Polyvinyl Chloride Production from VCM (Emulsion Polymerization)
Polyvinyl Chloride Production Costs Report | Issue C | Q2 2024
Report Details |
100 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
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
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.
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 three major sections: (1) Polymerization; (2) VCM removal; and (3) Finishing.
Polymerization. Initially, polymerization initiators, emulsifiers and additives are fed to an autoclave reactor. Subsequently, vinyl chloride monomer feed is gradually fed to the reactor, under agitation, forming a relatively stable emulsion. The initiator generates free radicals, which are transferred to the monomers creating then active centers in which polymer chains are formed. While the polymerization reaction is strongly exothermic, reaction heat is removed by water cooling in the reactor jacket and external condensers. The polymer is formed as PVC lattices, colloidal dispersions of spherical particles. The polymerization is interrupted when the conversion of VCM to PVC reaches about 90%.
VCM removal. The latex is fed to a stripping vessel, where residual vinyl chloride monomer is stripped by contacting the latex with steam under vacuum conditions. The VCM-rich off-gases are sent to a gas-holder and then compressed and cooled to condense VCM. The VCM thus obtained is recycled to the polymerization.
Finishing. The PVC latex is sent to a thin-film evaporator and a spray dryer for removing water from the polymer. The dry PVC powder is sent to a mill, where the coarse fraction of the dry PVC powder is removed/milled. Finally, the PVC powder is homogenized and packed.
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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
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 | Q2 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 (Bulk Polymerization)
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.
Details: 100 kta United States-based plant | Q2 2024 | 107 pages | Issue B 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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