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ESCAMBIA CKSI'.CCAL CClt/C ZJ-.T1CK INTEROFFICE MEMORANDUM Tot Mr. H. L. Harwell From) Re: J. D. Kramer January Monthly Report Amines and PVC' Diti. February 6, 1968 Copies: * AMINES Production for the month was: Month End January Plant Inventory * Actual Budget M lbs. Planned M lbs. M lbs. Actual Planned* 3/1/68 Methylamines, total Mono Di Tri 149 2, 249 2, 826 4, 648 149 750 3 1 1 1, 333 0 1, 083 2, 404 2, 744 0 416 1,111 571 4, 454 800 2; 954 700 Ethylamines, total MEA DEA TEA 1. 999 1,929 38 32 1, 353 1,083 208 62 3, 974 3, 283 625 66 3, 766 3, 016 700 50 4, 5B3 3, 783 700 100 Isopropylamines, total 3,593** 1,383 2, 641 1, 288 1, 313 MIPA D1PA 3,593 0 1,333 50 2, 52S 113 1, 238 50 1,200 113 Isobutyronitrile TOTAL 0 150 5,741** 5, 135 796 929 10,237 10,631 700 11,050 * Last monthly forecast. ** New ALL time records! AP00045774 Mr. H. L. Harwell -2- February 6, 1968 Isopropylamines were produced in the number 1 plant until January 29, when, the plant was switched to methylamines. The run on isopropyl was highly successful and resulted in a new record. The modified converter designed for use on MIPA was also an outstanding success in that temperature control was excellent and there was no apparent catalyst degradation for the entire run. Ethylamines were produced the entire month in the number 2 plant. Ether yield was the same as for December but is still below expectations. The methylamines plant was devoted to isopropylamines production Ml this period and as a result, no methylamines were produced, except offspecification material reworked via the batch stills. Amines variances for the month were: Methyl Ethyl Isopropyl $ 2,355 unfavorable $27,313 favorable $44,484 favorable The unfavorable variance in methyl reflects the startup cost on the 30 th and 31 b t. The favorable variance in ethyl reflects continuous operation all month without a single outage. The process costs were also lower due to the lack of downtime. The favorable variance in isopropyl reflects the very good yield and production rates in the new reactors. The plant was continued on isopropyl an extra week until the 29th due to the extra sales of MIPA. This extra week allowed an extra million pounds of production, which really helped the variance. During February the variance should be'near zero. The shorter month and the recycle of TMA will keep the variance down. Also, no isopropyl amines will be made. Variance in March should be $20M favorable. POLYVINYL CHLORIDE January production was 3, 368, 000 pounds as compared to the budgeted 4, 080, 000 pounds. The below budget rate was due to the planned five day shut down to install the new refrigeration machines. AP00045775 Mr. H. Li. Harwell -3- February 6, 1968 Volume variance was an unfavorable $21,046 in January, as compared to the projected $10, 800. The difference is due primarily to underestimating the maintenance cost6 expected for the plant shutdown repairs. A scheduled plant shutdown was taken on January 22 - 27, to install the new higher capacity refrigeration machines. The machines have operated smoothly since they were put on'line. Major maintenance work completed during the plant outage is summarized below: a. Changed the reactor motor hydraulic drive oil. \ b. Installed new stainless bottom in number 2 blend tank and relined numbers 1, 2 and 3 blend tanks. c. Changed steam coils on both dryers. d. Revised piping on high pressure water cleaning system. Mr, D. Kell of Rockwell Manufacturing visited the plant on January 22 to discuss the reactor hydraulic oil system. Conditions were reviewed for obtaining the maximum horsepower and improving the speed control on the existing reactor motor drives. Reactor speed control has been excellent as compared to previous experience after changing to a higher viscosity oil and using refrigerated water on the hydraulic oil cooler. We plan to optimize the present operation and determine the horsepower actually being obtained at the reactor drives. Any further improvements needed in reactor drive motor horse power rating will then be developed with Rockwell. The high pressure water system was put in service near month end and reactor cleaning techniques are being developed. One bulk car and two trucks were accepted by Phillips Film in January. The plant quality control chemist observed the sampling and test procedures on each of these shipments oh the customer's site and rejections appear to be caused by sampling problems. The initial shipment was not satisfactory based on the normal sampling procedures, but was accepted after sampling methods were changed. The sampling thief was found to introduce a large amount of metal filing contamination and has now been replaced with one made from. PVC. Standardization sampling procedures is needed with Phillips so that we can correctly and properly approve resin for shipment. We plan to propose a procedure to Phillips. APOOO Mr. H. L. Harwell -4- February 6, 1968 A quality problem at Filmco is believed to be caused by coarse size particles based on an investigation by the Polymer group at 'Wilton. Produc tion of an experimental lot screened through a 70 mesh screen is planned for testing at the customer's plant in February. Engineering is proceeding on the specialty resins project and the major equipment is on order. * February's cost variance is projected at $7, 400 favorable with a production volume of 3, 833 million pounds. \ 3. D. Kramer AP00045777 ESCAMBIA CHEMICAL CORPCRATIGIs7 XNTBROFFICS MEMORANDUM Tot Mr. A. K. McMillan From! R.i M. B. Rogers PVC Monthly Report January, 1968 Date: Copies: February 5, 1968 SUMMARY s January prime production was 8, 368, 000 lbs. against 3, 400, 000 lbs. projected. The monthly average budgeted production of 4, 080, 000 lbs. was not possible because of a five-day shutdown, to install the new refrigeration machines. The shutdown went on schedule and the new refrigeration machines are running smoothly. Reactor agitator speed control appears markedly improved by changing to a higher viscosity hydraulic drive oil and putting refrigerated water on. the oil cooler. A program for determining optimum mechanical clearances and operating conditions was developed with the hydraulic system manufacturer's representative. The high pressure water system was put in service and reactor cleaning techniques are being developed. Rejections by Phillips Films appear to be caused by sampling problems. A sample thief with a PVC liner to eliminate metal shavings proved success ful at the customer's plant. A truck rejection by Filmco appeared to be caused by larger size particles which do not fuse completely in their blown film application. A rescreening operation was unsuccessful. Finer screens will be used as the next production run is dried. Variance for January was $22, 040unfavorable due primarily to volume variance and major maintenance during the shutdown. AP00045778 Mr. A. K. McMillan -2- February 5, 1968 STATISTICS January________ Actual Budget December Actual Budget Prime Production, M lbs. Month Year to Date 3, 368 3, 368 4, 080 4, 080 4, 064 46, 900 4, 300 51, 000 Off-Grade Production, % of Total Month Year to Date 6.0 3. 0 4. 0 3. 3 6. 0 3. 0 4. 1 3. 3 Bulk Production, % of Prime ' Month Year to Date 47.2 47.2 57. 5 57. 5 44. 4 55. 0 62 62 Shipments, M lbs. Prime Off-Grade 3, 759 4, 256 422 - 170 - VC1 Efficiency, % Month Year to Date Reactor Availability, % of Available Hours Month Year to Date 94. 8 94. 8 * 83. 6 * 83, 6 94 96.2 94 94.2 84. 0 81.7 94 94 - * Based on operating time only and excludes 1, 680 reactor hours lost during refrigeration installation shutdown. Reactor Downtime, % of Available Hours Mixing Solutions in Reactor Cleaning it Washing Reactor Scheduling Charges Changing Types Copolymer Production 1. 1 7.2 2. 1 1. 3 0. 0 0. 6 5. 3 2.9 2. 1 0. 3 - Slow Recovery 0. 1 0.2 AP00045779 Mr. A. K. McMillan - 3- February 5, 1968 STATISTICS (continued) Reactor Downtime % of Available Hours (continued) Low Drying Rates & Dryer Dine Cleanout Hydraulic Motor Repairs ' Misc. Reactor Maintenance Dryer Maintenance Electrical or Instr. Maint. Miscellaneous Experimental Batches Total Product Mix, M Lbs. Prime Resin Group I Group II Group III Group IV Group V Group VI Group VII Total * Ground resin not included in total. Payroll Regular Unscheduled Overtime January Actual Budget December A ctual Budget 1. 8 0. 1 0. 1 0. 0 0. 1 2.5 0 16. 4 - - - - 1,4 0. 3 0. 1 0 0. 2 2.4 0.2 16. 0 - - - - - 1, 886 1, 210 272 0 6 0 0 3, 368 2, 154 1, 010 603 23 262 32 0 4, 084 1. 759 I, 080 255 215 700 55 (170)1' 2. 786 975 539 0 0/ . 0 (65)* 4, 064 4, 300 Janua ry Hours % 4, 810 314 6. 1 December Hours % 6, 557 405 5. S AP00045780 Mr. A. K. McMillan -4- February 5, 1-968 PRODUCTION 1000 Series Types produced: 1185, 1200,1225, 1217, 1230, 1250, 1250X-2. One shipment of 1250X-2 was rejected by the customer, Filmco, because of an unusual type of gel or ''fisheye" believed to be caused by larger size particles. The gel level was made satisfactory experimentally by laboratory screening through a 60 mesh screen, but an attempt to rescreen in. the plant was unsuccessful. A finer scalping screen will be used in drying the next production run. Attempts to control particle size by minor recipe variations were unsuccessful. \ Extensive tests show that metal particles from the sampling probe is the major cause of apparent contamination and rejections of type 1250 by Phillips Films, . The sampling problem was demonstrated by N. S, Barranco at the customer's plant January 13 when a load that would have been rejected by the customer's standard sampling procedure was accepted after sampling revisions. A rigid white PVC core in a stainless steel sheath appears to give minimum contamination, and this type sampler is to be fabricated for the customer. Other improvements in the production operation and in the loading equipment and procedures were continued to further reduce the base contami nation in the resin. 2000 Series Types produced: 2185, 2200, 2225, 2160, 2250, and 2170. The low bulk density problem with type 2185 persisted through several recipe variations in the Pensacola plant and Wilton pilot plant. An earlier recipe using a different surface active agent produced satisfactory product. Production of other types was normal. 3000 and 4000 Series Types produced: 3185. Type 3185 production was all prime grade, but none met the more stringent, handpicked ,J4185 SP" size distribution requirements through several recipe variations. Improved agitation with the newly charged higher viscosity hydraulic drive oil is expected to improve particle size control in future runs. AP00045781 Mr. A. K. McMillan. -5- February 5, 1968 6000 Series Copolymers No copolymers were produced in January. 8000 Series Types produced: 8217. Production was routine. Ground Resins \ Closer control and various minor operating improvements have reduced ground fusion rejections from over 25% to less than 5%. The major outstanding quality problem is a mottled or salt-and-pepper effect in 4183-2S fusion resin ground from type 3185 for one critical customer, G. S. Plastics. Standard type 2185 is difficult to grind and excessive tailings are produced by the screening required for a satisfactory product. Old 2185 produced in 1965 by an experimental recipe was ground into an excellent product acceptable to G. S. Plastics. It may be necessary to produce this type specifically for grinding feed. Tailings and Off-Grade Off-grade production was as follows: Off-Grade Type 2185 Type 2225 Reason Off-Grade * Low bulk density High fisheyes Quantity 42,200 38,000 % of Total Production 1.2 1. 1 Tailings -- 95,200 2. 6 Floor Sweeps -- 38,000 1. 1 Total 6. 0 MAINTENANCE The PVC plant was shut down January 22-27 for installation of new refrigeration machines, Major maintenance performed during the shutdown was as follows: 1. Put stainless steel bottom in Number 2 blend tank and sandblasted and recoated the carbon steel sides and top in blend tanks 1, 2, and 3, AP00045782 Mr. A. K. McMillan -6- February 5, i968 2. Changed the reactor motor hydraulic drive oil. 3. Installed new steam coils in the north dryer and replaced the south dryer coils with used coils that had been cleaned and pressure tested. 4. Exchanged reactor baffles between Number 2 and Number 4 reactors to have the worst baffle in Number 4 which is to be removed for reglassing, 5. Repaired all reactor relief valves and all malfunctioning hydraulic oil and vinyl chloride valves. \ 6. Repaired baffles in dryers. 7. Cleaned and checked weigh tank scales. 8. Repaired holes in the north stripper. 9. Revised the centrifuge slurry feed line to accommodate magnetic flow meters. 10. Revised the high pressure water cleaning system piping. The shutdown went on schedule and the new refrigeration machines are operating well. Mr. D. Kell of Rockwell Manufacturing visited the plant January 22 to discuss the reactor hydraulic drive system and oil changeout during the shutdown. A procedure for determining optimum oil viscosity and reducing pump clearances to increase power was developed. GENERAL Quality problems with Phillips type 1250 and Filmco 1250X-2 were discussed under PRODUCTION, 1000 Series, above. Catalyst levels are being increased in about 4% increments to re establish reaction cycle time limits with the new refrigeration machines. Reductions up to 1/2 hour have been achieved, but data is limited at month's end. A check with Research established that heat stability may be affected by too much catalyst, and heat stability checks will be included in the cycle time reduction program. APOOC Mr. A. K. McMillan -7- February 5, 1963 Piping revisions and control problems have slowed effective use of the high pressure water cleaning system, Various nozzle arrangements were constructed and the equipment is in service by operations, The manu facturer's representative is scheduled in the plant the second week in February to help with additional refinements in hardware and technique. Engineering is proceeding on the specialties equipment modifications. The dust collection equipment is ejected by March 1. The dryer filters and centrifuge discharge scroll may be delayed beyond March if expediting efforts are unsuccessful. The funds for the specialties air compressor may be combined in a central air supply system and a temporary compressor arrange ment would be required initially. VARIANCE Variance analysis for January is as follows: FAVORABLE By-product Credit VCL Monomer Price Efficiency $ 6,360 13, 200 1, 360 Process Costs Elec. -Steam Salaries Misc. 380 440 670 Packaging Vol. Variance 1,090 Subtotal $2 3, 500 UNFAVORABLE Volume Variance $24, 360 Process Costs Maintenance Payroll Overhead Laboratory 12, 010 713 2, 107 Packaging-Process Costs 2, 260 Other (by difference) 4, 090 $45,540 Net Unfavorable - $22, 040 FEBRUARY PROJECTION Production {29 days) Cost Variance Monomer Price Volume Net 3, 833, 000 lbs. ($14, 300) 6, 900 7,400) Favorable 777- Z? M. B. Rogers AP00045784