Document Yjra4z9GOzBYJpge1awMwwwYK

company confidential > Monsanto Anniston Plant TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Anni ston J. T. Bell A. G. Hill G. L. Jessee L. C. Lahman J. C. Landwehr H. E. Schulte W. F. Taffee 'Q&ilL'Ur -H-.--irr- Williams1 ^ A Month Summary JUNE 1970 COST IMPROVEMENT RESULTS Est. Act. Target % of Target $46,720 $43,465 107% General Offices YTD $481,577 $394,975 122% 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 Agricultural Division The Parathion plant test of Process Amendments "Chlorination in the Presence of Acetone" and "Hydrocarbon Dilution of Resi due" started 6/22/70. Distilled intermediate assays have risen from 93% to 98+%. The diesel fuel addition to the still started on 6/29/70 and first indications were that increased yields and good residue handling would be realized. On the 4th distillation batch with hydrocarbon dilution, an operating prob lem resulted in formation of plastic sulfur in the still and residue hold tank preventing normal handling. It was necessary to suspend the test on 7/2/70 in order to clean out equipment. Laboratory work has tentatively confirmed the suspected cause for plastic sulfur precipitation. Field testing is expected to resume the week of 7/6/70, incorporating the neces sary countermeasures and controls to overcome the problem with plastic sulfur. OTHER LOCATIONS A. H. Forsten Alvin, Texas P. O. DeGarmo South Second D. W. Jackson W.G.K. Organic Division HB-40 design proceeding essentially on schedule. Therminol heater manufacturers' data needed to complete ACSM drawings. In strumentation drawings out for review, electrical drawings on the board. 881 manhours were devoted to this project in June. The waste Aroclor Sump Project AFE 3427 ($22,500 NFC) has been approved. Construction has started and is expected to be com pleted by early September. DSW 014948 % N - 30 6 REV 1 '9<,s COMPANY CONFIDENTIAL INFORMATION "This document contains confidential information which is the property of Monsanto Company. Only those portions of the document relevant to a duly authorized individual's need to know may be exerpted for him. The report must not be sent outside the Company without written approval and the recipient is accountable for its safe keeping, exerpting or otherwise disclosing of its contents and for its proper disposal." STLCOPCB4003324 ) 2. Organic Division - continued A Tentative Process Amendment, to make low color Solid Aroclor 5460 by distilling in the presence of caustic soda, has been written and submitted for approval. The field test is anticipated for August 1970. Operation of the Polyphenyl Pilot Unit continues to be smooth. The promoter scanning study outlined in Work Plan IV issued on 5/20/70 is proceeding on schedule and is still targeted for completion on 7/13/70. Laboratory studies on treatment of high color HB-40 made from Santowax C have shown that Attapulgus Clay will remove color bodies. However, initial studies show that clay usage is very high. Further work is cur rently being directed toward defining the usage rates. Pollution Control A project premise is in review to provide a drying bed for the sludge which is collected in the HC1 neutralization pit mixing basin. Analyses are 90% complete on second Aroclor department Waste Audit. Equipment is on order and the Pollution Control Engineer, assisted by a CO-OP, will conduct a pilot plant study of the parathion waste treatment aeration basins to retard the production of solids in this process. Solids to the City of Anniston Waste Treatment Plant are being controlled at close to the ordinance limit of 700 ppm by sewering excess to the waste lagoon. The Eimco filter is also operating to remove solids from clarifier bottoms. Quality Control The Plant Quality Score was 86.9, down 1.4 from May, with a YTD score of 85.6 against a target of 95.0. The semi-annual review of process quality capability showed a relaxation of control on 45 standards versus an im provement on 31 standards, a substantial decline from the historical 3:1 improvement to relaxation ratio. () J. C. Landwehr DSW 014949 STLCOPCB4003325 ) PLANT LABORATORIES ANALYTICAL AND QUALITY CONTROL - S. 0. Kemp 3. Complaint Report Quality Number _______ Material NY 28 P Aroclor 5460 _______ Customer Manhattan Adhesives Reason Specks YTD Quality Complaints/100 Shipments 0.35 Target 0.20 DSW 014950 STLCOPCB4003326 COMMUNITY RELATIONS, PERSONNEL, RECRUITING AND DEVELOPMENT 4. Community Relations 1. S. 0. Kemp, Laboratory Supervisor, attended the Annual Industrial Management Club Midsouth Round Table held at Pine Mountain, Georgia, May 2930. Development 1. Safety Committee presented departmental safety program June 30 entitled "Automobile Safety." Personnel 1. Michael L. Marcum (University of Tennessee) and Danny J. Johnson (University of Alabama), Chemical Engineering students, reported for work in TSD as summer employes June 8. Mickey will report to W. B. Dunlap and Danny will work in ED&S. 2. Coby Riggins, BSChE University of South Florida, reported to work July 1. His initial assignment is as a Manufacturing Cost Accountant in Accounting. After 4 months he will report to TSD as a Process Engineer. 3. Frederick D. Ramsey, Jr., BSChE Auburn University, reported to work June 29 as Chemical Engineer I, Process Group B. Ricky will report to V. R. Haupt. 4. Danny F. Pittman, BSChE University of South Alabama, reported to work June 15 in Process Research and Development reporting to J. L. Brown. 5. Lee O. Chambers (Auburn University) and John M. Jones (Georgia Tech), two TSD CO-OPs, have completed their last working quarter and resumed their studies. 6. R. V. Carlisle, Electrical/Instrument Technician in TSD, will assume duties in Maintenance Engineering effective July 1 reporting to J. w. Kennedy. 7. Transfer-promotions in TSD and Lab effective June 15 were: G. W. Miller to Production Department as Production supervisor for Aroclor, Muriatic Acid and Packaging. J. T. Bell promoted to Chief Chemist. J. L. Brown promoted to PR&D Group Leader reporting to J. T. Bell. J. F. Benson to Maintenance department as Corrective Maintenance Engineer reporting to J. W. Kennedy. E. E. Bowles to Maintenance department as Corrective Maintenance Engineer reporting to J. W. Kennedy. DSW 014951 STLCOPCB4003327 ) COMMUNITY RELATIONS, PERSONNEL, RECRUITING AND DEVELOPMENT - continued 5. 8. J. T. Bell attended a Parathion Research meeting in St. Louis on June 4. 9. David Dixon, CO-OP, returned to work June 29 and will be conducting a waste treatment study this summer. visitors 1. Messrs. Earl Billen and John Thompson, Inorganic Division - St. Louis, visited Ag and TSD to discuss ^2^5' DSW 014952 STLCOPCB4003328 ) 1970 DISTRIBUTION OF TIME BY TECHNICAL SERVICE EXISTING PRODUCT TECHNOLOGY IMF ROVE RLE N T NEW PRODUCT EVALUATIONS MAJOR PROJECT SUPPORT PROCESS CONTROL IMPROVEMENT TECHNOLOGY AND TECHNICAL SUPPORT 15 TECHNICAL MANPOWER 15 5 PLANT IMPROVEMENT PROGRAM REAL ESTATE MANAGEMENT DSW 014953 STLCOPCB4003329 ) ORGANIC PIVISICN 1970 TSD COST IMPROVEMENT FUNCTIONAL FLUIDS TAR EST ACT Disposal of Liauid Montar TAR EST ACT ~3 Aroclor Still New Burners TAR EST ACT #2 Still Entrainment TAR EST Separator ACT 1242 Distillatio n 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 GCT NOV DL ECLC 1500 600 600 losq 0 c 1080 ,0 C 1500 1080 0 n 1080 0 1080 1080 1080 500 500 3000 - 1080 1080 3000 1080 150C 1500 1500 1500 1500 1500 C 100 1000 1520 C 100 1000 150C 1500 1500 _1500 3000 3000 3000 3000 2000 1000 3000 2000 1000 3000 2000 1000 3750 0 1000 1000 3750 3750 3750 3750 3750 3750 00 0 2250 2250 2250 2250 3750 2250 3750 2250 2000 3500 3500 4580 4580 4580 4530 4580 4580 4580 C 00 00 2000 2000 2000 3550 1950 344C 3550 3050 344C 30000 5000C 4950C 5000C 1000C 36000 24000 5190C 5590C 1050C 38500 30000 360 360 4580 360 4580j 1 \ 360 ------ 1 ostt 014954 STLCOPCB4003330 ORGANIC DIVISION 1970 TSD COST IMPROVEMENT FUNCTIONAL FLUIDS & PLASTICIZERS Artelor Ware house Reduced Headcount Improved Santowax Yield TAR JAM FEB MAR APR .MAY JUN JUL AUC' ESTACT (af: ECTIM 3 BOT i BUS I MESS GROUP S) TAR __LQ0.CL 1000 EST 1000 1000 ACT 1000 1000 1000 1000 1000 TAR EST ACT 4000 4000 4000. 4000 .4000 5900 2800 5800 4000 4450 2800 5800 SEP OCT MOV DEC 4nnn dono 4QQQ 4Q0Q H3-40 Reduce Nickel Catalyst Usage Substitution of Santowax C for Santowax R TAR EST ACT TAR EST ACT TAR 1160 700 700 700 1330 525 1230 1335 525 2080 700 425 zoo 700 700 20Q0d . 2QCQ( EST ACT GENERAL CHEMICALS TAR EST ACT CBIP HENYL PNP, HC11 Biphenyl Cool ing Water Treatment FNP Modify Acidifies Dump valve Svste m Install Entraintent Separator Production Optimize Reactoi Variables-PNP Re-use Well Water TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT 600 670 670 600 _60.Q. _6q.ql 680 580 600 680 580 600 '600 67C 675 625 62E 625 625 3150 -2150. 520 1277 2164 520 3016 2164 4 fiy 12: 1604 12' ' 1605 600 600 440 625 625 625 625 625 625| 625 5500 5500 5500 5500 550G 5500 4610. 4630 4630 463 0 4630 4630 : 5Q0 _4.Q0 1 jrnUnU )* I f Untargeted PNCB Heel Credits HC1 KCT Catch Tank & Coalescer 150 M Gallon Storage Tank HC1 Instrumentation TAR EST ACT TAR 5700 EST 2500 ACT 2500 TAR "THUS EST ACT TAR 4300 4300 EST ACT TAR 2275 563 3078 1650 920 2275 563 3078 1650 5700 5700 5700 57Q0 7560 9000 1030C 6545 7560 9000 1030C 6545 4T00 T300 4300 4300 4300 4300 4300 4300 4300 4300 4300 1875 4000 1230C 4000 1230C 4300 4300 4300 1875 1875 3440 6500 3440 1875 1875 1875 1875 1375 1875 EST ACT ___ TAR -- EST ------- - -- -- ----------------- ---- DSW Q14955 ACT STLCOPCB4003331 ) 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 - Total Organic Month - M $ Total Organic YTD - M $ JAN TAR FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC EST ACT TAR EST ACT TAR EST ACT TAR EST 950 900 940 950 950 950 950 950 900 916 790 ~mr 914 840 790 810 845 1000 1000 1000 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 ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT 40.6 36.29 36. 33: 40.6 36.29 36.33 72.1 9 4.' 5 4 99.86 112.7 130.9 136.2 96.88 103.6 109.1 209.6 239.8 245.3 58.07 44.62 27.97 70.39 74.''61' 43V 53 70.89 77.98 267.6 312.3 340.2 3T5T7 390.8 437.7 316.2 394.1 34.12 374.3 30.52 404.9 30.88 435.7 64.68 500.4 51.68 552.1 51.63 603.8 DSW 014956 STLCOPCB4003332 AG Division 1970TSD COST IMPROVEMENT JAN TAR FEB MAR APR MAY JEN JUL a.UG SEP CCT NCV PARATHXCNS EST ACT Replace t3 Chiorinator TAR EST ACT 4360 4860 3500 3500 2TW 0 2340 3500 3500 i I".prove CljStill Yields TAR EST ACT 3000 0 0 3000 0 3C00 3000 3000 3000 Increase Chlor TAR inator Coolings EST 8500 3500 8500 ACT Acetone Recovery Chlorine Unloading TAR EST ACT TAR EST ACT 2800 1957 1957 2250 3634 3634 2800 1069 1069 2250 4237 4237 2800 1225 1225 2250 3350 3350 2800 1935 1935 3200 1406 1406 2800 130 130 3200 34 31 3431 2800 715 3200 2430 2800 2800 2300 3200 3200 2800 2500! Optimize Methyl, TAR 3000 3000 3000 1500 PNP/PCT Ratio EST ACT 00 0 Optimize Ethyl PNP/PCT Ratio TAR EST ACT 500 0 0 750 2641 2641 750 0 0 SCO Change Cooling TAR 200 200 200 H20 - Item 737 EST 310 230 270 ACT 310 230 270 Untargeted: Plant Test - TAR EST ACT 2430 2430 5270 5270 TAR EST ACT Totcll AG -- Month M $ TAR EST ACT 5.75 5.90 5.90 6.0 6.0 6.0 8.IT TT3T 10.63 8.17 4.85 10.6: 15.5 11.2 11.2 15.5 3.15 15.5 22.5 14.3 14.3 3.3 Total AG YTD M $ TAR EST ACT 5.75 11.75 17.75 23.75 5.90 14.03 18.92 29.55 5.90 14.08 18.92 29.55 39.25 54.75 40. ii 43.87 40.73 70.25 92.75 107.1 121.4 124.7 TAR EST ACT Total Plant Month M $ TAR 46.35 78.1 102.9 64.07 60.12 43.47 FIST 42.19 102.3 108.5 'sr: 02~ 85.79 46.72 ACT 42.23 108.0 113.9 81.52 89.15 49.62 53.02 45.13 78.98 54.93 Total Plant YTD M $ 46.33 124.5 227.3 291.4 EST 42.19 145.0 258.8 345.3 ACT 42.2 3 150.3 264.2 345.8 351.5 395.0 -444.6 1 497.6 542.8 621.8 431.5 431.6 434.9 676.7 DLJ --EC 125. 5 2.1 7 23. DSW 014957 STLCOPCB4003333