Document qk5VqZXvrzjav2o8bVa5peyDx

/\ MV a*d C%e*ntca& CSCAMtl A PWANT inc. INTEROFFICE MEMORANDUM To: Mr. R. E. Davis From: E. A. Primeau Rs: PVC Monthly Report October, 1972 Dote: Copies: November 7, 1972 SUMMARY Prime production for October was 5, 393 M lbs. versus a budget of 5, 300 M Lbs. and an October 20 forecast of 5, 350 M lbs. Off-grade, tailings and sweeps amounted to 78 M lbs. which represents 1.4% of total production versus a budget of 4.5%. A total of 626 charges were made, an average of 2. 0 per day. The variance generated by PVC for October was $(3, 885).-unfa:vo*able. The variance resulted from: 1. PVC Bulk 2. PVC Bagging {$3, 741) $ 856 The forecast variance on October 20 was $1, 100 favorabLe. The items affecting the variance were: Forecast ActuaL Raw Materials Process Costs VoLume Machine Hours (2,500) ( 510) 510 3, 000 $(6. 345) 144 1, 460 L, 000 Total $ 500 $(3,741) ANALYSIS OF VARIANCE Raw materials were unfavorable due to (1) the low production of off-grade resin ($4, 796 unfavorable by-product credit) and (2) $3, 649 unfavorable variance in VC1 due to the usage of 1.08 lbs. of Vcl/lb. of resin versus a budget of X. 06 lbs. This was partially offset by $1, 533 favorable variance in process chemicals and $567 favorable variance in royalties. AP00043 Mr. R. E. Davis PVC 2- - November 7, 1972 ANALYSIS OF VARIANCE (cont'd) Process costs were basically at budget being $144. favorable', . Volume variance was $1*460 favorable due to the production of 93M lbs. of prime resin over budget. Machine hour variance was $1, 000 favorable due to the 31-day month. November production is projected to be 5, 130 M lbs. and variance is projected to be ($2, 000) unfavorable, primarily due to an unfavorable machine hour variance for 30-day month. DISCUSSION During October, the PVC plant produced six resin types. Two types, 1230P and 2200, accounted for 67% of the prime production. The average number of charges per day was 20. The south reactor line was utilized 26 days in October to produce 2, 503 M pounds of 1230P resin in 279 charges. The average yield per hour of 1230P was 667 pounds versus a budget of 664 pounds per hour. Early in October, Mr. Fair of the Brighton Corporation visited the plant to review the modifications made on the drawings for the new stainless steeL reactor (to replace No. 9 reactor). He saw no problems and delivery of the reactor is scheduled for January 15, 1973. However, the delivery may be delayed until February 15 due to a delay in receiving the agitator from Philadelphia Gear. WhiLe Mr. Fair was in the plant, he entered No. 10 stainless reactor and examined the stained area. The stain was removed by buffing and has not reappeared. The program to test EDTA in 1230P and 1225 charges to reduce reactor fouLing was continued. ResuLts to date have been excellent in reducing fouling. Reactor No. II was charged 75 times without chemical cleaning and reactor No. IQ 50 times. Based on our experience, we feel (1) EDTA should be used in all 1200 resins and (2) FDA approval should be obtained for critical applications such as water piping. CHEMICAL CLEANING The solvent recovery unit was operated the first six days of October to clean up the DMF in the 35, 000 gallon storage tank. On October 7, the unit was shut down to make required modifications for processing NMP and to install a new discharge spiraL in the Artisan unit. AP00047579 Mr. R. E. Davis PVC -3- November 7, 1972 CHEMICAL CLEANING {contd) On October 24, chemical cleaning of the reactors was started using NMF. Reactors No. 2, 4, 6, and 11 were cleaned with NMF. During the Last three days of the month, an attempt was made to operate the Artisan unit to recover NMF. Difficulties were experienced in holding a vacuum and the entire unit was tested for leaks. No significant leaks were found but the main jets were found to be partially plugged. The jets were cleaned and repaired, and the unit will be restarted to recover NMP on November 1, 1972. DRYER STUDIES A dryer study was initiated in conjunction with engineers from Louisville Dryer to increase capacity of our rotary dryers. Wet resin cake was sent to Louisville Dryer for testing and the tests were carried out on October 11 and 12, witnessed by W. C. Wilde. The data from the tests should give Louisville Dryer the information necessary to state what is needed to expand drying capacity on the rotary dryers and to design a fluid bed dryer for the proposed PVC expansion. PVC BAGGING A totaL of 2, 001 M lbs. of PVC was bagged at a cost of $11, 970 in October. Variance is as foLlows: Volume Spending Total PVC LOADING AND SHIPPING $ 671 $ 135 $ 856 A total of 5,919 M lbs. of resin was shipped from Pace. Bulk shipments accounted for 3, 489 M lbs. Starting inventory was l, 235 Mlbs. and dosing inventory 790 M Lbs. SHORT RANGE OPERATING PLANS 1. Continue training of new personnel. 2. Install a larger condensate tank and revise condensate piping to return all condensate to boilers. AP00047580 Mr. R. E. Davis PVC -4- November 7, 1972 SHORT RANGE OPERATING PLANS (contrd) 3. Contact Bird Machinery to study requirements to improve centrifuge capacity. LONG RANGE PLANS 1. Continue work to increase monomer to water ratio. 2. Update PVC operating manuals. 3. InstalL replacement reactor for No. 7. Attachment E. A. Primeau AP00047581 STATISTICS October & FY to Date Prime Product Homopolymer Subtotal 5, 393 5, 39 3 Off-Grade Homopolymer Tails Sweeps Subtotal 0 70 8 78 Total Production 5, 471 Off-Grade, % of Total Production Bulk Production, % Prime VCM Efficiency, % Reactor Availability, % Production, #/gal. yr. Off-Grade Analysis Type 0 1.4 61.8 92. 0 95. 0 1, 329 Lot No. 0 Quality 0 Product Sequence - October North Line Batches South Line 2200 2225 2250 1225 2200 2225 2160 2200 2250 1225 2200 1225 2225 2250 2200 14 6 15 30 20 20 8 16 20 19 20 9 20 6 69 292 1230 1225 1230 1225 1230 Budget 5, 300 5, 300 _ 250 5, 550 4. 5 - 94. 5 92. 5 1, 307 Reason 0 Batches 74 22 175 33 30 335 AP00047582 STATISTICS PVC Downtime Analysis October and Year to Date Hours Cleaning Reactors Schedule Charges Behind on Recovery Hold to Drop Plugged Drop Valves Change Type Slow Drying Hydraulic Motor Maintenance Miscellaneous Total 541 56 109 148 22 15 0 17 50 958 Production Summary '% 6. 6 0.6 1. 3 1. 8 0. 3 0. 2 0 0.2 0. 6 11.6 ii Type 1225 1230 2160 2200 2225 2250 2185 Sweeps October and Year to Date M lbs. 1, 040 2, 521 67 1, 119 370 344 2 8 5, 471 Page 2 EAP- 11/7/72 AP00047583 AP00047584