Document zdvX1GQyoBGj1Y1NJ4d9qY43R

ESCAMBIA CHEMICAL CORPORATION PLASTICS fr RESINS Monthly Report December - 1969 AP00046458 ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM To: From: Re: T. L. Carey A. R. Adams/V. J. Grande Dote: January 14, 1970 Copies: PVC Monthly Report December, 1969 SUMMARY The Plastics Division generated $10,000 income before taxes in December for a cumulative, fiscal year-to-date loss of $8,000 before taxes as against the budgeted loss of $103,000 - a $95, 000 improvement over budget. This is largely attributed to favorable production variances and lower than anticipated R D costs. Sales volume for December was 96% of budget and it reflects an excellent selling job in the face of major volume losses of 590M lbs. at normally steady accounts. The bulk of this reduced business was at Nixon-Baldwin due to a labor strike and Robbins because of its inability to meet Liberal credit conditions. "With either of these pieces of business, sales would have been at or above budget. The year-to-date average selling price is 11. 53 cents per pound versus the budget of 11.68. The effect of the price increase initiated on November fifteenth has not developed sufficiently to identify at present. The prognosis for the price sticking is good on the whole, but we anticipate limited exceptions. Efforts to fortify the price increase by building inventory coupled with production volumes in excess of budget and a slow-down in automotive and construction have produced a critical inventory situation. Sales will have to achieve volumes in excess of production capability to alleviate the present condition. Off-grade sales nearly doubled in December as projected. Southbridge Plastics made its first truckload purchase of PVC 6180 and looks very promising. This is in line with sales strategy to broaden the customer list for this and other,product types. Also, Goodyear has resumed its purchase of PVC 2185 for bottles and could reach levels comparable to Kerr Glass' purchases. We continue to be stymied in attempts to make bulk shipments to Phillips. Credit and collections look to be in order with the exception of the Robbins situation which is constantly in view. Mr. T. L. Carey -2- Janiiary 14, 1970 The sales agent agreements for the Midwest and West Coast have been terminated and the product inventory in Los Angeles has been sold on a basis to end the warehouse expense. Mr. Jack Davidson has joined the Marketing staff as a Project Manager-Market Development for plastisols and saran. SPECIFIC DETAILS Marketing December sales volume was 3, 798 M lbs. or 96% of the budgeted 3, 960 M lbs. , which upon analysis shows an excellent selling job to overcome 590,000 lbs. of outages, most of- which were at the normally steady Nixon-Baldwin and Robbins accounts. Detailed below are the major outages and the counterbalancing overages to result in the 96% of budget actual. Volume Analysis Reduced Volumes over Normal M Lbs. Increased Volumes over Normal M lbs. Nixon-Baldwin Robbins Kerr Glass Jarrow Products CLopay Reductions 280 180 50 30 50 590 Harte and Company General Tire Goodrich Plastic Calendering Southbridge USM L.A. W.hse &r Mj.sc. Small Consumers Increases 60 40 40 80 30 90 90 ----------- 430 The major volume accounts appear to be on target thus far in January with the probable exception of Robbins. Sales expects to achieve budgeted volume and price for the upcoming month. Coincidentally, the fiscal year-to-date volume performance is also 96% of budget - 12, 184,M lbs. versus 12, 690 M lbs. This outage is expected to be overcome during fiscal 1970. The price increase initiated in mid-November continues to look promising although it did not manifest itself in December. The impact of this should be seen in January even though very few exceptions to the increase are realistically anticipated. AP00046460 Ivlr. T. Carey -3- January 14, 1970 Southbridge Plastics' first T/L purchase of PVC 6180 is most encouraging as is Goodyear's accelerated purchases of PVC 2185 for bottles. Goodyear promises to be as important in this application as Kerr Glass which is pressuring Escambia on price and volume no surprise. Creative Packaging has progressed to plant scale evaluation of PVC 2185 for bottles also. The solution to the Phillips bulk shipment problem continues to elude us. PVC inventory is at a crucial level because of intentional hedging in the market place for higher prices at a later date and the continued volume overage in the plant. This will be given top priority in the next few weeks. Production The favorable Production variance was a reflection of producing 4, 573 M lbs. versus the budgeted 4, 200 M lbs. January is also expected to be favorable but on a smaller scale. A used 5, 000 gallon glass-lined reactor has been purchased to provide intermediate capability for producing 5-6 million pounds of PVC (or some saran) prior to the new plant installation. Technical Development R St D, in cooperation with Production, successfully completed a one-batch plant trial of a candidate micropearl for fusion. Lab evaluations are encouraging and limited field testing will commence in January. VJG/ic L> V. J. Grande APOOC ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM To: Mr. T. L. Carey From: Re: A. K. McMillan PVC Monthly Report December, 1969 Dote: Copies: January 9, 1970 The PVC plant continued to operate at the high production rates that have been maintained for the past few months. Minimum maintenance, reactor downtime and off-grade production resulted in a prime production of 4, 573 M lbs, as compared to the 4, 200 M lb. budget. Cost variance was $23, 650 favorable as compared to the $19, 000 predicted because of higher than forecasted production. Year to date variance is $70, 650 favorable. Production for January is estimated at 4, 500 M lbs, and variance at $18, 000 favorable. A small production loss will be incurred in January to instaLL a regLassed reactor. Production exceeded, shipments by 1, 168 M lbs. in December and increased plant inventory to 6, 741 M lbs. An additional inventory increase of approximately 800, 000 lbs. is forecasted for January. At month end off-site storage in the Pensacola area totalled 2, 227 M lbs. Sales forecasts for the next several months will be reviewed during January to determine if production rate cuts will be required to control inventory levels. The second stainless steel blend tank was installed in January. Automatic sampling installations were also completed on both product lines. An RFE was prepared requesting $15, 830 to conduct a trial cleaning of the reactors using the DuPont solvent cleaning process. If successful, this cleaning method is calculated to yield a 11% return on investment. A 5, 000 gallon used gLass-lined reactor was purchased in January. This is the only satisfactory used reactor we were able to iocate and we exercised a purchase option before a sale was finalized to another customer. A. K. McMillan AP00046462 ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM To: Mr. A. K. McMillan From: Re: G. B. H. Speed PVC Production Report December, 1969 Dote: Copies: January 2, 1970 SUMMARY Production of prime resin was 4, 573 M lbs. , exceeding budget by 373 M lbs. Tailings and off-grade totaled 197M Lbs. or 4. 1% of production. Storage space for finished product continues to be a problem. Production exceeded shipments by 1, 168 M lbs. resulting in an inventory of 6, 741 M lbs. Off-site storage in the PensacoLa area consists of 1, 579 M lbs. at Gulf City and 648 M lbs, at the Port Authority. Inventories are forecasted to increase by 800 M lbs. in January. Monomer efficiency continues slightly beLow budget at 94.5%. Reactor availability was 86. 3%. During the month the two new stainless steel blend tanks were installed. Automatic samplers were also installed in each product line under CE 6939. The production of PVC-6180, a co-polymer, was successfully made on the north line with less than normal off-grade. The use of a proven antifoam agent allowed production on the north line which has a smaller stripping vessel than the south line. A trial batch of PVC-4185M micropearls was produced at the request of Research. The batch processed easily and dropped cleanly. Productions and variances for December and January are as follows December January Production (prime), M lbs. Variance (favorable), $ 4, 573 (23, 650) 4, 500 (18,000) Production for January will be down by about 75 M lbs. during the replacement of No. 2 reactor with a reglassed vessel. Mr. A. K. McMillan -2- January 2, 1970 STATISTICS Deccmber Actual Budget Year to Date Actual Budget Prime Production, M lbs. Off-Grade Product, M lbs. % of Total Bulk Production, % of Prime VC1 Efficiency, % Reactor Availability, % 4, 573 197 4. 1 44.5 94.5 86. 3 4, 200 252 6.0 42.0 95.0 13, 422 546 3. 9 42.9 * 94. 5 85.2 12,470 748 6. 0 42. 0 95. 0 Reactor Downtime, % Cleaning Scheduling Charges Changing types Dryer Maintenance Low Drying Rates Maintenance Miscellaneous 9.2 1.9 0.4 0. 1 0. 2 0. 6 1. 3 7.7 1.6 0. 7 0. 3 0. 5 0. 5 3. 5 Total 1 3. 7 14. 8 OFF-GRADE AND TAILINGS Off-Grade Tailings Floor Sweeps TYPe 8217 6180 Quantity Reason 108 M 24 M 45 M 20 M Too coarse. High sed. No. % Of Total Production 2. 3 0. 5 0. 9 0. 4 4. 1 AP00046464 Mr. A. K. McMillan - 3- January 2, 1970 D1SCUSSION Operations for the month were routine with a minimum number of upsets and maintenance problems. A total of 14 different types were made in 24 separate rune. The only major problem encountered during the month was with the production of PVC 3217. Out of six lots produced only one passed the particLe size specifications. The problem has been referred to Research. An experimental batch of PVC-4185M micropearls was charged at the request of Research. No problems were encountered during production. Agitation was sufficient during the entire cycle. The production of PVC-6180 was switched to the north line in order to reduce the high sediment off-grade product. This reduction was believed possible since the north line product collector contains Less filter bags where cross-contamination can occur. The production was successful with the use of an antifoam agent which reduced the foaming tendency of PVC 6180 that previously prevented use of the smaLl north line stripper. In the area of process improvement the following major projects were worked on during the month: 1. Automatic product samplers were instaLLed in both the north and south product Lines. 2. An RFE was prepared requesting $15, 380 to conduct a trial cleaning of reactors using tetrahydrofuran. 3. An evaluation of centrifuge wash water quantity and temperature was completed. No improvements in capacity or product quality was found over present operations. 4. New PVC-impregnated nylon boots were installed on the rotex screens. The new boots are Less expensive, should last longer and eliminate a source of contamination. G. B. H. Speed APOOQ To: From: Re: ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM Mr. G. B. H. Speed D. V. Lowe Dole: Copies: PVC Process Improvements Progress Report - December, 1969 January 2, 1970 December progress on PVC plant process improvements is reported in the following sections: REACTION* SYSTEM Solvent Cleaning of PVC Reaction Vessels An RFE was prepared for funds to conduct a cleaning trial of PVC reactors with tetrahydrofuran (THF). Although such a trial, costing $15, 380, would itself realize no immediate return on investment, a future THF solvent cleaning and recovery system would yield 11. 1% return on investment in the existing plant or 21.2% return in the expanded {110 MM lbs, /yr. ) plant. Automation of Reactor Drop Valves Yarway was requested late in December to expedite delivery of quotes on pneumatic and manual gear-operated devices for automation of our PVC reactor bottom ram vaLves. As soon as this information is received (expected January 5) a cost estimate and RFE will be prepared for automation of these valves. Process Water Charge Pumps New pump impellers of sufficient diameter to increase charge water flow to PVC reactors by approximately 50% have been received in the plant. They will be installed soon. Reactor Building Exhaust Fans A cost estimate has been prepared for connecting all air exhaust and make-up fans in the reactor building electrically so that they may be started simultaneously. In January an RFE will be prepared for funds to accomplish this interconnection. AP00046466 Mr. G. B. H. Speed -2- January 2, 1970 Estimation of New 5, QQO Gallon PVC Reactor Preliminary sketches of the expanded process flow and locations of process and utility tie-in points for installation of a new 5, 000 gallon PVC reactor were made. The sketches were transmitted to the Drafting Department for finalizing whereby they will be useful in evolution of a firm engineering cost estimate for this project. Reactor Wash-Out Bag The new wash-out bag constructed of wool felt was received and is successful in containing loose polymer when hooked to the bottom of a reactor during cleaning operations. A new bag, however, of improved design was put on order. CEA 6914 - "Additional Monomer Compressor1* The piping drawing for installation and interconnection of major equipment items for this project was checked and revised to allow addition of needed valves. Valving will be such that the Peco filters as well as any of the three future compressors can "spare" one another in service. FINISHING SECTION Replacement Collector Bags Most of the filter bags in the north PVC product collector were changed out for the new dacron style bags prior to a production run of PVC 6180. The bags performed well with the result that only 24, 000 pounds of off-grade resin was produced due to high sediment number. Evaluation of Centrifuge Wash Efficiency A report was issued during the month which evaluated and summarized the effect of variations in centrifuge wash water temperature and rate upon quality of resins produced. It was shown that, at Least under the conditions of the test and with the particular resins evaluated, most physicaL properties of the resins did not vary significantly under changing wash water conditions. It appeared, however, that oven heat stability of most resins was better when washed at Lower temperatures. AP00046467 Mr. G. B. H. Speed -3- January 2, 1970 New Rotex Screener Accessories Shipment of new rotex inspection port covers made of nylon, was scheduled for December 31. These new covers wilL reduce PVC "dusting0 to the atmosphere from the rotex units. New transition boots made of PVC - impregnated nylon were installed above and below the south rotex screener replacing rubber boots. The new boots are performing well and will result in a cost savings via elimination of the older style units. New Automatic Resin Sampler One newly purchased "Quality Control" automatic resin sampler has been installed under the south rotex screener a^id ib in continuous service. There were no difficulties in startup of the new equipment and resin samples are now being extracted every three minutes from a cross-section of the transfer duct. The vendor is to supply a set of teflon replacement seals as soon as they become available. The automatic sampler purchased for the north finishing line will be installed in January. New PVC Holding Bin Fan Switch A new start-stop switch for the air blower above the PVC holding bins has been installed at the rotex level of the finishing building. The finishing operators have been instructed to use this switch to stop the fan before opening the hatch on any holding bin and manually extracting a resin sample. In this manner, the "dusting" out of the hatch due to air pressure will be eliminated and housekeeping should improve. The fan will be restarted after sampling, CEA 6917 - "PVC Dryer Modifications and Improvements" Plans were made to pipe up the 600 psig steam coils included in this project so that their operation may continue in the event of faiLure of any of the individual coiLs. Valving will be provided for complete isolation of individual coils when desired. A formal drawing was prepared by the Drafting Department and given approval. Plans were Likewise finalized for disposal of the high-temperature condensate from these coils. The condensate will contact 2 3 gpm of well water in the existing receiver tank and the condensate pumps modified to handle the additional flow. A second drawing of this system has also been prepared. AP00046468 Mr. G. B. H. Speed -4- January Z, 1970 Installation of Additional Stainless Steel Blend Tank Another new 304 8. s. blend tank was installed in the No. 4 position replacing the old epoxy-lined tank. This was the second tank to be replaced and will result in lower maintenance costs as well as higher quality of product. New Air Grids for Alpine Product Collector The rusted carbon steel air grid headers in the top of the Alpine product collector were replaced with new stainless steel grids during December. Just as in replacement of old grids in the north and south product collectors as previously reported, this work wilL result in a reduction of the contamination susceptibility of our resin products and a reduction in future maintenance costs. GENERAL PROCESS Replacement Lift Truck in Warehouse Four separate vendors had been previously requested to quote on a new forklift truck to replace our aging electrically driven model. ALL vendors have been lax in delivery of their quotes to us. During December, they were requested once again, to expedite information and quotes . An RFE for the new model will be prepared as soon as possible. Study of PVC 3185/41S5-SP Data has been compiled on results of past PVC-3185 production and additional information will be collected in January as time allows. When this study and compilation of data is completed, a report will be issued detailing the history of Escambia's production of this resin. It will include recipes, yields, quality control results, sales, and profitability. It is hoped that such a report will help clarify the needs in optimization of 3185/4185 SP production in the future. Crawford and Russell - PVC Plant Expansion Much consideration was given during the month to the continuing design effort by Crawford and Russell Company toward a new PVC plant. Liaison was extended to them during December concerning specification of the following areas of the new plant: (a) The purification of recovered monomers. The alternatives seem to be either compLete recovery and purification of all monomers (VCM and VAC), AP00046469 Mr. G. B. H Speed -5- January Z, 197 0 Crawford and Russell - PVC Plant Expansion (cont-'d) complete recovery but with Impure VAC, or no recovery or purification of VAC at all. C&R will advise costs and potential economics of each system. (b) Solution makeup requirements and procedures. Sizes and types of tanks required as weLL as heat transfer needs. (c) Storage of raw materials and use rates. Handling procedures. (d) Capacities required in storage of in-process PVC resins and VCl liquid. (e) Operation of PVC rotary drying equipment and product collectors. Drying characteristics of our particular PVC resin types. Specification of a new rotary dryer. (f) Stripping procedures in the existing plant and requirements in the new plant. continue. Work with Crawford & Russell along these and other lines will David V, Lowe AP00046470 ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM To: From: Re: Dr. W. M. Smith Dote: D. J. Mann Copies: Monthly Summary FVC Research & Development December, 1969 January 8, 1970 A. R. Adams G. J. Mantell G. E. Schmauch F. L. Riddle W. K. Clark OPERATIONS I. Fusion Resins Objective: A. Polymerization Laboratory It was reported last month that the PVP/VA 1-535 protective colloid was effective in producing a fusible homopolymer resin with median particle sizes in the range of 70-80 microns and low densities (15-17 lbs./cu.ft.). By copoly merizing vinyl acetate in this recipe, bulk densities were increased to^20 lbs./cu.ft. This copolymer recipe, designated MP-2, gave a product which exhibited all of the desirable characteristics of a Micro-Pear1R. However, the heat stability properties of this copolymer were some what poorer than those of comparable homopolymers. Considerable effort wag devoted this month to the prepara tions of a Micro-Pearln polymer with improved heat stabi lity and a bulk density of at least 20 lbs./cu.ft. The results are summarized below: 1. Attempts to reduce the vinyl acetate content to less than 5# while maintaining a bulk density of 20 lbs./ cu.ft. were unsuccessful. 2. Lowering the PVP/VA 1-535 level in the homopolymer recipe did not affect bulk density. 3. Lowering of the polymerization temperature from 148F to as low as 138F did not affect bulk density. 4. FVP K-90/Aerosol 0T combinations gave bulk densities of AJ25 lbs./cu.ft., but the particle size was too coarse. AP00046471 Dr. W. M. Smith 2 January 8, 1970 OPERATIONS (Cont'd) 5. Methyl and ethyl acrylate monomers were studied as pos sible replacements for vinyl acetate. These monomers were more efficient than vinyl acetate at increasing the resin bulk density but did not appear to offer any improvement in heat stability. 6. Calcium chloride was effective in increasing the bulk density2 lbs./cu.ft. when used in relatively large amounts (1. 5-2.056). 7. A slight bulk density increase was noted with homopoly mers prepared at a pH of 9-10. At pHfs above 10, coarse resin was produced. B. Pilot Plant Reproducibility studies were continued on the MP-2 recipe with excellent results. The bulk density was'V 20 lbs./ cu.ft. with f\) 70$ fines in the 50-gallon reactor and 'V 50$ fines in the 10-gallon reactor. Lowering the 1-535 level appeared to reduce the fines to about 50$ in the 50-gallon reactor. The PVC homopolymer based on the MP-2 recipe has consistently given bulk densities r\jl6 lbs./cu.ft. The process modifica tions that gave higher bulk densities were: 1. greater pressure drop at end of run 100# L.'P) 2. low levels of TCE, vinylidene chloride, and acrylic monomers 3. initial pH of 9-10 Attempts were also made with the MP-2 recipe to lower the 1-535 level and make a 4185-SP type product. Run #3-972 with 1.0 part 1-535 was quite promising, although it had 28$ fines (specification * 10$ maximum) and a bulk density of 19.3 lbs./cu.ft. (specification = 23-29). Efforts are being continued to make 4185-SP by this approach. C. Plant Trial A successful plant trial was conducted using the MP-2 recipe, and approximately 7000 pounds of product was made. Although the volatile and contamination levels were higher than expected, the overall resin properties very closely matched those obtained in the 50-gallon reactor. AP00046472 Dr. W. M. Smith - 5- January 8, 1970 OPERATIONS (Cont'd) As reported above, although the oven heat stability of MP-2 is somewhat poorer than that of a homopolymer, the effect on process and product performance is, as yet, unknown. In fact, its faster fusion may more than offset its lower heat stability. The adhesion properties of MP-2 are superior to those of homopolymers. Sampling of MP-2 for customer field trials has been recom mended by R&D. II. Rigid Copolymers (X-130) Objective: A. Pilot Plant Bottle polymerization studies of VC1/IB (9^.5/5.5) had indi cated that it was possible to prepare a VC1/IB copolymer with an R.V. of rO 1.85 and 'Nj 4.5# bound isobutylene by using Vazo 52 catalyst at 105F. However, when two runs were made in the pilot plant 10gallon reactor, the highest R.V. obtained was 1.59. It is believed that the actual isobutylene level available in bottle polymerization studies was somewhat lower than that charged due to volatilization losses. This then permitted the R.V. to increase to a level not otherwise possible, had all the isobutylene been retained. Future work will use isobutylene charges of rO j5.5$ in order to obtain the R.V.'s being sought. III. Heat Stable 6l80 Objective s A. Polymerization Laboratory A series of 6l8o copolymers were prepared in bottles in the presence of barium-cadmium stabilizers for added thermal stability properties. The polymerization ran satisfactorily, and resins with good particle size distribution and bulk density were obtained. These resins are being evaluated for heat stability. If the results look promising, polymeriza tion studies will be made with calcium-zinc stabilizer since it has FDA approval for food-grade applications. AP00046473 Dr. W. M. Smith - 4- January 8, 1970 OPERATIONS (Cont'd) B. Properties Laboratory The polymers prepared last month were evaluated for their heat stability properties with the following results: 1. Copolymers prepared with caustic-washed vinyl acetate did not provide significant heat stability improvement. 2. The use of Vazo 52 did not give any heat stability improvement over lauroyl peroxide. 3. Lower polymerization temperatures did not offer any heat stability improvement, 4. Calcium acetate in place of monobasic calcium phosphate showed some heat stability improvement. Calcium acetate plus acetic acid was no better than calcium acetate by itself. 5. The use .of FVP K-90 as protective colloid gave some improvement and was even better in combination with C-62 stabilizer, 6. Further evaluation of plant 6l80 resin that had been dried at higher rotary dryer speeds did not confirm the encouraging results first obtained and indicated that heat stability is not closely related to drying speed over the range studied. Resin shipped by bulk car (#60311) was monitored for speck content both before shipment from Pensacola and after arrival at the Flexi-Flow Terminal in New Jersey. The results showed an average of three (3) specks per 25 grams before shipping and four (^) specks after arrival. This result is probably best accounted for by the change in sea sons, and the real test of product quality will have to await the arrival of summer. IV. Saran Objective: To prepare sufficient quantities of both extrusion and solution grades of- saran to permit the initiation of selective field sampling and laboratory processing studies. A. Pilot Plant A successful run of V1610A resin (solution grade) was made in the 50-gallon reactor. AP00046474 Dr. W. M. Smith 5 January 8, 1970 OPERATIONS (Cont'd) B. Properties Laboratory The evaluation of the properties of both the SV1710E extrusion grade and the V1610A solution grade resins (solution viscosity, DTA, chlorine analysis) indicated that satisfactory products had been made. Samples of this resin are being provided to customers selected by Marketing, and laboratory applications studies have been initiated. V. Plastisol Extenders Objective: To develop 8000 series resins which will match Good year M-70 and Uniroyal VR-1G, respectively. A. Pilot Plant Two identical 8200 batches were made in the 50-gallon reactor and terminated at different pressure drops to study the effect on bulk density. The resin prepared with a 30-pound pressure drop had a bulk density of 34.1 lbs./ cu.ft., and the other with an 88-pound pressure drop had a bulk density of 35.5 ibs./cu.ft. B. Grinding Studies Grinding studies conducted at the Williams Patent C&M Company with material prepared according to the Lightfoot patent (U.S. Patent 2,511,595> how expired) and designated as 1260-X showed promise, according to a letter transmitted by Mr. J. P. Hensel, Regional Sales Manager. Resin containing 15$ moisture was efficiently ground to 90$ minus 200 mesh and dried to 0.2$ moisture with no apparent heat damage to the material, Williams Patent C&M Company has requested an additional 300 pounds of resin containing not more than 15$ moisture. VI. General Process/Product Development Objective: To evaluate new processes, ingredients, equipment, techniques, etc., necessary to remain abreast of advanced polymerization technology. AP00046475 Dr. W. M. Smith 6 January 8, 1970 OPERATIONS (Cont'd) A. Initiators It was found that the Liladox initiator evaluated last month contained 50# water, and this could explain the poor results obtained. Correcting for this, the Liladox still did not perform adequately and was much poorer than either IPP or Vazo 52. The 0.03 part Vazo 52 level closely matched the 0,02 part IPP. An order has been placed with DuPont for sufficient Vazo 52 to run a plant trial. After this has been accomplished, trade-off calculations will be made to compare Vazo 52 and IPP. B. Suspension System (British Patent 1,150,488) The above patent teaches the use of a polyvinyl alcohol, sorbitan monolaurate, and hexane suspension system that yieldB low reactor fouling. The pH of this system is 12. Our present 12J0X recipe, which uses FVA and polyoxyethylene sorbitan monolaurate, was modified to include n-hexane with the proper pH adjustment. The 1230X control was con siderably finer in particle size and had a higher built density (31.3 versus 27.3). Both recipes gave clean drops from the reactor with no visual signs of fouling. Although it is possible that on continued charging the recipe using n-hexane and the high pH might show less polymer build-up, the plant experience indicates that fouling problems with polyvinyl alcohol are negligible. No further studies with the new recipe are planned. /pad D. J. Mann AP00046476 ESCAMBIA CHEMICAL CORPORATION INTEROFFICE MEMORANDUM To: Dr. W. M. Smith From: Re: V. K. Clark Monthly Summary December, 1969 Technical Service Dote: Copies: January 9, 1970 I. Customer Service A. Tenneco Chemicals, Inc - Nlxon-Baldwin Division, New Jersey A. R. Adams requested relative viscosity results for correla tion with Nixon1s Tinius-Olsen test. (Reference 1) B. Tenneco Chemicals, Inc. - Nixon-Baldwin Division, Illinois This customer was furnished Information which he requested on formulating practices used in the manufacture.of sheeting intended for loose-leaf binder materials. (Reference 2) C. Elm Coated Fabrics A special metal analysis on PVC 9^50 was supplied to this customer for approval. (Reference 5) D. Jarrow Products Company Through the joint efforts of the PVC Product Coordination Committee, we are investigating the quality of our PVC 5225 supplied this customer. (Reference 4) E. Leeds Travelware (TSR 841) A service call on customer was made to witness initial trials of a semi-rigid travel bag rotational casting com pound. The trial was judged successful by customer. Arrangements are being made to try formulating variants to improve release and low temperature flexibility properties. Further production trials are scheduled for early January. (Reference 5) F. Harte and Company (Complaint No. 43) This customer rejected a bulk truckload of PVC 6l80. Upon investigation of samples submitted, we determined this AP00046477 Dr. W. M. Smith a January 9, 1970 I. Customer Service (Cont1d) F. Harte and Company (Complaint No. 43) (Cont'd) resin was not of our manufacture and that the complaint was unfounded. (Reference 6) G. General Tire Company, Ohio (Complaint No. 42) This customer rejected approximately 51,000 pounds of FVC 6l80 due to excessive contamination in the resin and pin holes/tears in the finished sheet. This complaint con firmed a similar complaint on the same lot of resin by Nixon-Baldwin. Our steps to eliminate reoccurance are expected to result in better quality of resin for the cus tomer. (Reference 7) H. Kerr Glass Manufacturing Company At customer's request, we submitted certain quality control results on sampled/purchased PYC 2185. (Reference 8) I. American Vinyl Company (TSR 840) Customer has informed us of his serious difficulties with exterior exposure of webbing for lawn furniture based on our FVC resins. There is not a question as to resin quality, but their difficulties stem from both extreme exposure conditions and formulating deficiencies. As a matter of self interest, we have entered into discussions and are attempting to advise them regarding colors, stabilizers, and other ingredients to help them to Improve product quality. (Reference 9) J. Higher Molding Company Submitted information to our salesman for comparable resins used by this company. (Reference 10) K. Clow Corporation (TSR 831) In Technical Service Report No. 831, the findings from our work indicated that our FVC 1230X and our PVC 2225 both showed important property advantages over Diamond FVC 450, The competitive resin is now being used by customer in his pipe production. It is believed that the advantages found more than justify extensive plant trials by the customer. (Reference 11) AP00046478 Dr. W. M. Smith - 3- January 9, 1970 I. Customer Service (Cont'd) L. Bottle Resin. - Gel Test We have made appreciable progress in our work to develop an extrusion gel count test suitable for plant quality control or resins intended for sale to customers for rigid dry blend bottle blow molding. The goals set for this test are outlined as follows: 1. test must be simple 2. test must use minimal quantities of material 3. test must be quick and conserving of manpower 4. test must correlate with use conditions In our work to date we have done the following: 1. Our present formulation uses only resin, stabilizer, processing aid, and carbon black. 2. A small, cold hobart dry blend based on 200-300 grams of resin appears entirely adequate. Blending and weighing should require no more than 10-15 minutes. 3. Our most recent formulation employs a new processing aid which produces the required processibility without altering or contributing to gel formation. 4. As now practiced, the test consists of extruding the hobart blend into a thin wall lay flat tube in our 3/4" Killion extruder. A multiplicity of samples can be extruded at 5-7 minute intervals. It is anticipated that the test will be ready for monitoring production prior to acceptance during the coming month. IX, Technical Service to APCI A. Vinylidene Die Back-up die designs were submitted to Houdry engineers for consideration as a measure of expediting early completion of vinylidene film line installation. (Reference 12) B. Vinylidene Lubrication Studies Initial formulating studies on our vinylidene resins have resulted in improvements in heat stability. A number of promising lubricant candidate materials have shown promise. (Reference 13) AP00046479 Dr. W. M. Smith 4 January 9* 1970 IX. Technical Service to APCI (Cont'd) C. Bulk Polymerized VC-DOP-Vago Mixture Comments and suggestions were made to Trexlertown polymer group on their hulk polymerization work. (Reference 14) D. Pechiney-St. G-obain Resins Intelligence information on quality of Pechiney bulk resins was forwarded to interested personnel at Trexlertown. (Reference 15) E. Processing Aids for Rlgids Parameters of value Judgments on processing aids being developed at Houdry were discussed in memoranda. (Reference 16) III, Development Programs A. Dielectric Heating Technical Service has agreed to furnish samples for R.F. heating trials at several laboratories. Materials to be furnished will include rigids for battery separator appli cations, foams, and loss factor variants in plasticizer. IV. Miscellaneous A. Test Method 4.4.1 A proposed extruded rod impact test was written up for consideration. B. Prilling of FVC Compounds Comments on prilling versus dice for compound form were forwarded to interested personnel at Trexlertown. (Reference 17) C. P. R. Browne has spent two weeks part-time in the FVC Sales Order.Department during vacation of A. R. Donaghy. V. Samples A. FVC Resins A total of 59 FVC samples (290 pounds) was sent to 23 com panies including APCI. AP00046480 Dr, W. M, Smith - 5- January 9> 1970 V. Samples (Cont'd) B. Dry Blend Compounds A total of eight dry blends (290 pounds) -was sent to three companies including APCI. /pad Reference 1 Reference 2 Reference 3 Reference 4 Reference 5 Reference 6 Reference 7 Reference 8 Reference 9 Reference 10 W. K. Clark Memo dated December 1, 1969 from P. R. Browne to W. K. Clark Letter dated December 2, 1969 from V. K* Clark to Mr. Marvin H. Burger, Tenneco Chemicals, Inc. - Nixon-Baldwin Division, Illinois Letter dated December 1, 1969 from P. R. Browne to Mr. Warren Sechrist, Elm Coated Fabrics Memos dated December 3 and December 18, 1969 from P. R. Browne to W. K. Clark Memo dated December 8, 1969 from W. K. Clark to W. M. Smith Memo dated December 11, 1969 from P. R. Browne to W. K. Clark Memo dated December 11, 1969 from P. R. Browne to W. K. Clark Letter dated December 11, 1969 from P. R. Browne to Mr. Clarence Rohrer, Kerr Manufacturing Co. Letter dated December 12, 1969 from W. K. Clark to Mr. Eric Wiborg, American Vinyl Company Memo dated December 12, 1969 from W. K. Clark to A. R. Adams Memo dated December 18, 1969 from P. R. Browne to W. K. Clark AP00046481 Dr. W. Id. Smith Reference 11 Reference 12 Reference 13 Reference 14 Reference 15 Reference 16 Reference 17 - 6- January 9, 1970 Technical Service Report No. 831 dated December 11, 1969 Memo dated December 15, 1969 from W. K. to -W. M. Smith Clark Memo dated December.il, 1969 from W. K. Clark to W. M. Smith Memo dated December 8, 1969 from W. K. Clark to W. M. Smith Memo dated December 3, 1969 from W. K. Clark to W. M. Smith Memo dated December 18, 1969 from kT. K. Clark to W. M. Smith Memo dated December 23, 1969 from W. K. Clark to E. E. Huntzinger Memo dated December 19, 19^9 from W. K. Clark to W. M. Smith AP00046482 13 rt> >1 tc o 3 3 n AP00046483 ESCAMBIA CHEMICAL CORPORATION ' Interoffice Memorandum To: Mr. T. L. Carey Date: Jan. 7 , 1970 From: E. M. Spurlock Re: Monthly Report - Personnel Department - December, 1969 PERSONNEL Division Activity for the Month No. of Employees Dec. 11/30/69 Addit. Dec. Separa. No. of Employees 12/31/69 Dec . 1969 Budget Rev. Executive Financial Dept. Laboratories, Res. & Dev. Plant Admin, 6c Process Plant Engr. 6c Maint. Personnel 6c Safety Purchasing 6c Traffic Ag. Chem. Sales Ind. Chem. Sales PVC Sales 2 53 44 212 132 12 31 152 7 8 0 2 1 4 2 0 1 7 0 __ 0 0 14 1 3 0 0 0 142 0 0 2 41 44 213 . 134 12 32 17 7 8 2 43 59 215 140 13 32 18 9 10 Total Escambia 653 17 160 510 541 Carroll Construction Company Office No. of Employees 11/30/69 3 No. of Employees 12/31/69 3 Maintenance Insulators Mechanics Yardmen Trashmen Laborers Janitors painters Welders pipefitters 2 13 2 2 7 9 10 1 __ 1 1 9 2 2 9 8 8 1 1 Total Maintenance 47 41 AP00046484 Monthly Report -2- January 7, 1970 PERSONNEL (Cont'd.) Carroll Construction Company No. of Employees No. of Employees _____ 11/30/69_____ _____ 12/31/69 PVC Laborers Area B Laborers Railroad Crew 77 29 28 11 Total Carroll Construction Co. 87 653 80 510 Grand Total 740 590 The difference between the December, 1969 budget and the actual number of employees at the end of December is represented by 31 vacancies. We are presently attempting to fill 15 of these vacancies. The corporate labor turnover rate on regular employees for the month of December was 26.09. This high rate was caused by the transfer of the Farm Service Center employees to Custom Farm Services, Inc.. We had a total of 57 walk-in applicants, 57 applications were issued, 26 were interviewed and 18 were tested. Of the 18, 4 were females and 2 passed their employment and typing tests and were employed. The balance of 14 were males and 5 qualified for employment. Three were hired and the balance placed in our active files. We received 6 applications and 377 resumes by mail. SAFETY The Corporation worked approximately 105,000 man-hours during the month. The approximate man-hours and the days worked to date without a disabling injury are as follows: Division Man-hours Days New York Office Sales Pensacola Plant Corporation 461,500 102,000 97,000 136,000 3,071 107 40 40 AP00046485 Monthly Report SAFETY (Cont'd.) 3 January 7, 1970 Medical Section The Medical Section treated 21 injuries for Escambia and 9 for Carroll, performed 8 pre-employment physicals and 5 annual physicals and gave a total of 13 immunization injections, EMPLOYEE RELATIONS Seven (7) 5-year service awards were presented. Annual Children's ChriBtmas Party was held on December 13, 1969 with approximately 470 children and adults in attendance. Beginning December 12th, we held continuous meetings with our employees on the merger of Escambia's benefit plans into the Air Products' program. Application cards have been completed by all employees. We met with representatives of Provident Life and Accident Insurance Company on December 22, 1969 relative to the procedures for handling Group Hospitalization and Group Life Insurance under the Air Products' program. Final arrangements were made for transferring Consumer Sales employees to Custom Farm Services, Inc, on December 31, 1969. I attended a 3-day AMA Management Training course on Management by Objectives in Dallas, Texas LABOR RELATIONS Some of our employees were disturbed by the change in employee benefit plans and we are attempting to resolve these differences by individual discussions. If we are unable ta resaLve these differences, this could lead to another organizing attempt. INSURANCE -We paid a total of 62 claims under our Group Hospitalization program which amounted to a total of $. 12,059.97 during the month of December. We settled 4 automobile collision accidents in the amount of $ 1,070.16 AP00046486 Monthly Report INSURANCE (Cont'd.) -4- January 7, 1970 We settled 1 property damage claim in the amount of $ 1,188.20. EMS: kc E. M. Spurlock AP00046487 AP00046488