Document gar4LRbQzQJbe4kQv5Qgo184V

To: T. H. Huffman Interoffice Communication From: Data: Subject: D. C. Skokna February 19, 1990 ABERDEEN MONTHLY PROGRESS REPORT JANUARY, 1990 r FEB 2 7. 90 v;;-.LiA^ l VB1A Safety There was one first aid and one recordable case reported during January. The recordable case involved a maintenance employee who suffered caustic bums to his feet. At month's end, the Aberdeen plant's employees have worked 3863 days <5,125,576 manhours) since the last lost time injury. ...... FY 1990 Kev Statistical Information Januarv ` Y.T.D. PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M 39.9 90.0 96.6 0.9936 5.3 98.3 5*5 99.9 1.4 85.5 < 8.4> <10.8> 218.0 143.0 83.0 96.7 0.9995 23.7 97.9 17.1 99.4 5.6 89.5 <12.8> 19.4 268.0 Caoacitv Utilization Factors Resin Flexible Compound Rigid Compound Plasticizer 105.6 69.0 93.2 73.3 95.4 76.1 99.4 77.0 Waste Reduction Indices (*} Offsite, Hazardous Wastes Recycled, Hazardous Wastes Offsite, Non-Hazardous Wastes Vulnerable By-Products Total Waste Water Air and Water 157.7m 57.9* 74.6'1' 100.5(,> 113.8< 82.6<u 141.5 60.6 81.3 95.7 115.7 83.3 (1) Three-month rolling average. CCR 000006198 T. H. Huffman 2/19/90 Aberdeen Monthly Progress Report - January, 1990 Page 3 5. Dayton Extruded Plastics (DEP) visited the plant to discuss dimensional stability problems they are having with our rigid compound. They agreed to participate in a D.O.E. involving the raw materials used in their dry blend. 6. All first and second level supervisors met with plant management to discuss barriers they experience to QMP. Also, information was exchanged about our plant's businesses. 7. Twenty-two employees were trained to be on the Facilitator Team. This group will work with the plant's natural teams. 8. On 1/26, a team evaluated the VCM Plant's quality - systems. 9. Sixty-three percent of the.-plant's natural teams met during the month. Projects The alternate natural gas line was tested, Ve will begin using natural gas from ACG via the new line on 2/1/90. Savings are approximately 1000 per day. Doug Skokna Plant Superintendent rah CC SAFETY - B. L. Trego, J. V. Uptain First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases January 1 X 2 1 0 Fiscal Y.T.D. 1990 6 9 2 0 Fiscal Y.T.D. 1989 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries bv Type 00 22 66 00 00 _1 0 98 Cuts and Abrasions Eye Injuries Bums Bruises S trains/Sprains Stings Other Totals 12 01 12 01 00 01 2 JL 29 1 0 2 2 2 0 -1 Non-Occupational Injuries Lost Workday Cases Days Lost 23 18 84 1 20 Safety Record Last lost time injury - 7/5/79 Days since - 3863 Employee hours since - 5,125,576 On January 31, 1990, the employees of the Aberdeen plant completed 3863 days with no lost time injury. "Hand Injury Prevention" was the principle topic for safety meetings during the month. The new Safety Handbook was completed and is ready for distribution in February's safety meetings. CCR 000006200 Continued Routine dosimetry results for the month were: Chemical VCM Lead Total Particulates < PEL Number Percent 75 100.00 15 88.2 8 100.00 > PEL Number Percent 0 0.0 2 11.8 0 0.0 Monthly Injury Summary Iniurv Class Department RWC Maintenance -i- FA :* -- Maintenance ? Description Caustic bums to both feet. Cut - right fore finger. (-- CCR 000006201 QUALITY MANAGEMENT PROCESS - M. R. Kane CAPCO (Cement Asbestos Products Company), which buys 5385 resin, visited the plant to learn about rigid compounding and Q.C. of rigid compound. CAPCO will begin manufacture of pipe at its Van Buren, AR facility during the first quarter of 1990. The additional pro duction will increase Vista's position from 24MM pounds to 36-40MM pounds. Twitchell's R&D Manager, Dwight Barry, visited the plant this month to learn about the production of 5415 resin. Twitchell produces coated yarns which are woven to make patterned fabrics. As a part of the visit, Dwight talked with the Technical Service Lab personnel and discussed their capabilities. Dan Preston from Dayton Extruded Plastics visited to discuss problems which DEP has experienced. The nature of the problem is dimensional instability (swell or shrink of the extruded part). As a result of our discussion, we decided to do a DOE involving the raw materials to their dry blend product. The experiment was designed and sent to Dayton for review. The material for each experimental run will be blended at Dayton's plant where the DOE runs will be made. Manager's QMP Meeting All of the first and second line supervisors met with plant management to discuss barriers they experience to QMP and also to receive information about the plant business. Meetings were held each of two days with half the group attending each day. The feedback from the meetings was positive and all involved agreed the meetings should be held annually. 0-Scorecard Submittal The plant Q-Scorecard was submitted for approval on January 26. The scorecard included goals in the following areas: 1) Natural Teams; 2) Cost Control; 3) Safety; 4) Waste Minimization; 5) Quality; and 6) a Linkage Measure. Development of departmental support scorecards has begun. Facilitator Training A meeting was held on January 23 to train all those who agreed to be a part of the Facilitator Team. There are twenty-two trained facilitators who will work with the plant natural teams. The natural teams will be taught team techniques and work on a project in their department as their case study. VCM Plant Quality Systems Evaluation CCR 000006202 An evaluation of the VCM plant's quality systems was performed on January 26. People involved were Mike Kane (Aberdeen), Dave Hollis (LCCP), and Jim Hall (Houston - Purchasing). All involved agreed that the exchange was mutually beneficial. COST VARIANCES - D. C. Skokna Variable Costs Product PVC Flexible Compound Rigid Compound Plasticizer January. 1989 Variance. $M Efficiency Price Total $136.0 53.2 14.4 ]4,4 $218.0 $1165.5 176.6 271.9 ____ULA $1624.6 $1301.5 229.8 286.3 25.0 $1842.6 PVC * VCM use was below budget. Flexible Compound - The favorable variance was due to product mix effects and a lower than normal scrap rate. The reduced scrap (0.011 lbs./lb. versus 0.0145 lbs./lb. standard) is .. due to the successful efforts of the Millscrap Reduction Team. . - Rigid Compound - A favorable product mix effect was partially offset by above budget raw material consumption. Plasticizer - VRP yields were above budget to give the overall positive variance. , Price Variances - VCM - Resin to Rigid Compound - Resin to Flexible Compound - Alfol* 610 - 610P to Flexible Compound - Natural Gas - Other Variances Total Fixed Cost Variances $1209.2 245.6 143.8 17.4 16.4 < 38.0> 30.2 $1624.6 - Payroll and Benefits * MM&C - Miscellaneous - TIficD - Clearances Total <$58.4> < 34.7> 88.5 14.3 8.1 <$10.8> Payroll and Benefits - Overtime in operations and maintenance was above budget due to operational needs and the holiday. M. M, & C. - Material costs for the Compound Department repairs were above budget. CCR 000006203 ( COST VARIANCES - Continued , Miscellaneous: Major variances in this category were: Moving. Home Assistance - $13.3M favorable. Unclassified - $18.4M favorable. Some charges related to the RFS trials were transferred to this project's capital AFE. Packaging Supplies - $21.3M favorable. T.L.& D. - This category was $14.3M unfavorable due to a $16.1M unfavorable FICA variance. The FICA is based on cash payroll which includes five pay periods this month. CCR 000006204 VINYL - J. D. Olson, K. W. Birck Safety The Vinyl Department did not have any first aid or OSHA recordable injuries during the month of January. The monthly safety meeting topic for the month was hand safety. A video tape on hand safety and pinchpoints was viewed and discussed. General 1. 5385 was produced this month in the New Module. 2. Reactor D745 was used to test a new reactor clean wall technology. The new technology appears to have the potential to replace reactor chem wash and rinsing. There has been no detectable adverse effect on any resin physical properties. 3. Lucidol 288 catalyst was used to produce a batch of 5415. There was no noticeable difference between this resin (in cluding Mets IR testing) and other 5415 resin normally made with Witco 939 catalyst. L-283 is a less expensive raw material. More extensive testing will continue in February. 4. The resin raw materials in the 744 account were valued at $345.4M. January YTD - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % Reactor Downtime 39.9 1287.1 105.6 928.0 29.9 90.0 71.7 96.8 96.6 143.0 1162.6 95.4 3349.0 27.2 83.0 70.7 86.3 96.7 Hours Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, New Module rinse/charge water conflicts, no place to dump, waiting on Q.C. data before charging and filter changes). 278.5 Maintenance downtime (hydroblast reactors and drill condensers D700 (IX) and D745 (2X), drill condensers D742, D743 and D744, repair agitator fluid coupling D742, repair agitator seal D300, repair Topaz unit, replace safety discs on D742 and D743, and miscellaneous instrument and valve repairs). 463.8 , CCR 0000062 / VINYL - Continued Dryer Downtime Reactor limited production. Operational downtime (centrifuge plugs, check for dust collector leaking, clean dryers, activator transfer problems, and flameouts). Maintenance downtime (centrifuge repairs, rotary and fluid bed repairs, shear pins, repair rotary valve, clean fluid bed scrubber, and repair Trunion bearings. % of Total Downtime 75.3 12.4 13.3 Key Maintenance Work - J. B. Autrey, J. B. Hegwood Reactor 745 was shut down during the month for hydroblasting and condenser drilling. This was done as part of the clean wall test run. The condenser was drilled and brushed in order to remove as much buildup on the tubes as possible. The condenser was then swabbed with the clean wall agent. Reactor 700 was shut down during the month for hydroblasting and condenser drilling. This was done as part of the contamination control program. Reactors 743 and 744 were shut down for condenser drilling during the month because of cooling control problems. Reactors 741 and 742 were shut down during the month for safety disc replacements. This completes all safety disc replacements for the year. Number seven dust collector was shut down for repairs to its screw conveyor and stub shaft during the month. The screw conveyor and stub shaft were replaced with a newly designed model. Number eight dryer was shut down during the month for repairs to its inlet screw and Trunion. The inlet screw was pulled and repaired and the Trunion was replaced. The fluid bed dryer was shut down for cleaning and Bird repairs during the month. The demister pads were pulled and cleaned because of an excessive calcium carbonate buildup. The Bird centrifuge was pulled and replaced with a spare because of an excessive vibration problem. The main breakers were replaced on the east hot water charge pump and the old unit dump Sweco motors during the month. All instrumentation for the low molecular weight project was calibrated during the month. Numbers three and four VC Corken compressors were removed and rebuilt during the month. There were six major valves changed out in the reactor area during the month. CCR 000006206 COMPOUND - J. E. Nickerson, K. G. Akins SaffctV The Compound Department worked without injury in January. The topic of the monthly safety meeting was pinchpoint awareness. The topic of this safety meeting was recommended by the team investi gating the November incident in which an operator severed the tip of his finger in a closing door. General Several maintenance problems caused some unusually high downtime in the Compound Department in January. The increase in downtime, coupled with increasing flexible compound demand, tightened production schedules. Line III was down eighty-two hours during the month awaiting parts to repair the FCM starter. Replacement of Velex seals was responsible for forty-five hours of downtime in the dry blend unit. Line V was idle for the entire month of January due to a combination of light orders and repairs to the twin screw gearbox. Line I was down for twenty-eight hours during production trials of Plenex polymer formulations. On January 6, the dry blend unit produced 356,554 pounds to set a new one-day production record. The previous record was 351,560 set on June 1, 1985. The setting of this new record was particularly significant as It came at a time when demand for our rigid compounds surged and the production schedule was extremely tight. Operating Comoound Production Davs _________Production (M Lbs.1) Month Ave./Dav Fiscal Y.T.D, Line I 28 Line III 27.5 Line V 0 Total % Prime Capacity Utilization Factor Downtime Line I 2126 76 3219 117 00 5345 98. 3 690 Hours 8232 13151 2339 23722 97.9 .761 - Product Changes - Plenex Compound Testing - Miscellaneous Maintenance - Mill Maintenance Quality Problems and Control 77 28 16 11 4 Line III - FCM Starter Repair - Product Changes - Quality Problems and Control - Dicer Problems and Maintenance - Miscellaneous Maintenance 82 58 9 8 6 CCR 000006207 t COMPOUND - Continued Operating Davs Month Production (M Lbs.1 Avg./Dav Fiscal Y.T.D, Rigid Compound 28.5 5470 % Prime 99.9 Capacity Utilization Factor .932 192 17097 99.4 .710 Downtime Hours - Welex Maintenance - Product Changes Miscellaneous Maintenance - Quality Problems andControl 53 50 28 19 Operating Davs Month Production (M Lbs.) Avg./Dav Fiscal Y.T.D. Plasticizer 29 % Prime Capacity Utilization Factor 1614 85.5 .733 56 6400 89.5 .770 Key Maintenance Work - J. B. Autrey, J. B. Hegwood The Line V twin screw extruder was shut down for repairs to its speed reducing and drive gearboxes during the month. The speed reducing gearbox was replaced with a new gearbox. The twin screw gearbox was rebuilt after it was found that a bearing failure had occurred. The vacuum jets on plasticizer reactors R-l and R-2 were removed for cleaning during the month because of an excessive calcium carbonate buildup. The . first quarterly PM program was completed on the dicers in the compound area this month. This should help reduce downtime and maintenance cost on dicers. Numbers one and two Welex were shut down during the month for repairs. The gate was replaced on #1 Welex because of a leak. The shaft, sheave and seals were replaced on #2 Welex. The temperature control loops were calibrated and the water flow meters cleaned on plasticizer reactors R-l, R-2, R-3 and R-4. The starter on Line III FCM drive was replaced during the month. CCR 000006208 UTILITIES J. B. Autrey, J. B. Hegwood The alternate natural gas line was tested during the month. We will start using natural gas from ACG Company on February 1, 1990, due to favorable pricing. The automatic water valve was repaired and the continuous blowdown line was replaced on boiler #1 during the month. The east propane pump was removed, rebuilt and reinstalled during the month. .. The control valves on boilers #1 and #3 were removed and rebuilt during the month. CCR 000006209 ENGINEERING - R. E. Polk, S. C. Hillman, C. J. McDonald PROJECTS IN DEVELOPMENT - GENERAL 5305 Graininess Work Decalcified water will be used instead of DI water for the calcium free water test run. Ion exchange with sodium will be used to remove the calcium. The test run is scheduled for March. EVC Clean Wall Technology The EVC clean wall test kicked off in January. The clean wall has reduced reactor fouling and cull production. It also eliminates the final reactor rinse to sewer. A closed reactor temporary addition system is being constructed for longer term testing. VCSH Work on the assignments continues on schedule. Plant engineers are still writing process descriptions/procedures, operator interface guidelines, and creating graphics panels. The team reviewed and re* vised process control diagrams (PCD's). TC Wastewater Compliance Air stripping of rinse water in the blend tanks apparently will reduce VCM levels below TC compliance levels. The test run was cut short because it created high hard particles in the resin. A revised rinsing procedure will be tested. Alternate Gas Supply The new supply line is operating. February pricing with the new line will save approximately $1000/day. Baghouse Replacement DCE is designing a new air baffling system. Improper baffling has led to premature bag failures. Plasticizer COD Reduction A screening design showed no potential to reduce plasticizer COD by adjusting the variables tested. Reaction time was the most significant variable and we already operate at the optimum value. CCR 000006210 ENGINEERING - R.E, POLK, S.C. HILLMAN, C.J. MCDONALD AFE NUMBER AG 56 D0J8 A519 A449 A909 cm D619 D42? D639 D74? 0789 0849 0859 F579 F469 F699 F739 F779 6569 6459 671? 6759 6819 6839 H679 H729 H749 8829 H879 A540 H500 HS10 H520 1530 ABEr.CEEN CHEMICAL PLANT APPROVED CAPITAL PROJECTS PROJECT DESCRIPTION STATUS ALTERNATE NATURAL GAS PIPELINE VINYL VALVE UP6RA0E PLANT ELECTRICAL UPGRADE VINYL CONTROL SYSTEM MODERNIZATION INERTS REMOVAL MODIFICATIONS NEN WATER NELL PROPANE STORAGE AREA DELUGE SYSTEM COMPOUND REOLEND TRANSFER SYSTEM BOILER SAFETY REVISIONS LEAD HANDLING AND EXPOSURE REDUCTION INERT 6AS PUR6IN6 OF PA TANKS COMPOUND LINE 3 SEMI-BULK LEAD HANDLINS COMPOUND SILO BRIDGE BREAKING COMPOUND BOXING HOPPER MAGNETS COMPOUND LINE 5 HEATED PLASTICIZER LQN MOLECULAR HEIGHT RESIN EXPANSION DRYER NO.8 CONTAMINATION REDUCTION DRYER NO. 4 CONTAMINATION REDUCTION DRYBLEND DIV. VALVE AND CHUTE REPLACEMENT NEN DRYER 8A6H0USES COMPOUND SEWEfi REVISIONS HASTE OIL REDUCTION VCM SIGHT GLASS REPLACEMENT PLANT HATER RECYCLE PLASTICIZER REACTOR AGITATORS TORQUE RHEOMETER REPLACEMENT PLANT DIVERTER VALVE REPLACEMENT RECOVERY SYSTEM COMPRESSOR - SPARE ROOF UP6RADE REDUCED FLAME It SMOKE COMPOUND PROJECT PLANT HATER SYSTEM HES7 INCINERATOR REPLACEMENT MISCELLANEOUS CAPITAL PROJECTS < II5H FURNITURE AND OFFICE EQUIPMENT THE SYSTEM HAS SEEN STARTED UP ANO IS OPERATIONAL. PUNCHLIST ITEMS ARE IN PROGRESS. INSTALLATION IS IN PROGRESS AND PLANNED FOR COMPLETION IN APRIL. CONSTRUCTION IS 90X COMPLETE AND IN PROGRESS. PROJECT COMPLETION IS PLANNED FOR MARCH. ENGINEERING IS IN PROGRESS. CONTROL ROQH PRE-WORK ITEMS ARE SCHEDULED FOR COMPLETION IN FEBRUARY. DESIGN IS IN PROGRESS HITH COMPLETION SCHEDULED FOR MARCH. CONSTRUCTION IS IN PROGRESS HI7H COMPLETION PLANNED FOR FEBRUARY. INSTALLATION HILL BE COMPLETED IN APRIL. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. THE PROJECT IS COMPLETE ANO HILL BE CLOSED TO FIELD CHAR6ES IN JANUARY. INSTALLATION IS IN PROGRESS HITH COMPLETION PLANNED FOR MAY. INSTALLATION IS CONPLETE EXCEPT FOR PUNCHLIST ITEMS. LONG LEAD ITEMS HAVE BEEN PLACED ON OROER. PROJECT COMPLETION IS PLANNED FOR 7/1. LONS LEAD ITEMS HAVE BEEN PLACED ON ORDER. INSTALLATION IS PLANNED FOR COMPLETION IN JUNE. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. ENGINEERING JS IN PR06RESS. PROJECT COMPLETION IS PLANNEO FOR MAY. INSTALLATION IS IN PR06RE5S HITH COMPLETION PLANNED FOR MARCH. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. PROJECT COMPLETION ZS PLANNED FOR FEBRUARY. INSTALLATION IB IN PROGRESS. PROJECT COMPLETION IS PLANNED FOR FEBRUARY. DESI6N IS IN PROGRESS. PROJECT COMPLETION IS PLANNED FOR MARCH. INSTALLATION IS CONPLETE EXCEPT FDR PUNCHLIST ITEMS. PROJECT COMPLETION IS PLANNED FOR MARCH. INSTALLATION IS SCHEDULED TO BE6IN IN MARCH HITH COMPLETION IN HAY. INSTALLATION IS IN PROGRESS NITH COMPLETION PLANNED FOR MARCH. DESIGN IS IN PR06RESS. PROJECT COMPLETION IS PLANNED FOR APRIL. DESIGN 15 IN PROGRESS. PROJECT COMPLETION IS PLANNED FOR JUNE, INSTALLATION IS COMPLETE FOR R-l. PROJECT COMPLETION IS PLANNED FOR APRIL. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. THE PROJECT HILL BE CLOSED TO FIELD CHARGES IN MARCH. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. THE COMPRESSOR IS SCHEDULED FOR DELIVERY IN FEBRUARY 1990. INSTALLATION IS 98X COMPLETE ANO IN PROGRESS. COMPLETION IS PLANNED FOR FEBRUARY. MODIFICATIONS TO LINE I FOR TEST RUNS HAVE BEEN COMPLETED. ENGINEERING IS IN PROGRESS. PROJECT COMPLETION IS PLANNED FDR HID-1991. ENGINEERING IS IN PROGRESS, ENGINEERING IS IN PROGRESS ON 13 PROJECTS. EQUIPMENT IS BEING QUOTED. ^7900000 ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were met for the month of January. Air A meeting was held with the State to review our new air permit with the engineers that would be working on it. They had several additional items they wanted in the air permit application. The application was revised per the comments of the State and a second meeting was held to discuss the revisions. The air permit is expected to be issued in February. Waste Make-up RCRA training was completed for all persons who missed during the month of December. Waste shipments for the month included: - .- - .- - One bulk load of floor sweep to Chemical Waste Management's (CWM) Lake Charles, Louisiana facility. - One bulk load of lead bags to CWM's Emelle, Alabama facility. The Governor of Alabama proposed to increase taxes on all imported waste disposed of at Emelle, Alabama by 550% to $l20/ton. Suoerfund We received a copy of NUS's report to EPA on the investigation of the four sites on our property. A meeting with EPA is scheduled in February to review the report and recommendations. Miscellaneous I attended Hazardous Materials Manager training during the month. Total environmental costs for the 1989 calendar year were calculated to be $2.4 million. The new dryer baghouses were $1.5 million of this total. The SPCC Plan Survey was completed during the month. Two work orders were written to repair dikes. I attended Interaction Management and facilitator training during the month. CCR 000006212 Jan-90 WASTE REDUCTION INCH SHEET ft OVERALL EXCLUDING 'TOTAL WASTE WATER* HQN-RECYCLED WASTE RECYCLE3/SQLD WASTE 3 HONTH IWRI 90 YTD 19B9FY 89.551 79.49Z 96,601 38.981 85.681 91.29Z 103.511 94.961 109.511 r. Offsite. Hazardous Wastes 157.661 141.511 100.681 a. Land Gan Wastes s. Hazardous Solids c. Non-Kazardaus Treated as Hazardous d.OOX 0.001 244.741 113.041 87.041 111.191 173.951 160.881 ' 95.771 JI. Recycled Hazaraous Wastes 57.921 60.57Z 103.S1Z Hi. Offsite. Won-Hazardous Waste a. Recycled Ncn-ftecvcled 74.441 81.301 95.371 141.401 67.031 109.021 78.161 9B.391 95.031 IV. Vuneraole 8v-?roducts V. fetal Waste Water 100.541 95.651 111.361 113.761 115.671 95.011 Air k Water a. SARA - Air z. 5ARA - Water r. Ncn-SARA - Air i. '!rr.-SARA - Water ' 82.551 63.321 91.901 85.751 B5.951 1228.631 1249.251 31.371 42.441 117.43: 8B.052 592.121 98.301 zi .mi r- cc* o6 ^3 i Jan-90 HASTE RECTIOH INDEX SHEET ' 19B8FY I. Offsite. Hazardous Hastes a. Land Ban Hastes 1. Phthalic Anhydride 321409 2412 2412 b. Hazardous Solids 1. Stabilizer Spill 2. Floor Sweep -' c. Non-Hazardous Treated is Hazardous 1. Plast. Filter Cake 2. lead Baas 3. API Sludae r;:V 4. Pit *1 Solids .r II. recycled Hazardous Hastes a. Recycled - 1. Separator Oil 2. Safety Kleen Solvent '- 7906B 16989 62079 239930 61670 68640 29620 80000 653226 653226 651700 1526 POUNDS 19B9FY 90 no 3 (tenth 329304 6006 6006 145636 0 0 124941 0 0 B9465 22425 67040 22037 5097 16940 22037 5097 16940 233833 56573 67880 29380 80000 123599 0 30100 66540 26959 102904 0 16200 66540 20164 6B8080 688080 686210 1870 126685 126685 125780 905 9328B 932BB 92600 688 III. Offsite. Non-Hazardous Haste .a. Recycled 1 Druas 2. Pallets 3. Aluainue Cans. Paper, and Box 4. Scrap rtetal b. Son-Recycled .1 landfill 2429430 247201 47600 145600 0 52000 2182229 2182229 2357718 247500 49600 145600 300 52000 2110218 2110218 632415 86295 10950 45999 496 28850 546120 546120 447085 861B5 10950 34405 396 40434 360900 360900 !V. Vunerable By-Products a. PVC i. Culls 2. Vacoue Vent Oust 3. Sifter Overflon 4. Pond Resin 5. Pit 42 Resin 3597456 3597456 471409 3294B0 801007 1915560 80000 4076656 4076656 330521 541016 504106 2621013 BQQOO 1101753 1101753 55210 1659B1 59151 794452 26959 891621 891B21 33690 124275 49939 663753 20164 V. Total Haste Hater a. Effluent 1. Pond 6 4424987560 4278245861 1638930897 124U6S141 4424987560 4278245B61 163B930B97 1241168141 4424987560 4278245861 1638930B97 1241168141 VI. Air & Hater a. SARA - Air 1. VCH 646617 73316 73316 604682 6S694 65694 172508 20177 20177 131603 15500 15500 CCR 000006214 Jan-90 WASTE SECTION INDEX SHEET . SARA - Water 1. VCH 2. fli-n-octyl Phthalate :. Non-SARA - Air 1. Particulates 2. Sulfur Dioxide 1. Non-SARA - Hater 1. BOO 2. TSS 3. COD 4. NH3 %Zsl &Ui ^rs " vv :' .r-u ____ _ . man 53 22 31 264206 263300 906 rA% ::Kz * ~?C,- ;u- 309040 43689 68392 195581 1378 vC"l_. im . ' -* POUNDS 1989FT 90 YT0 3 Hontb 333 21 312 264290 263300 990 274364 46750 53140 173276 1199 221 8 213 35905 35554 351 116204 27376 19876 6B696 257 168 -6 161 20434 20164 270 95501 22917 16137 56230 217 ' fi?^^ ' .y-.. - -*; T-' .; -r\ ; ^ J - -i; ' - 4-S* .* ' sjaav. g'y CCR 000 6*1 5 *~wi. > f ENERGY CONSERVATION - D. A. Moore January. 1990 I. Energy Conservation Data*1 > A. Unadjusted EUI ( 8.0%) B. Adjusted EUI ( 8.4%) C. BTU/Lb. Product 2661.0 D. Total Energy Consumption MMM BTU 138.1 Fiscal Y.T.D ( 12.0%) ( 12.8%) 2764.0 524.3 II. Plant Energy Conservation Program A. Maintenance There were sixty-four energy related items completed in December. Fifty-two of these items were steam leak repairs;-' The remaining twelve were steam trap repairs. III. Boiler Operation" ; Boiler 71 '' ` ^ -* ' Combustion Efficiency % Jan. . 90 Fiscal Y.T.D. No. 1 No. 2 No. 3 83.4% 83.2% 82.9% 83.5% 83.4% 83.1% CCR 000006216