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JOB NO:-
27/7130/1826
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PROGRESS REPORT TECHNICAL SERVICES DEPARTMENT AQ 2547?
REPORT:DATE:-
No. 2 January, 1967
Plttrlbutton :
The information ocntainod in thla Report la eonfidantlal and the recipient la aceountabla for Ita aafakeoplng. Tha lnforaatlon oontalnad auat not ba extracted or dleclooed, In part or In total, outaida Monaanto.
TITLE AUTHOR>
''Proeaaa Inprovenent Plan for Aroelora, Pyroelor A Diphenyl CaJili Parry (J>K> Blaooa)
PROBLEMI
To oontinua praaantatlon of a long ranga plan to laprova the produotlon ofAroclor, Pyroelor and Dlphanyl at Newport.
SUMMARYI
a) Rroelora
To aaet tha rive Yaar Salaa roraeaat, Aroclor oapaolty naoda to be expanded above tha prevent 9.36 S lba par annua atanderd. Tha problaa la to
aohlava thla lneraaaa oonalatant with laproving tha quality of tha flniehad product to achieve tha Coapany goala. Thaaa apply to tha electrical gradaa of 12*2 and 1264 and have been aat up for Power factor, Realatlvlty, Pater Content, Stability and Colour.
Potential chlorination capacity la adequate for the foraceat period but the lneraeeed gaaalng ratea -required will neceaeltate lnetallatlon of Brink Rlet Clialnatore to cut down antrelnnent and ao avoid bloekagaa and aalntein yield. The Jacket cooling la alao Inadequate and external faelllilee will ba required. Hlth theae addltlona, operation at the aaae levela aa M.C. will ba poealbla.
R oapaolty of 13 I lba/annuw haa bean dewonatrated In atlll triala with batch operation but dlatlllate colour la barely acceptable. It doea not neat the quality goal. Tha provlelon of lnproved antrelnnent eeparatlon and heat input faeilitlea are being lnveetlgeted. Although It la poealbla that tha exlatlng atlll nay be adequate for production beyond 1970 with oxtenelve nodlflcationa, tha lnetallatlon of a eaeond eyaten will ba required to anaure thla. The raeulting capacity would be adequate to cover 1972 production elth the 26JC exeeao availability reoonnanded at the St. Louie Quality Meeting In February, 1966.
HONS 056823
-2Evaluation of tha propoaad altamotiva treatment material (bauxite) for improvad electrical propartiaa will ba oontinuad , atarting with a plant trial undar batch oondltione* l>) Pvroolor Production raeilitiaa era adaquata for 1967/0 requiremente. Minor apaeifloation probleoe will ba inveetigeted* o) Dlohanvl Subject to approval of tha C.A.K. tha lnatallatlon of tha tubular unit olll bo procaadad alth, to mat dlphanyl raqulraoanta and avoid tha nacaaalty to laport <I.C. Olphanyl.
hONS 056824
RECAPITULATION Job Btatua
-3
vlno 8.T. II 44
SaaiiSl. li
Notae
Brink Plat Elinlnatore
Sentoaax Fual Uaa
Diphenyl Tubular Unit
C.A.R, tubalaaion lot. quarter '67
.
On line Tab. >67 4000
C.A.R. In preparation
6000 '
6000 3000
Savings from yield loss allminatlon* Cstda 2% at high chlorination ratss
4000
i,
4000 5000
Savings from raducsd oil usags * oasts disposal
: . .. 95000 305000 Savings from raducsd bsnzans
uaaga 4 flaka lnporta.
Productivity Aroelor
15000
110000 130000 -
Pyroolor
14000
1 7000 110000
1. CURRENT 1TATUB * MAJOR PROBLEM
113000
J2ZSS& 11*0000
1. Putin toll
a) Aroclora
Tha aajgr procooa problaa araa roaialna, tha production of loo pooar factor alactrleal grada Aroclor, in particular Aroolor 1242. Aaaoelatad 1th thla problaa la tha difficulty atlll anoountarad In obtaining rallabla oaaauraoanta of thla paraoatar.
Tha proooao bottlanoek oecuro in tha dlatlllatlon atop. Capacity la at proaant llaltad by tha ability of tho atlll to produce a dlatlllata of aooaptabla colour.
b)
No Major problaoa ara Involved in Pyroelor production, foao Minor dlffioultlaa ara atlll aaaoelatad alth ratraatnant of batchaa.
e) Plohanvl Thsrs ar* no major probisms associatsd with Diphanyl,
-ONS
-4-
2. Proow Yield
A) Aroolora
Principle tw aatorlal*, chlorine and diphenyl, ara aada on alta apart fro* flaka lapart required to oupplmant diphenyl production (at S% of total raqulraaant In 1966)
No aeaeuraaent facllltlaa oxlat at praaant to paralt an aeourata aatlaata of ylald.
M.C.L. uaagea oloaa to thoaa ofN.C. hava baan ahown pravloualy.
Currant uaagaa arai-
Thaoretieal Uaaga lb/1000 lb P.P.
tandard
Olffaranea Valua at 1967 ftaqulraaanta
Chlorlna 1242 1246 12S4 1260 1262
649 970 1090 1210 1250
904 1035 1165 1300 1335
4,300 490
2,300 1,100
60
"
Dlohanvl 1242 1248 1254 1260 1262
592 536 475 415 398
lna J.Od/lb
820 5,700
560 500
490 1,900
437 680
417 ________________ 30____________
1_________ Patti PlBhnrl
__________________
MONS 056626
-5-
Yield loeeee due to entrainment from tho chlorlnatora will bo
mlnimlaed by lnatallatlon of Brink Miet Cllminatora ao part of tho expansion programme, Tho capital ooot la approximately 13,000.
b) Pyroelor
Tho bulk of pyroelor production ia Pyroelor P,P,0. (Nominally 60JC 1260, 40% T.C.B. with Phanoxy Propano Oxide gee aeavangar at tha 0.2% laval). In addition, a amall demand axlata for Special Pyroelor(75% 1254, 29% TCl) Aroelor 1260 (A 1254) la tranaferred on a etanderd baaia of 620 lb/1000 lb F,P, (760 lb/1000 lb in tha oaaa of Special Pyroelor)
1964
1965
1966
Standard
T.C.9. uaagaa
lb/1000 lba r.P.
413 419 402 415
Tha lmprovamant haa reeultod from bulk handling of TC,B, and relaxation of an unnaeaaaarily tight raalatlvlty apeolfleetlon.
C) Dlohanvl
Diphenyl roqulramanta era in axeaaa of tha eapaelty of tha Load Pot unite. Operation to maxlmlaa banzone eonvaraion par paaa and banco production haa roeulted in higher banzana uaagaa.
1965
1966
Standard
Banzana uoago . gall/iOOO lb F.P.
157
160.2
162
If lnatallatlon of Tubular Diphenyl Oil la approved, Banzana aavlnga of 617,000 (at tho 5,5 i lb level) will aeorue from lower eonvaraion laval operation.
Tha existing hydrogen oompraaaor la undaraizad by appraximataly 20% and a larger unit alii bo required to achieve maximum banzana reoovery
if tha Load pote lnatallatlon la maintained, Tha oapltal coat for a new oompraaaor will be approximately 2,500.
3. a)
EXIITIMG OPACITY 4 F0MCS8TIP FUTU8C K0UIHMEHT1
L967 1*68 1969
1970 1971 1972
Sola* raqulramta
M lb. ftaqulraiaanti .1th
axtr. 29J( autg. availability N lb
10.2 ll.S 12.7 14.4
12.5 15.6
14.2 17.7
1.S 19.7
17. 22.0
* Raquiraaanta lnoluda tranafar to Pyroelor
Praaant Standard Capaeltyi Praaant rallzabla oapaoltys
9.35 5
1D.0 M lba (aaaunaa uaa of aa.l-oontinuoua faollltlaa)
HONS 05682 7
-6-
Cspscity incrsssss srs rsquirsd in ths arsas of chlorination and distillation to naat tha foraeaat figurss. Tha 29% oxeaaa capacity haa baan raeoamondad for all Aroolor plants (St* Louis Quality Stating fsbruary* 1966) to allow for ptak daaanda*
i) SMaUntfcUn
Existing capacity fetantlal oepeolty Capital
12 lb 20 S' lb 18000
Inatallatlon of a 4* chlorine transfer lina In October 1968 allaaa alaultanaaua gassing an all thraa shlarlnatara at lavala currently In operation by P.C. (up ta 1800 lb/hr)> At tha hlghar ehlarlnatlan rataa tha praaant oyolona aapatatera *111 b* unabl* to daal afflolantly alth tha lneraaaad antralnaant lead. Oaalgn oparatlan haa In any eaaa net baan achieved
due te pluggag* preble* alth farrle ehlarld*. It la prepeeed ta lnatall Brink Mint allalnatera ta alnlala* antralnaant loss**. Prallainary trial* at high ehlarlnatlan rataa have ahaan the ooellng ayataa (aatar Jackets) ta be lnadaquata. External oaallng all! bo provided! Thle *111 taka the for* of air eeelera alallar ta P.C. Installations! Hlth thla application of a.C. taohnology, ohlorlnatlan oparatlan* *111 hava aufflclant eapaelty far tha next 5 years.
11) OlatUlatlan
Standard Capacity
|). Potential Capacity (existing ayataa)
9.35 1 lb/annua
Intaraadlata 14 1 lb Potential 17 i lb
Plant trial* hava ahaan that batch eyola tines, giving eapaeltlaa of up te about 13 S lb par annua *f Arealar 1242 ora available alth tha aviating aqulpaant. At lavala In oxooaa af 10 1 lb, laa* af antralnaant aaparatlcn afflelancy
laada ta an Inoraaaa In praduot ealaur, A bread correlation bataaan batch colour
and dletlllatlon rat* axlata but alth oanalderabla variation bataaan betohee, Typloal raaulta far Arealar 1242 ara i-
Coll ATC
9
Cyala tin* hr*.
0*3
Capaolty (87* 0.8.7.) 9.4
mb.
Colour haran
3Q/40
10 7.8 io;0
40/90
13 6.2 12.6
40/80
In noreal oparatlan mxImjhAT of 9C la used an Araolar 1242 for the hlghar Arealar* (1260 and 1262) a higher apraad la uaad (up to 14C) ta alia* for the greater hoot laaaaa aaaaalatad alth the hlghar taaparatura of oparatlan,
Tha quality goals sat up In February, 1964 require a finished praduot
coleur of 10 APHA! Ta aohlev* thla, a distillation batoh colour of las* than 20 APHA
la nsoeeaary. Thus a ears efficient antralnaant separator *111 b* required if tha
till la te give eapaeltlaa over 10 1 lb ahllo atlll coating f,P colour requlraconto, Cstlaatsd capital coat la approxlaataly 12,000;
HONS 056828
7-
Installation of Ineraasad F.P, storage for Aroclor 1242E la scheduled on-line In April 1967. Ths provision of this facility will alloc ineraasad uee to bo mads of eemi-oontinuoua distillation. With Improved antrolnmant eeparatatlen to
allov realization of tha oapaclty of ths existing hasting system, a capacity of approx. 14 II lb. will ba available. (Assumes 40-50% Aroclor 1242 production sods on eeml-contlnuoue operation)
Further capacity increase will require nos equipment to Increase heat Input. Although Ineraasad esll arse (2* to 3") md a higher pumping rate (oost 11,000) sill be considered so ths first approocht experience st Krummrlch
has Indicated that a simple increase in coll dlamstor sill not give a significantly Increased heat input. In this event a nas hooter sill bs required at a oapltel coat of 5000. This step may become necessary at on earlier ataga If consistent operation of tha present eat up elth tha higher ooll temperature differences
leads to oxeasoive problems alth higher rates of ooll pluggege A failure. High
temperature differences sill also lead te a dacraaaa in plaid associated alth
ineraasad degradation of tho still oontanta In tha coil.
Associated equipment (Aroeler oondaneer, Aroclor cooling aatar condenser) has oapaclty up to spproxlaatsly 16 f lba/enotmu Replacement of these items sill involve a capital expenditure of 2.000
2) Potential Capacity (Duplicate eyetem)
20 I lb/armum
Capital 46,000
Aa an alternative to meat tha long term capacity increase,Installation of a second distillation unit similar to tho existing one, oon ba installed and space hoo boon left in tha plant laysut far this. This sill give excess oapaclty over tha feraeaat period and tha risk af nan-fulfillment of oalaa requirements sill be eliminated.
In vies of tha expanding sales forecasts, tha accent on quality of leetrieal grads Areelcro alth reapact to electrical properties and stability together with tha high quality ermoler produced by our competitor! and tho recommendation that each Monsanto location should have 29% surge capacity, it la
possible that thla should ba tha recommended course.
ill) Stereos
Installation af increased F.P. (12 42E ) storage and improved bulk loading facilities is in hand*
Completion i Capital a
4/67 21,800
Further ataraga capacity (an extra 12,000 galls) sill ba required during 1969 to meat increased salsa volume. Coat sill ba approximately 7,500
M0NS 056829
AVERAGE W ''TIES
Charge
lb.
Chlorination batch lb.
Charge tlaa Chlorination
Olachatge tlaa
hra
Cycla tlaa
Capacity B7jt 0.S.T.R lb/ an. (par chlorinator)
Average Capacity (par chlorinator)
Total Chlorination Capacity.
Present (Avereoel operation 1142 1148 1154 1160 1162
4650 4650 4650 4650 4650 6020 8950 10.100 11620 12220
Taroet (interaedlate) 142 1148 1154 1160
no chenoe no change
1162
0.3 0.3 0.3 13.0 1S.5 17.5 0.5 0.5 0.5
0.3 0.3
22.0 23.5 0.5 0.5
no change 9.2 11.4 14.4 16.2 19.7
no change
13.8 16.3 18.3 22.6 24.3 10.0 12.2 15.2 19.0 20.5
4.1 3.9 3.9 3.5 3.5
5.9 5.4 4.9 4.4 4.3
3.9 Mb (1967 product ratio)
5.6 1 lb (1969 Product ratio)
11.7 H lba/amu.
16.BR lba/annga
InttraiditU Cycle tiaee bN*d on 3 hour* oporotion ot 600 Ifc/hvj n--lroht at 800 lt^/hr
Potential
"
" " operation aa at M.C. 2 houre 600 Ib/hr
l hour 800 Ib/hr
Raaalndar 1200 Ib/hr
OHBXMt-
flaintenence 6%
Proeaaa
2%
Othar
5%
Taroat (PoUn*'-l)
1142 1146
1160
no change no change
1162
no change 7.0 8.5 }0.5 13.0 14.C
no change
7.8 9.3 11.3 13.8. 14.
7.5 7.0 6.5 6.0 6.C
7.2 Mb (1972 Product Ratio)
21.6 A lbe/annua -
'O
2 O *
1X42
Chargas aa par ehlorinator batohi
Charga tlaa hrai Blea tiaa hra Diaoharoa tiaa hra.
0.5
4.0 0.3
Cyola tlaa hra.
Capacity 97% O.l.T. I lb Par blow tank.
4.6 14.2
1148
0.5 4.0 0.3 4.0 15.7
1154
0.5 4.0 0.3 4,0 17.7
1160
0.5 4.0 0.3 4.0 20.3
1162
0.5 4.0 0.3 4.0 21.4
Av.r.o* capacity (1967 product rati.)
par Bloa tank Total capacity
IS.8 H lb/annu. 47.4 I lb/anniaa
Doan tlaa
Maintananea Proeaaa Othar
* us i*
tir-bloolng capacity la quit* adaquata for tha foraaaac raqulramnta and no addltiona ara nacaaaary.
HCNS 056631
Distillation (l) Batch Operation
10Praaant Average Operation
Taroat (Intermediate)
1242
1246
1254
1260
1262
1242
1248
1254
1260
1262
Charge (Average 875 gall) lb
Distillation Batch
lb
Tine cycle (tiees In hours)
Charge/heat up
Recycle
Distillation
Bottoms withdrawal *
11000 10700
2.0 0.25 6.0 0.15
11700 11400
2.2 0*25 6U 0.15
12400 12100
2.6 0.25 6.2 o;2
13100 12400
3.0 0*25 6.3 0.3
13400 12700
3.0 0.25 6.4 0.3
l.S 0.15 3.75 0.15
1.7 o;i5 4.0
0.15
awe sees
2.0 0.2 5.0 0.2
2.S 0.2 6.0 0.3
2.5 0.2 6.1
0.3
Cycle ties
6.4 6.7
9.25
9.65
9.95 5.55
6.0
7.4 9.0 9,1
Capacity 87% O.S.T. M lb/annus 9.3
9.6
9.6
9.3 9.3 14,1
13.9
12.0
10.2
10.2
ctual Oletillatlon Capacity R Ibe/annue
9.3S (1967 Product Ratio)
13.3 (i960 Product Ratio)
* Bottoeia withdrawal ties hee bean diatrlbutad through batchaa In run* Normally approximately 6 batches are distilled before drafting bottos on 1242* decreasing to 2-3 batches on 1260 - 1262* Capacity increase obtained by operation at exleue temperature differences aith efficient entrainment separation to prevent product colour degradation.
(11) Seml-Contlnuous Operation )on 1242 only)
Initial charge Recovery par cycle
lb lb
11000 65000
Present
Ties cycle (tiees in hours)
Charga/heat up
2.0
Recycle Distillation *
0;25 36.0
Bottoaa withdrawal
0.5
Cycle tlae
38.75
Capacity 07% O.3.T. f lb/an.
12.3
50% 1242 on semi-contlnuous R lb/ 10
(1967 Product Ratio)
pa * A reuses 6 receivers collected before boil-- doen and bottoms withdrawal.
11000 65000
Ittttl
1*5 0.15 30*0 o;s
31 US 13*4 14 (1968 Product Ratio)
MONS 0 5 6 8 3 2
mmut
- XI
Charge ee per Dletilletion Batch.
Charge tloo hre Cool'earth addition Treetnent tiae Filtration Transfer to head tank
Cycle tine
Capacity 90* 0.3.T ft lb
1242 0.2 0.3 2.7 0.4 1.0
4.6
19.2
1246 0.2 0.3 2.7 0.4 1.0
4.6
20.4
1254 0.2 0.3 2.7 0.4 1.4
5.0
20.0
1260 0.2 0.3 2.7 0.4 1.5
5.2
19.6
1252
0.2 0.3 2.7 0.4 1.5
5.2
20.0
With the present nethod of operation (single earth treatment)
capacity la adaquata for tha foreeaat period. The ehole aubjact of traataent le under review and Porocel trlele way result In receMeendatlone
for a proceee ewendewnt. In tha light of thla development,aodlfleetlons to the eyetea will be coneldered.
b) Pvroclor
1967 I960 1869 1970 1971 1972
Selea Fereoaet W lb 1.45 1.90 2
2*90 3.40 3.6S
Standard eopmeityi 2.4 V lb.
pysoolms bleadlmg oporetlone will-bo transferred to one of the Internal Aroelor etorage tanka whleh will be equipped with agitation. Tha Incroaaa of beftah air* will give capeoity peat 1972.
Coiaplotlani Capital e
i/m 91.000
c) 1987 IW8 1989 1970 1971 1971
01phem|i Maquirw- 7.8 9.6 9U 10.S 11.5 12.5
Thm amfmtflwg capacity of the lead pot unite ia 5.5 lb. Inetalletlon of tha prepwewP tdNlir unit la under review. Operation to produce 14 ft lb annua at Minima* ftnavne usage (appaoMlmataly 10* oonveraion) ie envleaged. Increaeed capacity to available at tha expense of yield. Capital coot for the projfct la- 3B5,000 Sovlogo- available (over operation of lead pots at 5.5 ft lb level with purehaaa of excess from ft.C.) srei-
1252 1970 1971 1972 96,000 123000 146000 171000
HONS 056833
- 12
4. QUALITY
e)
Promotion of Aroelor of sufficient quality for tho European export market (in particular, Scandinavian A Italy), oontinuaa to be a matter of oonearn. Although improvement of pomar factor la the moat Important goal, in general tho propartlaa of M,CL material are inferior to competition. The principle competition la from Boyar, Germany ( Clophan A 30 and A 50 equivalent to 1242 and 1254 respectively) and Prodoloe, Trance (Pyrolene 1499 end 1476) of the two Bayer producee the auparior material with pomar factor 0.002
Quality goele eat up at the It, Louie Quality Moating (Tab. 1966) Theoo are eoneldorebly in oxoeoe of ourront production capability.
Prooarty
Baal
Paaar Factor 100C 30 e/a
Volume Aoetlvlty x 10*
0.002 10,000
0.01S 7,000
0.002
5000 -15,000
Mater Content ppm
20
30
20
Colour
10 30
a!
Stability (TCC)
0.1
- 0.07
0,2
Throe ereae in mhieh effort la being made to improve electrical quality are involved,
(l) Manufacture of Aroelor of loo PF in atorage.
Major Nevport effort la concentrated on improving earth treatment technique, Tollomlng M,C, findInge on the effeetlvaneee of Poeooel treatment
(aetlvatad Bauxite) lab, teete mere oondueted at Nampert, fteeulte confirmed that Poroeel le auparior to Fullero Earth,
hm Faetor SO C/S 100C
ilD&SttiBfl <mlM
0.0S7
ffarocal Tmft
0.006
Traataant 0.045
Tut* on anathar typ, af Alumina (Spanea) ahoaad no aljnifleant laprovaaient ever earth traataant.
MQNS 056834
- 13
An extended plant trial la echeduled to ba run In Fabruary 1967 awing 30/80 aoeh Porocel In tha praaant treetaent procedure.
In lino alth tha policy af handling alaotrlcal Aroelara In alualnlua, lnoraaaad Araelar 1242 atoraga requiroMente aa balng lnatallad in thla eeterlel* Tha equipment oanalata af a tain ooiapartiaant 12,000 gallon tank eerved by a naa elualnlue piping eyetea, ffepleoeeent af tha batch treatment tank,hoed tank and proeaaa piping in alualnlua (at a napltal coat of 16,000) olll ba prograaaad If found naoaaaary to aaat quality goala,
(2) Pravontlon of dagradatlon during loading and ahlpplng.
Phaaad alth tha inotallatlon of tha lnoraaaad atoraga ara laprovad loading faellltlaa to handle tha Tote 4ina and tankar traffic* A ahaatad building la aohadulad far araetlon in February 1967 ahloh aill alialnata oontaalnatlon introduced during loading in poor another condition**
(3) laprovaaant af Maourwaant praelalon.
An P.T*8, daalgnad ooll auitabla for taatlng oatarlal In druaa or Tata 91ft# haa boon aheon ta funotlan aatlofaetarily In lab* trial* an a drua af Araelar 1242* A C,A,R, la in praparatlan for tha pravialon of a naa aaaaurlng bridge, Taatlng af ouWgelng aatarlal In altu la expeoted to /laid groatar praelaien duo t allalnatlan af eentaalnatlon during aanpllng* A reliable taaparatura oarralatlan aill bo raqulrad ta aako full uaa of tha inotallatlon,
M,C, raaulta have Indicated that etablllty iapravaaanta ara alao gained free Porooal traataant, Alternative aathodo propoaad include K0H aaahlng of tha crude and fraetlanatlon. No aork at Noaport In thla dlraotlon la propoaad at praaant*
(b) JExitfiLtt
Thera ara no aajor quality prebleae aaaaelatad alth tha Pyroolor output*
(o) Dlohanvl
No quality prebleaa ara involved,
5,4 a. PiUmMm nd lifita
That* ara n* aajor pollution problaae In gparatlana aaaaelatad with thaoo produota.
Tha neterlale lnvalvad In Diphenyl, Araelar and Pyreclar Productlan da praaant eafety caneldaretlana. Hydrogen praduead fraa tha canvaralan unlta la at praaant oampraaaad and axheuetad ta ataaaphara. Although fleae arraatara ara lnatallad, thla rapraaanta a potential hazard, Hydragan praAjoad in Tubular Ibilt aparatlana aill ba burned In the furnace.
Minor benzone ltake art aaaaelatad alth tha Inadequate capacity of tha hydragan oanpraaaor. Banzana haa a toxic rating. Thla preblan aill alao ba allalnatad by Inatallotlon of tha tubular unit.
HONS 056835
- 14 Tho Installation of faollltlao to bum Sontonax for atoen generation will raduoa tha preaont handling rieke eoeoolated with opan pana of the oolianatoriel* Prolonged exposure to Arsclors can load to akin disorders* To eliminate rlaka from spillage* protective clothing la provided* Tha P*P*0* gae scavenger uaad in Pyroclor production la a akin irritant. Addition to tha bland tank ia at preaant a Manual operation, recllltlee are being installed for transferring tha notarial fron Carboys to tho bland vaaaal which will alinlnata tho rieka of contact to tho operator*
HONS 056636
Pinduetlon Coata.
(a) itatjMl'
(1) CawtilM Coat.
- 15 -
Staam Elactricity Pro&aaa Matar Cooling Vatar
Fual Oil
Standard Unit Coat (4/000 lb)
237 32 44 18
-ii447
Total Coat for % of Total
1967 at Standard Convaralon
rata.
Coat.
9,932 1,237 1,700 696 3.710
17,273
15.3
1.9 2.6
1.1 5,7
Labour Labour Ovarhaada Suppliaa Containara Suparvlalon Raehanlsal Cxpanaa Analytical Lab T.6.0.
TOTAL DIIKOT
lAOIAtCT KHKC1ATUM
TOTAL 10DIOCCTS
216 43 10 s 61
336 39
ji
1,182
335 -1L
498
8,346 1,662
387 194 2,357 12,985 1,507
_JSL. 45,679
12,946 6.299
19,245
12.9 2.5 0.6 0.3 3.6 20.0 2.3 1.5
20.0 9.7
TOTAL COOVCKSXON COST, 1,882
64,926
MONS 056837
(ii) ffiOPUCTIOH COST 8Y OWE
1242 (> (>
(351 (4) (.) (a)
Carth
Um
rCl3 Chlorlna Diphanyl Convaraion
12 3 5
2716 *515
1682
6310 77.5 129 7D|ia
ii 43451
o.n 0.03 0.06
.* n.s i.t
12 3 5
3109 4078
1682
631.3 7.8
13.0 8096
10620
4380
0.13 0.03 0.06
35.0 45.9
18.9
12 3 5
3500 3626
1682
mo 27.5 45.8 32083 33238
15418
0.13 0.03 0.06 39.6 41.1
19.1
12 3 5
3905 3182
1682
Total tMi. Coat6933 230490
8809 23148
8828 80922
8789
1260 fb) <c)
w (9) (5)
10 0.14
2.5 0.03 4.17 0.06 3252 44.5
2652 36.2 1402 19.1
12 3
5 4010 3037
1682
2.5 0.14 0.63 0.03 1.04 0.06
835 45.8 633 34.8
___ 350 19.?
7325
8749 1822
HC1 Cradlt
4148 106958 4.6 4748 12348 5.3 5338 48868 6.0 5958
4968 6.8 6108 1278 7,0
Total Prod. Coat
Coluan (a)
Coluan (b)
Coluan (e)
8519 219795
415 21914
8295 76036
Standard Unit Caat ^000 lb Annual ooat for 1967 at tha atatdard rata Pareantaga of Total fealtlva Coat
8194
6829
8139 1695
<30
<n 00 o n Q
- 17
(b) Pyroclor P.P.O
Standard Unit Coat Total Coat for '67 (d/QPO It)at Standard Rata
Earth
Alumina TCS 1260 PPO
2 34 4386
5000 300
9602
i9 154
19862 23027 1360
44432
% of Total Production Coat
0.02 0.3 40.2 46.5 2.7
Staaa Elactricity
167 4
171
757 1.5 -IA 0.04 775
Labaur Labaur Ovarhaada Suppllaa Suparvlalan Noh. Exp* Anal. Lab. T.I.O.
TOTAL DXCT
186 38 IS 23 73
125
-A*
10,484
643 172
82 104 331 567
m
47,524
1.7
0.4 0.2 0.2 0.7
1.1 0.4
INDIKCT DCPICCMTXM TOTAL INOXICCTS
TOTAL COST
319 IP.918
1,446 iM
1.411
3.0 1.0
MONS 056639
Prrwlot
Car th TC8 1254
Stan Electricity
labour Labour Ovorhoodo Supplier Supervlalon Mechanical Capanaa Analytical Lab T.S.O
TOTAL DlMtCt
Indirect Oapraelation TOTAL IN01NCCT
TOTAL COST
- 10
Standard Unit Coat (d/ooo lb)
46 2,746 6.304 9,090
Total Coat for % of T
1967 at atandard Produc
rata
Coat.
t
69 0.4
4,144
25.8
9,506
59.2
13,719
112
05. 127
169
--22 192
1.1 0.2
265 53 30 34
110 190 __ zz
9,979
400 2.5 60 0.5 AS 0.3 SI 0.3 166 1.0 287 1.8 109 _ _aj_
15,049
466 _12_
661
733 _U
997
4.6 1.6
10,640
16,046
MQNS 056840
C) Plph.nvl
Barrtana CO, Laad Beaton*
Stooni Cloctricity Procoot Motor Cooling aotor Tual Oil
Labour Labour Overhead* Suppllaa Contalnoro Supervision Mechanical Cxpenaa Analytical Lab T.S.0
TOTAL DIRECT
- 19
Standard Unit Coat ta/flOP ----------
3,842 23 26
___ 21 3,929
234 44 18 73
JSA 963
363 73 33 8 73
607 33 _Uffi
6,107
Total Caat Tor 1967 % 0f Tatal
at atandard rata
Pradigtion cat
88,047 527 596
... 170 90,040
52,7
0.3 0.4 0.5
5,363 1,008
413 1,673
JU 22,078
3.2 0.6 . 0.2 1.0 - 8.2
8,319 1,673
756 183 1,673 13,911 756 2.406
141,767
-
5.0 1.0
0.5 0.1
1.0 8.3 O.S
1.4
Indirect Oapraclatlan
TOTAL INOIRCCT
817 300
1,0*7
11,646 13.2,2
25,140
7.1 8.0
TOTAL COIT
7,204 in
166,927
HONS 056841
c. IMWC PLAN F08 1967
Pra lact
Capital
1. laprava Quality
-
2. Install incrtaaad 21,800 tarigi 4 bulk
leading facillti*#
3. Install Brink* 4 Cvtamal cooling
faellltlaa on ehiarlnatara
8,000
4. Inoraaaa dlatlll-
tlgn eapaelty
Altamata (1)
U,S00
Utamata (2)
145,000
5. In-llna taatlng faeilltlaa
1 1,000
6* lapravad Pymalar 1 500 handling faollltlaa
7. Tubular Kaaotar
1305,000
- 20 -
lavInna n/a
TiIjBi tffort Ban-dara
Quality
40
Quality/ aaat
raqulraaanta
20
6,000
60
fiat. m 5/17 4/67
1/68
Rant
10
raqulraaanta
Safaty
20 10
4/67 (Intaraad). (1) 1/M (11) /
4/67
4/67
195,000
1?
MONS 056842
D, WgPMT nw PREVIOUS SOAL8
1) Quality laorovoaant
A plant trial of daubla aarth traatawnt yloldad no algnirieant lncraaaa In quality. An CVDP program* run an olngla aarth traataant did ahaa lapravad produot quality and tha aptlaua lavala aatabllahad ara naa baing aparatad.
Aa a raault af trlala an druaa, taa aadlflaatlana ta tha F.P. paekaga hava baan Intraduoad.
(1) A auparlar laoquar baaad an a 30)C apoxy 7Q|1 phanalla main haa
baan Intraduoad ahleh eaablnaa raalatanea ta paaat tmm*
dagradatlan alth graatar aaehanleal atrangth. ThMttdb pravant
datarlaratlan af tha produot aa a raault of flaklMMrtha lining
thraugh aaltraatoant In ahlpoant.
"'
(2) Addition af aarth ta tha F.P. paokaga aa a ahart taro aathad af
guarantaalng tha quality af notarial an arrival at tha ouataaar. Trial druaa aara aot ta I.C.A.A. lalaa Oapartaant raport that tha ouataaar haa found thla aatarlal aatlafaetary.
2) Tltlfllt mute
- C.A.A. aubalaalan aaa dalayad dua ta ra-ovaluatlan by C.C.O. af tha eapital raqulraaanta.
3) lncraaaa Ataolara araAmtlon oaaanlty ta IQ a lb
Inatallatlan af a 4* ohlarlna aupply lino In hvadn haa allooad aparatlan af ohlarlnatara at tha raqulrad lavol.
3.3 lb
19U produotlan flguraa ahaa that a oapaelty of 5.33 N lba aaa aohlavad In 1MC oaaparad ta 3113 I lba. In 1363 .
3) lncraaaa dlnhanvl capacity ta 3.3 lb
Thia prajaot aaa far installation of aojoum peta on tha taa aulatlng unlta. Thla prajaot aaa not earrlad out aalng to Ukallhoad af approval baing glvan ta tha Tubular Unit Prajaot.
3)
Invaatlgatlan aheaad hydrogan raeavary ta bo nan-faaalbla. No aathoda axlat for an aoanaalo elaan-up ta lavala at ahleh uaa could ba aada of tha hydrogan by athar planta.
T) Plant Aaalitlvltv Motor
A call aultabla for In-llna roalatlvlty and poaar factor aaaauroaanta aaa daalgnad by M.T.I. Suoooaaful ln-drua toata aara earrlad out In Daoaabar.
CJIP/t". 3.2.67
MGNS 056843