Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: C
ICC - Volume: 235
ICC - Report ID: 235-C
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Polyvinyl Chloride Production from VCM (Emulsion Polymerization)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 235-A,235-B
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-C.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-C.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Polymerization; (2) VCM removal; and (3) Finishing.</p><p>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%.</p><p>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.</p><p>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.</p>
ICC - Short Description: 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.
ICC - Main Product: Polyvinyl Chloride
ICC - Plant Capacity: 100.00
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Polyvinyl Chloride Production from VCM (Emulsion Polymerization)

Polyvinyl Chloride Production Costs Report | Issue C | Q2 2024

Production Cost Report

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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.

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Production Process Information

Process Consumptions

Labor Requirements

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Operating Cost Summary

Production Costs Datasheet

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Production Process Information

Process Consumptions

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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

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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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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   |   Q2 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   |   Q2 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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