Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: B
ICC - Volume: 235
ICC - Report ID: 235-B
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Polyvinyl Chloride Production from VCM (Bulk Polymerization)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 235-A,235-C
ICC - Related Reports List: 176-C,176-A
ICC - Report Location Code: USA
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ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/235-B.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>PVC</b>. Polyvinyl Chloride (a.k.a. PVC) is the third most commonly produced synthetic polymer, after Polyethylene and Polypropylene. It is a white, brittle solid and it comes in two basic forms: rigid PVC (RPVC) and flexible PVC. As one of the largest thermoplastic commodity produced, Polyvinyl Chloride is in fact a global product, used in a broad range of applications due to its remarkable versatility.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Vinyl Chloride</b>. Vinyl chloride, or vinyl chloride monomer (VCM), is a major chemical commodity, with worldwide importance related to its industrial use as the precursor to PVC. VCM is also used in a wide variety of copolymers. Inherent flame-retardant properties, wide range of plasticized compounds, and low cost of polymers produced from vinyl chloride have made it in fact a major industrial chemical, manufactured in about fifty countries. First commercially produced by catalytic hydrochlorination of acetylene, vinyl chloride nowadays is largely produced through ethylene-based, balanced vinyl chloride process. VCM production routes development have been tightly connected to the availability of key raw materials, particularly ethylene and chlorine, along with concerns related to energy efficiency, environmental impact, safety, and process reliability. Most of the existing VCM plants are actually integrated to EDC plants, where direct chlorination and oxychlorination processes are employed in parallel for EDC production.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/235-B.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises 2 major sections: (1) Polymerization; and (2) Classification & Storage.</p><p>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.</p><p>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.</p>
ICC - Short Description: 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.
ICC - Main Product: Polyvinyl Chloride
ICC - Plant Capacity: 100.00
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Polyvinyl Chloride Production from VCM (Bulk Polymerization)

Polyvinyl Chloride Production Costs Report | Issue B | Q3 2024

Production Cost Report

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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.

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Production Process Information

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Production Costs Datasheet

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Production Process Information

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Production Costs Datasheet

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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

Costs in Different Countries Add-on

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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

Other Polyvinyl Chloride Production Cost Reports

Polyvinyl Chloride Production from VCM (Suspension Polymerization)

This report presents the economics of Polyvinyl Chloride (PVC) production from vinyl chloride monomer (VCM) in the United States, via a typical suspension polymerization process. In this process, VCM droplets dispersed in water are polymerized to PVC.

Details: 400 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 400 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.

Polyvinyl Chloride Production from VCM (Emulsion Polymerization)

It presents the economics of Polyvinyl Chloride (PVC) production from vinyl chloride monomer (VCM) in the United States. The process examined is a typical emulsion polymerization process in aqueous medium with emulsifiers.

Details: 100 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue C   From $799 USD

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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Other Related Production Cost Reports

Vinyl Chloride Production from Ethylene Dichloride

This report presents the economics of Vinyl Chloride production from ethylene dichloride (EDC) in the United States using a typical thermal cracking process. In the process under analysis, EDC is thermally cracked to produce Vinyl Chloride, also generating hydrogen chloride as a by-product.

Details: 500 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 500 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.

Vinyl Chloride Production from Acetylene

This feasibility study reviews a typical hydrochlorination process for Vinyl Chloride production from acetylene. In this process, anhydrous hydrogen chloride is reacted in vapor phase with acetylene over a mercuric chloride catalyst producing Vinyl Chloride. The economic analysis presented is based on the construction of an industrial plant in the United States.

Details: 280 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue C   From $799 USD

The cost analyses presented in this report target a 280 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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