Document pmm4jLYoXgxQ3KqqyGnr8o8Ed
MPNSAHTO COMPANY location s Texas City, Texas
Date
t December 29, 1964
Subject Monthly Production Summary VCM Plant - December, 1964
cc J. H. Chamberlin Lo B. Bullock C. H. DUhon W. F. Gabel B. B. Etarfczog <J W. Kongable T. B* Shirley -- 3m L. Price G. T. Ryan B. j. Darby VCM Supervisors
To W. R. Bisbet
SUMMARY
VCM production was 10.1 MM lbs (121.2 M Ibs/year) 87.8% of rated edacity. Reaction was down 549 hours for lack of acetylene. Cracking was limited for 133 hours s B7 hours by Department 26 downtime, 38 hours by Department 21 downtime (10 hours concurrent with Department 26 shutdowns), and 18 hours by the HCl stripper, 22DS, reboiler switch. Quality control was poor during the month with high SCI production occurring intermittently.
EDC production was 14.3 MM lbs (171.6 MS Ibs/year) 114.2% of rated capacity.
Oxidative Chlorination production was 2.38 MM lbs (28.6 KBi Ibs/year) 82.436 of rated capacity. The unit was down 87 hours: 72 hours for cleaning fouled exchangers and repairs to the recycle compressor, 15 hours for instrument repairs. The unit ran the last half of the month with no feed gas analyzer, resulting in lower than standard conversions and higher caustic usage.
CBY 1107235 RSV0032250
Monthly production Summary VCM Plant - December, 1964
O
OPSRATIHG DETAILS ho Summary gable
This
Year to
Scheduled Month Standard Date
production
VCM, MM lbs EDC, MM IbS - Dept. 23
- O.C.
10.31 13.12
2.78
10.1 14.3
2.38
Acid, gallons Acid dumped, gallons APT, %
755,000 0
96.3
On-Stream Time
Cracking
100.0
Reaction
26.3
Dept. 23
96.5
Acid, absorber, % time needed
. 99.8
% available When needed 94.9
Dept. 26
89.7
2l2
99.9
11.5 12.5
2.89
0 0
91.3 91.3 91.3 91.3 91.3 91.3 91.3
124.5 158.0
18.4
Yields
CsH4 to EDC - Dept. - O.C.
Cla to EDC EDC to VCM CaHa to VCM
23
95.0 90.0 95.0 95.0 97.0
95.0 88.5 95.0 95.0 97.0
B. Operations and Maintenance
The HC1 stripper column, 22D6, reboiler was switched.
She VCM redistillation column, 22D14, reboiler was switched.
The Ho. 2 chlorine tank was entered and cleaned.
The VCM redistillation column operated for the fourth consecutive month without fouling.
CBY 1107236
RSV0032251
Monthly Production Summary VCM Plant - December, 1964
1
Page 3.
QgHarntQ DBM8 (continued)
the oxidative chlorination reactor catalyst tube supports appear to have worn in. Fluidizing gas was cut off three times with out any reactor pressure drop increase.
The oxidative chlorination feed gas chromatograph failed at aid-month, efforts at repair wore only of limited success, and a program to develop a parallel instrument was begun by the Analytical Instrument Group.
C. Personnel and Safety
All new men in the unit are now qualified on one job. thus eliminating overtime average of oxidative chlorination.
Safety meetings were held with all operators covering proper use of gas masks.
0. Costs
December Variances*
VCM
BDC
O.C,
Raw Materials
Price Performance
-11.000 0 0 000
Direct Conversion
Labor Repairs
Catalyst
- 3,000 -18,000
0
400 4- 2,000
0
400 0 0
Volume Off Scheduled Production Unscheduled capacity
Total
Grand Total
- 2,407 -31,433 -65,840
+ 3,152 + 1,636 4- 6,388 -63,937
- 3,143 - 942 - 4,485
CBY 1107237
RSV0032252
Monthly Production Summary VCM plant - December, 1964
Page 4
Opgaagms mmim (continued)
Variance Explanation!
VCKt
Saw Materials
performance
Direct Conversion
Labor
Labor force increased by 4 men since standard was developed.
Repairs
Late billing of the past 2 year's charges for acid proofing cement.
EDC: Labor Repairs
As in VCM. Reduced corrosion.
O.C.:
Labor
As in VCM.
January Variancess
VCM EDC O.C.
Saw Materials
Price Performance
00
0
ooo
Direct Conversion
Labor Repairs Catalyst i Volume
,1 Total
0 0 0
-33,100
-33,100
0 + 2,000
0
it h.WL
+ 3,340
+ 2.665 + 2,665
RFK/qlh
/.// Jr** W. H. slager
CBY 110723B
RSV0032253
VCM PUMP fiOMBMOf - 1964
VCM production was 124 Hi lbs (90% of rated capacity and 86.5% of budget). Rates were limited through the year by the CaH* shortage. To meet demand, 13.5 MM lbs was purchased from Sthyl and Carbide, and 13.45 MM lbs was obtained by swap and conversion arrangements with Daw end carbide. C*Ba cleanup system was put back in operation in October when economics were again favorable. Muriatic acid production totalled 5.13 MN lgallons due to lack of Cj>Bs and low on-stream time of oxidative. VCM cost was 6.6$ vs. budget of 6. It due to out-of-balance operation and oxidative performance.
SDC production from CaB* and Cl* was 158.5 MM lbs (105.5% of rated capacity).
Oxidative production was 18.5 MM lbs (53.4% of rated capacity). During much of the year, capacity was limited by plugged tubes and low conversion due to iron poisoning of the catalyst. Major revisions in October, including relining of the reactor and revision of the catalyst support system, corrected the source of catalyst poisoning and improved feed distribution so that capability was raised to 30 MM lbs/year.
1965 production is budgeted at 138 Hi lbs. Plans for 1965 are as follows:
Capacity
VCM from C3H2 VCM from BDC EDC from Cl2 EDC from BCl (O.C.)
25 MM lbs 113 MK lbs 15? MM lbs
30 Hi lbs
Cost Improved yields Department 23 and 26__ __+$30,000 variance frost std.
Reduce Maintenance cost 4% below sfcd. in 1965__ _jf81,000. Sold other fixed costs at standard.
Reduce quantity of rerun of off-spec VCK* Safety Reduce minor impuries by 10%.
CSV 1107239
RSV0032254
7> VCK Plant Summary - 1964
v> Page 2
Personnel
Upgrade operator capability through increased training.
Cannon itv Relations Reduce and reroute snog producing streams to eliminate our confer ibufeioru
jWK/qlh
CSV 1107240 RSV0032255