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CSCAMSIA PLANT
INC.
INTEROFFICE MEMORANDUM
To: From:
Re:
Mr. R. E. Davis
R. W. Beech PVC Monthly Report -
February, 1972
Dote: Copies:
March 6, 1972
SUMMARY
Production tor the month was 4769M pounds versus a budget of 4765 M pounds and a forecast on February 18 of 4800 M pounds. Off-grade, tails and sweep8 totaled 414 M pounds, 8. 0% versus a budget of 5.2%, Contamination, iisheyes and bulk density were causes of off-grade. A total of 602 charges were made, an average of 20. 7 per day.
The total variance for PVC is $6300 favorable broken down as follows:
1. PVC Bulk 2. PVC Bagging 3. PVC L.&S
{ 800) 5, 900 1, 200
The forecast for PVC bulk on January 20 was $4800 favorable. Major factors affecting PVC bulk variance are listed below:
Raw Materials Vinyl Chloride Vinyl Acetate Process Chemicals By-Product Credit Royalties
{ 9,900) 1, 400
8, 160
Process Costs Volume Process Spending Machine Hours
( 8, 150) 14,280
( 7, 300)
PVC-2185 was $5140 unfavorable on volume caused by 175M pounds of off-grade and PVC- 1200 was $ 10^0 unfavorable on volume caused by production slowdowns for contamination checks and cleanouts to assure Phillips grade production.
AP00047444
PVC
Monthly Report
-2-
March 6, 1972
SUMMARY (continued)
Production for March is forecast at 4925 M pounds with, a variance of $9240 favorable.
Production in February was 4769M pounds versus a budget of 4760 M pounds. This production was achieved mainly through production of fast cycle resin types as indicated by the unfavorable volume variance above. Total hours budgeted for those resins produced was 7253 versus an actual of 7656. We averaged 20. 7 batches per day.
An electric motor agitator drive was installed on the stainless steel reactor to drive the agitator at a constant 125 rpm. Performance on Pearls^
has improved markedly. Dr. Wiley Daniels of R&D was down to supervise a series of runs in the stainless reactor on PVC-2200. The results of this run and latest data is summarized in a report to R. W. Beech Irom W. C. Wilde, MPVC-2200 Production in the Stainless Steel Reactor*', dated February 25, 1972.
The solvent recovery and dehydration units did not operate this month. Mechanical revisions should be complete March 3 with startup on March 6. Reactors 1, 10, and 11 continue to be the onLy ones chemically cleaned.
We are encountering considerable difficulty in producing PVC-1200 and 1250 to meet the wet contamination test of Phillips Film. This is causing delays and lost production time. For example, PVC 1200 was $1020 unfavorable on volume in February. The writer made a visit to Calvert City concering this problem. The purpose was to study their operation and exchange information which might lead to improved performance on Phillips grade material.
PVC - BAGGING
A total of 3077 M pounds were bagged at a cost of $14, 410. Variance is $5,900 favorable as follows:
Volume Spending
$7,968 ( 2,065)
Greater than budget bagging was caused by the types produced in February.
AP00047445
PVC Monthly Report
-3-
March 6, 1972
STATISTICS
Prime Production
Homopoiymer Copolymer
Total
Off-Grade Ho mopolyme r Copolymer Tails
Sweeps Total
Total Production
Off-Grade, % Total Prod. Bulk Prod. , % Prime VCM Efficiency Reactor Availability Production, #/gal,yr.
Off-Grade Analysis
tYPc
2225 2160 2185 2185 2185 2185 2185 1225 6180
Lot No.
8655 8665 8667 8669 8670 8672 8674 8727 8755
Production Sequence
North Line
Batches
1225 1200
2225 2250 2200
30 25
4 30 20
February
Actual
Budget
4, 029 740
4, 7 6?
4, 128 637
4, 7 65
Year to Date
Actual
Budget
21, 637 3, 472
25, 109
21,609 3, 299
24, 908
229 36
123 10
414
5, 201
8. 0 43. 7 94. 6 84. 5 1263
261
5, 026
5. 2 94. 8 88. 5 1258
500 288 585
44 1, 417
26,526
5. 3 54. 1 94. 6 85. 1 1264
1, 364
26, 272
5.2
-
94. 8 88. 5 1258
Pounds
22,550 6, 000
36, 000 18.000 52,600 40, 000 28. 650 32, 000 36,000
Reasons
Fisheyes. Screens. Contamination. Contamination. Bulk Density, Bulk Density. Fisheyes. Contamination. Contamination.
South Line
6180 2185 8217 1225 1230P
Batches
88 29
4 39 53
AP00047446
PVC Monthly Report
.4-
Production Sequence (cont'd)
Nofth Line
1200 2200 2250 2200 2225 1200
Batches
45 44 20 69
5 20
South Line
1225 2160 6180
Downtime Analysis
Enter and Clean Reactors H. P. Water Cleaning Plugged Drop Valves Changing Types Low Drying Rates Mixing Solutions Behind on Recovery Hyd. Motor Maint. Scheduling Charges Miscellaneous
Production Summary (Prime Only)
Type
February
1185 1200 1225 12 30P 1250 2160 2185 2200 2225 2250 3185 6180 8217
674 1, 028
597
-
96 71 1, 094 48 385 740 36
February
Hours
%
371 165
23 128
26 7
48 13 205 198 1184
4. 8 2.2 0. 3 1.7 0. 3 0. 1 0. 6 0.2 2.7 2. 6
15.5
January
24b 774 895 646 159
-
1, 075 291 377
-
689
-
March 6, 1972
Batches 48 9 14
Year to Date
Hours
%
1937 720 168
449 108
81 503
78 985 978 6007
4. 8 1.8 0.4
1. 1 0. 3 0. 2 1. 3 0. 2 2.4 2. 4
14.9
Year to I
48 1, 330 4, 371 4, 908 1. 061
661 668 5, 510 668 1, 955 339 3, 472 120
AP00047447
PVC Monthly Report
-5-
March 6, L972
MAINTENANCE
1. Compressors (a) Replaced second stage valves in north recovery compressor.
(b) Adjusted cross-head on north compressor to stop knock.
(c) Repacked shaft seal on south compressor.
(d) Adjusted piston rod nut on south compressor to stop knock.
(e) Changed out valves in south compressor.
(i) Repaired loose nut on end of piston rod on south compressor.
2. Repaired overspeed trip on hydraulic oil pump steam turbine.
3. Installed electric motor agitator drive on #10 reactor.
4. Replaced automatic steam valve on. the north stripper.
5. Replaced steam sparger on #11 reactor.
6. Changed out motor and some parts in the starting gear on the north centrifuge.
DISCUSSION
The RFE for the 40 psig steam line has been approved. This RFE was revised and economics calculated on the difference of high pressure steam at standard cost and 40 psig steam at fuel value. On this basis the project shows an ROI of 30. 3% and a payout of 1. 64 years. Completion is expected by April 1, 1972.
A check on noise levels in the PVC Area indicated real improve ments lave been made in the area north of the reactor building. Previous readings of 113 - 115 decibels have dropped to 91 decibels. We have rerouted the jet exhaust through the roof on two jets and installed a muffler on the third jet.
AP00047448
PVC Monthly Report
-6-
March 6, L972
SHORT-RANGE OPERATIONAL PLANS
1. Send out inquiry for resin post blending.
2. Submit request to engineering lor estimate to recycle off-grade.
3. Prepare plans and sketches for addition of one reactor and Submit to Engineering for an estimate.
4. Prepare RFE to recycle effluent of Foxtrot pond to cooling tower at nitric acid.
LONG-RANGE OPERATIONAL PLANS
1. Submit RFE for an additional reactor at Pace.
2. Work with the PCC to reach a point where general purpose resins at Pace and Calvert are produced using the same recipe within mechanical limitations.
3. Submit RFE for hot water charging of reactors.
aw.
R. W. Beech
AP00047449
Personnel
f
AP00047450