Document ymB3X1J5EO4YpjjrnNOm6p7Or

I ^#5 MONSANTO COMPANY Location : Texas City, Texas Date t July 29, 1964 Subject : Monthly Production Sunwary VCM Plant - July 1964 TO : W. R. Nisbet cc: J. M. Chamberlin L. B. Bullock C. H. Duhon W. P. Gabel B. H, Hartsog J. W. Kongable J. G. McQuarrie/^ T. E. Shirley J. L, Price G. T. Ryan VCM Supervisors SUMMARY VCM production was 10.6 MS lbs. (92.1# of rated capacity). Reaction was down 88 hours with 54 hours because of acetylene availability. Rates were generally limited by C*H availability. Cracking was limited during the seoond half of the month by re frigeration problems and by VCM Redistillation Column {22D14) fouling. The 350 ton Carrier unit had a bearing failure - inspection of the machine showed major damage to the internals of the compressor, requiring extensive repairs. This limited total VCM production to approximately 60# of rated capacity for the last 5 days of the month. The VCM Redistillation Column fouled and was boiled out with EDC three times during the month. EDC production was 13*7 MM lbs. (109.5# of rated capacity). Downtime totalled 28 hours. Oxidative Chlorination production was 1.4 MM lbs. of EDC (48.5# of rated capacity. Downtime totalled 240 hours, 94 hours because of refrigeration failure, 72 hours for catalyst addition, 74 hours for maintenance (tube ferrule pulling, leaks, etc.). CBY 1107259 RSV0032154 Monthly Production Smrauary VCM Plant - July 1964 Page 2 Operating Details A. Summary Table Production This Scheduled Month Yr-to-Date Standard VCM, MM lbs. EDC, MM lbs. - Dept. 23 - O.C. 10.52 13.27 2.25 10,6 75.2 88.8 11.1 11.5 12.5 2.89 Acid, gallons Acid dumped, gallons HPT, $ 480,000 0 90 Onstream TlmeT Cracking Reaction Department 23 O.C. Acid Absorber, $ of time needed 21C2 100. 88.1 96.2 67.7^ 86.4 98.9 Yields This Month Standard CaH* to EDC - Dept. 23 - O.C. Cl# to EDC EDC to VCM C#Hs to VCM 95.0 90.0 95.0 95.5 97.0 95.0 92.0 95.0 95.5 97.0 B* Operations and Maintenance The No. 2 Cracker was retubed with 3" tubes. The No. 3 Reactor was retubed. The 22C3, 350 ton Carrier refrigeration unit compressor failed, requiring major overhaul. This restricted production for the last 5 days of the month to 6o of rated capacity. CBY 1107260 RSV0032155 Monthly Production Summary VCM Plant - July 1964 Page 3 B, Operations and Maintenance (continued) The 22C6, 150 ton Carrier refrigeration unit compressor coupling failed during the month requiring major repairs and limiting production slightly for 6 days. The EDC Heavy Ends Column, 22D9, Reboiler was switched once during the month. A major shutdown was taken in Department 26. The 26E3, Flare Gas Condenser, was replaced because of severe corrosion. The recycle compressor suction line was replaced because of severe corrosibn. The VCM Redistillation Column fouled 3 times in 6 days and required an EDC boll out each time. The HC1 Compressor, 21C2, was down for 8 hours because of a packing leak. v- C. Personnel and Safety Two E.l.F. engineers, Kiam Lehrman and Dov Grolsman were trained in Oxidative Chlorination production know-how. A major incident - a flash fire on the CsHa compressor, 22CT>occurred. This was the subject for special safety meetings with all personnel in VCM. Regular monthly safety meetings were held using the Safety Departments`s dunany model as the subject in training in resuscitation techniques. CBY 1107261 RSV0032156 > Monthly Production Summary VCM Plant - July 1964 Page 4 S Costs 1. July Variances VCM EDC O.C. Raw Materials Price Performance -10,000 -20,000 00 0 -10,000 Direct Conversion Labor _ Repairs Catalyst - 4,000 -10,000 - 4,000 - 700 0 0 - 700 - 5,000 - 5,000 Volume Off-scheduled Prod. Unscheduled Capacity Total + 917 ' - +1,144 -11,231 +2,048 -58,314 +2,492 - 7,123 - 5.265 -33,088 Variance Explanation VCM Raw Materials: Price - Excess EDC used due to low C3H3 availability. Performance - Below standard sales of HC1 to O.C. Direct Conversion: Labor Overtime coverage of O.C. Repairs Retubing Hl-3. Repairs to refrigeration units. CatalyBt CaHa purification out of service. CBV 1107262 RSV0032157 Monthly Production Summary VCM Plant - July 1964 Page 5 E Costs (continued) Variance Explanation (July) - continued O.C. Raw Materials - Below standard conversion due to low catalyst activity. Repairs - New 26E3, new recycle compressor suction line. Catalyst ^ - Plugged tubes causing extra catalyst usage, 2, August Variances Raw Materials VCM BDC O.C. Price Performance Direct Conversion -10,000 -20,000 00 0 -10,000 Labor Repairs Catalyst Volume - 4,000 -- 5 >000 - 4,000 - 700 0 0 - 700 0 - 5,000 Unscheduled Capacity Total - 1.604 -44,604 +2,048 +1,348 - 5.363 -21,063 RSV0032158