Document pmjO86ar8OQkgN1La2OgpeqeE
Job No.
Report No.
Date:
Title:
Aroclor Manufacturing Improvement Plan
Objective: To develop .a guide to Improvements in cost, capacity, nnd quality In the Anniston Aroclor plant.
Personnel: J. MaePheraon (L. C. Fuhrmeister)
Reported by: J. MaePherson
Summary: *
The major emphasi .will be on quality attainment in the liquid
Aroclor product Ijh.% and capacity increase in the solid Aroclors.
A summary of targets and commitments Is as follows:
v
Liquid Aroclors .
'
Year Tareet Capacity
Predicted Sales
Oualitv
Potential Savlnas/Earnlnas
1968 1969 1970 1971
53 53 65 65
42.7 44.7 46.3 49.5
Intermediate Product Strategy
229, 770 30,000
1,330, 000 30,000
Solid Aroclors
Xer Tarnct Capacity
Predicted Sales
Oualitv
Potential Savines/Earnlnzs
1968
1969 1970 1971
10.5 12 14 14
10.5 11.7 13.2
14.3
No Change No Change No Change No Change
150,100 233,800 238,200 121, 700
A commitment of 1920 technical man-hours will be required to support the target programs.
This Issuance of the MIP marks a departure from the previous PIP format a j. enough the contex is essentially the same. The plan ' Issued on 2/9/66 has been partially absorbed by a CED project with the result that only one major savings item (Afoclor still modification) was available for implementation; the item has not been installed as yet.
HONS 03617?
Section 1 2 3 4 5
7
9 10 11 12
I.
11.
III. IV. V. VI.
VII.
VIII.
X.
Title
Introduction
,
Summary of Major Targets for Future Efforts
Cencral Process Description
Market Analysis
Process Analysis
Capacity AnaLysis
Cost Analysis
Competitive Technology
Patent Status
Stream and Air Pollution
Job List
Appendix
Process Sketchs *
Comparison of Competitive Materials
Market Analysis
Production Schedules
Non-produc t ive Time
Project Networks
MIP Contributors
(1) Production
(2) PR&D
(3) Quality Operations Control
(4) Maintenance
TSD Jobs and Projects
Rofarences
Cost Analysis Data
MONS 036178
Soctlun 1 Page 1
Introduction The Process Improvement Plan (PIP) is being replaced by a Manufacturing
Improvement Plan (HIP). In general the contex is the same however the MIP is to present a broader base by including source information write-ups con tributed by personnel other than the area T.S.D. engineer. The procedures used to publish the MIP will be the same as for o PIP, the plan will be in the form of a progress report. Updating will be done when expedient to do so; certain sections may be updated quarterly while others only on necessity.
As with the PIPan MIP is to serve as a continuing guide to Improvements in cost, capacity, and quality.
The previous PIP was issued on 2/9/66. This plan was not Implemented because of product strategy changes. Divisional goals set In May 1966 required much improved quality, this was not a major objective of the previous PIP The major savings item in the 2/9/66 PIP was a labor savings project in the: finished goods area; this project has been absorbed in a CED project (Arocldr expansion CEA 1430). The second major item was a modification to the liquid Aroclor still to permit the use of indirect heating of the still and realizing fuel savings, less productdecompo>ltlon and reduced maintenance, this project has not been Installed as yet, tentative EDO is 3/1/68.
MGNS 036179
Section 2 Page 1
Recommendations to Attain Targets 1. Install adequate fixed bed refining capacity to handle all electrical
grade 1242/1254. 2. Install sttl_l modifications to allow still capacity to match chlorination
ability (65 M lba./yr.). 3. Maintain a T.S.D. effort of at least 1 engineer to attain estimated
savlngs/earnlngs. 4. Ensure that all personnel involved with Aroclor arc aware of the capacity
deficit situation in the solid product area.
HONS 036180
fag*
lUXE. I960 1969
VtilMItUY il tb/yy S3 S3
1970
65
1971
65
TA6C8TS
LL9Mld ArgclQEi
Salivated Potential Savinse/tamlOU
assn**
Intermediate
lehnr aavlnaa _______
O.S.T. aavlnea 8, 7 70
aarnlnca 221,000
total 229, 770
Product atratogy
10,000
20,000
--
30,000
Produce atrategy goal
Produce strategy goal
10,000 10,000
20,000 20,000
1, 300,000 1,330,000
--
30,000
1966 1969 1970 1971
10.5 . No Change 12 No Change 16 No Cliaitge IS No Changa
?0U4 **19\9*JL
Eatleatad fotentUl Savlnaa/EirnUaa
30,000
labor aavlnaa
__
O.S.T. aavlnaa 120,000
arnlnas
_
33,800
30,000
60,000
130,000
30,200
30,000
60,000
130,000
61, 700
60,000
60,000
total 130, 100 233,000 238,200 121, 700
HONS 036181
Section 3 Page 1
Synopsis of the Process
A. Chlorinator Arco
There are lour batch operated liquid chlotinutors, one batch
operated solid chlorinator, and one continuous chlorinator system. The
continuous system consists of four chlorinators cascaded with overflow in
scries.
.
The liquid chlorinators are charged with biphenyl and ferric chloride catalyst; charges for the solids chlorinator depend upon the Aroclor to be produced. Chlorine gas added through a sparger reacts with the charge to release HCl and heat; the HC1 gas goes to the Muriatic Acid department. The specific gravity of the crude is used as the monitoring and control variable.
Crude Aroclors from both batch and continuous chlorinator systems
ere transferred to a tank to be air blown before distillation. Figures 1,
2, and 3 in Appendix 1 are sketches of the batch, continuous, and solid
chlorinators.
`
B. Still Area
There are four stills In the Aroclor department; stills No. 2 and 3 arc used for liquid Aroclor} only, No. 4 is for solids only, and No. 1 can distill any grade of liquid or solid with the exception of 1268 and S460.
(1) Liquid Aroclors
Crude Aroclor is charged from a blowing tank or a feed tank
to a still. Hydrated line is added and a vacuum of 40 MM. Hg applied; the still charge Is then direct fired by circulation through a coil in a gas furnace,, the distillate goes forward to a receiver. The distillation la semi-continuous since ten receivers are distilled prior to drawing residue from the still. The receiver charge Is in turn transferred to a blending tank where It Is treated with Attapulgus clay and filtered. Finished product is transferred to storage tanxs prior to loading into drums or tank cara. Figure Is a sketch of a typical liquid still.
(2) Solid Aroclors
Distillation of 9olld aroclors Is similar to liquids with ' the exception that the vacuum Is approximately 10 MM. Hg. absoluta and that generally two still charges ere distilled before withdrawing residue.
Solid Aroclors 5460 and 1268 are flaked; all other refined solids are drummed from the receiver.
Figure 5 is a sketch of the solid still system.
HONS 03618*
Section J Page 2
* {
C. Chemical Equations
(1) Liquid Aroclors
Based on the forecasted demands through 1971, the average Liquid Aroclor could be called 1245.6.
Cl2Hl0 154.20
+ 3.66 Cl2 70.9
C12Hio(CL] 66+ 3'66 HCL
283.8
36.5
(2) Solid Aroclors
` Based on the forecasted demands through 1971, the average Solid Aroclor would contain 60.47, chlorine and 2.92% Biphenyl.
.971 Santowax R + .029 Biphenyl + 10 CI9
230.3
154.2
70.9
Solid Aroclor + 10 HCL
586.0
3*5
HONS 036183
Section 4 Page 1
3
Appendices IX ond III present (1) a comparison ui competitive materials with Aroclors 1242 ond 1254 and (2) an analysis if the world market for Aroclors. If Monsanto is to compete^ the following goals must be met:
1242/1254 Goals
In Plant Storage
As Packaged
1254 Resistivity 15,000>
PF (l!tc)
.3% l .1
10,000 <0.4%
1242 Resistivity 10,000>
5,000
PP (lkc)
0.6% 4 0.1) <0.9%
As Delivered
> 5,000 < 0.5% (4 0.1%)
> 3,000 < 1.0% <4 0.1)
Monsanto's share of the market in 1966 and the objectlvetfor 1971 are presented below:
Capacitor Aroclor
t
1966
1971
Domestic Non-Domestic
78.4%
71,5%
71.5% V` 67.2%
Transformer Askarcl
1966
1971
Domestic Non-Domestic
61% 59.5%
67.4% 65.8%
It must be emphasised that.the quality goals presented above were introduced at the Corporate Aroclor meeting held in St. Louis on May 9 and 10; these goals represent marketing necessity as of 1967. The Product Strategy quality goal; remain at a higher quality level since they represent n long range goal.
HONS 036184
Monsanto
OMOANIC ChCMICAlI DIVISION
FINISHED PRODUCT SPECIFICATION
waoouction
R. 0. Moodv/./R. O. Moody 3/23/67
lint
H. R. Ault/a/W. E. Ault 3/17/67
ACNCAAL OOeRIRTION
aaoouct
Export Grade
Aroclor 1254 - Electrical Grade
Anniston 3/23/67
326.13 MLKI COOS 1040-280-16-009
Section 5 Page
joswr.
127-L
su
.
1. R. Stark/s/L. R. Stark 3/21/67 QUALITY CONTROL (CHM ChemttO
S. W. Miller/s/G. W. Miller 2/23/67
CHCMICAL PQRWULA
'
Mixture
MOL WT.
AM0LI AOA ANALYSIS
Intatlve 4/27/66________________ 3x5 ot. Amber bottles
CHAR ACT ERISTIC
LIMITS
UNRESTRICTED INFORMATION
J. A. Iai-ddl* 2/21/67 utTMeo
(R) Color, APHA (R) Condition (R) Specific Gravity 0 65/15.3 *C (R) Acidity (mg KOH/gm.) (R) Moisture (H2O), ppm (R) Rtfractlva Index 0 2S'C (R) Inorganic (free) Chlorides, ppm (R) Pour Point, *C (R) Dielectric Constant
1000 Cycles 0 100*0 (R) Resistivity ohm-era
500 VDC 0 100*0, 0.1" Gap
(R) Hydrolysis Stability Test as chlorides, ppm
(R) Monsanto Stability Teat . as chlorides, ppm (R) Distillation Range, A81M D- 20, . corrected
10% Distilled by wt. 50% Distilled by wt. 90% Distilled by wt.
(R) Biphenyl, X Sulfates Dielectric Strength (9 25*C Plash Point Fire Point Vlecoelty 0 210*P (SUS) Corrosion Tast 6 hours 9 210*C with bright aluminum foil Change in wt. of A1 (%) A.C. Color, APHA A.C. Condition A.C. Acidity (mg. KOH/g.) A a C a Inorganic (free) chlorides, ppm
50 Max. Clear 1.495 - 1.505 0.010 Max. 35 Max. 1.6370 * 1.6390 0.05 Max. 7 - 12 , 4.15 - 4.35
10,000 x 10' Min.
1.0 Max.
0.5 Max.
366 - 378*C 371 - 383 *C 379 - 394*C 0.025 Max. None 35 KV, Min. None to Boll None to Boil 44 - 48
0.0 60 Max. Clear 0.010 Max. 0.05 Max.
RESTRICTED INFORMATION Power Factor <? 100*C & 60 Cycles
Report
(R) Routine Analysis, AU others Analysed by request Only
046 G-l 052 050 . 047 : 048 045 033 113
121
010
133
054
100
043 114 114 049
046 G-l 050 045
MQNS 036185
113
Monsanto
ONOANIC CHEMICALS OlVIltOM
Section 5
Page 2
1'*"""
Ex sort Grade
Aroclor 1242. El icttlcal Grade 27-L
PMODUCT CQQil
Ioept.
TENTATIVE SPECIFICATION AUTMONIttO SV
Anniston
626.12
6-12-67
1040-240-16-009
OUNCE OP SPECIFICATION
Sales
c. w. Miller_____________________________ P. G. Benlctnus Memo dated 5-11-67
ICniPTIOM
PSWMyLA
- -----
ISSUE*
CHAN ACT ENISTIC
--
|
EFFECTIVE UNTIL
6-1-68
UNRESTRICTED INFORMATION
SAMPLE POO AMALvfclt
3x5 pt. Amber bottles LIMIT*
J. A. Llddle 5/29/6 MS 7MOO
(R) Color, APHA. (R) Condition
(R) Specific Gravity (? 25*/l5.5*C (R) Acidity (mg KOH/gm) (R) Moisture, H2O, ppm (R) Refractive Index (3 25*C (R) Inorganic (free) Chlorides, ppm (R) Pour Point, *C (R) Dielectric Constant
1 XC 0 100*0 (R) Resistivity ohm-cm
300 VDC 0 100*C, 0.1" Cap (R) Hydrolyala Stability Taat
(as chlorides) ppa (R) Monsanto Stability Test
(as chlorides) ppm (R) Biphenyl, X (R) Dlatlllatlon Range (ASTM D-20,
Correctsd) 10% Distilled by wt.
90X Dlatlllad by wt. Sulfates Dielectric Strength 9 25*C Flaeh Point (*P> Fire Point Vlacoalty 0 100*F (BUS)
40 Max. Clear 1.381 - 1.392 0.010 Max. 35 Max. 1.6240 - 1.6260 0.05 Max. -14 or lower 4.70 - 4.90
5,000 x 109 Min.
0.5 Max.
0.4 Max.
0.05 Max.
325*0 Min. 360*C Max. None 35 XV Min. 338 - 392 Mona to Boll 82 92
046 G-l 052 050 047 04* 045 053 113
121
010
133
100 054
12169 (WCR) 043 114 114 049
RESTRICTED IMPORMAIIOII
Typical Values
Power Factor 0 lOO'C 60 cycles
1000 cycles
Raport Report
0.30 - 0.50 0.08 - 0.10
113
//C. W. Millar - 5-31-67 C. W. Miller - Chief Chemist
/a/H. L Willlama - 6-1-67 H. L. Williams - Production
/e/Wm. E. Ault - 6-8-67 W. B. Ault - Seles
.
/a/t. R. Stark - 6-12-67 L. R. Stark - Research
Hoy,/,. Anolyslt. All olhort Anmlyni tf r.fM.1 only
HONS 036186
1
Section 5 Png* 3
5. Process Analysis
Liquid Aroclors
A comparison of the Product Strategy quality goals and YTD Anniston performance Is as follows:
Color (APHA)
Water (ppm)
Resistivity @ 100C (xio9 ohm-cm)
Aroclors
1242
1254
14 IB
24 26
1,450
7, 7 50
Project Strategy Con Is f 1242 6 1254)
10 Max.
20 Max.
10,000 Min.
Power Factor @ 10OC (7. at 60 cps)
2.70
.85
0.2 Max.
Thermal Chemical Chloride Stability (ppm)
.26
.42
0.1 Nut.
Intermediate product specificationsar presented on the specification sheets included in this section.
To attain the targeted quality goals It will be necessary to (1)
improve the treatment capability of Aroclor refining, (2) reduce the atmospheric contamination during processing and storage, and (3) eliminate ionic contamination from the handling equipment.
It is possible to produce target quality 1234/1242 guides by multiple (3 or 4) batch absorbent treatments using Porocel (activated bauxite LVH grade). An apparent tachological breakthrough for the treatment operation is the
utilization of a fixed bed abeorbtion unit chargedwlth Procel; figure _____ shows a resistivity versus time for an experimented unit Installed on the No. 2 liquid still system in May 1967. The technique deflnately will product goal quality 1242. Laboratory tests are being conducted on Aroclor 1234, it is anticipated that 1254 will upgrade eesily. The installed unit is considered a pilot unit for a largei/ capacity bed to be designed in December 1967.
Degradation of product occurs during transfer to the storage tanks,
on occasion while in storage, and in loading operations. The quality decrease
is attributed to atmospheric contamination since the blending tanks and storage
tanks (with the exception of the two major tanks for 1254 6'.242 storage) arc free
breathers and to ionic contamination from exposed surfaces in the galvanized
piping and tank linings.
In-plant projects have been approved to install
nitrogen blanketing facilities on the storage tanks and refining systems. A
comprehensive project, CEA 1430 - Aroclor Expansion, has been prepared by CED
to provide improved storage end handling of product.Aroclors. In the liquid area this
will Include 11 new bulk storage tanks, 3 blend tanks, pumps, filters, separate
product pipe lines, tank car and tank truck loading facilities.
.
HONS 0361*7
Section 5 Page 4
Seeking all possible innovations to assist in the quality drive it has been proposed that Anniston PR&D initiate a program to define process conditioruneeded to determine when air blowing of the crude liquid is complete; TSD will prepare a project to remove contaminants from the blowing air supply.
The basic weakness of the Liquid Aroclor area is the fact that all the still
systems are botch operations and half of the available chlorinators are batch
units. Conversion to continuous would offer increased capacity, improved labor
efficiency, and optimum quality control. Projects oriented to continuous
operation Include (1) nn Anniston PR & D program to evaluate pulling sidestreams
for various grades of Aroclors from a continuous chlorination system, (2) a
proposed Oil) evaluation of crude blowing and distilling in the same unit, and
(3) a CED evaluation of converting Mo. 3 liquid still system to continuous
operation.
.
A basic need in the liquid Aroclor area is the establishment of the relation* ship between product isomer distribution and sales specifications; this in turn will
lead to control of proceas variables affecting isomer ratios and the establishment of optimum operating conditions. A TSD project to do such a study is active.
The handling of the residue (Hontars) from the stills offers a hezafd to the operators and promotes labor inefficiency. Current practice Is to drain the still residue into drums and transport the drums to the company dump. A survey of the Montar problems has been completed, evaluation and recoimendetlons will be completed by 12/15/68. '
Solid Aroclors
Solid quality is specified by softening point and color of the finished product. Quality problems were not evident until Santowax-R from the new still
(on stream Dec. 1966) was used for routine production of Aroclor 5460. Immediate production problems Included excessive HC1 evalution during distillation, Increased still residues, high product color, and Longer chlorinntor cycles. Laboratory investigations indicated that a higher quaterphcnyl content in the Santowax-R was responsible; PR & D work is continuing in an effort to provide relationships between polyphenyl content, crude chlorlator levels, and yields. A TSD study based on the lab data, will be Implemented to determine the most economical operating conditions.
A primary need la an in-line analytical Instrument to measure chlorine content of the chlorlnator charge either continuously or on demand with short US time. TSD will conduct a survey of available Instrumentation and recomnend a section besed on the duties (buy, deveiope, or wait).
Residue handling is a hazard as In the liquid still area, a major difference is that the majority of residue (Montar 5) is solid. Recommendations
for handling the solids Montars will be generated during the analysis of the Montar survey.
MQNS 036183
Section 6 Page 1 Cnpnclty Analysis Detailed analysis of the liquid and solid product lines follows however It Is important that the capacity goals of the Anniston plant be presented before any discussion. Table _____ is fl projection of the commitments and desirable capacity goals for the Aroclor plant.
i
HONS 03618?
Section & Page 2
TABLE ____
Anniston Copaclty Goals
M lbs./yr.
1968
1969
1970
1971
1972
Liquid commitment . surge (30%)
42.74 44.67 46.26 49.51 51.72 12.80 13.40 13.88 14.85 15.50
Total
55.54 58.07 60.14 64.36 67.22
Solid commitment surge (30%)
Total
10.47 3.14
13.61
11.66 3.50
15.16
13.15 3.94
17.09
14.33 4.30
18.63
15.02 4.51
19.53
HUNS 036190
Section 6 Page 3
Mould Aroclors
A brief summary of the liquid Aroclors production is ns follows:
1966
1967 YTD (Aug.)
Actual production
40, 735, 885
Scheduled production 41, 663,295
Capacity rate (Ibs/hr)
(1) design
5,974
(2) demonstrated
6,059
29, 639, 219 29, 821, 118
5,974 6, 779
87.51
The capacity raLes necessary to make scheduled production were 5430 lbs/hr for 1966 and 5955 lbs/hr for YTD, these rates are based on the actual O.S.T. However If the scheduled production had been equivalent to 48 FI lbs/yr the rates would had to.have been 6255 lbs/hr and 6430 lbs/hr based on the same O.S.T., rates of this magnitude have been demonstrated but It is stilllmperatlve that the O.S.T. of the liquid area be improved. It Is obvious that O.S.T. itself does not set the production rate, it is the combination of capacity rate and productive time. The objective is to eliminate es many cautas of the non-productive time as possible and to permit the plant to 9et its productive capacity by varying the capacity rate. Appendix V presents a tabulation of the non-productive time for 1966 and 1967 YTD (May). Table ____ is a comparison of downtime for 1966, 1967 TYD, 1967 projection, and the standard values.
TABLE _____ Liquid Aroclors Downtime Comparison
Repair Process Other
Standard Hours
259 173 Ul 605
1966
220 355 369 944
1967 YTD (Aug.)
196 122 317 635
1967 Prolection
294 163 475 952
Table _____ presents a summary of downtime causes and corrective aetione; the estimated time savings arc 5B.0 process hours and 104.3 other' hours. An additional 29.3 other hours should not re-occur. A projection, based on successful completion of the indicated actions, for future downtime is:
Repair Process Other Total Hours
294 125 342 761
MGNS 036191
Section 6 Page 4 O.S.T. for this downtime sum would be 91.27,, requiring a capacity rate of 6100 lbs/hr. which has been demonstrated. Capacity beyond 48 M lbs/yr can be gainud by Installing level Instruments on the still receivers, blend tanks, and filtrate receivers and by replacing the existing still receiver pump with identical but new pumps.__ The capacity rate estimated for this modification is 6650 lbs/hr or 53 M lbs/yr.; a project has been approved for this modification. The 53 M lbs/yr. must be considered on iriterim production plateau since the chlorination capacity is estimated at 65 M lbs/yr. Steps to exceed the 53 M lb. level include items such as improved preheat for the sitll feed, improved-still condensers, and higher capacity vacuum jets; an estimated in vestment of $85,000 will allow the still system to match the chlorination capacity. It appears that Anniston can meet the capactiy goals through 1971.
HONS 036192
TABU
Downtime Causa
Corrective Action
Time Savinas - hr* )
Responsibility
l. Walling on room In blond tank*
t. Expert grade 12<*2 to be re lined in llxed bed refining unit.
b. Install second fixed bed refining unit to handle ell 12*2; first
unit to handle all 1254.
14.5 Process 0.5 Process
| Unit installed, production I to accept as mnnuf. unit ,t . nd of 12/10/6^ demonstiu' j tIon period.(12/10/67)
,1.5.1). to design bated in j data from first unit. EDC . for Installed unlt-6/1/08.
2. Waiting on crude
Charge trim size of chlorine valvee on batch chlorlnators.
35 Process
1 Maintenance
3. Clj, plant ilown
Install drowning system so that icoclor doe* not hove accept 2lj sir mixture during maintenance operations In chlorine plant.
27.5 Othor
i T.S.D. to dosign drowning syMetn - EMC?
li. Bxport grad* Aroclor
'
5. Inventory Adjustment
a. Same as 1. a. >. Seme as l. b.
Install adequate finished product storage.
20 Other 12 Other
44. B Other
: l. 0. 1. b.
C.E.D. design package; \ estimated Installation date
10/15/68.
6. a. Uow CU pressure b. Kmpty filj cor
Install Eh Jpot/loedlng station to hendlo additional cert.
17.3 Other
Project approved, T.S.D./
j consultant doatgn package 1 toady by 12/15/67.
i n
HONS 036193
Secttort 6 Page 6
Solid Aroclors
A summary o the Solid Aroclor3 production ie as follows:
1966
1967 YTD (Aua)
Actual production Scheduled production Capacity rate (lbs/hr)
(1) design (2) demonstrated
8, 287, 766 9, 435, 599
1247 1789 73.23
6, 280,503 6, 275,675
1289 1485 79.17
Design capnclty for the plant is 10 M lb/yr.; design rates for
1967 hnvebeen adjusted to reflect the change In O.S.T. standard, 90% versus
93% (1966). When discussing capacity it important to remember that the plant
ability is measured by both O.S.T. and capacity rate. For Instance, in 1966 a
1789 Ib/hr rate was recorded with an 81.46% O.S.T. und a 1312 lb/hr rate was
experienced with 88.69% O.S.T.; YTD O.S.T. was 79.17% with a 1349 lbs/hr,Th first objective in the solid Aroclor area is to reduce as many downtime cauaia
as possible in order to Improve the O.S.T. and_malntain capacity rates at '
levels required to meet design production (10 M lbs/yr).
-
Appendix V presents a tabulation of the non-productive time for 1966 and 1967 Y.T.D. Table _____ is a;compariaon of downtime for 1966, 1967 Y.T.D., 1967 projection, and the standard values.
TABLE _____
Solid Aroclors Downtime Comparison
Standard Hours
1966
1967 VTD (Auk.)
1967 Prolectlon
Repair Process Other
431 172 172 775
732
1039 486
2257
630
209 168 1007
945 314 252 1511
Corrective actions for some if the downtime causes are presented in
Table
. Predicated on the successful completion of the proposed projects,
future downtime la estimated at:
Repair Process Other
868 313 104 1285
_ This no,o-productive time represents 14.8% downtime or 85.2% O.S.T.;
at 10 M lbs/yr. this would be capacity rate of 1360 lbs/hr., this rate has
been demonstrated. To produce more than 10 M lbs/yr there must be:
.
1. bottleneck elimination 2. improved yield 3. Improved O.S.T.
MGNS 036194
Section 6 Page 7
The most immediate bottleneck is the solids flnker; this unit can process 10.2 M lbs/yr. A new fLaker capable if handling 16 M lbs/yr is to be installed, estimated incentive for this new unit is presented in Appendix VIII. Timing of this installation will depend upon whether the unit is to be part of n CCD design package or an in-plant project.
The estimated capacity of the solids system is;
1349 lbs X 8640 hr X .90 O.S.T. X 90 goal yield
= 13 M lb/yr
hr . yr
73 actual YTD yield
To gain this 13 M lb., yield must be improved from the YTD 737, to 90% And the O.S.T. advanced to 90%; the improved O.S.T. must be gained while maintaining at least a 1349 Ibs/hr capacity rate.
A Increase in yield can be gained by an improvement in the quality of the erode (5060) produced In the No.9 chlorinator. From January l - January 4, 1967 the solids still had difficulty In finishing a distillation and experienced high evaluation of HCl at the end of a batch. The problems were traced to high quoterphenyl content (17.20%) In ssntowax R for the new still system. A Lab oratory investigation of this phenomena roported that not only did reduced j quaterphenyl content Improve yield but also reduced the chlorination time. ased on these preliminary lab results, the first estimate of the capacity gain at; a
5% quaterphenyl content would be:
1590 ibi X 8640 hr X ,90 O.S.T. X 90 yield
- 15.26 M lb/yr.
hr yr '
73 yield YTD
This calculation assumes an 2 hour decrease in chlorination time and an Improvement In yield to 90%. A plant study on the effects of varying quater phenyl content is scheduled to be completed by December 1967; data from the study
will permit a firmer estimate.
The program to-date has the ability to improve the O.S.T. to 82.5%; continued planning and updating of the project networks will be required to push the O.S.T. to 90%. Efforts will be continued to define targets for O.S.T. im provement .
' Another opportlnuity to gain in capacity to gain in capacity rate is in chlorine quality; YTD chlorine delivered to the Aroclor chlorinators la 82.4%, chlorine quality at the header from the Ci2 plant is 90%. The chlorine used in the solid system has a higher quality since the Clo vaporiser output is predominately used by solids, estimated quality is 90%. However if the delivered CI2 quality can be raised to 90% the solid feed chlorine quality would become
approximately 94.5%; this could raise the capacity rate from 1349 ibs/hr to 1415 lbs/hr. If the SW-R yield studies are fruitful that projected 1590 lbs/hr could be raised to 1672 Ibs/hr., 16.02 M lbs/yr at 907. O.S.T. and 90% yield.
Based on the analysis it would appear that Anniston can meet the solid
goals through 1970. If the solids market continules to expand it may be necessary
to install a second solids chlorinator.
,
A summary of capacity calculations is presented after Table
HONS 036195
Downtime Cauae 1. Still clrculotln 11a plugged
2. (a) Switch Cl2 cor (b) Low pressure, C12 cars (c) empty C12 car
3. Clj plant down
4. (a) Chlorlnator pump (b) C1^ dlatrubutora
TABU Corractlva Aetlon lnatall flowmeter capable of withstanding high temperatures
Install RR spur to handle two additional Cl] tank cars; loading stations will be required.
Install drowning system so that Aroclor does not have to aeeapt Cl^/alr mixture during maintenance operations in Cl^ plant.
improve availability of apart parte
11.3 Process ; TSD select and Install 46.5 Repair 1 Instrument - CPC - f
148 Other 90 Other 30 Ropalr
1 Project approved; TSD . working on desLgn,
Installation will be construced EDC 2/1/68
j TSD to design system EDC '
i
i i | Halntanancu
HUNS 036196
Section 6 Page 9
Solid Aroclor Production Potential October 18, 1967
17,500 lbs batch
* @ 16.hr/batch
13 hr/batch
* Includes downtime 1 a real cycle
1. No damage In yield or cycle time: improved O.S.T. only
17,500 lbs x 8640 hr x batch x .7917 O.S.T. = 9.21 M Ibs/yr
. batch
yr
13 hr
9.21 M lbs/yr x .8500 9.88 M Ibs/yr .7917
9.21 M lbs/yr x .9000 - 10.48 M lbs/yr .7917
i
2. Yield raised from 73% to 90%
lbs/vr
O.3.T.
11.38 12.18 12.92
.7917 .8500 .9000
3. Yield raised from 73% to 90% and cycle time dropped from 13 his to 11 hrs.
lbs/yr
O.S.T.
13.42 14.40 . 15.26
.7917 .8500 .9000
4. Yield - 90%
cyole time - 11 hr
improved Cl? quality; YTD supplied by Cl. plant 82.5 % YTD es.t. at solid chlorine i 90%*
combination of CI2 plant, chlorine + vaporizer supply
Target quality * 94.5 for solid system
lbs/vr
O.S.T.
14.10 15.10 16.02
.7917 .8500 .9000
MONS 036197
Page 10
HONS 036198
Section 7 Page l
Cost Analysis
l. Cost Variances
Table I presents a summary of the YTD variances (July 1967) for Liquid and Solid Aroclors. Comments on the individual variance item* and copies of the YTD lost report are presented in Appendix X.
The total product cost variance for 1967 is projected to be $340,000; of this amount 74% ($252,000) will be in direct conversion costs. These costs are due for the most part to unforscen Increases in TSD, Research, and Experimental costs and in some items unrealistic cost standards. A savings item in tills cost category is the production department containers; this cost in incurred by the present procedures for handling the waste Montars from the Aroclor plant. A study is being conducted to determine possible alternate handling techniques, potential savings arc estimated to be $9,300/yr.
A target in the material costs is chlorine. Total CI2 variances for the Aroclor plant amount to approximately $70,000/year. Programs required to reclaim these costa include (1) an improved monitoring system for the cell efficiency in the chlorine plant, (2) a study to determine how to improve chlorine quality, and (3) a study of chlorinator efflcicnces in the Aroclor department. Anticipated dates for the recovery of the $7 0,000 are not available at this time.
Of particular Interest are labor savings to he gained by the
installation of improved drumming, flaking, and storage facilities (CEA 1430) in
the Aroclor department. Labor requirements to meet projected production rates
are compared below in two categories, with existing facilities am! with the
improved plant:
(CEA 1430)
Year
Existing Plant
ImDrovcd Facilities
1968
1969 1970 1971
11 12 12 13
8 8 8 8
Labor savings by CEA 1430 may range from $30,000 to $50,000/yr.
An unusual cost item Is the handling of Montar 5 which is tt\e
residue from the Solids still. The material is solid in three basic forms (1)
coarse crush 375 lbs/drum (2) fine crush 375 lbs/drum, and (3) fine crush
350 lbs/drum. A comparison of 3clling price and cost are as follows:
$/lb Selling Price
Cost
Coarse crush 375 lbs/drum
$.053
$.0569
Fine crush 375 Ibs/drum
* $.053
$.0835
Fine crush 350 Ibs/drum
$.053
$.0606 .
HONS 036199
Section 7 Page 2
A study will be made on the production of labor costs in the
handling of this product. However this will continue to be a marginal item
since drum/material costs are as follows:
$/lb
Drum/Material Costs
Selling Price
Coarse crush 375 lb/drum Fine crush 375 lb/drum Fine crush 350 lb/drum
$ .0412 $ .0412 5 .0412
$ .053 $ .053 $ .053
The required reduction In labor costs is as follows:
Labor Cost
to match
Present Labor
Hanuf. Cost
Labor Cost Reduc tion
Coarse crush 375 lb/drum Fine crush 375 Ih/drum Fine crush 350 lb/drum
$ .0157 $ .0423 $ .0183
9 .012 $ .012 9 .012
9 .0037 9 .0303 9 .0063
TABLE I
YTD (July 1967) Cost Variances for Aroclors
Direct Conv. Indirect Product
Material Cost
Cost
Conv.
Cost
Liquid Total Solid Total
$ 18,234 $ 19, 567-
$ 119, 794 $ 227 9 7, 648- 9 5,857-
9 138, 175 9 42,615-
Potential Raw Material Savings
Improve Sontowax R/Blphenyl yields in the Solid Aroclors product line. If all yields can be raised to 90% the following material savings potentials exist:
1968
1969
1970
1U
1972
Solid Aroclors $30, 100 $33,800 $ 38,200 $ 41,700 $ 43, 700
Production Cost Standard yields are as follows:
Santowax R
Biphenvl
1269 4465 5442 5460
78 92 78
78 78
YTD (July) yields ore 73% vs. 78%.
MOMS 036*00
Anniston, Alabama September 22, 1967 AHOCLOK CO:C?STITIOH
Georgo R. Buchanan General Offices
Section 0 PaSe l |
A Manufacturing-IaprovacMmt Flan is beIns prepared for the Aroclor
product line at Anniston. Ona section of thlo report is entitled competitive technology.Comparison of competitive materials lias bean
performed at Anniston, however, a description of tho competing componioo is not available. Can you provide data on Bayer, Prodelec,
nnd V Items euch ao hono office, aocots, product linos,
etc, would be raoat dosirablo,
.
Thank you
JMikd
John MacPhorson
HONS 036201
Annloton, Alabama
November 8, 1967
'
Section 9 Pug<> 1
R. C. Layer Patent Attorney Conaral Offlcea
A Manufacturing Irjprovoment Plan is being prepared for the Aroclor
product line at Annloton. One section of' this report lo entitled
patent otatua. Can you furnish a brief description of the patent
situation for tho Aroclors?
.
Thank you.
v
JMPikd
MONS 036i0i
Section Id Page l
Stream ond Air Pollution
A survey of the Aroclor plant pollution will be completed by
2/15/68.
-
HONS 036203
TITLE
OftAWN BY
*k<*s
CMCCKRO
APPAOVIO
,,
DATE sS'2-4jr
CALI
AUTM. MO. JOS NO.
TS-A 804-5
MOMS 036204
MONS 036205
036208
BY.?.
............DATE.'^/*'-L..
SUBJECT..............................................................
chkd nr'f.oati:5/'AAv................ Soup.
l.`. - u;~'
SHLLI NO JOB NO..
OJ .
WCi. A 6 S O R 8 6 R
HONS 036210
UY . 3
......DAI t;
CHKD. riYj.'.i'? ..DATE. K 1.%/M'.
SUUJiiCT.
Section 12
HONS 036211
See l i on 12
cuva;;y cow-vr-, - .. RESEARCH AND DEVELOP,'.',ENT REPORT
ANNISTON PLANT
OTHER LOCATIONS
J. R. Savage - WCK P. E. llcislcr - WGK D. C. Armstrong - WGK A. F. Regan - MCL C. K. Coleman - MCL H. L. Hubbard - So. 2nd
GENERAL OFFICE
H. C. Carder P. G. Benignus R. A. Stccnrod G. R. Buchanan H. 0. Hehner R. A. Munch C. M. Williams J. Crcsce
v,, >
AppcinJ;.: II | Ke/ioi I `Jo.
V.'-L,< 1 l.
| Job No.. ..
170-50)
Dofo._ ___ . ..5-5-67 .
ANNISTON PLANT
W. B. Papageorge v L, C. Puhrmclster - \J. MacPhorson
J. G. Bryant V, R. Haupt
W. B. Dunlap
Tiller
Quality Report on Japanese Kanechlor 300 and Bayer Clophcn A-50
Personnel: Problem:
S. 0. Kemp and G. W. Miller
Quality Surveillance of Competitive Insulating Fluids In Competition with Monsanto Aroclor
Jutlificotion; Protection of Domestic Sales and Increase Potential for Foreign Sales
Summery:
Bayer Clophen A-50 is quite superior to Anniston and WGK Aroclor 1254 in electrical properties. This material as received exhibited a resistivity ' of 150,000 x 10^ and thermal chemical chloride stability of 0.27 ppm.
Japanese Kanechlor 300 is also superior to Anniston and WGK Aroclor 1242. Even though this material had a 9,600 x 10^ resistivity and 0.08 ppm TC it Is still considerably better than any routine domestic production in Monsanto operations.
Gt W/Miller /dp
HONS 036212
Research and Development Report No. I
Job No. 370-503
-2 -
Section 12 Appendix II Page 2
Background
The last report concerning competitive Aroclor type material was issued during October 1966. In that report (435-5-66) a comparison of Clophen A-30, Pyralene 1499, and Aroclors from the three Monsanto production facilities was presented. Also presented was a comparison of Pyralene 1476 and Anniston Aroclor 1254.
The additional data presented In conjunction with values cited from the above report should serve as a useful data source for summarization of Monsanto's marketing position at the end of 1966.
Discussion
Bayer Clophen A-50
This material was received in a 16 gauge, welded seam galvanized steel drum. Even though the drum was equipped with rolling hoops It was dented in several locations during transit. It is apparently characteristic of Bayer to use drums equipped with aide wall bungs.
A* in previous sampling of competitive drums this material was sampled by Insertion of a clean glass tube and displaced into clean bottles with dry nitrogen. One temple of the material was obtained at room temperature; however, due to the high viscosity the drum was necessarily transferred to the Aroclor Department hot house to aid In sampling. Analysis of the sample drawn prior to warming the drum gave a resistivity of 190,000 x 10^. This value could not be achieved alter warming. Several replicate tests on the samples collected from the warm drum showed a maximum of 150,000 x 10^. All stability tests were performed in duplicate or triplicate.
The dielectric fluid compares favorably with Monsanto Aroclor 1254 specifications In all araas except that gravity and Index are too low and the dielectric constant is above our spec limit.
Isomer distribution and a full analysis report are included In the attached tables.
Japanese Kanechlor 300
This material was received in a 35 gallon welded seam galvanized steal drum. This matorial was sampled Indoors without any heat being applied.
The material was submitted to at least two analyses on all electrical and stability
properties.
.
There ere no teet properties on this material which are not within the specification limits of Aroclor 1242.
Isomer analysis and a full analysis report arc included In the attached tables.
HONS 036213
Research and Development Report Ho. I
Job No. 370-503
-3
Section 12 Appendix It Page 3
Future
Two five pint samples of these materials arc being forwarded to WCK for analysis It would be appropriate to report WGK results on the aforementioned materials in this report; however, in the interest of having this data available at the May 9 quality conference the report contains only Anniston results. If serious dis crepancies develop in the data comparison with WGK, a follow-up report will be issued.
/dp Att. 4
O. W. Mlfter'
MONS 036214
Research ontl Development Report No. 1 Job No. 370-503
-4 -
Sect ton 12 Appendix H Page 4
Table l
Comparison of Competitive Materials With Monsanto Aroclor 1242
Property
Bayer Ciophen
A-30
Color, AP11A
<5
Acid No.
0.001
Ref. Ind. <? 25 *C 1.6237
Sp. Or. <? 25C
1.378
Prodelec Pyralene
1499
<5
0.002
1.6245
1.387
Anniston AH-248 15
0.001
1.6248 1.386
MCL 2-16 15 0.001
1.6249 1.388
WGK B 0450
15
... ... ...
Vlec. <? 100F, SUS 79.8
85.7
90.2
86.9 ---
Moisture, ppm
63
Free Chlorides, ppm 0,01
HST, ppm Cl
0.11
(. a. Stab., ppm Cl 0.06
TC Stab., ppm Cl 0.07
Meat. Stab., ppm Cl 0.40
Reelet. x 109,
OHM/CM, 100'C ?.f. 9 ioo'c
60 cycles 1 KC
15,200
0.22 0.06
35 0.01 0.16 0.06 0.12 0.48 1,270
4.6 0.33
`
30 0.01 0.14 0.11 0.28 0.51 1,980
2.0 0.17
52 0.01 0.32 0.12 0.48 1.56 1,900
3.4 0.25
28 0.01 0.50 0.16 0.48 0.93 1,030
4.8 0.26
D.K. 0 100'C, .
DU filiation LOR 90X
4.90
327 348
4.87
330 352
4.83
326 352
4.80
327 348
4.90
... ...
Type drum
Steel, gelv. Steel, welded
dipped,
seams. Type of
16 ge.
lining to be
determined
One coat phenolic lining
Two coats Bottle phenollc lining
Appearance of drum Good, no dents
Head bent, rim seam split. lining flaking
Good as produced
Good, no Bottle major
dents
300
10 0.001 1.6248 1.390
24 o, 009
0.11 0.06 0.08 0.36 9,600
0.55 0.13 4.82 331 352 Steel welded seams, ga Ivanlzed Good
HONS 036215
Research and Development Report No. I Job No. 370-503
5
Section 12 Appendix II Pnge 5
Tabic II
Comparison of Competitive Material With Aroclor 1254
Test Date
Property Color, APHA Acid No. Ref. Ind. @ 25'C Sp. Cr. @ 25*C Vise. @ 210'F, SUS
10-15-66
Prodelcc Pyralene
1476
10
0.002
1.6380
1.503
46.2
10-5-66
Aroclor 1254 AH-68
20
0.002
1.6382
1.504
45.9
4-30-67
Bayer Clophen
A-50
7
0.001
1.6365
1.490
Moisture, ppm Pree Chlorides, ppm Hydrolysis Stab., ppm Cl
30 0.02 0.14
20 0.02 0.14
30 ' 0.009
0.07
Thermal Chem. Stab., ppm Cl Woetlnghouse Stab., ppm Cl Resist, x 109, OHM/CM, 100*C Power Factor @ 100*C, 60 cycles
1 KC Dielectric Constant, (3 100*C, 60 cycles Distillation - 10%
501 90% Monsanto Stability, ppm Cl Type drum
.,>pearencft of drum
0.32
1.00
3,180
1.5 0.14
4.23
368 376 387
0.18
Steel, welded seams, 16 ga. Type of lining to be determined
Good, no dents
0.30
0.28
1.13 5,880
0.62 150,000
0.60 0.10
0.288 0.09
4.25
370 376 388
4.37
365 373 387
0.14
0.10
One coat phenolic lining
Steel welded
seams. GaIvsnized rolling hoops
Good as produced Good
MONS 036216
Research and Development Report No. 1 Job No. 370-503
6
Scciiv'-,'. L ''
AppenJi:: II 6
Table III GLC Analyses of Competitive Aroclor 1242
Peak 1 2
Japan Kanechlor Anniston 300 WGK
0.03 0.79
0.01 0.01
0.11 0.13
England 0.05 0.18
Baver Prodelec Identification
Trace 0.009
Biphenyl
0.003 0.01
2 Chloro
3-4-5 6-7 8-9-10 11
0.25 ' 4.39
11.79 1.15
Trace 3.02 8.57 1.15
0.04 0.07 3.30 3.69 9.98 10.19 0.74 1.26
0.03 Trace 4.91 3.44 12.36 8.91 1.19 1.06
3 Chloro-4 Chloro
2.2'; 2,6
2,5; 2,4; 2,3'; 2,4'; 2,3 3,5
12-13-14-15 16-17-18-19-20
21.64 27.56
24.03 32.27
26.50 25.04 32.72 32.78
26.33 28.23 31.32 34.26
3,4; 3.4'; 2.5.2' 4; 4; 2,3,2' 2,5,4'; 3,4,2'; 2,3,4
21-22-23-24
7.50
7.08
7.05 6.59
5.79 6.79
25-26-27
10.04
10.22
9.69 8.84
8.58 9.51
3,4,4'
28-29-30-31
8.07
7.24
6.26 6.23
5.29 6.66
32-33-34
3.50
3.31
2.51 2.64
2.32 2.60
33-36-37-38-39-40 1.57
1.19
0.69 0.87
0.85 0.77
41-42
0.69
0.62
0.23 0.36
0.46 0.40
43-44-45-46 '
0,41
0.39
0.11 0.25
0.31 0.22
47-48-49 50-51
0.09 0.04
0.21 0.04
0.02 0.02
0.08
o.n
0.16 0.03
0.09 0.02
52
0.01
0.04
Trace 0.03
0.01 0.005
53-54-55-56
0.07
0.13
0.02 0.22
0.03 0.09
57
ND4
0.08
NDA 0.02
NDA NDA
r"-59-60
0.06
0.10
Trace 0.26
0.01 0.01
61-62-63
Trace
0.08
NDA 0.17
NDA Trace
64
NDA
Trace
NDA 0.10
NDA NDA
HONS 036217
Research and Development Report No. I Job No. 370-503
7
Section 12 Appendix II Page 7
Peak 1 2 3-4-5 6-7 . 8-9-10
n
12-13-14-15 16-17-18-19-20
1-22-23-24 25-26-27 28-29-30-31 32-33-34 35-36-37-38-39-40 41-42 43-44-45-46 . 47-48-49 50-51-52 53-54-55-56 57 58-59-60 61-62-63 ,4
Table IV
GLC Analyses of Competitive Aroclor 1254
Anniston 1254
WGK 1254
Bayer Clophen
A-50
0.015 0.01 Trace 0.07
0.02 0.36 0.16 0.04
Trace Trace 0.01 0.23
0.46
0.19
0.75
0.05
0.01
0.03
1.09
0.48
0.76
1.59
0.81
l.n
8,34
`
7.80
8.03
4.01
3.59
4.61
13.29
13.09
14.27
16.11
16.24
16.66
17.77
18.23
19.35
13.14
14.12
12.85
11.05
11.65
10.23
8.32
8.77
7.10
1.98
2.02
1.68
1.56
1.56
1.37
0.64
0.66
0.39
0.50
0.62
0.50
NDA
Trace
Trace
NDA NDA 0.02
Prodelec Pyrnlene
1476 Trace Trace 0.12 Trace 0.30 0.04 0.90 1.35 8.08 3.32 12.35 15.80 18.10 14.26 11.93 8.70 2.10 1.36 0.80 0.46 Trace NDA
MONS 036218
Section 12
Appendix III Page 1
TABLE I
THE WORLD MARKET FOR CAPACITOR AROCT.OR
Total Potential and Monsanto Share 19o5 and 1971 (Estimated)
Metric Tons ( no-: nf.
DOMESTIC MARKETS
1266
1971
USA UK Prance Germany Japan
Total
Total
11,000 930 515
1,100 -bXP
15,845
Monsanto Share
11,000 930 0 0 0
11,930
Total
13,000 1,400 1,000 1,400 3.300
20,100
Monsanto Objective
13,000 1,400 0 0 0
14,400
NON-DOMESTIC MARKETS
EFTA EEC E. Europe Asia-Pacific Rest of
Americas Rest of World
Total
740 1,370
305 330
1,035 -J.7P
*M50
Grand Total
19,395
285 200
90 235
975 100
1,885
13,815
925 1,850
725 665
1,940 6C0
6,705
26,805
500 0
300 500
1,900 400
3,600
18,COO
MONS 036219
See Lion 12 Appendix IH Page 2
TABLE IX
NON-DOMESTIC MARKETS FOR CAPACITOR AROCT.hR BY AREA - BY COUNTRY
Metric Tons
Austria Denraark Finland Norway Sweden Switzerland
Total
Italy Belgium Holland
Total
Czechoslovakia East Germany Hungary Poland Romania Yugoslavia
Total
EFTA
70 25 95 30 290 230
7*10
EEC '1266
8oo
350 220
1,370
EASTERN EUROPE
i2S6
20 100
15 70 15 85
305
1321
80 *15 100 50 350 300
925
1971
1,050 500 800
1,850
1971
A5 200
50 200 100
U2
725
HONS 036i20
S ec Lion 12 Appendix HI Pi.gc 3
TABLE II (continued)
NOK-DOMS:STIC MARKETS FOB CAPACITOR AKOCLOR BY AREA - BY COUNTRY
Australia India Hong Kong
Total
Argentina Brazil Mexico Canada
Total
Israel South Africa Spain
Total
Metric Tons ASIA-PACIFIC
rg66 170 150
10 330
REST OF THE AMERICAS 1966
. 100 250 135 52
1,035
REST OF THE WORLD
30 0
340 370
1221 350 300
15 665
1271 380 450 360 750 1,940
1271 50 50
500 600
HONS 036221
See Lion 12
A|)|>onJi.'; Ill l'nge 4
TABLE III
ESTIMATED WORLD PRODUCTION CAPACITY*
;
USA France UK Germany Italy Spain Japan
TOTAL AROCLORS
Million Pounds
Monsanto Prodelec MCL
80 10 10
Bayer Caffaro FI lx
10 2 1
Kanegafuchl
-I 120
Tons 36,200
A, 600 4,600 4,600 1,000
500 3,500 55,000
*Also produced in East Germany and Russia
MONS 036222
TABUS IV
known would market by producer - m66
tMe trie Tons)
MAJOR DOMESTIC MARKETS
B.F.T.A, E.E.C. H, EUROPE ASIA-PACIFIC RSST OP AMERICAS REST OP WORLD
TOTAL
M.C.L.
930 220 200 90 210
0 _2 1,7A0
BAYEH
1,100 155 805 115 50 50 0
2,275
PRODELEC
515 365 300 100 50
0 _22 1,360
CAFFARO FLXX
00 00 65 0 00 00 00 _0 250 65 250
KANEOAFUCH1
1,700 0 0 0 0 0 0
1,700
M.C. TOTAL
11,000 0 0 0
20 965
0 12,005
15.2*5 'i 0
30 i,or,
?70 19 ,y\j
HONS 036223
(
R.M. POSITION Bsnsonc Chlorine
PROD, QUALITY l?sh IP.ki
ANALYTICAL
DATE PROD. STARTED Years
PRODUCT RANGE
SALES ORGANIZATION Strength Method Visit Frequency
Customer Relations
TECHNICAL SERVICE
OTHER ASSETS
.
SUPPLY SITUATION
TABLE V
ELECTRICAL AROCLOR TABLE OP COMPETITIVE STRENGTHS
KCL/WC
Buy/Make Make
Good/Fair Pair/Falr
Adequate 1951/1930
i 35 Very large
Is
BAYER
Buy Lake
Adequate 1930
35 Very large
PRODELEC
Buy (Progil) Kake (Progil)
Good Good Adequate 1930-1939
27 Limited
(Progil)
Good Dircct/Agcnts
Much respect Good
Good Dlroet/Agents Europe more than MOL Much respect
Good
Good Direct/Agents Europe more than MCL Much respect
Good, 7'
BPTA (Large Comp,)
Drums OX Bulk ?
EEC (Large Comp.)
Drums OX Bulk Oood
EEC (Progil) Drums OK Bulk Good
CAPFARO
Buy Make
Good Fair Adequate Poet 1945
Limited
Italy only . VN Direct Italy OK Bit amateur Not as good as
Big Three Local
Drums OK
MQNS 036ii4
Tftb.V ! (I'K !)
RESEARCH EFFORT
NEW PRODUCTS
AROCLOJl
.
IMPORTANCE (:#)
FRICK LEADERS/
gutters
philosophy
<
MCL/MC Needs MC/MCL liaison Yes
BAYER . Rot obviously
energetic No
PRODFXEC Very active
Very active (1500)
CAFFARO Non-existent
No
Small but valuable
Small but valuable
large
Kodlum
Stability
Stability
Leaders
Cutters
Common schedule Common schedule Common schedule To capacity
MONS 036225
Section 12 Appendix 111 l'atc a
TABLE I THS WORLD MARKET FOR TRANSFORMER ASKARKL
TOTAL POTENTIAL AND MONSANTO SHARE 1966 AND 1971 (ESTIMATED)
looo pounds - (finished' blends)
DOMESTIC MARKETS
USA UK Franco Qermany Japan
TOTAL
.
1966
TOTAL MONSANTO SHARK
17000 650
6100 3600 1600
17000 650 0
0 0
28950
' 17650
TOTAL
25000 3000 7000 4000 2500
41500
1971
MONSANTO SHARE
25000 3000 0 0
_____ 0
28000
NON-DOMESTIC MARKETS
EFTA EEC Eastern Europe Asia-Pacific Rost of Americas Rest of World
TOTAL
520 2000
175 620 3380 --.ZIP
7445
GRAND TOTAL
36322
30 0
25 270 3380 300
V 4005
.21655
730 2500
250 750 38607 1040
9130
50630
200 0
100 500 38607 700
5360
12360,
HONS 036226
TABI.V- II
SucLiou l?. / J > |> L' 11<i Lx III i'ngc 9
NON-DOMESTIC MARKETS KOH TRANSFORMER ASKARKL BY AREA - BY COUNTRY
1000 POUNDS (FINISHED BIBNDS)
Austria
Denmark
Finland
Sweden
Switzerland
Norway
Portugal
' TOTAL
EFTA 1966
100 None None None
300 20
' 100 520 .
. .
1971 150
None None None
400 30
150 730
Italy Belgium Holland
TOTAL
EEC 1966
750 1200
50 2000
.1222 1000 1400
100 2500
HONS 036227
Czechoslovakia Eaot Geraany Hungary Poland nomanla Yugoslavia
TOTAL
EASTERS EURO?.!-;
1266
None
7 None
;
25 None
150
175
Section 12 Append lx lI Frtye 10
222i None
7 None
50 None
200 250
Australia India Hong Kong
. '
TOTAL
ASIA-PACIFIC
1266
`280
.
340 "
'.
None
620
3211 350 400 None 750
HONS 036228
See l lull 12 A|>|>CiiJi;: HI I'.lfaO 11
Arcentlna
Brazil Mexico Canada Chill
.
Puerto Rico Panama
TOTAL
REST Ob1 THE AKHICAS
166 TO
1211 120
200 400
170 ,
300
2900 ao 10
: __ 10 3380
3000 20 10
__ 10 3860
REST OP THE WORLD
Israel
South Africa Spain
Pakistan
.
TOTAL
.1266 70
150 500
3Q 750
1211
100 " , 200
', :
700 __ 40
1040
HONS 036229
Zl
TAME j-K- 32
KNOWN WORLD MARKET BY PRODUCER - 1966
1000 POUNDS (FINISHED BLENDS)
MARKET
MONSANTO UK BAYER PRODELAC CAFFARO FLIX
Major Dome otic Markets 650
3600
6100
0
0
KANKOA- MONSANTO
PUCHI
USA
1600
17000
TOTAL 28950
erta
30 270 220 0 0
0
0 520
ESC
0 350 900 750 0
0
0 2000
Eastern Europe Aola-Paoiflo
25
0 jl50
00
0
0 175
260 200 150 0 0 0 10 620
Root of Americas
0
0
0 0
0
0 3380
3380
Root of tho World
300
0 50 0 400 0 0
750
TOTAL 1265
4420
7570
750 400
1600 20390
36395
HONS 036230
Monsanto
...........
t' M.M ,,
........... TO
:
.... H. J. Day, St. Louis General Offices
September 7, 1967
LIQUID AROCLORS Requirements Through 1972
Mr. H. W, Tlppee
.
' H, C, Carder G, R, Buchanan J. Cresce
^WtTWrrmeister P. E. Heisler B. &, Hoomor N. L, Sample R. P, Stevens Jaclc Kolloy Hill Williams Bob Yates
- HC/wiB - GEt/CH
- JCRER '' ICrui.wmrii - dhogw. - j:sa;*p
- RSTZV - vruf.v.trlc
- Annlstoi - RYATE
The attached shown the U. S. requirements for Liquid Arocloro through 1972. This la based on sales estimates received by this group on August 17, 1967.
Note that the forecast Is down somewhat from that calculated on July 13, I96T! Current Anniston capacity is A8,000 i'i lbs,/year and WOK oapaoity Is SO,BOO K lbs/yr., total, 76,800 M lbs./year. It might be Interest ing to note that 7 months 1967 total liquid aroclor production has been at an annual rate of 73,700 n lbs./year and inventories at this writing are at a maximum. -
/U-
H. J. Day
Jms
Attachment !
MQNS 036231
'\
Section 1?. AppciuUx IV V{jc 2
XiXQUT.D AROCLOHS 5-YEAR FORECAST (IN THOUSANDS OF LBS.)
TOTAL REQUIRED FROM U.S. PLANTS
Krummrich 1242
1248
1254 1260 1262
1960
16,107 5,049 4,031 6,638 125
32,750
1969
1970 .
19,037 4,596 5,039 6,953 135
35,760
21,404 4,571 5,462 7,345
. ______
39,007
1971
23,772 4,447 '957 8,l4o 155
42,471
1972
25,572 4,861 6,257 e,405 165
45,340
Anniston . 1242 1248 1254 1260 1262 1221 1232
DIV. TOTAL
' 28,636 1,782 8,647 2,291 630 110 593
42,739
75,489
29,745 1,908 9,426 2,360 649 120
__42
44,671
80,431
30,691 1,993 9,555 2,725 64l 130 526
46,261
85,268
33,491 2,308 9,445 2,078 656 140
____ m.
49,511
91,982
35,247 2,708 9,265
m
51,718 97,05a
H. J. Day 9/7/67
HONS 036232
II, J Day,.. St ,._bpu:ls General Offices
Section }2 Api'cml ix IV Page 3
September 8, ly67 SOLID AltOCLOKS REQUIREMENTS THROUGH 1972
Mr. H. W. yippee
H. B. imCer
H. C. Carder J. Greece
Lou Pulirwelstor L. B. Houmer
Don Harrinor N. I.. Sample R. p. Stevens
V/. p, Waychoff
Hill Williams Bob Yates
- KUDO
- J1CAJUJ - JctiliS
- Anniston - DHOSli
- DrtAKK - NSAMP - KSTEV
- WWAYC
- Anniston - RYATE
The attacheO shows the Anniston requirements for Solid Arocloro through 1972. This is based on sales estimates received by this group on August 17, 1967.
/Juts Attachment
H. J. Day
MONS 036233
See Lion l?. Appendix IV Pnge h
SOLID AROCLOKS ' FIVE-YEAR FORECAST (IN THOUSANDS OF DBS.)
TOTAL REQUIRED FROM ANNISTON
mi-.1268
5060 5-442 5460 - 5
Rated Capacity Deficit
1968
290 25
865 A10 180 . 8699
10A69
1QOOO
A69
MS.
300 25
925 A 20 210 9780
11660
iqooo
1660
197Q
3io 25
985 AAo 2Ao 11150
13150
ippoo
3150
mi
320 25
10A3 A 50 270
12220
IA330
lQlOOO
A330
mi
330 25
1105 A 66 300
12800
16020
lqooo
8020
H. J. nay 9/0/C7
HONS 036234
Gcctj'.'n 12 Appenv'L. V Page l
^occnr. Non-jnrocuc t i.vc T j me
Plowed lines Uniting on room in blend tank
Switch products Lack of still capacity Druming out receiver Waiting on crude Vacuum troubles Kopeck pomp Misco 1 Umcous
196/) DM KV
43.4 2 To
33.7
4.5
3.1
49.6
2.4
202.0 22.0
23.6
1.3
1.6 1.6
20.0
TM
340.41 71 .4
1?67 VJj>. )>N 15.8 23.0d
47.9 2 4.1 11.3
102.1
1. 1966 DN Time report is for February - December, years1 total is 3S5 including January.
2. Requires change to C12 control valve trim.
3. Due to export grade
4. For projection, use 10 hrs. for WOR in blond tanks and 20 hours UCC.
Liquid Aroclor
Other Non-productlvc Time
Faulty Cl- car Low Cl. pressure CI2 plant down No CI2 car Switch CI2 cars Empty Cl2 car Poor Clj quality Steam preys line. Product change Rcbri.ck furnace Export grade Aroclor Lack of still capacity Inventory adjustment Product demand low Refining pilot plant Miscellaneous W.itor linos
1966
DN KV
15.9
2.3 12.5
17.5
7.8
6.4
7.2
25.2
16.1
9.7
15.9
11.4
44.6
23.2
50.0
91.1
12.0 12.6
----
iro1' "6575
1967 YTD 1Ul'vi DM RV
7.1 27.5
3.2
10.2 9.0
32.0
44.8
15.0 44.4 14.3
2o7~.T~
--
~
MOWS 036235
SceLi/m 1,'
Append]. V rage 2
1. 1966 DM line is foL Feb. - December, year 1 s Lota). i.r, 369 including January.
2. For projection of 1967 Vl'D u?e only 16 hr:;. for export DN, 0 hr*. DN for pilot plant, 3 hrs. for low Clj pres sure, 5 hrs. Cor empty cars and 0 hrs. for voter lines.
Liquid Ai'ocl.or
Uepair Nonproductive Vine
1966 DN RV
1967 YTD (Lav) DN KV
Still receiver pumps
Still circulating pumps
Blend tank pump
Catalyst check
Chlorinntor coil replacement
Still circulotingcoil
Cl vaporizer
Piping failures Miscellaneous
;
37.6 28.2
12.0 90.6 19.8
6.0
1.2
.
___
18.5
4.6 11.8 11.5 50.7
7.7 7.7
___
37.3
____
....
..
--
212.O1 18.5
131.3
l. 1966 DN line is for File - December, year's total is 220 including January.
MGNS 036236
Sci:L.!.;>n )
Append.'.:: V 3
Sol ic'
hv;;;
. iiH1L"P ~<>d
71 :>'C*
190 6 WN itv
Clj feed liw:; plugged Chlovinntion cooler plugged Still cireulotting lino
plugged Uniting or fInker Vacuum trouble Waiting on crude Miscellaneous Waiting on room, blow tank
Chock softening point Plugged liner Operating errors
Drumming 4465 Vaporizer
28.9 3.0
VO. 3 159.6 194.6
37.0 186
37.1 2.0
92.0 57.0 21.0 21.6
*910.1
61.4 21.0
--
"8277?
l967t_XV0..(.i;--v)
i);<T '
Y`*
7.5 2.0
LI.3 6.0 8.0
1.0 10.0
8.8
___
457b
___
~8
Solid Aroclovs
Other Non-productive Tima
1266 DN RV
1967 VXD (I i-y1 DN KV
Santow'x-U Cost Switch Cl2 car Low pressure Cl. car Motor in 8M-il 1
CI2 plant down Empty Cl. cars CI2 quality Cooling water problems Steam problems Therminol TJ.c-in Miscellaneous Product change over Equipment mod if lent ion Still Therminol System
83.5 38.7 -
88.0
66.2 32.4
13.0
32.0
38.5 39.2 88.6
-
--
487.7 "27 4"
72.1 75.8"'
6.51 17.6 39.7 26.11
2.5 11.5 11.0 30.9
-
--
29177
27.6 7.5
"8. B
31.7 -
--
"7T7&
1. Use 30 hru. switching. 2 hrs. 1 iv pressure. 10 hrs. empty cars tor projection tine saving based on projection.
MONS 036237
Solid AH'l1' J 0!'
J_966 ON* RV
Flaker-grinder rvi-.m :ilng Theruinol leak
Demister No. 9 chlo.rinntor Weigh Lank agitator ChLorinator pump Still pump
Still entrainment separator Chlorinntor CI2 distributors Therminol system Clp vaporiser Cl flovj control valve Vacuum jot Durst furnace coil Miscellaneous Off-gas condenser Vacuum problems F laker Steam leaks Instruments
152.7 To
31.0 75.6 157.7
21.6
_
T.3
48.0 64.0 23.1 11.3 89.4
3To _ .J
__
729.5 40.0
Sec I'i.tm !'/ Append/... V I'n-c A
1967 Vl m.' *"''
51.7 55.8 23.8 11. 5 18.0 13.0 82.8 33.0 35.5 7.0 13.1 9.0 46.5 66.0
RV 51.6
15.0
466.7
66.6
MONS 036238
Hlb*./y
ow& WcuK?. (Kamt <r*f*<riTv
'** a/* /^V'
*.* 7a ste. >(i*ari.is> o/.* /*
^^TiN^fTigrO OC/fi^y
Append!:: VI
Pete l
MOWS 036^39
HONS 036240
MONS 036241
St cL .1 I. VII
lc;c }. VI'/.. till* Contributors
1. Production - a separate sect ion vill.jjqt be written by lit? Production Supervisor since the basic outline of the till' developed in conversations between Production mid 'i'SI).
2. PR{rJ) - to be written by 2/15/68. 3. Quality Operations Control - to be written by 2/15/68. A. Maintenance. - to be written.
HONS 036242
Authority ( No. :
2026
'
?'<>!;
2?)y
2?.T
'nn
7374
2342
7170
7566
TA8LB
Description Annrovod Prolcct*
Plnlm*. to Manifold Instruments
Aroclor Still Revision
Aroc'or Alnm System
. 11 Deoartnwnt : Conltnl
626.08
i 11.000
S.ivlnpn D.T. --
826.03 826.03
1 13.600 ' 1.450
3.900 2. 070
Success factor 931 857. 407.
t'ly.ed Bc.d Tower for r.rClnlnit Aroclor 326.OH
1 2.515 Ou.-lltv
l.rve1 Im'lentor on IA Still Receiver 826.17
2.020
l. 3o:>
7 57.
Vortical Condenser on 04 Still
826.17
It.illr-iod Sour for Chlorino Tank Cars 826.17
16.600 ' 31. 700
6. 800 21.200
G57.
Drunoot line for roc Lor 4465 Oirboltloneck Liquid Aroclor
Still Svstem I'liitecui. 1 llc.it Supply for
i l Root Tank.
826.17 826.08 626.08
1.495 3.400
17. 130 221.000
1. 520
--
907. 05''1 100T
MONS 036243
> >***. **>Hi* \ 'w' '
'* r"^AO^C*- 4%i u***.,
*~*\ _ * _ _/. v ..
-
'
' U twiki.
' :..
.
. .
.
Too
Vfc* ..."
.
' :: ..
TT -
.. .......
<
.
.'
'.
Myb UVIUA Ttiu.
...
.
'.
|
'
S 5. z
.
1
.
S,
f-
1-
'l
8
;
1*?
'
vI ji
; ft
C*uk* 54 1 71 f /
,
....
_ Ji'-
voi %v/ *04%
'' `
' '
ifc.lv
.
o*t.
T
4U4* v*o.o %tiw w*otMb
..
'
'
t.4u-
-
., " .;
'. ;_
S4 ' ".o o o
. r.'
?a*
0*0*4.gou. M0O0*0Vf Mo.lwilL
VTa`. 4(4 /*a*fc4-
/ '.
.
tu*. +''-/
vu*y
*jfc ,-T '
\m.*v I*
"
..
'. >*
^i-
. .' *
o ^ J
-,
.
. H4fc. fc*%**rt*
. ..
:
..
.
'-
*
5! 5
-... , - "* .
' i?
/'
.
i ' s
5*1*1*** %lMko4
*W* *<**% / *Tu* 04'Ot*M<4rv/ .
tMft/ - a%i%?amc * <6 04* CA i4o
..
Mn 'to (OBNBItV Ul.'VMrv CX*OHTV evutthwiruos* ;tvt*u , *.*
6>4f>lM4^0 , . .
..
o**wubo
|$ ' ]
. yt
.
_ | j*
54* . 44 \/ &T(*fc
.to*j00n.T.^rfc H*ttU CiiMMMrfMk \m
CowT>4M40VA n4*iT/
.
,
ooor^tMMta
m*.*> cwa4*i7
*!
/ *4
: r
Cuvkv/ *>v v%ph hpj***it 54 45%> / \4*kora/9t4k
: %M.*y . 1*4.14
ri,.<a. %44%/ft40
vtu*v.
4io.i4
t4VTA'M*
44* 5 40- t 4fc|
. .
1
1*0. n b,.*v>
CV4l#4-A*tlO. Vt)6Y vn* **r/
%*.%*
* ; t f
HONS 036244
HONS 0362<t5
f! is
TO-. TUT
"IOU / An^Un. <14* W4
t*.n ror w-i3! `J '
U-V
TMm M%ATl>% MV.
Vov 74- /ayfcu.
VTltL *T W*Tv*Ofc <,,w '
MI "wZTT
`if
**L &L..d v>tf. T*u/
^>Wgv
V(AtA
Mrni
***. **/
7vrr*u- u**1*/>* ** *"
tip-, TTfc/ac^
. ________
k>.Tfwr*#
b<4.jiwec<.
\7o . -t- /ao*. w>o>.c.
V>-*. TU
^<^4<L W*Uc Ia*?)**^ vi.l vtfc
l
VimVI* TOT
mr
HONS 036246
1
References 1'. TSD Job No. 370-500,. Report No. 2, 4-20-67. 2. TSD Job No. 370-500, Report No. 1, 2-13-67.
Section 12 Appendix IX
Page 1
MONS 036247
Section 12
Appendix X Page 1
Coat Analyst! A. Liquid Aroclors Cost Variances
1. Net material cost: major contributor (767, of total variance) la the chlorine coat; delivery of plant chlorine to Aroclor Is baaed on cell efficiency, standard Is based an pegged numbers. A program ia planned for the Improvement of cell efficiency monitoring.
2. Indirect conversion:
.
(a) ateam - this is an assigned valve, true value will recorded when steam meters are Installed.
. (b) gas - negative variance 19 a result of pushing the stills
(lower efficiency) to gain higher production rates
(c) labor - variance is the result of high overtime
(d) packing containers - high negative variance is the result Increased export demand and the use of an Improved drum *
($0.50/drum)
*
(e) laboratory - high production rates have required increased
laboratory effort.
-
(f) production deportment containers - increased production rates
have exceeded predicted usage
(g) Pilot plant exp. * high positive variance resulted from delay
in project for waste heat recovery
(h) Technical Services - Increase in personnel assigned
(1) experimental - bauxite refining unit was installed under
experimental expense funds
(j) research expense - increased activity (k) plant process research - Increased personnel assigned plus higher
activity level
(l) mechanical expense - low budget
B. Solid Aroclors Cost Variances
' l. Net materiel cost: major contributor (70Z of total variance) le the chlorine cost; again this la a pegged value rather then
, a true measurement. The program planned for the improvement of . .chlorine cell monitoring will Improve chlorine assignment to
solid Aroclors.
2. Indirect conversion:
*
(e) steam - this is an assigned value, cost ehould improve as steam metere we installed
(b) gas ~ YTD reflects three months below capacity production
HONS 036248
Section 12 Appendix X Page 2 (c) packing containers - low estimate of required amount (d) laboratory - YH> reflects increased sampling in previous months with production difficulties (o) technical services - Increased personnel assigned to department () mechanical expense - low budget
HONS 036249
f Section 12 Appendix X - Page 3
COST REPORT YEAR TO DATE - ORGANIC OIVISICN
ANNISTON, ALA*
'LIQUID AROCICRS
OEPT 62606 PRCDUCT10N CODE 62608
ACTUAL PRODUCTION - YEAR TO CATE 25,819.494
SCHEDULED PRODUCTION - YEAR TO DATE 25,822,900
JULY 1967
* MATERIAL
YEAR TO OATE CUANTITIES
OR EXPENSE
ACTUAL QUANTITY SCHEO. CUANTITY OVER-UNDER SCH.
STEAM
MBTU
ELECTRICITY CKWH
80,065 6,661
60,412 10,325
19,6731,444
. HATER PLANT MGAL
266,373
257,682
10,691-
GAS MBTU
54,472
47,337
7,135-
LA8CR
HRS
16*903
15,287
1,616-
PACKING LABOR
'4,556
4,956
LA8CRATCRY HRS
2,469
1.931
518-
CLAY ATTAPULGUS
2S,i00
33,560
8,460
FERRIC CHLORIDE
2.C55
7,745
5,690
LIME KYCRATED
141,567
129,078
12,689-
NITROGEN PORCCEL
194,000 14,189
. . 4 .
154,00014,185-
BIPFENYl
14,786,618
;14,914,095
127,477
CHLCRINE
29,882,429
29,117,633
764,792-
H C L 100
12,193,770-
12,193,770-
. MCN1ARS
876,248-
613,831-.
37,583-
530 533 542 545 570 601 610 19400 33510 38600
43100 48289 82601
82638 82851
82868
0 0 0 0 0 0
0
0
0 0 0 0 0
Q 0 0
MATERIAL OR EXPENSE CLAY ATTAPULGUS FERRIC CHLORIOE LIME HYDRATEO ( NITROGEN V PORCCEL BIPEENYL
CHLCRINE H C L ICOt MONTARS NET MATERIAL COST
. : YEAR TO DATE AMOUNTS
ACTUAL COST SCHEOULEO COST OVER-UNOER SCH.
' 989
1.397'
* 4i2
329 1,242
913
1,986 330.. ,
1,442 ***
144330-
$73'
573-
709,327
719,543
6,216
641,210
621,871
19,339-
198,148-
198,148-
19,328-
16,328-
1,000-
11,140,864
1,127,019
'13,845-
' : 19400
33910 38000 43100 48289 62601 82631 62851
82666
0 0 0 0 0
0 0 0 0 4
i
RAH NATL. HAND. TOTAL MATERIAL COST ,
' 4,389 1,14?,293
1,127,019
4,38918,234-
530 a X
MQNS 036250
Section 12 Apptndix X Page 4
. C' COST REPGRT YEAR TO DATE - ORGANIC DIVISION
C\ ANNISTON, ALA.
LICUIO AROCLORS
DEPT. 62608 PRODUCTION CODE 62608
l ACTUAL PRODUCTION - YEAR TO CATE 25,815,696
SCHEDULED PRODUCTION - YEAR TO CATE 25,822,500
JULY 1967
` STEAM ELECTRICITY
WATER PLANT
' " 'GAS
r-,
LABCR SALARIES
. PAYROLL OVERHEAD
, SUPPLIES
L PACKING LABOR
PKG CONTAINERS
PACKING 0/H
LABCRATORY
CLOTHING LAUNORY
PROC OEPT CONTNR
PILCT PLANT EXP
TECHNICAL SERVIS
EXPERIMENTAL
RESEARCH EXP
PLT PROCESS RES
. MECH EXPENSE
TOT OIRECT CCNVERSION
jTOT CIRECT MFC. COST
i DEPRECIATION
1 FACT. INO. EXP. TOTAL INCIRECT CONV.
PERFORMANCE VOL. TOTAL PRCDUCT COST ' PRICE C MAT. MIX
UNSCHEDL1E0 CAP. INV. VALLE C TOT VAR.
39,29* 5,716 J.TTO
16,295 *3,681
9,862 13,318 . - 11,899 : 15,718 96,601
3,563 16,COT
1.379 11,718
26,029 27,766 3C.708 12,261 23,850 59,587 . 692,579 1,837,832
56,079 60,269 96,328
1,736,160
30,768 . 8,666
5,67$ 16,595 58,363
9,599 13,783
9,525 15,796 69,705
1,763 16,959
971 . 1,931 . 59,703
11. ,7.6.7.
1,033 5,900 6 C,366 372,7R5 1,695,806
58,766 37,337 96,101
80 1,595,985
93,639967-
1,501,379
8,5*5- ^ ' ' 930
96' i,too5,338- <
263665 2,176-
78 28,696- / ' 1,800-'
3,068-^ 408-
9,787-33,876 15,97930,70811,228-17,95019,243119,796138,028-
2,685 2,912-
227-
80 138,17593,639-
967232,781-
530 533 562 565 570 575 578 590 601 602 603 610 614 618 620 621 635 651 657 694
691 700
994
996 997
HONS 036251
Section 12 - Appendix X - Page 5
COST REPCR7 TEAR TO DATE - OKGANIC division
ANNISTON, ALA.
REF SOI ARCCLORS
DEPT. 82617 PRODUCTION CODE 82617
ACTUAL PRODUCTION - YEAR TO CATE 5 ,647,469
SCHEDULED PRODUCTION - YEAR 10 OATE 5 ,990,324
JULY 1967
MATERIAL
YEAR TO OATE QUANTITIES
OR EXPENSE
ACTUAL QUANTITY SCHEC. OUANTITY OVER-UNDER SCH.
STEAM
MBTU
32.944
24 * 384 ' 8,560-
ELECTRICITY CKKH
4*460
5,071
611
WATER PLANT MGAL
63,693
61,165
2,728-
GAS MBTU
A3,263
35,807
7,456-
LABCR
HRS '
8,222
8,365
143
PACKING LABOR
5,138
5,138
LABORATORY HRS
' ` 650
337
313-
1 FERRIC CHLORIDE
528 1,694
766
LIME KYORATEO
37,047
28,237
9,610-
BIPFENYL
181,803
176,827
4,976-
SAN10WAX R
. 2,568,658
2,821,296
147*364-
CHCRINE
:9,276,064
8,693,577
582,487-
H C L 1C0S .
3,857,071-
3,857,071-
MONTARS
120,707-
120,707
SOLID AROCLOR RE
1,462,695-
1,462,695-
MATERIAL OR EXPENSE FERRIC CHLORIOE LIME HYCRATEO BIPFENYL SAN10WAX R
( CHLCRINE H C L ICO*
montars
SOLID AROCLOR RE NET MATERIAL COST
' - . - YEAR:TO DATE AMOUNTS
ACTUAL COST SCHEOULED COST OVEft-UKOER SCH,'
' 150
273
123
422 314 108-
8,784
8,537
247-
.132,292
125,775
6,517-
228,27i
213,569
14.703-
62,677-
62,677-
3,211-
3,211
35,836-
35,836-
268,196
249,955
18,241-
530 533 542 545 570 601 610 33510 .38600 82601 82602 82636 82851 82668 82869
33510 38600 82601 12602 82638 82851 82868 82869
,
RAM MATl. HAN0. TOTAL HATEFUL COST
1.326 269,522
249,955
1,326-
530
HONS 036252
Section 12 Appendix X Pege 6
COST REPORT YEAR TO DATE - ORGANIC OTVISION
ANNISTON, ALA.
REF SOL ARCCLORS
DEPT. 82617 PRODUCTION CODE 82617
ACTUAL PRODUCTION - YEAR TO CATE 5.6A7.A69
SCHEOULEO PRODUCTION - YEAR 10 OATE 5,990,329
JULY 1967
.1 '
\
ir
ii ;' ;
>
!
STEAN ELECTRICITY
HATER PLANT GAS
LABCR SALARIES PAYROLL OVERHEAO SUPPLIES PACKING LABOR
PNG CONTAINERS PACKING 0/H LABCRATCRY
CLOTHING LAUNDRY PROC DEPT CONTNR TECFNICAL SERVIS EXPERIMENTAL
i PLT PROC RES MECF EXPENSE
`tot DIRECT CCNVERSION TOT OIRECT MFG. COST
1 DEPRECIATION FACT. IND. EXP. TOTAL INCIRECT CONV*
: PERFORNANCE VOL.
TOTAL PRCOUCT COST
PRICE t MAT. MIX . UNSCHEDLLEO CAP. 1NV. VALLE TOT VAR.
16.469 3.092
1.965 12,931 30,951
6,716 7,596
90T 15,277 19,634
572 6,718
682 5,802 6,656
937
. . ....
26,878 '159,566
629,C88
62,130 23,882 66,012
695,100
12,623 3,501 1*921
11,281 31*885
4*645 8,617 3,500 16,303 11,863
298 2,625
593 12,181
6,130
100 600 23,250 151*916 601,873
60,655 19*720 60,175
9,563652,685
36,15530,654 666*984
3,866609 24-
1,650- . 936 1 131 -
1,021 ' 2,593 1,026 7,776-
2762,093-
876,379
526937100 600 3*6287*64627,215-
1*6756,1625,837-
9,36362,615-! 36,15530,656 66,116-
530 533 542 565 570 575 578 590 601 602 603 610 616 618 621 635 651 657 694
698 700
^94
996 997
f" HONS 036253