PVC Final Report 1234

Project on, Dissertation On Manufacturing Of PVC
CHAPTER 1
INTRODUCTION
FAMT,RATNAGIRI Page 1
INTRODUCTION
Polyvinyl chloride also known as polyvinyl chloride, Commonly abbreviated as

(PVC), is the world third-most widely produced synthetic plastic polymer after polyethylene
& polypropylene.
PVC, is a thermoplastic. It turns soft when heated and hard when cooled. Polyvinyl
chloride is made by polymerization of the monomer vinyl chloride (chloroethene)
CH2=CHCl. PVC can be made softer and more flexible by adding plasticizers. Phthalates are
often used to soften PVC in this way.
Vinyl polymers are the most common type of plastic. In popular usage, "vinyl" refers
mostly to PVC, but there are two other vinyl polymers which are more common. The most
common is polyethylene, the second most common is polypropylene. Another, less used,
is polystyrene.
PVC comes in two forms:-
1. Rigid
2. Flexible
The rigid form of PVC used in construction for pipe & in profile application such as
doors & windows. It is also used for bottles, other non-food packing, & cards (such as bank
or membership cards). It can be made softer & more flexible by the addition of plasticizers,
The most widely used being phthalates. In the form it is also used in plumbing, electric cable
insulation, lathers & photography products.
Pure polyvinyl chloride is a while, brittle solid. It is insoluble in alcohol but slightly
soluble in “Tetrahydrofuran”.
Fig.1.1: PVC Pipes
1.1 WHAT IS PVC ?

Plastics are also called synthetic resins and are broadly classified into two categories:
thermosetting resins and thermoplastic resins.
The thermosetting resins include phenol resin and melamine resin, which are
thermally hardened and never become soft again. Thermoplastic resins include PVC,
polyethylene (PE), polystyrene (PS) and polypropylene (PP), which can be re-softened by
heating.
Usually, thermoplastics are supplied in the form of pelletized material (compounds)

with additives (antioxidants, etc.) already blended in it. However, PVC resin is often supplied
in powder form and long term storage is possible since the material is resistant to oxidation
and degradation. Various additives and pigments are added to PVC during the processing
stage, and the blend is then converted into PVC products.
PVC is sometimes known as ‘Vinyl’ in Europe and predominantly so in North

America. In Europe, ‘Vinyl’ usually refers to certain specific flexible applications, such as
flooring, decorative sheets and artificial leather.
PVC is a thermoplastic made of 57% chlorine (derived from industrial grade salt)
and 43% carbon (derived predominantly from oil / gas via ethylene). It is less dependent than
other polymers on crude oil or natural gas, which is nonrenewable, and hence can be regarded
as a natural resource saving plastic, in contrast to plastics such as PE, PP, PET and PS, which
are totally dependent on oil or gas. This chlorine gives to PVC excellent fire resistance.
The chemical reaction of PVC is:
n CH2=CH Polymerization
CH2-CH
n
Cl Cl
VINYLCHLORIDE MONOMER POLY VINYL CHLORIDE
IUPAC NAME: Poly(1-chloroethene) .
OTHER NAME: POLYCHLOROETHYLEN.
1.2 APPLICATIONS
1.2.1 Pipes:
Roughly half of the world's polyvinyl chloride resin manufactured annually is used for
producing pipes for municipal and industrial applications. In the water distribution market, it
accounts for 66% of the market in the U.S., and in sanitary sewer pipe applications, it
accounts for 75%. Buried PVC pipes in both water and sanitary sewer applications that are 4
inches (100 mm) in diameter and larger are typically joined by means of a gasket-sealed
joint. The most common type of gasket utilized in North America is a metal reinforced
elastomeric, commonly referred to as a Rebar sealing system. Its light weight, low cost, and
low maintenance make it attractive. However, it must be carefully installed and bedded to
ensure longitudinal cracking and overbilling does not occur. Additionally, PVC pipes can be
fused together using various solvent cements, or heat-fused (butt-fusion process, similar to
joining HDPE pipe), creating permanent joints that are virtually impervious to leakage.
Fig.1.2: Pipe
1.2.2 Electric cables:
PVC is commonly used as the insulation on electrical cables; PVC used for this
purpose needs to be plasticized. Flexible PVC coated wire and cable for electrical use has
traditionally been stabilized with lead, but these are being replaced with calcium-based
systems.
In a fire, PVC-coated wires can form hydrogen chloride fumes; the chlorine serves
to scavenge free radicals and is the source of the material's fire retardance. While hydrogen
chloride fumes can also pose a health hazard in their own right, it dissolves in moisture and
breaks down onto surfaces, particularly in areas where the air is cool enough to breathe, and
is not available for inhalation. Frequently in applications where smoke is a major hazard
(notably in tunnels and communal areas), PVC-free cable insulation is preferred, such as low
smoke zero halogen insulation.
Fig.1.3: Electric Cable
1.2.3 Construction:
"A modern Tudorbethan" house with PVC gutters and downspouts, fascia, decorative
imitation "half-timbering", windows, and doors
PVC is a common, strong but lightweight plastic used in construction. It is made

softer and more flexible by the addition of plasticizers. If no plasticizers are added, it is
known as PVC (unplasticized polyvinyl chloride) or rigid PVC.
PVC is extensively used in the building industry as a low-maintenance material,

particularly in Ireland, the United Kingdom, in the United States and Canada. In the U.S. and
Canada it is known as vinyl or vinyl siding. The material comes in a range of colors and
finishes, including a photo-effect wood finish, and is used as a substitute for painted wood,
mostly for window frames and sills when installing insulated glazing in new buildings, or to
replace older single-glazed windows. Other useinclude fascia, and siding or weatherboarding.
This material has almost entirely replaced the use of cast iron for plumbing and drainage,
being used for waste pipes, drainpipes, gutters and downspouts. PVC is known as having
strong resistance against chemicals, sunlight, and oxidation from water.
Fig.1.4: Construction
1.2.4 Flooring:
Flexible PVC flooring is inexpensive and used in a variety of buildings covering the
home, hospitals, offices, schools, etc. Complex and 3D designs are possible, which are then
protected by a clear wear layer. A middle vinyl foam layer also gives a comfortable and safe
feel. The smooth, tough surface of the upper wear layer prevents the buildup of dirt, which
prevents microbes from breeding in areas that need to be kept sterile, such as hospitals and
clinics.
Fig.1.5: Flooring
1.2.5 Wire rope:
PVC coating placed onto wire rope and aircraft cable is used for general purpose
applications. The coating process consists of a jacketing application via
pressurized extrusion. The benefits of PVC coating on wire rope are for not only aesthetics,
but for ergonomics, abrasion protection and visibility. It is found in a variety of industries and
environments both indoor and out.
Fig.1.6: Wire Rope
CHAPTER 2
HISTORY AND LITERATURE SURVEY
HISTORY AND LITERATURE SURVEY
Man has worked hard from the earliest times to develop synthetic materials which
would offer benefits not found in the natural products around him.
PVC is one of the oldest synthetic materials with the longest history in industrial
production. Its early history is of multiple and accidental discovery in different places at
different times as well as unsuccessful quests for commercial application.
Fig 2.1: B.F.GOODRICH
Early researchers accidentally discovered PVC on at least two occasions in the 19th
century. The first, in 1838, was by the French physicist and chemist Henri Victor Renault and
the second in 1872 by the German Eugene Baumann. On both occasions, the polymer
appeared as a white solid inside flasks of the newly discovered vinyl chloride gas that had
been left.
In 1913, German inventor Friedrich Heinrich August Kate took out a patent on PVC. The
most significant breakthrough occurred in the United States when the company,
B.F.Goodrich hired the industrial scientist Waldo Simon to develop a synthetic replacement
for the increasingly costly natural rubber. His experiments again produced polyvinyl chloride.
However, the material was threatened by the recession in the 1920s and it was under threat of
abandonment that Simon conceived the idea of PVC as a water resistant coating for fabrics.
Sales took off quickly with a rapidly expanding product range. Demand accelerated again
during the Second World War, when PVC quickly replaced traditional material to insulate
wiring on military.
During the 1950's many more companies started to produce PVC and volumes
increased dramatically around the world. Developers quickly found further, innovative uses
through the decade and refined methods to enhance durability, opening the door to
applications in the building trades. By the middle of the 20th century, five companies were
producing PVC, and ground-breaking uses for PVC, or ‘vinyl’ as it is also known, continued
to be found during the 1960s. A vinyl-based latex was used on inflatable structures and fabric
coatings, and at the same time, methods for improving PVC's durability were developed,
allowing applications in the building industry.
 YEAR AND COUNTRY WHICH STARTED USING “PVC” IN DAILY

USE:-
i. In 1912: The first industrial developments were initiated in Germany.

ii. In 1932: The first tube made a PVC co polymer was produced. Nearly three years
later PVC pipe was used in daily purpose.
iii. In 1936 :PVC pipe began to be installed for residential drinking water
distribution & sewage purpose & still in services
iv. In 1955: First PVC distribution pipe laid in US.
IN INDIA 60 YEARS AGO THE FIRST PVC INDUSTRY WAS ESTABLISHED

IN MUMBAI (1951)
The chemical process for making PVC involves taking the simplest unit, called the
monomer, and linking these monomer molecules together in the polymerization process.
This is the case for PVC, which is made from vinyl chloride monomer known usually by its
initials VCM through polymerization. Some monomers exist in the form of reactive gaseous
chemical substances, and some of these may cause health hazards when in direct contact with
humans. In these cases they are manufactured and processed under strict control for health,
safety and environmental protection. On the other hand, polymers such as PVC, which are
manufactured from monomers through polymerization, are solid and chemically stable
substances, therefore do not affect human health. VCM, which is the raw material for PVC, is
a gas at ambient temperature but is usually stored in liquid form under pressure. Ethylene and
chlorine are raw materials for PVC.
CHAPTER 3
MANUFACTURING PROCESS, RAW MATERIALS &

PROPERTIES
MANUFACTURING PROCESS, RAW MATERIALS &

PROPERTIES
3.1 DIFFERENT MANUFACTURING PROCESS
3.1.1 Bulk Polymerization
Bulk polymerization are alternative but far less common technologies to manufacture
PVC. Emulsion polymerization produces finer resin grades with much smaller particles,..
Bulk (or mass) polymerization yields PVC resin similar to suspension PVC. The difference is
that polymerization occurs in the absence of water. It s primarily used for products that
require high transparency and good plasticizing properties.
Fig.3.1: Bulk Polymerization
3.1.2 Suspension Polymerization
As a first step in the production of suspension PVC, also known as S-PVC, VCM is
fed into the polymerisation reactor alongside water and suspending agents. Through high-
speed agitation, small droplets of VCM are formed. It is these droplets that eventually made
PVC.
As a next step in PVC manufacture, an initiator or catalyst soluble in VCM is fed into
the reactor. It is here, under pressure and at temperature ranging from 40 to 60°C, that the
VCM droplets are turned into PVC. The PVC obtained through this method is suspended in
water.
At the final stage of the S-PVC process, the slurry discharged from the polymerisation
reactor is stripped of un-reacted VCM; most of the water is removed, usually by
centrifugation, and the solid is dried. The end result is PVC in the form of a white powder, or
resin, which is non-toxic, odourless and inert. Importantly, all un-reacted VCM is recovered
and recycled as raw material.
Fig.3.2: Suspension Polymerization
3.1.3 Emulsion Polymerization
Emulsion polymerization is a type of radical polymerization that usually starts with

an emulsion incorporating water, monomer, and surfactant. The most common type of
emulsion polymerization is an oil-in-water emulsion, in which droplets of monomer (the oil)
are emulsified (with surfactants) in a continuous phase of water. Water-soluble polymers,
such as certain polyvinyl alcohols or hydroxyethyl celluloses, can also be used to act as
emulsifiers/stabilizers. The name "emulsion polymerization" is a misnomer that arises from a
historical misconception. Rather than occurring in emulsion droplets, polymerization takes
place in the latex particles that form spontaneously in the first few minutes of the process.
These latex particles are typically 100 nm in size, and are made of many individual polymer
chains. The particles are stopped from coagulating with each other because each particle is
surrounded by the surfactant ('soap'); the charge on the surfactant repels other particles
electrostatic ally. When water-soluble polymers are used as stabilizers instead of soap, the
repulsion between particles arises because these water-soluble polymers form a 'hairy layer'
around a particle that repels other particles, because pushing particles together would involve
compressing these chains.
Emulsion polymerization is used to manufacture several commercially important

polymers. Many of these polymers are used as solid materials and must be isolated from the
aqueous dispersion after polymerization. In other cases the dispersion itself is the end
product. A dispersion resulting from emulsion polymerization is often called
a latex (especially if derived from a synthetic rubber) or an emulsion (even though "eulsion"
strictly speaking refers to a dispersion of an immiscible liquid in water).
Fig.3.3: Emulsion Polymerization
3.1.4 SELECTION OF MANUFACTURING PROCESS:
I. PVC is produced by polymerization of vinyl chloride monomer (VCM). The

manufacturing process of PVC includes three methods Bulk polymerization (10%),
Suspension polymerization (82%), Emulsion polymerization (8%).
II. As emulsion polymerization has fine resin than suspension polymerization and Bulk
polymerization so Emulsion polymerization is considered for manufacturing of PVC.
Its Flow sheet in details
III. Since the Emulsion polymerization carries more percentage in formation of PVC. So
we will discuss the suspension polymerization in detail.
3.2 RAW MATERIAL:
The vinyl chloride monomer is combined with other raw materials in the reactor in the
following typical suspension PVC recipe. A description of the various raw materials follows.
Raw Material Parts Vinyl Chloride Monomer 100 Initiator .03 Primary Suspending Agent .03
Secondary Suspending Agent .05 Chain Transfer Agent .50 Water 200 Process Conditions
Reaction Temperature 55°C Reaction Time 6-8 hours Reaction Pressure 830 kPa Initiators.
The initiator decomposes to produce free radicals. The free radicals react with the vinyl
chloride monomer causing the polymerization reaction to occur. For suspension resin the
initiators must be soluble in the monomer, and are usually organic peroxides and ago
compounds. Primary Suspending Agent The primary suspending agent is used to stabilize the
dispersed monomer droplets. It also protects the particle, prevents reaction wall buildup and
influences particle size, porosity and bulk density.
They are nonionic water soluble polymers, such as cellulose derivatives, PVC or
gelatin. Secondary Suspending Agent. The secondary suspending agent will not stabilize by
themselves. They are used to modify the resin particles to improve the porosity to
monomaniac and polymeric plasticizers and raise the bulk density. They are either monomers
or water soluble compounds, such as nonionic surface active materials. Chain Transfer
Agent. The chain transfer agent reacts with the growing polymer chain to cause lower
molecular weights. They are compounds such as chlorinated hydrocarbons, or mercaptans.
Water. Water is used as an efficient heat transfer medium to conduct the heat away because
of the exothermic reaction. It also acts as a fluidizing medium for resin. It should be deionizer
so that there are not impurities in the water to deactivate the initiators or cause unwanted side
reactions.
As in production of PVC suspension polymerization is most wildly used and also

carries more % then E-polymer & B-polymer. So the description and a flow sheet of
suspension polymerization is as follows:
PVC is produced by polymerization of vinyl chloride monomer (VCM). The main

polymerization methods include suspension, emulsion, and bulk (mass) methods. About 80%
of production involves suspension polymerization. First, the raw material VCM is pressurized
and liquefied, and then fed into the polymerization reactor, which contains water and
suspending agents in advance. Next, the initiator is fed into the reactor, and PVC is produced.
The role of water is to remove and control the heat given off in the polymerization process.
PVC forms as a tiny particle which grows and when they reach a desired size the reaction is
stopped and any unreacted vinyl chloride is distilled off and re-used. The PVC is separated
off and dried to form a white powder also known as PVC resin (see flow diagram).
Emulsion polymerization produces finer resin grades having much smaller particles, which
are required by certain applications.
3.3 PROPERTIES:
3.3.1 PROPERTIES OF PVC

Table 3.1: Properties of PVC
Property Value
Technical Name Polyvinyl Chloride (PVC)
Chemical Formula (C2H3Cl)n
Melt Temperature 212 - 500 °F (100 - 260°C)
Heat Deflection Temperature (HDT) 92 °C (198 °F)
Tensile Strength Flexible PVC: 6.9 - 25 MPa (1000 - 3625 PSI)
Rigid PVC: 34 - 62 MPa (4930 - 9000 PSI)
Specific Gravity 1.35 - 1.45
3.3.2 PHYSICAL PROPERTIES
Table 3.2: Physical properties of PVC
Property Rigid PVC Flexible PVC
Density [g/cm3] 1.3–1.45 1.1–1.35
Thermal conductivity [W/(m·K)] 0.14–0.28 0.14–0.17
Yield strength [psi] 4500–8700 1450–3600
Young's modulus [psi] 490,000 -
Flexural strength (yield) [psi] 10,500 -
Compression strength [psi] 9500 -
Coefficient of thermal expansion (linear) [mm/(mm °C)] 5×10−5 -
Vicat B [°C] 65–100 Not recommended
Resistivity [Ω m] 1016 1012–1015
Surface resistivity [Ω] 1013–1014 1011–1012
3.3.3 CHEMICAL PROPERTIES:
PVC is chemically resistant to acids, salts, bases, fats, and alcohols; therefore, it is
used in sewerage piping. It is also resistant to some solvents, mainly PVC. Plasticized PVC,
also known as PVC, is in some cases less resistant to solvents. For example, PVC is resistant
to fuel and some paint thinners. Some solvents may only swell it or deform it but not dissolve
it, but some of them, like tetra hydro furan or acetone, may damage it.
CHAPTER 4
MATERIAL BALANCE
MATERIAL BALANCE
The process of manufacture of desired product from a given raw material involves
Series of steps where in physical & chemical changes take place in the material. The steps
where, In raw material undergoes chemical reaction with or without catalyst to produce
desired product is the heart of the process & chemical reaction takes places are very
important from the design point of view of a chemical reactors.
4.1 Conversion:
The conversion is always based on the limiting reactant and it gives idea,
regarding the degree of completion of a reaction. The unreacted quantities of raw material are
easily obtained knowing the charged quantities with the help of conversion. It also gives idea
regarding whether recycling is to be done or not for the process to be economical feasible.
Consider the reaction,

A+B=C
Where, A= Limiting reactant, B= excess, C = product
%Conversion=kilogram of A reacted X 100

kilogram of A feeded
1023.72X100 = 92%
1112.73
4.2 Reactor Material Balance
Basis: 25000 kg/day production of Emulation poly vinyl chloride.
Vinyl Chloride Monomer
Activator Reactor LATEX (Unreacted VCM)
Stabilizer
Fig.4.1: Reactor Material Balance
Overall Material Balance for Reactor:
VCM + Emulsifier + Activator = LATEX ( Unreacted VCM )
[(1.148m3/ hr × 970 kg/m3) × 99.984 % × 92 %] + [2.171 m3/hr × 1000 kg/hr] + [0.030

m3/hr ×1000 kg/m3] = ‘x’ × 1132 kg/m3
1023.72 kg/hr + 2171 kg/hr.] + 30 kg/hr] = ‘x’ ×1132 kg/m3
x = 2.848 m3/hr.
(Let X be the latex containing unreacted Vinyl chloride monomer
In put = Out put
* Material Balance of Vinyl chloride monomer:

(Vinyl chloride monomer x Conversion ) = LATEX
(1.148m³/ hr × 970 kg/m³) ×0.92 = X
1112.73 kg/hr × 0.99984 × 0.92 = 1023 kg/hr +83.72 kg/hr
LATEX ‘X’ : 1023 kg/hr.
(In above overall material balance the values of Emulsifier & Activator is calculated below )
 Emulsifier:
kg/hr × 1000 kg/ m³ = 2171 kg/hr
 For solid:
2171hr 1.3 % = 28.22 kg/hr (solid) + 2142.78 kg/hr (Demineralized Water)
 Activator:
0.30kg /hr × 1000 kg/ m³ = 30 kg/hr
Degassing :
(Let ‘Y’ be the pure latex)

[‘x’ = 3.42 m3/hr × 1132 kg/m3] + [384.04 kg/hr + 19.20 kg/hr] = ‘Y’ + 133.85 kg/hr
[3871 kg/hr+384.04 kg/hr+19.20 kg/hr] = ‘Y’ + 133.83 kg/hr
4274.24 kg/hr = ‘Y’ + 133.83 kg/hr
‘Y’ = 4274.24 kg/hr -133.83 kg/hr
‘Y’ =4140.41 kg/hr
‘Y’ = 4140.41 kg/hr/1125 Kg/m3
‘Y’ = 3.680 m³/hr
4.3 Dryer Material Balance:
Basis : 2848 kg/hr of wet solid feed to spray dryer
Water removed
50% solid, Latex 2848 kg/hr SPRAY Product contains,(0.1-0.3% moisture)

DRYER
Hot Air
Fig.4.2: Spray Dryer
Let, x is kg of product obtaind and y is the kg of water removed.
Overall Material Balance:
X+Y = 2848 kg/ hr
Y= 1419.71 kg/hr
(a) Material Balance of Solid

Solid in wet material = solid in product
50 % solid
0.5 × 2848 kg/hr = ‘X’ × 0.997
X = (0.5 × 2848)/0.997
X = 1428.28 kg/hr
b) Material Balance of Water

Water in the wet material = water in the product + water removed
0.5 × 2848 kg/hr = (0.003 × 1428.28) kg/hr + 1419.71 kg/hr
1423.99 kg/hr = 1423.99 kg/hr
CHAPTER 5
ENERGY BALANCE
ENERGY BALANCE
5.1 INLET STREAMS

 VINYLE CHLORIDE MONOMER
Q1 = m.cp. ΔT (2) = 1112.73 kg/hr× 0.43 kcal/ (kg oC) × (30 - 0)
=14354.217 kcal/hr
 EMULSIFIER
Q2 = m.cp. ΔT=[2171 kg/hr× 1 kcal/(kg 0C) × (30 – 0)]
= 65130 kcal/hr
 ACTIVATOR
Q3 = m.cp. ΔT = [30 kg/hr× 1 kcal/ (kg oC) × (30 – 0)]
= 900 kcal/hr
 HEAT OF REACTION
Q4=VCM Reacted× Heat of reaction
=1023.72 kg/hr×370 kcal/kg
=378776.4 kcal/hr
 COOLING WATER SUPPLY

m.cp. ΔT =308.40 m3/hr× 1000 kg/m3× 1kcal/(kg 0C) × (34 - 0)
= 10484564 kcal/hr
 AGITATOR POWER INPUT

=11kw/hr × 860
= 9460 kcal/hr
5.2 OUTPUT STREAMS:

 LATEX
m.cp.ΔT = [83.72 kg/hr× 0.205 kcal/(kg֯C) X (55.5 - 0)]RVCM + [2201 kg/hr
× 1 kcal/(kg ֯C)× (55.5 - 0)]DMWater + [1023.72 kg/hr× 0.567 kcal/(kg֯C)
× (55.5- 0)]PVC
= 155322.95 kcal/hr.
 COOLING WATER RETURN

m.cp. ΔT = 308.40 m3/hr. × 1000 kg/m3 ×1 kcal/(kg 0C) × (35.6 – 0)
=10977955 kcal/hr.
Fig.5.1: Batch Reactor
 OVERALL ENERGY BALANCE

VCM + EF2 + Activator + Heat of Reaction+ C.W. S.+ Agitator Power I/P = Latex + C.W.R.
14354.21 kcal/hr+ 65130 kcal/hr + 900 kcal/hr + 568375.5 kcal/hr + 10484564 kcal/hr +
9460kcal/hr = 155322.95 kcal/hr + 10977955 kcal/hr
= 11133277.95 kcal/hr = 11133277.95 kcal/hr.
To calculate overall heat transfer coefficient

m × cp ×ΔT = U × A × LMTD
(308.37 m3/hr × 1000 kg/m3) ×1 kcal/(kg֯C) ×(35.6 – 34) = U ×84 m2 × 20.69 ֯C
493392 kcal/hr = U ×1737.93 (m2.֯C)
U = 493392 kcal/hr/ 1534.76 (m2.֯C)
U = 283.90 kcal/(hr.m².oC)
5.3 Degassing Energy Balance

5.3.1 Overall Energy Balance
Latex + Steam + D.M.water + C.W.S = Latex + RVCM + C.W.R.
155322.95 kcal/hr. + 194324 kcal/hr + 538 kcal/hr. + 33600 kcal/hr
= 254775.46 kcal/hr + 1373 kcal/hr + 66000 kcal/hr
383784 Kcal/hr=322148.46 Kcal/hr
Heat Loss=61635.54 Kcal/hr
%Heat Loss=6.22%Loss
5.3.2 Component balance

5.3.2.1 INPUT STREAMS
 LATEX
m.cp. ΔT = [83.72 kg/hr. × 0.205 kcal/(kg ֯C) × (55.5 - 0)]RVCM + [2201 kg/hr
× 1 kcal/(kg֯C)× (55.5 - 0)]DM water + [1023.72 kg/hr. ×0.567 kcal/(kg֯C)
×(55.5 - 0)]PVC
= 952.52kcal/hr + 122155.5 kcal/hr + 32214.93 kcal/hr
= 155322.95 kcal/hr
 STEAM
m × λ = 384.04 kg/hr × 506 kcal/kg
= 194324 kcal/hr
 DEMINERLIZED WATER
19.20 kg/hr × 1 kcal/(kg 0C) × (28 – 0) ֯C
= 538 kcal/hr
 COOLING WATER SUPPLY

m.cp. ΔT = 1200 kg/hr × 1 kcal/(kg֯C) × (28 – 0)֯C
= 33600 kcal/hr
5.3.2.2 OUTPUT STREAMS

 Latex
m.cp. ΔT = [0.02 kg/hr. × 0.205 kcal/(kg 0C) × ( 80 – 0)]RVCM+[2604.24 kg/hr.
× 1 kcal/(kg֯C)× (80 - 0)]DMWater + [1023.72kg/hr × 0.567 kcal/(kg֯C)
× ( 80- 0) ֯C]PVC
= 0.328 kcal/hr + 208339.20 kcal/hr + 46435.93 kcal/hr
= 254775.46 kcal/hr
 Reacted Vinyl Chloride Monomer

m.cp. ΔT = [83.72 kg/hr × 0.205 kcal/(kg 0C) × (80 – 0) 0C]
= 1373 kcal/hr
 Cooling water return

m.cp. ΔT = 1200 kg/hr × 1 kcal/(kg 0C) × (55 – 0) 0C
= 66000 kcal/hr
CHAPTER 6
MECHANICAL DESIGN OF BATCH REACTOR
MECHANICAL DESIGN OF BATCH REACTOR
BASICS:
The batch reactor is used as reactor;
- The height of reactor =14.150 m.
- Inner diameter of reactor =1.656 m.
- Volume of reactor =30m³.
The agitator used is tack blade
- Length of Agitator =1.415 m.
- Diameter of Agitator =0.3m.
So while designing the reactor following parameter are considered as follows:
- Reactor Jacket.
- Reactor Thickness.
- Shell Thickness.
- Agitator
- Material Of Construction (MOC).
- Reactor Support Type.
(some values which are to be assumed while designing the reactor)
 SHELL THICKNESS
(a) Cylindrical Shell :
Taking pressure as 5 bar
5bar- 0.5 N/mm².
Design Pressure =1.1(0.5)
=0.605
t = P *D₀
2 *f*J-P
= 0.605*1615 /2*96*0.85 -0.605
= 7.48 mm.
(b) External Pressure
Assuming Internal pressure = 0.35 N/mm².
External design pressure = 1.1(0.35)
= 0.385 N/mm².
Pc = 2.42*E*(t/D˳)^5/2 / (1-μ^2)^3/2*((t/D˳)- 0.45(t/D˳)^1/2)
= 0.84
 USING THICKNESS:
t = 7.9 mm (assumed data.)
L = effective length + 1/3*dish end length.
= 14150 + 60 +1/3*(360)
= 16000 mm.
D = Di + 2t
= 1615 +(2*7.9)
D = 1631 mm.
 CRITICAL STRESS:
fc = Pc*D˳ /2t
= 86.71 N/mm².
Assume;
Fa = 11.64 N/mm².
Pa= (1/4)*Pc
=(1/4)*0.84
Pa = 0.21
 THICKNESS OF JACKET:
The jacket used outside of reactor is –“PLAIN JACKET”.
Internal design pressure = 1.1*0.35
= 0.385 N/mm².
t̡̡̡̡ = P *D₀ +c
2 *f*J-P
= 0.385*1631 / (2*0.85*96 – 0.385) + 1.5
t = 5.41 mm
appromiate value = 8 mm.
 HEAD AND DISH OF REACTOR:
Here ;
Shallow dish and torispherical head is used,
th= P * R₀ +c
2 *f*J-P
W= ¼(3 + √Rc/R1)
= ¼(3+√1631/72)
th= 1.933
th = P*RcW/2*f*J +C
= 0.605*1631*1.9533/ 2*96*0.85 +1.5
= 13.09 mm
 NOZZLE (Inlet and outlet)
tn =P*Di/(2*f*J-P)
= 0.6*1656/(2*096*0.85 – 0.6)
= 6.11 mm
tn= 6.11 + 1.5
= 7.610 mm.
(Nozzels used reinforcing pad )
 BAFFLES
The baffles used will be normal type.
Number of Baffles = 6
 BOLT
The Material Of Construction (M.O.C) of Bolt will be
- M48
- Hot rolled carbon steel.
The minimum bolt load for atmospheric condition:
Wm1= ᴨ*b*G*Ya
= ᴨ*2.75*1660*190×10^3
= 1807012.67 N
Wm2= ᴨ*(2b)*Gm*P +ᴨ/4*G²*P
=4615313.76 N
The number of bolts required;
=1660/2.54
=65.35
(The bolts are always multiples of 4)
So;
We will consider the number of Bolts=68.
 The bolt area

Abolt= Wm1/fa
= 1807012.67/54.5
Ab= 33156.18 mm2.
 Bolt area for stresses

(As we have assume that the (M16) ,so the nominal diameter will be – 48)
A= 0.51; b=2.09
Ab= a(X)b
= 0.51(48)2.09
= 1664.80
Hence , 65 number of bolts will be required and the nominal diameter is 48 mm(M
48).
 The Total Bolt area
Abt= 65*1664.80
= 108212.57 mm2.
 SUPPORTS
In this process the supports are most commonly use are
“SKIRT SUPPORTS”.
Dimeter of vessel – 1.63 m
Height of the vessel – 14.15 m
Weight of the vessel with attechement – 25000 kg
Dimeter of the skirt – 1.631 m
Height of the skirt – 1.4 m
Wind pressure – 1285 N/mm2
Skirt –
Fd = ∑ W/ Π*D0*tsk
= 25000/3.142*1631*tsk
= 115.30/tsk
 Stress due to wind load
Total height = 14150+1400
= 15550 mm
The bending movement up to the base,
Mw=fw*H/2
(Assume:- fw=114146.6 N)
Mw=114146.6*42.3/2
= 2.41*109 N/mm
Fwb=Mw/z
=4*Mw/(3.142*(1631)2)*tsk
=1153.50 / tsk N/mm2
Sesmic and wind load cannot occur simultaneously. Therefore we will design with wind load
only.
Maximum tensile stress = Permisible strss
115.350/tsk - 47.84/tsk = 140
tsk = 0.48
Maximum compressible stress = (115.350+47.84)/Gsk
=1/3*Yeild point
= 1/3-*200
tsk =163.19/66.7
= 2.94 mm
(Use plate thikness=20 mm)
CHAPTER 7
COST ESTIMATION
COST ESTIMATION
The production basis for a typical tiny unit would be as under:
Working hours/day - 8 (1 shift)
Working days in a year - 300
Annual Production capacity - 40 MT PVC Pipes as follows:
Table 7.1: Cost of Pipe

According to size
Sl.No. Dia of the pipe (mm) Production in Weight per Total production
length (meter) running meter (MT)
(Kgs.)
1. 90 75,000 1,000 75.00
2. 110 53,571 1,415 75.00
The unit has been assumed to operate at 70%, 80% and 90% of its installed capacity in the
first, second and third year and onwards of its operation.
7.1 Raw Material:
The main raw material required is compounded PVC resin. Presently both PVC
& Polyethylene plastics raw materials are indigenously manufactured. Other
compounding materials like plasticizers, stabilizers, lubricants and fillers are also
manufactured in India. No problem is envisaged for procurement of PVC resin and the
other required compounding materials. The raw materials required are as follows:
PVC resin : 150.00MT

•
DOP : 6.80 MT
•
Stabilizer : 3.20MT
•
Processing acids : 1.20MT
•
Colourant : 0.70MT
•
Filler : 10.20MT
•
7.2 Process: The various process steps involved in the manufacture of rigid PVC pipes are
as follows:
• EXTRUSION
• SIZING
• TRACTION
• CUTTING
7.2.2 Extrusion:- PVC uncompounded resin, unlike some other thermoplastics is not
suitable for direct processing. To confer the required processing and end
instability, it is necessary to mix additives to the PVC resin. Following are some of
the additives which are generally used for the manufacture of rigid PVC pipes.
 Plasticizers:- The common plasticizer in use are DOP, DIOP, DBP, DOA,
DEP, Reoplast, Paraplex etc.
 Stabilizers:- The common stabilizers are lead, barium, cadmium, tib, stearate
etc.
 Lubricants:- Widely used lubricants are Buty-Stearate, Glycerol Moni-

Stearate, Epoxidised Monoester of oleic acid, stearic acid etc.
 Fillers:- Fillers are also used for producing special quality product . (e.g.
calcined clay is used to improve the electrical properties of cable compounds).
Before the extrusion operation PVC resin is to be compounded with

plasticizers, stabilizers, lubricants and fillers to improve processibility and improve
the endure stability. PVC resin is compounded with other ingredients in a high speed
mixer. The compound resin is fed to the double screw extruder where the inserts and
die body for the required pipe diameter are fitted. The PVC compounds are then
passed through a heated chamber and they get melted under the compression of the
screw and temperature of the barrel. The marking on the pipe is done at the time of
extrusion.
 Sizing:- The pipes coming out from the extruder is cooled in the sizing
operation. There are basically two types of sizing used for manufacturing of
pipes. They are (i) Pressure sizing & (ii) Vacuum sizing.
 Traction:- The next operation needed after sizing is traction. The tube
traction unit is required for continuous haulage of the pipes being extruded by
the extruder.
 Cutting:- The last operation needed is cutting. There are basically two cutting
techniques for rigid PVC pipes viz. manual and automatic. The pipes are then
tented for ISI marks and are ready for dispatching.
 Machinery:- The major equipment required for the unit are as follows:
 Windsor Model TSC-80 Rigid PVC Pipe plant for pipes 90 and 110mm OD – 1
No.
 High speed mixer capacity 100 kgs with controls and cooling arrangement – 1 No.
 Heavy duty scrap grinder – 1 No.
 Overhead water tank – 1 No.
 Air compressor 2 HP – 1 No.
 Pipe storage racks – 10 Nos.
 Location:- The suitable locations for the project may be –
o Tinsukia, Bongaigaon in Assam.
o Jorabat/ Byrnihat in Meghalaya.
o Naharlagun in Arunachal Pradesh.
o Dimapur in Nagaland.
o Agartala in Tripura
 Infrastructure:- The basic infrastructure required are :
Land : 6,000 sq.ft.
Building : 1,800 sq.ft.
Power : 25 KW
Water : 1,500 Ltr. Per day.
10 Nos. (Administrative (3), Factory

Manpower : Staff (7),
 Total Capital Requirement:- The total capital requirement including fixed capital
and working capital is estimated at Rs 45.00 lakhs as follows. Of this, the project cost
comprising fixed capital and margin money on working capital is Rs 39.00 lakhs.
A. Fixed Capital:
Fixed Capital Rs in lakh
Land & Building Rented
Machinery 30.00
Miscellaneous fixed assets 3.30
Preliminary and pre-operative expenses 2.20
Total (A) = 35.50
B. Working Capital:
Raw materials & Packing material 1 month 4.60

Finished goods 2 weeks 2.50
Working expenses 1 month 0.90

Receivables 1 week 1.50
Total (B) 9.50
Total (A)+(B) = 45.00

Note: Working capital may be financed as:
Bank Finance ….. Rs 6.00 Lakhs
Margin Money ….. Rs 3.50 Lakhs
Rs 9.50 Lakhs
 Means of Finance:-
The project cost of Rs 39.00 lakhs including margin money for working,
Promoter’s contribution (35%) …. Rs 13.65 lakhs

Term Loan (65%) …. Rs 25.35lakhs
Rs 39.00 lakhs
 Operating Expenses:- The annual operating expenses are estimated at Rs

71.95 lakhs (70% capacity utilization) as given below:
(Rs in lakhs)
1. Raw materials 55.00
2. Utilities 1.00
3. Wages & Salaries 6.00
4. Overheads 1.50
5. Selling expenses @ 1% on annual sales 1.10
6. Interest on term loan (14%) 3.55
7. Interest on Bank Finance for
working capital (13%) 0.80

8. Depreciation @10% 3.00
71.95
 Sales Realization:- The basis on which average ex-factory sales realization

from the sale of PVC pipe is based is provided below:,
Table 7.2: Total Cost
Items Production Unit Sales Price Annual Sales Price (Rs)

(Meter) (Rs per Meter)
PVC pipe 90mm 75,000 75/- 56,25,000
PVC Pipe 110mm 53,571 100/- 53,57,100
TOTAL 109,82.100
Say : Rs 110.00 lakh
Based on this the annual sales realization is estimated to be Rs 110.00 lakhs and at
70% capacity utilization the same is Rs 77.00 lakhs.
 Profitability:- Based on the sales realization and the operating expenses, the
profit would be Rs 5.05 lakhs per year (70% capacity utilization). This works out
to a return on investment of 13%. The plant will break even at 54% of the rated
capacity.
 Highlight:- The major highlights of the project are as follows:
Total capital requirement : Rs 45.00 lakhs

Promoter’s contribution : Rs 13.65 lakhs
Annual sales realization (70%
cap.) : Rs 77.00 lakhs
Annual operating expenses (70% cap.) : Rs 71.95 lakhs

Annual profit (pre-tax) : Rs 5.05 lakhs
Pre-tax Return on Sales : 8%
Break Even Point : 54%
No.of persons employed : 10
CHAPTER 8
CONCLUSION
CONCLUSTION
Commodity plastics comprising of Polyethylene (PE), Polypropylene (PP), Polyvinyl

Chloride (PVC) and Polystyrene account for bulk of the plastic consumption in India. There
are several factors like low per-capita consumption, manufacturing focus, end use industry
growth, availability of feedstock, increasing urbanization, changing lifestyle, demographic
dividend etc. promoting growth of plastic across India. However specific to Northern India
we observe a lack of planned downstream plastic processing plants within the region and
near-by regions of Eastern India to make use of these factors. Spill off benefit of promoting
plastic processing is the huge inherent employment potential. Many application areas of
plastics also have overlaps that make market driven material substitution a good possibility.
There are strategic objectives driven by part consolidation and sustainability compulsions by
the user industry that have made material selection converge to a polymer to promote
recycling. An organized development addressing cost effective plastic processing along with
streamlining operations of recycling of plastics could pave a growth path for downstream
plastic manufacturers in Northern India.
REFERENCE
1. Barton, F.C. (1932 [1931]). Victrolac Motion Picture Records. Journal of the Society
of Motion Picture Engineers, April 1932 18(4):452–460 (accessed at archive.org on 5
August 2011)
2. W. V. Titow (31 December 1984). PVC technology. Springer. pp. 6–. ISBN 978-0-
85334-249-6. Retrieved 6 October 2011.
3. Baumann, E. (1872) "Ueber einige Vinylverbindungen" (On some vinyl
compounds), Annalen der Chemie und Pharmacie, 163 : 308–322.
4. Chanda, Manas; Roy, Salil K. (2006). Plastics technology handbook. CRC Press.
pp. 1–6. ISBN 978-0-8493-7039-7.
5. Handbook of Plastics, Elastomers, and Composites, Fourth Edition, 2002 by The
McGraw-Hill, Charles A. Harper Editor-in-Chief. ISBN 0-07-138476-6
6. David F. Cadogan and Christopher J. Howick "Plasticizers" in Ullmann's
Encyclopedia of Industrial Chemistry 2000, Wiley-VCH,
Weinheim. doi: 10.1002/14356007.a20_439
7. Karlen, Kaley. "Health Concerns and Environmental Issues with PVC-Containing
Building Materials in Green Buildings" (PDF). Integrated Waste Management Board.
California Environmental Protection Agency, USA. Retrieved 26 August 2015.
8. Cost estimation from MAX. S. PETERS, TIMMER HAUS- PLANT DESIGN &
Economic For Chemical Engineerin
Manufacturing of PVC
FAMT, RATNAGIRI Page 52

PVC Final Report 1234

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PVC Final Report 1234

Uploaded by

Copyright:

Available Formats

Project on, Dissertation On Manufacturing Of PVC

Polyvinyl chloride also known as polyvinyl chloride, Commonly abbreviated as

PVC comes in two forms:-

Fig.1.1: PVC Pipes

1.1 WHAT IS PVC ?

Usually, thermoplastics are supplied in the form of pelletized material (compounds)

PVC is sometimes known as ‘Vinyl’ in Europe and predominantly so in North

The chemical reaction of PVC is:

IUPAC NAME: Poly(1-chloroethene) .

OTHER NAME: POLYCHLOROETHYLEN.

1.2.2 Electric cables:

Fig.1.3: Electric Cable

PVC is a common, strong but lightweight plastic used in construction. It is made

PVC is extensively used in the building industry as a low-maintenance material,

1.2.5 Wire rope:

Fig.1.6: Wire Rope

HISTORY AND LITERATURE SURVEY

HISTORY AND LITERATURE SURVEY

Fig 2.1: B.F.GOODRICH

 YEAR AND COUNTRY WHICH STARTED USING “PVC” IN DAILY

i. In 1912: The first industrial developments were initiated in Germany.

IN INDIA 60 YEARS AGO THE FIRST PVC INDUSTRY WAS ESTABLISHED

MANUFACTURING PROCESS, RAW MATERIALS &

MANUFACTURING PROCESS, RAW MATERIALS &

3.1 DIFFERENT MANUFACTURING PROCESS

3.1.1 Bulk Polymerization

Fig.3.1: Bulk Polymerization

3.1.2 Suspension Polymerization

Fig.3.2: Suspension Polymerization

3.1.3 Emulsion Polymerization

Emulsion polymerization is a type of radical polymerization that usually starts with

Emulsion polymerization is used to manufacture several commercially important

Fig.3.3: Emulsion Polymerization

3.1.4 SELECTION OF MANUFACTURING PROCESS:

I. PVC is produced by polymerization of vinyl chloride monomer (VCM). The

3.2 RAW MATERIAL:

As in production of PVC suspension polymerization is most wildly used and also

PVC is produced by polymerization of vinyl chloride monomer (VCM). The main

3.3.1 PROPERTIES OF PVC

Technical Name Polyvinyl Chloride (PVC)

Chemical Formula (C2H3Cl)n

Melt Temperature 212 - 500 °F (100 - 260°C)

Heat Deflection Temperature (HDT) 92 °C (198 °F)

Tensile Strength Flexible PVC: 6.9 - 25 MPa (1000 - 3625 PSI)

Rigid PVC: 34 - 62 MPa (4930 - 9000 PSI)

Specific Gravity 1.35 - 1.45

3.3.2 PHYSICAL PROPERTIES

Table 3.2: Physical properties of PVC

Property Rigid PVC Flexible PVC

Density [g/cm3] 1.3–1.45 1.1–1.35

Thermal conductivity [W/(m·K)] 0.14–0.28 0.14–0.17

Yield strength [psi] 4500–8700 1450–3600

Young's modulus [psi] 490,000 -

Flexural strength (yield) [psi] 10,500 -

Compression strength [psi] 9500 -

Coefficient of thermal expansion (linear) [mm/(mm °C)] 5×10−5 -

Vicat B [°C] 65–100 Not recommended

Resistivity [Ω m] 1016 1012–1015

Surface resistivity [Ω] 1013–1014 1011–1012

3.3.3 CHEMICAL PROPERTIES:

Consider the reaction,

%Conversion=kilogram of A reacted X 100

4.2 Reactor Material Balance

Pc = 2.42E(t/D˳)^5/2 / (1-μ^2)^3/2*((t/D˳)- 0.45(t/D˳)^1/2)

= 0.60516311.9533/ 2960.85 +1.5