Document dYNnj4Rv5ZK0rL3m7qygN6rj9

W Chmusaii- ItCAHIIA PLANT IMC. INTEROFFICE MEMORANDUM Tot R. E. Jones From: W. J. Stueben Dot: Copies: 7 October 1976 Re: Monthly Report - Safety Dept. - September 1976 The Safety Engineer spent two days observing the operation of the change house at Pasadena Plant. Some of the principles used at Pasadena will be applied to projects at Escambia. The Dispensary/Safety Office Building was put into service during September. All of the plant medical, safety and security services are now at the plant gate enabling us to handle plant emergencies in a much safer manner. The plant fire truck was upgraded with additional fire fighting equipment and a cap for the load bed. Planned additional changes will enable the fire truck to get to a fire with more equipment sooner than we are now able to do. Industrial Hygiene Programs were discussed at length with J. Novak and R. R. Spiegelhalter. Included were plans to sample all chemicals currently proposed for regulation by OSHA and the Amines Plant. The Safety Engineer attended a Process Hazards Review Seminar at Trexlertown. This will allow better communication when discussing the concepts of failure mode analysis and fault free analysis. Inputs were also made in the following areas: PVC expansion, Nitric Acid plant failure, Amines susceptability, plant security, escape respirators, DNT plant reactivation, emergency procedures and Calvert City safety. WJS:jsr W. J. Stueben AP00041951 AP00041952 cut/ G6e*mfxt$- IMC. CSCAMliA PLANT INTIROFFICI MEMORANDUM To: A. K. McMillan Dote: From: R. E. Jones Cop let: p#. Monthly Report - October, 1976 10 November 1976 The Escambia Plant operation continues good with positive variances being generated in most areas. The ammonia plant contribution to plant variance was particularly good as production of 8, 047 tons (114% of standard) was achieved with a corresponding good efficiency of 41.2 MM BTU/ton (standard 45.7). The ammonia plant has operated continuously since June 19 without an outage for defouling the primary waste heat boiler. We are projecting that this run will continue until the scheduled January turnaround. The colder month operations should continue to show the same type results as those recorded in October. Nitric acid production of 14, 137 tons was 112% of standard with sales limiting during the first 12 days of the month. The No. 1 plant was shut down on 27 September for a scheduled outage for extensive Masar column inspection to determine cause of carry-over. Velocities in the risers to the Sulzer packing area were very high causing a venturi effect and subsequent entrainment. After modifications! we are still experiencing some entrainment and recommendations have been received from, Koch to enlarge the liquid distribution ports which were causing some atomisation of the liquid feed to this section. These modiflcationr will be made in November for both plants. The No. 2 plant operated continuously during the month except for a short duration outage resulting from trip-out caused by failure of a boiler feedwater pressure regulator. At month end gauze efficiencies had declined to a point where a shutdown to change gauze will be taken early in November. Area B operations were all in excess of budget due to high sales requirements. Monthly production figures for the ammonium nitrate area follow: 1 AP00041953 A. K. McMillan 2- - 10 November 1976 83% AN Prills Urea Urea/ Solutio ns Bay-Sol October Actual Budget 14,995 14, 210 2, 020 5, 687 1,732 8,705 7,439 1,798 4, 435 135 Year to Date Actual Budget 14,995 14,210 2, 020 5, 687 1,732 8, 705 7,439 1. 798 4, 435 135 Continued above budgeted sales requirements are to be expected for November and December and should continue to show thLs Improvement in the A.N. area operations. Methanol production for October was 1,755 M gallons or 48% of budget as limited by sales. During this period the No. 2 reformer traLn Is being modified for better operations. Mixed gas feed preheat will be increased to increase throughput and the current brick roofs in these reformers will be replaced with an insulating blanket type refractory. This work is scheduled for completion by November 15. Gas efficiencies continue to be below budget due to the lower rates induced by the reformer outages caused by the reduced sales requirements. PVC continues to exhibit excellent results with another record production established for October at 7, 7 16 M lbs. The previous record was 7, 500 M lbs. established last August. Off-grade production continues very low at 0.6%. VCM efficiencies were also above budget at 96% for the month. Personnel monitoring showed 80% of the 8-hour TWA samples below 1.0 ppm, and 95% of the 15-minute TWA below 5.0 ppm. November is expected to continue to reflect the current excellent operations. Preparations are continuing for the December shutdown to tie in the new facilities. The Amines plants operated very well in October in spite of continued efficiency problems with the high temperature ethylamines process. Alkyl efficiencies were very low at about 75% as reaction temperatures were maintained very high (790-800F) in order to reduce ethyl crudes inventories to minimum levels as this was the last ethylamines production run scheduled for Pace. The No. 1 plant was turned around to methylamines production on the 11th and remained down until month end for several process modifications necessary to achieve the budgeted 300M lbs. /day rates consistantly. With 1 AP00041954 A. K. McMillan -3- 10 November 1976 a scheduled four month idle plant time for this plant, no sales were lost because of the outage. Startup operations were hampered somewhat by the continued presence of the ethylamine tars throughout the reaction system, and some high pressure drops are occurring at present due to buildup of these tars and may limit rates for this run. The No. 2 plant continued on MIPA production with the best results ever recorded. Both raw material efficiencies and product rates exceeded budget throughout the run and achieved the greatest production level for a total MIPA run. On 25 October the run was shut down for product turnaround to DNPA and the plant is in startup operations at present. October effluent results continue to be better than interim NPDES limits in spite of higher flows resulting from the use of once-through well water in the ammonia plant cascade cooler. Plant effluent loading was 1055 lbs. /day of TotaL-N at 2.3 MGD total water. Revisions are being- made in the plant to utilize the cascade cooler water as cooling tower makeup water. November flows should return to normal. The final effluent treatment project is proceeding on schedule with a forecasted 15 November startup of the facility. All critical equipment has been installed with the exception of the ''Echo'1 pond baffles. The project remains on budget. November is expected to show continued good results as above budget performance is expected in all areas with the exception of methanol. Methanol will be operating at maximum levels by month end. Preparations continue at a high level for the PVC expansion tie-in and startup. This project continues to look very good with respect to budget. Amines will produce methyls and DNPA in November and both products are expected to perform at budget rates and efficiencies. REJifls Attachments .Jones 1 AP0004I955 -4 J AP00041956 ( ) Unfavorable Variance from Standard PRODUCT COST VARIANCE STATEMENT FORWARD REPORT November 16, 1976 Facility PaCe " period Year End, FY 1977 oduction (000) 'Actual Production Related Variances I. Raw Material Conversion 3. Volume c) Offgrade 0. Spending (Use) (at ltd. $fult) Ammonia Nitric Acid 63% AN 84,800 86,327 151, 300 172, 087 169,358 200,245 Prills Urea/Sol. Methanol Amines 130,620 23, 226 147,000 26, 261 40, 120 68,680 38,065 68,680 PVC 115,700 116,628 Total _ 91 10 - 72 5 (14) (11) (100) 53 19 48 57--------- .. - - 42 27 114 15 198 10 9b 27 133 _ _ - 24 (24) (?) (4) (5) - 84 _ _ 36 139 ... _ 4B_._ - - - 33 33 - 84 _ 69 ZZC 35 (34) (37) 47 37 48 _j6ri in 13 1 10) 4ii 13 31 55 . 46 _ 16_____ 161 (30) _ _ 66_ 40 76 7 - - 43 -- ! 13 - .9 .. - 32 _ (47.) ,,,, - 331 J 19,____ | -- 14P,,, _JJU_____ --. 55.9-., IV. Soendinp (Rate) Total Spending (Rate) 3 2 -------5--------- - --TZ------- 4 1 1 - 6 7 13 1 20 39 20 112 (I) 1" (2) (1) 4 (3) 44 m) TTTJ ___ d1k6,_ -_ 6 12 21 (41) 10 -- 30 )TAI PRODUCTION RELATED VARIANCES 372 i 49 73 65 29 171 (65) . 6a 862 AP00041957 i ( ) Unfavorable Variance From Standard PRODUCT COST VARIANCE STATEMENT FORWARD REPORT Pace Page Z Year End 5. v. Purchase Price Variances a) Raw Material b) Purchased Utilities c) Feedstock Mix d) Other (maint. mat'l, op. sup.,etc.) Total Purchase Price *.VI. Business Variances a) Volume b) Systems Variance c) Other Total Business Variances Ammonia Nitric Acid 83% AN . -1 - - -- - --_ -1 - . (1, 130) (T7BD> 389 116 _ -"3B3------------- 116 Prills (1) 2 1 292 - 292 Urea/Sol. Methanol Amines PVC Total 12 335 (21-9)___ 127 - 22 74 36 - _' _- - 34 342 (215) _ | 163 661 _ 661 (208) - (26) (2341 5 13 (36) -US) __ (340) 363 "T3F) (13) . .. 915 (754) ___L9JL 63 TOTAL PRODUCT COST VARIANCES FROM STANDARD YU. Budeeted Variances from Standard a) Raw Material Cost b) Purchased Utilities Cost c) Volume d) Spending e) System Total Budgeted Variances TOTAL VARIANCES FROM BUDGET a) Production Related b) Purchased Price Variances (758) 539 ZB .. - <T) (3, 176) (3,149) _ _ _ 2,391 539 373 "T2r^ 27046 149 1 389 189 18 18 171 73 98 358 690 (29) 259 (160) 1,088 _ (12) (121 370 . 66 1 303 _ <n | _ (?) (i)...... _ (7) 691 33 - 658 (22) 171 34 (227) n 66) _ (51 (170) (172) _ h (22) 4 (190) (144) (165) 12) (23 (}.177) ( 3. 51 11| 429 30 4, 599 ! (65) 507 an____ ____ 90' 890 (43) 472 1 -(17J______ 3. 237 id AP00041958