Document rpypKoYN3obON19amnnKaXZd0
BIBLEfREylEW - November 8, 1966
In'our review of 1966 performance, and plans for 1967, we
will include the principal Profit Improvement projects, but not
necessarily all of them. Some of our objectives, for instance
Safety, and in some departments Anti-Pollution programs, are
not part of our Profit Improvement Program but we believe they
are an important part of our objectives.
The acetylene complex this year is operating under a dif
ferent situation because of the serious decrease in AN demand.
This situation has affected not only the Texas City AN plant,
but because of C2H2 distribution has had an effect on all the
C2H2 users and so has influenced our plans. Our two vinyl monomer
plants which we are going to cover first, are each having a record
year in 1966, but each has its own special problems. Vinyl acetate
is a sold out plant and we expect to buy 40-50 M pounds of vinyl
acetate this year in order to meet the demand. Since our incre
mental manufacturing cost for vinyl acetate is about 6^ per pound,
and we are paying about ll*yf per pound for purchased VAM we have
a big incentive to produce more pounds of vinyl acetate. So this
is the direction of our objectives.
CSY 1110662
The vinyl acetate plant has also been a victim of the AN de
mand cut because of the new acetylene distribution that has re
sulted. We no longer expect to be purchasing acetylene from
Carbide and we will be operating the vinyl chloride reaction
step at maximum rates. Both of these operating changes result in
RSV0032739
k
t
i
'\
l
2- -
a lower available acetylene pressure in the inlet to the vinyl
^ acetate plant. This decreases the amount of acetylene that we
can get into the vinyl acetate plant and decreases our vinyl
acetate make. Unless we can do something about increasing the
amount of acetylene that we can get to vinyl acetate, our
production in 1967 will only be about 56 M pounds versus a 60 M
pound budget. So we do have plans to correct this situation.
We expect to produce about 155 M pounds of VCM and this will just about balance the VCM demand as we now understand it. To do this we plan to operate HCI-C2H2 route to VCM at maximum rates and shut down our oxidative process. Because of reduced refrigera tion demand with oxidative shutdown, we believe we can produce about 5 M pounds more VCM and reduce our manufacturing costs. This also results in some problems since we have not run the test on the oxidative process with the higher oxygen concentration, and this process, once proved, is believed to have some commercial value. The alternate of operating versus not operating the oxidative unit has to be evaluated and a decision made as to which direction we want to go. Meanwhile, our plans and numbers you see are based on shutting down the oxidative unit.
Ray Rosenberg will discuss operating objectives first, then Tom Shirley will go over the PT&E objectives, and finally Carl Duhon will cover maintenance goals and objectives.
CBY 1118663
RSV0032740
%b
A
We will now hear from the rest of our acetylene complex. The two products, AN and methanol, are operating under opposite situations. The AN plant, of course, is cut way back so we must look at reducing costs in any way we can. This situation has been a prime influence on our objectives for 1967. The methanol plant, however, is another sold out plant and even though we expect to pick up an additional 12.5 M gallons of methanol as a result of becoming sole owners of the methanol plant in March, we still expect to purchase at least 10 m gallons in order to meet demand as we now know it. Methanol plant's main goals, because of their very low incremental manufacturing cost and be cause of high demand, are therefore aimed at producing more gallons of methanol.
Oxygen and acetylene, the mother and father of our entire acetylene complex, although they did not fully achieve their goals in 1966, did achieve substantial savings and I believe over the years have shown more dollar improvement and cost re duction than any other of our plants, and 1967 will be no exception
t0 thlS'
CBY 1118664
In order of their appearance, but not necessarily their
importance, we will cover the oxygen-acetylene plants first, then
the methanol plant, and finally the AN plant. In each case we will
first discuss operations objectives and then PT&E objectives, and
finally, Andy Kuehl will cover maintenance goals and objectives
for the whole group of plants. Art Simons will start with the oxygen-acetylene plant.
RSV0032741
VCM
/ % C PF/yFormance 1167 GOALS
CBY ma665 T}SV0(m742
i
Safety
/?
' ft 7
GOAL AcrCfl**Otf) goal
A4/A/CJf IA/J, /?ATt TWSSmM A4AUU0VPJ /G S~
A/f/AYOX /SsXtOUS Pa770
*A
3/7 V/
2TC> 8/,
D/SABI/A/ -Z*sj u/r y E'/A&j
S Pi Ld~J
o/
o
a (3
o /O
RiAivr Ma.*j //ousstSSTsa/g jDusp.
AA
AA
PX>6*AA*
_Z/VrLUOS S+rSTY /v
^oS P*Aa/*S/as& f' sntSCvT/o*/
Aa/AlVZS /#C/*f*TS TO 0TTT*A#orJF /T P*TTT*as SXtrT**
PpPAfAL
SAF~Ty J*f<r7?'A'&X
QViPMA*7~ /A ?A HJSP7~/oass
SAT* tv WtSMSasT CtffCtrS
Quality all oPmsatosb cat a aS/a/wu** t>y 3 ucas UPOA T~ OPfJfAT/A'YL ASajVUAL.
AA
CBY 1118666 RSV0032743
CAPACrry : MM LBS
/ rac
Dspt-
Djtpt- 2.3
7~t?u-
Z VCM
F&oMt C* M-
/><?>*/ 3 DC
Total
ity &
30
/to
/ fo
'fY Ac.7~
20 /to
/<BO
27
/ /tr
37 / 03
/*-S~
cay 1118667
RSV0032744
Cost
Raw Materials Other Direct XwOlRECTS
Total , *VLe
6109A66L 3.35 01..23.3+ 5+2
nAecet. +.// 01..3233 S'. 67
Resume, of 1166 Cost Sav/a/gs
/, Lower CU cost
rsiq ooo
z. Lowe* CzH* cost
/ 32, OOO
3. +. 5. 6.
Lowe* Deer 26 catalyst- cost Reddeep Lab costs SRteadbu/lc/ezdat/Toaa/r oMe RaRroed. cpoAL/ry
/HS,G,(OoOo (,0,600 ys.ooo
2 ^ ooo / 62, 060 so, ooo / 2^000 ! 2,00 0 Ef, 60 6
7 RuMP/ATE MaO# scrub / REDUCE SO. USAGE'
38. OOO ) 7, too
a 9
Reduce Ae/o Mare ToRttAaClTtOUSaCaut/.a/UoSsAGE
_* 48 96, 6 00
/ 5477, oooooo *744, 060
* Ver iw ome/f/At. J944 goal.
1118668 RSV0032745
VCM 1967 GOALS
CAPACITY 4 COS7S
V C A f P/?oi>ucr/oA/, m m U s /v *
U /s /r CosT; ^ / u
Voi UM, MMU, 89
Cost, */u
6.72
y EAR
ff /36 6.S2 .9/
/J? 6.49
/24 C.so
/34 e./z
/+$ (/JS-) ~.67 (**)
CBY 1118669 RSV0032746
P/tObuce /SS-MMU* VCM
F/t*M CfrAc*-/#o /?*** /?r*cTs**/
93 S7
.A c
/.
?
y/ &y :
'> A/7"/> C>
<T~i //.
/) -/*?'
7^A"'
Costs
/w*" Mattr/au O TMMK bt/rs* Tj-
-ZTVa/^-ffVTV 7* 7***.
/f ^ ^
A C T.
A, / / /. 23
0. 23 67
/ fc 7
<3 CAU
j, 30 O. *5"
Q.2LST *57 O O
CAY 1118670 RSV0032747
COST GOAL TO BE ACCOMPl/Se/eD
BV TM 0110 U//NO SAV/M6S
I1L7 Goal.
COST SAVING ITMS TNUOPEfiSN goal OS S'*/LB
~'
' ''W WMIMLW I
---
/. Lo\A/ER Ctl M- COST
2. Lower C./x Cost'
3. Lower Cx. tff cost
f. Lowe* Ma/a/t: COST Uru.iZAT/0# c>t CU
^ S 7,006
2 f&, Goo
/ 2-/y qco / 72,000 / Co ooo
` & OS oo-
COST SAV///G ITEMS NOT IN OoAL
6 OPTIMIZE DC C.RAtPtA/6 OiAKCtd * 25,000
7 Opt/mizs catalyst i/sa&e'Uove) so, ooo
8. TMPAovS VCM y/Lt> (JUt/E)
40,000
T t >51 OOO
Total sav/hos
* 9^3 ooo
CBV U18671 RSV0032748
Quality Duplicate HGC peffohmamce os ^8% SPEC. GRADE PPOQUCTloH Accomplish by / Close opsfat/ohs comtpol C. PT*TT srvotes on ahal-YT/oal
Methods- sop cohtpol
CB* *118672
RSV0032749
VAM
/psppopma/c^-
' H7 <3>op^s
CBy 1118673 RSV0032750
Safety
/
& O AL
C
AltCWU OCT)
/ to 7
Mt*o* T/VJ RATE' JtJJS/MM HAwvPS / />
/SEP/coj /?AT/0
8/,
23-?
'V,
/ /a a//
D/SABAJM& JTASJt/Xy f/RE* Spyu-e
O > O
Plavt M&*j //0(,ssArdrY/A> J5*r
AA- E
* AA/A/UAi. Htt/SStreep/AS*. A*/A*a
ID O O
K E
-O C O E~
PffO&fiAAf
JTA/Ct-tsOE~ SAFETY X/iS AU. JOE PLAA/A/fA/<i / EKSCU TfOA/
A A/AL YZ JTA'C/edTA'T* T~0 OETEGPf/VE /F pATTEpA/ EX/S7-J
PmtHAL / Z#s?o*//Ai. Safety Meet/a/as
Vpi>ArE- Orseat/as& Y/aa/fal.
UP&4TC "Oa/ Oku. ' /*Saasi/al.
S A FTy STpvtPAtsAsr CAYEctes
CBY U18674
RSV0032751
Capacity ' mm lbs
/9 Lt
6b>Al
S7.6
/t&6
4ct
C+,0
COSTS
f?A* MaT8/AS J-A/&/JPSCT*
if* C . &e> At-
6,33 /. /*-- . 7/ <s. /?
J?L C Act
.* /. 30 <6? 2+7
CBV 1L18675 RSV0032752
VAM Capacity
^EPNO S UPON AcETY.A/^ >/STRfMOT/o^/
AcbtY^n- D/str/bvrtt>*r
Purchases
VCA/7 Osaojt
/ 9 Co >
Max
M/a/
/7
O
O A/1A*
VAM Equivalent
b/?OM /-/&ADRR Prom VC/W ArrA
Total VAM
SO M ISM
65 M
"t-SOM
/ 1.2 M
S>2M
CBY 1118676 RSV0032753
Capacity Goals
A Produce 63.6 MM Lbs in /9&7
2. INCREASE CAPABILITIES EEOasJ
SB. 2 to 7S MM Lb/yr rate-
Accompl/s/y by
/. Cap/taL ADD/T/oa/s --*36^ Ooo O. Sc Seoul e
SB. 2 T& B2-0 Mfi* L&SYR RATE ( JAM. 'B7)
RTSS
Pit E.
GZO TO e+.O MM LB AYR RATE (APRIL '4 7)
P.T.7z
Rlt: E~_
GilO TP 7SA MR L4/YR RATE < JAtY. '>&)
C.E.D.
b. Results
0). Reduce cost op vaai pppchas&s
*3 7si 00 o
//V /fB7. *tM /# /fcs
(2)- ReovcE COST OP AAAAttfPAert/RtS/O
TO &O0*/ls ZA/ /?B8,
2. Decrease uacoord/a/a teo d o u//v ts/we
B SO, 000 LBS VAM
CBY 1118677
3. REDUCE~ 72Zt TO CHAA/QE Ot/T CATALYST BY / SR/ET I ZS,OOQ LBS VAM
RSV0032754
V A M P fto duc t/ oa/^ M A I Los / y n
U a j t Co s t , u b/ * /
VAlW /9>7 GOALS
CAPAC/7Y / COSTS
BO
63 '66 *67 YA*
Vott/*f~ MM13J 28.7 V
Cd>57"y
A3./S
+32 />.>+
ss./ 8.7+
( 636) 8+7 C 8.2^)
13
U //
/*
f
3
7
CBY 1118678 RSV0032755
CoST-5
Raw Ma
O DtRsSC7~S
Sa/0//?'C7~'S
Total , ^/lB
/?< A c^ -
6.
1.3 0
.6 ?
<5.4 7
!Jt>7 Goal.
4. 2_ 2
J.3 2.
7/
3.2S~
Cost Savjass Stems Snclvoeo 7/v Goal Above'
/. Lower Acet/c Act* Cost 2.. Lower Acetv^e/ve Cost
3. Lower Mai/vt. Cos~r
?! it, 200
SSyC>oO 33, OOP
/ 9 9,800
Cost Savia/g Stem A/ot Sw Coal.
4. Optimize catalyst usaoe CApril)
ZS^OOO
Total. Sav/a/g s
?zz*,aoo
CBY 1118679 RSV0032756
Quality
DuPL/CATE
P&/?E0RMAASC
I- Mo ope spec.. Material s#/ppej> 2 Mo CUST0ASE/? CO MPL At/V7~^
C8Y 1118680 RSV0032757
19 66
VCM tf VAM MAINTENANCE GOALS
CBY 1118681 RSV0032758
Maintain VCM Plant for $660,000
540,000 Below 1966 5f4
66 Goal 9 Mo. Cost 66 Est.
$660,000 $561,000
$736,000
Why Goal Was Not Met
1. Upgrading of HCL Plant $30,000
2. Excessive Catalyst Charges $2 2,000
3. Corrosion
$ 2 0,000
4.22C3-2 Overspeed 3$12,000
CBY 1118682 RSV0032759
Year
CBY 1118683 RSV0032760
Maintain VAM Plant for $ 138,000
<512,000 Below 1966 Std.
66 G oa 1
9 Mo. Cost
G6 Est.
1138,000
$138,000
$186,000
Why Goal Was Not Met
1. Foul iny Problems
$ 18,000
Z. Corrosion
$ 13,000
3. Electrical Problems
$ 9,000
4. Debottle-necking Cost
$ 8,000
CBY 1118684 RSV0032761
RSV0032762
I%7 \/CM t VAM Maintenance Goals I. Maintenance Cost Dept. 66 Est. 67 Gaul
$ Gain
VCM $736000 $56^000 $172000 /
VAM (186000 $153,000 $ 33,000
PLAN 1. Improve preventitive maintenance program
2. Monitor equipment with I.R.D. CBy U1868S 3.Improve catalyst unloading equipment 4.Improve catalyst unloading procedures 5. Coupling improvement program 6. Low maintenance cost in dept. 26
RSV0032763
I. Increase Maintenance Productivity
Dept.
66 Actual 67 Goal
VCM 56 % 64 % VAM 65% 67%
PLAN 1. Stabilization of manpower 2. Afternoon line-up of leadman 3. Backlog of fill-in work 4. Job clean-up
CBv 1118687 RSV0032764
Decrease Maintenance Overtime Dept. 66Actual 67Goal VCM I2> 9.62 VAM 11.45* 6.0> PLAN
1. Better analysis of overtime 2. Reduction of mechanical failures 3. Improved workmanship
CBY 1118688 RSV0032765
PT&E PROGRAMS FOR VAM & VCM 1966-1967
VAM-1 VAM COST - 1966 Stopped purification fouling Value - 65 M lb/yr rate
Demonstrated new catalyst Harshaw (78^) Calsicat (75^)
Value - $40,000/yr. plus
-VAM.-2
VAM TECHNOLOGY - 1966
Reactor system fouling:
Methyl-acetylene Other higher acetylenes
Quality upsets: Bi-acetylene Divinylsulfide Benzene
"VAM-1
VAM QUALITY STATUS
Monsanto equal to or better: Borden, Shawinigan, Niacet, and National Starch.
Monsanto much better than: Celanese (P), Air Reduction, and Du Pont.
ACETYLENE
Distribution Purchases VCM Usage
1966 @ Max @ Min
VAM-5 ------- \
1967 Zero @ Max
VAM Equivalent From Header From VCM Area
50 M 15 M
45.0 M 11.2 M
TOTAL VAM
65 M 56.2 M
ACETYLENE SUPPLY Purchased
Acetylene Plant
Dept 18
H2S04 Acetylene Purifications
H3PO4
To VAM
To VCM
To AN
V55T5Z
REDUCE VAM PURCHASES Itl A
Cost
Value Opera tior
1 $24,000 $208,000 2 25,000 106,000 3 15,000 131,000 Exp . 300.000 880.000
1-1-67 1-1-67 4-1-67 1-1-68
$364,000 $1,300,000 1968
y
CBY 1118689 RSV0032766
VCM-1
VCM-2
VCM QUALITY - 1966
All specifications met
Polymer problems at Spfld. Trouble shooting Help on analytical work
Chloride/Acidity test Being evaluated
VCM COST - 1966
Successess
Control product column
Control EDC cracking
New catalyst in oxidative
VALUE
$226,000/yr
Failure
Ion-exchange for HC1 removal from VCM
could have been $50,000/yr Ji
VCM-3 VCM TECHNOLOGY - 1966 ^ PLANT Oxidative chlorination with 12.57. 02 in feed.
To 40 M from 27.5 M EDC/yi
Fenwal Protection installed
LAB 157. 0, feed tested KA 101 catalyst tested Potential 50 M EDC/yr & 25% lower catalyst cost
r VCM-4 VCM QUALITY STATUS
Dow has least impurities
Monsanto has most impurities
Goodrich, Monochem, Tenneco, and Union Carbide (TC) do not meet our specifications.
Methyl chloride is the only impurity above 5 ppm in our VCM.
VCM- 5 VCM QUALITY - 1967 Assist Spfld. on problems
Improve analytical methods
Set up a new specification based on the Chloride/Acidity test to replace the present HC1 test.
YClfcfi.
VCM COSTS - 1967
Catalyst in Hydration and VCM reactors
VCM loss from product column EDC cracking system optimum
VALUE $115,000 in 1967
JA ./
CBV 1118690
RSV0032767
VCM- 7
^ VCM - 1967
Firm up the justification for oxidative chlorination plant demonstration of 15% oxygen feed and KA 101 catalyst.
Cost -
$ 300,000
r CEV PROJECT
Studies completed. Decided to buy.
Glass-1
1
Value -
$1,500,000
J
______ / Glass-
C WEST PLANT EVALUATIONS
Continuing:
1. What to do with O2-C2H2 2. Alternate routes to VAM 3. New methanol plant 4. Possible combinations
NH,-Me0H-Ac0H-VAM
^_____
> PERSONNEL
J/
Glass-3
>
Beginning of Yr.
'66 *67
2_c2h2 Methanol
3-112
3-1/2
2-1/2 5-1/2
VCM
41
VCM-Oxidative 4
1-1/2
VAM
3 4-1/2
TOTAL 18 15
_________
J/ V
_ JA
Gla ss-4
f PERSONNEL CHANGES '66
f
Transfers to Mfg Transfers to other PT&E Resigned
TOTAL LOSSES New hires
4 4 _2
10 _7
NET CHANGE DOWN
L
3
l____ /
yy
C0Y H18691
RSV0032768
OXYGEN
ACETYLENE
1966 PERFORMANCE
1967
GOALS PROGRAMS
CSV 1118692 RSV0032769
MINOR INJ RATE
IMIS/MM MANHOURS
COAL 2 00
ACTUAL 205"
MINOR/SiiRIOD-S RATIO S/f
7fl
DISABLING INJ.
o
o
TIRES
Oo
SPILLS
oo
PLANT MGR'S. HLSP INSP.
Ah AO Ah
OVERTIME
5"7oS 7
L9G7 PROGRAMS PROCESS HAZARD REVIEWS
Equipment and area inspections
operating manual review and upgrade
OPERATOR TRAINING
FORMAL AND INFORMAL SAFETY Concentration on Personnel
Tf?AIbllblG Relations
%7
-GOAL 2 00
S/I O o o AA
S7dg7
CBY 1118693 RSV0032770
!<? PERTORMANrr
SAFETY -
minor intuRizs
O &ISA8LI N II
O pj^ES
O 5PUIS RETRAINING of Ope&fi-To&s
TRAINING nF ^UDeRYlSPRS Rewrite, operating manuals
Oi/E^T)Mp
(TotlL
ftCMit VELJ) ftc Hl^tCl=-2> ftcH/E/E D
Achieve 25
ftcrt IE V(b> ftcH/eZEL ft eft/e za D
tt 81.
ACTUAI
77.
OXYC EM
VOLUME. RJ.P Total
MF& Cost
Acetylfnf volume R2.R TOTAL M re. COST
22 0 M To^5 203N\ 77a/s
rZ.70 M
* I CD fz\
*5723/77/7 *6.+D/7oh
102 MM Z,g
?ljO0 7 m.
<o.DCEm/8
77lss.
CBY 1118694 RSV0032771
\%7 goals
SAFETY -
^zswinor injuries
O 0>/5 fl oUNG 11
o fires
o SP/LLS
Pollution- tighten controls
TRfUN Supervisors
train Hourly Mid new capital
Capital s-pending- /U/d/d
.Expelsa spending- Ai/oid Permanent or Long Term
RPRSonnlL - Train Key Superi/isidn To operate Plant Condition People For plant phase-out
PIP
OYYGEh/
Acetylene
^I55jooo
*G07j0oo
v'olumf OXYGEN
Acetylene.
Hqst~
oxygbn
Acetylene
2-4-D,000 Tons
104- MM LBS.
X
ET&O/T^N
Co.OG C ents/LB.
CflY U18695 RSV0032772
11
-p, 9
*o
to h~ ~f.
O^ |
OXYGEN 1967 GOf\L
v.*
'***..,
VOLUME (Tons) Cost t/ko(V
VOLUME (t.ni) Cost */isON
GOAL 220 M
ACTUAL 20 3 M
6.
232 m
6.25~
2fOM
C8y 1Z18696
*SV32773
11]
4
o
oo
m
5
OXYGEN 1967 GOAI S
-------------**..
TONS
COST &TON STEAD UTILITIES HANPOUER REPAIRS OTHERS IIMDIRECTS
CREDITS
NITROGEN AIR
OXYGEN
STD GOAL ACTUAL. STD
ACT1JAI
18J00 18,340 18,180 19,79019;
q 89 5 83 6|40 6 25 5 60
002
766 647 675
c11 1374083676
002 a1
10
41
67 34 27
176
02 00 d 1
85 53 68 80 35
95
002a11 664623175436
2 39
0 0
58 64
0al
95 33 44
00 0
333
335 058
0
0 Cl
33
33 06
0 0 0
30 37
05
0 0 0
30 37 05
CBY 1118697 RSV0032774
OXYGEN P.l.R
1
B. MAIN AIR COMPRESSOR TURBINE EFFICIENCY
1 CONTROL CHARTS 2 TURBINE DESALTING 3 CONDENSER CLEANING
C MATH MODEL OF 0- PLT.
GAIN OPER./* 2 2 500
1
OPER. 47,000
PT.+E. 28,500
2. REPAIR COSTS A.REVERSING EXCHANGER B.MAIN AIR COMPRESSORS
1 PM PROGRAM
2 THRUST BEARINGS
C. AIR DRIER PM. PROGRAM
OPER 15.000 40.000
MAIN! MECH.S. OPER. . 2.000
TOTAL & 155,000
1968 REALIZATION 1. RAISE 0 RECOVERY TO 90 % RT+E. ^16,800 2. USE WASTE LPN AS PURGE PT+E 48.000
GAS IQTAIr r 64.800
CBY 1118698 RSV0032775
RED-COST $/|O O LB S
BLACK-AVG. MONTHLY PROD M LBS
ACETYLENE GOALS 196 7
VOLUME (wm LBS)
196,6
^TANLARD
GOAL.
qs:2
102.0
COST (cenTS/LB.)
6.9+
G.00
VOLUME (mmlBs)
13EJL 100 104-
Cost (cents/lb')
(&>GB
(o.O(o
acti/ai <17.0 6. S'?
CBY 1118699 RSV0032776
LO
CD
ACETYLENE GOALS 1 96 7
e:
CBY 1118700 RSV0032777
ACETYLENE PIP
1. CONVERTER YIELDS
(operate)
IMPROVE CONTROL (^CONTROL CHARTS)
Lower operating p-Chemical cleaning
JS a.j n
^77,000
.OPE GA S TO BOILER HOUSE (operations) ^150,000
IMPROVE CONTROL OF PLANT COLLEYS I EM
3._LPWER SOLVENT(NMP) USAGE
$80,000
OPTIMIZE MONOCHEM
Fouling Rates-Down time- RepmRS(OPR) (so,000)
CONTROL OF WATcr in Solvent
(jOPRj
control or Polymer FITTER' CAKe(>T-,) (D,DOOj
CRACKED CAS f.OMP. STEAM
(pp^; *
OPTIMIZE TURBINE EFC AND DOWNTIME *48,000
5. REPLACE DIESEL WITH CARBON Bl kCK Oil Q>T-if37,000
6. REDUCE REPAIR CO.STS
15,000
BAG FILTERS" IMPROVE REPAIR EFR (m/NNt) ($0,000)
optimum on-stream
improve capacity
(opr_j (?tL)
Converters- improve repair eff. c^mr) (40,000)
C HEM. CLEAN Q> VESSELS (OPR/'
y
cracked Sas compressors
f opr.528,000)
OPTIMIZE. PREVENTIVE. MfUNT Am M/UnT
RUN-LENCTH, AND FOC/LIW6 V PURIfication-Optimize monochem
CBY 1118701
TotAL
RSV0032778
PROCESS TECHNOLOGY & ENGINEERING 1966-1967 GOALS & OBJECTIVES
PERFORMANCE & PLANS - OXYGEN-ACETYLENE
CBY 1118702 RSV0032779
CBY 1118703 RSV0032780
(9 6?T ^o/s-u*s
CBY 111870% RSV0032781
S A FELT V
^ll NOR.
Xm>Jo^iE.S
Tot-/\
---- 1^6<^------
L. A cjtuau.
IS 19
o 2.
IS ^.o
1^6,7
^OA L
IV
o
IV
Pro:
I. TuCLUbE. ^AFE-Ty IN ALL -JOB "PLANNlW^BoTI4 OPESACnoUS AlJb rWAlNTEWAUCE.
AnALVZE. all ACCIbeiJTS AMb IWJUEIE.S ftub "TftkE. FROKHPT COK-EECT/U6- ACTIO W.
3. PeoMCITE^ sA^ETy WITH EFFECTIVE; mEAWIfJ^FL
^afet/ mEernu^i which iwctubE all PFE^OK)AJL KE^utAE.Ly AS^IAiuab -Rs ttepT, 31.
CBY 1118705
RSY0032782
PEtg.FO^JV\ A
I46S"
PRO])UCT/6 0/ rvt ML.
ICTTAL IHF^. CtfST
U)IT GmT, 4/aL
2S", q 57 3,240,700
K.3C
^>AL 1466
04,442 ^3,2^30
12.23
26,7i> *3,171, Sbo
12. Z3
I, Teuio C"S/ rWoUTH-5^ BSTUJEBKJ "TOTAL t>EFT
Z. H*b Cs> PARmAL E3E FRONT'S.
3. 31C.5-3 ceAkifc^HATT" failure,
cm^t t(3,ooo
RERM6.S FrtJb 500,000 AL. 'PTSO^OCTmDAJ.
4. ETv/AtLO ATIOIU of -Haesha^ catalyst:
id
CBY 1118706 RSV0032783
(c{ior7 Pf^o^Arv\ ^
pRODucnoiO, n ml.
"Tcrr^L
Cost-
(J<U/T Cb-iT, <t/AL.
>ro$s 'Fkew'
PROFIT X*PROVE weAJT*
K (p C>
X(C'(o<\ Z
^3,24,4, 300
12.23 4 2., 074,(00
/OAL
1<T67
30,000
4 3, X77,<?oo
(0,^3
4 2,72?., too 4 &48, o^o
(, EumiuftTE a TcrrAU DEJFeosT Auti iaEt>ucF PactiAt--
PEFROSTS FR0Af > -* 3 .
2..QOO.OCO 6fll.
"*EuiHtAJftTE. OlAJOR EGpUlPwe/UT FAlUUfcFS *UCN AS ElO^flUE.
C<2*N<SMAFT5. $ 113,000
500,000 ^AL,
3. 2.S% IMC(2EASE> YlELb U)ITH tfAfcSWAUJ CATALYST 400/00 4AI
4. XmPiaoYE E-QuiPhaeut oN-stream time., 4oo,oqo 6Al
5. Shutdoujo chemical tceatmj^ By Ap?l (.
^44>,|oo .
^> , TmcEBASE. CfP-6A^ CEEfc>i*r BY |(OCEEASt^>^ 31 C4 00wP12E5so_ CA-PACiry. 8V Jao, (. ^4o.pod
CBY 1116707 RSV0032784
PROCESS TECHNOLOGY A ENGINEERING 1966-1967 GOALS A OBJECTIVES
PERFORMANCE A PLANS FOR METHANOL
CBY 1118708 RSV0032785
,MeOU-7 PT&E *67 Programs
I. QUALITY
II. CAPACITY
III. COST REDUCTION
IV. NEW METHANOL PLANT STUDIES
V________
J
f II. CAPACITY
Me OH-9
A. Linde Unit Reduce downtime Improve Syn. Gas Quality.
Value '67: 2 M gals. MeOH ($330,000)
V Jz \MeOh-11
COST REDUCTION
Commercialize resin-bed process for removing iron carbonyl.
'67 Goal - $46,100 from obsoleting present chem ical treating.
J
QUALITY
.MpQH- 8
"\
Objective: Meet division goal.
Program: Identify and mini mize impurities.
II. CAPACITY
\MeOH-1
B. Reactor Yield Optimize Bed Temp. Profile Use 2d chg. Rarshaw Check all catalyst before use.
Value 67: 400,000 gallons ($66,000)
MeOH- 12 IV. NEW PLANT STUDIES
Objective: Define methanol synthesis^ technology for new 100 M gal/yr metha nol plant based on steam reforming.
Potential: $2-3 M/yr increased Division pro' fit.
CBY 1118709 RSV0032786
AN HCN REVIEW FOR
1966
CBY 111871 RSV0032787
SAFETY
GOAL* Equal or beai best previous
Safety performance
Operator Inj. ~.o+al Inj. Serious Inj. Lost Time Inj. Fires Spills HCN Incidents Housekeeping
Goal <8 <33 <2
0 0 0 AA
1966 YTD II 27 I 0 0 0 AA
CBY 111B711 RSV0032788
CAPACITY
Goal: Make every lb. of AN needed fo best balance AN cosf 4 CZHZ distrSupply HCN demand most economically
Budget Goal 56 YTD `66
HCN 75.4 (754) 54.1 (666)
Crude AN 130.2 130.2 325 109.7
Pure AN 132.8 ([32jD 91.3 (mT)
TBA
4.5 3.37 451
LN 6.45 6.45 6.54 3.02
CBY 1118712 RSV0032789
QUALITY
om___________________R__E_SULT. S
1. All AN W+ AN 200 Spec. 2. No product qualify compla'm-Vs
2 " minor-
3. Resolve specs 'Tor Ac H +0
Unoff* c i a t spec
mee+ Carbide needs.
st on AN <0.02
Rev ise opera+ior5 4 equip, Lo
AN <0.02
meet- these specs I^Qtr 66
4. Work with LA on phosphate
Reduced from
redaction in waste NH^CI which 1.5-2.0 7- io
Comes "Prom LN.
0.5- 1.0 7
CBY 1118713 RSV0032790
RSV0032791
i
COSTS
HCN
'65
Actual Budge!
Goa 1
'66 YTD
'66 Pred.
Prod-, PI lbs 75.3
754 (754) 54.1 (6&6^)
Ram Mf 1, Utilities, Repairs , Catalyst, t/* Ofher Dir. J Indi reefs, /* Total Cost, t/*
1.871 0.341 0.420 0.081
0.543
. 0501 (3.840)
1.683 0311 0518 0.153 0.490
fl-5// 3.666
1.644 0.311 0.455
0106 0.476 OSH 3.503
1.459
/.472
0350 0.368
0300 0.412
0.035 0.03/
0.547 0570
0548 0.561
3.379 r3.47^
'65 Actual
AN
*66
Budge!
*66
Goa 1
'66 YTD
'66 PrU
Prod., M lbs
134.4 1376 <J32^> 91.3 (joae)
Raw Hail, */* 6.986
Utilities,
0.55*4
Repairs,
0410
Cafalusf, A 1.496
Other Viry $-/* 0.579
Tndirects, $/* 0776
Total Cost, t/* I(YflflOT)
6.143 0.562 0.5/3
/.284 0.643 0.7// 9.863
6.143 0.562
0446 1.525 0.639
Q0a.7/s11V)
6.266 6.270 0.579 0.57O
0.466 0.530
1526 1.460 0.666 0.650 0.761 0.76/ 10.264 dmb
CBY 1118715 RSV0032792
1966 YTD VARIANCF5
*fl|ru Sepf.
m
Variance
Off Sch
Unsch Cap Total Volume
+ 39.273
- 70.652
- 3 J.379
Performance
+ 36.999
Price
+ 99,070
Total Wariance
AN
+ 105.680
Variance,
Off Sch l/nsch Cap Total Volu me
- 8.347
- 1(7638 " 125.985
Performance Price
- 248.955
CBY 1118716
~ 45247
RSV0032793
1366 PROFIT IMPROVEMENT
Project
6G Goal 66 Est
HCN 1. NH3 pipeline to reduce raw materiaI cost
*169,000
# 224,000
2. Optimize individual 14lager gauzes -for better yields 30,000
25,000
3. Maintenance cost reduction 15,000 59,000
4. Optimize gauze ihicKness Iota 1
_20.000
0
*234,000 *308,000
AM
1. Improve reactor control *60,000 67[000 tor better HCN C^H* fields
2. Catalyst usage reduction 227,000 220,000
3. Maintenance cost reduction 50,000 91,000
4 Improved recovery tram 20029 OH recycle
Iota 1
-- 4$000
4 337,000 *422^000
CBY 1118717
RSV0032794
1967 GOALS
For
AN i HCN
CBY 1118718 RSV0032795
SAFFTY
Goal: Equal or beat best previous
performance
Besf Perf
1967 Goal.
Operator Xnj.
Tofu I rnj.
Serious Xr\jLost Time Xnj. Fires Spiffs HCN XncidenTs
Housekeeping
7
32
f
0
0 0
AA
7 or less
32 or less I or less
0
0
0
AA
Projects
i. Upgrade NH3 pipeline system instrument's -to
greater reliability sa-Fe /y.
2. Evaluate neu) level indicator probe in HCfSl
Storage $ adopt it proved superior-.
3. M aintai n department# / satety f ho uze.keepi n
index programs.
CBV 1118719 RSV0032796
1 *
capacity
GOALS'-
AN -
Produce (juanfil^ of AN (up to 140 RtJfjr rate) as determined by
marketing demands 4 economic
optimisation of West Plant C.B. Pad !i tie
HCN- Produce quantity adequate for A N>
TBA, 4 LN requirements up -bo plant-
capability (90
TBA-
Expand TBA Capacity from 4,5" "fro
5.4 Meffective 4-1-G71 Produce
TBA required within Capability,
LN - Meet all Lactic Acid re^uiremenfs
tor LN in manner so as to not limit Lactic Acid operations.
CBY 1118720 RSV0032797
QUA! ITY
GOALS:
I. All AM to meet AN 200 specs. 2 No product quality complaints.
3. Work u/iih P774 E and Laboratory to better define MVK analytical and quality control technology.
CBY 1118721 RSV0032798
HCN COST
Prod, M |bs
1966
- Est.
66.6
Raw Mafl, fy* UfilifiSj /* Repairs, $/* Caialysi, t/* Other D\r^A Indirec+s^ $/*
1.472 0.368 0.412 0.091 0.S7O 0.561
Total Cost,
3.474
196 7 Budqeh 63.94-
1.52 0.37 0.49 0./2 0.62
0.59
3.71
1967 Goa 1 63.9+
1.50 0.37 0.43 0.12 0.62 0.53
3.63
CBY 1118722 RSV0032799
AN COST
Prod., PI lbs.
066 E s+.
108 6
Raw Plafl, $/* U'f i I tis, Repairs, $/* Catalys+'tA Other Dir, /# Indirect^, /#
.270 0.570 0.530 l.40 0.650 0.761
Total Cost,
10.241
1967 Budge!
107.10
1967 Goa 1
107.10
590 0.640.54 1.27 0.87 0.86
5.79 0.640.51 1.27 0.85 0.86
10.08
9.92
CBY 1118723 RSV0032800
1967 PROFIT IMPROVEMENT
Project
'J/ VJUML
HCN
1. Misc. equip, improvements
*17,000
2. Evaluate IS layer gauze
3. Reduced maint. costs
Total
15,000
22000
* 54,000
AhL
I- Catalyst usage reduction
2 Reduced maint. costs
3. Improve CzHziHCN yields
t Increased AcH production
4 safes
51 Reduce sample load +o Control
Lab
Totci |
CBY m72*
230,000 33,000 85000 33,000
20,000
*
401 non
RSV0032801
P0I1UT1QN f.ONTROl
Goals =
I. Establish mechanism to prsvenh
Dept, 19-20 SUrnp overt low -to -the. Sewer.
2 Main+ain do se control ov,?r Te<?-d (waste s) 'to D*pf. 4 4o ai/c>id sluq s
cyanicfe polymer- and b.tah cirr.monio ! l<.
G>. >*n<dy and implement it
f :;>
Ttiirfher means of re.duc-jrr> :iir n n d
h a >/ po I Inti on.
CBy 1118 725 RSV0032802
PFRSQNNFI
GOALS:
1. Counsel all supervisors in 1967
2. Counsel hourly personnel as necessity for msfrucfi'on, correction, commendation> guidance^ etc.
3 Stimulate Communications ujith a) Weekly supervisory meetings. b) Chief Operator meeting at least
Once per quarter.
4: Train all operators to qualify for all Jobs in their respective depart
ments. by J-l-68.
5. Obtain adequate hourly sta ff i ng 4o
maintain overtime between S' 3 Vi
with critical monitoring of absenteeism
C0Y 1I1Q7?& RSV0032803
1966
TECHNICAL
RESULTS
car 111B727 RSV0032804
$ SUMMARY OR 1966 PROGRAM
GROSS
probab SAVINGS
POTENTIAL ility ^ TIMES
SAVINGS AREA (*Ar)
of
SUCCESS
WW
HCN 30M
80% *I8M * 2ff1
AN R* IH0M(y|elds)
15011 (catalyst)
izsnResidue
Recovery
60% 60%
99%'
`42H `84M
'90t1
`6on '!2r>n
LN 7511
TOTAL 520M
70% '25n '52M
% l45M`375r
1 Assuming project approved
CSV 1118728 RSV0032805
RAW MATERIAL USAGE 1965 VS 1966
Ibs.HCN
/I00 lbs.AN
lbs. Cu
--
57- --
56*
ss- -
-
*tio-
lO xO 53'
2
52* -
- ----
51-
1966
RSV003280*
SIGNIFICANT DATES
AUGUST65 - REACTORS AGAIN IN GOOD MECHANICAL REPAIR
MARCH 66 -SWITCH TO HCN CONTROL FROM "MVA CONTROL
JULY `66 - REVISED CONTROLLERS INSTALLED
CBY 1118730 RSV0032807
POUNDS OF C,H
RSV0032808
*. HCN/ 100 lbs. AN
HCN USAGE
RSV0032809
lbs. C u / 100 IU. AN
CATALYST
USAGE
x
CBY 1118733 RSV0032810
o
196?
GENERAL TECHNICAL SUPPORT
FOR BOTH AN AND HCN
EMPHASIS ON
a. Reactor studies to reduce raw MATERIAL 4CATALYST USAGE "TARGET : 62 IbsGtVL/lOO IbsAN <5.9lbs.Cu /100 lbs.AN -PROBABILITY OF SUCCESS 60% 'VALUE -RM" $90M/sfR.(CH.') 1$ IOOMAr. (cktaiyst)
b.Optimum low rate operation
C.SURVEY TO DEFINE LOSSES UNDER PRESENT CONDITIONS AND REDUCTION OF LOSSES AS NECESSARY
CBY 1118734
RSV0032811
COM PLEX
AND
METHANOL
CBY m735
RSV0032812
c
SAFETY FOR 19GG
goal: REDUCE 5ERI0U5 injuries
TO TOTAL INJURIES BY 1-5
RATIO.
NO LOSS TIME INJURIES.
MfTHOD'lB/isrF DISCUS5 ION ON SAFETY WITH LEAD-
MAN ON EACH JOB LI HE-UP. Z.HOIO SAFETY MferMOS WITH CRAFTSMAN
PRIOR TQ AND DURING SHUTDOWNS
STRESSING INCREASED HAZAADS DUE
TO HEAVy WORKLOAD AMD IMCPfasFD numbers of craftsman assigned. 3. Hake a safsty meftia4 w/fm /ill our?,pe
JtPFAV/sapS PALOM JV SHuTDOWp. 4 (0MCFM7~AP7EP EFFoPTS Ta ST/MfLA rzr
SAFery awaffmfss amp att/tvofs of All zomf afs/swfc* Pfjc s<ja^a/fl. s CoNr/Nue 70 pfimfim with PpaPUcr/M
ANY PorFMT/ML PXACFSS AA^FPDS.
4 TOOL BOX IIYSPECTIOAI OvFPrFPLY OF All Ma>wisy/amcf 7*l &a* s rMF Z.OMF.
CBY 1118736
RSV0032813
SAFETY RECORD
FOR
DEPT
Ofc C,. ^CONVERSION
I9U 9JM0.ACI %L IIMBIM
INJUR ES INJURIES
(MINOR/(Ml NaK/$Ffc*Ms)
9/1
GH* PURIFICATION WASTE DISPOSAL
7/e
9jfL
H. C.N.
T. B. A.
9/0 %
AN
LN
l/o Vo
Me OH
total
J/L *s/l
GOAL 1967.' MAINTAIN THE RATIO OF
SERIOUS INJURIES TO
TOTAL INJURIES WHICH
IS 1-8.
1118737
RSV0032814
c PRODUCTIVITY FOR 1964 - L967
AREA
GOAL ACTUAL EST GOAL
I9U
I9U I9U
1947
0t CvHt COKVERSION
70Z G3.Z7. 452 70%
ClUl PURIFICATION WASTE DISPOSAL
45%
C-4|t- BAG FILTER L5%
6&3Z
6/.#
40%
65%
>5Z
H.C.N.
T.B.A.
AN
LN
MtfOH
TOTAL
!o5% 10.8% 10% 70%
Q.UT. jOZ (o57o 70%\ 65.5% i3Z 70%
47% 63./% 43.6% 67.8a
CBY 111B738 RSV0032815
It/IETHOD: 1 CLOSER SUPERVISION IN ALL AREAS DURING TIMES OF LOW PRODUCTIVITY
Z. AFTERNOON MEETINGS WILL BE
HELD FOR THE NEXT DAY LINE-UP ON SCHEDULE WORK.
A. CHECK AVAILABILITY OF MATERIAL B PERSONNEL GO TO WORK AT
0800 WITHOUT JOB LINEUP IN THE MORNING
3 MAINTAIN ADEQUATE LOW PRIORITY OR BACKLOG JOBS IN EACH AREA FOR FILL-IN ON EACH DAILY SCHEDULE.
4- PERFORM MORE CLEAN- UP Gt: A DAILY BASIS.
5. CHECK MAINTENANCE PERSONNEL DURING REDUCED RATE AND TOTAL SHUTDOWN TO ACQUIRE MORE SAMPLES.
CBY 1118739
RSV0032816
OVERTIME
1366- 1967
AREA
AOk CONVERSION
C H* PURIFICATION
WASTE DISPOSAL
Ci Hr-BAG F/LTER
H.CN.
TRA.
AN
LN
Me OH TOTALS
GOAL
13GG
707.
ACTUAL ESI GOAL ixi 1344 1347 68% /o.7% 702
8.07. 8.07,
55%
53% <95% 6.02
442 45% 6.5% 4IZ 4.2% 502
8.0Z
3.07, 1M7o
5.SZ 12 CZ
6 0% 02
I4-.07. 8.07c 737, 6.4?
CBY 1118740 0 f * RSV0032817
METHOD :i. CLOSER SUPERVISION OF
i CRITICAL JOBS. ^ BETTER UTILIZATION OF STABLE MAN POWER IN THE ZONE 3 PERFORM PREVENTATIVE MAINTENANCE ON CRITICAL EQUIPMENT DURING REDUCED PATE PERlOD.fNO LOSS OP PRODUCTS.) +. ADEQUATE SUPERVISION ON OFF SHIFT BASIS TO UTILIZE SHIFT PERSONNEL. IMPROVE COST ON OFF SHIFT. 5. MORE REALISTIC 5TAFFING OF CRITICAL JOBS ON DAT SHIFT. (TO REDUCE CALL OUT AND OVER TIME ON DAT SHIFT.)
CBY 111B741 *<" * a
RSV0032818
AN COMPLEX
AND
METHANOL
AREA
9mACT l2tno.EST. STP.
1966 7966 /97
GOAL 1967
O* C*H* HC.M
AN
WASTE ^b.a. lN
MeOH
*131,046 * 4-8,595 * 37, 993 t /L6&9 J 77,36/ * 3,343
120,48/ ZZ47,046
# 10?
4 9/, 4-49 \ Zo.OQO * % 668
t 4,X,/f
* /Z.9S4-
*14/200
*133,196
* *70,000
f 469,000 i 3* 700
* 49.100
*L 24,000 *378.000
*142200 * 761,796
*\2S3,600
*435,000
4 s/.ozo 4 49,zoo
# 7.4,006
Z8t>. OOC
TorAL- *2/4,080 *374,4-^4 *ZJ67,Z% *Z,OaU/6
iZWST-/9U J/963,436 GOOl /967*z,oo3,z/6
11187^2 CB*
A *Ojz tf A 06
RSV0032819
' AN COMPLEX AND
METHANOL
S.D.R. ACCURAL 1365-13U '-*1,836,480 5.D.R. EXPENDED EXTRAPOLATED - /, 786,833
TOTAL E.PR. CREDIT-* i!0,677
Sp.R.ACCURAL 1367 -*78SSZ
S. 0. R. EXPENDED EXTRtfDUTEK,
/967
*360,000
/967SDR CREDIT ^23 8j9Z
CBY 1118743 RSV0032820
/ IMPROVE MENT
OVER 1146
SAFETY:
19t>4>-REDUCE THE RATIO OF SERIOUS IN Tunis's To MINOR INJURIES TO 1-8.
134.7-SAME AS 1966QR BETTER
PRODUCTIVITY: 1966-GOAL 67% 196,7- INCREASE TO 67857.
OVERTIME:
1964- GOAL 767. 19 67-DECREASE Goal TO 6.<4-%
MAI NT. STD-
1966- COfi L *2/42.000
19 4.7- 6OftL^O0S,Z/b
l9UrEST&`Mb.+36
/H7-6crE-Z,O03: ZJ6
CBV ill 8744
RSV0032821