Document X72xLe1MX0DmdN1aGkzrzYR5x

Messrs. L. F. Steinbach j , L. Ledbetter R, E. Howard J. F. Quinn R,, J. Stratmeyer/Wo A, Kuhn W,, Bo Papageorge - Anniston MONSANTO COMPANY ORGANIC CHEMICALS DIVISION October 15, 1968 To The Business Director, Plasticizers and General Chemicals Organic Chemicals Division_________________ .__________________ _ Estimate No. 3015 Department No,, 826,17 (Solid Aroclor) Anniston Plant - Anniston, Alabama_________________ __________ Solid Aroclor Instrumentation Capital Addition Alteration Expense Appropriation Requested Net Savings $14,000 $ 800 $14,800 $62,800 DESCRIPTION This project proposes to install 5 radiation instruments in the Solid Aroclor Department. Two of these instruments will monitor crude and refined Solid Aroclor specific gravity and one will give a low level alarm; on the Solid Aroclor still. Also included in the project are instruments to more closely control coolant temperature to the Solid Aroclor still condenser. APPROVALS Plant Manager Technical Production Manager Business Director PCB-ARCH-EXT0377906 Esfcimate No, J015 Dept, 826.17 " 2 - - NEED FOR PROJECT Installation of this project will result in net savings of $62,800/year. It will also improve safety and product quality. Projects have been approved that will bring Solid Aroclor capacity back to standard of 835,000 lbs/month. This project will result in a further in crease to 950,000 lbs/month. Details on the overall program to increase capacity are stated in the Aroclor Manufacturing Improvement Plan issued July 1968. Under present operating procedure up to 22" of undistilled product is left in the still pot to insure maximum protection of the submerged still pump (TSD Job 37O-83I Report No, 1). The ability to distill this extra amount while leaving enough material in the still to protect the pump is worth $100,400/year,, To accomplish this, one instrument measuring specific gra vity will be placed on the $4 still receiver and a low level alarm installed on the still pot. These two instruments will eliminate the guesswork in deciding when a distillation batch is complete. The still operator can con tinue the distillation until he gets the desired specific gravity in the receiver or until he gets a low level alarm on the still. The ability to do this will result in an increased yield from the Solid Aroclor still. At present, it is necessary to shutdown the Solid Aroclor chlorinator for 1/2 hour when checking a sample for chlorination completion. Instal lation of a density measuring instrument will eliminate the non-productive time at the end of a batch. Coolant temperature to the $4 still condenser varies as much as + 20C. This allows Aroclor vapor to reach the jet, condense, and plug up vacuum lines. Better control of the coolant temperature will result in elimi nating 88 hours/yr. of downtime, SAVINGS AND OTHER BENEFITS The $4 still low level alarm and still receiver density measurement could result in a 12% yield increase worth $100.400/yr,, Installation of a density measuring instrument on the #9 chlorinator circulating line will decrease the batch cycle 1/2 hour, which is worth $9400/yr. potential savings. Closer control of the still condenser coolant temperature could reduce downtime up to 88 hours/yr,, which gives a potential savings of $4100/yr, PCB-ARCH-EXT0377907 Estimate No. J>015 Dept. 826.17 -3- SAVINGS AND OTHER BENEFITS (Cont'd) Description Potential Savings Success Factor low level alarm $100,400/yr. 6s still receiver density measurement 0.58 #9 chlorinator density measure ment $ 9,400/yr. 0.50 still condenser coolant control $ 4,100/yr. 0.50 Totals $ll3,900/yr. _ less dep. and maint. .(15%) Net Savings Savings Claimed $58,200/yr. $ 4,700/yr. $ 2,000/yr. $64,900/yr,, 2.100 $62,800/yr. Type Yield Capacity Downtime Another benefit is better product quality. The density instrument on the $9 chlorinator will reduce the possibility of over-chlorinating Solid Aroclors^ thereby creating a more uniform product. SAFETY Eliminating the need to take a sample at the end of a batch will reduce the number of hot Aroclor samples that have to be handled. The radiation system to be used is constructed with personnel safety as the first consideration. It is designed so that radioactive field inten sity is less than the tolerance level recommended by the AEC. STREAM AND AIR POLLUTION No change in stream or air pollution will occur because of this project. STATUS OF PROJECT Preliminary design is complete. Equipment delivery is 4-6 weeks. EDC is December 15 f 1968. Verbal approval for $8000 received 8/22/68. ALTERNATE COURSE Continue operating as at present. This is not recommended because the in creased demand for Solid Aroclor requires greater production. RECOMMENDATION Approval of this project is recommended. Prepared by; C,, R. Mcllwain TSD Engineer Submitted by; ^ H. L. Williams Production Superintendent PCB-ARCH-EXT0377908