Polyvinyl Chloride Production from VCM (Bulk Polymerization)
Polyvinyl Chloride Production Costs Report | Issue B | Q3 2024
Report Details |
100 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 100 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study presents the economics of Polyvinyl Chloride (PVC) production from vinyl chloride monomer (VCM) in the United States. The process examined is a typical bulk polymerization process.
The report provides a comprehensive study of Polyvinyl Chloride production and related Polyvinyl Chloride production cost, covering three key aspects: a complete description of the Polyvinyl Chloride production process examined; an in-depth analysis of the related Polyvinyl Chloride plant capital cost (Capex); and an evaluation of the respective Polyvinyl Chloride plant operating costs (Opex).
The Polyvinyl Chloride production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Polyvinyl Chloride plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Polyvinyl Chloride plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic

The process under analysis comprises 2 major sections: (1) Polymerization; and (2) Classification & Storage.
Polymerization. In the first stage, the vinyl chloride monomer (VCM) is polymerized in an autoclave reactor, under vigorous agitation promoted by a turbine agitator. The reaction is initiated by acetyl cyclohexyl sulfonyl peroxide (ACSP). When the VCM conversion rate reaches approximately 10% by weight, the polymer slurry is transferred to a second polymerization step. The polymer slurry, along with VCM feed and initiators, are then fed to vertical reactors. The reaction is also conducted under agitation. The molecular weight of the polymer being formed is controlled according to reaction media temperature. The reaction is continued until 80–85% of the vinyl chloride monomer is converted, when PVC grains reach 130 - 160 µm diameter. Off-gases from polymerization, composed primarily of unreacted VCM, are compressed and then passed through heat exchangers using cooling water and chilled water, in such a way that the VCM is condensed and is recycled to the polymerization.
Classification & Storage. The PVC powder from the Polymerization is dropped into a hopper, from which it is classified by means of screeners. The PVC product is directed to the Product Silos, while oversize polymer particles are diverted to a grinder and returned to the screens. The PVC powder is pneumatically conveyed to the blending silos for homogenization. Subsequently, part of the PVC is packed in begs, while the other part is directly sent to storage silos.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Polyvinyl Chloride production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Polyvinyl Chloride process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Polyvinyl Chloride production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Polyvinyl Chloride plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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The cost analyses presented in this report target a 100 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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