Document owMwwNpVvGZpJv707Er246Yr

C7$bfeoductl a*ut C%emicat- A ESCAMSIA PLANT INC. INTEROFFICE MEMORANDUM To: E. A. Primeau Prom: D. H. Francke Re: PVC Monthly Report, January, 1976 Date: Copies: 12 February 1976 J. T. Barr J. M. Diamond J. E. Greasel Summary PVC production for the month of January, 1976 was 6,443M lbs. of resin. This was a rate of 208M lbs. per day or 95. 1% of budget. Major losses in production were attributable to #10 reactor being out of service for 7 days for electropolishing, contamination problems resulting in reduced rates and loss of volume due to PVC1225 being made on the North dine where production'rates are lower than budgeted. Vinyl chloride efficiency for January, 1976 remained at 95. 5% or at budget. Personnel monitoring for January, 1976 showed an increase in the number of high (greater than 1.0 ppm) 8 hour TWA sample* over previous months. This increase was probably attributable to thedncreaaed production rates and, due to the use of air masks, did not represent trde inhaled exposure. Also, the 15 minute TWA samples remained low with 100% less than 5. 0 ppm. The reactor building averaged 2. 1 ppm for the month with weekly averages ranging from 0.75 ppm to 3, 21 ppm. Total variance from budget for January was ($38M) unfavorable. Major contributing unfavorable variances include ($8M) onstream for #10 reactor, ($11M) maintenance materials due to delivery of previously ordered spare parts, ($28M) business volume due tc. product mix, and ($17M) due to undistributed chemical cleaning costs to Calvert City. The major favorable variances for the month were $13M throughput volume, $10M labor charges, $9M support services, $47M price variance, and $17M systems variance. AP00041688 PVC Monthly Rpt. , Jan., 1976 Page 2 D. H. Francke J aima ry Production for the month, of January, 1976 consisted of PVC1225, PVC1230 and PVC2200. There were contamination problems in each product type during the month. Most of the contamination appeared to be from resin which had come out of the charge system. This material probably got into the charge system due to an operational problem and due to the volume, bypassed the filters into the reactors. A complete system cleanup seemed to eliminate the problem. PVC1225 production was good during the month. All of the production was on the North product line due to the need for PVC 1230 on the South line. This helped keep the production rate below the budgeted 737 lbs. per hour (based on a 100% running time) at an actual rate of 707 lbs. /hr. This was basically due to the fact that the reaction cycles on the North line are longer than on the South line and because of the reactors. Fisheye levels were generally higher than recent previous production. Although still below the specification level, this increase is probably a reflection of 'increased charging rates. PVC 1230 production was good with the only quality problem being the contamination mentioned above. Actual production rates of 791 lbs. /hr. (based on 100% running time) compared poorly with the budgeted 937 lbs. /hr. rate (same basis). This was due primarily to the outage of #10 reactor. 'With this taken into consideration, the actual rate was 910 lbs. /hr. The remaining difference reflects the contamination problems and lower conversions experienced. Budgeted rates for PVC1225 and PVC1230 were figured on an 80% conversion. Both products are experiencing lower conversions of 78% and 75% respectively. This lower conversion is a reflection of lower pressure drops to enhance stripping and possibly the higher rates (shorter reaction times) being seen. If this reduced conversion is considered, the production rates of 707 lbs, /hr. for PVC 1225 and 910 lbs. /hr. for PVC 1230 (#10 reactor downtime taken into effect) would be comparable with rates of 719 lbs. /hr. and 880 lbs. /hr. which are the budgeted equivalents of PVC1225 and PVC123Q. AP00041689 PVC Monthly Rpt., Jan., 1976 Page 3 D. H. Francke PVC 2200 production, during the month continued to experience fisheye problems with basically high 5 minute counts and 7 minute counts between 150 and 200. The fisheye size was very small and no material was offgraded. In attempts to lower the fisheye levels, the use of lauroyl peroxide was reinstituted along with the use of E-33M (t-Butyl Perneodeconate). The respective levels were varied to achieve the best fisheye levels. This helped but did not completely solve the problem. The particle size distribution was also high with most samples having 40-50% retained on a 50 mesh screen. Variations in the Ultra Wet 60 and MBCP levels made little or no effect in the particle size. This problem will continue to be worked on in February. A special two lot run of PVC 2200 using a latex additive was made during January. .This run showed some improve ment in both fiaheyes and particle size. The material was bagged for customer samples. The problem with fisheyes is a continually reoccurring problem with the PVC 2200. This problem continues to need to be worked on in the laboratory to provide the unit with information on the effective ratios of MBCP/Ultra Wet 60L, their effectiveness vs. pH, and the effects of different initiators or combinations on fisheyes and/or the suspending system. This work must get some priority over currently planned work if consistently good PVC 2200 is to be made, a necessity if some customers are to use PVC 2200. Residual monomer levels in finished resin continued at the levels experienced in December, 1975. Although the levels in the lots fluctuated, the shipment analysis continued to be below 50 ppm. The fluctuation in the lot analysis is a reflection of the increased charging rates, even with the new stripper. Below is a summary of the analysis for the month. The numbers in parenthesis under PVC 1230 and PVC 2200 are the averages if several high readings were not included in the averages. Although these high values were not reasonable, the analysis was not repeated since they were on lot composites, not bulk cars. # Lots Avg. VCM 1225 31 41 PVC Resins Residual VCM January, 1976 1230 91 (85) 53 (43) 2200 26 (24) 40 (31) # Shipments Avg. VCM 6 27 19 31 5 16 AP00041690 PVC Monthly Rpt. , Jan. , Page 4 D. H. Francke 1976 Maintenance repairs during January were generally minor with respect to production. Considerable electrical time was spent on determining the sudden cause of problems with running two fans and one pump on the east PVC cooling tower. It seemed that with one pump and one fan, running power would remain on the tower. With startup of the second fan, the circuit would trip. The cause was traced back to an improper trip being used and the addition of two Masar backup pumps on the same circuit, which were running. This problem was corrected. The valve on the Nash compressor separator level control caused extensive problems when it began to plug. The replacement valve had never been received so the order was canceled and a spare automatic valve from the old vinyl acetate charge system was installed. #10 reactor was finally electropolished in January. The reactor was out of service for 7 days (16B reactor hours) while the work was done. The walls had been mildly attacked but they took what was called a "good" polish. The reactor was put back in service and is running very well from a fouling aspect. High amperage is still causing cleaning on a 7-8 batch frequency but fouling is minimum at that time. Prior to pblishing, cleaning due to fouling was every 3-5 batches. Considerable OSHA related work was done during January. This was generated from two sources. First, all purge systems were reworked to secure good sealing and diBpersion and process equipment continued to be tied into compressors, both activities designed to reduce worker exposure. The duct work and valving in the purge systems were checked for leaks and were repaired where needed. To eliminate back draft into the building from these vents, one was extended to above the building and two others had rain caps removed to permit line velocity to carry the gases further above the building. Work on the process equipment included piping to connect the weigh tanks and filters into the recovery system to facilitate maintenance work. The second source of projects for OSHA compliance for a "mock" OSHA inspection by the plant and group safety engineers. This inspection generated some specific items which were quickly corrected plus several general areas which are being worked on. Personnel Monitoring The personnel monitoring during January continued with the frequency being twice/ month per man entering the PVC area. The sampling schedule is set up to monitor each person entering the PVC area during the month on an 8 hour TWA and a 15 minute TWA sample. The result for January showed that on a total of 67-8 hour TWA samples, 28% were below 0. 5 ppm, 48% were below 1.0 ppm and 78% were below 3.0 ppm. Of a total of 42-15 minute TWA samples, 69% were below 0. 5 ppm, 79% were below 1.0 ppm, 96% were below 3.0 ppm and 100% were below 5.0 ppm. AP00041691 PVC Monthly Rpt. , Jan. , 1976 Page 5 D. H. Francke PPM Supervisor Senior Reactor Solution Recovery Finishing Utility A rtisan Maintenance Subtotals % of Totals (67) <. 5 1 3 1 1 3 1 2 3 4 19 2B% 8 HOUR SAMPLES . 5-1 3 1 2 1 2 1 3 13 20% 1 -3 3 3 2 1 2 3 4 1 1 20 30% 3-5 1 1 1 1 4 6% 5-10 1 3 4 6% 10-15 >15 21 l 12 43 6% 4% Supervisor Senior Reactor Solution Recovery Finishing Utility A rtisan Maintenance Subtotals % of Totals (42) 4 3 4 3 4 2 4 2 3 29 69% 15 MINUTE SAMPLES 1 1 1 2 4 10% 1 1 1 3 7 17% 2 2 4% j AP00041692 PVC Monthly Rpt, , Jan. , 1976 Page 6 D. H. Francke The area monitoring system showed some fluctuation in levels in the reactor building during the month. The system showed weekly averages through the month of 3.21 ppm, 1.07 ppm, 2. 24 ppm, 2. 39 ppm, and . 75 ppm. The monthly average was 2. 10 ppm. The reduction in the final week's average is at least in part due to the revisions and repairs to the purge systems and a restating of the procedures for operators to follow in keeping VC1 levels down. These areas will continue to be worked on for more improvements, Future Plans Continued work on OSHA compliance and projects will progress through the future with a major effort over the next several months to assure compliance. This work will include: 1 . Upgrading of the area monitoring system by the use of a computer designed for chromatographic analysis. This upgrading will be necessary to assure reliability, provide expandability for the future and to provide capability to analyze other contaminants which may be regulated in the future (TCE, DMF, etc.). 2. Continued work on increasing the recovery capabilities of VC1 from all equipment prior to opening. 3. Improved operator/maintenance training and training programs. Work on the improvement of fisheye levels in PVC2200 will be done at the plant to try and achieve the necessary relationships between suspending agents, initiators and pH to control future runs. DHF/cd Attachments D. H. Francke AP00041693 AP00041694 A. Production Reliltd Vlritnct I. Raw Material Efficiency JANUARY VARIANCE FORECAST PVC Dec. 30th 15th 26th Actual 7 (4) 06) L II. Volume a] Throughput b] Onstream c) Offgrade 29 . 3 III. Soendine (Use! a) Labor z b) Maintenance Labor c) Maintenance Material d) Utilities e) Othe r Total Spending (Use) (2) Z 15 17 IV. Soendlnc (Rate) a) Facility Service* and Overheads b) Nonfacility Service* and Overheads c) Depreciation, Taxes A In*. d) labor. Salaries, Fringes Total Spending {Rata) TOTAL PROD. RELATED VARIANCE B. V. Purchase Price Variance a) Raw Material b) Purchased Utility 4 4 60 7Z 4 e) Other Total Purchase Price "76" C. VI. Business Variances a) Volume b) System Variance 3 c) Other (17) Total Bualnaas Variances (14) TOTAL PROD. COST VARIANCES FROM STD. 1Z2 15 - 1 5 . _ 2 ZO 27 Z . Z 41 (40) 2 (38T (28) 7 (3) (30) (27) 6 (6) 4 5 Z 20 27 2 Z 17 (40) 2 !38f (19) 7 19) (21) (42) VU. Bttdgete4 Variance* a) Raw Material Coat b) Purchased Utilities Cost c) Volume d) Spending a) System Total Budgeted Variance 49 _ 18 - 15 62 TOTAL VARIANCES FROM BUDGET 40 49 . 18 . IS 82 (109) 49 - 18 - 1S 82 (124) 13 m 7 5 5 (11) (1) 9 7 3 Z __-- 26 47 (0 46 (28) (17) (28) 44 49 - 16 - 15 82 (36) Variance Exolanation 15th - VC1 efficiency at *96.0%, high initiator oaaga due to higher rates. 28th - VCI off. at 94.5%, high initiator usage both due to higher ratea. ]5th - Production higher than ltd. 28th - prod, elightly below bud. due 110 reactor O.O.S and contamination problem*. 15th - salary costs based on pay increases not yot experienced. Act. - unexpected chge. from material ordered In FY1975. 15th - lower than budgeted uaa of service organisations 1 Sth - VCM price increased to 13f/Lb, as compared to budget of 1 2. Of/lb. Act. - VCM price based on rolling avg. Materials bought in Dec. used in Jan. 15th - product mix volume effect. 1 5th - return of only partial DMF commitment from Calvert City. -H MATERIAL RALANCE ESCAMBIA PVC PLANT .t - _________________________ . ____MONTH ENDINfl 31 JAN 76____ PMR015 *1 1 RS RS % OF VCL chargeq. SUB -TOTAL TOTAL SUB-TOTAL TOTAL A VCL USED RASED ON RILLING WEIGHTS______ =! n PVC OUT TO PRODUCT ft,74ft.411 ion. no 95, 5? 1. PVC PRIME 6< 31A * 000 __ 2.--PVC.. offopade______________________ ,________ 128*000 HJ 93.62 ______ 1 .Qfl r. PVC LOSSFS iti ft:i 1. PVC TO DUMP AS SCRAP 40iA 73 ftfl.47ft _____2- DRYER DISCHARGE__________________________________328 SflU.Th_L.INEL65___________________________________________________ 5 NORTH 1 TNF 1A3 3. PVC TN FFFl IlFWT WATFO 47*377 61 .Oft . ...... .76 1 , 31 _ n VCL LOSSES___ ____________ __ _______ ___ ______________ ______ 37.RS2 *1 L - 1 . DRYER DISCHARGE 37.44ft SOUTH 1 TNF ?4127 NORTH LINE 13*319 2. STRIPPER EVACUATION 5*276 _________ ____ NORTH_______________________ 3.9B9 SOUTH1 *?87 ______________________________________________ 1- VCI TN FFFMIFNT WATER IRA 4. VCI FROM OPEN REACTORS IA.557 5. VCL FROM Rt.ENO TANK VENT 1 * 237 6* VCL FROM CONDENSER VENT 7. VCL FROM RFACTORS VFNT 7*540 ft- VCI FROM PURIFICATION COM1MN ____ 9- VCL WF I6HT_ OT FFERFNCF__________________ 30.590- ** TOTAL ACCOUNTED FOR OUT i* \- IOTA! UN ACCOUNT ED_TjD 8. 6*572* 330 AI&aA&I. fi f PA u c . 55 5ft - .08 .01 .25 .02 11 .on .no ___.45- 97. 39 2.61 AP00041695 MATERIAL BALANCE ESCAMBIA PVC PLANT ;i __________________________ Y T D ENDINO 31 JAN 76____ PMP015 *r i-- I PS SUB-TOTAL PS _* ,OE__YCI__ CHARGEQ-- TOTAL SUB-TOTAL TOTAL '! k VOL USED RASED ON BILL TNG WEIGHTS .1 23.569.466^ 100.OQ____ o, PVC OUT TO PRODUCT )| l. PVC PRIME ?. PVC OFF--GRADF 4 22*496*550 21*249*000 1 *20?t_55O-- 90*36 ______ 5*13 95.49 r. PVC LOSSES .[ 1. PVC TO DUMP AS SCRAP 1 OR * 313 ?. DRYER DISCHARGE______________________ _______ ' 1*435 >i SOUTH LTMF 710 nl NORTH l.TNF 72S ?. PVC TN FFFI UFNT WATFR 67*255 tr, 1 0 VCL LOSSES *11 1. DRYER DISCHARGE 1 04.545 SOUTH 1 TNF 70.761 NORTH LINE 33*784 s 2. STRIPPER EVACUATION 18*032 ri NORTH 13*479 SOUTH 4 t 053 3. VCI TN FFF! UFNT WATFR 0* 4. VCI FROM OPFM REACTORS S S. VCL FROM RI.FNO TANK VENT 2*024 75*404 3.397 6. VCL FROM CONOENSER VENT 28*561 K\ 7. VCI FROM RFACTORS VFNT 10*000 4 A. VCL FROM PURIFICATION COI UMN 9. VCL WEIGHT DIFFERENCE _____ 1 fl * 782- 177*003 .46 ________ lQJ___ .75 .29 223.2R1 __ _____ .44___ .95 .08 .01 .32 01 12 .04 .00 ..Qfl- r TOTAL ACCOUNTED FOR OUT H' TOTAI UNACCOUNTED FOR 22*896*834 ____ 662 63_2_ 97*19 2*81 u AP00041696 AP00041697