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CELANESE CHEMICAL COMPANY Chemcel Plant Bishop, Texas To: C. W. Harrison From: W. H. Meyer WHM-203-78 September 25, 1978 Fourth Quarter 1978 Work Plans Laboratory Chemical P. E. Hime G D. Boyd J. Chervenka T. N. Dowdy H. A. Ducote K. G Gallimore R. S. Hahn B. P. Hanson M. D. Harvey J. R. Higgins J. M. Hodges M. A. John B. C. Kerr C. W. Lee D. E. Lockwood Dr. C. E. Loeffler Dr. R. P. Lowry W. W. Massey A. G. McGehee R. A. Mickelson J. C. Rubiano k J. M. Sawyer G. R. Scholz W. L. Sharp R. W. Swanbeck H. H. Thigpen O. Towery J. -L. Trumbley P. J. Volpe DISTRIBUTION Plastics I J. L. Merian A. C. Abshier C. A. Amond W. C. Beyer R. L. Bunkley E. Munoz K. A. Rose Dr. J. D. Bennett A. R. Hancock CCCTC G. J. Fisher W. E. Heinz Dr. C. C. Hobbs W. J. Humphrey W. T. McNair Dr. D. R. Napier W. E. Taylor Central Files (2) J. N. Gann J. W. Dunn J. M. Ramey Dr. Tom Golson J. E. Sanborn W. H. Tuke F. B. McAndrews Dr. F. Zitomer - Bay City - Clear Lab - New York - Dallas - B%T?ort T - Pampa - Summit - Summit File: 004151 CELANESE CHEMICAL COMPANY Cheracel Plant Bishop, Texas To: C. W. Harrison From: W. H. Meyer WHM-203-78 September 2S, 1978 Fourth Quarter 1978 Work Plans Laboratory Attached are the fourth quarter 1978 work plans for the Laboratory ate agreed to at our priority meeting. The schedules cover work plans for each?' chemist in the Special Problems Area, and the Analytical and Quality Assurance Group work plans. It should be noted that product quality problems, low utfi-t efficiencies and other unit problems will reduce time spent on cost reduction (development) projects. WHM/as Attached Report 004152 AREAS I, IV, and 0X0 UNIT Group Leader - G. D. Boyd Methanol Oxidation, Formaldehyde Blending T. A. Jasek Obj ective Raw Materials Savings Plans 1. Sample for Iron in the air across MO-II and MO-III air filters in the fourth quarter and issue a report in the fourth. Summarize all catalyst contain- ' te . ination data to aid in decision.onlpiir scrubbing. Completion of this Objective will be dependent upon time needed for Unit Support. 2. Continue MO Catalyst screening study as needed and samples are available. 3. MO Catalyst Reuse - Issue report finalizing Lab evaluation of catalyst washing by end of fourth quarter. Raw Materials Savings (Increase Unit Efficiency) Reduce Methylal in MO Distillation Column - Issue recommendations for Plant Trial and conduct trial during fourth quarter, if feasible. 004153 y/HM-203-78 -2- September 25, 1978 Objective MOB MOB Plans Maintain daily contact with MO Units and Blending Units and provide Tech nical support as needed. Follow-up on recommendation to install Metalose Addition system downstream of anion beds as required. Utilities, BOD S. G. Smith, G. R. Stasney, J. R. White Obj ective____________________ ____________________ Plans ': ft-; Support Unit Expansion Anaerobic-Aerobic Laboratory Pilot (Cost Reduction) Study - Study operation and feasibility of two-stage anaerobic-aerobic treatment of Bishop effluent. Plans are to: 1. determine HS content of the anaerobic vent gas, 2. implement installation of the Process Controller, 3. determine the anaerobic treatability of aerobic sludge blowdown. ___ V 4. anaerobically treat the non- burnable portion of polyol effluent. 004154 WHM-203-78 Obj ective - Support Unit Expansion (Cost Reduction) MOB V -3- September 25, 1978 Plans 5. perform sludge settling tests on aerobic sludge to develop clarifier design criteria, 6. demonstrate an organic loading to the anaerobic filter of 0.75 lb. C0D/ft3/day, 7. collect data to determine the need for equalization between the anaerobic and aerobic sections, ' i8. start-up a Laboratory bench- ; scale anaerobic filter to develop ~ start-up procedures by the end of the fourth quarter. Aerobic Treatment of Bishop Nylon Unit Effluent - Determine the aerobic treatability of nylon effluent. Plans are to finish the study and issue a report early in the fourth quarter. Maintain contact with Utilities and BOD Units and provide technical sup port as needed. 004155 WHM-203-78 -4- September 25, 1978 Obj ective________________________________ __________________ Plans Increase Demineralizer Capacity Evaluate DOW and Rohm and Haas high capacity weak base resins as possible replacement for present Rohm and Haas IR-94. OSHA Monitoring J. M. Jackson __________________ Obj ective Define Employee Exposure to Formaldehyde Define Employee Exposure to TPP Define Employee Exposure to Asbestos MOB Plans Complete Area and personnel monitoring in MO II, III, and IV, and the Paraform Unit. Report data by the end of fourth quarter. Obtain area and personnel data. Report data by end of fourth quarter. Monitor Maintenance employees during insulation removal, as required. Provide emergency monitoring of air borne contaminants, if necessary. 004156 WHM-203-78 -6- September 25, 1978 Objective_____________ Cost Reduction MOB __________________ Plans are complete. Early fourth quarter completion. Recover BG from V-778 residue. Screen ideas and formulate program by late fourth quarter. Maintain daily contract with the unit and provide technical support as needed. Obj ective DAA Raw Material Savings MOB __ V Diacetone Alcohol P. J. Buras >? Plans Reduce Acetone losses to Mesityl Oxide by adding water to the reactor feed the first few days after catalyst regeneration. Schedule Plant trial late in fourth quarter. Identify an unknown component recently discovered in DAA product at relatively high levels. Determine how to control its production in the unit. Complete in mid fourth quarter. 004157 WHM-203-78 -7- September 25, 1978 _____________ MOB Obj ective______________ __________________ Plans Qualify Union Carbide Acetone as DAA feed by providing analytical coverage and assisting in the plant trial scheduled in mid October. Complete documentation by mid Novermber. MOB Maintain frequent contact with unit and provide technical support as needed. Esters, Methylal Paraform Formceli M. E. Harris Obj ective Energy Conservation Plans Assist as needed in the second attempt to start up the new Ester Unit Reactor Column (T-343). Simulate T-343 in the Laboratory to determine reflux require ments (minimum energy) and test control concepts. Provide analytical coverage during the next T-343 start, up as needed. Complete by Dec. 1. Cost Reduction, Energy Conservation and MOB Develop more Laboratory data on the effect of certain metal ion contaminants in the Paraform feed on Paraform 004158 WHM-203-78 -8- September 25, 1978 _____________ Obj ective______________ __________________ Plans evaporator fouling and Paraform flake quality. This data may lead to ways to minimize Paraform evaoprator clean outs (energy and raw material savings), solve problems associated with crude methanol feed to MO (energy conservation) and improve Paraform flake quality in terms of color and lumps (MOB). Cost Reduction Assist in obtaining microprocessor^ control of the Ester Unit by providing Laboratory cross check of the unit' analyzer as required. MOB Maintain frequent contact with the units and provide technical support as needed. Methanol Synthesis II F. R. Dow _______________ Obj ective MOB (Cost Reduction)' Plans Continue the non-routine monitoring of incoming natural gas for composition, BTU, and sulfur concentration. 004159 WHM-203-78 -9- September 25, 1978 t Obj ective MOB (Crude Methanol composition and purification tower profiles) Plans Determine the paraffin concentration in Crude Methanol and determine which purifi cation tower trays have the highest concentrations. MOB (Inlet and Outlet Sulphur concen- trations in the Sulfur Guard Beds) Confirmation of the Process Analyzer Sulfur analysis is necessary so that optimum Sulfur removal and steam usage can be attained. Support the One Column Purification Trial Run (Cost Redaction) Provide analytical and technical si||port for One Column Purification Trial Run. MOB Maintain daily contact with the Unit and provide technical support as needed. MOB Provide Lab support as.needed for test of Hydrazine addition to DPG Reformer and Lurgi Converter. Trimethylolpropane L. Mayerle - Objective Raw Materials Savings Plans Reduce Formaldehyde losses in the TMP reaction system. Continue spot deter minations of the Methanol production in 004160 WHM-203-78 -10- September 25, 1978 Obj ective_____________ _______________ Plans the reactors. Evaluate the effect of cleaning the reactors during the next shutdown (scheduled for October). MOB Maintain contact with unit to provide technical support as needed. Pentaerythritol R. G. Hilbrich, L. Mayerle Obj ective Energy Conservation nm_________________ ____________ Support Process Engineering project to recover energy from "A" evaporator'steam jet. Continue work in fourth quarter to develop a process for reuse and/or dispose of the resulting condensate. (Hilbrich) Raw Material Savings Initiate a study to recover PE from the Virginia Chemical Industries Centrate or from AML. Study will begin in the fourth quarter, 1978 to screen ideas. It is anticipated that the study will continue well into 1979. (Hilbrich) MOB Maintain frequent contact with unit and provide technical support as needed. (Hilbrich) 004161 WHM-203-78 -11- September 25, 1978 Obj ective Cost Reduction MOB Plans Remove crystallization inhibitors from "A" Crystallizer feed or T-286 residue to increase efficiency of the "A" Crystallization step. Laboratory work began in mid Sept. Project may carry over into first quarter, 1979. (Mayerle) Complete particulates sampling during Tech production to provide data f^p the air emissions survey. (Mayerto) Maintenance*of Technology B. C. Kerr _____ Objective MOB (Preparation of technical report abstracts and abstract cards) Plans Continue program for abstracting technical reports and preparation of abstract cards. MOB (Issue an up-dated Raw Materials Specification Manual) _l I. Incorporate the necessary revisions to proposed Purchase Specifications submitted on the basis of the draft Specification mailed previously. 2. Prepare typed copy and obtain signature approvals from the appropriate Superintendents. 004162 > WHM-203-78 -12- September 25, 1978 __________ * Objective_______________ _Plans 3. Issue the completed Specifications by November 15. MOB (Review Plant Process Control and Quality Assurance Procedures) 1. Review Unit Lab sample schedules. 2. Review Unit Lab Analytical Methods. 3. Review Unit sampling points and procedures." 4. Review Main Lab Quality Assurance sampling and anlytical procedures. 5. The above reviews will be .carded out with consultation with unit anS laboratory supervision. 6. Make recommendations, where needed, for revisions in plant procedures. MOB Provide technical support, as a Staff Chemist, as needed. ANALYTICAL and QUALITY ASSURANCE GROUP Group Leader - A. G. McGehee Objective MOB (Cost Reduction - Support of Lab Projects) Plans Continue analytical support of Lab Pilot Anerobic/aerobic studies and Rhodium Loss Accountability Program. 004163  m WHM-203-78 -13- September 25, 1978 Obj ective MOB (Support Plant Operations) MOB (Review QC Organization) Safety MOB V (Maintain Analytical Technology) t Plans 1. Continue Group readiness and ability to contribute to day to day trouble shooting of Plant processer and quality problems. Continue communication efforts through Unit Chemists. . 2. Provide analytical support to proposed MS Unit one column purification run. ' fc- Investigate/evaluate various methods of assumption of routine. Complete discriptive write up and solidify plans in late 4th quarter. 1. Continue emphasis.on Laboratory Safety and SNE Group attendance at general safety meetings. 2. Complete vent hood addition and upgrading program. Started 9-78. Continue in process review and update of Chemcel GC Methodology. Eight methods under review. Expect 4 complete by end of 4th quarter. 004164 i WHM-203-78 -14- September 25, 1978 _______________ Obj ective MOB (Training) MOB (Support Effective Laboratory Service to Plant) MOB (Maintain Quality of Plant Products) __________________ Plans___________ 1. Fill SNE vacancy (9-15-75) and complete initial training of replacement during 4th quarter. 2. Continue cross section refresher training as work load permits. 3. Complete initial training of newly assigned Instrument Sectiop workforce (50%) while maintaining quality of analysis. 1. Support Plastics move to theiir'new Laboratory. 2. Complete recommendations on Lab GC Computer replacement project. 3. Review Solutions Preparation work load and unit supply and distribution procedures - Effect streamlined org anization and manpower savings. 4. Investigate and finalize plans for Telautograph transmittance of Lab results to Unit operations. Maintain legitimate complaint record at ^0.15 % level. 004165 WHM-203-78 -15- Sept ember 25, 1978 _____________ Obj ective______________ MOB (Cost Reduction) __________________ Plans Review QC procedures on minimum of four products and make recommendations during quarter. MOB (Cost Reduction) 1. Review QC Group organization and make recommendations for improvement by end of 4th quarter. 2. Sucessfully employ and train permanent QC Secretary - (reports 9-25-78). ' jj| : 3. Transfer routine clerical functions to QC Sec. during quarter. 4. Identify additional routine job functions for assumption by QC Sec. when basic training complete. 004166