for steam and the need to have the old BStW boiLer down for maintenance as soon as possible. The amines plant expansion is continuing on schedule with completion estimated by April 1, 1967. It is hoped to have the 66" ammonia column usable as a batch still the last week in December. Other phases of the project will be completed in February and March, depending on the delivery of key equipment. PLANT IMPROVEMENT Mr. Bodamer has been assigned to activate the amines pilot plant. As soon as the necessary operating people are available, work will commence. AP00045605 Mr. T. L. Carey -3- November 10, 1966 The first phase of the program consists of distillation studies on DEA, TEA, and DXPA to prove out the separations planned and the suitability of the equipment. Necessary plant assistance work in the amines area will be handled by R. E. Jones. The principal effort here has to be to establish operating conditions and process controls which will maintain yields and production rates at maximum. He also will cover any assistance desired or necessary in the ammonia'-methanol-nitric acid area. While the DNT operation has been satisfactorily proved, it is necessary to evaluate what must be done to minimize the sulfuric acid use and to determine what combination of nitric and/or sulfuric acid concentration might be used to minimize the sulfuric acid cost if it is not possible to dispose of the spent sulfuric acid in the fertilizer operation. Mr. R. W. Beech, who joined Escambia in October, is developing the above mentioned information and also will detail the process changes necessary to bring the DNT production rate to a 20 MM lbs/yr. rate and a 28 MM lbs/yr, rate. If the Wyandotte and Olin sales approach the projected rates, it will be necessary to have a DNT plant expansion completed by August 1, 1967 to the 20 MM lbs/yr. rate and by January 1, 1968 to the 28 MM lbs/yr. rate. As soon as Mr. Beech is through with this phase of the work, he will be assigned to other plant improvement projects. mdc AP00045606 OCTOBER, 1966 6301 6309 6333 6365 6583 6604 6603 6613 6616 6617 6632 6633 6640 6642 6647 6650 6652 SUMMARY Of PROJECT WORK STATUS Tttle Appropriation MS Water Softener* to Pro vide Water for Boiler 18.0 Air Condition L Encloe Wet Bey Control Room 6.0 Ammonia Recovery Pree ure Control Syetem 3. 3 DNT Plant 1070.0 Equipment to Produce 1BN 6 DEA - Aminee New 600 pei 100, 000#/Hr. Boiler Upgrading Water Treatment 22 3.9 320.0 105.0 Product Coating Syetem - NP 15.5 Provide Offlcee, Locker Room and Storage Additional Bulk Car Loading Facilities - PVC H.P, Water Pump, H.P, Scrubber - No. 1 Plant 54. 3 10.4 4.0 Plant Steam Recorder Maintenance Shop - Area B 1.8 26.0 Purchase of Lab Equipment Ammo-Phoe Production 2 3.4 200.0 Committed Revised Completion MS MS Date 13.9 18.0 12/15/66 5.4 5.4 10/31/66 Rcma rke Equipment due eerly Dec. Field piping in progreie. Complete. 1.5 1330.0 2 34.7 3. 3 1330.0 234.7 12/1/66 10/1/66 10/26/66 Instrument! all received. Waiting for available instru ment manpower. Job complete. Letter being issued on overrun. Job complete. 286.0 103. 3 7.5 none 320.0 (05.0 15.5 14. 3 12/1/66 12/15/66 Indefinite Indefinite Field work on schedule. All equipment on hsnd. Field piping in progreea. Equipment due early Dec. Clay feeder installed.on temporary bail* for teat run. Approval etlll pending. 10. 1 10.4 10/31/66 Completed during month. 1.5 1.2 20. 0 9.9 208.0 4.0 l.B 26.0 23.4 208.0 Indefinite Indefinite 1/31/67 Indefinite Installation dependent on Production's decision as to proper use of pump. Waiting for shutdown to install. Foundation work started. Building, heating and air conditioning equipment order ed. Job complete. Aminee Plant Expenelone 1360.0 466. 1 1360.0 4/1/67 Major equipment on order. Job on proposed schedule. 1SS0-18829 1580-18862 Independent Raw Water Supply PVC Revise Condensate Syetem from PVC Dryers 9.7 J. 0 1580-18870 1580-18871 1770-6003 Connect Well Water Syetem Between PVC end MeOH Install Monitor Nozsles at NH j and MeOH Syntheele PVC Reactor Reglaeiing 2.7 4.4 3.0 7.6 5.1 none none 23. 1 9.7 12/1/66 Work in progress. 3.0 11/30/66 Foundations and pumps were installed. Proceeding with piping and electrical as man power permits. 2.7 Indefinite Approved during month. 4.4 Indefinite Approved during month. 38. 0 Indefinite Spare reactor being regtaesed at Claacote with scheduled shipping date of December 2. li/7/66 /fie AP00045607 P ersonnel ESCAMBIA CHEMICAL CORPORATION Interoffice Memorandum TO: Mr* T. L. Carey Date* November 2, 1966 From: E, M. Spurlock Re; Monthly Report - Personnel Department - October, 1966 PERSONNEL Activity for the Month Division No. of Employees 9/30/66 October Additions October Separations No. of Employees 10/31/66 1966 Budget Admin. & General Research Agri. Chemicals Industrial Chemicals Production TotalB 57 57 163 16 ' kkk 737 1 0 3 0 13 3 1 3 1 --2 17 55 56 56 59 163 160 15 18 khk U06 733 699 There were 177 walk-in applicants, 128 applications were issued and 11 were received by mail. Forty-six applicants were interviewed and 4l were tested. TRAINING School was held for the operation of forklifts and U forklift operators were licensed. School was held for the operation of trackmoblles and 2 trackmoblle operators were licensed. Training In the use of band fire extinguishers and wheeled extinguishers was held for all Process Operators on A,B and C shifts who had not had this training on four or more occasions. Two supervisors attended the National Safety Congress. SAETSTY The Corporation worked approximately 130,000 man-hours during the month. The approximate man-hours and the days worked to date without a disabling^injury are as follows; AP00045608 Monthly Report SAFETY (CODt'd.) -2- Division New York Office Research Division Atlanta Division Pensacola Plant Corporation Man-hours 362,000 859,000 20,898 102,000 55,500 November 2, 1966 Dajra 1,914 3^394 18 41 18 The Atlanta Division experienced two disabling injuries during the month. The FVC Laboratory completed tea years without a disabling injury. Medical Section The Medical Section treated 17 injuries for EBcambla and 31 for Carroll, performed 7 pre-employment and 17 annual physicals and gave a total of 23 immunization injections. EMPLOYEE RELATIONS One 5-year service award was presented. Two 10-year service awards were presented. Flans have been made for Escambia Vives' Luncheon. This annual event will be held at Scenic Hills Country dub on November 9, 1966. LABOR RELATIONS We have received a petition from the united Association of Journeymen and Apprentices of the Plumbing and Pipefitting Industry of the united States and Canada, AFL-CIO Local No. 366, through the National Labor Relations Board to represent the Maintenance employees. INSURANCE We paid a total of 7? claims under our Group Hospitalization program which amounted to a total of $ 14,714.62 during the month of October. We settled the following claims during the month of October: Six claims amounting to $ 1,531*69 under our Automobile Physical Damage Insurance. Two claims amounting to $ 1,316*55 under our Public Liability and Property Damage Insurance. Two claims amounting to $ 428.40 under our Manufacturers Output Insurance, EMS;kc AP00045609 PRODUCTION MONTHLY REPORT November, 1966 AP00045610 im a ry ESCAMBIA CHEMICAL CORPORATION Interoffice Memorandum To: Mr. H. F. Roderick From: T. L. Carey Subject: Monthly Report - November, 1966 Date: December 5, 1966 The Amines operations were a very bright spot in November. It was a record production month and yields were essentially at budget. Total variance was a negative $43, 920. Of this, approximately $30, 000 is due to budgeting errors or omissions {depreciation, steam allocation, lab chargee and inventory adjustment). Maintenance accounted for approxi mately $15^.000 variance and was due to replacing the ammonia preheater tube bundle with a stainless steel bundle, re-tubing the superheater with stainless tubes and disassembly and cleaning of the forward flow heat exchanger. All in the No. 2 plant. Yields were: Methyl Amines + $ 9,758 Ethyl Amines - 19,566 *{$15, 000 due to high cost raw materials) Is opropyl Amines - 4,510 Volume was 4, 979, 000 lbs. - more than 1, 000, 000 lbs. better than the best previous record. These results are highly gratifying. PRODUCTION UNITS - McMILLAN The following is a tabulation of the plant result's of those plants under the supervision of Mr. McMillan and his Area Superintendents: J. MARTS Steam Water Ammonia Nitric Acid Methanol Total Variance from Budget November Year To Date - 1,740 $ - 39,348 + 2,740 + 28,011 + 6,927 + 148,457 -13,654 5,079 -16,875 4- 61,866 $ + 193,907 AP00045611 Mx. H. F. Roderick -2 - December 5, 1966 J. RUSSELL Ammonium Nitrate Urea U-34 Solutions Bay-Sol Prills Total M. SMITH PVC S. BARFIELD * Phos. Acid Nitro-Phos. Ammonium Phos. Total Variance from Budget November Year To Date 442 $ + 4, 880 + 709 - 14,241 960 - 6, 734 - 1,972 + 15,064 +38,949 + 180,932 + 179,901 +22,097 $ + 124,892 - 8,971 -41,939 - $ _ 109,616 (Idle plants) - 250, 029<Inv. adj. and 1 Mo. Idle plant) + 23.505 - 336,140 TOTAL ALL UNITS $ + 162,460 better than budget. # These units have been placed under the supervision of J. Russell and are now operating essentially at budget except for inventory adjustment. Inventory adjustment carryover from last year plus one month idle NP plant amounts to $175, 000. Phos. Acid $109, 000. Even including all of these costa, cost per ton is $2.50 less than last year. METHACRYLATE In accord with Mr. Roderick's decision this plant is in. the process of being shut down and placed on standby. Detailed plans are being formulated to carry out these instructions. The plant will use up the raw materials on hand and process them through to finished product. It is anticipated that forces will be reduced by approximately 30 people. There will be a gradual reduction through to mid-January. The two Dow people have returned to their home operations. November HIBA production was another new record. -- * T. L. Ca/ey AP00045612