Document YredVxdMxn0gayEwJo7eQvv7E

CELANESE CHEMICAL COMPANY Chemcel Pla'at Bishop, Texas To: R. R. Graham From: G, D. Boyd yj GDB-90-80 January 8, 1981 1981 First Quarter Work Plans Laboratory Department Attached is the 1981 First Quarter Work Plan for the Laboratory Department. GDB:jr DISTRIBUTION: Chemical J. J. Fritsch W. H. Brough R. R. Carpenter J. B. Brown K. G. Gallimore D. E. Lockwood J. M. Hodges R. W. James B. C. Kerr C. W. Lee R. P. Lowry A. G. McGehee D. G. Pausky ~ G. R. Scholz 0. W. Schnellenberger D. D. Siemonsma W. L. Sharp H. H. Thigpen R. S. Hahn J. B. Brown K. R. -Steles G D. Boyd Plastics A. C. Abshier R. G. Brandt H. L. Davis E. Munoz E. J. Heinz CCCTC G. J. Fisher W. E. Heinz W. T. McNair Central Files (2) J. N. Gann, Bay City J. E. Sanborn, Bayport J. L. Paul, Clear Lake T. H. Golson, Dallas W. H. Tuke, Pampa 004240 yfp* 303.2 GDB-90-80 Page Two 1st Quarter Work Plans SPECIAL PROBLEMS - Group I (Areas III and OSHA) H. H. Thigpen, Group Leader DIACETONE ALCOHOL - B-. K. Huelle OBJECTIVES PLANS MOB Maintain frequent contact with the unit (Keep the DAA Unit operating at and provide technical support as needed, planned efficiencies while producing good quality product.) TRIMETHYLOLPROPANE - R. L. Day, B. K. Huelle OBJECTIVES PLANS Cost Reduction (Increase TMP efficiencies.) Resume development studies on the hydro- || lysis of formals and recovery of TMP from jvv the heavy ends blow down stream (V-747 re-' sidue) if economics justify further work. Late first quarter. (Day) MOB (Determine cause of high acid in product and recommend solution.) Continue to collect data on base case levels of butyric acid in the butyraldehyde feed. This will be useful if high acid problems re appear. Complete late first' quarter. (Day) Cost Reduction/MOB (Determine the effect of sodium formate and temperature on TMP decom position.) Complete laboratory studies by end of first quarter. (Huelle) MOB (Keep the unit operating at planned efficiencies and producing good quality product. Maintain frequent contact with the units and provide technical support as needed. (Day) 1,3-BUTYLENE GLYCOL - B. K. Huelle. P. J. Buras OBJECTIVES PLANS Cost Reduction (Reduce steam usage and increase efficiency) Develop a low energy, high efficiency pro cess for separating AcH from aldol in T-219. Continue through first quarter. (Buras) 004241 GDB-90-80 Page Three 1st Quarter Work Plans Cost Reduction ( Remove C02 from AcH feed to minimize refrigeration machine foul ing.) MOB (Keep the unit running at planned efficiencies and pro ducing good quality product.) Support Process Engineering with experimental and analytical data as required (late first quarter). (Huelle) Maintain frequent contact with unit and provide technical support as needed; will pay close attention toBG efficiencies in first quarter. (Huelle) PARAFORM, FORMCELS, WEAK FORMALDEHYDE, ESTERS - D. R. Akin, R. L. Day OBJECTIVES Cost Reduction (Reduce corrosion in the acetate reactor column reboiler.) MQB (Minimize cloud problems) MOB (Keep the units running at planned efficiencies and pro ducing good quality product. PLANS Continue evaluation of copper phosphate corrosion inhibitor. Complete in late first quarter. (Day) Emphasize proper cook time, caustic levels and storage temperatures. Most cloud problems are related to improper control of one: of these parameters. (Akin) Maintain frequent contact with units and provide technical support as needed. (Akin) PENTAERYTHRITOL - P. J. Buras, D. R. Akin, B. K. Huelle OBJECTIVES PLANS MOB (Avoid putting AML or VCI centrate in solar ponds.) Identify the best process for removing or ganics from AML or centrate. Improved ex traction systems are being studied. Continue through first quarter. (Buras) MOB (Produce PE with low UV absorbance without reducing rates.) V Determine whether incomplete reaction of pentaerythrose is the cause of the unit problems. (This is a possibility based on lab data.) If this is not the unit problem, then other causes will be sought. Complete late in first quarter (Huelle) MOB, Cost Reduction (Develop a technique to monitor the PE reaction system to allow control of reactant ratios.) Lab data indicates that liquid chromatography with UV detector will monitor compounds which change in concentration as the desired con ditions are approached. First quarter work will determine whether the same correlations apply to actual unit operation. Continue through first quarter. (Huelle) 004242 GDB-90-80 Page Four 1st Quarter Work Plans MOB (Determine whether lube grade PE can be produced in the existing unit.) Cost Reduction (Develop an im proved formal hydrolysis system.) MOB (Predict good performance of PE for producing dibromo PE at Dow.) MOB (Keep the unit running at planned efficiencies while pro ducing good quality product.) Help conduct Plant test and analyze data in February. (Buras) Evaluate a system utilizing a co-catalyst of ion exchange and strong acid (formic or sul furic) in a continuous system which would not require regeneration of the ion exchange re sin. Continue through first quarter. (Akin) Collect data on samples of PE already used at Dow as well as future shipments to detect correlations which will predict good perfor mance at Dow. (Buras) Maintain frequent contact with the unit and provide technical support as needed. (Buras) ENVIRONMENTAL HEALTH - C. E. Gary, K. 7. Parker OBJECTIVES PLANS MOB (Collect data on personnel exposure to various chemicals.) Continue monitoring personnel for exposure to respirable dust, CO, noise. Continue develop ment work on methods for CO and various or ganic chemicals. 004243 I GDB-90-80 Page Five 1st Quarter Work Plans SPECIAL PROBLEMS - Group II (Areas I, III and IV). Otts Schnellenberger, Group Leader METHANOL OXIDATION, FORMALDEHYDE BLENDING - I. A. Jasek OBJECTIVES PLANS MOB (Continued efficient operation and quality pro duction.) Maintain frequent contact with operations and provide technical support as necessary. MOB (Product quality.) Complete analyses of methanol feed samples taken during the period of off-color pro duction during November; document work done on this problem. Raw Material/Energy Savings Continue catalyst modifier work in coordina tion with the Tech Center. Raw Material/Energy. Savings Raw Material Savings Complete work to define GC/MO reactor operat ing conditions and begin catalyst evaluations. r. Continue MO catalyst screening as needed.and as samples become available. Cost Reduction Continue the study to correlate the laboratory sinter test with catalyst performance in the unit. MOB (Safety) Provide AMR information for reactor startup heater project. UTILITIES/BOD - S. G. Smith. P. G. Welling. G. R. Stasney OBJECTIVES PLANS MOB V MOB (Support unit expansion.) Maintain contact with utilities and waste treatment operations and supply technical support as required to insure efficient operation. (Smith) 1. Provide technical support for the BOD II ' unit startup. (Smith) 2. Assist in training operations personnel in anaerobic/aerobic technology. (Smith) 3. Complete laboratory study to determine the effect of upflow velocity on anaerobic fil ter solids accumulation. (Welling) 4. Conduct laboratory-study to determine the effects of extreme COD and composition variations on anaerobic filter performance. (Should be completed during this quarter.) (Welling) 004244 GDB-90-80 Page Six 1st Quarter Work Plans MOB (To reduce solar pond inventory.) MOB (Reduction of solar pond odor.) MOB OXO-BUTANOL - J. D. Preslay OBJECTIVES MOB (Continued efficient operation and quality production.) Cost Reduction MOB Cost Reduction Cost Reduction Cost Reduction (Reduction 6 Rhodium deactivation rate.) MOB 1. Continue the laboratory study to deter mine the aerobic treatability of'solar pond contents. (Welling) 2. Begin a laboratory study to determine the treatability of solar pond contents in the anaerobic filter with aerobic polishing. (Welling) 3. Begin a laboratory study to determine the treatability of aerobic, sludge blow down in the anaerobic filter and the ef fect on filter solids accumulation. (Wellin' Document the laboratory odor control study conducted during the fourth quarter of 1980 and work with Process Engineering to further evaluate alternatives. (Smith) Provide backup support as required in the H) area. (Smith) fl- PLANS Maintain frequent contact with operations and supply technical support as necessary. Document study of hydrocarbon extraction of in active catalyst/foaming agents from Oxo catalyst solution. Assist in maintenance of Rhodium accounting. Continue analytical support for Process Engineering coaslescer study. Complete reactivation work with MEA contaminated Oxo catalyst from Run 6. Provide technical and analytical support as necessary for the Process Engineering project to implement continuous addition of rhodium to the Oxo reactor. Provide backup support in the MS area. * 004245 GDB-90-80 Page Seven 1st Quarter Work Plans METHANOL SYNTHESIS, SHIFT LOOP, GIRDLER - J. C. Bustabad OBJECTIVES PLANS MOB (Continued efficient operation and quality pro duction.) Maintain frequent contact with operations and provide technical assistance as neces sary. Energy Savings Document laboratory support provided for the Dow corrosion inhibitor trial conducted during the 4th quarter of 1980. Energy Savings Provide analytical support for the elimination of fugative gas leaks to the Area II flare. MOB Provide technical and analytical support for MEA system control. ' MOB Provide technical support for MEA system corrosion inhibitor screening, testing"an|" trials. Energy Savings Provide analytical support for the conversion of B Train purification system to single column operation. Energy Savings Provide analytical support for evaluation of reformer fuel gas combustion control based on carbon monoxide concentration in the flue gas.. MOB Provide backup support as required in the Oxo Butanol area. 004246 GOB 90-80 Page Eight 1st Quarter Work Plans STAFF CHEMIST B. C. Kerr OBJECTIVES Solar Pond Disposal Project ' Technical Report Abstracting Staff Support PLANS Continue to investigate procedures for the elimination of existing solar pond effluent; provide support for the Waste Management Task Force, as required. Continuing Project. Continuing Project: 1. Assistance to chemists, as needed. 2. Special assignments by Laboratory Super intendent . . 3. Technical assistance to other departments. 4. Special problems for Operations. 004247 GDB-90-80 Page Nine 1st Quarter Work Plans ANALYTICAL GROUP A. G. McGehee, Group Leader OBJECTIVES MOB (Analytical and support of Plant Operations. MOB (Maintain quality of Plant products.) ~ PLANS I. Build Group readiness and abilities. A. Upgrade expertise and encourage spec ialization. 1. Assign based on identified special interests and talents. 2. Modify Instrument Section work schedule to allow for better con tinuity. 3. Increase theory training in in strumentation via inhouse and vendor supplied seminars. 1st quarter em phasis on Liquid Chromatography and Ion Exchange Chromatography'. B. Train new SNE group replacements- -*-i' scheduled for 1st quarter. II. Maintain review and update of analytical methodology. A. Review, update and reissue 25% of water analysis methods. B. Review all routine GC methods. 1. Identify and assign needs in 1st quarter. III. Monitor purchased solutions project. A. Publish to date interim report on qualit: of service/product. Note: This purchased service scheduled to terminate at end of 1st quarter. IV. Continue Laboratory instrument update (pur chase, replacements) in conjunction with scheduled 1981 phase of 5 year capital plan. A. Select and plan for purchase of 2 re placement GC's and 2 replacement recorder: during 1st or 2nd quarter -Instrument Section. I. Devise and institute new methods of Quality Assurance reporting - to better reflect quality of Plant production and shipping efforts. A. Continue to use Lab Monthly Report as vehicle. B. Change customer complaint policies to rate all complaints as "valid" and to provide for better resolution/publica tion. 004248 GDB-90--80 Page Ten 1st Quarter Work Plans MOB and Cost Reduction MOB (Building and Laboratory services.) II. Continue program of review, update, re issue of Unit sample schedule/analytical methodology. A. Complete B.6. Unit and initiate work on next identified Unit. III. Contribute to Laboratory projects of a data gathering, evaluation, development nature. Potential in environmental/waste management related projects. Provide manpower and analytical assistance to special analytical services projects. I. Assign one additional SHE headcount to this area in 1st quarter. II. Provide for increased group involvement in special projects - selection and assignjpent. A. Complete analysis requirements for t'enewal of Plant NPDES permits. B. Facilitate and institute proposed TDWR waste water discharge permit revisions. C. Provide for continue/expanded efforts at identification, quantification of Plant effluent parameters. 1. Goal of recovery, elimination and prevention of recharge. I. Maintain effective cost control (budget) pro gram in the Laboratory. A. Implement graphic presentation to monitor key cost centers. II. Maintain an effective maintenance and preven tative maintenance program in the Laboratory. A. Pending - 1. Restoration of acid diges tion exhaust hood to routine service. 2. Institution of revised treatment for Lab oratory cooling towers (2). SPECIAL ANALYTICAL -_F. R. Dow, B. W. Wise, J. E, Russell OBJECTIVES PLANS Cost Reduction and MOB (Identify uses for LC and Capillary GC sys tems. Continue evaluation of possible applications for PE unit control analysis, Oxo Rx components, BG Aldol- analyses. Also evaluate Capillary GC for potential applications. This is a continuing project. (Dow, Wise) 004249 GDB-90-80 Page Eleven 1st Quarter Work Plans MOB (EPA, RCRA, TDWR requirements) MOB (Provide assistance for BOD start-up.) MOB (EPA, RCRA, TDWR) Continue evaluation of Capillary GC for the qualitative identification of components in solar ponds and monitor veils. (Dow, Wise) Utilize the Capillary GC to monitor the BOD feed and outfall. (Dow, Wise) 1. Develop methods for Ion Chromatograph analyses of waste water treatment unit (BOD) nutrients. (Russell) 2. Evaluate possible applications for the new Ion Chromatograph for special analytical problems. The possible_uses include the determination of 1)- Cl in NaFo,,2) amines in MeOH, 3) SClT, N0" , Ba , Mo0" , in MEA solution^ 4) SO^ in AML, and 5) short chain - organic acids and inorganics in solar aonds and groundwater. Other uses will be defined as experience permits. (Russell) / 3. Have EPA approved samplers constructed for possible future needs. Materials for con striction have been received. (Russell) 4. Determine the levels of amines in competitive MeOH samples. (Russell) 004250