Document e7R0w2OGvDvqn5a37V5RgvjnE

ABD00282757 VINYL - P. E. Markey Operating Parameter .1 Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Batches Charged 4. Charging Rate, Batches/C.D. 5. Reactor Stream Factor, % 6. Average Dryer Rate, Lbs./r. 7. Dryer Stream Factor, % 8. Accounting Days February 32.7 1167 775 27.6 88.8 6712 80.5 28 Y.T.D. 59.7 1012 1453 24.6 80.6 6635 70.6 59 Production Vinyl Department production for February was 32.7 MM pounds which was 107% of the budgeted production volume and also exceeded the Business Area targeted production level of 31.0 MM Lbs. The production level represents the second highest production month on record for Aberdeen and the daily production rate for the month topped all previous months. February also marked the most energy efficient month of Aberdeen operation on record. Reactors 1. Condenser cleanings on reactors 745, D-600, and D-500 resulted in a reactor stream factor penalty of 2.2%. 2. A circuit board failure on the 584 Modicon interlock programmable controller resulted in a 0.56% stream factor penalty on the affected reactors 700 and 745. 3. D-400 agitator motor failed resulting in a 0.5% stream factor penalty. 4. Pluggage of the new module charge water preheater with calcium carbonate and downtime associated with hydroblasting resulted in a, 0.4% reactor stream factor penalty. A positive shutoff valve was installed which should drastically reduce future fouling of this nature. 5. Reactor valve changeouts resulted in a 0.5% reactor stream factor penalty. 6. Replacement of D-600 agitator seal resulted in a 0.5% reactor stream factor penalty. 7. D-700 agitation system was restored to the original agitation system following a four-month trial of the high speed, high shear blades designed for low gel resin production. Hydroblasting and agitation revisions resulted in a 1,0% reactor stream factor penalty. ABD00282758 VINYL - (Continued) 8. A total of six coarse batches were experienced due to D-700 agitation problems and an experimental cold weather charge procedure resulting in a 1.0% reactor stream factor penalty. Dryers 1. Dryer production for the month was essentially balanced with reactor production capacity. The dryer stream factor was 80.5%. One rotary dryer was held down the entire month. Product Quality Summary Resin Type 5265 5305 5385 5425 5465 Sifter Overflow Pond Resin TOTAL Prime 321,887 5,520,012 21,310,766 2,939,364 2,301,581 - - 32,393,612 "BC" "H" _ - 5700 - 5700 _ - - - - 294,760 ( 3,700) 291,060 % of Total Production 1.0 16.9 65.2 9.0 7.0 0.9 0.0 100.0 Budget Prime Product Mix % 12.5 11.25 57.5 13.75 5.0 - - 100.0 Quality performance for February was 99.1% customer grade with 0.01% "BC" produce tion and 0.89% "H" grade. A total of four railcars were shipped as "B" grade during the month which repre sented 3.1% of the 126 total resin hopper cars shipped. Ship Date Car No. Customer Product Reason 2/17/83 2/21/83 2/23/83 2/28/83 PTLX 41852 CONX 45752 PTLX 41662 CONX 45817 World of Plastics Clow Corporation World of Plastics H&W Industries Resifted Sifter Overflow Resifted Sifter Overflow 5385 5385 Quality Quality 40 Mesh* 40 Mesh* *Note: Product contained greater than 40 mesh size particles due to a tear detected in a dryer sifter overflow. ABD00282759 s VINYL - (Continued) The vinyl area received 28 short lead time emergency type orders comprising 11.2% of the 249 Aberdeen resin shipments in February. Variable Cost Performance Variable costs for the month were favorable $869 M with $762 M due to price and $107 M due to efficiency. Resin variable cost for the month was 19.538<t/lb. vs. the budgeted 22.220^/lb. The $762 M favorable price variance was primarily attributable to lower than budgeted delivered monomer pricing of- 17.23</lb. vs the budgeted 19.165</lb., resulting in a favorable price variance of $639.6 M. Lower than budgeted pricing of L-225 initiator, $43.6 M; natural gas, $45.5M; and electricity, $31.7 M, comprised most of the balance. The $107 M favorable efficiency variance can be attributed to favorable variances of $11.7 M in VCM efficiency, $14.1 M in combined process additives, $42.8 M in the utilities area, $16.7 M due to deviations from the budgeted mix, and $22 M due to lower than budgeted offgrade production. Vinyl efficiency for February was 1.01096 lbs. VCM/lb. PVC versus the budgeted 1.01277. Y.T.D. VCM efficiency is 1.00778 lb./lb. No pond resin was dried during the month. General 1. Packaging for the month totaled 491,250 pounds. 2. Resin raw material inventory in the 744 account totaled $202 M at month end. 3. A total of six coarse batches were experienced during the month. Four were associated with an experimental cold weather charge procedure which was aborted following three coarse batches in D-600 and one coarse batch in D^500, The remaining two coarse batches were attributable to experimental blades in D-700 reactor and related erratic particle size control. 4. Economical Lucidol L-54 was requalified during the month for low molecular weight resin production. Initiator bomb relief testinq by the producer indicate a 50% dilution in 0MS would be safely'compatible'with our plant initiator injection systems. L-54 use will resume in March. 5. Plant energy consumption for the month was 2673 BTU/lb.representing the most efficient month of operation on record at the Aberdeen Plant. The accomplishment can be linked to the high production-rate and improved administrative controls plant wide. 6. Training sessions on the proper operation and troubleshooting of rotating mechanical seals were conducted for all vinyl operating personnel with support from MED's John Griffith.