Document baQpoJ87roGNM92D14nbO1pOy

MANUFACTURING IMPROVEMENT PLAN FOR PLANT INCINERATOR DEPARTMENT 790 PREPARED BY: BARBARA CARLISLE APPROVED: J. PEDUZZI, PROD. SUPERVISOR ISSUE DATE: jT/77 j j ------ VA'/7> W. A. KUHN, MANAGER OF PLANT SERVICES AND CAPITAL PLANNING DSW 185622 STLCOPCB4051771 -TABLE OP CONTENTS- Page OVERVIEW. . .............................................1 CAPACITY....................................... 2 COSTS..................................................................2 SAFETY........................................................ . 4 ENERGY..................................................................4 DSW 185623 STLCOPCB4051772 DISTRIBUTION D. P. Alt F. J. Basile E. R. Billen J. W. Boehm K. E. Boucher P. Brewer R. E. Bunge B. K. Carlisle W. C. Engman R. W. Flint R. L. Harness H. J. Horner W. A. Kuhn - B3NH A. E. Ieisy D. K. Lynch D. Metherd R. H. Munch - TIB P. S. Neuhoff C. P. Orr - G2WD C*______Raton------- -B2SfC J. Peduzzi R. A. Pohl - B2SB E. M. Potter - B2NK J. Schriner W. L. Smull L. W. Sprandel R. Sterghos B. R. Williams DS\N 185624 STLCOPCB4051773 MANUFACTURING IMPROVEMENT PLAN PLANT INCINERATOR DEPARTMENT 790 __________ Page 1 March 1977 WGK OVERVIEW The specific purpose of the plant incinerator, since its origin, has been to destroy Aroclors. Other plant wastes, such as ONA, PNA, Chlorophenols and Santophen I have also been incin erated to utilize excess capacity. MCB pilot plant wastes are scheduled to be incinerated in 1977 as well. Since a permanent shutdown of the Aroclor Department (Dept. 246) will occur late in 1977, eliminating internally generated Aroclor wastes, shutdown of the plant incinerator must be considered as a strong possibility. The current waste inventory of 2 M pounds (a four-month supply) and the 3 M pounds of wastes to be generated during 1977 by Dept. 246 would allow the incinerator to operate near capacity through 1977. An area-wide incinerator is scheduled for start-up in early 1980. It is to be capable of disposing of all known and projected incineratable Monsanto wastes in the St. Louis area. Presently, all WGK wastes, with the possible exception of Aroclors, could be incinerated outside the plant for less cost than at the plant unit. Operation and retention of this facility after 1977 appears to be economically undesirable, unless a viable specific need for high temperature incineration is identified. The position of the business group toward disposal of customer Aroclor wastes needs to be reconfirmed; the previous position has been that all customers will be referred to contract incinerators on the basis of lower cost to the customer and no liability to Monsanto. It might, however, be' desirable to retain the incinerator as a test unit for obtaining design data for the area-wide incinerator. During 1977, a formal economic evaluation will be completed to determine the best course of action for incineration between now and when the new area-wide incinerator is brought on-stream. Until this decision is made, technical effort in the unit will be kept to an absolute minimum. DSW 185625 STLCOPCB4051774 MANUFACTURING IMPROVEMENT PLAN PLANT INCINERATOR DEPARTMENT 790 Page 2 March 1977 WGK A. CAPACITY The incinerator is budgeted to dispose of 6m# of residue in 1977. While the incinerator standard capacity is 500.000 lbs/month, waste receipts are expected to total 550.000 lbs/month until 9/77 when they will drop to under 200.000 lbs/month, for a total of 5.1R pounds for the year. The table that follows shows the amounts of the various wastes expected to be incinerated in 1977. Dept.______Product Projected Waste Incineration, M lbs. 219/222 ONA/PNA .30 226/237 Chlorophenols .72 239 Santophen I .84 MCB Pilot Plant .11 Aroclors Customer Returns .47 246 Aroclors & Montars 2.64 5.08 B. COSTS Budgeted incineration cost for 1977 is $.133/pound based on burning 6M pounds. The 1976 cost was $.106/pound. DSW 185626 STLCOPCB4051775 MANUFACTURING IMPROVEMENT PLAN PLANT INCINERATOR DEPARTMENT 790 Page 3 March 1977 WGK COSTS (cont*d) The following table shows estimated 1976 and 1977 costs for contract incineration of plant wastes that could alternatively be incinerated in the plant. Department1976 Cost.1977 Cost Contract Incineration Cost $/lb. (includes freight) 237 248 221 247 238 229 Chlorophenols Santophen I ONA/PNA MCB Pilot Plant Metafractions MIBK Lab solvents S-160 Benzyl Chloride .070 .071 -- -- .091 .173 .067 -- -- .07-.10 .07-.10 .07-.10 .07-.10 :i2i .106 .082 .071 .068 Of the possibilities for Aroclor waste replacement that have been considered thus far. Metafractions and MIBK are the most logical, although they still do not economically justify continued operation of the incinerator. The very low cost of contract incineration of Benzyl Chloride/S-160 makes it a less desirable alternative. Rough estimates show that, omitting the costs of a NOx control system which would be necessary, costs of plant incineration would be as follows, based on 1977 costs and 5 M pounds incineration capacity: (416,000 lbs/mo.) Total Dept. Cost Out of Pocket Cost Out of Pocket Cost (including depreciation cost) (excluding depreciation cos ____ $63,600/mo. 15.3^/lb. $46,200/mo. ll.l<r/lb. $40,900/mo, 9.8C/lb. Total outside incineration cost for the 5 M pounds considered DSW 185627 STLCOPCB4051776 MANUFACTURING IMPROVEMENT PLAN PLANT INCINERATOR DEPARTMENT 790 Page 4 March 1977 WGK COST (cont'd) in the previous situation would be $46,600/mo. or 11.3C/lb. lbs/mo. Chlorophenols 60,000 Santophen I 70,000 ONA 25,000 MCB Pilot Plant 10,000 Metafractions/MIBK 251,000 Total 416,000 Outside incineration, estimated $/mo. .10 .10 .10 .10 .12 6,000 7,000 2,500 1,000 30,100 46,600 It should be noted that the above numbers are preliminary and only indicate the need for a formal economic evaluation to determine the future of the existing incinerator. C. SAFETY The departmental Safety audit was begun late in the year, and is expected to be completed'during the second quarter of this year. D. ENERGY Due to the anticipated shutdown of the WGK incinerator anywhere betweer early 1978 and early 1980, the energy audit scheduled in 1976 was deferred indefinitely. The incinerator is a relatively low energy consumer as indicated by the following table: ITEM INCINERATOR USAGE TOTAL WGK USAGE % OF TOTAL WGK USAGE DSW 185628 Steam (MMBTU) Gas (MMBTU) Electric (CKWH) Plant Water (M Gal) Purchased Water (M Gal) 970 568 833 4083 848 300030 21700 72300 790300 167094 .32 2.6 1.1 .5 .5 STLCOPCB4051777