Document QX6d63ebnEa81NyNa1kyR9qoR

G^&t7%0c6icfc W Ckmim& INC. ESCAMBIA PLANT INTEROFFICE MEMORANDUM To: R. E. Davis From: E. A. Primeau Re. PVC Monthly Report January, 1973 Dots: Copies: February 8, 1973 SUMMARY Prime resin production for January was 5, 440 M pounds versus a budget of 5, 300 M pounds and a January 20th forecast of 5, 400. M pounds. Off-grade, tails and sweeps amounted to 60 M pounds which represent 1. 1% of total production versus a budget of 4. 5%. A total of 623 charges were made--an average of 20 per day. R. F. E. data for the installation of a 3, 700 gallon reactor as No. 12 reactor was prepared and submitted to the Valley Forge Accounting Department on January 26, 1973. An R. F. E. was prepared to purchase the valves and actuators necessary to automate the charge system on No. 11, 5, 000 gallon, glass-lined reactor. The variance generated by PVC for January was ($266) The variance resulted from: 1) PVC Bulk 2) PVC Bagging ($2, 565) $2,299 The forecast variance on January 20th was $2, 100 favorable. The item affecting the variance were: Forecast Actual Raw Materials Process Costs Volume Machine Hours ($2, 000) ($1,400) $1. 000 $3, 000 $ 600 $1, 316 ($6, 093) $1, 121 $3, 300 ($ 266) AP00040799 R. E. Davis PVC Monthly Report - January, Page 2 1973 ANALYSIS OF VARIANCE Raw materials were favorable due to a favorable variance in vinyl chloride of $2. 5 M, in process chemicals of $2. 2 M, and in royalties of $1. 5 M. This was partially offset by an unfavorable variance in by-product credit of ($4. 9) due to low production of off-grade. Volume variance was $1. 1 M favorable due to above budget production of resin. Machine hour variance was $3. 3 M favorable due to January being a 31-day month. Projected production for month of February is 4, 900, 000 pounds with a favorable variance of $2, 400. DISCUSSION During January, the PVC plant produced six resin types. One type 1230 P accounted for 49. 9% of the total prime resin production. The Alpine Mill was utilized to regrind 2, 000 pounds of 3185 resin produced at Calvert City. Almost no size reduction was obtained from the first mill pass and only 4185-2S was produced in the second pass through the mill. A separate memo was written to V. J. Grande, detailing the work done. CHEMICAL CLEANING The new recovery jets arrived in mid-January and were installed. The modification and installation of the larger evaporators was completed and put into operations on January 20th. Currently, the unit is being tested. Thus far, the feed to the Artisan unit has been increased from 600 pounds per hour to 780 pounds per hour. However, the Moyno pump has been plugging an average of two to three times per day. On January 31st, a section of the inner shell of the Rototherm unit collapsed. Maintenance is attempting to repair the shell but a new shell will have to be purchased and installed as sections of the shell wall measure 3/16" as opposed to the original thickness of 7/16". A drawing of the unit has been sent out for quotes. Artisan wants $11, 000 for the shell and have a delivery of 26 to 30 weeks. AP00040800 R. E. Davis PVC Monthly Report - January, Page 3 1973 PVC EXPANSION Data required for an R. F. E. to install a 3, 700 gallon stainless steel reactor was sent to the Valley Forge Accounting Office on January 26, 1973. Additional cases are currently being studied for the installation of a 10 M gallon or 20 M gallon stainless steel reactor. PVC BAGGING A total of 2, 185 M pounds of PVC was bagged at a cost of $11, 511 in January. Variance is as follows: Volume Spending Total Actual $ 549 $1, 750 $2,299 Forecast $ 500 $1, 000 $1,500 PVC LOADING & SHIPPING A total of 5, 589 M pounds of resin was shipped from Pace. Starting resin inventory was 599 M pounds and closing inventory was 518 M pounds. EAP:lm Attach. <> E. A. Frimeau AP00040801 STATISTICS January Actual Budget Prime Production Homopolymer Subtotal 5. 440 5, 440 5, 300 5, 300 Off-Grade Homopolymer Tails Sweeps Subtotal 0 50 10 60 231 Total Production 5, 500 5, 531 O. G., % Total Prod. Bulk Prod. , % Prime VCM Efficiency % Reactor Avail. % Production, #/Gal. Yr. 1. 1 60. 0 93. 6 95. 1 1, 343 4. 5 94. 5 92.5 1, 307 Off-Grade Analysis Production Sequence - January None North Line Type Batches 2160 2185 2200 2160 2250 1225 2200 2160 2250 2200 1225 2250 2200 7 5 29 9 11 19 31 22 19 60 32 31 5 280 Year-to- Date Actual Budget 21, 487 21, 487 21, 029 21, 029 0 225 36 261 21, 748 1. 2 59.2 93. 0 94. 3 1, 337 - 943 21, 972 4. 5 -94. 5 92. 5 1. 3 07 South Line Type Batches 1225 1230 1225 1230 1225 13 129 34 162 5 343 AP00040802 Statistics - continued Page 2 Production Summary - M Pounds Type January 1160 1200 1225 1230 1250 2160 2185 2200 2225 2250 -- 917 2,7 T4 -- 314 31 990 -474 5, 440 Downtime Analysis - Hours Cleaning Reactors Schedule Charges Behind on Recovery Hold to Drop Plugged Drop Valves Change Type Slow Drying Hydraulic Motor Maint. Misc. January 532 22 152 69 44 10 20 34 54 937 Year-to-Date 17 15 3. 826 10, 225 853 132 4. 3 00 546 1, 644 21, 558 % Year-to-Date 6.5 0. 3 1. 8 0. 8 0. 5 0. 1 0. 2 0. 4 0. 7 2, 172 344 432 519 100 87 274 121 177 11.3 4, 226 % 6. 7 1. 1 1.. 3 1. 6 0. 3 0. 3 0..8 0. 4 0-5 13. 0 AP00040803 AP00040804