Document oM6ZNDKV6kgwyawxg2bGDBqRg
COMPANY CONFIDENTIAL
MANUFACTURING IMPROVEMENT PLAN
FOR
AROCLOR, PYRANOL AND AROCLOR INCINERATION
DEPARTMENTS 346, 259 AND 831
Prepared by: K. E. Boucher
fOM IMF FILES OF TMk WGK UBCWAKWy
please return
Issue Date: 1/14/74
) Sc teg J. R. Savage \V'
MONS 041354
M. I ,P . DISTRIBUTION
K. E. Boucher
c. L. Bra tsch
c. N. Deubner
R. Eden
W. C. Engman
G. j. Geers
R. L. Helder
G. A. Hippe
H. J . Horner*^
G. L. Johnson
R. M. Kountz - F4WA
V*. A. Kuhn
- B3NA
A. E. Lelsy
D. K. Lynch
R. H. Munch
- JFQ
c. Pa Con - B2SC
E. M. Potter - B2NK
W. R. Richard - T3A
J . R. Savage - B2SL
G. w. Watson
MONS 041355
TABLE OF CONTENTS Page
SUMMARY................................................................. 1
DETAILED WORK FLAN................................... 2
GENERAL PLAN:
A. CAPACITY REQUIREMENT.............. 5
B. COST - YIELD................................... C. COST IMPROVEMENT........................
6 7
D. POLLUTION CONTROL...................... 6
' E. PROCESS CONTROL............................. 9
F. PLANT IMPROVEMENT...................... 9
G. SAFETY................................................... 10
HONS 041356
MANUFACTURING IMPROVEMENT PLAN FOR AROCLOR, PYRANOL & AROCLOR INCINERATION DEPARTMENTS 246 , 259 AND 831
Page 1 12/73 WGK
SUMMARY
Current Aroclor capacity is more than adequate to meet fore casted requirements through 1984. MCS 1016 sales are expected to significantly drop during the next few years. To continue to fully use the Aroclor facilities, the manufacture of Monochloroblpheny1 Is being planned.
Projected incinerator equipment usage for returned scrap Aroclor will be only 4-3 months. To help meet the Illinois solid waste regulations, WGK plans to use the Incinerator to dispose of up to 3 M pounds of process wastes each year beginning July, 1974.
Major technical effort for 1974 will be:
1. Design facilities for the manufacture of Monochlorobiphe.nyl.
2. Restrict the loss of PCB's to the environment.
3. Provide ways to conserve energy in the operating departments.
4. Install facilities at the Aroclor Incinerator to handle WGK process wastes.
Total technical effort is estimated at 33 man-months of which 13 man-months will be process engineering. Identified projects cost $266,000 capital ($73,000 for the off-gas HC1 scrubber to be Installed January, 1974).
MOMS 041337
MANC FACTURXKG IMPROVEMENT PLAIS FOR AROCLOR, PYRA50L 6 AROCLOR INCisERATIOK - OEPT. 246. 259 i 831
ITEM SAFETY
POTENTIAL BENEFITS
WORK PLAN FOR 1974
CAPITAL (Roush Estimate)
TSD MANPOWER
ODDS OP
(Man-months)
SUCCESS PROCESS OTHER
EDC
Complete 8 high priority safety Safety - Reduction
recommendation from department of potential hazards
safety audit.
.
$20000
90Z 1
2 1/1/75
Provide automatic CI2 shut off Safety in case of electrical failure
$5,000
95Z 0
1 10/1/74
Improve column furnace controls Safety when switching from gas to oil.
$3,000
95Z 0
1 12/1/74
Provide drum unloading pump at Safety incinerator.
$2,300 Expense 95Z 1
$32,300
2
0 4/1/74 4
PROCESS CONTROL
Modify chlorinator and/or 1016 Reduce amount of distillation technique to pro Montars duce less distilled 1016 residue .
75Z 1
0 8/1/74
Maintain balance between Aroclor 1254 and MCS 1016
Eliminate burning of distilled resi due.
90Z 0
0 1/1/75
Provide temperature controls on Work simplification three Aroclor storage tanks at the incinerator.
'
$ 6,000 $ 6,000
`
100Z
0 # 1 11/1/74 11
Pge 2 12/73 WGK
GROBP RESPONSIBLE
TSD, Maint, Production TSD, Maint TSD, Maint TSD. Maint
TSD, Prod.
Marketing & Sales TSD, Maint.
HONS 041358
i 1
): 1i
i
!1
|
MANUFACTURING IMPROVEMENT PLAN
FOR AROCLOR, PTRA50L & AROCLOR INCINERATION nrPARTMENTS 246 . 259 AMP 831
Page _J_
12/73 VGK
POTENTIAL
ITEM
BENEFITS
PLANT IMPROVEMENT/EARNINGS EXPENSE
WORK PLAR FOR 1974
CAPITAL (Rough Estimate)
TSD MANPOWER
ODDS OF
(Man-nonths)
SUCCESS PROCESS OTHER
EDC
Provide storage area for lime on second level
Improved house keeping and work simplification
$ 2,000
1002
0
1 10/1/74
Pave area between department and R.R. track
Improved house keeping and pollu tion control
$ 4,500 $ 5,500
100Z
0 0
1 10/1/74 2
POLLUTION CONTROL
Identify sources of PCB's dis charges to get down to 1.0#/day level for the total plant effluent.
Environmental con trol of PCB within expected EPA guidelines.
90% 1
0
Commission 4th storage for the . handling of WGK plant process
wastes at the incinerator.
Meet Illinois solid wastes regulations for WGK plant.
$10,000
90% 1
3 7/1/74
Purchase a trailer to transfer Environmental con
Montars to the incinerator.
trol of PCB's.
$ 3,000
95% 0
0
Install off-gas HC1 Arodor c scrubber Project #8020
Environmental con trol of PCB's
$73,000
95% 1
0 1/15/74
> Eliminate air blowing in the Aroclor Dept. Project #4438
* - Provide fume scrubber for \ phenol unloading at the 3 incinerator area.
Environmental con trol of PCB?s.
Air pollution *
$ 5,000 $ 5,000
85% 1 90% 0
0 3/1/74 1 12/1/74
Install new interlocks on
Aroclor column condenser, jet system.
Air pollution Environmental control of PCB's
$ 5,000 $101,000
90% 0
4
1 10/1/74
5
GROUP RESPONSIBLE Maint.
Maint.
Pollution Group TSD, Prod.
Pollution Group TSD, Maint TSD TSD, Maint, Prod, TSD, Maint. TSD, Maint.
TSD, Maint t
MANUFACTURING IMPROVEMENT PLAN
FOR AROCLOR, PTRAXOL & AROCLOR INCINERATION DEPARTMENTS 246, 259 AND 831
Rage 4 12/73 VGK
ITEM COST IMPROVEMENT
POTENTIAL BENEFITS
WORK PLAN FOR 1976
CAPITAL (Rough Estimate)
TSD MANPOWER
ODDS OP
(Man-months)
SUCCESS PROCESS 1 OTHER
EDC
GROOP RESPONSIBLE
Reduce city water usage In Aroclor Dept. by. 150 gpra Project #4438
$14,000/yr in C.W. cost plus potential reduced treatment cost of $18,500/yr.
$9000 Expense
, 902
0
0 4/1/74
TSD, Maint.
installed
Provide monochlorobiphenyl manu Reduce fixed & bud
facturing facilities in the
geted cost for
Aroclor department
Aroclor production
Potential savings
4Qf74 - $49,000.
$120,000
902 4
8 10/1/74 TSD, Maint, Prod, Research
Investigate waste heat recovery $40,000/yr at the incinerator.
CAPACITY
Install absorber for new MCS 1489 blend at the Aroclor department.
New sales
To be determined $ 129,000
257.
$20,000
902
10
58
1` 12
10/1/74
l i 6/1/74
TSD TSD, Maint.
s
x
'
fro
_
041360
MANUFACTURING IMPROVEMENT PLAN FOR AROCLOR, PYRANOL & AROCLOR INCINERATION DEPARTMENTS 246 , 259 AND 831WGK
Page 5 12/73
A CAPACITY REQUIREMENTS
Budgeted sales for Aroclor and Pyranols are shown below from the 11/27/73 MIC Company Production Plan.
SALES AND USE FORECAST
Product
1974
1975
1976
1979
1016 1221 1242 1254
27.5 0.1 7.1 8.9
14.8
0.1 6.5 9.0
11.1 0.1 6.6 9.0
9.5 0.0 6.3 8.5
above Includes Aroclor required for the following:
19 84
5.4 0.0 4.6 8.1
Product
Using 1242 Inerteen 54201 CM
Using 1254 Pyranol A13B3B-3
Inerteen 70-30
1974 7.0 . 1.1 6.6
1975 6.5 1.1 6.7
1976 6.5 1.1 6.7
1979 6.2 1.1 6.4
1984 4.6 1.1 6.3
Existing capacity In more than adequate.
Product
1016
1221 ^ 1242 > 1254 '
Pyranols & Blends
Capacity 50.AM lb/yr (present actual)
_ 21.6M lb/yr
20.3M lb/yr
MONS 041361
MANUFACTURING IMPROVEMENT PLAN FOR AROCLOR, PYRANOL & AROCLOR INCINERATION DEPARTMENTS 246. 259 AND 831WGK
Page 6 12/73
A. CAPACITY REQUIREMENTS (continued)
Additions 1 chlorination and dlstllla tion cap acity la av allable Monochlor ob ipbenyl ma nu facture is be ing cons idered Ex pec ted requlreme nt 6 are 6 M lb /yr by fou r th quarter of 19 74 an d 1 5 M lb/yr by f 0 urth quart er 1975 or f irs t quarte r 1976 . An nua 1 savings f or Aroclor p ro ductlon by sp reading the b a se f 0 r f lxed and budge te d coats ar e $50,000/ye ar for the fourth q uar ter 197
In order to make 6 M po unda/year of Monochlo roblph en y l the MCS 1016 prod UC tion capac ity will nee d t 0 be Inc reased f rom 50 , 4M lb/yr to 64 a 6M lb/yr. This debot tie necking can be a cco mpl ishe by removi ng the Arocl or distillat Ion column blankl ng s t rip 8 an altering th e chlorlna to r CI2 feed CO ntrol va lvea.
By June, 19 74, a new ca pacltor bl end may be made 1 n the Ar oclo
depar linen t. MCS 1489 a 10% blen d 0 f Toly 1x yIsulf on e i n MCS 1016 will r equtre the a ddition of an other po rocel ad sor ber .
B. COjLTj-...YIELD
The value of the dif f er ence betwee n 19 74 bud ge t e d usage a nd th eory
la e qual to $ 340, 000. Of this amo unt $98,000 1 s the valu e 0 f the HC1 gas that Is n ot rec overed. In stallation 0 f the hydro chi or lc
acid facillti es t 0 pe rm It recov ery of the off- ga s HC1 wll 1 b e on hold until au file lent e nvironme nta 1 justificat lo n exists In th e f utu re. $235 ,000 la yi eld loss In Biphenyl an d Chlorine. Abo ut half of thl6 Is 1 068 S8 Montar res ldue. The r emaining ar e
pegged CI2 losses and unaccountable.
1. Raw Material Efficiency
Budget
Product
Material
Usace tf/ewt
Aroclor 1016 (81104)
Chlorine . Biphenyl HC1 (credit)
91.04 62.61
27.68
Theory #/cwt
82.60 59.86 42.47
Difference #/cwt
1974 Budget Cost__$///
Value of Dlf f erence 927.55M S/yi
8.44 2.75 14.79
.04290 .09675 .01100
$100,000 73,000 45,000
Aroclor (81100)
Pyranols (81090)
Chlorine Biphenyl HC1 (credit)
107.399 52.516 32.658
TCB 15.24
99.881 51.466 65.316
7.518 1.05 32.658
.04290 .09675 .01100
14.93
0.31
.143 TOTAL
814.71851 Sly
$ 47,000 150,000 53,000
814.718M Sly
1-A __
$339,500
MOMS 04136i
MANUFACTURING IMPROVEMENT PLAN FOR AROCLOR, PYRANOL fi. AROCLOR INCINERATION DEPARTMENTS 246, 259 AND 831
Page 7 12/73 WGK
B COST - YIELD (continued)
2 Raw Materials
Alternate raw material sources have not been considered. Major raw materials - chlorine and biphenyl - are produced by Monsanto.
If Monochlorobiphenyl is produced, biphenyl may be supplied by Dow, the customer.
Raw material specifications are adequate with regard to the quality of the finished goods produced.
3. Total Production Cost - Bulk
MCS 1016 Aroclors Pyranols
13.208 C/0 14.308 C/# 15.872 c/tf
c COST IMPROVEMENT
In the area of cost improvement the major technical effort in 1974 will be twofold.
1. Provide facilities for Monochlorobiphenyl manufacture ($49,000/year savings).
2. Evaluate various ways to conserve energy ($40,000/yr potential savings).
A project to reduce city water usage in the Aroclor department has been designed and will be installed by May, 1974.
Monochlorobiphenyl - The existing MCS 1016 production equipment will be altered so to have the following capacity by 4th Qtr., 1974.
Product
Capacity
Annual Months Occupancy
MCS 1016
5.4 M 0/mo. 5.1 mo. @ 27^5M #/yr
Monochlorobiphenyl 1.4 M 0/mo. 5.7 mo. @ 8 M #/yr
The new Monochlorobiphenyl department will have the capability of making 8 M fl/yr of mono while still producing 1016 at budget. To meet 1254/1242 sales the number of active chlorinators may need to be increased from 2 to 3.
HONS 041363
MANUFACTURING IMPROVEMENT PLAN FOR AROCLOR, PYRANOL & AROCLOR INCINERATION DEPARTMENTS 246, 259 AND B31
Page 8 12/73 V7GK
C. COST IMPROVEMENT (continued)
Energy Conservation
At the incinerator the beat release at a design feed rate of 1250 lbs/hr is about 12 M BTU/hr. Assuming an efficiency of 75%, 80% on-stream time about 6.4 M lb/hr of 200 pound steam could be generated saving some $40,000/year. Installation of a waste heat boiler will be evaluated.
When Monochlorobiphenyl is manufactured, city water usage at the column will be increased from 125 gpm to 175 pm. The Aroclor column will have a heat load of about 12 M BTU/hr and the resulting sewered water will be near 100C. By finding a use for this water, not only would there be considerable energy saved, but elimination of this water to the 6ewer would help to reduce the plant effluent to less than 4370 gpm. Possible con tamination with PCB's due to leaks may considerably reduce the probability of actually achieving this water reduction.
D. POLLUTION CONTROL
Our objective at WGK is to continue Aroclor production while limiting the discharge of PCB's from the manufacturing depart ment and the incinerator area to the lowest technical achievable level.
A total of $101,000 will be spent on pollution control. Of this amount, $73,000 capital is for the new 30 tray off-gas scrubber that will remove about 90% of the organics in the chlorlnator off-gas HC1. This scrubber is scheduled to be started up In January, 1974.
To get down to 1.0 #/day PCB level plant sources of PCB's dis charges to the sewer are to be Identified. Extensive sewer sampling program is now underway by the Plant Pollution Group to determine where PCB's enter into our plant effluent. This survey is expected to provide additional jobs in 1974 to further reduce PCB's discharged to the environment.
The work plan has two items to further reduce known PCB's losses. Air blowing of crude Aroclor to remove residual HC1 gas will be eliminated by lime treatment and temperature Interlocks are to be installed on the column vent condenser to prevent the discharge of vapors to the atmosphere.
HONS 041364
MANUFACTURING IMPROVEMENT PLAN FOR AROCLOR, PYRANOL & AROCLOR INCINERATION DEPARTMENTS 246. 259 AND 831:
Page 9 12/73 WGK
D. POLLUTION CONTROL (continued)
To meet the Illinois solid waste regulation, various WGK process wastes are to be burned at the Aroclor incinerator. Some technical effort is needed to provide trailer unloading facilities.
In 1973, the transfer of Montars from the Aroclor department to the incinerator was successfully demonstrated. The old trailer used during the tests was in poor condition; a new trailer will be purchased. When burning Montars, solids are formed which slowed down the incinerator rate. These solids were ironcalcium phosphates formed by the mixing of Montars and scrap Pydrols. Production must keep these two materials from each other to prevent future problems.
The remaining pollution job is the installation of a fume scrubber at the Phenol unloading dock. Phenol is handled by the incin erator department.
E. PROCESS CONTROL
Distilled 1016 residufe is now disposed of by further batch chlorination to Aroclor 1234. The balance between MCS 1016 produced and Aroclor 1254 must be maintained to avoid the incineration of distilled 1016 residue. To prevent an imbalance:
1. Marketing must continue to maintain Aroclor 1254 sales.
2. Various operating changes at the chi orins tor 1 s and distilla tion column can be Investigated to see if the amount of 1016 residue can be reduced.
Based on the current sales forecast, no imbalance exists. How ever, in 1973 some residue had to be incinerated.
P PLANT IMPROVEMENT
Two items are planned in 1974, both holdovers from the 1973 work plan. A storage area for lime bags is needed at the second operating floor, and to Improve housekeeping the area between the Aroclor department and the railroad track needs to bo paved.
MONS 041365
MANUFACTURING IMPROVEMENT PLAN FOR AROCLOR, PYRANOL & AROCLOR INCINERATION DEPARTMENTS 246 259 AND 831
Page 10 12/73 WGK
E. SAFETY
The plan calls for the completion of eight high priority items from the 1972 department safety audit. In addition, three new safety jobs have been added.
HONS 0413b6
