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To: W. C. Kolar Interoffice Communication From: Date: p# e. Markey November 21, 19 8 4 Subject: VCM PLANT BUDGETED VARIABLE COSTS VISTA As you are aware the plant is experiencing some difficulties with the recent reduction of budgeted chlorine price in the current fiscal 1985 variable cost budget. The problem stems from the fact that the revised budgeted chlorine pricing failed to re flect an appropriate price change in the "chlorine equivalent" HCl price. As a consequence budgeted HC1 pricing remained disproportionately high. The final result of these changes is distorted variable costs and variances. Attached for your review are two versions of IPA's? the revised budget version and the plant preferred version which reflects an HCl "chlorine equivalent" price as tied to the recently reduced budgeted chlorine price. Also attached is a comparison table of 1985 budgeted variable costs which detail the impact of HCl pricing based on the original chlorine price and HCl pricing based on the revised chlorine price. The differences are substantial. We would like to meet with you at the plant at your convenience to review the situation and attempt to resolve the differences. The objective would be to develop a method which will provide accurate variable costs and variances which reflect actual plant operation. If you have any questions or comments on the attached information, please give me a call at ext. 5065. P. E. Markey Plant Superintendent br cc: RAC-JHB-MLA-MCM-JRP CWH 000005649 ffimtQ guveer i/mM LAKE CHARLES VCM PLANT LHC DEPT . NO. 306 PROD. FORECAST - 1107.OMrt LBS. RAW MATERIALS AND BY-PRODUCTS UNITS FIRST QUARTER STANDARDS PER POUND PROD. CT S/UN IT U NI T 7 L E< CT 5/LB INDIVIDUAL PRODUCT ANALYSIS ETHYLENE DICHLORIDE OCTOBER r1984 ACTUAL CDSTS QUANTITY DOLLARS CTS/UNIT PER POUND UNIT/LB PRDD . CTS/LB VARIANCE CENTS/ TOTAL POUND DOLLARS DUE TO PRICE El: 1' . CHLORINE ETHYLENE OXYGEN HI' L FROM HYDROGEN VCM SECTION LBS . LBS. LBS. LBS. LBS. 6.0000 19.5000 1.7560 C7.9267} 14.6807 0.4070 0.2860 0.0747 0.3248 0.0001 2.4420 5.5770 0,1312 2.5746 0.0015 32031700 26497710 7947860 34231262 4375 1764944 4902076 125643 1834453 642 5.5100 18.5000 1.5808 5.3590 14.6743 0.350600 0.290000 0.087000 0.374700 0.0 1.9318 5.3656 0.1375 2.0079 0.0007 ( 0.5102 0.2114 0.0063) ( 0.5667 0.0008 466128 193139 5756) 517749 731 156955 264977 13925 873956 0 ( ( < 309173 71830) 19 6 01) 361207) 711 less; by- p r o n u c: r y L I Gill ENDS HEAVY ENDS LBS. LBS . 0.0 0.0 { 0.0020) ( 0.0075) 0.0 0.0 ( 17675) ( 642372) 0 0.0 (0.000200) 0.0 0 0.0 (0.007000) 0.0 0.0 0.0 00 0 00 0 PROCESSING (LOSS) GAIN LBS . ( 0.0831) < 8690968) (0.095100) PROCESSING SUPPLIES OXYCHLORINATION CATALYST 8XYCHL0RINATION DILUENT HYDROGENATION CATALYST SULPHURIC ACIIi CAUSTIC SOLUTION NITROGEN-GASEOUS AMINE COOLING WATER CHEMICALS MOLECULAR SIEVES LIMESTONE AN T I FOUL.ANT CHEMICALS OTHE R SUBTOTAL 1.0000 LBS. LBS. LBS. LBS . LBS . MSCF LBS. LBS. LBS. LBS. LBS. 739.97B6 129.6B24 1258.3870 3.8504 7.6806 83.6694 116.5173 121.3929 214.1200 0.9838 87.9376 152.3833 0.000039 0.000052 0.0 0.000109 0.003910 0.000355 0.000029 0.000066 0.000007 0.006309 0.000027 0.000021 10.7263 0.0289 0.0067 0.0 0.0004 0.0300 0.0297 0.0034 0.0080 0.0015 0.0062 0.0024 0.0032 91361892 2519 2B47 0 13571 322208 29208 1768 7922 0 535700 1220 2144 8627758 17329 2973 0 689 21685 35679 2126 7060 0 3781 1160 3409 1.000000 687.9317 104.4257 0.0 S.0770 6.7301 122.1549 120.24B9 89.1189 0.0 0.7058 95.0820 159.0019 0.000028 0.000031 0.0 0.000149 0.003527 0.000320 0.000019 0.000087 0.0 0.005863 0.000013 0.000023 9.4435 1.2828 1171991 1314813 C 142022) 0.0190 0.0099 0.0033 0.0034 0.0 0.0 0.0008 ( 0.0004 ) ( 0.0237 0,0063 0.0391 ( 0.0094 ) ( 0.0023 0.0011 0.0077 0.0003 0.0 0.0015 0.0041 - 0.0021 0.0013 0.0011 0.0037 ( 0.0005 ) ( 9045 3106 0 365) ( 5 75 6 8580)( 1005 ( 274 1370 1919 1005 ( 457 ) ( 1311 719 0 166) ( 3063 11241 ) 66) 2557 ( 0 1439 87 ) 142) ( 7734 2387 0 19 9) 2693 2653 1071 3 2 f! 3 > 13/0 4 30 1 092 3 1> UTILITIES ELECTRICITY WATER STEAM NATURAL GAS SUBTOTAL KWH M/DALS. M/LBS. MSCF. 5.3372 28.4000 550.4932 344.0800 0.033990 0.000343 0.000334 0.000050 0.1204 0.1814 0.0097 0.2114 0.0172 346372B 35174 30355 4992 95891 125101 9989 171570 17447 3.6117 28.3988 565.2117 349.4992 0.037912 0.000385 0.000332 0.000055 0.1050 0.0154 0.1369 0.0109 0.1878 0.0191 ( ( 0.0445 0.0012)( 0.0236 0.0019)( 14070 ( 40656 1096 ) 21561 ( 1736)< 2 5 6 3) 59767 < 0( 4 4 6B) 271 ) ( 1 6 6 1 ; 1/1)1' 1 0 9 6 . 26029 1 465 i HEAVY ENDS DISPOSAL COST LIGHT ENDS TO SALES LIGHT ENDS TO INCINERATOR SUBTOTAL LBS . LBS . LBS . TOTAL 0.4197 4.4202 -5.5000 -55000 0.007500 0.002000 0.0 ( 0.0332 0.0110) 0.0 / 11.288_6S') 671565 0 0 324107 27809 0 0 9075565 4.1409 0.0 0.0 0.007351 0.0 0.0 0.3547 0.0650 59385 0.0304 0.0 0.0 ( 0.0028 0.0110)( 0.0 2558 10050) 0 9.9336 1.3550 1237954 55028 1876 0 0 ( 1369154 ( 4 35 / 60J 10050'. 0 131200) PROD. DISTRIBUTION 1 ETHYLENE DICHL ORIDE 1 POUNDS DOLLARS PRODUCTION VARIANCE SUBTOTAL 1 91361892 9075565 1 1237954 1 91361892 10313519 TO-SALES T0-VCM SECTION TO-INTERPLANT TO-EXCHANDE TO-PROCESSOR to nr: f frnm > tmv 1 l 1 1 l 1 882200 39867131 0 0 0 995QB 10144741 0 0 0 i C/LB i 9.9336 1.3550 1 1.2886 i i i 11.2886 11.2886 11.2886 11.2886 11.2806 11 n o r* / i i i i i 1 CUH OOOQO O Li XJ oTO to n ro to tO "7 --i o co I' n o tO c i> n n - n w ro x tn rs n o i- ^ ^ c n to c o = TO to c m x to to to o to to O A A ro x Ml -4 IS) 2 --i 2 c x n o c 7? 5 n 2 H a a d n e z o n -o --I o x r to TO -1 2 to c m m o O 2 TO O 71 -- m to M- 2 mo to *-- -n --- ~ ~p n tn TO n 77 m n ro m tn TO -- O r~ r* to z> n n O ii m --4 --4 A -< TO T* tn o o 3? C 2 tn m -< TO 7? |_l 3 r> 2 1 nm 2 2 n to 2 ro r> -4 n tn t: 3> w~ o CO -v 2 -< co o TO c t-- n i- n TO c T> o n tn x> o --< -- n tn XA tn w o to o m T' 7? O 2 Ci TO 3> A i--i Al 2m TO <z TO X' TO n C o 2 TO TO rn 2 J> m n --l TO -n m O -H 3? 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Cl IJ i O'i. O- so j. r.n -i* sj J IJCUISi -4- C' p- CO cn O' cs c* cp cn vl L0 CO OP S' S3 C O WOCOO 000 W >J w vi co cn J. '.1 o SJ O O O' oo c CO CO 0 cc O to --( 00 v. -- Xo 3 --4 -* C rjocn -- O OP- C4 43 O ts C' S3 O SS II " v socn o- a CO *=* Vr- oo o oo p- o ij cn P-OP- -- O to O' -- o co cn cj j f j om C2 c co c V I ~o u cn t-- VI V V -- ts co cn s-- r j cs -O r If) I -- 'p <> - r*. c" '.* Co \ ( cn o -- IJ " V -- CUH 000005652 .M I CHARL ES UCH PLANT i.o i t*r-t . no. 3Q7 I III'. PtlRCCAST - 670MM LPS nil MATERIALS AND BY-PRODUCTS UNITS FIRST QUARTER STANDARDS PER POUND PROD . CTS/UNI7 LJNIT/LP CTS/LB INDIVIDUAL PRODUCT ANALYSIS VINYL CHLORIDE HONOMI R OCTOBER, 19114 ACTUAL. COSTS QUANTITY DOLI ARS CTS/tJNI T PER FOUND UNIT /LD PROD. CTS/I.B VARIANCE CENTS/ TOTAL POIJN D DOLLARS CO DUE ro PRICE EFF . CUH 0 0 0 0 0 5 6 i im:- pure: produced I I'C --PURCHASED I '-5 : U'( - PRODUCTS Hi m'.'Y FIJI'S IH.L TO EDC SECTION H' l. TO METHYL CHLORIDE MIL 11) INCINERATOR lbs. IPS . LPS. 1 PS. l.PS. LPS. 10.6094 10.6094 1.6161 0.0 17.1459 0.0 09067131 96 1 B 94 9 0927041 1017 4 4 4 9.9336 10.5775 1.-109000 0 . 15 6 3 0 0 1-1.5016 1 . 6 51' 0 ( 2.6443 1627314 1 . 6528)( 1017453) 607322 1 0204 92 3 0 6 n < 10205211 0.0 ( 0.0035) 0,0 < 190148) 5.8356 5.0356 ( 0.5370)( < 0.0 4 6 5 ) ( 3.1337) 0.2714) < ( 3425<?C06) < 1660000) ( 5.8356 0.0 0.0 0 0 1 0 35 V07 ) 80959) 0 0.0 < 0 003100) 5.3590 (0 5 5 6 5 0 0 ) ( 5.3590 < 0 027000)< 0.0 00 0 . 9H2! ) ( 1 44! ) ( 0 0.0 0.1512) ( 0. 126?)< 0.0 0 93078)( 73119)( 0 0 16 2803 > 7 9 12) ( 0 0 70205 70207 ) 0 1 i 11Lt58I NO (LOSS) GAIN LPS. ( 0.0 2 V1) ( 1 01 6 6 C 7 ) (0.029500 ) [ Hi:i SSI MG SUPPLIES i iMisim pi am: P .`.l C. I U M CHLORIDE !;i JI PHIIR I C AC 1 D Mi'liPOrUJINnuC cum. INR WATER CHEMICALS rr.uz ik IHRBON IF! RACHl GRIDE SUBTOTAL lds. LPS. LPS . IDS. LPS. ids. IPS . 1 . 0000 25.2871 19.7060 3.0504 244.0268 12 1 .3929 5 5. //3 6 29.6098 0.0012C9 0.000036 0.000120 0.000001 0.00 00 72 0.000192 0.000239 13.7408 0.0326 0.C007 0.0005 0.0002 0.0037 0.0107 0.0071 61559359 63400 0 90 4 R 0 5202 0 5300 8019539 15315 0 459 0 4707 0 14 1? 1.000000 24.5433 0.0 5.0729 0.0 09.1140 0.0 26.7726 0.001014 0.0 0.000147 0.0 0.000086 0.0 0.000006 13.0274 0.0249 0,0 0.0007 0.0 0.0076 0,0 0.0023 ( 0.7134 0.0077 0.0007 0.0002 ) ( 0.0002 0.0011 0.0107 0.0048 439164 4 740 43 1 12 3) ( 1 23 677 6587 29 55 439195 ' 4 6 -1 0 111 > < o 1 705 ( 0 1 55 31 > 1 2 7 6 4il l2 125 1 028 ) A 5 i? 7 20 0 0 III MILS I I ECTRICITY WATER SIEAM NATURAL GAS SUBTOTAL NUH M/GALS. M/LBS. MSCF. 5.3372 28.4000 550.4932 344.0800 0.008 3 9 B 0.000315 0.000499 0.001302 0.0605 0.0448 0.00B9 0.2747 0.4480 517560 19786 23051 78210 21900 1 0694 5619 134805 273344 3.6119 20.395? 565.1964 349.5001 0.0 0 0 4 012 0.000321 0.00 0.387 0.001270 0i0 3 55 0.0304 0.0091 0.2190 0.4440 ( 0.0250 0.0144 0.0002) < 0.0557 0.0040 15390 8865 123) 34239 ( 2-162 ( 2213 3 9 50 ( 0( 350 7 ) 4 2 3 9) 1317 ' I,) 1 23 > 37796 670 1 TAUY niDS DISPOSAL COST -NClNfRATOR COST DC Purct, /jj- SVC T'^Nrr /jf. fc/ -Jo Svc- /)f ffc/ -7, /If- SUPTOTAL LPS. S"M6 total 0.7764 4.4202 0,0674 0.003500 0.010149 0.0155 0.0819 14.6751 C* &7 QX O 0. 77X /,// o /. 0 ?76 0 . o ?// <?. 5 Id- -7,07if (o-o4&oy(o*0t?7fy 198789 0 <5? o o o 432462 0232 A7239 8529372 C7 O D O 4.1411 0.0 O 0 0 0 0.7025 0.0739 45493 1134 44209 0.003229 0.0134 0.0021 1 293 0.0 V 0-r0?S7-- V-5 201 *- 4<P7-d-C< O.ooS^y *- < 32^3> 555 0 7 31! ".-4-3 .8555 * -,0--8-l-'9'6 W.-504S4 1 4-13147 p 6+4 ) ^^7#077 C O o o o 35?- < 0>S,o33 o o / O-r/C 75,67C- - & 10,37# o </ /a 5?> <y/',3So >"<7/6, V<tf> 75-,/ss1 O o ^0.0cr/7:i'?<S7yPS^Xz;l//7/:x>N-5',/' ToT/L Vo 2137 3- I3SC.C0 Or riP C (x- -"r- X.CCrCl 7 -1 ' C ' 'i /- EDC Chlorine Original C/Unit C/Lb. 3.1500 3.3170 1985 VCM PLANT BUDGETED VARIABLE COSTS COMPARISON TABLE 1st Qtr. C/Unit C/Lb. 6.000 2.4420 REVISED IPA'S 2nd Qtr. 3rd Qtr. C/Unit C/Lb. C/Unit C/Lb. 6.000 2.4420 7.500 3.0525 <5 Uo'i x o . , 4 th Qtr. C/Unit C/Lb. 7.900 3.2153 Ethylene 21.7500 6.2205 19.500 5.5770 20.000 5.7200 20.000 5.7200 20.500 5.8630 All Other 3.2696 3.2696 3.2696 3.2696 3.2696 Total EDC (Method A) * Total EDC (Method B) * 12.8071 11.2886 10.6094 11.4316 10.7524 12.0421 11.8370 12.3479 12.2689 VCM EDC 12.8071 20.6976 11.2886 18.2435 11.4316 18.4746 12.0421 19.4612 12.3479 19.9554 All Other ( 3.6909) ( 3.6909) ( 3.6909) ( 3.6909) ( 3.6909) Total VCM (Method A) * Total VCM (Method B) * 17.0067 14.5526 14.6751 14.7837 14.9062 15.7703 15.8078 16.2645 16.2787 Incinerator No Change NOTES Method A reflects the current budget with originally budgeted HC1 price and revised chlorine price. Method B reflects the current budget with HC1 pricing revised to a "chlorine equivalent" price basis.