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Job No. Report No. Date; Title; Aroclor Manufacturing Improvement Plan Objective: To develop ,a guide to improvements in cost, capacity, and quality in the Anniston Aroclor plant. Personnel: J. MacPherson (L. C. Fuhrmeister) Reported by: J. MacPherson Summary: * , The major emphasis will be on quality attainment in the liquid Aroclor product line and capacity increase in the solid Aroclors. A summary of targets and commitments is as follows: Liquid Aroclors Year Target Capacity Predicted Sales Quality Potential Savings/Earnings 1968 1969 1970 1971 53 53 65 65 42.7 44.7 46.3 49.5 Intermediate Product Strategy s Solid Aroclors 229,770 30,000 1, 330,000 30,000 . Year Target Capacity Predicted Sales Quality Potential Savings/Earnings 1968 1969 1970 1971 10.5 12 14 14 10.5 11.7 13.2 14.3 No Change No Change No Change No Change 150,100 233,800 238,200 121,700 A commitment of 1920 technical man-hours will be required to support the target programs. This issuance of the MIP marks a departure from the previous PIP format although the contex is essentially the same. The plan issued on 2/9/66 has been partially absorbed by a CED project with the result that only one major savings item (Aroclor still modification) was available for implementation; the item has not been installed as yet. 0265523 TOWOLDMON0044020 Section 1 2 3 4 5 6 7 8 9 10 11 12 X. XX. HI. IV. V. VI. VII. VIII. IX. X. Title ' Introduction Summary of Major Targets for Future Efforts General Process Description . Market Analysis Process Analysis Capacity Analysis Cost Analysis Competitive Technology Patent Status Stream and Air Pollution Job List Appendix Process Sketchs ` Comparison of Competitive Materials Market Analysis Production Schedules Non-productive Time Project networks MIP Contributors (1) Production (2) PR&D (3) Quality Operations Control (4) Maintenance TSD Jobs and Projects References Cost Analysis Data 0265524 TOWOLDMONOQ44021 Section 1 Page 1 Introduction The Process Improvement Plan (PIP) is being replaced by a Manufacturing Improvement Plan (MIP). In general the contex is the same however the KIP is to present a broader base by including source information write-ups con tributed by personnel other than the area T.S.D. engineer. The procedures used to publish the MIP will be the same as for a PIP, the plan will be in the form: of a progress report. Updating will be done when expedient to do so; certain sections may be updated quarterly while others only on necessity. As with the PIPan MIP is to serve as a continuing guide to improvements in cost, capacity, and quality. The previous PIP was issued on 2/9/66. This plan was not implemented because of product strategy changes. Divisional goals set in May 1966 required a much improved quality, this was not a major objective of the previous PIP. The major savings item in the 2/9/66 PIP was a labor savings project in the finished goods area; this project has been absorbed in a CED project (Aroclor expansion CEA 1430). The second major item was a modification to the liquid Aroclor still to permit the use of indirect heating of the still and realizing fuel savings, less product decomposition and reduced maintenance, this project has not been installed as yet, tentative EDC is 3/1/68,. 0^65525 TOWOLDMONOQ44022 Section 2 Page 1 Recommendations to Attain Targets 1. Install adequate fixed bed refining capacity to handle all electrical grade 1242/1254. 2. Install still modifications to allow still capacity to match chlorination ability (65 M lbs./yr.). 3. Maintain a T.S.D. effort of at least 1 engineer to attain estimated savings/earnings. . 4. Ensure that all personnel involved with Aroclor are aware of the capacity deficit situation in the solid product area. 0265526 TOWOLDMONOQ44023 S ection Page 2 0265527 r\j Year 1968 1969 Capacity M Xb/yr 53 53 1970 65 1971 . 65 TARGETS Liquid Aroclors Estimated Potential Savings/Earnings Quality labor saving;s O.S.T. savings earnings total Intermediate 8, 770 221,000 229, 770 Product strategy goal * 10, 000 20, 000 -- 30,000 Product strategy goal 10, 000 20, 000 1,300,000 1, 330,000 Product strategy goal 10, 000 20, 000 -- "30,000 Year 1968 1969 1970 1971 Capacity M Ib/yr Quality 10.5 _ No Change 12 No Change 14 No Change 15 No Change Solid .Aroclors Estimated Potential Savings/Earnings material savings labor savings O.S.T. savings earnings 30, 000 33,800 -- 30, 000 120, 000 40, 000 -- 130, 000 38,200 30, 000 40, 000 130, 000 41, 700 40, 000 40,000 total 150, 100 233,800 238,200 121, 700 > TOWOLDMONOQ44024 Section 3 Page 1 Synopsis of the Process A. Chlorinator Area There are four batch operated liquid chlorinators, one batch operated solid chlorinator, and one continuous chlorinator system. The continuous system consists of four chlorinators cascaded with overflow in series. , The liquid chlorinators are charged with biphenyl and ferric chloride catalyst; charges for the solids chlorinator depend upon the Aroclor to be produced. Chlorine gas added through a sparger reacts with the charge to release HC1 and heat; the HC1 gas goes to the Muriatic Acid department. The specific gravity of the crude is used as the monitoring and control variable. Crude Aroclors from both batch and continuous chlorinator systems are transferred to a tank to be air blown before distillation. Figures 1, 2, and 3 in Appendix I are sketches of the batch, continuous, and solid chlorinators. B. Still Area There are four stills in the Aroclor department; stills No. 2 and 3 are used for liquid Aroclors only, No. 4 is for solids only, and No. 1 can distill any grade of liquid or solid with the exception of 1268 anc) 5460. (1) Liquid Aroclors Crude Aroclor is charged from a blowing tank or a feed tank to a still. Rydrated line is added and a vacuum of 40 MM. Hg applied; the still charge is then direct fired by circulation through a coil in a gas furnace, the distillate goes forward to a receiver. The distillation is semi-continuous since ten receivers are distilled prior to drawing residue from the still. The receiver charge is in turn transferred to a blending tank where it is treated with Attapulgus clay and filtered. Finished product is transferred to storage tanks prior to loading into drums or tank cars. Figure 4 is a sketch of a typical liquid still. (2) Solid Aroclors 1 Distillation of solid aroclors is similar to liquids with the exception that the vacuum is approximately 10 MM. Hg. absolute and that generally two still charges are distilled before withdrawing residue. Solid Aroclors 5460 and 1268 are flaked; all other refined solids are drummed from the,receiver. Figure 5 is a sketch of the solid still system. 0265528 TOWOLDMONOQ44025 Section 3 Page 2 C. Chemical Equations (1) Liquid Aroclors Based on the forecasted demands through 1971, the average Liquid Aroclor could be called 1245.6. C12H10 + 3.66 Cl2 154.20 70.9 C12H10(CS.66+ 3'66 HCL 283.8 36.5 (2) Solid Aroclors * Based on the forecasted demands through 1971, the average Solid Aroclor would contain 60.4% chlorine and 2.92% Biphenyl, .971 Santowax R + .029 Biphenyl + 10 CI2 230.3 154.2 70.9 Solid Aroclor + 10 HCL 586.0 36.5 0265529 TOWOLDMONOQ44026 Section 4 Page 1 3. Market Analysis Appendices II and III present (1) a comparison of competitive materials with Aroclors 1242 and 1254 and (2) an analysis if the world market for Arcclors. If Monsanto is to compete^ the following goals must be met: .. ' 1242/1254 Goals In Plant Storage As Packaged As Delivered 1254 Resistivity 15. 00D> PF (lkc) .3% 4 .1 10,000 <0.4% > 5,000 < 0.5% (i 0.1%) 1242 Resistivity 10. 000> 5,000 PF (lkc) 0.6X4 0.1) <0.9% > 3,000 < 1.0% (4 0.1) Monsanto's share of the market in 1966 and the objective$for 1971 are presented below: Capacitor Aroclor 1966 1971 Domestic Non-Domestic 78.4% 71.5% 71.5% 67.2% Transformer Askarel 1966 1971 Domestic Non-Domestic 61% 59.5% 67.4% 65.8% . It must be emphasized that the quality goals presented above were introduced at the Corporate Aroclor meeting held in St. Louis on May 9 and 10; these goals represent marketing necessity as of 1967. The Product Strategy quality goalq remain at a higher quality level since they represent a long range goal. 0266530 TOWOLDMON0044027 Monsanto ' OROANIC CHEMICALS DIVISION FINISHED PRODUCT 0 SPECIFICATION PRODUCTION R, G. Moody/s/R. G. Moody 3/23/67 SALES . W. E. Ault/s/W. E. Ault 3/17/67 GENERAL DESCRIPTION PRODUCT Export Grade Aroclor 1254 - Electrical Grade PLANT PROOUCT CODE Page 1 . JoEPT. 127-L USE Anniston DATE EFFECTIVE 326.13 SALE* CODE Sales 3/23/67 APPROVALS RESEARCH L040-280-16-009 L. R. Stark/s/L. R. Stark 3/21/67 QUALITY CONTROL (Chlet Chemist) G. W. Mlller/s/G. W. Miller 2/23/67 CHEMICAL FORMULA - Mixture MOL WT. SUPERSEDES SPECS. OF Tentative 4/27/66 CHARACTERISTIC UNRESTRICTED INFORMATION AMPLE FOR ANALVIlt 3x5 pt. Amber bottles LIMIT* IIIUED D V J. A. Liddle 2/21/67 - METHOD (R) Color, APHA (R) Condition (R) Specific Gravity @ 65/15.5 "C '(R) Acidity (mg KOH/gm.) (R) Moisture (H2O), ppm (R) Refractive Index @ 25C (R) Inorganic (free) Chlorides, ppm (R) Pour Point, C (R) Dielectric Constant . 1000 Cycles @ 100eC (R) Resistivity ohm-cm 500 VDC @ 100"C, 0.1" Gap (R) Hydrolysis Stability Test . as chlorides, ppm (R) Monsanto Stability Test . as chlorides, ppm (R) Distillation Range, ASTM D- 20, . . corrected 107. Distilled by vt. 50% Distilled by wt. 90% Distilled by wt. (R) Biphenyl, X Sulfates Dielectric Strength @ 25C Flash Point Fire Point ' ViscoBity @ 210"F (SUS) Corrosion Test 6 hours @ 210C with bright aluminum foil Change in wt. of A1 (%) A.C. Color, APHA A.C. Condition A.C. Acidity (mg. KOH/g.) A.C. Inorganic (free) \ . chlorides, ppm 50 Max. Clear 1.495 - 1.505 0.010 Max. 35 Max. ' 1.6370 - 1.6390 0.05 Max. 7 -12 , 4.15 - 4.35 10,000 x 109 Min. 1.0 Max. 0.5 Max. e 366 - 378'C 371 - 383C 379 - 394C 0.025 Max. None 35 KV, Min. None to Boll None to Boil 44 - 48 0.0 60 Max* Clear 0.010 Max. 0.05 Max. . S 046 G-l 052 050 047 048 045 053 113 121 010 133 054 100 043 114 114 049 046 G-l 050 045 RESTRICTED INFORMATION Power Factor @ 100C & 60 Cycles Report (R) Routine -Analysis, All others Analyzed by request Only 0265531 113 TOWOLDMONOQ44028 Monsanto TENTATIVE SPECIFICATION AUTHORIZED BY G. W. Miller OENENAL DESCRIPTION product Export Grade Aroclor 1242. Electrical Grade PLANT PRODUCT coots Anniston DATE EFFECTIVE 826.12 ' SALES CODE 6-12-67 1040-240-16-009 SOURCE OF SPECIFICATION P. G. Benignue Memo dated 5-11-67 Page 2 use 1 1DEPT. I 27-L Sales . CHEMICAL FORMULA EFFECTIVE UNTIL 6-1-68 CHAN ACT ERISTIC UNRESTRICTED INFORMATION I SAMPLE FON ANALYSIS..................... 13 x 5 pt. Amber bottles LIMITS J A. Llddle 5/29/67 METHOD (R) Color, APHA. (R) Condition (R) Specific Gravity <? 25*715.5SC (R) Acidity (mg KOH/gm) (R) Moisture, HgO, ppm (R) Refractive Index @ 25C (R) Inorganic (free) Chlorides, ppm (R) Pour Point, "C (R) Dielectric Constant 1 KC @ 100C . (R) Resistivity ohra-cm 500 VDC @ 100*"C, 0.1" Gap (R) Hydrolysis Stability Test (as chlorides) ppm (R) Monsanto Stability Test (as chlorides) ppm (R) Biphenyl, % (R) Distillation Range (ASTM D-20, Corrected) 10% Distilled by wt. 90% Distilled by wt. Sulfates Dielectric Strength @ 25C Flash Point (F) Fire Point Viscosity @ 100F (SUS) 40 Max. Clear 1.381 - 1.392 0.010 Max. 35 Max. 1.6240 - 1.6260 0.05 Max. -14 or lower 4.70 - 4.90 5,000 x 109 Min. 0.5 Max. 0.4 Max. 0.05 Max. 325C Min. 360'C Max. None 35 KV Min. 338 - 392 None to Boil 82 - 92 046 G-l 052 050 047 048 045 053 113 121 010 133 100 054 12169 043 114 114 049 RESTRICTED INFORMATION Typical Values Power Factor (3 100C 60 cycles 1000 cycles Report Report 0.30-0.50 0.08 - 0.10 il3 /s/G. H. Miller - 5-31-67 G. W. Miller - Chief Chemist /s/H. L Williams - 6-1-67 H. L. Williams - Production /s/Wm. E. Ault - 6-8-67 W. E. Ault - Sales .. /s/L. R. Stark - 6-12-67 L. R. Stark - Research (R) Routine Analysis, All others Analysed by request only. TOWOLDMONOQ44029 Section 5 Page 3 5. Process Analysis Liquid Aroclors , A comparison of the Product Strategy quality goals and YTD Anniston performance is as follows: Aroclors 1242 1254 Project Strategy Goals (1242 & 12541 Color (APHA) 14 18 10 Max. Water (ppm) 24 26 ' ' . 20 Max. Resistivity @ 100C (xlOv ohm-cm) 1.450 7,750 10,000 Min. Power Factor @ 100C ' (% at 60 cps) 2.70 .85 0.2 Max. Thermal Chemical Chloride Stability (ppm) .26 .42 0.1 Max. Intermediate product specifications are presented on the specification sheets included in this section. <> To attain the targeted quality goals it will be necessary to (1) improve the treatment capability of Aroclor refining, (2) reduce the atmospheric contamination during processing and storage, and (3) eliminate ionic contamination from the handling equipment. It is possible to produce target quality 1254/1242 guides by multiple (3 or 4) batch absorbent treatments using Porocel (activated bauxite LVM grade). An apparent techological breakthrough for the treatment operation is the utilization of a fixed bed absorbtion unit chargedwith Procel; figure _____ shows a resistivity versus time for an experimented unit installed on the No. 2 liquid still system in May 1967. The technique definately will product goal quality 1242. Laboratory tests are being conducted on Aroclor 1254, it is anticipated that 1254 will upgrade easily. The installed unit is considered a pilot unit for a larger^ capacity bed to be designed in December 1967. Degradation of product occurs during transfer to the storage tanks, on occasion while in storage, and in loading operations. The quality decrease is attributed to atmospheric contamination since the blending tanks and storage tanks (with the exception of the two major tanks for 1254 & 1242 storage) are free breathers'and to ionic contamination from exposed surfaces in the galvanized piping and tank linings. . In-plant projects have been approved to install nitrogen blanketing facilities on the storage tanks and refining systems. A comprehensive project, CEA 1430 - Aroclor Expansion, has been prepared by CED to provide improved storage and handling of product.Aroclors. In the liquid area this will include 11 new bulk storage tanks, 3 blend tanks, pumps, filters, separate product pipe lines, tank car and tank truck loading facilities. . 0265533 TOWOLDMON0044030 Section 5 Page 4 Seeking all possible innovations to assist in the quality drive it has been proposed that Anniston PR&D initiate a program, to define process conditionSneeded to determine when air blowing of the crude liquid is complete; TSD will prepare a project to remove contaminants from the blowing air supply. The basic weakness of the Liquid. Aroclor area is the fact that all the still systems are batch operations and half of the available chlorinators are batch units. Conversion to continuous would offer increased capacity, improved labor efficiency, and optimum quality control. Projects oriented to continuous operation include (1) an Anniston PR & D program to evaluate pulling sidestreams for various grades of Aroclors from a continuous chlorination system, (2) a proposed XKD evaluation of crude blowing and distilling in the same unit, and (3) a CED evaluation of converting No. 3 liquid still system to continuous operation. . . A basic need in the liquid Aroclor area is the establishment of the relation ship between product isomer distribution and sales specifications; this in turn will lead to control of process, variables affecting isomer ratios and the establishment of optimum operating conditions. A TSD project to do such a study is active. The handling of the residue (Montars) from the stills offers a hazard to the operators and promotes labor inefficiency. Current practice is to drain the still residue into drums and transport the drums to the company dump. A survey of the Montar problems has been completed, evaluation and recommendations will be completed by 12/15/68. Solid Aroclors Solid quality is specified by softening point and color of the finished product. Quality problems were not evident until Santowax-R from the new still (on stream Dec. 1966) was used for routine production of Aroclor 5460. Immediate production problems included excessive HC1 evalution during distillation, increased still residues, high product color, and longer chlorinator cycles. Laboratory Investigations indicated that a higher quaterphenyl content in the Santowax-R was responsible; PR & D work is continuing in an effort to provide relationships between polyphenyl content, crude chloriator levels, and yields. A TSD study based on the lab data, will be implemented to determine the most economical . operating conditions. A primary need is an in-line analytical instrument to measure chlorine content of the chlorinator charge either continuously or on demand with short lag time. TSD will conduct a survey of available instrumentation and recommend a section based on the duties (buy, develope, or wait). . Residue handling is a hazard as in the liquid still area, a major difference is that the majority of residue (Montar 5) is solid. Recommendations for handling the solids Montars will be generated during the analysis of the Montar survey. ^6553, TOWOLDMONOQ44031 Section 6 Page 1 Capacity Analysis ` Detailed analysis of the liquid and solid product lines follows however it is important that the capacity goals of the Anniston plant be presented before any discussion. Table ____ is a projection of the commitments and desirable capacity goals for the Aroclor plant. I 0265535 TOWOLDMONOQ44032 Section 6 Page 2 TABLE _____ Anniston Capacity Goals M lbs./yr. Liquid commitment surge (30%) 1968 42.74 12.80 1969 44.67 13.40 1970 46.26 13.88 1971 49.51 14.85 1972 51.72 15.50 Total 55.54 58.07 60.14 64.36 67.22 Solid commitment surge (30%) Total 10.47 3.14 13.61 11.66 3.50 15.16 13.15 3.94 17.09 14.33 4.30 18.63 15.02 4.51 19.53 0265536 TOWOLDMONOQ44033 Section 6 Page 3 Liquid Aroclors A brief summary of the liquid Aroclors production is as follows: 1966 1967 YTD (Aug.) Actual production 40, 735, 885 Scheduled production 41, 663, 295 Capacity rate (lbs/hr) (1) design 5,974 (2) demonstrated 6,059 O.S.T. 88.92 29,639,219 29, 821, 118 5,974 . 6,779 87.51 The capacity rates necessary to make scheduled production were 5430 lbs/hr for 1966 and 5955 lbs/hr for YTD, these rates are based on the actual O.S.T. ' However if the scheduled production had been equivalent to 48 H lbs/yr the rates would had to.have been 6255 lbs/hr and 6430 Ibs/hr based on the same O.S.T., rates of this magnitude have been demonstrated but it is 6tillImperative that the O.S.T. of the liquid area be improved. It is obvious that O.S.T. itself does not set the production rate, it is the combination of capacity rate and productive time. The objective is to eliminate as many causes of the non-productive time as possible and to permit the plant to set its productive capacity by varying the capacity rate. Appendix V presents a tabulation of the non-productive time for 1966 and 1967 YTD (May). Table _____ is a comparison of downtime for 1966, 1967 TYD, 1967 projection, and the standard values. TABLE _____ Liquid Aroclors Downtime Comparison Repair Process Other Standard Hours 259 173 173 605 1966 220 355 369 944 1967 YTD (Aug.) 196 122 317 635 1967 Pro 294 183 475 952 Table __ presents a summary of downtime causes and corrective actions; the estimated time savings are 58.0 process hours and 104.3 other'hours. An additional 29.3 other hours should not re-occur. A projection, based on successful completion of the indicated actions, for future downtime is: Repair Process Other Total Hours 294 125 342 761 0265537 TOWOLDMONOQ44034 Section 6 Page 4 O.S.T. for this downtime sum would be 91.2%, requiring a capacity rate of 6100 lbs/hr. which has been demonstrated. Capacity beyond 48 M lbs/yr can be gained by installing level instruments on the still receivers, blend tanks, and filtrate receivers and by replacing the existing still receiver pump with identical but new pumps._ The capacity rate estimated for this modification is 6650 lbs/hr or 53 M lbs/yr.; a project has been approved for this modification. . The 53 M lbs/yr. must be considered on interim production plateau since the chlorination capacity is estimated at 65 M lbs/yr. Steps to exceed the 53 M lb. level include items such as improved preheat for the sitll feed, improved still condensers, and higher capacity vacuum jets; an estimated in vestment of $85,000 will allow the still system to match the chlorination capacity. It appears that Anniston can meet the capactiy goals through 1971. 0265536 TOWOLDMONOQ44035 TABLE Downtime Cause * Corrective Action Time Savings - hrs. i. Waiting on room in blend tanks a. Expert grade 1242 to be refined in fixed bed refining unit. b. Install second fixed bed refining unit to handle all 1242; first unit to handle all 1254. 14.5 Process 8.5 Process Responsibility Unit installed, production to accept as manuf. unit at end of 12/10/67r- demonstra tion period.(12/10/67) T.S.D. to design based on data from first unit. EDC for installed unit-6/1/68. 2. Waiting on crude Charge trim size of chlorine valves on batch chlorinators. 35 Process Maintenance 3. GI2 plant down 4. Export grade Aroclor * ` 5. Inventory Adjustment Install drowning system so that Aroclor does not have accept CI2 air mixture during maintenance operations in chlorine plant. a. Same as 1. a. |b. Same as 1. b. i Install adequate finished product storage. 27.5 Other ' 20 Other . 12 Other 44.8 Other T.S.D. to design drowning system - EDC? 1. a. 1. b. . C.E.D. design package; estimated installation date 10/15/68. 6. a. Low CI2 pressure b. Empty Cl^ cars 0265539 Install RR spot/loading station to handle additional cars. 17.3 Other Project approved,- T.S.D./ consultant design package ready by 12/15/67. ha>3 wrt> C/i o o(r-** Ln O O' TOWOLDMONOQ44036 Section 6 Page 6 Solid Aroclors A summary of the Solid Aroclors production is as follows: 1966 1967 YTD (Aug) Actual production Scheduled production Capacity rate (Ibs/hr) (1) design (2) demonstrated O.S.T. 8,287,766 9,435, 599 1247 1789 73.23 6,280,503 6,275,675 1289 1485 79.17 Design capacity for the plant is 10 M lb/yr.; design rates for 1967 have,been adjusted to reflect the change in O.S.T. standard, 907 versus 93% (1966). When discussing capacity it important to remember that the plant ability is measured by both O.S.T. and capacity rate. For instance, in 1966 a 1789 lb/hr rate was recorded with an 81.46% O.S.T. and a 1312 Ib/hr rate was experienced with 88.69% O.S.T.; YTD O.S.T. was 79.17% with a 1349 lbs/hr,The first objective in the solid Aroclor area is to reduce as many downtime causes as possible in order to improve the O.S.T. and_maintain capacity rates at levels required to meet design production (10 M lbs/yr). Appendix V presents a tabulation of the non-productive time for 1966 and 1967 Y.T.D. Table _____ is a*comparison of downtime for 1966, 1967 Y.T.D., 1967 projection, and the standard values. TABLE Solid Aroclors Downtime Comparison Standard Hours 1966 1967 YTD (Aur.) 1967 Prolection Repair Process Other 431 172 172 775 732 1039 486 2257 630 209 168 1007 945 314 252 1511 Corrective actions for some if the downtime causes are presented in Table . Predicated on the successful completion of the proposed projects, future downtime is estimated at: Repair Process Other 868 313 104 1285 __ This nop-productive time represents 14.8% downtime or 85.2% O.S.T.; at 10 M lbs/yr. ^his would be capacity rat of *1360 lbs/hr., this rate has been demonstrated. To produce more than 10 M lbs/yr there must be: . 1. bottleneck elimination 2. improved yield 3. Improved O.S.T. 026^-0 TOWOLDMONOQ44037 Section 6 Page 7 ' Th most immediate bottleneck is the solids flaker; this unit can process 10.2 M lbs/yr. A new flaker capable if handling 16 M lbs/yr is to be installed, estimated incentive for this new unit is presented in Appendix VIII. Timing of this installation will depend upon whether the unit is to be part of a CED design package or an in-plant project. The estimated capacity of the solids system is: 1349 lbs X 8640 hr X .90 O.S.T. X 90 goal yield = 13 M lb/yr hr 4 yr 73 actual YTD yield To gain this 13 M lb., yield must be improved from the YTD 737. to 907. and the O.S.T. advanced to 907.; the improved O.S.T. must be gained while maintaining at least a 1349 lbs/hr capacity rate. A increase in yield can be gained by an improvement in the quality of the crOde (5060) produced in the No.9 chlorinator. From January 1 - January 4, 1967 the solids still had difficulty in finishing a distillation and experienced high evaluation of HC1 at the end of a batch. The problems were traced to high quaterphenyl content (17.207.) in santowax R for the new still system. A lab oratory investigation of this phenomena reported that not only did reduced quaterphenyl content improve yield but also reduced the chlorination time. Based on these preliminary lab results, the first estimate of the capacity gain at a 57. quaterphenyl content would be: 1590 lbs X 8640 hr X *90 O.S.T. X 90 yield *= 15.26 M lb/yr. hr yr ' 73 yield YTD This calculation assumes an 2 hour decrease in chlorination time and an improvement in yield to 907*. A plant study on the effects of varying quater phenyl content is scheduled to be completed by December 1967; data from the study will permit a firmer estimate. The program to-date has the ability to improve the O.S.T. to 82.57.; continued planning and updating of the project networks will be required to push the O.S.T. to 90%. Efforts will be continued to define targets for O.S.T. im provement. * Another opportinuity to gain in capacity to gain in capacity rate is in chlorine quality; YTD chlorine delivered to the Aroclor chlorinators is 82.47., chlorine quality at the header from the CI2 plant is 907.. The chlorine used in the solid system has a higher quality since the CI2 vaporizer output is predominately used by solids, estimated quality is 907.. However if the delivered CI2 quality can be raised to 907. the solid feed chlorine quality would become approximately 94.5%; this could raise the capacity rate from 1349 lbs/hr to 1415 lbs/hr. If the SW-R yield studies, are fruitful that projected 1590 lbs/hr could be raised to 1672 lbs/hr., 16.02 M lbs/yr at 907. O.S.T. and 907. yield. Based on the analysis it would appear that Anniston can meet the solid goals through 1970. If the solids market continuies to expand it may be necessary to install a second solids chlorinator. . .t A summary of capacity calculations is presented after Table `. 0265541 TOWOLDMONOQ44038 . Downtime Cause 1. Still circulatin line plugged TABLE Corrective Action Install flowmeter capable of withstanding high temperatures Time Savins Hours 11.3 Process 46.5 Repair Responsibility * TSD select and install instrument - EDC - ? 2. (a) Switch CI2 car (b) Low pressure, CI2 cars (c) empty CI2 car Install RR spur to handle two additional CI2 tank cars; loading stations will be required. 148 Other Project approved; TSD working on design, installation will be construced - EDC 2/1/68 3. Cl^ plant down 4. (a) Chlorinator pump (b) Cl^ distrubutors Install drowning system so that Aroclor does not have to accept C12/air'mixture during maintenance operations in Cl plant. ^ A Improve availability of spare parts 90 Other 30 Repair TSD to design system EDC Maintenance zn ctoo a n> <-f o1S> oo o 3 O' \r O' > rv TOWOLDMONOQ44039 Section 6 Page 9 Solid Aroclor Production Potential October 18. 1967 17. 500 lbs batch * @ 16 hr/batch 13*hr/batch * includes downtime 1 = real cycle 1. No damage in yield or cycle time: improved O.S.T. only 17,500 lbs x 8640 hr x batch x .7917 O.S.T. = 9.21 M lbs/yr . batch yr 13 hr 9.21 M lbs/yr x 8500 = 9.88 M lbs/yr .7917 9.21 M lbs/yr x .9000 = 10.48 M lbs/yr .7917 2. Yield raised from 73% to 90% lbs/yr O.S.T. f' 11.38 12.18 12.92 .7917 .8500 .9000 . 3. Yield raised from 73% to 90% and cycle time dropped from 13 hrs to 11 hrs. lbs/yr O.S.T. 13.42 14.40 . 15.26 .7917 .8500 .9000 4. Yield = 90% cycle time = 11 hr improved Cl,, quality; YTD supplied by Cl. plant = 82.5 % YTD at solid chlorine = 90%* ^combination of CI2 plant, chlorine + vaporizer supply Target quality 94.5 for solid system lbs/yr O.S.T. . 14.10 15.10 16.02 .7917 .8500 .9000 0265543 TOWOLDMON0044040 It, FT Ibb/^R. ' i* 13 12. 11 C-V Cus" * VI t*2*>, t<_ QvMiTV a V>vo 9o -C.VCVC" . \\ ttf^V (^GMU7>1 a> ^vo 0 1 *p QJ V >H PI St-*.o So oa.io > i'J uej,. VVSS920 S ection 6 Page 10 7S SO SZ. s-f- S4 SS So 92^ TOWOLDMONOQ44041 Section 7 Page 1 Cost Analysis 1. Cost Variances Table I presents a summary of the YTD variances (July 1967) for Liquid and Solid Aroclors. Comments on the individual variance items and copies of the YTD dost report are presented in Appendix X. . The total product cost variance for 1967 is projected to be $340,000; of this amount 74% ($252,000) will be in direct conversion costs. These costs are due for the most part to unforseen increases in TSD, Research, and Experimental costs and in some items unrealistic cost standards. A savings item in this cost category is the production department containers; this cost in incurred by the present procedures for handling the waste Montars ' from the Aroclor plant. A study is being conducted to determine possible alternate handling techniques, potential savings are estimated to be $9,300/yr. A target in the material costs is chlorine. Total CI2 variances for the Aroclor plant amount to approximately $70,000/year. Programs required to reclaim these costs include (1) an improved monitoring system for the cell efficiency in the chlorine plant, (2) a study to determine how to improve chlorine quality, and (3) a study of chlorinator efficiences in the Aroclor department. Anticipated dates for the recovery of the $70,000 are not available at this time. Of particular interest are labor savings to be gained by the installation of improved drumming, flaking, and storage facilities (CEA 1430) in the Aroclor department. Labor requirements to meet projected production rates are compared below in two categories, with existing facilities and with the improved plant: (CEA 1A30) Year Existing Plant Improved Facilities 1968 1969 1970 1971 11 12 12 13 8 8 8 8 Labor savings by CEA 1430 may range from $30,000 to $50,000/yr. An unusual cost item is the handling of Montar 5 which is the residue from the Solids still. The material is solid in three basic forms (1) coarse crush 375 lbs/drum (2) fine crush 375 Ibs/drum, and (3) fine crush 350 ibs/drum. A comparison of selling price and cost are as follows: $/lb Selling Price Cost Coarse crush 375 lbs/drum $.053 $.0569 Fine crush 375 lbs/drum . ' $.053 $.0835 Fine crush 350 lbs/drum $.053 $.0606 02655A5 TOWOLDMONOQ44042 Section 7 Page 2 A study will be made on the production of labor costs in the handling of this product. However this will continue to be a marginal item since drum/material costs are as follows: mk Drum/Material Costs . Selling Price Coarse crush 375 lb/drum Fine crush 375 lb/drum Fine crush 350 Ib/drum $ .0412 $ .0412 $ .0412 $ .053 $ .053 $ .053 The required reduction in labor costs is a; Present Labor follows: Labor Cost to match Manuf..Cost Labor Cost Reduction Coarse crush 375 Ib/drum Fine crush 375 lb/drum Fine crush 350 lb/drum $ .0157 $ .0423 $ .0183 $ .012 $ .012 $ .012 $ .0037 $ .0303 $ .0063 TABLE 1 YTD (July 1967) Cost Variances for Aroclors Direct Cony. Indirect Material Cost Cost Conv. Product Cost Liquid Total Solid Total $ 18,234- $ 119, 794- $ 227$ 19,567- $ 7,648- $ 5,857- $ 138, 175 $ 42,615- Potential Raw Material Savings # Improve Santowax R/Biphenyl yields in the Solid Aroclors product line. If all yields can be raised to 90% the following material savings potentials exist: # 1968 1969 1970 1971 1972 Solid Aroclors $30,100 $33, 800 $ 38,200 $ 41, 700 $ 43, 700 < Production Cost Standard yields are as follows: Santowax R Biphenvl 1269 4465 5442 5460 78 92 78 78 78 YTD (July) yields are 73% vs. 78%. 0266546 TOWOLDMONOQ44043 ' Anniston, Alabama September 22, 1967 . AROCLOR COMPETITIOH George R. Buchanan General Offices Section 8 Page 1 ' A Manufacturing-Improvement Plan is being prepared for the Aroclor product line at Anniston. Ona section of this report is entitled competitive technology.Comparison of competitive materials has been performed at Annioton, however, a description of the competing companies is not available. Can you provide data on Beyer, Prodelec, and V Items such as home office, assets, product linos, etc, would be most desirable, . Thank you JM:kd John MacPhoreon 0265547 TOWOLDMONOQ44044 Anniston, Alabama November 8, 196V 1 Section 9 Page 1 R. C. Loyer Patent Attorney General- Offices A Manufacturing Improvement Plan is being prepared for the Aroclor product line at AnniBton. One section of: this report 1g entitled patent status. Can you furnish a brief description of the patent situation for the Aroclors? , Thnnk you. JMPikd John MacPherson TOWOLDMONOQ44045 Section 10 Page 1 Stream and Air Pollution A survey of the Aroclor plant pollution will be completed by ` 2/15/68. 026554*9 TOWOLDMONOQ44046 TOWOLDMONOQ44047 A ;VENT c" r\ -WATER OUT rj[___ -XXX i fil1-l AROCLOR FEED FRO/A BLOWING "ANK OR ROOF TANK t7 ', luCc)------ \ wI II li II HT~n ('I STILL RECEIVER PUMP np^/cuu jla x ~ r . STEAK'; VACUUM JET FILTL-R ARCCLCR STILL- FLOW SHEET TO AFOCLC STORAGE TANKS, TA'CARS. OR DRu.v.3. - ' f T 0265551 ANNISTON PLANT - MONSANTO CHEMICAL COMPANY - ANNISTON. ALA. TITLE . AROCLQR STILL- FLOW SHETET . AUTK.-NO. - : DRAWN 0Y HAE APPROVED DATE 3-IO-&4 SCALE MONE job no. : . DEPT. ARCCLOR TS-A-704 TOWOLDMONOQ44048 TOWOLDMONOQ44049 TOWOLDMON0044050 & j- ^ ^ ' 1 " ^ * rx&***,**Lvtetrr** -. ^ j? ***** r*axm&\ / ^t , ,, > -- *" </ .' -'i: ' 'f*-'-^A- :- - * " ^-v.--XX f^ X * < XX -- - ,5-^*-. /*? ?,' i" tv.Jj,4jS , . #"WrK------/ ' f7'f [. tV\ '4^tl X ;^fc4;r * sas^r - - "X *' ;> @* ^ . ,, .. ^s. Xs> wr/wr^.T ,,>^.v,,. T- . - 0*=O-VXf%^l ~C" . > "' ' , . **.' >.---- J>.<' V&v*' * .?-^ " x^iy.' " ;> J, ' *- *!&!* "V /-J%TVt ^o-'"\ fc >* f&? * ,s,, , ,, .V V y?s *, $ 'fyi^A %&.-, 0265554 TOWOLDMONOQ44051 0265555 TOWOLDMONOQ44052 BY ............ DATE.^/?TMTM. CHKD. BY!?A*yft:.DATE.S#./$.k.. SUBJECT........................................................................... SHEET NO JOB NO...... .OF. Section 12 Appendix I Page 6 MCC ABSORBER 0265556 TOWOLDMONOQ44053 BY..5,kjd*?,..... ...DATE.f.h/kk. CHKD. By3AvftV: .DATE ^JA. SUBJECT.................................................................................... ..Ll.QD.IL)..M-.QEE' CrPiZi....CL&AV. FROM cdiortiNAT&Ct* t-4- .......... . SHEET NO.................OF. JOB NO............................... Section 12 Appendix I 0265357 TOWOLDMONOQ44054 Section 12 - Appendix IX COMPANY CONFIDENTIAL I Report No. _ RESEARRCCH AND DEVELOPMENT REPORT ANNISTON PLANT I Job No._ R Date____ Page 1 1 370-503 5-5-67 OTHER LOCATIONS J. R. Savage - WGK P. E. Heisler - WGK D. C. Armstrong - WGK A. F. Regan - MCL C. R. Coleman - MCL H. L. Hubbard - So. 2nd GENERAL OFFICE H. C. Carder P. G. Benignus R. A. Steenrod G. R. Buchanan H. 0. Hehner R. A. Munch C. M. Williams J. Cresce ANNISTON PLANT W. B. Papageorge L, C. Fuhrmeister J. MacPherson J, G. Bryant V, R, Haupt W. B. Dunlap Title: Quality Report on Japanese Kanechlor 300 and Bayer Clophen A-50 Personnel: Problem: S. 0. Kemp and G. W. Miller Quality Surveillance of Competitive Insulating Fluids in Competition with Monsanto Aroclor Justification: Protection of Domestic Sales and Increase Potential for Foreign Sales Summary: Bayer Clophen A-50 is quite superior to Anniston and WGK Aroclor 1254 in , electrical properties. This material as received exhibited a resistivity ' of 150,000 x 10^ and thermal' chemical chloride stability of 0.27 ppm. Japanese Kanechlor 300 is also superior to Anniston and WGK Aroclor 1242. Even though this material had a 9,600 x 10^ resistivity and 0.08 ppm TC it is still considerably better than any routine domestic production in Monsanto operations. ' /dp Gl W^Miller 0265558 TOWOLDMONOQ44055  Research and Development Report No. 1 Job No. 370-503 -2 - Section 12 Appendix XI Page 2 Background The last report concerning competitive Aroclor type material was issued during October 1966. In that report (435-5-66) a comparison of Clophen A-30, Pyralene 1499, and Aroclors from the three Monsanto production facilities was presented. Also presented was a comparison of Pyralene 1476 and Anniston Aroclor 1254. The additional data presented in conjunction with values cited from the above report should serve as a useful data source for summarization of Monsanto's marketing position at the end of 1966. Discussion Bayer Clophen A-50 This material was received in a 16 gauge, welded seam galvanized steel drum. Even though the drum was equipped with rolling hoops it was dented in several locations during transit. It is apparently characteristic of Bayer to use drums equipped with side wall bungs. As in previous sampling of competitive drums this material was sampled by insertion of a clean glass tube and displaced into clean bottles with dry nitrogen. One sample of the material was obtained at room temperature; however, due to the high viscosity the drum was necessarily transferred to the Aroclor Department hot house to aid in sampling. Analysis of the sample drawn prior to warming the drum gave a resistivity of 190,000 x 10. This value could not be achieved after warming. Several replicate tests on the samples collected from the warm drum showed a maximum of 150,000 x 10. All stability tests were performed in duplicate or triplicate. The dielectric fluid compares favorably with Monsanto Aroclor 1254 specifications in all areas except that gravity and index are too low and the dielectric constant is above our spec limit. Isomer distribution and a full analysis report are included in the attached tables. Japanese Kanechlor 300 This material was received in a 35 gallon welded seam galvanized steel drum. This material was sampled Indoors without any heat being applied. The material was submitted to at least two analyses on all electrical and stability properties. . There are no test properties on this material which are not within the specification limits of Aroclor 1242. Isomer analysis and a full analysis report are included in the attached tables. 0*65559 TOWOLDMONOQ44056 Research and Development Report No. 1 Job No. 370-503 -3 Section 12 Appendix II Page 3 Future Two five pint samples of these materials are being forwarded to WGK for analysis. It would be appropriate to report WGK results on the aforementioned materials in this report; however, in the interest of having this data available at the May 9 quality conference the report contains only Anniston results. If serious dis crepancies develop in the data comparison with WGK, a follow-up report will be Issued. /dp Att. 4 G. W. MilTer TOWOLDMONOQ44057 ` Research and Development Report No. 1 Job No. 370-503 -4 - Section 12 Appendix II Page A ' ' Table I Comparison of Competitive Materials With Monsanto Aroclor 1242 Property Bayer Clophen ' A-30 Prodelec Pyralene 1499 " Anniston AH-248 MCL Z-16 WGK B #450 Kanechlor 300 Japan Color, APHA <5 <5 15 15 15 10 Acid No. 0.001 Ref. Ind. @ 25C 1.6237 Sp. Gr. @ 25eC 1.378 Vise. @ 100F, SUS 79.8 0.002 1.6245 1.387 85.7 0.001 1.6248 1.386 90.2 0.001 1.6249 1.388 86.9 -- ... ... ... 0.001 1.6248 1.390 Moisture, ppm 63 Free Chlorides, ppm 0.01 35 0.01 30 0.01 52 0.01 28 0.01 24 O.OO? 0^09 HST, ppm Cl 0.11 ( n. Stab., ppm Cl 0.06 0.16 0.14 0.06 * 0.11 0.32 0.12 0.50 0.16 0.11 0.06 TC Stab., ppm Cl 0.07 0.12 0.28 0.48 0.48 0.08 West. Stab., ppm Cl 0.40 Resist, x 10, OHM/CM, 100C P.F. @ 100-C 60 cycles 1 KC 15,200 0.22 0.06 0.48 1,270 4.6 0.33 0.51 1,980 2.0 0.17 1.56 1,900 0.93 1,030 3.4 0.25 4.8 0.28 0.36 9,600 0.55 0.13 D.K. @ 100"C, >M>cvcles Distillation 107. 90% 4.90 327 348 4.87 330 352 4.83 328 352 4.80 327 348 4.90 -- 4.82 331 352 Type drum Steel, galv. Steel, welded dlpped, seams. Type of 16 ga. lining to be determined One coat phenolic lining Two coats Bottle phenolic lining Steel welded seams, ga lvanized Appearance of drum Good, no . dents Head bent, rim seam split, lining flaking Good as produced Good, no major dents Bottle Good *6556J TOWOLDMONOQ44058  ' Research and Development Report No. 1 Job No. 370-503 -5- Section 12 Appendix II Page 5 - Table II Comparison of Competitive Material With Aroclor 1254 Test Date Property 10-15-66 Prodelec Pyralene 1476 10-5-66 Aroclor 1254 AH-68 4-30-67 Bayer Clophen A-50 Color, APHA 10 20 7 Acid No. 0.002 . 0.002 0.001 Ref. Ind. @ 25"C 1.6380 1.6382 1.6365 Sp. Gr. @ 25C 1.503 1.504 1.490 Vise. @ 210F, SUS 46.2 45.9 Moisture, ppm 30 20 30 Tree Chlorides, ppm 0.02 0.02 0.009 Hydrolysis Stab., ppm Cl 0.14 0.14 0.07 Thermal Chem. Stab., ppm Cl 0.32 0.30 0.28 We6tinghouse Stab., ppm Cl Resist, x 109, OHM/CM, 100C 1.00 3,180 1.13 5,880 0.62 150,000 Power Factor @ 100C, 60 cycles 1 KC 1.5 0.14 0.60 0.10 0.288 0.09 Dielectric Constant, @ 100C, 60 cycles 4.23 4.25 4.37 Distillation - 10% 507. 90% 368 370 365 376 376 373 387 388 387 Monsanto Stability, ppm Cl -0.18 0.14 0.10 Type drum Steel, welded seams, 16 ga. Type of lining to be determined One coat phenolic lining Steel welded seams. Galvanized rolling hoops ..^pearance of drum Good, no dents Good as produced Good 0265562 TOWOLDMONOQ44059 '' . Research and Development Report No. 1 Job No. 370-503 r" .' / -6- ' Table III . GLC Analyses of Competitive Aroclor 1242 Section 12 Appendix IX Page 6 Peak . Japan Kanechlor . Anniston 300 WGK England Bayer Prodelec Identification i 0.03 0.01 0.11 0.05 Trace 0.009 Biphenyl 2 0.79 0.01 0.13 0.18 0.003 0.01 2 Chloro 3-4-5 0.25 Trace 0.04 0.07 0.03 Trace 3 Chloro-4 Chloro 6-7 ` 4.39 3.02 3.30 3.69 4.91 3.44 2,2'; 2.6 8-9-10 11 11.79 1.15 8.57 1.15 9.98 0.74 10.19 1.26 12.36 8.91 1.19 1.06 2,5; 2,4; 2,3'; 2,4'; 2,3 3,5 12-13-14-15 J6-17-18-19-20 f 21-22-23-24 21.64 27.56 7.50 24.03 32.27 7.08 26.50 25.04 32.72 32.78 7.05 6.59 26.33 28.23 31,32 34.26 5.79 6.79 3,4; 3,4'; 2,5,2' 4; 4; 2,3,2' 2,5,4'; 3,4,2'; 2,3,4 25-26-27 10.04 10.22 9.69 8.84 8.58 9.51 3,4,4' 28-29-30-31 8.07 7.24 6.26 6.23 5.29 6.66 32-33-34 3.50 3.31 2.51 2.64 2.32 2.60 35-36-37-38-39-40 1.57 1.19 0.69 0.87 0.85 0.77 41-42 0.69 ' 0.62 0.23 0.36 0.46 0.40 43-44-45-46 ' 0.41 0.39 0.11 0.25 0.31 0.22 47-48-49 0.09 0.21 0.02 0.08 0.16 0.09 50-51 0.04 0,04 0.02 0.11 0.03 0.02 52 0.01 0.04 Trace 0.03 0.01 0.005 53-54-55-56 0.07 0.13 0.02 0.22 0.03 0.09 57 NDA 0.08 NDA 0.02 NDA NDA ^'-59-60 0.06 0.10 Trace 0.26 0.01 0.01 61-62-63 Trace 0.08 NDA 0.17 NDA Trace 64 NDA Trace NDA 0.10 NDA NDA 0265563 TOWOLDMON0044060 1 . Research and Development Report Ho. I Job No, 370-503 -7- Section 12 Appendix II Page 7 0 Table IV GLC Analyses of Competitive Aroclor 1254 Peak 1" Anniston 1254 0.015 WGK 1254 0.02 Bayer Clophen A-50 Trace Prodelec Pyralene 1476 Trace 2 0.01 0.36 . Trace Trace 3-6-5 Trace 0.16 0.01 0.12 6-7 . 0.07 6.04 . 0.23 Trace 8-9-10 0.46 0.19 0.75 0.30 11 0.05 0.01 0.03 0.04 12-13-16-15 1.09 o:48 0.76 0.90 16-17-18-19-20 1.59 0.81 1.11 1.35 1-22-23-26 8.34 > 7.80 8.03 8.08 25-26-27 4.01 3.59 4.61 3.32 28-29-30-31 13.29 13.09 14.27 12.35 32-33-36 16.11 16.24 16.66 15.80 35-36-37-38-39-60 17.77 18.23 19,35 18.10 41-62 13.14 14.12 12.85 14.26 43-44-45-46 . 11.05 11.65 10.23 11.93 47-48-49 8.32 8.77 7.10 8.70 50-51-52 1.98 2.02 1.68 2.10 53-54-55-56 1.56 1.56 1.37 1.36 57 0.64 0.66 0.39 0.80 58-59-60 0.50 0.62 0.50 0.46 61-62-63 NDA Trace Trace Trace A NBA NDA 0.02 NDA 0265564 TOWOLDMONOQ44061 Section 12 Appendix III Page 1 TABLE I THE WORLD MARKET FOR CAPACITOR AROCLOR Total Potential and Monsanto Share 1966 and 1971 (Estimated) DOMESTIC MARKETS Metric Tons C ud4 \ks USA UK Prance Germany Japan Total 166 Total 11,000 930 515 1,100 ...1,.1.0.0 15,245 Monsanto Share 11,000 930 0 0 0 11,930 1971 . Total Monsanto Objective 13,000 1,^00 1,000 1,400 3.300 13,000 1,400 0 0 9 20,100 14,400 NON-DOMESTIC MARKETS EFTA EEC E. Europe Asia-Pacific Rest of Americas Rest of World Total 740 1,370 305 330 1,035 370 4,150 Grand Total 19,395 285 200 90 235 975 100 1,885 13,815 925 1,850 725 665 1,940 600 6,705 500 0 300 500 1,900 400 3,600 26,805 18,COO OZ***6* TOWOLDMONOQ44062 Section 12 Appendix III Page 2 . TABLE II NON-DOMESTIC MARKETS FOR CAPACITOR AROCLOR BY AREA - BY COUNTRY Metric Tons Austria Denmark Finland Norway Sweden Switzerland Total Italy Belgium Holland Total Czechoslovakia East Germany Hungary Poland Romania Yugoslavia Total EFTA 12. 70 25 95 30 290 230 740 EEC '1266 800 350 220 1,370 EASTERN EUROPE 1966 20 100 15 70 15 85 305 1971 80 . 45 100 . 50 350 300 925 1971 1,050 500 300 1,850 1971 45 200 50 200 100 120 725 0265566 TOWOLDMONOQ44063 Section 12 Appendix III Page 3 TABLE II (continued) NON-DOMESTIC MARKETS FOR CAPACITOR AROCLOR BY AREA - BY COUNTRY Australia India Hong Kong Total Metric Tons ASIA-PACIFIC 2266 170 150 _10 330 1971 350 300 15 665 Argentina Brazil Mexico Canada Total REST OF THE AMERICAS 1966= . 100 250 135 550 1,035 mi 380 450 360 750 1,940 Israel South Africa Spain Total REST OF THE WORLD 1266 30 0 lie 370 1971 50 50 500 600 265567 TOWOLDMONOQ44064 Section 12 Appendix III Page 4 TABLE III ESTIMATED WORLD PRODUCTION CAPACITY* * USA Prance UK Germany Italy Spain Japan TOTAL AROCLORS Monsanto Prodelec MCL Bayer Caffaro Flix Kanegafuchi Million Pounds 80 . 10 10 10 2 1 _7 120 Tons 36,200 4,600 4,600 4,600 1,000 500 3,500 55,000 *Also produced in East Germany and Russia 568 TOWOLDMONOQ44065 TABLE IV KNOWN WORLD MARKET BY PRODUCER - 1966 (Metric Tons) MAJOR DOMESTIC MARKETS E.F.T.A. E.E.C. E. EUROPE ASIA-PACIFIC REST OF AMERICAS REST OF WORLD TOTAL M.C.L. 930 220 200 90 210 0 90 1,740 BAYER PRODELEC 1,100 155 805 115 50 50 . 0 2,275 515 365 300 100 50 0 -22 1,360 CAFFARO FLIX 0 -0 00 65 0 00 00 00 _0 250 65 250 KANEGAFUCHI M.C. TOTAL 1,700 11,000 00 0' 0 00 0 20 0 _____ 0 985 0 1,700 ' 12,005 15,245 740 1,370 305 330 1,035 ____ 212 19,395 O0TOO T*T03O tTt"Oot 3 P* D, O H 3 rsj v/ WM N? sj\ O' TABLE V R.M.POSITION Benzene Chlorine PROD. QUALITY 1254 1242 ANALYTICAL DATE PROD. STARTED Years PRODUCT RANGE SALES ORGANIZATION Strength Method Visit Frequency Customer Relations TECHNICAL SERVICE OTHER ASSETS . SUPPLY SITUATION ELECTRICAL AROCLOR TABLE OF COMPETITIVE STRENGTHS MCL/HC Buy/Make Make Good/Fair Fair/Fair Adequate 1951/1930 14 35 Very large BAYER Buy Make Good Good Adequate 1930 35 ' Very large PRODELEC Buy (Progil) Make (Progil) Good Good Adequate 1938-1939 27 Limited (Progil) CAFFARO Buy Make Good Fair Adequate Post 1945 Limited Good Direct/Agents Much respect Good EFTA (Large Comp.) Drums OK Bulk ? Good Direct/Agents Europe more than MCL Much respect Good EEC (Large Comp.) Drums OK Bulk Good Good Direct/Agents Europe more than MCL Much respect Good /f< . EEC (Progil) Drums OK Bulk Good Italy only Direct Italy OK Bit amateur Not as good Big Three Local Drums OK (H S S 9 Z 0 S e c tio n 12 A ppend I I Iix TOWOLDMONOQ44067 RESEARCH EFFORT NEW PRODUCTS AROCLOR . IMPORTANCE {!%) PRICE LEADERS/ CUTTERS PHILOSOPHY mcl/kc Needs MC/MCL liaison Yes ' BAYER Not obviously energetic No PRODELEC Very active Very active (1500) CAFFARO Non-existent No Small but valuable Small but valuable Large Medium - Stability Stability Leaders Cutters Common schedule Common schedule Common schedule To capacity S e c tio n 12 A ppend I I Iix Page 7 0265571 TOWOLDMONOQ44068 Section 12 6 Appendix III Page 8 TABLE I THE WORLD MARKET FOR TRANSFORMER ASKAREL TOTAL POTENTIAL AND MONSANTO SHARE 1966 AND 1971 (ESTIMATED) 1000 POUNDS - (FINISHED BLENDS) DOMESTIC MARKETS USA UK France Germany Japan TOTAL TOTAL 17000 650 6100 3600 1600 28950 ' MONSANTO SHARE . TOTAL 17000 25000 650 3000 0 7000 0 : 4000 0 2500 ' 17650 41500 2211 - MONSANTO SHARE 25000 3000 0 0 0 28000 NON-DOMESTIC MARKETS EFTA ' EEC Eastern Europe Asia-Pacific Rest of Americas ReBt of World 520 2000 175 620 3380 750 TOTAL 7445 30 0 25 . 270 3380 300 , x 4005 GRAND TOTAL *#" 35285 .21655 730 2500 250 750 38607 1040 9130 50630 200 0 100 500 3860? 700 5360 32360. 0265572 TOWOLDMONOQ44069 Section 12 Appendix III Page 9 . TABLE II NON-DOMESTIC MARKETS FOR TRANSFORMER ASKAREL BY AREA - BY COUNTRY 1000 POUNDS (FINISHED BIENDS) EFTA ; 126 Austria : 100 Denmark . None Finland ' \ None Sweden None Switzerland 300 Norway Portugal . 20 * 100 ' TOTAL 520 **r * \ Italy Belgium Holland . TOTAL EEC 1966 750 1200 50 2000 1971 150 None None None 400 30 150 730 1971 1000 1400 iqq 2500 ., * 0265573 ' ** TOWOLDMON0044070 Section 12 Appendix HI Page 10 1 EASTERN EUROPE 126 : -'I-/' ' 1971 Czechoslovakia ' None None East Germany . , ? Hungary . ' None ; None Poland Homanla ; i \ 25 ' : None . 50 None Yugoslavia ; 150 ' 200 TOTAL 175 . ' "/ 250 Australia India ' ; ASIA-PACIFIC ; 1266 ,i. r '280 'Ji; 1211 ' 350 \ 7, 34o . ' . . 400 Hong Kong None None . TOTAL . 620 ; 750 0265574 TOWOLDMONOQ44071 Section 12 Appendix III Page 11 REST OP THE AMERICAS Argentina 1266 70 1221 ; 120 .. Brazil ' Mexico , . 200 * ; 400 -.'w?:".: V.K,,, 170 . 300 Canada . Chill i1 Puerto Rico .r 2900 ' v. v` : ' . 20 ; -'V\' ' : . ' 10 , ...... ' 3000 : 20 ' t ' v ' 10 Panama ' . v 7___10 10 , , TOTAL 3380 3860 :V ; ' ' ' i. Israel ' k )' , - REST OP THE WORLD v/: .1966 ,, mi ` ` 7 ,, 100 South Africa v 150 ~' 200 : Spain . P. ' .akistan ; '. . J. : 500 700 " 30 ' ` - 40 v TOTAL 750 , 1040 -' . . i, iii- 1 .*.y *' } ' . <* '1 ^:'.v; ^;:. 5 "V 1 .,;V. H;,, V. _ oZ***7' ^ '1 . .. TOWOLDMONOQ44072 S e c tio n 12I I I A p p e n d ix Page 12 \ TABLE -H5- 32 KNOWN WORLD MARKET BY PRODUCER - 1966 . 3 1000 POUNDS (FINISHED BLENDS) ' MARKET MONSANTO UK BAYER PRODELAC CAFFARO FLIX KANEGA- MONSANTO FUCHI USA Major Domestic Markets 650 3600 6100 0 0 1600 17000 TOTAL 28950 Efta 30 270 220 ' 0 0 0 0 520 EEC 0 350 . 900 750 0 0 0 2000 Eastern Europe 25 0 .150 0 0 o'. 0 175 Asia-Pacific " 260 200 150 - 0 0 0 10 620 Rest of Americas 0 0 o' ' 0 0 0 3380 3330 Rest of the World 300 0 50 0 400 0 0 750 TOTAL 1265 4420 7570 750 400 1600 20390 36395 TOWOLDMONOQ44073 H. J. Day, St. Louis General Offices Section 12 Appendix IV Page 1 September 7j 19^7 .. LIQUID AROCLORS Requirements Through 1972 Mr. H. W. Tlppee .H, C. Carder G. R. Duchanan J, Cresce *5XoU Wrrmelstes. prK.'Helsler" D.. B. Hosmer N.- L, Sample R, P. Stevens Jack Molloy Hill Williams Bob Yates - HOARD - GBUCH - JCRES y ;v * ;Anniston " `'-''KrummriC - DHOSM - NSAKP - RSTEV - Krummric - Anniston - RYATE The attached shows the U. S. requirements for Liquid . Aroclors through 1972. This is based on sales estimates received by this group on August 17, 1967. Note that the forecast is down somewhat from that calculated on July 13., 1967^ Current Anniston capacity is 40,000 M lbs./year and WGK capacity is 28,800 M lbs/yr., total, 7o,800 M lbs./year. It might be interest ing to note that 7 months 1967 total liquid aroclor production has been at an annual rate of 73,700 M lbs./year and inventories at this writing are at a maximum. : Jms Attachment ....... .. v ' H. J. Day- '. ' '. 0265577 TOWOLDMONOQ44074 Section 12 Appendix IV Page 2 LIQUID AROCLORS 5-YEAR FORECAST (IN THOUSANDS OF LBS.) TOTAL REQUIRED FROM U.S. PLANTS Krummrlch 1242 1248 : 1254 1260 1262 1968 1969 1970 1971 1972 16,107 5,049 4,831 6,638 __ 121 32,750 19,037 4,596 5,039 6,953 135 35,760 21,484 4,571 . 5,462 7,345 145 39,007 23,772 4,447 5,957 8,140 155 42,471 25,572 4,861 6,257 8,485 165 45,340 Anniston 1242 1248- 1254 1260 1262 1221 . 1232 ": : DIV, TOTAL ; 28,636 1,782 8,647 2,291 630 110 593 42,739 75,489 29,745 1,98 9,426 2,360 649 120 463 44,671 80,431 30,691 ' 1,993 9,555 2,725 641 130 526 46,261 85,268 33,491 2,308 9,445 2.878 656 140 593 49,511 91,982 35,247 2,708 9,265 3,009 694 150 645 51,718 97,058 II. J. Day 9/7/67 . 02655 78 TOWOLDMONOQ44075 Section 12 Appendix IV Page 3 {L.J. Hay. St. Louis General Offices _ __ September 8, 1967 R. B. linger _ RBILG SOLID AROCLORS H. C. Carder J. Cresce - HOARD - JCRES REQUIREMENTS THROUGH 1972 Lou Fuhrmeister - Anniston D. B. Hosmer .. DHOSM Don Marriner - DMARR Mr. H. W. Tippee N. L. Sample R. P. Stevens - NSAMP - RSTEV W. F. Waychoff - WWAYC Hill Williams - Anniston Bob Yates - RYATE The attached shows the Anniston requirements for Aroclors through 1972. This is based on sales estimates received by this group on August 17, 1967. /Jms Attachment H. J. Day 0265579 TOWOLDMONOQ44076 Section 12 Appendix IV Page 4 SOLID AROCLORS FIVE-YEAR FORECAST (IN THOUSANDS OF LBS.) TOTAL REQUIRED FROM ANNISTON 1268 2665 , 4465 - < 5060 5442 5460 - S' Rated Capacity Deficit 1968 290 25 865 410 18b 8699 10469 1QOOO 469 1969 300 25 925 420 210 9780 11660 lopoo 1660 I2Z2 310 25 985 440 240 11150 13150 10,000 3150 1971 320 25 1045 450 270 12220 14330 1Q000 4330 1972 330 25 1105 46b 300 12800 15020 1Q000 5020 H. J. Day 9/8/67 0265560 TOWOLDMONOQ44077 Section 12 Appendix V Page 1 Liquid Aroclor Process Non-productive Time Plugged lines Waiting on room in blend tank Switch products Lack of still capacity Druming out receiver Waiting on crude Vacuum troubles Repack pump Miscellaneous 1966 DN RV 43.4 2.0 33.7 4.5 3.1 49.6 2.4 202.0 22.8 23.6 1.3 1.8 1.6 20.0 .-- 340.41 71.4 1967 YTD (May) DN 15.8. 23.0- 47.9' 4.1 11.3 102.1 1. 1966 DN Time report is for February - December, years' total is 355 including January. 2. Requires change to CI2 control valve trim. 3. Due to export grade 4. For projection, use 10 hrs. for WOR in blend tanks and 20 hours WOC. Liquid Aroclor Other Non-productive Time Faulty Cl^ car Low Cl^ pressure CI2 plant down No CI2 car Switch CI2 cars Empty CI2 car Poor CI2 quality Steam press line Product change Rebrick furnace Export grade Aroclor Lack of still capacity Inventory adjustment Product demand low Refining pilot plant Miscellaneous Water lines 1966 DN RV 15.9 2.3 12.5 17.5 7.8 6.4 7.2 25.2 16.1 9.7 15.9 .. -- - - -- 11.4 44.6 -. 23.2 50.0 91.1 ____ 12.0 ------ 318.9' 12.6 -- 65.5 1967 YTD (May) DN EL 7.1 27.5 -- - 10.2 .. 9.0 3.2 -- ___ -- ___ 0265581 - 32.0 44.8 15.0 44.4 14.3 204.3 -- - -- 3.2 TOWOLDMONOQ44078 Section 12 Appendix V Page 2 1. 1966 DN line is for Feb. - December, year's total is 369 including January. 2. For projection of 1967 YTD use only 16 hrs. for export DN, 0 hrs. DN for pilot plant, 3 hrs. for low CI2 pressure, 5 hrs. for empty cars and 0 hrs. for water lines. Liquid Aroclor Repair Non-productive Time 1966 DN RV Still receiver pumps 37.4 Still circulating pumps 28.2 Blend tank pump Catalyst check Chlorinator coil replacement Still circulatingcoil 12.0 CI2 vaporizer 90.6 Piping failures 19.8 Miscellaneous f' 4.0 1.2 18.5 '' 1967 YTD (May) DN 4.6 11.8 11.5 50.7 7.7 7.7 37.3 212.01 18.5 131.3 1. 1966 DN line is for File - December, year's total is 220 including January. 0265582 TOWOLDMONOQ44079 Section 12 Appendix V Page 3 Solid Aroclors Process Non-productive Time < CI2 feed lines plugged Chlorination cooler plugged Still circulating line plugged Waiting or flaker Vacuum trouble Waiting on crude Miscellaneous Waiting on room, blow tank Check softening point Plugged lines Operating errors Drumming 4465 Vaporizer 1966 DN RV 28.9 3.0 -- 70.3 159.6 194.6 37.0 186 37.1 2.0 92.0 57.0 21.0 21.6 61.4 21.0 -- *910.1 82.4 1967 YTD (May) DN RV 7.5 2.0 11.3 6.0 8.0 1.0 10.0 8.8 -- 45.8 -- 8.8 Solid Aroclors Other Non-productive Time 1966 DN RV 1967 YTD DN RV Santowax-R Cost Switch Cl^ car Low pressure Cl car Water in SW-R CI2 plant down Empty Cl, cars Cl, quality Cooling water problems Steam problems Therminol Tie-in Miscellaneous Product chcnge over Equipment modification Still Therminol System 83.5 38.7 88.0 66.2 32.4 13.0 32.0 38.5 39.2 88.6 487.7 -- 32.4, ' 72.1 75.8.1 6.51 17.6 39.7 24.11 2.5 11.5 11.0 30.9 27.6 7.5 8.8 31.7 -- 291.7 -- 75.6 1. Use 30 hrs. switching, 2 hrs. low pressure, 10 hrs. empty cars for projection time saving based on projection. 0265^83 TOWOLDMON0044080 Solid Aroclor Repair Non-productive Time 1966 DN RV Flaker-grinder gumming __ Therminol leak __ Demister No.9 chlo.rinator _ Weigh tank agitator __ Chlorinator pump __ Still pump 152.7 Still entrainment separator __ Chlorinator Cl^ distributors 31.8 Therminol system 75.6 CI2 vaporizer 157.7 Cl,, flow control valve __ Vacuum Jet 21.6 Burst furnace coil __ Miscellaneous 54.3 Off-gas condenser 48.0 Vacuum problems 64.0 Flaker 23.1 Steam leaks 11.3 Instruments o 89.4 5.0 35.0 729.5 40.0 Section 12 Appendix V Page 4 1967 YTD (May) DN RV 51.7 55.8 23.8 11.5 18.0 13.0 82.8 33.0 35.5 7.0 13.1 9.0 46.5 66.0 __ _ 51.6 _ __ _ __ _ _ 15.0 __ _ _ 466.7 66.6 0265584 TOWOLDMONOQ44081 teVCiN5*T<sQ CftCv^Ty '^<.<1 t^-to fl-y > S e c tio n 12 Appendix V I Page 1 0265585 TOWOLDMONOQ44082 TV fa*) [O 090 / looo bQu'O Anoexuf*. QuAO-Ty 6iM.^ C<*-*WvWlfy A- lo,Na es>*VTvvtry o^ V^A^Tu*** tsv^iOT 6n*oiy /w^cioAS 'U42./ij.r4, 0>Hm D>-m< 98SS9?0 S e c tio n 12 Appendix V I Page 2 \ *on TOWOLDMONOQ44083 TO CO cro u^iop Amcu>g. capftoTv Poj*tecrc fctMQAJ VTrttTl? F'*/>/<> sr ^r Wiury ^ts^^Tvost >t^, c r *+' \w./n^.. 'W'S'/fcOi ^A&v<.Ti8m VC'fc. /^.. \o/v**/fcv S e c tio n 12 Appendix V I Page 3 0265587 TOWOLDMONOQ44084 Section 12 Appendix VII Page 1 VII. MIP Contributors 1. Production - a separate section will not be written by the Production Supervisor since the basic outline of the MIP developed in conversations between Production and TSD. 2. PR&D - to be written by 2/15/68. 3. Quality Operations Control - to be written by 2/15/68. A. Maintenance - to be written. 0265588 TOWOLDMONOQ44085 Authority No. 2026 2098 2219 2239 2323 2324 2342 2379 2545 i ! i ! I 2566_________ ! TABLE Description Approved Prolects ' Piping to Manifold Instruments Aroclor Still Revision Aroclor Alarm System 1 Department ( | 826.08 * 826.08 i 826.08 Capital 11.000 * Savings B.T. 1 l ! Success Factor 90% 13.600 1.450 5.900 2.870 857. ! 607. Fixed Bed Tower for Refining Aroclor 826.08 Level Indicator on #4 Still Receiver 826.17 i Vertical Condenser on #4 Still ! 826.17 Railroad Spur for Chlorine Tank Cars 826.17 Drumout line for Aroclor 4465 Debottleneck Liquid Aroclor Still System i" i 826.17 ] 826.08 Platecoil Heat Supply for ] #1 Roof Tank______________________________ I 826.08 2.515 1 2.020 | i 16.600 ! Quality 1.500 - 6.800 31. 700 ! 21.200 ! 1.495 ! 3.400 907. ' 757. 857. 857. 907. ' 17.130 '221.000 857. j i. j ' 1.500 :____________________ ! 100% S e c tio n 12 Appendix V III Page 1 0265589 TOWOLDMONOQ44086  *V' .. ' 'oVm yt 7-0 ^*-.1 *C \ 2_ S-Q* X *- ' U^UW3 . . / '. .- - ^ '. . '. . .. .: . 'y- ' .- . . ..-- ' : '. ' - - ^ --r- - ' -- r.". 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STH.V. sn'o`. 3-^V/ Sko'i'i Hi-OV OP6t2A-to*JA<. no*. 416 /-***- ^>0' 4 vru,\_ j-y . tkteu_ v: . .' n.......... ? ? * Sto: 41.x / VCt*-C>V . .. .6ft . . .. MOM CjqP ?IATB OsX. . , q | *o i*j^AUATie\J . ` *. j-io *, 4ft %/ . . . `. .. Jin .- . .i ... . . ; . . . - .' ..... . . . ". . . .. . uo: .' ' . 324 %.t, %, . .,, 00 .CocaU'TTl-'T'T?A"COA ClHeaMATo^6 Xo PV CooT'/ua-ftic^ . . .. no* / . . . ............. . `ttftifOV . ea"ofiAvwjcff XiAW7oo*Me^r M**J cvwjOiUCErfi. %A6.i"7 5-10: 4S"| / ajst f ..... . . 142... ' - -' . . ' . ... ; -; ;. 7J- '._ ' $ z C wueiivtT ShWLv ^ystm J-io*- +S^ f . no; 4-r3/a5 4-J- > ;: %.V 1*6.17 0265590 . . .' - -40 - // , , J Cvz.` / STaQ-*&6 tw *>TKHsA / KkjTwv t^iibuue.. ^ >, ^-4-j / 5Cg.^ /, -- ^V3VTa.ijCc. 'O CsiJ 0C-Ci.4 14*40 Kj^STD "to IsV^N^Te U,V.Tg CA-T-6CiTV l*P Co^^ju-CW^ . tv%re*j , kiXa'vi.oG' / . ' - fiVO ' .. .. 60 10 O -- \ t FL^vcer*. \tAPOoviftNkg-AiT Vt.ov no *. 4S^ / 449d _ .\ I^ivTca'Ac& ua-siOust^ ^*o ; 4rv y ' x *5"Jo : +6 t . ; .. . . 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P<ZaU-<N3^ oP So<_t J> ' ". ,4b. ! ` -o * 0 *S7o; "7isr . . ... -_ .* * _ # P utc<^ .. . . . . . | ............... .... . . 4o . ._ C ? 0 3n^-. "I02_ / r?Mm AojcXott. ^"4^3 YueX<Ji l>n' ' ' .' JlSPT. ; X j ; .. ' / *- . '- " t^otBxu ^ ^fAC ', . 4^0 .'... ' -34*.; " " ' ......... \ 'X-" ..; . av " <? A< UO*S TAajvC. 37D' 714- /y4L_ ' CcU., AJ >4- Vt\u_ weviTtJi Co'u ` .' : >.+- cQ o* f ^yttAAjoL -JTtf. *7<U/ "CiVsj\C. ' ' . ...... ,. - '.,# . * 't ' ' ' <V ' ' . " i . 1 d? ? _ 1- ; ^TAPv> /NiTrto^Wo/ CULO'V^tf Mb*ras ' n.-. t*c/ . : *TJTAU- Ul's l.*c?u`d C2eJ>,v^^ -i"7o', 7^Tfa/aC4C . . KjrTfWVf/o 5c^*oiC.UT U<?. 6A4 & -* 17o 77 /aTi<V- ' . vj,<4-v._ k;i*Ke i .4 %7: 771- ... . 14 X o 0 nc ; *' ' isio-cy j i ' rr 'rli-OV P] J; sir Vi*.eV 1 S-X..JV 3 3' 3 2. <, Vit.cV H HH 1 33 9' 3 . -- - TOWOLDMONOQ44089 References 1. TSD Job No. 370-500, Report No. 2, 4-20-67. 2. TSD Job No. 370-500, Report No. 1, 2-13-67. Section 12 Appendix IX. Page 1 0265593 TOWOLDMON0044090 Section 12 Appendix X Page 1 Cost Analysis A. Liquid Aroclors Cost Variances 1. Net material cost: major contributor (76% of total variance) is the chlorine cost; delivery of plant chlorine to Aroclor is based on cell efficiency, standard is based on pegged numbers. A program is planned for the improvement of cell efficiency monitoring. . 2. Indirect conversion: .. (a) steam - this is an assigned valve, true value will recorded when steam meters are installed. . (b) gas - negative variance is a result of pushing the stills (lower efficiency) to gain higher production rates (c) labor - variance is the result of high overtime (d) packing containers - high negative variance is the result increased export demand and the use of an improved drum ($0.50/drum) (e) laboratory - high production rates have required increased laboratory effort. (f) production department containers - increased production rates have exceeded predicted usage (g) Pilot plant exp. - high positive variance resulted from delay in project for waste heat recovery (h) Technical Services - increase in personnel assigned (i) experimental - bauxite, refining unit was installed under experimental expense funds (j) research expense - increased activity (k) plant process research - increased personnel assigned plus higher activity level a) mechanical expense - low budget B. Solid Aroclors Cost Variances 1. Net material cost: major contributor (70% of total variance) is the chlorine cost; again this is a pegged value rather than a true measurement. The program planned for the improvement of chlorine cell monitoring will improve chlorine assignment to 6olid Aroclors. 2. Indirect conversion: (a) steam - this is an assigned value, cost should improve as steam meters we installed. . (b) gas - YID reflects three months below capacity production 0265594 TOWOLDMONOQ44091 Section 12 Appendix X Page 2 (c) packing containers - low estimate of required amount (d) laboratory - YTD reflects increased sampling in previous months with production difficulties , (e) technical services - increased personnel assigned to department (f) mechanical expense - low budget 0265595 TOWOLDMONOQ44092 ICO ST REPORT YEAR TO OATE ( '............. ... .......... Section i2 (- Appendix X - Page 3 ORGANIC DIVISION ANNISTON* ALA. `LIQUID AROCLORS DEPT. 82608 PRODUCTION CODE 82608 ACTUAL PRODUCTION - YEAR TO OATE 25,815,494 ^ SCHEDULED PRODUCTION - YEAR TO DATE 25,822,500 JULY 1967 ' . MATERIAL YEAR TO DATE QUANTITIES OR EXPENSE ACTUAL QUANTITY SCHED. QUANTITY OVER-UNDER SCH. STEAM MBTU 60*085 60,412 19,673- 53 0 ELECTRICITY CKWH . HATER PLANT MGAL 8,881 268,373 10,325 257,682 1,444 ' 10,691- 533 542 GAS MBTU 54,472 -47,337 7,135- 54 5 LABOR HRS 16,903 15,287 1,616- 570 PACKING LABOR 4,956 4,956 601 LABORATORY HRS 2,449 1,931 518- 610 CLAY ATTAPULGUS ` 25,100 '33,560 8,460 19400 FERRIC CHLORIDE 2,055 7,745 5,690 33510 LIME HYCRATED 141,967 129,078 . 12,889- 38800 NITROGEN ' PORCCEL ' 154,000 14,185 . . , . . J .. 154,000- . 43100 14,185- 48289 ' BIPHENYL 14,786,618 14,914,095 127,477 82601 CHLORINE 25,882,425 25,117,633 764,792- 82638 HCL 100* 12,193,770- : 12,193,770- 82851 MCN1ARS 876,248- ' 613,831- 37,583- 82868 0- 0 o; o; o; o; o; o; o; o; o; o; o; o; o; o; MATERIAL OR EXPENSE CLAY ATTAPULGUS FERRIC CHLORIDE LIME HYDRATED ( NITROGEN V PORCCEL BIPHENYL CHLORINE HCL ICO* MONTARS . IET MATERIAL COST : . : . . : : YEAR TO DATE AMOUNTS ACTUAL COST SCHEDULED COST ;OVER-UNDER SCH. ` 985 1,397 412 . 329 1,242 913 1,586 . 1,442 144- 330. 573 * . ^ - * * - ' . 330573- 709,327 715,543 6,216 641,210 621,871 19,339- 198,148- ' I9e,148- 15,328- 161,328- 1,000- 1,140,864 1,127,019 13,845- 19400 33510 38800 43100 48289 82601 82638 82851 62868 '- * 0 0 0 0 0 0 0 0' 0' RAW MATL. HAND. TOTAL MATERIAL .COST 4,389 :1,145,253 1,127,019 4,38918,234- 530 0< *** __ A.. 0245596 TOWOLDMONOQ44093  ........... -a ?............. ............... . '. 0 4 ' Section 12 Appendix X Page 4 C'- ' COST REPGRT YEAR TO DATE - ORGANIC DIVISION o ANNISTON, 'LIQUID AROCLORS DEPT. 82608 PRODUCTION CODE 82608 ACTUAL PRODUCTION - YEAR TO CATE 25,815,494 . SCHEDULED PRODUCTION - YEAR TO CATE 25,822,500 JULY 1967 ' STEAM ELECTRICITY ' HATER PLANT GAS LABCR . SALARIES . . PAYROLL OVERHEAD ( SUPPLIES V. PACKING LABOR PKG CONTAINERS PACKING 0/V LABORATORY i CLOTHING LAUNDRY PROC DEPT CONTNR PILCT PLANT EXP TECHNICAL SERVIS EXPERIMENTAL RESEARCH EXP PLT PROCESS RES . MECE EXPENSE TOT DIRECT CONVERSION TOT DIRECT MFG. COST ! DEPRECIATION FACT. INC. EXP. TOTAL INDIRECT CONV. PERFORMANCE VOL. TOTAL PRCDUCT COST , ' PRICE 6 MAT. MIX UNSCHEDULED CAP. INV. VALLE TOT VAR. 39,293 5,716 5,770 16,295 63,681 9,862 13,318 .. . 11,699 15,716 96,401 3,543 18,007 1,379 11,718 26,029 27,746 '30,708 12,261 23,850 59,587 . 492,579 1,637,832 56,079 40,249 96,328 1,734,160 30,768 . 6,646 ' 5,676 14,595 58,343 . 9,599 13,783 9,525 15,794 69,705 1,743 14,959 971 . 1,931 59,703 11,767 ' 1,033 5,900 40,344 372,785 1,499,804 58,764 37,337 . 96,101 . 80 1,595,985 93,639- 9671,501,379 8,525- ^ ' 930 941,700- ^ 5,338- ^ 263465 2,174- ^ 78 26,696- ' : 1,800- ' 3,048-' 408- 9,787-' 33,674 15,97930,708-11,228-17,95019,243119,794138,028- 2,685 2,912- 227- 80 : 138,175- 93,639967- 232,781- 53 0 53 3 54 2 54 5 570 575 57e 590 601 602 603 610 614 618 620 621 63 5 651 657 694 o c 0 0 c c c c 0 c c c c c c c c 0 c c ' 69 8 i 70 0 1 994 1 996 1 997 1 -------- ---- ------- . A" .... '\J ---- --------- ' ozb^ql :----- - - - TOWOLDMONOQ44094 ." ( '- Section 12 - Appendix X - Page 5 COST REPORT YEAR TO DATE - ORGANIC DIVISION ANNISTON, ALA. REF SOL* ARCCLORS OEPT. 8Z617 PRODUCTION CODE 82617 * ACTUAL PRODUCTION - YEAR TO CATE .5,647,969 . SCHEDULED PRODUCTION - YEAR TO DATE 5,990,324 JULY 1967 MATERIAL YEAR Tt` DATE QUANTITIES OR EXPENSE ACTUAL QUANTITY SCHEO. QUANTITY OVER-UNDER SCH. STEAM MBTU . 32,944 24,384 ` 8,560- ELECTRICITY CKWH 4,460 5,071 . 611 HATER PLANT MGAL 83,893 81,165 : 2,728- GAS M8TU 43,263- 35,807 7,456- LABCR HRS - PACKING LABOR 8- ,2' 22" 8,365 5,138 143 5,138 LABORATORY HRS ' ` 650 337 313- ' FERRIC CHLORIDE 928 1,694 766 LIME HYDRATED 37,847 28,237 9,610- BIPFENYL . 181,803 176,827 4,976- SANTOHAX R' . 2,968,658 2,821,294 147,364- CHLCRINE ;9,276,064 8,693,577 582,487- H C L ICO* . 3,857,071- 3,857,071- M0N1ARS 120,707- 120,707 SOL ID AROCLOR RE 1,462,695- 1,462,695- MATERIAL ' * . \ .. ' . . YEAR:TO DATE AMOUNTS OR EXPENSE . ACTUAL COST SCHEDULED COST OVER- UNDER SCH. FERRIC CHLORIDE ' ' 150 273 123 LIME HYCRATED 422 314 108- BIPFENYL ' 8,784 8,537 247- SANTOHAX R .132,292 125,775 6,517- ( CHLCRINE - 228,272 213,569 :14,703- H C L ICO* MONTARS 62,6773,211- . 6", 2'* ,6` 77- - 3,211 SOLID AROCLOR RE 35,836- 35,836- NET MATERIAL COST 268,196 249,955 18,241- 530 53 3 542 54 5 570 601 610 33510 .38800 82601 82602 82638 82851 82868 82869 33510 38800 82601 82602 82638 82851 82868 82869 ' RAW MATL. HAND. TOTAL MATERIAL COST 1,326 _i_i_1_, .* n...269,522 249,955 1,326- 530 ' ^?r5*T_ .... ,... C c c c c c C c C 0 c 0 0 0 0 0 0 0 0 0 0 0 0 t <) 0265598 TOWOLDMONOQ44095 .* * Section 12 Appendix X Page 6 . rs' COST REPORT YEAR TO DATE - ORGANIC DIVISION o ANNISTON, ALA. REF SOL ARCCLORS DEPT. 82617 PRODUCTION CODE 82617 ACTUAL PRODUCTION - YEAR TO CATE 5,647,469 ' SCHEDULED PRODUCTION - YEAR TO DATE 5,990,324 JULY 1967 STEAM . : 16,269 ' ELECTRICITY '3,092 HATER PLANT 1,945 GAS . 12,931 LABOR 30,951 . SALARIES 4,714 PAYROLL OVERHEAD 7,596 SUPPLIES 907 PACKING LABOR 15,277 (" PKG CONTAINERS 19,639 V. PACKING 0/H 572 LABCRATCRY 4,718 CLOTHING LAUNDRY 682 PROC DEPT CONTNR 5,802 } TECENICAL SERVIS 6,656 EXPERIMENTAL ! -- 937 j PLT PROC RES . . - . ; - MECE EXPENSE 26,878 TOT DIRECT CONVERSION 159,566 :70T DIRECT MFC-. COST '429,C88 DEPRECIATION FACT. IND. EXP. TOTAL INDIRECT CONV. 42,130 23,882 66,012 ; PERFORMANCE VOL. TOTAL PRODUCT COST I PRICE 6 MAT. MIX i UNSCHEDULED CAP, INV. VALLE TOT VAR. 495,100 . 12,423 3,501 1,921 11,281 31,885 . ' 4,845 8,617 3,500 16,303 11,863 298 2,625 595 ;12,181 6,130 100 600 23,250 1151,918 4C1,873 40,455 19,720 60,175 S.563452,485 34,15530,654 448,984 3,846409 24- ... 1,650. 934 131 i1,021 2,593 1,026 7,7762742,093876,379 ` 526937' 100 600 3,6287,648- 27,215- 1,6754,1625,837- 9,56342,615-. 34,15530,654 46,116- 530 0 533 c 542 c 54 5 c 570 c 575 C 578 c 590 c 601 c 60 2 c 603 c 610 C 614 C 618 c 621 C 635 c 651 c 657 C 694 c 698 I 700 1 994 1 996 1 997 1 0265599 O . TOWOLDMONOQ44096