Poly Vinyl Chloride

Plant
(Monomer Section)
Shriram Vinyl and Chemical
Industries
Prepared by-
Created By : Megh

Megh Sharma
 Contents
1. Introduction to PVC Plant
2. Poly Vinyl Chloride
3. Vinyl Chloride
4. Manufacturing Reactions
5. Production Process
6. Challenges in Production
7. Polymer Section
8. RVCM & Drying and Packing
9. Summary

Created By : Megh
1. Introduction to PVC Plant
PVC plant was commissioned in 1962. Technology was provided by
Japanese company “Shin – Etsu”. Initial capacity was 40 TPD.
Current capacity of PVC plant is 200 TPD.

PVC plant

RVCM and
Monomer Polymer Drying,
Packing
Created By : Megh
 2.PVC – Poly Vinyl Chloride

•Polyvinyl chloride is the world's third-most widely produced synthetic plastic

polymer.
•PVC was accidentally synthesized in 1872 by German chemist Eugen Baumann.
•Uses: doors and windows,bottles, packaging, cards, Disposable syringes, tubes,
Pipes etcetera.
Flexible
Property RPVC PVC
1.3-
Density (g/cm3) 1.45 1.1-1.35
Thermal Conductivity 0.14- 0.14-
(W/(m·K) 0.28 0.17
Created By : Megh
Melt temperature (F) 212-500
Specific gravity 1.35-1.45
 3. Vinyl Chloride
•C2H3Cl; IUPAC name- Chloroethene
•VCM is among the top twenty largest petrochemicals in world
production.

Property
Boiling Point -14
Melting Point -153.7
Flash point -78
Auto Ignition
Temperature 472
LEL 3.6%v/v
HEL 33% v/v
Created By : Megh
 4. Manufacture of Vinyl
Chloride (monomer)

C2H2 + HCl → C2H3Cl +Δ

•Vinyl Chloride is manufactured by “Hydrohalogenation” of Acetylene
(gas) via HCl (gas).
•Catalyst used in reaction is HgCl2 (Mercuric Chloride).
•Reaction takes place in Multi tubular type packed bed Reactor.
•Favourable Conditions:
•Le-chateliers principle.
•1:1.1 :: Acetylene : HCl
•Temperature 96-100 deg. C

Created By : Megh
5. Production Process
 Hydro Halogenation of Acetylene
 Raw materials
 HCl (from Caustic Soda plant)
 Acetylene (from Carbide plant)

 Utilities
 CaCl2 brine (chilling and dehumidification)

 Toluene (Acetylene Removal)

 NaOH
Created By : Megh
 5.1 HCl Stripping

Water Brine cooler Water Brine cooler

cooler 1,2 1,2 cooler 1,2 1,2

To mixing To mixing
tank old tank new

HCl tank HCl tank

1,2,3 Buffer tank Buffer tank 1,2,3
old new

Created By : Megh
 5.2 Acetylene Dehumidification

To To
reactors reactors
1-14 15-25

Dryers Dryers
Mix. Mix.
C2H2 1,2,3 4,5 C2H2
Tank Tank

Dehu- Dehu-
hmidf HCl from hmidf
-ier Buffer Tank -ier

Old New
Brine Acetylene Brine
cooler from cooler
carbide
Cacl2 Brine Created By : Megh Cacl2 Brine
 5.3 VC Reactors
VC VC
Scrubbers Scrubbers
new old
Caustic Caustic
Solution Solution
VC VC
Reactors Reactors
15-25 1-14

Mix. Mix.
Tank Tank
New Old
Created By : Megh
 5.4 Synthessis Section

water NaOH
water Sol.
De
Scru Scru Acid
bber bber ifier
1 2
Gas holder
From
VC Reactors
1-14
water NaOH
Sol.
water Scru Scru De
bber bber Acid
3 4 ifier
To
From VCM purifification
Created By : Megh
VC Reactors
15-25
 5.5 Rectification Section
I distillation
Tower
Chilled
Caustic
De Drye
Humi VC
rs Compressors
difier
1-5 1-7
old

Chilled
Caustic
De
Humi Drye
difier rs
new 6-7
Created By : Megh
 5.6 First Towers
From
Compressors
PC 1,2,3 PC 4,5,6 PGC 4,5,6
VC 1,2,3

I tower I tower To Recovery

old New Towers

Bottom
Tank 1
Created By : Megh
 5.7 Second Towers

TC 1,2,3 TC 4,5,6

II II
From Bottom tower tower From IRT /
tank 1 / IRT old VCM New Bottom tank
Tanks 1

Bottom
Tank 2
Created By : Megh
High
Boilers
 5.8 Recvovery Section

To Mix.
tank

Brine Recovery Brine

cooler Tower cooler

From PGC Solvennt TRT

Tank Tank

Toluene
PreCooler

Toluene Created By : Megh

Pump
 6. Challeneges in VC Production

•Scaling Crusting, Choking by Autopolymerisation. (factors viz water ,

Temp.)
•High Explosive nature of VC (2.3%-36%) in air.
•Phosphene - Catalyst Poison.
3Ph3 + 2 HgCl2  6HCl
•HCl Stripper.
•Mercuric Chloride, High Boilers handling.

Created By : Megh
 7. Polymer Section

•Polymer Section Takes VC Monomer from Monomer Section and

carries out Polymerisation.
•Batch Process.
•Presently polymer Reactors, 2 KF (Kanega Fuci) (80m3) cap. ~ 17
Tons and a Chisso Reactor (100m3) cap. ~ 35T per batch
•Chisso – Latest and Fully automatic technology,, best in class.
•KF – Relatively old, Fully Automatic Technology .
•Sequential Process.

Created By : Megh
 7.1 Polymerisation Reaction
Mechanism

1. Chain Initiation R-O-O-R  2[R-O] +

2. Chain Propogation

R-O + + CH3Cl  R-O- C-C +- H3 – Cl

R-O- C +- H3 – Cl + CH3Cl  R-O- C3-C +- H3 – Cl

3. Chain Transfer
4. Chain Termination – Removal of VC from reactor
Created By : Megh
 7.2 Polymer Process
Catalyst
and
addittives

Polymer
HPBD
R-18 Reactor V-666 II
V-600 Tank/ tower
tanks tank
1,2,3 tank New
Stripper

Solvent
Taken

Created By : Megh
 8. RVCM and Drying, Packing

•RVCM – Residual Vinyl Chloride Monomer Stripping Tower, is

employed to remove all the residual Vinyl Chloride present in The PVC resin
to comply it to standards of Food and health grade plastic.

•Drying and packing section Dries the Resin Slurry and then it is sent for
Packing.

•Chisso Dryer

•Flash and Fluid Dryer

Created By : Megh
 8.1 RVCM and D,P, Process

Wet
De-
HPBD
Mon Tank
Tank/ omer 2,3,4
Dryer
Stripper Tank Storage
Silos
1-6

Packing

Created By : Megh
9. Summary

 Monomer-
 commisioning, capacity
 Polymer –
 Reactors, Chisso , KF
 Drying packing-
 RVCM tower, Dryers
 Expansion – 220 TPD

Created By : Megh
Thank you
Querries,
Suggestions!

Created By : Megh