Document mbj0B2MjdLpm17wXE8NaKMbOk

-J"' " ` v*-f-t<^V, COMPANY CONFIDENTIAL VW"j* Wt<* SXi-r+NW*-* ^ > Tg*---, `VC'- Anniston Plant . -v \ TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Anniston Summary C. K. Eastman A. G. Hill L. C. Lahman J. C. Landwehr G. W. Miller W. B. Papageorge W. F. Taffee . H. L. Williams Month September, 1969 Cost Improvement Results - , Est. Act. $63,120 Target $66,285 % of Target 95.SZ General Offices YTD $430,976 $438,570 98.5* H. S. Bergen / \ C. Carder V /. Danna (5) P. B. Hodges D. B. Hosmer (2) W. A. Kuhn J. A. Morgan W. R. Roblrds J. E, Smith J. A. Stephens R. J. Stratmeyer H. S. Trail OTHER LOCATIONS A. H. Foreten Alvin, Texas D. W. Jackson WGK M. Patrick So. 2nd St Organic Division The Solid Aroclor 5460 yield increase instrumentation has been installed. Calibration and start-up will begin when 5460 is produced in early October, The Sandvik belt test on Montar 5 was successfully completed. Installation costs will be estimated in October, Muriatic Acid - MIP was reviewed in plant on 9/10. Necessary revisions to be completed during October. Agricultural Division ; The Acetone Recovery project was verbally approved 9/29 for $32,125 capital and $28,600 expense. Expected savings are $40,000/yr. C.E.p. has suspended scoping and estimating activities on original Sulfur Recovery Project and will evaluate alternates to obtain the major yield savings at a lower capital cost. Niran - Tentative Process Amendments are being prepared for plant trials of Freon-21 replacing Freon-11 as chlorinator coolant and HCl replacing nitrogen as chlorination sparge gas. .. ....., - : - v .' DSNIM 377550 v- " COMPANY CONFIDENTIAL INFORMATION "This document contains confidential information which is the property of Monsanto Company. Only those portions of the document relevant to a duly authorized individual's need to know may be exerpted for him. The report must not be sent outside the Company without written approval and the recipient is accountable for its safe keeping, exerpting or otherwise disclosing of its contents and for its proper disposal." STLCOPCB4099282 Company Confidential 2. Utilities Evaluation of Central Air Compressor system started, with December report target. Design & Drafting Data being gathered for electrical protective device study which will lead to recommendations to improve reliability of overload protective devices in important feeders. Construction drawings forwarded for Biphenyl Pilot Unit building and Parathion emergency generators. Pollution Control HC1 neutralization pit continues to successfully treat all waste acid. Construction 95% complete on test unit for removal of solids in Waste Treatment Plant effluent. Start-up targeted for early October. Quality Control The Plant Quality Score was 86.1, down 7.6 from August with a YTD score of 88.1 against a 1969 target of 95.0 minimum. Unfavorable trends continue in Aroclor 5460 solubility, Aroclor 1242 low dis tillation and TC Chlorides. Raw material benzol remain at low distillation level, with intermittent high toluene. . C. Landwehr :kd DSW 377551 STLCOPCB4099283 ORGANIC DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV .DEC Sol.Aro. Level TAR 2250 2250 2250 2250 250. 225Q. 2250 2250 2250 Ind. & -Still SpG EST AFE 3015 ACT Solid Aro. TAR Lower 5060 Soft. Point ESTJ ACT --- "- 2600 2600 2600, 2600 2600 2600 2600 2600 2600 1500 5490 4390 215 C 4670 800C 4230 773O 3475 1500 5490 4890 2150 467 C 800C 423U 7730 - -- Sol.Aro.-Still Coolant temp. TAR EST. 160 170 160 170 160 170 160 170 160 - -- -- AFE 3015 ACT Sol .Aro. -Chlortor TAR Batch End EST: AFE 3015 ACT 390 -- 390 390 390 - -- ' ** 390 390 '" 390 390 590 Sol.Aro. Yield . TAR SW/R Composition EST. AFE 3016 ' ACT 2750 2750 2750 2750 2750 ?750 2750 2750 , * Solid Aro. Montar 5 Flake AFE 2949 TAR EST ACT 1080 1080 1080 1030 1080 1080 1080 1080 ---" Sol .Aro. Blend 4465 TAR EST.: ACT 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500. 1690 1920 1680 1490 710 1180 990 221r 1690 1920 1680 1490 710 1180 990 220 Sol.Aro.-Vertical Still Cond. AFE 2324 TAR EST: ACT 70 80 70 80 70 70 90 90 9 0 90 -- 70 90 90 90 90 - Sol.Aro.Cl2 T/C Dock AFE 2342 TAR EST: ACT 940 0 0 940 950 " Sol.Aro.-New Cl2 TAR Unload - No Delay EST' CED 1831 ACT 900 900 950 940 950 940 2330 5050 2320 1650 233O 2050 2320 950 940 950 Solid Aro.-Flake TAR & Drum ESI. CED 1430 ACT Liq.Aro. TAR 48-53 M #/yr. EST AFE 2545 ACT 3000 3000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 C00J rA ro '0 0 0 looo 2000 2000 2000 3000 3000 0 10 00 2000 2000 3000 300L 3000 3000 - - - *- - -- 0 5500 0 5500 -- -- - Liq.Aro."No.2 TAR 3000 3000 Still Entrain Sep. EST. AFE 3093 ACT Liq.Aro. -Montar Disposal AFE 2952 Warehouse Reduce Manpower CEA 1452 TAR EST/ ACT TAR EST; ACT 1080 1080 1080 1080 1080 1080 1080 1080 1080 1080 0 00 00 0 - 0 00 00 - 000 K' 000 ro 2000 3000 3000 3000 3000 3000 3000 3000 3000 3000 2000 2000 200C 3000 3 000 3000 3 000 3000 30.0C 2000 200C 200C 3000 3000 3000 3000 3OOP Liq.Aro.New TAR Burners #3 Still EST ACT 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 0 0 1500 3000 900 0 - 0 0 1500 3000 900 - Biphenyl Relocate TAR No. 1 Preheat EST CEA 1892 ACT HB-40 TAR 2nd Autoclave AFE 3102 EST ACT 500 500 500 1500 15 0C 0 1560 0 6 10 3000 3000 3000 2230 2580 0 3490 242C 0 500 1870 1370 500 .0 0 500 500 500 0 "151)0 0 0 1500 500 - 500 3000 3000 3000 3000 3000 3000 3000 600 9000 6000 5600 4200" 5UU 600 10,40d 8600 7450 6950 500 3000 500 3000 DSW 377552 STLCOPCB4099284 ORGANIC DIVISION 1969 TSD COST IMPROVEMENT Bi0 Improve Tower Treat. AFE ^155 Improve Pit. Power Factor Central Air System Optimize Rx Time PNP Reduce Mole Ratio NaOH/PNCB PNP New Wash Water Pump " PNP AFE 2998 Automatic pH Control PNP HC1 Filter Pump New Blow Tank HC1. 150,000 Gal.-HCl Storage Tank AFE 2468 Produce Staley Grade Acid AFE 3076 Clg-Plt, Shutdown CEA mi Hg Recover from Residue Hg Wash Tank AFE 2802 Biphenyl Productivity Total Organic By Month M $ Total Organic YTD M $ TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR Est ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT TAR EST ACT 450 0 0 900 0 0 450 5 0 900 500 500 450 0 450 584 585 450 645 450 450 450 900 900 900 900 ~9U(T 900 83O 990 900 900 900 1000 1000 1000 1000 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 0 3420 0 0 0 2940 riser 0 0 3420 0 0 0 2940 2370 4000 4000 4000 4000 4000 4000 4000 4000 4000 0 00 000 0 00 0 0 50 50 50 50 50 50 50 50 25 50 50 50 50 50 50 50 25 50 50 50 50 50 50 500 500 500 mo 330 330 200 200 200 350 340 330 340 330 340 200 200 200 200 200 200 200 200 500 200 200 200 200 200 200 1760 1760 1780 1760 1760 1780 1760 1760 1780 0 _ .' 0 2640 3290 2990 0 2830 $^$0 780 780 790 780 780 790 ** 8880 8880 8880 8880 8880 8880 8880 8880 223C +2385 L9900 i-1990C +2855 19900 250 250 3910 0 3910 . 0 250 0 0 250 0 0 250 250 250 250 00 00 0 00 5600 5600 5600 5600 Tgoo 5600 5600 5600 5600 5600 5600 5600 0 9(J0u 15,00C 0 0 0 3ffiiDl 2700 0 1800 5900 13500 0 0 0 307 8C 2700 250 29^3 $7.5 42.$ 51.1 51.6 51.6 51.6 52.7 50.. 6 27" 1 30.2 11.5 36.3 39.^5 107.4 53844 49.41C 16.5 23.8 27.8 11.4 25.75 45.9 110.$ 258J6 2JO 50.1 79.4 116.9 159.2 21(33 23lT 3133 3S.1 `417.8 47_1._3 521_.9_ 46.9 78.8 79.6 115.9 144.4 25a5 $1555 368.86 3 16.5 40.3 68.1 79.5 105.2 151.1 251.25] 319.45 2 luded for May & June **$27,780 adjustment included for months January thru June. DSW 377553 STLCOPCB4099285 AG DIVISION 1969 TSD COST IMPROVEMENT ANNUAL Cooling Tower TAR Repiping EST AFE 2598 Optimize N2 & -ACT TAR Cl2 Levels EST ACT Increase Waste TAR Acid Sales EST -ACT Chlorinator R.I. TAR EST AFE 2244 ACT : EVOP Condensation TAR Rx. EST ACT Cl2 Unloading TAR EST CEA 1831 ACT Recycle Wash TAR Water est: AFE 2960 ACT ' Parathion Recovery TAR EST AFE 2655 ACT. Reduce Acetone Losses TAR EST ACT Formulations TAR EST AFE 2897 ACT Change Cooling TAR H20 Item 7J7 EST AFE -5067 ACT Well H^O to Jets TAR EST ACT Ag. Division by Month TAR EST ACT Ag. Division YTD TAR EST ACT Ag. Division TAR untargeted-R.M. EST Charges optimizati- rACT Organic Div. TAR Untargeted - HC1 EST Catch Tank& Coale^ eACT Ag Div.-Untargeted TAR $3 Cl2 Change out EST ACT JAN 750 0 0 750 0 750 0 FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC 4^0 0 0 420 0 0 410 0 0 410 6 0 420 0 0 420 0 410 420 420 6600 6700 6700 6600 6700 6700 0 00 0 00 00 00 0 i 03 400 300 400 500 300 400 300 300 00 0 0 00 0 0. 0 O 0 250 250 250 250 250 250 00 0 * 00 750 500 500 750 750 0 12,615 0 12,615 5000 5000 5000 2000 2000 2000 0 0 1580 00 290 0 0 290 0 0 290 0 290 290 290 5800 5800 5800 - IW ON 4> OO 00 oo ip *il0 , 4300 4300 1600 1600 1600 1600 1600 1600 3000 6600 10,GCCi 4570 2000 3950 43OO 10,400 928^ 4570 1205 125 125 125 125 125 125 120 130 155 272 333 310 120 180 171 272 333 125 500 125 500 125 500 750 500 9145 9145 917-5 14675 1468 5 14685 .14575 1 448 5 14485 12$5 3,12C 6,730 10,155 4842 4033 1371C 0 12/35 4,420 10,580 9459 484: 1500 POOC 11145 20290 44i rd 58785 73470 38C45 102530 117015 12,65 23,015 37,770 41,91c 45,949 6^114 0 12,65 L7^035 27,615 37,07441,916 48,4% 0 17 OC 369 C 0 5000 0 1700 00 0 6250 596C 4690 I330lj 935C 6817 4920 - 4180 3250 DSW 377554 STLCOPCB4099286 AROCLOR Company confidential 5. E. E. Bowles, C. R. Mcllwain, J. W. Mattern, (V. R. Haupt) Evaluate QuaterphenylPolyphenyl Effects on Solid Aroclor Yields;NFC 1969 Savings $63,200 $14.000 TSD Objective B - 8(a) Radioactive source for level alarm installed. Representative from Ohmart Corp. conducted radiation survey and instrument checkout. Start up delayed because of department downtime and producing Solid Aroclors other than 5460. Expect to start mid October. Montar Use and Disposal Savings $13,000 TSD Objective Project 2952 ____________ NFC $10.000B - 8(g) Request to change route of piping to avoid going through the Chlorine plant has delayed installation of project. Necessary equipment delivery date is estimated at 4-6 weeks. Sandvik Belt Cooler for Solid Aroclor Expan- TSD Objective Montar 5 Solidificationsion EvaluationB - 8( j) The Pilot Unit Testing has been successfully completed with good results. Price and size estimations have not been finalized. However, preliminary "ball park" figures show that a belt to handle 8000^/hr. requires a cooling width of 4 ft. x 55 ft. long. The purchase price of this size unit is in the 35 M dollar range. Porocel Columns CEP 2152_________________ Assist ProductionTSD Job No. 950 North Porocel columns to treat chlorobenzenes were started up on September 19, 1969. Results of first trial were inconclusive. Further quality improvement tests are planned. The start-up of the South columns has been delayed by the Aroclor fire. Start-up is now planned for the week of October 6, 1969. BIPHENYL-SANTOWAX W. G. Niemeyer, D. A. Self, J. M. Jones, (V. R. Haupt) Debottleneck BiphenylSantowax Distillation Area to 87,6 M lbs./yr. Biphenyl______ Capacity Increase TSD Objective B - 7(a) Installation of by-pass loops with blow-out connections for the two Santowax C flow meters was scheduled for 9/10/69. However, only about one fourth of the planned work was completed. The problem was that the operators were not able to unplug the recycle line and it was not safe to cut and weld on the line. Maintenance is now scheduled to unplug the line. A capacity/performance test run will be conducted on the Santowax distillation column after the meters are re-installed and calibrated. DSW 377555 STLCOPCB4099287 BIPHENYL-SANTOWAX - (continued) .Company confidential 4 Low Biphenyl Santowax for FDA 5460;Support B - 7(b) Sales TSD Objective A tower water loop study is in progress to try to increase the cooling water flow to the Biphenyl/Santowax distillation area. Increased cool ing water flow to the distillation area is required to produce low biphenyl Santowax. . Prediction and Control of Dust Explosion Potential in Biphenyl Flaker Packaging System_______ '____________ SafetyTSD Job No. 951 At our last plant meeting on this problem, we decided to convert the biphenyl packer from fluidizing with air to fluidizing with nitrogen. However, the estimated operating expense for nitrogen is much higher than originally thought. The estimated operating cost for nitrogen will be $13,000 to $14,000 per year compared to $1500 that was originally esti mated. We plan to proceed with this conversion, in spite of the high cost, to eliminate a hazardous situation. Inert gas generation equipment will be evaluated to compare operating costs and most economical method used long term. Designed Experiment Run on Process TSD Objective No. 1 Biphenyl Furnace____________ StudyB - 7(e) All the samples have been analyzed. Preparation of a progress report is in progress. Test results will be used to update math model of this process. Install Knockout Tank on Santowax Jet Vent . SafetyTSD Job No. 862 Complete design package was transmitted to Maintenance for construction on September 9, 1969. Natural Gas Safety Shut-off Interlock Switch Safety TSD Job No. 948 Complete design package was transmitted to Maintenance for construction on September 25, 1969. S^377556 STLCOPCB4099288 Company confidential 5. HC1 G. L. Moore, L. 0. Chambers, K. G. Hale, (A. G. McCarty) Production of Staley Grade Acid - AFE-5076 __________ New Earnings $288 M TSD Objective Potential Savings $71.000B - 10(c) Savings of $13,300 resulted from the Coalescer and Catch Tank project during September. Spare elements of a modified design are being completed by the vendor. Plant pilot carbon treatment studies are scheduled to be run in November. The objectives are; 1) Accumulate design data necessary to expand the carbon treatment area, and 2) determine the carbon treatment and condi tions necessary to produce "Staley" acid. An experimental project for pilot test facilities is being issued ($700 experimental expense). ' Issue HC1 MIP __________ TSD Objective Planning;___________________ B - 1(b) Plant review was held on 9/10/69. Revisions are being made to several sections as a result of plant review. Revised copies will be submitted for final review by 10/31. Reduce High Free Cla in Muriatic Acid _______ :Quality ___________________ TSD Job No. 950 An expense project is being issued to install necessary piping to air blow a second storage tank and provide a temporary air supply until the cause and/or cure to the high Cla problem can be found. PNP L. 0. Chambers, K. G. Hale, (A. G. McCarty) Debottleneck to 1.8 M ___________________ Capacity Savings $27.500________ TSD Objective B - 9(a) Process changes targeted at reducing PNCB usage resulted in let-down problems during September. No savings resulted in September. Additional changes will be made and monitored by P. & Q.A. to attempt PNCB usage optimization. NIRAN K. G. Hale, D. W. Dudley, T. W. Lawrence, (A. G. McCarty) Demonstrate Parathion Savings $17,400 TSD Objective Recovery ________________ _______10-15% Reduced CODB - 5(a) No change in status. Construction in progress on test facilities. DSW 377557 STLCOPCB4099289 Company confidential 6. NIRAN - (continued) Acetone Recovery___________________ Savings $12,900 20% Reduced COD TSD Objective B - 5(0 Recovery tests on #3 condensation reactor indicate a 30% reduction in acetone loss. Gross savings (ethyl and methyl) from increasing acetone recovery is $40,000 per year plus a 20% reduction in COD load. Project 3340 was verbally approved 9/29 for $32,125 capital and $28,600 expense. Manpower evaluations are presently underway to determine what parts of the project will be installed during the '69 fall turn-around. Central Chlorine Unloading for Niran ________________________ Savings $21,000 _____________,______________ TSD Objective ________ B - 6(a) Evaluation of rebuilding 12 year old compressor vs. purchasing new com pressor favors the new compressor. Compressor will not be purchased or installed until late winter to prove worth of air pad on "cold chlorine cars" during winter. Sulfur Recovery $271,000/yr. Net Sevings from Residue 53% Reduction in S0oB - 5(d) TSD Objective C.E D. has suspended work on the Sulfur Recovery scope and will evaluate alternates to obtain yield savings at a lower capital cost. The new objective would be to remove sulfur and recycle organics, but not clean-up sulfur for re-use. ... Profit New Sales and Productivity Improve Chlorinator Savings $48,000/mo. per 0.5 Hour TSD Objective Cooling SystemReduction in Chlorination TimeB - 5(g) A Tentative Process Amendment is being prepared to cover plant trial of Freon-21. If approval is given, expect to begin trial approximately one month prior to the end of the 1969-1970 Ethyl run and extend approximately one month into the 1970 Methyl run. Improve Intermediate Distillation CapacityCapacity TSD Job No. 972 Possibilities are remote for obtaining significant increases in inter mediate distillation capacity with existing equipment. It is felt that thin-film or wiped-film equipment may be suitable for processing this type of material rapidly. Contacts will be made with thin-film vendors to explore the possibility of application to this problem. DSW 377558 STLCOPCB4099290 NIRAN - (continued) Company confidential 7. Replace Nitrogen with HC1 for Chlorination Sparge Savings $60.000TSD Job No. 605 _ Anniston PR&D has shown that HC1 sparge produces no adverse effects during chlorination compared to nitrogen sparge. Since HC1 is produced during chlorination, it could possible be recovered for use as sparge gas replacing nitrogen. A tentative Process Amendment will be prepared covering a plant trial of sparging with cylinder HC1. PROCESS AND QUALITY ANALYSIS J. L. Murphree, Allen Hale, (W. B. Dunlap) Process Surveillance . An 18 month downward trend in distillation level of raw material benzol was revealed, culminating in 6 tank cars out of specifications. Toluene in benzol was found to be out of spec. These factors may be related to a documented increase in Aroclor 1242 TC Chlorides over the last 5 months. PNP-Identification of Potential Savings Critical Variables______________ $60.000_____________ TSD Objective C - 3 TSD Job No. 8^9 A final report on yield study was written. Reactor settings will be ad justed and controlled experimentally to verify the statistical prediction of the study. Potential Savings Niran Still Control; _____________ $79.000TSD Job No. 964 An AFE was approved to obtain and install control equipment. Design and drafting is scheduled for the 4th quarter. Installation EDC is 3/1/70. ENGINEERING DESIGN AND SERVICES . . Mechanical/Electrical/lnstrument Design and Drafting ' . J. C, Price, J. A. Veazey, J. 0. House, G. W. Richey, B. D. Morgan, R. V. Carlisle, R, L. Brewer, J. K. Rennie, (W. F. Taffee) Design was completed on Project 3161 - $3.8 M, Automatic Temperature Control of Thio Acid Reactors #1 & 2. Review drawings were transmitted with con struction drawings to follow in October. Design is in progress on Project 3H8 - $9.7M, Modify Agitator Interlocks on all critical vessels in the Niran department. Transmittal is expected in October. os**1559 STLCOPCB4099291 ENGINEERING DESIGN AND SERVICES - (continued) Company confidential 8. The following project safety reviews were held or attended: Fire Pump Capacity Check Equipment (AFE 5227 - $4.1 M), Install Pressure Control Valves in Fire Protection System (AFE 5211 " $5.7 M), Biphenyl Pilot Unit (AFE 5297 - $15 M). A program is underway to gather data necessary for preparation of a short circuit coordination study of the electrical portion of the Niran department. The results of this study will lead to the compilation of a program for testing switches, circuit breakers, protective relays and, in general, all major electrical equipment that could cause prolonged downtime due to its failure. Training and supervisory time remained at a high level this month because of time necessary due to three recent manpower additions to the department. One E & I Technician is on loan to the Maintenance department to instruct maintenance employes in an electrical instrument course. Premises were prepared and forwarded for the following projects: Niran Intermediate Tank-Car Cleaning, Building 27 Dismantling, Eliminate "Head Knocker" at Aroclor. Drafting Review drawings were completed for the following projects: Install 4" Heat Exchanger in Biphenyl (AFE 5282 - $1.4 M), Final Wash TankPNP (AFE 5542 - $2.0 M), Automatic Temperature Control of Thio Acid Reactors (AFE 5161 - $5.8 M), Dual Chlorine Relief Valves - Niran (AFE 55IO - $5.5 M), Acetone Recovery (Electrical) (AFE 53^0 " $50.7 M). Construction drawings were completed for the following projects: Replacement of Water Loop-HCl (AFE 32b0 " $8.4 M), Biphenyl Pilot Unit (AFE 5297 - $15 M), Debottleneck Solid Aroclor (AFE 2897 - $20 M), Replace Niran Generators (AFE 5505 - $41.9 M), Install Nash Compressor at Eimco Filter-Waste Treatment (AFE 2820 - $4.6 M), Acetone Recovery - (Piping) (AFE 5540 - $50.7 M). UTILITIES ENGINEERING J. C. Price, J. 0. House, M. L. Marcum, (W. F. Taffee) Transmitted review drawings for Test Heat Exchanger (AFE 5282 - $1.4M) on Biphenyl Cooling Water. The design package will be transmitted in October. Started preparation of Utilities Improvement Items for inclusion in the Aroclor MIP. Started evaluations of projects to replace existing air com pressors with a Central Plant Air Compressor (estimated gross savings $12.0 M 16.0 M per year) and to Improve Plant Power Factor (estimated gross savings $5.0 M r $9.0 M). The premise for the power factor project is expected to be forwarded in October and for the compressor project in late November or early December. Continued work on Steam Plant MIP with completion scheduled for December 15. dS\N 37756 STLCOPCB4099292 Company confidential 9. PIANT IMPROVEMENT G. C. Goodwin, (W. F. Taffee) A premise was prepared and forwarded for Renovating Niran Control Room and Lunchroom. Design package was forwarded for: Up-grading Fire Pro tection System (AFE 3293.- $7.1 M). Messrs. K. B. Davis and J. Harrison of the Alabama State Highway Depart ment visited the plant on September 26, to discuss the relocation of Highway 202 across Monsanto property. They presented two schemes for the connection of old Highway 202 to the new 202 on the southeast side of the plant. POLLUTION CONTROL- E. G. Wright, (W. F. Taffee) Air & Ha0 Pollution Complaints Community and TSD Objective Governmental Relations ______ B - 2 No air or water pollution complaints were received at the Anniston Plant during September. P.C.B. in Choccolocco Creek ________ Pollution Abatement TSD Objective _______F - ^ The first set of samples taken from Choccolocco Creek show levels of P.C.B. from 2 to 8 PPB. These levels will be checked at periodic inter vals beginning in October with another set of samples from the creek. HC. Neutralization Pit Production Assistance TSD Objective F -4 The pit continued to neutralize all of the acid sewered this month. No un-neutralized HC1 has left the plant since August 8. The pit is showing no signs of reaching a break-through point at the present time. Plans are to continue to extensively monitor the pit until it has reached the break-through point. Choccolocco Creek Wildlife Studies ______ Pollution Abatement TSD Objective F - 4 __________ Requested Drs. Gunning and Suttkus to do another study of Choccolocco during the fall season. This study will probably be conducted during late October, Samples of the fish and other wildlife from the creek will be collected, frozen, and sent to Organic Research for P.C.B. analysis. This will provide some base data for evaluating the magnitude of the P.C.B. problem in Choccolocco. DS\N 377561 STLCOPCB4099293 Company confidential 10. POLLUTION CONTROL - (continued) Eimco Filter at Waste Treatment Production Assistance TSD Objective F - 4 TSD Job No. 808 Construction is 95% complete. Start-up is scheduled for the first or second week in October. Waste Treatment All wastes were effectively treated during September. High solids continue to be a problem. Successful operation of the Eimco filter should eliminate the problem. Average daily values for Monsanto's effluent are as follows: PNP COD Parathion BOD Specifications 5 PPM ^=200 PPM -==1.0 PPM (max.) ^200 PPM DSW 377562 STLCOPCB4099294 PLANT LABORATORIES G. W. Miller Company confidential 11. PROCESS RESEARCH AND DEVELOPMENT J. T. Bell Of the 105 PR&D mandays available in September, 63 were expended on projects outlined in the 1969 PR&D Program. The use of the remaining mandays were divided among vacation, supervision, illness, and miscellaneous. Blend Scavenger Improved Aroclor Refinement (Aroclor) ______ Electrical PropertiesJ. L. .Brown Evaluation of Type 4A Molecular Sieve as an absorbant for column refinement of Aroclor-Scavenger mixes was begun on 9/24 with completion targeted for 10/15/69. HB-40 Process Studies Determine Process _______ Variables _________________ W. H. Howard Equipment failure has temporarily suspended attempts to prepare HB-40 via a continuous process. This aspect of the study is to be continued on 10/3. The effect of quaterphenyl level on reaction times and catalyst requirements has been determined by a batch process. Santowax C has been hydrogenated to HB-40 with an extended reaction period. Biphenyl Tubular Pilot Studies Obtain Desired _____ Biphenyl/Terphenyl Ratio J. L. Brown Plans for the Biphenyl Pilot Laboratory were completed on 9/9 and trans mitted to maintenance. The plans were issued for bids on 9/10. A delay of 15 days caused by failure of contractors to bid promptly has been encountered with construction now targeted to begin on 10/15. Low Color Aroclor 5460 Develop Alternate Process _____ ;G. L. Arnett The distillation of Aroclor 5060 and 5460 over a combination of lime and NaOH is effective in reducing color. DTA studies indicate thermal stability of the combination of Aroclor 5060, NaOH, and lime up to 400C. Samples have been forwarded to St. Louis for corrosion studies. A PR&D report is being prepared. Parathion Isomer Reduction ____________Increased Yields ________ ;G. L. Arnett This project has been delayed by illness but will resume by 10/6. DSW 377563 STLCOPCB4099295 PLANT LABORATORIES -(Cont'd) Company confidential 12. PROCESS RESEARCH AND DEVELOPMENT -(Cont'd) Parathion Condensation Reaction Studies Increased YieldsI. Ransaw The project work plan has been interrupted to derive a method for determining the actual % conversion in the condensation reaction. The reliability of the method is to be determined by 10/3 with the study, as written in the work plan, to resume on 10/6. Acetone Recovery (Parathion)Reduce COD LoadG. L. Arnett Sample analyses have been made to support a plant demonstration of increased acetone removal in the condensation step. This study has been terminated. ANALYTICAL AND QUALITY CONTROL S. 0. Kemp Complaint Report Quality Number Material Customer 12-A-69 13-A-69 14-A-69 Aroclor 5460 HB-40 Aroclor 1268 Swift Addyston Plant Central Solvents YTD Quality Complaints/100 Shipments 0.24 Reason Organic Matter Color High Melt Point Target 0.20 DS\N 377564 STLCOPCB4099296 .Company confidential 13 COMMUNITY RELATIONS. PERSONNEL. RECRUITING. AND DEVELOPMENT Community Relations 1. J. C. Landwehr, W. F. Taffee and E. G. Wright attended a talk by Dr. Roy Ledbetter, Alabama State Extension Entomologist, on the positive benefits of DDT at the September meeting of the Decatur, Ala. Kiwanis Club, September 11. Personnel 1. Brode D. Morgan, BSEE from the University of Arkansas, reported to work on September 2 as Electrical-Instrument Engineer I. 2. Ralph Noel, D.O. student, Cobb High School, started to work in ED&S September 18, 1969. , 3. G. L. Moore, Co-Op from Ga. Tech, has returned to school to complete studies to obtain degree in Chemical Engineering. 4. All members of TSD attended a seminar on Parathion Poisoning Symptoms conducted by Ishmeal Ransaw, September 16, 1969. 5. All members of TSD attended Job Holders meeting conducted by W. B. Papageorge, September 24, 1969. ' Recruiting 1. Summer employes reported to school September 15: P. D. Kinnear to the University of Chicago, M. L. Marcum to the University of Tennessee, J. L. Gaines to Auburn University, and A. I. Hale to the University of Mississippi. Development 1. J. C. Landwehr participated in Innovation Exchange Program at Bridgeview Plant (Chicago), September 25-26. 2. V. R. Haupt visited the Newport England Plant to assist with Biphenyl problems, September 4-20. 3. G. L. Arnett held a seminar at the Luling Plant, Luling, La., to train decontamination team, September 25. Visitors 1. Bob McCutchan visited the laboratory September 17 concerning Aroclor. 2. W. A. Kuhn visited September 3-4 and was special guest at the seminar and barbecue for new employes. 3. George Hunt from S&PP section of CED visited the plant on September 30 concerning the electrical failure in the Aroclor department on September 27. DSW 377565 STLCOPCB4099297 PROCESS IMPROVEMENT T- 1 DISTRIBUTION OF TIME BY TECHNICAL SERVICE Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. NEW PRODUCTS PLANT IMPROVEMENT ( ASSIST OPERATIONS SPECIAL ENGINEERING SERVICES TECHNICAL MANPOWER MISCELLANEOUS ACTIVITIES AND ABSENCES DSW 377566 STLCOPCB4099298 IN MAINTENANCE FOR CONSTRUCTION 600 1 500 ~ 400 500 200 100 00 IN MAINTENANCE COMPLETED NOT CLOSED TSD PROJECT SUMMARY -------- --1 1-- ----- --j1--~ i1 s=s4 --__ --------- PROJECTS SUBMITTED FOR APPROVAL cQZo < CO o H APPROVED PROJECTS IN TSD DSW 377567 STLCOPCB4099299 LABORATORY ADMINISTRATION 0 ANALYTICAL SAMPLES 60 1967 1968 J F M A M J j i 56 i i 52 * i 48 i f A iV i44 ^ fi i ^h,// \\ 0 40 l 1V . 2400 2300 2200 ANALYTICAL MANPOWER 2100 2000 1900 1800 1700 ------i-- i i i . 1 I1 A, \1 ii i i 1 i . ^'IkJr __ ___ LU 'i *i Ii A - S 0 * ND _ Manpower/sample $/Manhours % Total Plant Operating Cost 2.0 1.5 1.0 0.5 SSBSSiSgj I czilj: (. Overtime L 111 ' 11 STLCOPCB4099300