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Anniston Plant
TECHNICAL SERVICES DEPARTMENT
MONTHLY REPORT
Anniston
C. K. Eastman A. J. Koenig J. C. Landwehr L. J. Boesch 6. W. Miller U. B. Papageorge W. F. Taffee H. L. Williams
Summary December, 1968
Cost Improvement Results For Twelve Months
Estimated Actual $36,510
Target $32,100
% of Target 114%
$412,965
$492,600
83%
General Offices
H. C. Carder W. R. Robirds
Danna (5) 0. Hehner S.. B. Hodges D. B. Hosmer (2) W. A. Kuhn C. F. Luecke H. L. Payton N. L. Sample J. E. Smith R. J. Stratmeyer H. S. Trail
Estimated Actual Cost Improvement * 83%
102% of target - 304 M actual vs. 297 M target. Major contri butors included: new 6" gas line at Biphenyl I3I M vs. 40 M target and 6 M untargeted savings in Aroclor from statistical study.
Agricultural Division:
55% of target - 108 M actual vs. 195 M target. Savings on higher chlorination levels will accrue in 1970 with installa tion of sulfur recovery facilities. Parathion recovery savings will be realized when equipment modification are completed.
Organic Division
i OTHER LOCATIONS 1
D. W. Jackson-WGK T. M. Patrick-
So.2nd.St
The Santowax R column was Installed on schedule and operating as expected. Control Instrumentation will be installed in February 1969 to complete this significant improvement.
Solid Aroclor yield improvement design package will be trans-
mltted week of January 6, 1969.
.
Project to make Solid Aroclor in Liquid Aroclor will be trans mitted week of January 6, 1969.
^ 5 <0
Plant production of Aroclor 4465 by the blending process started in December 1968.
AN-aoe
The Above projects have been expedited to meet greatly expanded 1969 Solid Aroclor demand.--------------------------------------:----------------------------------
COMPANY CONFIDENTIAL INFORMATION
"This document contains confidential information which is the property of Monsanto Company. Only those portions of the document relevant to a duly authorized individual's need to know may be exerpted for him. The report must not be sent outside the Company without written approval and the recipient is accountable for its safe keeping, exerpting or otherwise disclosing of its contents and for its proper disposal."
STLCOPCB4099085
Company Confidential 2.
Organic Division (Continued) CED has accepted bid on Biphenyl Hydrogen purification system for HB-40 from Chemical Design Inc. The second clave was installed and is being tested before routine operation. Staley Grade HC1 project has been given first priority in project design group. Project transmittal targeted for 2/7/69.
Agricultural Division Sulfur Recovery project preliminary scope to be completed jointly by CED and Anniston TSD in January. Final clean-up methods indicate recovered sulfur quality better than specification grade for PgSg manufacture. Parathion recovery expense project approved for inspecting unit to determine cause of pluggage.
Design and Drafting Design packages for emergency radio communications and plant fire alarm system and Organic Division Safety Showers were transmitted and long delivery items were ordered. Solid Aroclor Instrumentation and Solid Aroclor in Liquid System reviews were completed and forwarded.
CED Liaison Modifications to equipment were provided on Biphenyl and Aroclor flakers and pallet conveyors in support of start-up on Aroclor Expansion and Warehouse.
DSW 377233
STLCOPCB4099086
STLCOPCB4099088
NO. 3 4 0 -B DIETZGEN GRAPH PAPER
B X B PER IN C H
EUGENE DIETZQEM CO. M A D E IN U . S. A .
AROCLOR
E. E. Bowles, C. R. Mcllwain, (V. R. Haupt)
Cost Improvement
Month
YTD
Target
.
$4,910
$58,250
Actual
$4,335
$46,600
Company Confidential 3.
Evaluate QuaterphenylPolyphenyl Effects on Solid Aroclor Yields
1969 Savings $63,200 NFC $14,000
TSD Objective B-8 (a)
Minor corrections to the design package remain before transmittal to Planning & Scheduling week of January 6, 1969. This project will allow increase in Solid Aroclor 5460 yield which is needed to help meet 1969's production forecast.
Make Solid Aroclor
Meet 1969 Forecast
TSD Objective
in Liquid Aroclor System__________;______________,______________________ 1969
Design package to allow making Solid Aroclor 5460 in the Nol Liquid Still system will be transmitted week of January 6. This is a minimum type project which adds steam tracing to chlorinator piping and ties in with the new flaking system.
Solid Aroclor 4465
Savings $12,000
by Blending _______ ; NFCzero
TSD Objective 1969 _______________
First lot of 4465 by blending was shipped in December. All of 1969's production
of 4465 will be made by blending.
'
Therminol System
Evaluation
TSD Objective __________ 1969
Higher priority work has delayed completion of evaluation.
Liquid Still Debottlenecking'
Evalua t ion
TSD Objective
____________________ 1969
_______
An evaluation of the operating capability of the Liquid Aroclor facilities remaining after the conversion of a portion of the system toSolid Aroclor is planned for first quarter 1969.
DSW 377236
STLCOPCB4099089
Company Confidential 4.
AROCLOR (Continued)
Installation of Entrainment
Capacity Increase
TSD Objective
Separator - No. 2 Liquid
NFC $4,500
1969(Job 868)
Aroclor Still__________________________________________________
Project 3093 was approved 12/19/68. Drafting is scheduled for the second quarter 1969. Completion is now targeted for December, 1969.
Drum Flushing
Quality
TSD Objective
NFC $60.000 ___________ 1969 (Job 872)
Preliminary design and cost estimate is complete. Results will be detailed in
TSD Progress Report 370:872:1 to be completed in early January, 1969. Estimated
cost is $60,000 with a yearly operating cost of $14,000. No further work is
planned on this project ia-4r96r9 until priority has been established by the
Business Group.
`
BIPHENYL-SANTOWAX
W. G. Niemeyer, (V. R. Haupt)
Cost Improvement
Month
YTD
Target
$3,335
$40,155
Actual
$31,600
$131,930
Debottleneck Biphenyl Stills to 87,6 fl lbs/yr.
Capacity
TSD Objective
______ IncreaseB-7 (a)
CED field construction started on foundations for new Santowax C surge tank and Santowax C column feed pumps. Equipment installation scheduled for February, 1969.
No. 1 Furnace Upgrade
Capacity
TSD Objective
Liaison (CEA-1892)Increase;B-7 (c)________________________________
No. 1 biphenyl furnace is running well since its start-up on November 23. A few small items need to be completed in the furnace area.
The 300,000 gallon benzene storage tank is under construction and is scheduled for completion by mid January, 1969.
Biphenyl-Santowax MIP _______________________ ;B-l (a)
TSD Objective
No work this month due to installation and start-up of Santowax R column project.
DSW 377237 STLCOPCB4099090
Company Confidential 5.
BIPHENYL-SANTOWAX (Continued)
Santowax R
Quality
Distillation Column______ ;____________________
TSD Objective __________________B-7 (d)
Santowax distillation area was shutdown for installation of this project at 7:00 a.m., December 17. The 8 tray column, new Montar 9 pump and related piping was installed by 3:00 p.m., December 19. The new equipment was started-up by midnight on December 19, The new Montar 9 pump is performing well. Now able to pump Montar 9 bottoms to the pit without breaking the still vacuum. The new bellows type high temperature mechanical seal installed on this pump is also performing well. After two weeks of running time, the seal shows no trace of leakage.
The quality of the Santowax R overhead product has been erratic, as expected, during the first two weeks of operation. We cannot expect consistent Santowax R quality until additional instrumentation is installed in February on Project No. 3016 to control the still. The Santowax R production rate has been sufficient to meet HB-40 and Solid Aroclor demand.
HB-40
J. L. Brown, (6. W. Miller) V. R. Haupt
Alternate Hydrogen
Project Scope
TSD Objective
Supply..___________________________
_____________________ 1969
Progress reports summarizing complete PR&D evaluation were Issued. CED has accepted bid from Chemical Design Inc. to supply the Biphenyl Hydrogen clean up system.
Installation of 2nd
Rate Increase
TSD Job AFE 3102
Autoclave up to 200.000 lbs /mo.;___________________________________________
_________
The second autoclave was installed at the close of December. Debugging of the system is in progress before starting routine operation of both claves.
CHLORINE
D. W. Dudley (A, G. McCarty)
Cost Improvement
Month
Target
$1,350
Actual
$ -0-
YTD $42,770 $57,755
DSW 377238 STLCOPCB4099091
CHLORINE (Continued)
Company Confidential 6*
Reduce Mercury Usage
Savings $1,700
to 0.75 lbs. Hg/Ton Cl9_________________
'
TSD Objective _________ B-6 (b)
Project to install acid wash tank for recovering mercury from "butler" is 99% complete. Wrap-up is scheduled for early January and project will be turned over to production by mid January.
Brine Dechlorination
Savings $6^875
TSD Objective
_________________________ _______________________ B-6 (c)
No change in status. Waiting for maintenance to detect and repair leaks in vacuum system.
Central Chlorine
CED Liason
Unloading______________ ______ _______ CEA 1831
TSD Job 860
Scope of CEA 1831 was approved in December. Construction drawings underway. Construction scheduled to begin in early January.
0. J. Norris, G. L. Moore, (A. G. McCarty)
Cost Improvement
Month
YTD
Target
$1 ,830
$9,750
Actual
$ 400
$4,600
Production of Staley
Increased Sales
Grade Acid_And $9.400 Savings B-10 (c)
TSD Objective
December demand for water-white acid exceeded ability to produce. Drafting priority for coalescer project moved up in an effort to demonstrate Staley Grade Acid production as soon as possible. Transmitted data targeted for 2/7/69.
Muriatic Acid Storage Savings $21.200
TSD Job 497
Foundation work completed. Tank contractor began field construction 12/30. Construction now expected to be complete by 2/1/69.
0S\N 377239
STLCOPCB4099092
0. J. Norris, G. L. Moore, (A. G. McCarty)
Cost Improvement
Month
YTD
Target
$2,500
$119,000
Actual
0
$ 55,100
Company Confidential 7.
Debottleneck to
Capacity
TSD Objective
1.8 M #/mo.______________________________
__________________________ 1969
Reactor recycle studies continuing. Samples show what appears to be ortho and meta nitrochlorobenzene. Definite identification requires additional lab time. Further studies in the lab and in the field are scheduled in January to deter mine what effects, if any, these isomers are having on the reaction rate and cool-down step.
Study of Molar Ratio NaOH/PNCB ;B-9 (c)
EVOP
TSD Objective
Tentative amendment to drop mole ratio approved in plant and now being sent to St. Louis. Tests in field should begin by mid to late January. Recent reports from W.G.K. TSD shows lowering molar ratio may increase reaction time necessary for complete conversion on PNCB. No change in tests are planned unless this rate decrease shows up in the field.
Revise MIP ____ ______________________________________________
Plant review on rough draft scheduled for 1/9/69.
TSD Objective B-l (g)--
NIRAN
K. G. Hale, D. W. Dudley (A. G. McCarty)
Cost Improvement
Month
YTD
Target
$19,325
$195,415
Actual
0
$108,850
DSW 377240 STLCOPCB4099093
Company Confidential 8.
NIRAN (Continued)
Demonstrate Parathion Recovery
Savings $70,000 and TSD Objective
10-15% Reduced COD
B-5 (a)
Loading_________________________________________________
Project No. 3106 ($3,000 expense) was approved 12/6/68 to cover inspection of
parathion coalescer for cause of pluggage. Inspection of unit is scheduled
for mid January.
.
Parathion Formulations-
Meet Budgeted ____________ Sales'
TSD Job 845 . '.;_______________ _
A brief evaluation of parathion formulation capability shows the existing capacity to be borderline, but adequate with close scheduling, for supplying the 1969 requirement. A debottlenecking project ($8,000 NFC) would increase flexibility somewhat but would really do little towards improving these substandard facilities. A small productivity gain ($3,100) can be achieved by operating the formulations plant at full capacity in 1969.
Sulfur Recovery from Residue
$500,000/yr. Savings, TSD Objective 40% Reduction in S0>>B-5 (d)
A data report with recommendations (covering the pilot centrifuge tests) will be issued by the Bird representative by 1/10/69. Completion of preliminary scope by C.E.D. and Anniston TSD is expected during 1/69.
Final clean-up methods have produced sulfur with carbon below that for P2S5 process specification. Process development work is near completion. Written process will be out by mid January.
Submerged Pump for
Savings $1,500
TSD Objective
RI Control of
. B-5 (c)
Chlorination________________ ________________________________ ________________
MRO to pull pump and inspect prior to starting tests has been issued. The inspection was requested because of the long delay when the pump was not run. It is also a safety measure to protect the glass-lined vessel.
Fume Collection System
Reduce Corrosive
TSD Objective
in Parathion Department_________ Atmosphere ________________ F-10
____________
Reason for fan failure appears to be combination of erosion (from sandblasting) and corrosion. Request has been sent to Division Materials Technologist for recommendations on a replacement.
OS^
STLCOPCB4099094
Company Confidential 9.
ENGINEERING DESIGN AND SERVICES
Mechanical /Electrical/Instrument Design and DraftingJ. C. Price. J. A. Veazey.
R. L. Brewer. J. K. Rennie.
V, T. Langdon. CW, F, Taffee)
Highlights
....................
Forwarded AFE for deluge system at Niran soda ash tank. Niran cubicle sight windows. Niran agitator alarms and purchase of corrosion testing instruments. Transmitted design packages for plant fire alarm system, plant emergency radio communications and Organic Division safety showers. Design and drafting for lighting and safety chain at Niran limestone pit. Solid Aroclor Instrumentation. Solid Aroclor in Liquid Aroclor system. No. 9 Aroclor chlorinator pump and PNP pump (Item 225) was completed. Assisted in start-up of Santowax R still and completed 1969"drafting and E/I design schedule.
Winterize Safety Showers
Safety
TSD Objective
____________ :___________ ___________________________________________________ A-5
Transmittal of design package for Organic Division showers in December completed this objective.
Procedure for Electrical
Safety
TSD Objective
Testing____________________________________________________ _________
A-6
Due to very great manpower required to develop complete program, TSD and Maintenance action was postponed until review can be carried out with SfitPP as to the minimum program that will give critical protection.
Niran Interlocks
Safety
TSD Objective A-7
AFE forwarded for review. Design scheduled for completion in December, 1969.
Photograph Drawings
Security
TSD Objective
__________________ ____________-____________________________________________ D-l
Cost of photographing drawings was prohibitive and no further action was taken.
TSD Guideline for
Function
TSD Objective
Transmittal of Design
D-4
Information;_____________________________________________________ ,
No action during 1968.
DSW 377242
STLCOPCB4099095
Company Confidential 10.
UTILITIES ENGINEERING
J. C. Price, L. 0. Chambers (W. F. Taffee)
Rough drafts of progress reports on Plant Power Factor Improvement and Plant Central Compressed Air System were completed. Completed final design on Biphenyl Gas Meter and Cooling Water on Trane Compressor projects and forwarded for drafting. Completed first quarter 1969 work plan.
PLANT IMPROVEMENT
G. C. Goodwin (W. F. Taffee)
AFE's for all remaining 1968 program projects have been forwarded for approval.
Report on 1968 program will be completed by 1/15/69.
Proposed final scope of 1969 program was completed.
POLLUTION CONTROL
E. G. Wright (W. F. Taffee)
Reporting Spills and
Pollution Abatement
Other Non-Routine Operating
Conditions in the Plant ______________,
TSD Objective F-4
Five air pollution complaints were reported by plant personnel during December. Three were due to SO2, one due to H2S and one due to CI2 fumes.
Install Solids Removal
Pollution Abatement
Equipment at Waste
Treatment Plant__________________________________________ _;
TSD Job 808
Firm bids have been received from electrical and piping contractors. Project revision is being prepared.
Contacts with
Community & Govt.
Regulatory AgenciesRelations
TSD Objective _____ F_~2__;
Toured city treatment plant and introduced Lloyd Boesch, new Agricultural Super intendent, to Bob Hendrick, the supervisor of the city plant.
Air Sampling Program
Pollution Abatement Pollution Control Obj.
_________________________________________________ __________
F-,5 . ............-
Arranged for a low cost automatic SO2 analyzer to be used on a trial basis. Analyzer was put into operation.
DSW 377243 STLCOPCB4099096
Company Confidential 11.
POLLUTION CONTROL (Continued)
Waste Treatment
All wastes were effectively treated during December. Average daily values for Monsanto's effluent are as follows:
Average Daily
Specifications
PNP
1 ppm
5.0
COD
62 ppm
<200
Parathion
0.09 ppm
1.0
BOD
3 ppm
<200
PROCESS AND QUALITY ANALYSIS
W. B. Dunlap
?2Sc Parathion Correlation Study
Potential $50,000 Savings
TSD Job
A monitor system was set up to provide a long-term correlation of distilled intermediate quality with parathion quality. Routine GLC analyses will measure isomers in parathion, and in distilled intermediate with extreme assays.
Solid Aroclor
$23,000 Savings
TSD Job 831
Statistical Control;;________________________________________________ ___
A study of yield information based on existing inventory methods showed a high variability which obscures cost sheet verification of process improvement. Precise judgment on cost improvement requires reduction of this error.
Quality
The BF-T.Index was 98.7 with 8 lots rejected out of 604; 5 out of 511 from the Organic Division. The Plant Quality Score was 94.5, up 4.0 from November, with YTD score of 95.0 against a target 93.0 minimum.
DSW 377244 STLCOPCB4099097
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* . . V' V **.
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Mi!
PLANT LABORATORIES
. G. W. Miller
Company Confidential 12
PROCESS RESEARCH AND DEVELOPMENT J. T. Bell
HB-40 Biphenyl Hydrogen Puflfication J. L. Brown
1. The PR&D effort directed toward purification of biphenyl hydrogen by use of the Solid Bed Heatless Adsorption Pilot Unit has essentially been completed. Reports No. 3 and 4 (Anniston 370:861) have been issued with results of the comprehensive evaluation.
2. The pilot unit will be disassembled and returned to Chemical Design Inc. by 1-10-69.
j>-Nitrophenol j. l. Brown
1. A preliminary study into the chemical and/or physical causes of irregular cooling periods in PNP reaction cycles has been initiated. A comprehensive investigation is scheduled to begin 1-23-69.
2. Samples from the PNP 260 tank (reactor let-down collection tank) have been analyzed but a correlation between the composition of the tank contents and cooling period has not been established. The samples have varied in composition from the nitrochlorobenzenes to sodium PNP. The ortho and meta isomers of chlorobenzene have been established as present in varying amounts in some samples.
Parathion Emulsifiable Concentrates
J. L. Brown
A procedure was developed to upgrade deteriorated lots of Methyl M-4 emulsifiable concentrates. The material will be reformulated for export sales based on this information.
Aroclor 1272 G. L. Arnett
1. The preparation of 30 lbs. of Aroclor 1272 for customer evaluation is approximately 50% completed. The material is being prepared by chlorination of Aroclor 1268 catalyzed by iron turnings followed by distillation.
2. The chlorinated product prior to distillation is low in color. As a result of the low color, this material will be investigated as a substitute for the distilled product.
Aroclor 5460 Expansion G. L. Arnett
Viscosity and specific gravity data on Aroclors 5060 and 5460 were obtained at various temperatures to assist TSD-CED in design of an expanded Aroclor 5460 system.
DSW 377245 STLCOPCB4099098
PROCESS RESEARCH AND DEVELOPMENT (continued)
Company Confidential l3*
Sulfur Recovery I. Ransaw, W. H. Howard
1. The process for therrefinement of sulfur residues consists of alternate caustic and water Washings, followed by steam sparging and a filtration.
, ' By this procedure, samples were consistently refined to meet the speci fications of maximum organics, acidity, and ash.
2. The optimum NaOH concentration in the wash step has been established as 0.4%, below which higher residual organic levels were observed yet no improvement was found above this concentration. Samples with initial organic levels of between 8 and 19% were refined to meet specification by this procedure.
3. A tentative PR&D Process Report has been prepared and will be issued by 1-10-69.
Aroclor 1242 G. L. Arnett
Aroclor 1242 produced by the continuous system at WGK was analyzed by differential infrared analysis. The material is very similar to the Anniston produced Aroclor 1242.
ANALYTICAL AND QUALITY CONTROL
Complaint Report
Quality Number
.
Material
9-A-68
Aroclor 5442 Aroclor 1254
S. 0. Kemp
Customer Products Research
Reason
Color Viscosity
YTD Quality Complaints/100 Shipments 0.11 : Target 0.20
Service Number
Material
Customer
Reason
13-S-68 14-A-68
Aroclor 1242 Aroclor-HB-40
Sangamo Electric Dixie Solvents
Short Weight Failure to follow
SSI
YTD Service Complaints/100 Shipments 0.17 : Target 0.20
DSW 377246 STLCOPCB4099099
Company Confidential 14
COMMUNITY RELATIONS. PERSONNEL. RECRUITING. AND DEVELOPMENT
Personnel
1. J. M. Jones and L. 0. Chambers returned to Ga. Tech, and Auburn after co-op work quarter.
2. G. L. Moore and J. McGee reported for quarter work session.
3. PR&D expended 13 mandays (G. L. Arnett) to assist the Niran department in correcting an ethyl parathion spill in the S.S. Maltesholm.
Recruiting
1. For the year 1966 had 3 acceptances of technical offers out of eight offers made, 3 offers are pending on personnel available in 1st or 2nd quarter of 1969, and 2 offers were declined. (TSD Objective E-l, Hire at least 50% of all qualified personnel to whom offers are made.)
Development
.
1. S. 0. Kemp was promoted to Analytical Supervisor, G. L. Arnett was promoted to Research Chemist, and W. B. Dunlap was promoted and given expanded responsibility as Supervisor, Process and Quality Analysis. These promotions become effective 1/1/69.
2. Pilot course in Process Dyanmics and Control which was taught by Dr. Z. L. Taylor of Auburn University over leased telephone (VERB) equipment was concluded. The course made possible evaluation of this method of continuing education, and a survey of the students is underway to this end. One co-op student, John Jones, will receive degree credit from Georgia Tech based on his partic ipation. (TSD Objectives E-4, Liason with higher technical institutions and E-5, Development of Technical Personnel.)
3. J. C. Price attended "Management Process" course in St. Louis the week of 12/8/68. (TSD Objective E-3, Develop personal development goals for each Dept, member and review quarterly for results.)
Visitors
1. R. G. Corley from CED here 19 December to discuss Solid Aroclor expansion concerning control room.
2. R. M. Kountz and R. S. Yates here 4-5 December on scope of Solid Aroclor expansion.
3. J. R. Ryland visited concerning Bulk Chlorine Handling Project.
DSW 377247
STLCOPCB4099100
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Company Confidential .
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DISTRIBUTION OF TIME BY TECHNICAL SERVICE
Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec.
70!
1 1
1
60 J j
50 1 40 >}
30'
20 20
10
0 20
10
0 20
10
0 30 20
10 0
20 10
0
50 --r--
40 1
3
11 1 1 :_____1_____
20 10 1
1^ ____
yH 1_____ !____ _
T
11
1 1 1 1_____ I_____
Jan. Feb. March-Apr. May June July Aug. Sept. Oct. Nov. Dec.
DSW 377248
STLCOPCB4099101
IN MAINTENANCE
FOR CONSTRUCTION
IN MAINTENANCE COMPLETED
NOT CLOSED
PROJECTS SUBMITTED
FOR APPROVAL
APPROVED PROJECTS IN TSD
i. \ . .f ' ".
TSD PROJECT SUMMARY
LABORATORY ADMINISTRATION
Manpower/sample
$/Manhours
11 < vV 10.00 9.00
8.00 Ejaa&aggaa 7.00
% Total Plant Operating Cost
11 1 i_ 1,
"
1 r ^ _____
J
i
i
(
\. \
Overtime "U
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STLCOPCB4099103