Polyvinyl Chloride Production from VCM (Suspension Polymerization)
Polyvinyl Chloride Production Costs Report | Issue A | Q3 2024
Report Details |
400 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 400 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 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.
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 Recovery; and (3) Drying.
Polymerization. Vinyl chloride monomer feed stream, hot demineralized water and chemicals - polymerization initiators, dispersing agents and additives – are supplied to a stirred reactor. The reaction occurs substantially in the liquid phase, in VCM droplets dispersed in water, used as diluent. After VCM polymerization ignition, the heat from the highly exothermic reaction is removed by means of a cooling system, for an isothermal temperature control. The molecular weight of the polymer produced is defined by the length of the resulting polymer, which depends on the polymerization temperature. As the polymer is formed, it precipitates out of the reaction medium, floating in the liquid monomer phase. The polymerization is interrupted when the conversion of VCM to PVC reaches about 90%.
VCM Recovery. The polymer slurry is fed to a blowdown vessel, operated at a lower pressure. Most of the unreacted VCM flashes-off. The polymer slurry is pumped to a pre-degassing vessel and a sieve-tray degassing column, where remaining VCM is removed from the polymer suspension. The VCM-rich off-gases are compressed and condensed in liquid ring compressors and fed to a vessel, in such a way that non-condensed light contaminants are separated from the liquid VCM and released as waste gas. The VCM obtained is recycled to the polymerization.
Drying. The slurry is passed through a solid-bowl decantation centrifuge and a wet PVC cake containing only residual moisture is obtained. At this point, the wet PVC cake is conveyed to a drying step, which comprises a combination of a flash dryer with a cyclone dryer, where it is dried to a moisture content ranging from 0.2 - 0.3 wt%. The PVC powder obtained is then packed and sent to storage facilities.
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Production Process Information
Process Consumptions
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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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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.
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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.
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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