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Anniston C. K. Eastman W. H. Hunter A. E. Leiey G. W. Miller W. B. Papageorge W. F. Taffee H. L. Williams TSD Engineers General Offices J. 0. Bright H. C. Carder D. Danna (J) D. E. Cayard H. 0. Hehner A. Heininger D. B. Hosmer R. E. Howard C. F Luecke H. L. Payton N. L. Sample A, J. Speziale J. A. Stephens R, J. Stratmeyer H. S. Trail J. H. Zwerner Anniston Plant TECHNICAL SERVICES DEPARTMENT MONTHLY REPORT Summary September 1967 Bauxite Column for Aroclor 1242 has now treated 479,000 gallons and continues to satisfactorily upgrade the pro duct to meet our new, more stringent quality goals. The annual capacity of Biphenyl Tubular Unit can be lncreaaed to 87.5 M pounds of Biphenyl per year by retublng the firat unit to match the number 2 unit. Seventythousand dollars are required. The appropriation grade eatimate and writeup will be prepared In October. Evalua tion of alternate sources of benzene from two suppliers provided one lead which Is being investigated further. Information on on flexibility of our present supplier Is also being obtained. South Second St. C. E. Anagnostopoulos M. E. Gibbs H. L. Hubbard J. F. Quinn W. R. Richard J. R. Savage - JFQ Other Locations \ D. B. Edwards - DR J. W. Graves - Lullng W. R. Kellogg - Nltro G. F. Knollmeyer - Seattle J. F. White - Everett R. F. Wlesenborn - CB W. J. Wilson - WGK The 150,000 gallon HC1 Storage Tank project was transmitted to Planning and Scheduling. Bids have been aollclted. Evaluation of steel bottom cella for Chlorine department underway by CED/TSD. Anniston TSD portion to be completed by 10/20. Cell House Ventilation project continues to improve mercury level In house. Study of mercury loss during a shutdown Indicates need for further work to define ways of reducing the $13,000 loss indicated on one scheduled shutdown. Klran Still Residue tests continue with yield Improvements being confirmed In plant. Appropriation request ($30,000) forwarded covering Parathlon Recovery from wash water via membrane separator. Annual savings of $70,000 are expect ed In addition to major benefits of reducing load on waste treatment plant by 107.. Plant Warehouse project being finalized at Division level based on Information transmitted in August. Construction of Waste Heat Recovery facility essentially complete one month ahead of schedule. Mechanical check out has started. Training planned for week of 10/9. L. C. Fuhrmeleter -- KS> CONFIDENTIAL INFORMATION Thu document contain! confidential information which it the property of Moniento Company. Only thoe portion! of the document relevant fo a duly authornad individual'! need to know may be ercerpted for him. The report mult not be lent outiide the Company without written approval and the euthorned recipient ii accountable for ft* isfe keeping, encerpting or otharwii* ditcloting of itl content* and for it* proper dispoial. The docu ment remain the property o( Monsanto Company and thell be returned within two monthi to it* author, eicept upon ipecial authoriiation to hold to- a longer period " TOWOLDMONOQ44377 MEETINGS Mr. R. J. Stratmeyer will visit the plant 10/4-5. The next Engineering Planning Meeting is scheduled for 10/24. Messrs. D. B. Hosmer and H. C. Carder will be at Anniston 10/17-18 to discuss the Chlorine Department. 2. DETAILS ' AROCLOR J. MacPherson, C. R. Mcllwain, E. E. Bowles Job No. 456 - Fixed Bed Refining; (Quality) To date 479,000 gallons of Aroclor 1242 have been treated in the fixed bed refining unit; the initial Bauxite charge continues active with no change in treatmentability. Job 716 (AFE 2545 - $221.000 Debottleneck Liquid Aroclor Still System: net savings (B.T.). Project. 2545 proposes to debottleneck the liquid still capacities to 53 M, lbs./yr. by the installation of new still receiver pumps and level instruments on the still receivers, blend tanks, and filtrate receivers. Capital required is $17,130. Project comple tion is expected on about October 16, 1967. BIPHENYL-SANTOWAX L. L. Faulkner, J. M. Jones Job 744: Upgrading of 41 Tubular Unit To Equal #2 Efficiency. Plant review was held on the program to provide facilities for a 100 M per year Biphenyl Plant. Decision made to retube No. 1 furnace to be exactly like No. 2 furnace for an estimated $100,000 ($70,000 NFC). This will expand annual tube capacity to 87,5 M pounds Biphenyl. AFE for retubing will be forwarded by mid-October. Quotes for #1 Preheaters received September 29, and the order will be placed in early October. Job 765: Install Sojourn Pot on B Pass of #1 Tubular Unit Verbal approval was received to order a Sojourn Pot. The project is in Maintenance Planning. No installation date has been established. Job 769: Install 6" Gas Line To Tubular Area Project was transmitted to Maintenance & Construction September 6. Bids have been requested. Work will be expedited to complete installa tion by cold weather. 0346083 TOWOLDMONOQ44378 Job 780: Alternate Benzene Supply 3. Alternate suppliers for Anniston Benzene are under study. Benzene from two suppliers was analyzed. One supplier has specification grade material and will be further evaluated. Samples were received September 29. Information on flexibility of present supplier (Enjay) also being obtained. Job 790: Temporary Santowax Storage With the capacity operation of the biphenyl tubular units, more Santowax will be produced than can be consumed in Solid Aroclor and HB-40. In-Plant projects were approved for temporary storage of excess Santowax in the outside lake during periods when the storage tanks are full. Equipment was received.and cleaning of pit for storage was submitted for quotes. Work should be complete in October, CHLORINE D. W. Dudley, W. G. Niemeyer Job #411: (Savings Undetermined) - Steel Bottom Cells W. G. Kramper of CED visited plant to define responsibilities and objectives of steel bottom cell evaluation. Anniston's portion of evaluation to be complete by 10/20/67. CED Final Report to be Issued . 11/1/67. Job #1000; (Savings Undetermined) - MIP Background complete, work plan defined, rough draft to be issued by 10/6/67. Scope covers five year capacity projection and one year work plan for two Engineers. Job #704 (Plant Improvement) - Cell Room Ventilation Velometer tests in cell room indicate thorough air circulation. Cell house is now completely closed. Mercury concentrations continue to improve. Progress report to be issued by 10/5/67, indicating results and recommendations for further improvements. Job #591: /Annual Savings - $18.000) - Single Stage Decomposers Revision #1 forwarded to TPM September 9, 1967. Revision covers graphite conversions, wage increases and minor design changes effective since the project was initiated in November 1965. Total appropriation requested now is $28,500 expense compared to $15,940 in the initial project. 0346084 TOWOLDMONOQ44379 4. Job 46: (Savings Undefined) - Mercury Losses A. Studies are in progress for reclaiming mercury from various cell house effluent streams. B. Samples of brines taken during scheduled plant shutdown indicate mercury loss of $13,000 per shutdown. All data was taken on one cell and may not be indicative of the overall performance. Progress report with recommendations to be issued by 11/1/67. C. Radioactive inventory of mercury postponed until December 1967, because Central Research has pulled off the job due to a higher priority job. Job #491: (Savings to be Determined) - Debottleneck D. C. System Study underway with Electrical Engineer to determine power loss in D, C. system. Progress Report will be issued upon completion - EDC 10/13/67. Job #783: (Annual Saving - $40.000) - KC1 Overflow Design complete; APE being prepared - EDC 10/2/67. Scope covers mechanical shutoff of dechlorlnated brine and an alarm to alert operator. Job #4-76: (Annual Savings - $4,000) - HoSO/, Heat Exchanger Investigations indicate present carbon steel exchangers inadequate due to fouling on shell side. A new exchanger of Alloy 20 is recom mended, The present schedule calls for the APE to be completed by year end. HC1 K. J. Buturla, L. L. Faulkner Job #497: Muriatic Acid Storage The design package for the 150,000 gallon HC1 storage tank was trans mitted to Planning & Scheduling on September 7. Project is now awaiting the return of bids. A safety review is scheduled for the week of October 9. Job #746; HC1 Efficiency Studies Studies to improve recovery efficiency to 957. are continuing. The new butterfly valve has been received and is scheduled for installa tion in October. This valve should reduce unaccounted recovery losses. Sample valves were Installed September 28. Field tests for the material balance studies will begin the first week of October. 0346085 TOWOLDMONOQ44380 HC1 - continued 5. Job #1000: HC1 Long Range Plan The HC1 Manufacturing Improvement Flan was reviewed on September 22. Revisions are being Incorporated and final plan will be Issued the week of October 2. Reviewed plan shows revised Annual Savings of $90,000. PNP K. J. Buturla, L. L. Faulkner, W. B. Dunlap Job ^0450; Phase I - PNP Dehotjtlenecklng Piping revision of the tempered water system was completed September 29. Installation of larger charge line and new pre-mix tank has been sched uled for Fall Niran Turn-around in mid-October. A correlation study was coordinated between PNP, Parathlon departments and the Laboratory to reveal possible causes of high parathlon color. Strong associations were found with product of PNP department and with Intermediate still operation. New surveillance was provided at key check points to detect future shifts. NIRAN D. C. Malm, 0. J. Norris, K. G. Hale Job #732: (Annual Savings - $44.000) - Condensation Batch Sequence . Progress Report has been issued detailing preliminary estimate, design, and justification. The project cost will be $168,000 resulting in a return on investment (A.T.) of 4.8% and a payout period of 3.9 years. TSD work has halted pending an evaluation by CED. Job #600: Sulfur Recovery - (Annual Savings - $400.000 plus a 31% Reduction In S0p Load To Air) Solvent addition to still residue tests continue. The Chlorine charge to the chlorinators was dropped by 50# in order to continue tests and stay In specs, on Cl2 level and Crude Assay. Substantial yield Improvements are evident despite the Chlorine drop - Progress Report will be issued to Increase chlorination levels upon completion of lab chlorination and stability studies. A report will be issued summarizing lab work. Job #712 Parathlon Recovery - (Annual Savings - $70.000 plus A 10-15% Reduction In COD Loading) Appropriation request Issued for approval; NFC - $29,665, Expense - $970. A Progress Report detailing the pilot test results, saving and project costs has been issued. Planning for March 1968 on stream date. Job #774; Full Use of Cooling Tower - (Annual Savings - $8.900) Project package has been transmitted to Maintenance for Construction. 034608b TOWOLDMONOQ44381 NIRAN: continued 6. Job #499: Condensation EVOP - (Annual Savings - $59.000 Plus A 57. Reduction in COD Loading) . 4^PNP The yield figures for September on PUP were 46.84 100# Para which represents a 0.57 #/100 # para improvement over last year. The PCT yield in September was 55.38 jj^CT/100# para for a gain of 0.11 #/100#para. These figures represent a net saving of 15 centa/100# para over last year usage, ($3,750/month savings). The EVOP Program will continue on Niran where yield savings of $7,000/mo. were demonstrated last February. Job #777: Experimental Slurry Pump - (Safety) Project has been transmitted to Maintenance for installation of an experimental slurry pump. Pump delivery is estimated at 60 days. MECHANICAI. & ELECTRICAL INSTRUMENT DESIGN J. C. Price, J. A. Veatey AFE 2576: Elector For NaCI Elevator Pit (Safety) estimated capital $1500. The Control System for the Eductor was revised during September. The Revised Design Package will be transmitted in October. Job #597 Modifications To HC1 Elevator (Safety) Estimated Capital $18,000. Rough draft of Progress Report was prepared. The Progress Report and Revised Estimate will be completed in October. AFE #2046/2146: Improve Plant Lighting (Plant Improvement) Estimated Capital $1800 Completed design and transmitted design package for Improved lighting along Fifth Street. Design, Review, Estimating, and Procurement assistance was provided in the following areas: Aroclor Fixed bed refining and grinder relocation. Blohenvl-Santowax Santowax storage in Montar Plf, and fall-safe valves on Biphenyl storage tanks. Chlorine: KC1 overflow from Sparge Cars, NaCI Unloading, and Brine Dechlorination. 0346087 TOWOLDMONOQ44382 MECHANICAL & ELECTRICAL INSTRUMENT DESIGN - continued HC1: 150,000 Gallon Storage Tank. Niran: Condensation Step Batch Sequencing, Parathion Recovery, Fume Collection System. DRAFTING G. C. Goodwin, R. L. Brewer, R. Bradley, E. A. Brown Completed in September. .1 Biphenyl Santowax Line to Pit. 2. Niran Parathion Recovery. 5. Niran 4. Aroclor Slurry Pump. Grinder and Bagger. 5. Aroclor #3 Blend Tank to Fixed Bed. 6. Plant Safety Shelters. 7. Plant Lights on Fifth Street. 8. Waste Heat Flow Diagram. 9. P R & D In-line cell for Dielectric Measurement 10. P R & D Steam Line to Lab. 11. HC1 Filter Feed Pump Scheduled for October i. Niran 2. Niran 3. Aroclor 4. Aroclor 5. Biphenyl 6. Biphenyl 7. Plant 8. P*5 Fume Collection System. Malathion Evaluation. Revise Cl2 Railroad Spur. Drum Washing. Re-design Preheat on #1 Unit. Retube #1 Unit to be Like 2 Unit. Fire Alarm System. Eliminate Fumes in Building. 7 0346088 TOWOLDMONOQ44383 8. LIAISON AND PLANT IMPROVEMENT J. W. McGee, W. F. Taffee CEA 1252 - Utilities Several changes to be made to No. 8 boiler coincident with Fall Nlran turnaround. Contracting of work planned with control exercised by Anniston. CEA 1450 - Aroclor Expansion Appointment as Manufacturing Representative made In September. Manu facturing cost standards prepared by V. R. Haupt and J. MacPherson, and forwarded to TPM. Additional backup information provided to Division for Anniston portion of Aroclor Expansion project write-up. CEA 1452 - Warehouse Project being written at Division level by Carl Sigler. Return now greater than 10%. Overall project cost being re-studied by CED. W. F. Taffee visited J. F. Queeny Plant 9/12 to discuss warehouse practices and Central Drumming operation. Building 28 Work started 9/25 on Dispensary-hallway-office project. Dispensary and Safety Engineer temporarily housed in new salaried personnel locker room. Project for replacing worn out air conditioning unit (which must be moved to make room for Storeroom) submitted 9/27. New project includes heating to bring working conditions to accepted modern standard. Fire Break Progress Report, with recommendations, Issued. Herbicide spraying started, to be completed In October. Dead vegetation removal problem remains. Target date for decision 11/1/67. Dike Study Survey and recommendations completed and Progress Report published in September. All dikes will hold 100% of tank contents. Road Program Traffic survey results published on schedule. Railroad Survey Report delayed. Publication rescheduled for November. Long Range Utilities Replacement of 56" storm sewer under study by CED. Present proposal is replacement with asphalt coated corrugated steel drain at cost of slightly under $200,000. Long range electrical needs understudy by Aaron Williams to develop possible substation locations and sixes. 0346089 TOWOLDMONOQ44384 9. WASTE HEAT RECOVERY TEST C. E. Woodward, (W. F. Taffee) Project la approximately one month ahead of achedule with conatructlon eaeentlally complete at montha end. Mechanical checkout underway. Preparation and training for atart up accelerated to match early con atructlon completion. Target for atart la now 10/16. Techniques for analytically determining Therminol loaaea not yet reaolved. Necessary laboratory equipment received at montha end. Lack of theae techniques will not delay start-up but would require calculation of Therminol losses by material balance only. ENGINEERING MANPOWER DISTRIBUTION 7, Of Total TSD Time Category September Year-to-date Through Sept. 1. Process Improvement 41.16 48.86 2. New Products 3.97 4.93 3. Plant Improvement 11.04 6.42 4. Assist Operations 1.54 2.79 5. Special Engineering Services 5.07 9.04 6. Technical Manpower 9.09 8.41 7. Miscellaneous 28.32 19.56 August 56.7 9.7 6.0 3.9 9.8 5.7 18.2 Year-to-date Through August 49.7 5.1 5.9 3.0 9.5 8.3 18.5 Remarks: Category 1 reflects increase In Categories 3, 6 and 7. Technical Recruiting and housekeeping areas. Category 2 reflects shift of Warehouse from evaluation to liaison phase. QUALITY CONTROL AND STATISTICAL ASSISTANCE W. B. Dunlap The Right First Time Index was 98.7, with 7 lots rejected out of 549; 6 out of 485 from the Organic Division. The September Quality Score was 93.6, down 2.6 from August. 0 TOWOLDMONOQ44385 10. PERSONNEL 1. H. C. Carder visited the Plant 9/13*14. 2. George Crook reviewed recruiting practices with plant personnel at Anniston. 3. W. F. Taffee reviewed warehousing and Central Drumming practices with J. F. Queeny personnel 9/12. . 4. G. W. Miller attended the Management Fundamentals Course sponsored by Monsanto at St. Louis, 9/25*29. 5. W. F. Taffee attended the Comprehensive Interview Training Course in St. Louis, 9/18-22. 6. W. G. Kramper visited the plant 9/27-28, to discuss evaluation of steel bottom chlorine cells. 7. W. F. Taffee is participating in the instruction of the Auburn University Chemical Engineering Design Course under an Academic-Industry partnership approach for the fall quarter. This parallels a similar partnership described by Washington University-Monsanto CED at St. Louis, 9/15-16. 8. All TSD personnel attended a review of the new plant Disaster Plan held 9/21. ADDITIONS W, G. Niemeyer, Ch.E, - transferred from W.G.K. John Jones, Co-Op returning from Georgia Tech Starting Date 9/18. 9/18. TERMINATIONS . REASON J. W. McGee Co-Op, returning to Auburn University Clarence Angelette Summer employe, returned to Instructors position at Jacksonville State University E. E, Bowles Summer Student, returning to Auburn G. L. Moore Co-Op, returning to Georgia Tech Robinson Bradley Summer employe, returning to Auburn Fred Knickerbocker Ch.E,, resigned to pursue Medical Degree John Llddle Chemist; leave of absence to pursue M.S. in Chemistry at Georgia Tech DATE 9/8/67 9/8/67 9/15/67 9/15/67 9/15/67 9/15/67 9/15/67 0346091 TOWOLDMONOQ44386 11, SAFETY The September safety meeting for Technical Services was conducted by Ken Hale on "Horse play." The Safety graph "Does Your Accident Show? was also reviewed. The CHASE Committee Chairman reviewed their respective committee responsibilities. 03A6092 TOWOLDMONOQ44387