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v-UiVK-A.NY (JONFfDENTTAL t Monsanto Anniston Plant TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Anni ston Summary C. K. A. G. L. C. J. C. G. W. W. B. W. F. H. L. Eastman Hill Lahman Landwehr Miller j | Papageorge I Taffee Williams Month September, 1969 Cost Improvement Results Est. Act. $63,120 Target $66,285 % of Target 95.27. General Offices YTD $430,976 $438,570 98.37. H. S. Bergen H. C. Carder D. Danna (5) P. B. Hodges D. B. Hosmer (2) W. A. Kuhn J. A. Morgan W. R. Robirds J. E. Smith J. A. Stephens R. J. Stratmeyer H. S. Trail OTHER LOCATIONS A. H. Forsten Alvin, Texas D. W. Jackson WGK T. 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 costa 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.D. 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 HC1 replacing nitrogen as chlorination sparge gas. DSU 014862 -N - 30 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." STLCOPCB4003238 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 OSH 014863 STLCOPCB4003239 ) ORGANIC DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR KAY JUN JUL AUG SEP OCT NOV DEC Sol.Aro.Level TAR Ind.< -Still SpG ESI AFE 3015 ACT Solid Aro. TAR Lower 5060 EST. Soft. Point ACT 2250 2250 2250 2250 2250 2250 2250 2250 2250 -- -- " -- "- - 2600 ?6oo 2600 26oo ?6oo 2600 2600 ?600 2600 1500 5490 4390 215 C 467 C aooc 4230 iiyr 3475 1500 5490 48 90 2150 467 C 80oc 4<ou 77 30 - -- Sol.Aro.-Still Coolant temp. AFE 5015 TAR EST. ACT 160 170 160 170 160 170 160 1.70 160 -- - -` * Sol .Aro. -Chlortcc TAR Batch End EST. AFE 5015 ACT 390 390 390 390 390 390 390 390 390 ---- ' " " Sol.Aro. Yield TAR SW/R Composition EST AFE 5016 ACT 2750 2750 2750 2750 2750 2750 ?750 2750 " -- Solid Aro. Montar 5 Flake AFE 2949 TAR EST ACT 1080 1080 1080 1080 1080 1030 1080 1080 -- Sol.Aro. Blend 4465 TAR EST ACT 25 Q0 2500 2500 2500 2500 25QO 2500 2590 2500 2500 2500 2500 1690 1920 1630 1490 710 1690 1920 1680 149C 710 1180 990 use 990 229 220 - Sol.Aro.-Verti- TAR cal Still Cond. EST' AFE 2524 ACT 70 80 70 80 70 70 90 90 9 0 90 - - " 70 90 90 90 90 - Sol.Aro.Cl2 T/C Dock AFE 2542 TAR EST ACT 940 940 950 0-0" Sol.Aro.-New Cl2 TAR Unload - No Delay F.ST CED 1851 ACT 950 940 950 940 950 940 950 900 900 2330 2050 2320 1650 2?5 I2050 2320 Solid Aro.-Flake TAR & Drum EST. CED 1450 ACT Liq.Aro. TAR 3000 3000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 0 0 IfloTT 2000 2000 2000 300C 3000 3000 0 0 1000 2000 200C 3000 30C1 3000 3000 3000 - - - - - - - - - - 48-53 M #/yr. AFE 2545 EST ACT 0 550c 0 550c - * Liq.Aro.'No.2 TAR 3000 3000 Still Entrain Sep. EST.- AFE 5095 ACT Liq.Aro.-Montar TAR Disposal EST AFE 2952 ACT Warehouse TAR Reduce Manpower EST. CEA 1452 ACT Liq.Aro.New TAR Burners #3 Still EST ACT 1080 1080 1080 1080 1080 1080 1080 1080 1080 1080 0 00 00 0 - 0 00 00 - 2000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 2000 2000 200C 3000 3000 3000 3000 3009 300C 2000 200C 20CC 3000 3000 3000 300C 3OOC 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 500 500 500 500 500 500 500 500 500 500 500 500 1500 0 1560 1870 0 0 TFUt 0 - 150C 0 6 10 137 0 0 0 150C 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 5000- 2230 2530 0 3490 24 2 C 0 600 9 (JOG 6000 560 c ZT2GD 5 99 600 10,40C 8600 /4 DU 6950 1 DSW 014864 STLCOPCB4003240 ) ORGANIC DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MY JUN JUL AUG . SEP OCT NOV DEC BiO Improve Tower Treat. AFE 5155 Improve Pit. Power Factor TAR EST ACT TAR EST ACT 450 450 450 450 430 450 450 450 0u 0 584 645 00 0 585 900 900 900 900 900 900 900 900 0 500 900 -ffir 900 0 500 83O 990 Central Air System TAR EST 1000 1000 1000 1000 - ACT Optimize Rx Time PNP TAR EST ACT 3? 00 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 0 5420 0 0 0 2940 i2ur 0 0 5420 0 0 0 2940 2370 Reduce Mole Ratio NaOH/PNCB PNP TAR EST ACT 4000 4000 4000 4000 4000 4000 4000 4000 4000 0 00 00 0 0 00 0 0 New Wash Water Pump * PNP AFE 2998 Automatic pH TAR EST ACT TAR 50 50 50 50 50 50 50 50 25 50 50 50 50 50 50 50 25 $n 50 50 50 50 50 500 500 500 Control EST PNP ACT HC1 Filter Pump TAR ^0 330 540 EST 330 33O 340 ACT 330 3 30 340 New Blow Tank HC1 TAR 200 200 200 200 200 200 EST 200 200 200 200 500 200 ACT 200 200 200 200 200 200 150,000 Gal.-HCl Storage Tank AFE 2468 TAR EST ACT 17$0 1760 1780 1760 1760 1780 1760 1760 1780 - u -. 0 2640 3290 2990 0 2830 343 Produce Staley Grade Acid AFE '>076 TAR EST ACT 799 799 799 780 780 790 -- - Cla Plt. Shutdown TAR EST CEA 1851 ACT 8??0 8880 8880 8880 8880 8880 8880 3380 6655 42335 19900 *i99a 223C do55 v2355 19900 Hg Recover from Residue TAR 250 g50 250 ?50 EST 3910 0 00 ACT ^910 0 0 0 Hg Wash Tank AFE 2802 Biphenyl Productivity TAR EST ACT TAR EST ACT 250 250 250 230 00 00 0u 00 5600 5600 5600 5600 5600 5600 TSoo 5600 5600 5600 5600 5600 0 9u0u 15,OCX 0 0 0 3(3733; 2700 0 1800 5900 13530 0 0 0 3078C 2700 Total Organic By Month M $ Total Organic YTD M $ TAR EST ACT TAR EST ACT 23.; 26.3 29.3 37.5 42. ? 51.1 51.6 51.6 51.6 52.7 5j-AJCLgj 27.1 30.2 11.5 56.3 39.165 107.4 53344 49.410 16.5 23.3 27.3 11.4 25.75 45.9 1102E 258J6 > 25- 3 50.1 79.4 116.9 159 .2 210.3 2ZTJ 417.8 471.-1521.9 46.9 78.8 79.6 11519 144.4 253.5 315J3L 368.86 2 16.5 40.3 68.1 79.5 105.2 151.1(361.35 131945 2 _ ** $27,780 adjustment included for months January thru June. DSW 014865 STLCOPCB4003241 > AG DIVISION 1969 TSD COST IMPROVEMENT ANNUAL JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Cooling Tower Rep iping AFE 2598 Optimize N2 & Cl2 Levels TAR EST -ACT TAR EST ACT 420 420 410 410 420 420 410 420 420 0 00 0 00 00 00 0 6600 6700 67 00 6600 6700 67 00 0 00 0 00 00 00 0 Increase Waste Acid Sales TAR EST ACT 400 500 500 400 500 3OO 400 500 300 00 0 0 00 00 0 0 0 Chlorinator R.I. AFE 2244 EVOP Condensation TAR EST ACT TAR 750 750 500 250 250 250 250' 250 250 00 0 00 500 750 750 Rx. EST 0 0 12,615 ACT 0 0 32,615 Cl2 Unloading CEA 1851 Recycle Wash Water AFE 2960 Parathion Recovery TAR EST ACT TAR EST ACT TAR 5000 5000 5000 2000 2000 2000 0 0 1580 00 290 290 290 290 290 290 00 0 00 580015800 5800 EST AFE 2655 Reduce Acetone ACT. TAR 4500 4300 4300 Losses EST Formulations AFE 2897 Change Cooling HsO Item 7J7 AFE 5067 Well H-O to Jets ACT TAR EST ACT TAR EST ACT TAR EST 1600 1600 1600 1600 1600 1600 3000 6600 10,001 4570 2000 3950 5300 10,400 9235 4570 1205 125 125 125 125 125 125 125 125 125 120 130 155 272 333 310 120 180 171 272 333 500 500 500 ACT Ag. Division by Month TAR 750 750 50C 9145 9145 91 *5 14^75 .146.8 5 1464?. ,14575, 1 443 s 14485-^ EST 12615)3,12 t 6,750 10,155 4842 4033 13,7 k ACT 0 0 12^15 1,420 10,580 9459 484 l 6488 Ag. Division TAR YTD EST ACT Ag. Division TAR untargeted-R.M. EST Charges ODtimizatiJ rACT TAR Untargeted - HC1 EST Catch Tank& Coale: eXCT Ag Div.-Untargeted TAR 750 1500 9000 11145 P029C 9<342> 441 nr 53785 75470 83045 1025 5 117015 12,635 %315 37,770 41,93c 45,949 63114 0 0 12^15t/,035 27615 57.074 41,936 48,404 0 17 0C 3690 1700 0 00 0 5000 6250 596C 4690 1330c 0 9?5C 6317 4920 l 1 EST - 4180 ^3 Cl2 change out ACT 3250 DSW 014866 STLCOPCB4003242 > AROCLOR Company confidential 3. E. E. Bowles, C. R. Mcllwain, J. W. Mattern, (V. R. Haupt) Evaluate Quaterphenyl- Polyphenyl Effects on 1969 Savings $63,200 Solid Aroclor YieldsNFC$14.000B - 8(a) TSD Objective 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 Arodors other than 5460. Expect to start mid October. Montar Use and Disposal Savings $13,000 Project 2952NFC $10.000B - 8(g) TSD Objective 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 Montar 5 Solidification Solid Aroclor Expansion Evaluation TSD Objective B - 8(1) 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 Assist CEP 2152ProductionTSD 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. Eaupt) Debottleneck Biphenyl- Santowax Distillation Area Capacity TSD Objective to 87,6 M lba./vr. BiphenylIncreaseB - 7(a) Installation of by-pass loops with blow-out connections for the two Santowax C flow meters was scheduled foT 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 01486? STLCOPCB4003243 BIPHENYL-SANTOWAX - (continued) Company confidential 4. Low Biphenyl Santowax for FDA 5460 Sale* Support TSD Objective B - 7(b) 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 Safety TSD 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 No. 1 Biphenvl Furnace Process Study TSD Objective B - 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 Safety TSD 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. DSW 014868 STLCOPCB4003244 Company confidential 5. HC1 G. L. Moore, L. 0. Chambers, K. G. Hale, (A. G. McCarty) Production of Staley Grade New Earnings $288 M TSD Objective Acid - AFE-^076Potential 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). TSD Objective Issue HC1 MIPPlanningB - 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 QualityTSD 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 $27.500B - 9(a) Capacity Savings TSD Objective 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 Recovery Savings $17,400 10-1571 Reduced COD TSD Objective B - 5(a) No change in status. Construction in progress on test facilities. DSW 014869 STLCOPCB4003245 ) NIRAN - (continued) Company confidential 6. Acetone Recovery201 Reduced COD Savings $12,900 TSD Objective B - 5(i) Recovery tests on #3 condensation reactor indicate a 307. reduction in acetone loss. Gross savings (ethyl and methyl) from increasing acetone recovery is $40,000 per year plus a 201 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 Nlran. 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 Savings from Residue531 Reduction in SOoB - 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. Improve Chlorinator Cooling System Profit New Sales and Productivity Savings $48,000/mo. per 0.5 Hour TSD Objective Reduction 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 Capacity Capacity 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 wipad-fllm 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 014870 STLCOPCB4003246 ) NIRAN - (continued) Company confidential 7. Replace Nitrogen with HC1 for Chlorinatiop SpargeSaving* $60.000TSD Job No. 60^ 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-Identlfication of Potential Savings Critical Variables$60.000TSD Job No. 839 TSD Objective C - 3 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/Inatrument 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 - $9.7`M, Modify Agitator Interlocks on all critical vessels in the Niran department. Transmittal is expected in October. DSW 014871 STLCOPCB4003247 ENGINEERING DESIGN AND SERVICES - (continued) Company confidential 8. The following project safety reviews were held or attended: Fire Pump Capacity Check Equipment (AFE 3227 - $4.1 M), Install Pressure Control Valves in Fire Protection System (AFE 3211 - $5.7 M), Biphenyl Pilot Unit (AFE 3297 - $13 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 3282 - $1.4 M), Final Wash TankPNP (AFE 3342 - $2.0 M), Automatic Temperature Control of Thio Acid Reactors (AFE 3161 - $3.8 M), Dual Chlorine Relief Valves - Niran (AFE 3310 - $3.5 M), Acetone Recovery (Electrical) (AFE 3340 ~ $50.7 M). Construction drawings were completed for the following projects: Replacement of Water Loop-HCl (AFE 3240 - $8.4 M), Biphenyl Pilot Unit (AFE 3297 - $13 M), Debottleneck Solid Aroclor (AFE 2897 - $20 M), Replace Niran Generators (AFE 3305 - $41.9 M), Install Nash Compressor at Eimco Filter-Waste Treatment (AFE 2820 - $4.6 M), Acetone Recovery - (Piping) (AFE 3340 - $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 3282 - $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 - $9.0 M). The premise for the power factor project la expected to be forwarded in October and for the compressor project in late November or early December. Continued work on Steam Plant MIP with completion scheduled for December 15. 0$W 014872 STLCOPCB4003248 PLANT IMPROVEMENT Company confidential 9. G. C. Goodwin, (W. F. Taffee) A premiae 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 Conmunity and Governmental Relations TSD Objective B-P 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. TSD Objective HC. Neutralization PitProduction AssistanceF - 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 TSD Objective Wildlife StudiesPollution AbatementF - 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, apd 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. DSW 014873 STLCOPCB4003249 POLLUTION CONTROL - (continued) Company confidential 10. Eimco Filter at Waste Treatment Production Assistance TSD Objective F - 4 TSD Job No. 808 Construction is 957. 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 Average daily 1.0 PPM 123 .17 PPM 4 PPM Specifications 5 PPM <C200 PPM *=^-1.0 PPM (max.) <.200 PPM DSW 014874 STLCOPCB4003250 ) 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 Obtain Desired Pilot StudiesBlohenvl/Terphenvl RatioJ. 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 ProcessG. 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 014875 STLCOPCB4003251 PLANT LABORATORIES -(Cont'd) Company confidential 12. PROCESS RESEARCH AND DEVELOPMENT -(Cont'd) Parathion Condensation Reaction Studies Increased Yields I, Ransaw The project work plan has been interrupted to derive a method for determining the actual 7. 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 Load G. 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 OSW 014876 STLCOPCB4003252 ) Company confidential COMMUNITY RELATIONS. PERSONNEL, RECRUITING. AND DEVELOPMENT 13- 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. Kivanis 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. 3. 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 014877 STLCOPCB4003253 ) PROCESS IMPROVEMENT DISTRIBUTION OF TINS BY TECHNICAL SERVICE Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. NEW PRODUCTS PUNT IMPROVEMENT ASSIST OPERATIONS SPECIAL ENGINEERING SERVICES uo ewcuz TECHNICAL MANPOWER MISCELLANEOUS ACTIVITIES AND ABSENCES --------- DSW 014878 STLCOPCB4003254 ) IN MAINTENANCE FOR CONSTRUCTION IN MAINTENANCE COMPLETED NOT CLOSED PROJECTS SUBMITTED FOR APPROVAL tcod 3 j oa bo tQZo C<ZO3 o H z APPROVED PROJECTS IN TSD TSD PROJECT SUMMARY DSW 014879 STLCOPCB4003255 LABORATORY AT!:I*,T5TRATIO.i 60 ANALYTICAL SAMPLES 56 52 48 44 40 2400 2300 2200 ANALYTICAL MANPOWER 2100 2000 1900 1800 1700 0.6 Manpower/sample 0.4 0.2 11.00 10.00 $/Manhours 9.00 8.00 7.00 7. Total Plant Operating Cost 2.0 1.5 1.0 0.5 | 1\ -------1------1 Overtime 7. 7 ^ 3 1 1967 _____________________________ 1963 J F M A fi- J I | JA bo .'t u STLCOPCB4003256